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AMARDEEP .M. JADEJA

B.E. MECHANICAL (THIRD YEAR)

INDUS INSTITUTE OF ENGINEERING

& TECCHNOLOGY,AHMEDABAD.


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CON EN S

1) INTRODUCTION OF BOILER

2) AIR PREHEATER3) ASH HANDLING PLANT

4) FUEL OIL SYSTEM

5) COAL MILL

6) ID, FD & PA FAN

7) COOLING TOWER

8) FIRE FIGHTING SYSTEM

9) COAL HANDLING PLANT

10) TURBINE

11) SEA WATER SYSTEM

12) DM PLANT

13) TDBFP & MDBFP SYSTEM


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PLANTS:

Thermal Power Plant

Diesel Power Plant

Nuclear Power Plant Hydro Power Plant

Gas turbine Power Plant

Geothermal Power Plant

Installed capacity

59%26%

10%2% 3%

Coal Hydro Gas Nuclear Others


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THERMAL POWER PLANT:

A thermal power station is a power plant in which the prime

mover is steam driven. Water is heated, turns into steam andspins a steam turbine which either drives an electrical generatoror does some other work, like ship propulsion. After it passesthrough the turbine, the steam is condensed in a condenser and

recycled to where it was heated; this is known as a Rankine cycle Thermal power stations produce electricity by burning fuel in a

boiler to heat water to produce steam. The steam, at tremendouspressure, flows into a turbine, which spins a generator to

produce electricity. The steam is cooled, condensed back intowater, and returned to the boiler to start the process over.

Power generated by this power plant covers nearly 60% of allpower. They work with the help of coal, oil, natural gases, wasteheat etc.


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INTRODUCTION OF

BOILER


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What is Boiler?

A boiler is defined as "aclosed vessel in which

water or other liquid isheated, steam or vapor isgenerated, steam issuperheated, or anycombination thereof,under pressure orvacuum, for use externalto itself, by the directapplication of energy fromthe combustion of fuels,from electricity or nuclear

energy."

Boiler

INTRODUCTIONOFBOILER


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Boiler According to Indian Boiler

Regulations.

IBR Steam Boilers means any closed vesselexceeding 22.75 liters in capacity and which is

used expressively for generating steam underpressure and includes any mounting or otherfitting attached to such vessel, which is wholly,or partly under pressure when the steam is shutoff.


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Introduction to Adani Power 660

MW Boiler

Description Unit Value

Type Supercritical, Once Through Type,

Sliding Pressure, Single Furnace, New

Tangential Type, Single Reheat,

Balanced Draft, Dryed Slag Discharge,

Complete Steel Structure, Complete

Hanging Construction, Double Gas

Passes.

Manufacturer HARBIN BOILER COMPANY,

CHINA

Design Code

For Pressure

Parts

ASME, GB9222-88, IBR


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1. Lar ge Si ng le Funace

7. Low Nox Tangent ialBurner

6. Burn er t i l t ing forreheater steam

temperature contro l

3. Proven and economicheating s urface

arrangement

2. Spira l ly wou ndedevaporators for safe

and reliable evaporato r

5. Econom ic and safelow load and startup

system by ci rcu la ting

pump

8. Long l i fe and highPerformance mil ls

4. High Strength mater ialappl icat ion

Overall View Of Adani Boiler


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CRITICAL CONDITION

Definition

CRITICAL is a thermodynamic expressiondescribing the state of a substance beyond whichthere is no clear distinction between the liquidand gaseous phase.

The critical pressure & temperature for water are

Pressure = 225.56 Kg / cm2

Temperature = 374.15 C
http://d/Documents%20and%20Settings/Administrator/Local%20Settings/backup/Our%20Presentation/WORLD%20OF%20SUPER%20CRITICAL_PRESENTATION%20ON%2006.08.04/CRITICAL.ppthttp://d/Documents%20and%20Settings/Administrator/Local%20Settings/backup/Our%20Presentation/WORLD%20OF%20SUPER%20CRITICAL_PRESENTATION%20ON%2006.08.04/CRITICAL.ppt


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0

100

200

300

400

500

600

SUPER CRITICAL

BOILER CYCLEWITH SH, RH &

Regeneration

of ADANI 5 x 660 MW

540C 568C

Steam flow :2225 T/Hr

Steam temp : 540 c

Steam Pres : 256 kg/cm2

RH pre : 51.6 Kg/cm2

RH Temp : 568c

Feed water Temp : 291c

ENTROPY

TEMP


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WHY SUPERCRITICAL PRESSURE

The purpose of having high inlet steam pressure forturbine can be inferred from Previous deliberations.

A Boiler operating at a pressure above critical point is

called SUPERCRITICAL BOILER

A point where boiling water and dry saturated lines meet

so that associated latent heat is zero, this point is called

Critical Point and occurs at 225 kg/cm2 (abs) 374.15 C

temperature.


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SH

DRUM

ECOHTRBFP

W/WALL

DOWN COMER

RISERS

Natural CirculationBoiler

W/WALL

BFP HTR ECO

SH

SEPERATOR

ONCE THROUGH SYSTEM


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FLOW DIAGRAM OF SIPAT SUPER-CRITICAL BOILER

BP & EXT,d

WALLECONOMIZE FURNACE WALL FUR. ROOF

- FUR.

ROOF- B/P. ROOF

- B/P. FRONT & REAR

- B/P SDIDE (R.L)

- EXT. FLOOR &

- SIDE (SPIRAL & VERT.)

- FRONT & REAR (SPIRAL &

- Horizontal

- Pendant

SEPARAT

STORAGE

TK

S/H

-

S/H

- PLATEN

S/H

- FINAL

LT R/H

- PLATEN

HT R/H

- FINAL

BLR WTR fill in from F/W HTR

BWR

HP IP GENERATO

R

CONDENSOCW in

CW

LP


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Evaporator Wall Construction (1/3)

Upper Part

Vertical Wall

Lower Part

Spiral Wall

S iti l B il T h l


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Spiral wal l out let temp at BMCR (fron t wal l)

Spiral Wall Evaporator

Config urat ion of Evaporator panel

Spiral wall : Vert ical wall = 3 : 1

Supercritical Boiler Technology


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spiral wall spiral wall and windbox

WALL OF BOILER


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660 MW PLANT BOILER


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LTSH COILS

ECONOMISER COILS

ECONOMISER I/L HEADER

ECONOMISERO/L HEADER


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AIR PREHEATER


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The Air Preheater absorbs waste heat from flue gas,

and then transfers this heat to incoming cold air by

means of continuously rotating heat transfer elementsof specially formed metal plates.

Air Preheater is in general divided into two

types:

1.Regenerative

2. Recuperative


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1) Regenerative APH are also known as

storage type heat exchangers, have an energystorage medium, called the matrix, which isalternately exposed to the hot and cold fluids.

When the hot flue gases flow through the matrixin the first half of the cycle, the matrix is heatedand the gas is cooled. In the next half of thecycle when air flows through the matrix, air getsheated and the matrix is cooled. The cyclerepeats itself.


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2) Recuperative APH, heat is directlytransferred from the hot gases to the air acrossthe heat exchanging surface. They are commonly

tubular, although some plate types are still inuse. Tubular units are essentially counter-flowshell-and-tube heat exchangers in which the hotgases flow inside the vertical straight tubes and

air flows outside. Baffles are provided tomaximize air contact with the hot tubes.


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Regenerative Type Air Pre Heater

Nos.2

Speed of Rotation0.9rpm

Cooling water Consumption

18t/h

Air temperature at

Regenerative APH outlet -


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General Arrangement of Airpreheater

SASA

PA

FG FG

PA

TG House

Chimney

Ai P h i h i l ifi i d li


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Air Preheater, main technical specifications and list

of master drawings

Li f d i


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List of master drawing 1 General arrangement of Air Preheater.

2. Rotor assembly

3. Rotor radial seal assembly

4. Rotor module assembly. 5. Rotor post and trunnion assembly.

6. Hot end and hot intermediate layer elements and element baskets.

7. Cold end element and element basket.

8. Rotor housing assembly.

9. Hot end primary center section assembly.

10. Cold end primary center section assembly.

11. Hot end connecting plate assembly.

12. Cold end connecting plate assembly.

13. Guide bearing assembly.

14. Support bearing assembly.

15. Static seal assembly (hot end and cold end). 16. Axial and by-pass seal assembly.

17. Rotor drive assembly.

18. Sector plate assembly (hot end and cold end).

19. Air seal pipe, observation port and vapor or dust proof light assembly.

20. Stationary water washing device (hot end and cold end) and fire fighting device

21. Special tools and spare parts.


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Isometric view of Air Preheater


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AIR PRE-HEATER OPERATION

PRE START CHECKS

Support bearing/ guide bearing lubricating oil pumpsRUNNING and lubricating oil coolers are CHARGED.

Bearing temperature NOT HIGH (less than 60oC) Electrical supply to APH motor is AVAILABLE.

Local operation - Isolating valves of air motors are'OPEN' and bypass valves of air motor solenoids are

'CLOSED'. 'Air motors' lubricating oil level ADEQUATE

Service air pressure is ADEQUATE (> 5 Kg/cm2)


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APH STARTING PROCEDURE

WHEN BOTH APHS ARE OFF

START air motor of APH.

Air motors ON indications come on

Isolating dampers of APHs start opening. INSTRUCT local operator to check, locally for any abnormal

sounds from bearings/seals.

START air heater electrical motor.

Breaker CLOSED & its indication comes on UCB Associated air motor stops. Starting current shoots up and comes down to normal load

current.



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Isolating dampers of the air heater remain open.

Isolating dampers of the other air heater, not in service, startclosing if its air motor is not ON.

INSTRUCT local operator to check, locally for any abnormal

sounds from bearings/seals.

There should be no abnormal hunting in air heater amperesmeter readings.

There should be no abnormal sounds from air pre-heater

seals or bearings.

Bearing temperatures must be within the normal range (650C -75 0C)


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Parameters related to APH

Make : Ljungstorm

Type : Trisector

Oil used : TC 680 cyndol (Bearing)

EP 320 Parthan (Gear Box) Motor Drive :

Main Motor (Electric driven, AC)

Stand by motor (Electric driven, AC)

Motor: N=970rpm , Speed Reducer Assembly O/P: N=0.89rpm


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ASH HANDLING PLANT


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INTRODUCTION

Ash is a waste product of coal and solid fuel combustion. It contains

many harmful elements which can contaminate sub-soil water of water isallowed to seep through ash into soil. Further, percentage of ash presentin Indian coals is large. As a result, disposal of ash also uses upconsiderable area of land, which could otherwise be put to better use.

Therefore, it is desirable to put ash to use so that the problem ofproviding land area for its disposal is solved. All out efforts are beingmade for finding uses of ash. Presently, only negligible amount of totalash produced in the country is put to use. However, ash being a goodlandfill material can be used in bulk in projects like highwayconstruction. This is being done to as large an extent as possible.

Pollution Control Regulations have made it mandatory to dispose ash indry form only so that harmful elements do not find ingress in the sub-soil water


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ASH HANDLING SYSTEM In modern boilers ash is collected in two locations

namely (i) Bottom of the furnace and (ii) inElectrostatic Precipitators (or Dust CollectionSystems). Out of these two fractions generally the

quantity of ash collected in Electrostatic Precipitators(or Dust Collection Systems) is larger. Ash collected inthe Bottom of Furnace is generally small in quantityand is handled wet, whereas that collected in

Electrostatic Precipitators (or Dust CollectionSystems) is now collected by means of dry handlingsystems.


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Silos for

collection

of FLY-ASH

FLY ASH HANDLING SYSTEM


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FLY ASH HANDLING SYSTEM

The fly ash handling plant will remove fly ash from Electro

static precipitator (ESP) hoppers and transport it to thestorage silos. This will be carried out by pressure pneumaticconveying system on a continuous, cyclic basis. One boilerunit will be provided with one pneumatic conveying system

for handling fly ash collected in the ESP hopper. The systemlayout and the conveying pipeline configuration will bedesigned and constructed to enable evacuation of fly ash atmaximum design rate. The output of the system will be not

less than 200% of actual ash amount. The capacity of each setof system will be 30t/h.


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ELECTROSTATIC PRECIPATATOR

It is a device which captures the dust particles fromthe flue gas thereby reducing the chimney emission.

Precipitators function by electrostatically charging the dust

particles in the gas stream. The charged particles are then

attracted to and deposited on plates or other collection

devices. When enough dust has accumulated, thecollectors are shaken to dislodge the dust, causing it to fall

with the force of gravity to hoppers below. The dust is then

removed by a conveyor system for disposal or recycling


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LOCATION OF ESP

ESP CHIMNEYAPH

ECO


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Electro Static Precipitator

Basic Principle

ESP PROCESS STEPS


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ESP PROCESS STEPS

Collecting

electrode,

grounded

Rapping mechanismDischarge electrode with

Negative high tension (20-60kV)

4

Dust layer

1

1.Electron emission

2

2.Dust particle charging

3

3.Migration

4.dust collection

5

5.Rapping


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ESP

Flue gas

Gas distribution plate

Collector plate Emitter coil


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ESP TECHNICAL SPECIFICATIONS


Nos. of Gas Stream / ESP Double

Nos. of Parallel Path per Stream Nos. 38

Nos. of electrical fields in series Nos. 5

Total active treatment length per stream m 3.5

Treatment Time Seconds 15


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Total Number of Electrode Nos. 3192 x 2

Total numbers of Rappers per Unit Nos. 7

Total Nos. of Transformer Rectifier Unit Nos. 20

Capacity of Transformer Rectifier UnitEach

KVA 1.6A/72KV

Total No. of Dust Hoppers Nos. 40


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FUEL OIL SYSTEM


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There are two types of fuels are used

for ignition in combustion chamber.

1) Heavy fuel oil(HFO).

2) Light diesel oil (LDO).


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HEAVY FUEL OIL

The density of HFO is higher.

Cost is low compare to the LDO.

The viscosity is high.

The auxilary steam is mixed for easely flowingthrough pipe.

The storage tank of HFO is 2000 m3

BOILER LIGHT UP


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BOILER LIGHT-UP "HFO" inlet and re-circulation flow start increasing

"HFO header pressure very low" alarms clear off.

HFO temperature in the HFO header increases up to 110 oC.

OPEN Ignitor oil trip valve

Ignitor oil trip valve opens up.

Ignitor air fans A & B, start automatically.

Ignitor oil and ignitor air pressure increase up to 23 Kg/cm2 and 400mm wcl, respectively.

"Ignitor air to furnace DP low & "Ignitor oil/Atomising air pressurelow" & "Ignitor oil/HFO trip valve closed" alarms clear off.

CHECK these parameters are within their operation limits. Drum level normal (-60 mm. to 0, preferably on lower side).

BOILER LIGHT UP


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BOILER LIGHT-UP

HFO temp. 110 oC . (Min. temp. required is 95 oC).

HFO atomising steam pressure 8.75 Kg/cm2

Light oil pressure more than 15 Kg/cm2.

Ignitor atomising air pressure 5 to 7 Kg/cm2

Wind box pressure between 35 to 40 mm wcl

ADJUST HFO header pressure set point to 50%(13 Kg/cm2) andTRANSFER its control to auto.

HFO pressure controller transfers to auto and modulates to maintainthe set HFO header pressure.

CLOSE heavy fuel oil re-circulation valve. HFO re-circulation flow valve closes.

HFO re-circulation flow comes to minimum position


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LIGHT DIESEL OIL

The density of LDO is low.

Cost is high compare to the HFO.

The viscosity is low.

The fuel is easely flowing through pipe.

The storage tank of LDO is 300 m3


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COAL MILL


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INTODUCTION

As coal powder is the most important fuel in the powerplant, the plant owners need coal mill or coal pulverizerto grind the coal to micro powders.

Raw coal (crushed) is fed through hopper at the topof the coal pulverizer and falls down to grinder ring tobe pressed, crushed and milled into pieces by rollers.

After the first crush, coal powder fall into the second

and third layer. The pumping of the high-pressurecentrifugal blower put the outside air into the coal mill.

The coarse coal powder will be brought into theclassifier.


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TYPES OF MILLS

1) Ball mill

2) Ball and Race mill

3) Impact or Hammer mill

4) Bowl mill


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COAL

MILL

MILL LOCATION


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A

B

C

D

E

F

ESP

PASS A

ID-A

ID-B

PA-B FD-B

PA-A FD-A

FURNACE

WIND BOX

SCAPH

SA

PAFG

SA

PA

FG

SCAPH

ESP

PASS B

ESP

PASS C

ESP

PASS D

WIND BOX

ESP

I/LX

O

VER

DUCT

ESPO/LX

O

VER

DUCT

SA

X-OVER

DUCT

COLD PA

HOT PA

FLUE GAS

COLD SA

HOT SA

CHIMNEY

APH

APH

MILL

27C

324C

320C

1165C

ECO I/L 493C351C

136C

134C

129C

126C

Milling System


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Milling System PRE START CHECKS (Typical: Raymond Bowl Mill) Local

Ensure R.C. Bunker level satisfactory.

R.C. feeder and mill properly boxed up and no maintenance staff working. Gear box oil level normal. lubricatingoil coolers charged.

Pulveriser START PERMIT is AVAILABLE. (Boiler total airflow is