power point presentatation of peer group

7/31/2019 POWER POINT PRESENTATATION OF PEER GROUP

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SAMPLE HEAT RATE CALCULATIONS ABSTRACT FOR UNIT #1 to 6 FOR DEC. 07 CALCULATION FOR EFFICIENCY OF BOILER, TURBO-GENERATOR & OVERALL UNIT

S.No. Particulars : Unit I II III IV V VI

1 Gross C.V. Kcal/Kg 3845.71 3875.97 3828.86 3828.86 4079.45 4085.25

2 Total moisture in coal. % 11.15 11.12 11.46 11.46 11.48 11.54

3 Ash in coal % 36.64 36.40 36.12 35.31 34.59 34.68

4 Volatile Matter in coal % 20.91 21.05 20.40 21.20 21.50 21.40

5 Fixed Carbon % 31.39 31.52 32.10 32.10 32.12 32.08

6 Un burnt carbon in fly ash % 1.90 1.36 0.86 0.68 0.61 0.51

7 Un burnt carbon in bottom ash % 2.73 3.21 1.90 1.44 0.89 0.69

8 Flue gas temp. at APH outlet Degree C 136.36 148.97 143.81 145.60 136.00 126.14

9 Ambient Temperature Degree C 24.85 25.19 27.00 27.00 27.90 27.80

10 CO2 in flue gas at APH outlet % 15.67 15.12 14.47 14.87 13.89 13.89

11 Oxygen in flue gas at APH out let % 3.33 3.88 4.53 4.46 5.11 5.11

12 Average Vaccuum Kg/Sq cm 0.91 0.89 0.89 0.88 0.89 0.89

13 Average Main steam pressure before ESV. Kg/Sq cm 129.64 126.81 146.74 147.25 146.99 149.89

14 Average Main steam temperature before ESV Degree C 526.39 524.03 534.66 535.09 537.81 517.65

15 Average CRH Steam pressure after HPT Kg/Sq cm 36.70 34.28 36.25 36.79 37.59 37.67

16 Average R H Steam pressure before I.V. Kg/Sq cm 31.79 32.00 33.81 34.56 33.81 37.63

17 Average R H Steam temperature before I.V. Degree C 527.96 523.77 532.18 525.78 525.82 532.96

18 Average Feed water temperature at ECO. Inlet Degree C 189.25 195.35 248.97 245.81 245.75 236.68

19 D M water make-up % 2.64 2.80 6.24 4.89 0.87 1.22

20 Total Generation as on day L U 26.54 26.75 51.36 51.60 1557.50 1512.00

21 No. of hours m/c on bar. Hours 24.00 24.00 24.00 24.00

22 Avg. load M W 110.49 111.43 210.64 232.30 216.32 210.00

23 Total Quantity of oil used . K L 0.00 0.00 10.20 15.00

24 a)For start- up activities 10.20 15.00

b)For flame support

25 Oxygen in flue gas at APH Inlet % 2.33 2.88 3.33 3.46 3.50 3.40


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contd2

S.No Particulars : Unit Unit-I Unit-II Unit-III Unit-IV Unit-V Unit-VI

1) EFFICIENCY OF BOILER

Net C.V of coal Kcal/Kg 3618.94 3648.47 3600.62 3597.36 3846.58 3852.53

Total moisture in fired coal (A) Kg/Kg of coal 0.39 0.39 0.39 0.40 0.40 0.40

Heat of Moisture (B) Kcal/Kg 658.47 664.13 634.73 635.53 658.31 653.88

Total Carbon (C) Kg/Kg of coal 37.61 37.87 37.86 38.58 38.87 38.74

Nitrogen (D) % 1.85 1.85 1.86 1.85 1.84 1.84

Total oxygen required (E) Kg/Kg of coal 1.15 1.16 1.16 1.18 1.19 1.19

Hydrogen % 3.07 3.09 3.06 3.12 3.15 3.14

Dry flue gas Kg mole/Kg 0.20 0.21 0.22 0.22 0.23 0.23

Total Unburnt Carbon. Kg/Kg of coal 0.01 0.01 0.00 0.00 0.00 0.00

Loss due to un-burnt carbon in ash. % 1.72 1.43 0.88 0.67 0.49 0.40

Loss due to dry flue gas. % 5.41 6.14 5.13 5.19 6.01 5.55

Loss due to moisture & hydrogen infuel. % 7.05 7.08 6.88 6.99 6.81 6.75

Loss due to sensible heat in ash. % 0.57 0.59 0.52 0.51 0.50 0.49

Loss due to moisture in air. % 0.18 0.19 0.15 0.16 0.17 0.16

Radiation & un-accounted loss(assumed) % 5.00 5.00 4.50 4.50 1.50 1.50

Total Losses : % 19.94 20.43 18.06 18.01 15.48 14.85

Boiler efficiency.(Guaranteed 86.1% at % 80.06 79.57 81.94 81.99 84.52 85.15

MCR based/ on Coal HHV 4278

Kcal/Kg)


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contd3

(2) EFFICIENCY OF TURBO GENERATORI II III IV V VI

09/25/89 8923.50 8922.00 6672.00 6672.00 4998.00 1585.00

(Designed heat rate of Tur.-1980.64 Kcal/KWH)

Estimated heat rate of turbine due toaging factor (K cal/KWH) as on date :

Kcal/KWH 2272.01 2272.00 2052.89 2052.89 2034.47 1996.93

Increase in heat rate in K cal / KWH due to:-

Fall in vaccuum. Kcal/KWH 0.00 2.38 2.94 3.82 2.54 1.57

Fall in M S pressure Kcal/KWH 0.43 3.82 3.90 3.29 3.60 0.13

Fall in M S temperature Kcal/KWH 4.81 6.13 0.19 -0.05 -1.57 9.70

Fall in R H S Pressure Kcal/KWH 3.10 0.00 0.00 0.00 0.00 0.00

Fall in R H S Temperature Kcal/KWH 2.73 4.36 1.09 3.58 3.57 0.79

Fall in feed water temperature Kcal/KWH 37.87 33.22 -7.59 -5.19 -5.14 1.77

Kcal/KWH 48.94 49.92 0.53 5.46 3.00 13.96

Estimated heat rate of turbine Kcal/KWH 2320.96 2321.92 2053.42 2058.35 2037.47 2010.89

Efficiency of Turbine .( Designed 43.42 % ) % 37.05 37.04 41.88 41.78 42.21 42.77

(3) Over all Efficiency of the Unit

Thermal efficiency of the Unit. % 29.66 29.47 34.32 34.26 35.67 36.42Heat rate . Kcal/KWH 2899.1 2918.1 2506.0 2510.5 2410.7 2361.6

Increase in heat rate due to DM water makeup Kcal/KWH 0.00 15.68 30.04 23.57 4.03 5.54

Heat Value of oil Kcal/KWH 0.00 0.00 0.00 0.00 0.65 0.99

Windage loss ( Constant) Kcal/KWH 5.67 5.67 5.67 5.70 5.67 5.67

Total Heat Loss Kcal/KWH 5.67 21.34 35.70 29.27 10.35 12.20

Over all Heat rate of the Unit. Kcal/KWH 2904.72 2939.41 2541.73 2539.80 2421.06 2373.76Over all Thermal Efficiency of the Unit. % 29.61 29.26 33.84 33.86 35.52 36.23


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UNIT WISE & STATION WEIGHTED AVERAGE GCV OF COALFOR THE YEAR 2000-01 to 2006-07

Year

Unit-2

GCV of Coal inKcal/Kg

SP.Coalconsumption

(kg/kwh)

SP.Oil consumption(ml/kwh)

Avg GCV of Oil(Kcal/Ltr.)

Heat Rate(Kcal/Kwh)

2000-01 4437 0.637 1.073 8995 2836

2001-02 4326 0.639 0.901 9064 2772

2002-03 4202 0.663 0.460 9139 2790

2003-04 4104 0.713 0.546 8989 2931

2004-05 3813 0.737 0.465 9044 2814

2005-06 4039 0.738 0.495 9001 2985

2006-07 3952 0.754 0.448 9937 2986

Year

Unit-1


SP.Coalconsumption

(kg/kwh)



Heat Rate (Kcal/Kwh)

2000-01 4457 0.644 1.168 8972 2881

2001-02 4325 0.640 0.642 9054 2774

2002-03 4211 0.671 0.522 9071 2830

2003-04 4105 0.708 0.564 9042 2911

2004-05 3826 0.738 0.505 9092 2828

2005-06 4049 0.735 0.429 9093 2981

2006-07 3996 0.753 0.664 9945 3014


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Year

Unit-4


SP.Coalconsumption

(kg/kwh)



Heat Rate(Kcal/Kwh)

2000-01 4415 0.571 0.507 9061 2526

2001-02 4323 0.583 0.582 8977 2526

2002-03 4204 0.611 0.400 9148 2572

2003-04 4035 0.645 0.170 9082 2604

2004-05 3909 0.667 0.568 8983 2613

2005-06 4003 0.642 0.308 9115 2574

2006-07 3948 0.666 0.475 9904 2633

Year

Unit-3


SP.Coalconsumption

(kg/kwh)



Heat Rate(Kcal/Kwh)

2000-01 4406 0.588 0.294 8995 2593

2001-02 4328 0.583 0.584 9131 2529

2002-03 4196 0.611 0.440 9063 2568

2003-04 4047 0.645 0.440 8993 2614

2004-05 3922 0.640 0.434 9003 2514

2005-06 4013 0.642 0.304 9367 2580

2006-07 3933 0.671 0.580 9951 2644


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Year

Unit-6


SP.Coalconsumption

(kg/kwh)



Heat Rate(Kcal/Kwh)

2004-05 4126 0.641 1.469 8967 2658

2005-06 4081 0.597 0.774 9029 2445

2006-07 3895 0.615 0.574 9927 2403

Unit No. #6 Commercial Operation w.e.f. 1st Aug. 2004.

Year

Unit-5

GCV of Coal in

Kcal/Kg

SP.Coal

consumption(kg/kwh)

SP.Oil consumption

(ml/kwh)

Avg GCV of Oil

(Kcal/Ltr.)

Heat Rate (Kcal/Kwh)

2000-01 4289 0.611 0.789 9009 2627

2001-02 4227 0.638 0.567 9033 2702

2002-03 3926 0.654 0.399 9010 2571

2003-04 3906 0.684 0.430 9017 2675

2004-05 3938 0.664 0.633 9016 2621

2005-06 4073 0.633 0.543 9027 2582

2006-07 3901 0.669 0.679 9929 2617


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UNIT WISE & STATION WEIGHTED AVERAGE GCV OF COAL

FOR THE YEAR 2000-01 to 2006-07

Year

STATION

Station HR as

per RERC/CERC Norms

Design

SHR

GCV of Coalin Kcal/Kg

SP.Coalconsumption

(kg/kwh)

SP.Oilconsumption

(ml/kwh)

Avg GCV ofOil

(Kcal/Ltr.)

Heat Rate(Kcal/Kwh)

2000-01 4389 0.604 0.682 9005 2657

2348 Kcal/Kwh

2001-02 4300 0.611 0.628 9052 2633

2002-03 4131 0.635 0.431 9083 2627

2003-04 4022 0.670 0.394 9018 2698

2004-05 3927 0.672 0.671 9000 2645 2645

2005-06 4041 0.650 0.483 9084 2632 2621

2006-07 3932 0.675 0.572 9932 2661 2616


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STACK EMISSION & AMBIENT AIR QUALITYDATA FOR 2007-08

SPM SO2 NOx CO RPM

Stg-IV

(1x195 MW)

ug/C

um

ug/C

um

ug/C

um

ug/C

um

ug/C

um

Unit-I Unit-IIn t-

IIIUnit-IV Unit-V Unit-VI

150 150 150 150 150 150 500 120 120 5000 120

Apr 2007 118 126 130 120 51 85 194 17 12 640 86

May 2007 105 113 119 110 64 60 191 17 12 507 82

Jun 2007 131 125 124 68 54 61 176 14 11 554 76

Jul 2007 S/D S/D 115 121 111 70 159 10 8 517 66Aug 2007 114 S/D 122 120 112 68 180 10 8 509 79

Sep 2007 S/D 113 123 100 75 50 173 11 9 506 80

Oct 2007 123 128 110 131 45 186 10 9 512 82

Nov 2007 126 130 121 78 47 194 10 8 498 82

Month

Average Stack Emission Average Ambient Air Quality

SPM (mg/N.cum)

Stg-I (2x110

MW)

Stg-II & III (3 x 210

MW)

Permissible

limit (Max.)

SPM SO2 NOx CO RPM

Stg-IV

(1x195 MW)

Unit-I Unit-IIn t-

IIIUnit-IV Unit-V Unit-VI

150 150 150 150 150 150 500 120 120 5000 120

Apr 2007 118 126 130 120 51 85 194 17 12 640 86

May 2007 105 113 119 110 64 60 191 17 12 507 82

Jun 2007 131 125 124 68 54 61 176 14 11 554 76

Jul 2007 S/D S/D 115 121 111 70 159 10 8 517 66Aug 2007 114 S/D 122 120 112 68 180 10 8 509 79

Sep 2007 S/D 113 123 100 75 50 173 11 9 506 80

Oct 2007 123 128 110 131 45 62.12 186 10 9 512 82

Nov 2007 126 130 121 78 47 92.32 194 10 8 498 82

Permissible

limit (Max.)

Month


SPM (mg/N.cum)

Stg-I (2x110

MW)

Stg-II & III (3 x 210

MW)


10/63

STACK EMISSION & AMBIENT AIR QUALITY DATA 2006-07

Month


SPM (mg/N.cum) SPM SO2 NOx CO RPM

Stg-I(2x110 MW)

Stg-II & III(3 x 210 MW)

Stg-IV(1x195MW)

ug/Cum

ug/Cum

ug/Cum

ug/Cum

ug/Cum

Unit-IUnit-

IIUnit-

IIIUnit-

IVUnit-V Unit-VI

Permissible limit(Max.)

150 150 150 150 150 150 500 120 120 5000 120

Apr 2006 60 68 98 69 61 70 200 16 13 607 91May 2006 78 S/D 110 84 62 66 191 30 27 512 83

Jun 2006 94 105 S/D 106 89 87 191 20 17 490 84

Jul 2006 S/D 93 89 68 61 73 184 18 15 446 77

Aug 2006 65 106 107 128 71 76 168 11 9 455 66

Sep 2006 111 112 123 S/D 96 87 168 14 11 559 73

Oct 2006 102 123 119 88 117 92 153 15 13 567 67

Nov 2006 86 101 99 75 86 93 158 17 14 557 70

Dec 2006 103 107 107 59 81 89 159 15 18 546 66

Jan 2007 72 110 120 64 51 89 173 16 19 490 75

Feb 2007 113 129 74 93 45 89 174 12 15 528 74

Mar 2007 123 S/D 106 96 52 89 170 16 11 491 73


11/63

TRADE EFFLUENT ANALYSIS RESULT OF KSTPS

Month

Condenser Cooling Water Stage-I Condenser Cooling Water Stage-II&III

pH Temp.inlet C

Temp.outet C

Temp.Diff. C

Free ofmg/lt

pH Temp.inlet C

Temp.outet C

Temp.Diff. C

Free ofmg/lt

Max. limit 6.5-8.5 10 0.5 6.5-8.5 10 0.5

Apr 06 7.9 33.6 42.2 8.6 Nil 7.9 33.6 40.0 6.4 Nil

May 06 8.1 35.4 44.0 8.6 Nil 8.1 35.4 43.1 7.7 Nil

Jun 06 7.9 35.4 44.0 8.6 Nil 8.0 35.4 43.0 7.6 Nil

Jul 06 7.7 33.6 42.3 8.7 Nil 7.7 33.6 41.7 8.1 Nil

Aug 06 7.7 31.2 39.5 8.3 Nil 7.8 31.2 38.7 7.5 Nil

Sep 06 7.8 30.0 38.8 8.8 Nil 7.7 30.0 38.0 8.0 Nil

Oct 06 7.6 29.8 38.3 8.5 Nil 7.7 29.8 36.5 6.7 Nil

Nov 06 7.7 28.5 37.2 8.7 Nil 7.7 28.5 36.2 7.7 Nil

Dec 06 7.7 23.0 32.0 9.0 Nil 7.8 23.0 31.0 8.0 Nil

Jan 07 7.7 23.2 32.0 8.8 Nil 7.8 23.2 31.2 8.0 Nil

Feb 07 7.7 25.5 34.4 8.9 Nil 7.7 25.5 33.5 8.0 Nil

Mar 07 7.8 26.5 35.2 8.7 Nil 7.8 26.5 34.6 8.1 Nil


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Month

Cooling Tower Stage-IV Ash pond

Free clmg/lt.

Zincmg/lt

Cromiummg/lt

Phosphatemg/lt

pH TSSmg/lt

oil& greasemg/lt

Max. limit 0.5 1.0 0.2 5.0 6.5-8.5 100.0 20.0

Apr 06 Nil ND ND 0.63 7.59 69.00 4.80

May 06 Nil ND ND 0.60 7.65 63.00 5.20

Jun 06 Nil ND ND 0.61 7.52 56.00 4.10

Jul 06 Nil ND ND 0.62 7.43 59.00 3.90

Aug 06 Nil ND ND S/D 7.41 69.20 5.00

Sep 06 Nil ND ND 0.68 7.35 71.00 4.40

Oct 06 Nil ND ND 0.68 7.47 66.0 5.40

Nov 06 Nil ND ND ND 7.66 65.0 4.70

Dec 06 Nil ND ND ND 7.56 68.00 5.10

Jan 07 Nil ND ND ND 7.50 73.00 4.50

Feb 07 Nil ND ND 2.1 7.45 68.00 3.10

Mar 07 Nil ND ND 1.2 7.35 65.00 3.60


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Month

Boiler blow down mix drain Unit-IV Boiler blow down mix drain Unit-V Boiler blow down mix drain Unit-VI

TSS

mg/lt

Oil &

Grease

mg/lt

Cu.

mg/lt

Fe

mg/lt

TSS

mg/lt

Oil &

Greasemg/lt

Cu.

mg/lt

Fe

mg/lt

TSS

mg/lt

Oil &

Greasemg/lt

Cu.

mg/lt

Fe

mg/lt

Max. limit 100.0 20.0 1.0 1.0 100.0 20.0 1.0 1.0 100.0 20.0 1.0 1.0

Apr 06 5.20 1.10 0.10 0.11 5.10 1.00 0.10 0.10 5.20 1.1 0.10 0.11

May 06 5.10 1.00 0.10 0.10 5.20 1.10 0.10 0.11 5.20 1.10 0.10 0.10

Jun 06 5.10 1.00 0.10 0.10 5.20 1.10 0.10 0.10 5.20 1.10 0.10 0.10

Jul 06 5.20 1.04 0.10 0.10 5.10 1.00 0.10 0.10 5.16 1.02 0.10 0.10

Aug 06 5.10 1.00 0.10 0.11 5.20 1.05 0.10 0.11 S/D S/D S/D S/D

Sep 06 S/D S/D S/D S/D 5.30 1.10 0.10 0.11 5.20 1.10 0.10 0.11

Oct 06 5.08 1.00 0.10 0.10 5.08 1.00 0.10 0.10 5.10 1.00 0.10 0.10

Nov 06 5.20 1.05 0.10 0.10 5.07 1.03 0.10 0.10 5.15 1.05 0.10 0.10

Dec 06 5.32 1.02 0.10 0.10 4.97 1.00 0.10 0.10 4.95 1.00 0.10 0.10

Jan 07 5.13 1.00 0.10 0.10 5.07 1.10 0.10 0.10 5.13 1.00 0.10 0.10

Feb 07 5.70 0.42 0.01 0.11 5.00 0.18 0.01 0.11 5.50 0.43 0.01 0.10

Mar 07 5.25 1.00 0.01 0.11 4.50 1.00 0.01 0.09 4.50 1.00 0.01 0.10


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Month

Boiler blow down mix drain Unit-I Boiler blow down mix drain Unit-II Boiler blow down mix drain Unit-III

TSSmg/lt

Oil &Greas

emg/lt

Cu.mg/lt

Femg/lt

TSSmg/lt

Oil &Greasemg/lt

Cu.mg/lt

Femg/lt

TSSmg/lt

Oil &Greasemg/lt

Cu.mg/lt

Femg/lt

Max. limit 100.0 20.0 1.0 1.0 100.0 20.0 1.0 1.0 100.0 20.0 1.0 1.0

Apr 06 5.20 1.00 0.10 0.11 5.20 1.00 0.10 0.10 5.30 1.10 0.10 0.11

May 06 5.20 1.10 0.10 0.10 5.20 1.10 0.10 0.11 5.20 1.10 0.10 0.11

Jun 06 5.10 1.00 0.10 0.10 5.10 1.00 0.10 0.11 S/D S/D S/D S/D

Jul 06 5.20 1.15 0.10 0.11 5.20 1.12 0.10 0.11 5.12 1.05 0.10 0.10

Aug 06 5.07 1.00 0.10 0.10 5.07 1.00 0.10 0.10 5.17 1.02 0.10 0.10

Sep 06 5.05 1.00 0.10 0.10 5.10 1.00 0.10 0.10 5.07 1.00 0.10 0.10

Oct 06 5.20 1.10 0.10 0.11 5.12 1.04 0.10 0.10 5.16 1.04 0.10 0.10

Nov 06 5.02 1.00 0.10 0.11 4.80 1.03 0.10 0.10 5.10 1.00 0.10 0.10

Dec 06 5.07 1.02 0.10 0.10 4.87 1.00 0.10 0.10 5.02 1.00 0.10 0.10

Jan 07 5.10 1.00 0.10 0.10 5.03 1.00 0.10 0.10 5.13 1.00 0.10 0.10

Feb 07 7.00 0.35 0.01 0.1 5.2 0.45 0.01 0.10 6.50 0.41 0.01 0.10

Mar 07 5.70 1.00 0.01 0.09 5.00 1.00 0.01 0.10 5.25 1.00 0.01 0.10


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ESP DATA

Unit

No.

Rating

(MW )

No. of

existingfields

No. of

fieldsadded

Efficiency of

revamped /retrofitted ESP

Designed

emission levelafterretrofitting

(in mg/Cu.M)

Month of

commi-ssioning

I 110 10 7 99.82% 105 Nov.93

II 110 10 7 99.82% 105 July, 94

III 210 24 4 99.84% 80 Sept. 92

IV 210 24 4 99.84% 80 July, 92

V 210 28 - 99.94% 30 March, 94

VI 195 28 - 99.94% 30 July, 03


16/63

DESIGN STACK DATAParticulars Stage-I

(2x110 MW)

Stage-II

(2x210 MW)

Stage-III

(1x210 MW)

Stage-IV

(1x195 MW)

Stack height (Mtr.) 180 (Onestack two

flues)

180 (One stackthree flues. Oneflue for Stg.III

180 (II stack) 180(Single)

Flue gas Temp. at inletof ESP in C

141 136 136 136

Assumed temp. at exit

point with 5 C Temp. fall

136 131 131 131

Stack top inside dia. (M) 4.125 4.90 4.90 4.50

Stack top inside venturidiameter (Mtr.)

3.20 4.13 4.13 4.13

Flue gas exit velocity atstack top 174 M (M/sec.)

13.84 18.7 18.7 18.7

Flue gas exit velocity atventuri (M/sec.)

25 27.4 27.4 27.4

Coal consumption(T/day) with ash content

2x2000

33.5% (ash)

2x3550

33.5% (ash)

1x3550

33.5% (ash)

1x3550

33.5% (ash)

Emission rate (Kg. hr)(Calculated from designgas flow & SPM)

74.8 100.1 87.6 87.6


17/63

ELECTROSTATIC PRECIPITATOR (ESPs) DESIGN DATA

S.No. Description Stage-I Stage-II Stage-III Stage-IV

1- Manufacturer BHEL BHEL BHEL BHEL

2- Arrangement(Inline) In line In line In line In line

3- Type of ESP Rigid frame Rigid frame Rigid frame Rigid frame

4- No.of ESP Boxes 4 2 2 2

5- Gas flow 198 m3 / Sec. 347 m3 / Sec. 348 m3 / Sec. 419 m3 / Sec.

6- Total gas treated 400 TPH 600 TPH 600 TPH 600 TPH

7- Gas temperature at inlet 141 Deg.C. 134 Deg.C. 129 Deg.C. 132 Deg.C.

8- Design efficiency 99.82% 99.84% 99.94% 99.94%

9- Number of bus sections 2 4 4 4

10- What % of bus sectionscan be de-emergized to

meet design efficiency

NA NA NA NA

11- Net specific collection area 128 m2/ m3 /Sec. 187 m2/ m3 /Sec. 331 m2/ m3 /Sec. 275 m2/ m3 /Sec.

12- Number of fields per boiler 17 28 28 28

13- Fields in operation at full load 17 28 28 28

14- Any fly ash treatment used No No No No

15- Hopper fly ash handling system Pneumatic Pneumatic Pneumatic Pneumatic


18/63

ELECTROSTATIC PRECIPITATOR (ESPs)Contd

16-Hopper heating system

design detail6 KW 6 KW 6 KW 6 KW

17- Type of supervisorycontrol for ESP

i-Monitoring of automatic

HV controlsAICE AICE ICE BAPCON

ii- T-R-Sets Manual Manual Manual Manual

iii- Rapping system Auto run Auto run Auto run Auto run

iv-Ash Hopper level

indicatorsNot installed Partly installed Auto Auto

v- Hopper Heaters Auto Auto Auto Auto

18-Is opacity used as a feed

back in controlNo No No No

19-Are there mass

emissions

or opacity regulatorylimits

150 mg/Nm3 150 mg/Nm3 150 mg/Nm3 150 mg/Nm3

20-Any co-relation done

between mass emissions

&

opacity

No No No No

21-Estimated power needs

for

ESP Control

715KVA 820 KVA 415 KVA 440 KVA

22-No x control & FGD

SystemNot installed Not installed Not installed Not installed


19/63

STEAM GENERATOR (BOILER)

INCLUDING DUCTS & VALVES :

Description Stage-I Stage-II Stage-III Stage-IVType Natural circulation, Single drum, Radiant reheat type,

Tangentially fired, balanced draught, Make: BHEL

Make BHEL

Size /Capacity 375 T/HR 880 T/HR 690 T/HR 670 T/HR

Steam Pressure (atboiler outlet)

138 Kg./sqm. 155 Kg./sqm. 155Kg./sqm.

155Kg./sqm.

Steam Temperature

(at boiler outlet)

540C

Type of air pre-heater Rotary regenerative tri sector

Fuel used :

Primary

Secondary

Others

Pulverised coal

HSD/FO/LSHS

Nil

Boiler efficiency 86.8% 86.1% 86.1% 86.1%

EQUIPMENT DETAILS

STEAM GENERATOR


20/63

STEAM GENERATORDescription Unit 1 & 2 Unit 3 & 4 Unit No. 5 Unit No. 6.

Manufacturer: M/s BHEL M/s BHEL M/s BHEL M/s BHEL

Type- Drum/Once Through: Drum Type Drum Type Drum Type Drum Type

Division Wall: Fusion welded wall

Balance Draft or Forced Draft: Balanced Draft

Operating Pressure With % Overpressure (Drum Pr. Inkg/cm)

148.96 164.9 164.9 164.9

Super Heater Pr. In kg/cm : 138 154.35 154.16 154

Super Heater & Reheater Outlet Tempr.: 540C 540C 540C 540C

Firing Configuration: Tangential Tilting

No. of Installed Pulverizer: 4 Nos. 6 Nos. 3 Nos. 3 Nos.

No. Pulverizers To Meet Design Steam Flow: 3 Nos. 4 Nos. 2 Nos. 2 Nos.

Type of Pulverizer: Bowl Mill Bowl Mill Ball Mill Ball Mill

Manufacturer: M/s BHEL M/s BHEL M/s BHEL M/s BHEL

No. of Burners Per Pulverizer: 4 Nos. 4 Nos. 8 Nos. 8 Nos.

Burner Manufacturer: M/s BHEL M/s BHEL M/s BHEL M/s BHEL

No. of Wall Soot Blowers: 40 Nos. 52 Nos. 56 Nos. 56 Nos.

No. of Retractable Soot Blower: 28 Nos. 24 Nos. 22 Nos. 18 Nos.

Soot Blowing Media (Air or Steam) Steam Steam Steam Steam

Rated Main Steam Flow - T/Hr. 338 TPH 630.8 TPH 630.8 TPH 627 TPH

Reheater Steam Flow - T/Hr. 316 TPH 567.8 TPH 567.8 TPH 563 TPH

Primary Fuel Coal Coal Coal Coal

Secondary Fuel - - - -

Ignition Fuel HSD/FO HSD/FO HSD/FO HSD/FO

Circulation (Natural or Forced?) Natural Natural Natural Natural

FANS MANUFACTURER


21/63

FANS MANUFACTURERDescription Unit 1 & 2 Unit 3 & 4 Unit No. 5 Unit No. 6.

Fans Manufacturer:

FD & ID (If Balanced Draft Furnace) M/s BHEL M/s BHEL M/s BHEL M/s BHEL

Primary Fans: M/s BHEL M/s BHEL M/s BHEL M/s BHEL

Numbers Installed PA Fan 3 Nos. 3 Nos. 3 Nos. 3 Nos.

Numbers Installed FD Fan 2 Nos. 2 Nos. 2 Nos. 2 Nos.

Numbers Installed ID Fan 3 Nos. 4 Nos. 5 Nos. 6 Nos.

Capacity SCFM Each PA Fan: 45.79 70.00 66.00 66.00

Capacity SCFM Each FD Fan: 48.57 105.30 89.00 89.00

Capacity SCFM Each ID Fan: 148.3 230.00 230.00 230.00

Total Discharge Pressure - (H2O At MCR For PA): 1300 1210 1220 1220

Total Discharge Pressure - (H2O At MCR For FD): 377 520 475 475

Total Discharge Pressure - (H2O At MCR For ID): 384 398 500 500

Total Suction Pressure- (H2O For FD/ID/PA?)

Controls Used (Blade Pitch, Inlet Vanes) PA IGV Damper Damper Damper

Controls Used (Blade Pitch, Inlet Vanes) FD IGV IGV IGV IGV

Controls Used (Blade Pitch, Inlet Vanes) ID Speed Speed Speed Speed

Motor Size - KW (FD/ID/PA) 300/850/820 800/1400/1250 600/1700/1250 1500/1700/1250

Type of Fans (Axial, Centrifugal?) FD Fan Radial Axial Axial Axial

Type of Fans (Axial, Centrifugal?) ID & PA Fan Radial Radial Radial Radial

Any Air Preheating of Air SCAPH SCAPH SCAPH SCAPH

Air Preheater Manufacturer : M/s BHEL M/s BHEL M/s BHEL M/s BHEL

Type (Coils In Duct Work?)

Source of Heat: Flue Gas Flue Gas Flue Gas Flue Gas

If Coils, Heating Medium In Coil: Steam Steam Steam Steam


22/63

MAIN & REHEAT STEAM TEMPEATUREDescription Unit 1 & 2 Unit 3 & 4 Unit No. 5 Unit No. 6.

- Main Steam Temperature 540C 540C 540C 540C

- Reheat Steam Temperature 540C 540

C 540

C 540

C

- Design Steam Temperatures 540C 540C 540C 540C

-Trend Over Load Range If Possible

Attemperator Requested At Full and Low Loads:

- Main Attemperator Flow 12.0 TPH 22.7 TPH 17.5 TPH 9.0 TPH

- Reheater Attemperator Flow - - - -

- Design Attemperator Temperatures - - - -

- Trend Over Load Range If Possible

Boiler Data Requested At Full and Low Loads:

- Fly ash & Bottom Ash LOI

- Exit Gas Temperature 120 C 120 C 120 C 120 C

- SO3 Dew point Temperature

- Coal Fineness Data (100 mesh) % 85-92 85-92 98-99 98-99

- Air Heater Leakage Based On Past Testing 12.50% 12.50% 12.50% 12.50%

- Design Air Heater Leakage

- Excess Air 3.40% 3.40% 3.40% 3.40%

- Design Excess Air 4.00% 4.00% 4.00% 4.00%

- Excess Air Curve Control Over Load Range

- Steam Coil Preheating Flow

- Number of SB Out of Service & Location Nil Nil Nil Nil

- Operator Soot blower Guideline. Yes Yes Yes Yes


23/63

BOILER AUXILIARIES :

Description Stage-I Stage-II Stage-III Stage-IV

(a) I.D. FANS:

Type Radial Radial Radial Radial

Size /Capacity 850 KW

143 Cum/sec.

1400 KW

230 Cum/sec.

1700 KW

230 Cum/sec.

1700 KW

230 Cum/sec.

Quantity (Nos.) 2x3 2x3 1x3 1x3

(b) F.D. FANS:

Type Radial Axial Axial Axial


48.57 Cum/sec.

800 KW

105.3 Cum/sec.

600 KW

89 Cum/sec.

600 KW

89 Cum/sec.

Quantity (Nos.) 2x2=4 2x2=4 2 2

(c) P.A. FANS:

Type Radial Radial Radial Radial


45.79 Cum/sec.

1250 KW

70 Cum/sec.

1250 KW

66Cum/sec.

1250 KW

66Cum/sec.

Quantity (Nos.) 2x2 2x2 3 3

EQUIPMENT DETAILS


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(d) COAL MILLS:

Type

PressurisedBowl Mills

PressurisedBowl Mills

PressurisedTube Mills

PressurisedTube Mills

Size /Capacity 34 T/HR

340 KW

36.9 T/HR

340 KW

78.5 T/HR

2100 KW

78.5 T/HR

2100 KW


EQUIPMENT DETAILS


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COAL FEEDERS

Description Unit 1 & 2 Unit 3 & 4 Unit No. 5 Unit No. 6.

Coal Feeder Manufacturer: M/s BHEL M/s BHEL M/s BHEL M/s BHEL

No. of Feeders 4 Nos. 6 Nos. 6 Nos. 6 Nos.

Type (Gravimetric?): Volumetric Gravimetric Gravimetric Gravimetric

Economizer Inlet Temperature F: 238C 244C 246C 246C

Air Heater Manufacturer M/s BHEL M/s BHEL M/s BHEL M/s BHEL

Type : Rotay Regenrative Tri sector

Number- Primary 2 Nos. 2 Nos. 2 Nos. 2 Nos.

Secondary - - - -

Design Gas Temperature Leaving Air Heater

Excluding Air Leakage, F : - - - -

Including Air Leakage, F : 145 C 132 C 136 C 134 C

Boiler Bottom - Wet or Dry: Wet Wet Wet Wet

Source of Attemperator Water

For Superheater Feed Water Feed Water Feed Water Feed Water

For Reheater: Feed Water Feed Water Feed Water Feed Water

Control System provided With Steam Generator Yes Yes Yes Yes

Combustion and Burner Controls: Auto Auto Auto Auto

Q S


26/63

(B) TURBINE


Type Three casing, condensingsteam impulse turbinewith reheating & nonregulated 8 Nos.extractions without HP/LPbypass.

Three casing, condensing steamreaction turbine with reheating nonregulated 6 Nos. extractions with HP/LPbypass.

Make BHEL (SKODA) BHEL (KWU)

No. of stages percylinder

HP 8

IP 12

LP 2x4

HP 25

IP 2x20

LP 2x8

HP 25

IP 2x19

LP 2x8

Exhaust Pressure 0.10 Kg./cm2 0.1033 Kg./cm2 0.1187 Kg./cm2

Exhaust Temp. 46 Deg.C 49 Deg. C

Critical speed 1500 to 2500 RPM 1526 to 2127 RPM

Type of governingsystem

Nozzle Throttle

Type of governing

/control fluid

Turbine Oil -46

EQUIPMENT DETAILS

EQUIPMENT DETAILS


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TURBINE AUX. :(a) Boiler Feed Pump:

Type 200 KHI FK 6D30 FK 6D30 FK 6D30


(4000 KW)

387 Cum/HR

(3500 KW)

445 Cum/HR

(4000 KW)

445 Cum/HR

(4000 KW)


(b) C.E.P.

Type

150 CJWS CanisterEN5J40D30A

CanisterEN5J40D30A

CanisterEN5J40D30A


(225 KW)

687 Cum/HR

(500 KW)

662 Cum/HR

(500 KW)

662 Cum/HR

(500 KW)


EQUIPMENT DETAILS


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(c) C.T. Pump

Type

WKS CHC100/320

CHC100/320

CPHM 80-32

Size /Capacity 68.38CUM/HR

(55 kw)

100 CUM/HR

(15 KW)

100 cum/hr

(15 KW)

75 M/HR.(15 kw)

Quantity (Nos.) 2x4=8 2X3=6 3 2

EQUIPMENT DETAILS


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PLANT COMPONENT & DESIGN INFORMATION

S.No. Equipment Unit #1&2

Stg.I

Unit #3&4

Stg.II

Unit #5&6

Stg. III & IV

1 TURBINE

(a) Manufacturer BHEL,Hyderabad BHEL BHEL

(b) Type 3 Casing condensingsteam turbine (impulsetype with two curtis wheelin HP Stage) withreheating and nonregulating extraction

3 Cylinders tandumcompound / reaction,reheat, regerative/condensing turbine

Same as Unit # 3 & 4

(c) Guaranteed Grossrating MW

110 MW 210 MW Unit # 5 -210 MWUnit # 6 195 MW

(d) Design ExhaustPressure

0.10 abs 0.1033 abs 0.1033 abs

(e) Design inletsteam conditionPr./Temp.

MS Pr. 130 ata 535 Deg.C

RH Pr. 31.63 ata 535

Deg.C

MS Pr. 150 Kg/CM2 535Deg.C

RH Pr. 34.55 Kg;/cm2 535Deg.C


-do-

(f) Design Steamflow

363.5 TPH 632.76 TPH U # 5 628 TPH

U # 6 626 TPH

(g) Provision for overpressureoperation Yes/No%

Over Pr. Ms 146 ata OverTemp. 545 Deg.C

Over Pr. RH 35 ata OverTemp. 545 Deg.C

Yes but limited to 12 hrs.per year

Yes but limited to 12hrs. per year


30/63


SNo. TURBINE Unit #1&2

Stg.I

Unit #3&4

Stg.II

Unit #5&6

Stg. III & IV

C.E.P. : Condensate Pump

a) Manufacturer BHEL BHEL BHEL

b) No. of pumpsinstalled

3 Nos. 2 Nos. Unit # 5 : 2

Unit # 6 : 2

c) No. required at fullload 2 Nos. 1 No. Unit # 5 : 1 No.Unit # 6 : 1 No.

d) Capacity of eachlbs/hr. at Temp. rating

350 lbs/hr. at 40 Deg.C (160TPH)

1381 lbs/Hr. (627 TPH) Unit # 5 : 1458 lbs/Hr.

Unit # 6 : 1458 lbs/hr.

e) Design head at temp.rating

270 M WCL at 40 deg.C 21 Kg/cm2 Unit # 5 : 21 Kg/cm2

Unit # 6 : 21 Kg/cm2

f) Type of Pump Vertical, Multistage withelectric drive

Vertical, Multistage,centrifuge pump withElectric drive


g) Stages 8 Stages 5 Stages U # 5 : 6 Stages

U # 6 : 6 Stages

h) Type of flow control Through pneumatic control

valve

Through pneumatic

Control Valve

Same as Unit # 3 4


31/63


S.No. TURBINE Unit #1&2

Stg.I

Unit #3&4

Stg.II

Unit #5&6

Stg. III & IV

Main Condenser


b) Type Two pass, divided waterbox type

Two pass, Surface type Two pass surfacetype

c) Surface area(Sq.ft)

36360 Sq.ft (3380 M2) 123668 Sq.ft 123668 Sq.ft for eachunit

d) No. of pass Two Two for each unit Two for each unit

e) No. of shells 4 (Two shells percondenser)

One for each unit One for each unit

f) Designcondensate flowrate

259 TPH 435 TPH 435 TPH

g) Design condenserback pressure

0.10 abs 0.1033 abs 0.1033 ABS


32/63



Stg.I

Unit #3&4

Stg.II

Unit #5&6

Stg. III & IV

h) DesignCirculatingWater Inlettemp.

32 deg.C 33 Deg.C for each unit 33 Deg.C for eachunit

i) Design circulatingwater flow

15400 TPH for bothcondenser

27000 TPH each unit Same as Unit # 3 & 4

j) Tube length /

OD/Gauge

7500mm / 22mmm /1 mm

thk

7.5mm/ 25,4mm/ 1 mm

same for both units

7.6 M/25.4mm/ 1mm

k) Material tube

Tube sheet

Aluminium brass/ CuproNickel 90-10

Rolled steel plate

Cupro Nickel 90-10 samefor both units

Mild steel

Cupro Nickel 90-10same for both units

Mild steel

l) Method of tubesheet installed

(Rolled) ?m) Designed water

circulation flowrate

2m/sec. 1.81m/sec. 1.81m/sec.

n) Design water boxpressure

3.5 Kg/cm2 3.5 Kg/cm2 U # 5 : 3.5 Kg/cm2

U # 6 : 3.5 Kg.cm2


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Stg.I

Unit #3&4

Stg.II

Unit #5&6

Stg. III & IV

o) Orientation(transerverse)

p) Multi pressure No Single pressure No single pressure No Single pressure

q) Temp. rise 9.25 Deg.C 8.76 Deg.C for each unit 8.76 Deg.C for eachunit

r) Type of airremovalequipment (Mech.Vac. Pump)

Through steam jet ejector Through steam jet ejector U # 5 : Throughsteam jet ejector

U # 6 : Vacuum pumpwith steam jet ejector

s) Type of tubecleaning system

NIL NIL NIL

t) Type of

Expansion Joints

Rubber expansion joint Rubber expansion joint Rubber expansion

joint

v) Any Aux.condenser

No No No


34/63



Stg.I

Unit #3&4

Stg.II

Unit #5&6

Stg. III & IV

FEED WATER HEATER


b) By Pass capability Yes Yes Yes

c) Low Pressure:

i) No.of stages

ii) No.of heaters

iii) Location ofheaters & Stages

(Condenser Neck)

5

7

3 Heaters are locatedoutside condenser and 4heaters on LP casing

3

3

All 3 Heaters are outsidethe condenser

3

3


d) High Pressure

i) No.of Stages

ii) No.of heater

per stage

iii) Tube material

iv) Configuration

One

One

Stainless steel SS-304

LP Heater Vertical, Crossflow, Four Pass

HP Heater Vertical ,Cross flow, Double pass

Two

One

SS-304

LP Heater Vertical ,Cross flow, Double pass

Two

One

SS-304



35/63

PLANT COMPONENT & DESIGN INFORMATIONS.No. TURBINE Unit #1&2

Stg.I

Unit #3&4

Stg.II

Unit #5&6

Stg. III & IV

DEAERATING HEATERa) Heater Type Re-boiling Spray Tray type At 24 M elevation Spray

tray reboiling typeAt 24 M ElevationSpray Tray Reboilingtype

b) Physical location At 42 M Elevation

c) Storage capacity 265000 lbs (120 tonnes) 286000 lbs (130 Tonnes) 286000 lbs (130Tonnes)

d) CondensateCentering Temp.

Leaving

304 Deg. F (151 Deg.C)

350 Deg. F (176 Deg.C)

248 Deg. F (120 Deg.C)

323 Deg. F( 162 Deg.C)

248 Deg. F (120 Deg.C)

323 Deg. F (162 Deg.C)

BOILER FEEDPUMP


b) Numbers Two Three Three

c) Capacity Per Hr. 980000 lbs / Hr. (445 TPH) 852000 lbs/Hr. (387 TPH) 980000 lbs/Hr. (445TPH)

d) Design SuctionHead Pressure

7.83 atg 16 Kg/cm2 16 Kg/cm2

e) Design Pressurehead dischargePr.

177.85 atg 209.1 Kg/cm2 U # 5 : 212.7 Kg/cm2

U # 6 : 212. 7 Kg/cm2


36/63



Stg.I

Unit #3&4

Stg.II

Unit #5&6

Stg. III & IV

f) Boiler feed pumpdrive

(i) Elect. Or Steam Electric drive Electric Drive Electric drive

(ii) Manufacturer BHEL BHEL BHEL

(iii) Horse Power 5362 HP (4000 KW) 4691 HP (3500 KW) U # 5 : 4691 HP (3500KW)

U # 6 : 5362 HP (4000 KW)

EQUIPMENT DETAILS


37/63

(B) GENERATOR


Make BHEL

Type 234260 / 2 H THW-210-2A THW-210-2A THRI 108/44

Rated capacity 137.5 MVA 247.0 MVA 247.0 MVA 229.4 MVA

Power factor 0.80 Lagging 0.85 Lagging

Frequency 50 Hz.

EQUIPMENT DETAILS


38/63

GENERATOR WITH SEAL OIL SYSTEM,

HYDROGEN GAS/ STATOR COOLINGWATER SYSTEM


Type TG234260/2H THW-210-2A THW-210-2A THRI108/44

Size /Capacity 137.5 MVA 247.0 MVA 247.0 MVA 229.4 MVA


EQUIPMENT DETAILS

EQUIPMENT DETAILS


39/63

EQUIPMENT DETAILS(C) GENERATOR

SNo. Particulars Unit #1 Unit #2 Unit #3 Unit #4 Unit #5 Unit #6

1. Manufacturer BHEL BHEL BHEL BHEL BHEL BHEL2. Type of excitation system Static Static Static Static Static Brushless

3. Rotor Cooling Media Hydrogen Hydrogen Hydrogen Hydrogen Hydrogen Hydrogen

4. Stator Cooling Media Hydrogen Hydrogen DM water &Hydrogen

DM water &Hydrogen

DM water &Hydrogen

Hydrogen

5. Rating 137.5 MVA 137.5 MVA 247 MVA 247 MVA 247 MVA 229.41 MVA

6. Maximum gross outputwith valves wide open(with design exhaustpressure, makeup over

110 MW 110 MW 210 MW 210 MW 210 MW 195 MW

7. Approx. Aux. Power

8. Maxm. Net output (Gross-Aux.) MW

9. Voltage- KV 11 KV 11 KV 15.75 KV 15.75 KV 15.75 KV 15.75 KV

10. Amperes 7220 Amp. 7220 Amp. 9050 Amp. 9050 Amp. 9050 Amp. 8410 Amp.

11. Power factor 0.8 Lag. 0.8 Lag. 0.85 Lag. 0.85 Lag. 0.85 Lag. 0.85 Lag.

12. Short circuit ratio 0.5 0.5 0.49 0.49 0.49 0.48

13. Normal/ Maxm. H2pressure

2.00 Kg./cm

2.30 Kg./cm

2.00 Kg./cm

2.30 Kg./cm

3.50 Kg./cm

3.70 Kg./cm

3.50 Kg./cm

3.70 Kg./cm

3.50 Kg./cm

3.70 Kg./cm

2.00 Kg./cm

2.20 Kg./cm


40/63


TRANSFORMERS

(a) Generator

Transformers

Type 11/220 KV 15.75/240KV

15.75/240KV

15.75/240KV

Size /Capacity 125 MVA 250 MVA 250 MVA 250 MVA

Quantity (Nos.) 2 1 1

(b) Station

Transformers

Type 220/7/7 KV 220/7/7 KV 220/7/7 KV

Size /Capacity 50 MVA 50 MVA 50 MVA

Quantity (Nos.) 2 1 1

EQUIPMENT DETAILS


41/63


(c) ServiceTransformers

Type :

0.5 MVA - 1+1 - -

1.0 MVA 9 6 2 1

1.6 MVA 4 12 6 3+2

2.0 MVA - 6 4 2

Total :

0.5 MVA 2 Nos. (Oil-1 No.+ Dry-1 No.)

1.0 MVA 18 Nos. (Oil 18 Nos.)

1.6 MVA 27 Nos. (Oil 25 No. + Dry - 2 Nos.)

2.0 MVA 12 Nos. (Oil 10 Nos. + Dry 2 Nos.)

EQUIPMENT DETAILS

EQUIPMENT DETAILS


42/63


COMMON AUXILIARIES:

(A) Clarification cum filtration Plant

Type Clarifiocculator bridge & rapid gravity filter bed

Size /Capacity Rated -1000

Cum/HrMax,. 1250

Cum/Hr

Rated -1750

Cum/HrMax,. 2000

Cum/Hr

Rated -500

Cum/Hr

Rated -500

Cum/Hr

Quantity (Nos.) 1 1 1 1

(B) C.W. SYSTEM :

Type Vertical shaft mixed flow turbine pumps

Size / Capacity 8.275

Cum/Hr.

16.000

Cum/Hr.

16.000Cum/Hr.

16.000Cum/Hr.

Quantity 5 5 3 3

EQUIPMENT DETAILS

EQUIPMENT DETAILS


43/63


(C)D.M. Cum-Softening Plant

Type Ion exchange process

Size /Capacity DM Plant

Rated 60 Cum/Hr

Max. 70 Cum/Hr.

Soft Plant

Rated 100 Cum/Hr.

Max. 125 Cum/Hr.

DM Plant

Rated 80 Cum/Hr

Max. 90 Cum/Hr.

Soft Plant

Rated 210

Cum/Hr.Max. 210 Cum/Hr.

DM Plant

Rated 80 Cum/Hr

Max. 90 Cum/Hr.

Soft Plant

Rated 210 Cum/Hr.

Max. 210 Cum/Hr.

Quantity (Nos.) DM plant-2

Soft plant-4

DM plant-3

Soft plant-3

DM plant-1

Soft plant-1

(D) Electro Static Precipitator

Type 2FAA-5X32-11090-2 FAA-6x36(36)-2x90125-2 FAA-7x45-2x1092135-2 FAA-7x45-2x1092135-2

Size / Capacity 128 m/m/sec. 187 m/m/sec. 331.7 m/m/sec. 275.8m/m/sec.

Quantity 2 2 1 1

EQUIPMENT DETAILS

EQUIPMENT DETAILS


44/63


(E) Ash Handling Plant

Type B.A. - Wet system

Fly Ash - Pneumatic/ Wet system

Size /Capacity BA 80 TPH

FA 85 TPH

BA 2x 80TPH

FA 180 TPH

BA 2x76 TPH

FA 148 TPH

BA 2x76 TPH

FA 148 TPH

Quantity (Nos.) 1 1 1 1

(F) Bearing Cooling Water System

Type Recirculation typeclose cycle

Recirculationtype closecycle



Size / Capacity 500 CUM/Hr.

1100 CUM/Hr.

1100 CU M/Hr. 3000 CU M/Hr.

Quantity 5 8 4 2

EQUIPMENT DETAILS

EQUIPMENT DETAILS


45/63


(G)Air Compressor

Type Reciprocating type

Size /Capacity (i)

(ii)

(iii)

600 Cfm

200 Cfm

15 Cum/Min.

600 Cfm 600 Cfm 19.7Cum/Min

Quantity (Nos.)(i)

(ii)(iii)

2

44

7 5 5

(H) Hydrogen generating Plant

Type Electrolysis type

Size / Capacity 10 Cu M/Hr

Quantity (Nos.) 1

(I) Raw watersystem

Type - VT type -

Size / Capacity - 2400 M/Hr. -

Quantity (Nos.) - 6 -

EQUIPMENT DETAILS

EQUIPMENT DETAILS


46/63


(J) B.C.W. Raw water Pump Stg.I

Type VT type - - -

Size /Capacity 1200 M/Hr - - -

Quantity (Nos.) 3 - - -

(K) Clarified Raw Water pump Stage-I

Type VT type

Size / Capacity 600 M/Hr

Quantity (Nos.) 3

EQUIPMENT DETAILS

CIRCULATING WATER PUMPS


47/63

CIRCULATING WATER PUMPS

S.No. Technical Details Stage-I Stage-II Stage-III Stage-IV

1. Manufacturer M/s. WorthingtonPump India Ltd.

M/s. Jyoti Ltd. M/s. BHEL M/s. KBL

2. No. Installed 5 Nos. 5 Nos. 3 Nos. 3 Nos.

3. Capacity of each

design flow8275 M /Hr. 16000 M/Hr. 16000 M /Hr. 16000 M /Hr.

4. No. of operational atDesigned Unit Load

4 Nos. 4 Nos. 2 Nos. 2 Nos.

5. Design head 19.4 MWC 25.3 MWC 26.5 MWC 25.1 MWC

6. Type of pumps Vertical Turbine Vertical mixed flow Vertical mixed

flow

Vertical Turbine

7. Type of Motor 3 PhaseAsynchronous

motor

3 Phase squirrelcage CACW

motor

3 PhaseAsynchronous

motor

3 Phase squirrelcage motor

COOLING TOWER


48/63

COOLING TOWER1- Manufacturer M/s Gammon India Ltd.

2- Type IDCT

3- Design flow rate 34000 CMH(16 Cells)4- Heat Removed (10 K.Cal/Hr.) 275400 to 504900

5- Circulating water flow 34000 CMH(16 Cells)

6- Hot Water Temperature 42 C

7- Temperature range 42C to 32 C

8- Design Wet Bulb Temperature 27.8 C

9- Approach to wet bulb 4.2 C

10- Fill material / Depth Pre Cast RCC Splash bar / 3 Meter

11- Make up / blow down flow rate 600 M /Hr. / 300 M /Hr.

12- No. of Cells 16 + 2 (standby)

13- Chemical treatment used H2 SO4, Chlorine

14- Design Cycle of concentration 4.5 COC

WATER TREATING EQUIPMENT


49/63

WATER TREATING EQUIPMENT

Raw Water Quality information : Turbidity : 350 NTU ( Mansoon Average)pH : 8.0Total Hardness ( as CaCo3 ) : 100

Silica : 3 to 5 ppm

Water treatment equipment supplier : M/s Geo- Miller , Delhi.

Treatment stems involved :Raw water Clarification filtration- F.A.C - S.A. C. - W. B.A. - S.B.A. M.B ( DM Water)

Base Exchanger ( soft water )

Make Up water uses : Steam Cycle ( Boiler) , Stator cooling

Make Up water quality : pH : 6.8 to 7.2Conductivity : < 0.2 umho/ cmHardness : NilTotal silica : < 0.01ppmChloride : Nil

Make Up rate : - 50 to 60 M/hr.

Storage details for condensate makeup water :- 750 M in each unit No. 3,4,5,& 6& 300 M in each unit No. 1 & 2

Feed point for condensate make up : Hot Well

S O Q


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LIST OF PLANT EQUIPMENT

Sl.

No.

Description AHP Stage-I AHP Stage-II AHP Stage-III AHP Stage-IV

(2 x 110 MW) (2 x 210 MW) (1 x 210 MW) (1 x 195 MW)

1 ManufacturesBottom Ash

Handling

Design

M/s Indure Pvt. Ltd.,

New Delhi

M/s Burn Standard &

Company Ltd.,

Howrah, W.B.

M/s DCIPS Ltd., Kolkata,

W.B.M/s BHEL (ISG),

Banglore (K.S.)

2 Capacity ofbottom ash

hopper

Maximum coal consumption

at MCR is 75 Ton / hours at

3728 calorific value Kcal /

Kg. with ash contents of

42%

160 Ton / hours at

3728 calorific value

Kcal / Kg. with ash

contents of 42%

160 Ton / hours at 3728

calorific value Kcal / Kg.

with ash contents of 42%

160 Ton / hours at 3728

calorific value Kcal /

Kg. with ash contents

of 42%

Maximum bottom ash

collection value 7.5 MT per

hour Total for 8 hour shift 60

Tonnes

Maximum bottom ash

collection value 16

Tonnes per hour Total

for 8 hour shift 128

Tonnes

Maximum bottom ash

collection rate 16

Tonnes per hour.

Total collection in 8

hours of shift 128

Tonnes

Maximum bottom ash

collection rate 16

Tonnes per hour. Total

collection in 8 hours of

shift 128 Tonnes

3 Bottom ash

disposed to

Ash dyke (ash pond)

distance about 3.0 KM.

Ash dyke (ash pond)

distance about2.5 KM.

Ash dyke (ash pond)

distance about 2.5KM.

Ash dyke (ash pond)

distance about 2.0 KM.

4 Economizerash handling

and storage

design

420 Kg. x 4 ECO hoppers =

1680 Kg. / Hrs. / Unit

900 Kg. x 4 ECO

hoppers = 3600 Kg. /

Hrs./Unit

900 Kg. x 4 ECO hoppers

= 3600 Kg. / Hrs./Unit900 Kg. x 4 ECO

hoppers = 3600 Kg. /

Hrs./Unit

8 x 1680 = 13,440 Kg. in

each shift of 8 Hrs./Unit8 x 3600 = 28,800 Kg.

in each shift of 8

Hrs./Unit

8 x 3600 = 28,800 Kg. in

each shift of 8 Hrs./Unit

8 x 3600 = 28,800 Kg.

in each shift of 8

Hrs./Unit


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LIST OF PLANT EQUIPMENTContd..

Sl .

No.

Description AHP Stage-I AHP Stage-II AHP Stage-III AHP Stage-IV

(2 x 110 MW) (2 x 210 MW) (1 x 210 MW) (1 x 195 MW)

5 Fly ash handlingand storage

i) Both wet and dry i) Both wet and dry i) Both wet and dry i) Dry

(dry /wet, ash

pond / storageSilo)

ii) Ash ponds ii) Ash ponds ii) Ash ponds ii) Storage Silo

iii) Storage Silo iii) Storage Silo iii) Storage Silo a) 1 x 500 MT + 1x100

MT

a) 2 x 75 MT = 150 MT a) 1 x 200 MT a) 1 x 300 MT b) 2 x 500 MT

b) 1 x 500 MT b) 1 x 500 MT b) 2 x 500 MT

6 Fly ash handlingequipments

design details

(vacuum pumps

or wet pumps or

screw conveyors)

i) Water exhauster i) Water exhauster i) Water exhauster i) Dense phase

ii) Vacuum pumps (Mech.

Exhauster)ii) Vacuum pumps

(Mech. Exhauster)ii) Dense phase system ii) Vacuum pumps

(Mech.

Exhauster)

iii) Dense phase

system

C&I EQUIPMENT


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C&I EQUIPMENTS.No DESCRIPTION

STAGE - I STAGE II STAGEIII STAGE-IV,

UNIT # 1 & 2 UNIT # 3 & 4 UNIT # 5 UNIT # 6

1 Control Concept Used (Analog, digital,

distributed Microprocessor, etc.)

Analog Analog DCS (H&B)

Contronic-E

DCS (ABB)

Symphony Melody

2 Manufacturer I .L .Kota SIEMEN (BHEL), PROCONTROL MAX DNA (BHEL)

H&B (M/s ILK) (BHEL), Hartmann ABB, Symphony

& Braun ( IL Kota) Melody (ILK)

3 Operation Stations (CRTs or Panel

Mounted)

DESK Panel Mounted CRT CRT

(M/s ILK)

4 Alarm Station (CRTs or Annunciator) Annunciation Annunciator System CRT & Audio CRT & Audio

(M/s ILK) Visual Visual

5 Engineers Stations (CRTs) NIL Only for DAS CRT CRT

6 Data logging features (Strip charts, Only Records

available.

Data logging through DAS Data Acquisition Data Acquisition

Log sheets or Data logger) System System

7 Historical data storage and retrieval

capabilities.

-do- Yes, DAS

Symphony (ABB)

Yes Yes

8. Are major plant systems controlled by

Central Supervisory equipment or by

Standard Contractor supplied control

system (i.e. separate, Turbine-Generator

controls, Boiler feed pump controls,

Soot blower controls, Burner controls,

ESP), If so Manufacturers of

such controls for these systems.

Nil

C-34 Transdata

system supplied by

H&B and IL Kota.

Turbine: EAST

Packages (BHEL)

BFP's, Burner controls,.

Fam. Drum level,

Furnance Draft etc.

Contronic e (M/s. ILK)

Soot blowers :

Relay Logics

Central Supervisory

-do-

Central Supervisory

-do-

9 Balance of plant controls Combustion

controls, feed water and condensate,

minor plant loops, ash handling, coal

handling, water treatment.

Combustion

Control

Feed water

control.

ombustion Control

Feed water control.

Combustion Control

Feed water control,

Minor plant loops.

Combustion Control

Feed water control,

Minor plant loops.

EQUIPMENT DETAILS


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COAL HANDLING PLANT

(A) Locomotive

Type WDS-6

Size /Capacity 1400 HP

Quantity (Nos.) 2+1

(B) Locomotive

Type WDS-45


Quantity (Nos.)

(C ) Railway Track with associated Point &

Crossing Tack points etc.

Type Broad gauge

Size /Capacity 52 Kg. rails C-Class

Quantity (Nos.) 35+11

EQUIPMENT DETAILS

EQUIPMENT DETAILS


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(D) Wagon Tippler Area

(1) Wagon Tippler No. 1 & 4 with Beetle

Charger & Associated equipment Stg.I & II

Type Rotaside - - -

Size /Capacity 95 MT 12Tips/Hr.

- - -

Quantity (Nos.) 4 - - -

(2) Wagon Tippler No. 5 with associated equipment

such as Side Arm Charger Stg.III

Type Rotaside XL

Size /Capacity 100 MT 24 Tips/Hr.

Quantity (Nos.) 2

(3) Apron feeder

Type -

Size /Capacity 1350 TPH

Quantity (Nos.) 1

EQUIPMENT DETAILS

EQUIPMENT DETAILS


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(4) Scrapper Conveyor

Type -


Quantity (Nos.) 1

(5) Rotary Breaker

Type 12 x 21

Size /Capacity Rated 1350 TPH

Quantity (Nos.) 1

(6) Roll Crusher

Type 80 SA Breaker (Roll crusher)


Quantity (Nos.) 1(E) Crusher Area

(1) Crusher No. 2, 3& 6

Type Ring Graulator TK-16-54B


Quantity (Nos.) 3 Nos.

Q

EQUIPMENT DETAILS


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(2) Crusher No. 4, 5, &7

Type Ring Graulator, RG-721



(3) Crusher No. 8, 9 & 10

Type Ring GraulatorEKK 48X93



(F) FLOW FEEDER M/Cs AREA

Flow Feeder M/c. No. 1 & 2Type Rotary discharge machine block model



EQUIPMENT DETAILS

EQUIPMENT DETAILS


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Description Stage-I Stage-II

Stage-III

Stage-IV

(G) STACKER RECLAIMER AREA(1) Stacker Reclaimer M/c. (M/c. S.No. HM-225) & HM-313

manufactured & supplied by M/s. ELECON

Type ASK-550

Size /Capacity 1350 TPH Stacking & reclaiming


(H) DOZERS AREA:

(1) Dozer

Type BEML/Komatsu/ Cummins/D.155

Size /Capacity 320 HPQuantity (Nos.) 5 Nos.

(2) Dozer




EQUIPMENT DETAILS

EQUIPMENT DETAILS


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(H) DOZERS AREA:

(1) Dozer




(2) Dozer




EQUIPMENT DETAILS

EQUIPMENT DETAILS


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Description Stage-I Stage-II Stage-III

Stage-IV

(3) Dozer

Type TIL/Caterpillar/ D6H


Quantity (Nos.) 2

(I) (a) FUEL OIL DECANTING PUMPS AREA :

Type / Make FO -Flowmore

HSD -Flowmore

FO - Roto

HSD Roto

FO -Roto

Size /Capacity FO - 100 KL/H

HSD - 30KL/H

FO - 210 KL/H

HSD 100KL/H

FO -250

KL/H

Quantity (Nos.) FO 4

HSD 2

FO 4

HSD - 2

FO 2

EQUIPMENT DETAILS

EQUIPMENT DETAILS


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Stage-IV

(I) (b) OIL TANK AREA :Type

F.O. Tank

HSD Tank

LDO Tank

F.O.

H.S.D.

LDO Tank

3000 KL ( 2 Nos.)

700 KL (1 (No.)

700 KL (1 No.)

4120 KL (1 No.)

800 KL ( 1 No.)

800 KL (1 No.)

(J) WORKSHOP AREA :

(1) Lathe Machine Type : Vikram 1250 mm Bed, 390 mm dia. 1No.

(2) Lathe Machine Type : NH-26/1000, HMT, 575 mm dia. 1 No.

(3) Lathe Machine Type : NH-26/3000, HMT, 575 mm - 1 No.

EQUIPMENT DETAILS

EQUIPMENT DETAILS


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(4) Milling Machine Type : FN-30 `HMT make - 1 No.

(5) Tool Cutter Grinder Type : CTC-28/T `HMT make - 1 No.

(6) Radial Drill machine Type : RM-63 HMT Sr. No. 33174 (80 MM) -1 No.

(7) E.O.T. Crane 5 T capacity , Universal ropeways 1 No.

(8) Drill Machine (WNP) Bajaj DS -40, 1 - 1 No.

9) Power Hacksawmachine

1 No.

EQUIPMENT DETAILS

EQUIPMENT DETAILS


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Stage-IV

(10) Shaping machine ROP MODEL RPS-600 - 1 No.

(11) Power Hacksaw

(Hydraulic)

`BESTO Make, 8 1 No.

(12) Hydraulic press 100 MT 1 No.

(K) CONVEYOR SYSTEM AREA

Conveyor System of-

Type Nylone belts Nylone belts Nylonebelts

Nylonebelts

Size /Capacity 750 /1350 TPH 1350 TPH 1350TPH

1350 TPH

Quantity Stage-wise

(in Mtr.)

5689 5491 4415 356

Total Quantity 1595 Mtrs.

EQUIPMENT DETAILS


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power point presentatation of peer group

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