6.5 6.6 6.

Water Wall 6.5.1 Data Sheet Economizer 6.6.1. Data Sheet Super Heater System 6.7.1 Convection Super Heater. 6.7.2 Radiant Super Heater 6.7.3 Bed Super Heater 6.7.4 Bed Super Heater outlet link 6.7.5 Main Steam Pipe 6.7.6 Protection and control 6.7.7 Data Sheet 6.7.8 Data Sheet 6.7.9 Desuperheater 6.7.10 Data Sheet Feed water system 6.8.1 Deaerator 6.8.2 Design & Construction 6.8.3 Feed Water Storage Tank 6.8.4 Deareating heater 6.8.5 Shell 6.8.6 Tray and Spray valves 6.8.7 Data Sheet 6.8.8. Feed Water Pump 6.8.9. Pump capacity calculation 6.8.10 Pump Head Calculation 6.8.11 Feed Water control Air and Gas circuit 6.9.1 FD Air system 6.9.2 Tubular Air Heater 6.9.3 Ducting System 6.9.4 Primary Air System 6.9.5 Fuel Gas System Electrostatic Precipitator 6.10.1 ESP Design Basis Fans 6.11.1 Design Basis

6.8

6.9

6.10 6.11

6.12 6.13 6.14 6.15 6.16 6.17 6.18 6.19

Fuel & Ash System 6.12.1 Fuel System 6.12.2 Ash System Dosing System 6.13.1 LP Dosing 6.13.2 HP Dosing Flash Steam Recovery System Start-up oil Burner System Steam and Water Analysis System Insulation Refractory and Insulation Boiler structural and Auxiliaries 6.19.1 Structural Steel 6.19.2 Platform, Stairways & Grating Piping System 7.1 Power Cycle Piping 7.2 Low Pressure Utility Piping 7.3 Cooling Water Piping 7.4 Design Basis for Piping 7.5 Main Steam Piping 7.6 Boiler Feed Water Piping 7.7 Valves 7.8 Condensate Piping 7.9 Piping for Raw water, Cooling Water 7.10 Air Pipe Line 7.11 DM Water Pipe Line 7.12 Effluent 7.13 Service and Portable Water Pipe Line 7.14 Condenser Cooling Water Piping 7.15 Auxiliary Cooling Water Piping 7.16 Fire Water Piping PUMPS 8.1 General 8.2 Equipment Sizing (Head) 8.3 Special Technical Requirements / Materials selection of Pump COOLING TOWER 9.1 Cooling Tower sizing calculation 9.2 Cooling Tower Specification

7.0

8.0

9.0

10.0

WATER TREATMENT SYSTEM 10.1 Raw water system 10.2 Raw water cum Fire water storage Tank 10.3 Raw water Transfer pumps 10.4 Water Treatment plant system 10.5 Treated Water Distribution system FUEL HANDLING SYSTEM 11.1 Fuel Handling System sizing 11.2 System Description 11.2.1 Coal Storage System 11.2.2 Coal Reclaim System 11.2.3 Coal Crushing, Screening & Boiler Feeding System 11.3 General Design Basis 11.4 Technical particulars EOT CRANE 12.1 System Description 12.2 Technical particulars ASH HANDLING SYSTEM 13.1 Bed Ash handling system 13.2 Fly Ash handling system COMPRESSED AIR SYSTEM 14.1 Instrument Air System 14.1.1 Instrument Air Compressors 14.1.2 System Sizing 14.1.3 Technical Details of Instrument Air Compressor 14.1.4 Air Driers 14.1.5 Technical Particulars 14.1.6 Instrument Air Receiver 14.2 Service Air System 14.2.1 Service Air Compressor 14.2.2 Service Air Receiver CHIMNEY 15.1 Site Information & Design Criteria 15.2 Chimney sizing calculation 15.3 Highlights WASTER WATER MANAGEMENT SYSTEM AIR CONDITIONING AND VENTILATION SYSTEM HOLD FIRR FIGHTING AND PROTECTION SYTEM HOLD

11.0

12.0

13.0

14.0

15.0

16.0 17.0 18.0

19.0

ANNEXURES I. Water Treatment Plant Scheme II. Fuel Handling System Scheme III. General Arrangement of Chimney IV. Waste Water Management Scheme

1.0. INTRODUCTION AND SITE DATA 1.1. INTRODUCTION This document aims to establish the criteria for basic and detail Engineering, Sizing and specification of the Power Plant Equipment, Systems, Components and Piping for the 1 x 43 MW captive Power Plant at Sithapuram, Nalgonda District, Andhra Pradesh, being set up by M/s. Sithapuram Power Limited (SPL). The basic design inputs like Fuel analysis, Water analysis, Site conditions, etc, have been spelt out in various sections of this document, which is as per SPL inputs. This document is to be read in conjunction with design basis report for Electrical Systems, Civil Works and Instrumentation systems. Steam turbine generator including condensing plant is excluded from CVPL scope and hence not included in this document. It may be noted that during the course of Engineering, as more details are worked out and complete guaranteed details of equipment and systems are available from different Vendors, to be accommodated without compromising the overall plant performance, operability & reliability. 1.2 SITE DATA AMBIENT CONDITIONS Plant Elevation above Mean Sea Level (MSL) Temperatures - Maximum Temperature 50C - Amblent Temperature (Design) 36C - Minimum Temperature 8C - Plant Design Wet 27C Bulb Temperature - Plant Design Wet for 50C Electrical Equipment - Relative Humidity 85% Wind Design Wind Velocity Seismic Coefficient Zone Design Climatic Condition III As per IS 1893 2002 Hot and Dusty 112M

As per IS

Soil Bearing Capacity Finished Floor Level (FFL) Finished Ground Level (FGL) 2.0 2.1

25 Tons/m 2 (+) 72.5 m above MSL (+) 72.2 m above MSL

UNITS OF MEASUREMENTS AND ABBREVIATIONS UNITS OF MEASUREMENT TPH Deg. C KV KW MW MLC MWC No (s). Tons Per Hour Degree Celsius Kilograms per square Centimeter Kilo Wait Mega Wait Meters of Liquid Column Meters of Water Column Numbers (s)

2.2

ABBRIVATIONS DBR MSL FFL FGL RL STG FHS AHS CEP SHP HP LP PRDS PRV CV MCW ACW DM UF MCF RO SAC Design Basis Report Mean Sea Level Finished Floor Level Finished Ground Level Reference Level Steam Turbine Generator Fuel Handling System Ash Handling System Condensate Extraction Pump Superheated High Pressure High Pressure Low Pressure Pressure Reducing & De-superheating system Pressure Reducing Valve Control Valve Main Cooling Water System (for Condenser) Auxiliary Cooling Water System De-Mineralized System Ultra Filtration Micron Cartridge Filter Reverse Osmosis Strong Acid Cation exchanger

SBA MB TDH BFP EOT MOC 3. CODES & STANDARDS

Strong Base Anion exchanger Mixed Bed exchanger Total Dynamic Head Boiler Feed PumpElectrically operated overhead traveling crane Material of Consturction

The design and construction of the various systems., equipment & components will be in accordance with the relevant Indian and International Standards. This shall also be in accordance with the applicable laws and regulations of the Central / State Government and relevant Statutory bodies of the government. A summary of the codes and Industry standards acts & law generally to be used in the design and construction is listed below. International Standard Organization (ISO). International Electro-technical Commission (IEC) American Society of Mechanical Engineers (ASME) American National Standard Institute (ANSI) American Institute of Steel Construction (AISC) American Welding Society (AWS) Architecture Institute of Japan (AIJ) National Fire Protection Association (NFPA), USA. National Electrical Manufacturers Association (NEMA), USA. Japanese Electro-technical Committee (JEC) Institute of Electrical and Electronic Engineers (IEEE), USA. Federal Occupational Safety and Health Organization (OSHA), USA Instrument Society of America (ISA) National Electric Code (NEC), USA Heat Exchanger Institute (HEI), USA. Tubular Exchanger Manufacturer & Associates (TEMA), USA. Hydraulic Institute Standard (HIS), USA International Electro-technical Commission Publication. Performance Test code for Steam Turbines (PTC), USA DIN Standards British Standards (BS) Japanese Industrial Standards (JIS) Electric Power Research Institute (ERPI), USA Standards of Manufacturer Standardization Society (MSS), USA Bureau of Indian Standards (BIS) Indian Electricity Rules. Indian Boiler Regulation (IBR)

Environment (Protection) Act, USA Indian Explosives Act. Indian Factory Act. Loss Prevention Association of India (LPA) Emission regulations of Central Pollution Control Board (CPCB) India Pollution control regulations of Department of Environment, Govt. of India Central Board of Irrigation and Power (CBIP) Publications, India. American Water Works Association (AWWA) Tariff Advisory Committee (TAC)

If not mentioned otherwise, only the latest publication of the Codes & Standards will be used. In case for certain system / equipment / component where no national / international standard is available, general Good Engineering Practice will be followed. In some specific cases, Manufacturers Standard may be adopted if found to be proven and meeting the requirement of high degree reliability. 4. POWER PLANT CONFIGURATION 4.1 PLANT CONFIGURATION

The Power Plant consists of the following major Mechanical systems and equipment. Two (2) numbers Boilers: Atmospheric Fluidized Bed Combustion (AFBC) type, each generating 90 TPH at 89 kg/cm2 (a) pressure and 515C temperature at the Main Steam Valve. Two (2) number Electro static precipitator (ESP), one each per boiler designed for. 100 mg/nm3 with one field out of operation with 100% Performance Indian Coal firing. One (1) number RCC Chimney common for both the boilers. The height of the chimney will be 96.50 meters. One (1) number STG: Multi-stage, single flow, condensing type Steam Turbine Generator, with three bleeds for regenerative heating, generating 43 MW at 11 KV voltage level with an inlet steam at 85 kg/cm2 (a), 510C with necessary auxiliaries like lube oil & control oil system, governor system, ejector system, gland sealing system etc. In VWO condition the steam turbine generator is capable to generate 45.15 MW. STG Condensing Plant consists of Condenser with air evacuation system, and condensate extraction pumps. Regenerative feed heating system consists of one LP heater, one Deaerator, one HP heater. Turbine by pass system Capacity 25% of Turbine MCR. Boiler Feed Water Pumping system with 3 x 100% Motor driven boiler feed water pumps. (100% corresponds to 90 TPH BMCR capacity of boiler) One cooling tower with 4 cell (3 Working + 1 Standby) in counter flow design and RCC construction and cooling water pumping system.

Fuel handling system: Dense phase pneumatic handling system for conveying bed ash and fly ash to bed ash silo (1 No.) and any fly ash silos (2 Nos). Water system consists of raw water intake system from river, (customer scope), Pre Treatment Plant, Ultra filtration, Reverse Osmosis & DM Water system, Potable and service water system and effluent system. Compressed air system consists of plant air compressors, and Air drying plant for instrument air Air conditioning & Ventilation System Fire Protection System for the power plant, transformer area, fuel oil area and switchyard area. Inter-connecting piping system. EOT crane for TG building and miscellaneous hoists and monorails.

The fuel used for the boiler will be 100% Indian coal or Imported coal. The turbine exhaust steam will be condensed in a two-pass, divided water box type water-cooled surface condenser provided with the turbine. The condensate extraction pumps shall pump condensate from the condenser hot well to the Deaerator. The condensate is pumped through the inter/after/condensers, Gland Steam Condenser, Drain cooler, LP heater before reaching the Deaerator. Make up water for the power cycle shall be Demineralized (DM) Water. Make-up water will be added to the Deaerator through a level control station. Feed water to the Boilers shall be fed by three boilers feed pumps (3 x 100% where 100% corresponds to one Boilers MCR requirement), which shall take the suction from the Deaerator. Feed water to the boiler pumped to the boiler will be further re-generatively heated by a high-pressure bleed from the Steam Turbine in the HP Heater. 4.2 PLANT STARTUP, OPERATION AND CONTROL PHILOSOPHY.

The Boiler start-up will be monitored from the Central Control Room through a dedicated Distributed Controlled System (DCS) terminal. The total power plant with all its auxiliaries will have a single seat of control, which is the control room in the powerhouse building. All controls are connected to a centralized DCS. However, Coal Handling Plant (CHP), Water Treatment Plant, Ash Handling system & Air Compressors will be controlled from local PLC with DCS Monitoring connectivity. 5. POWER PLANT LAYOUT

The following factors are considered in developing the plant layout. Adequate clearance and access around each equipment for routine inspection and maintenance.

The design shall incorporate every reasonable pre-action and provision for the safety of all the personnel. The design shall comply with all appropriate regulations relating to safety. The plant layout shall be designed to localize and minimize the effects of any fire or explosion. Recommendations of TAC, LPA will be followed. Convenience of Power evacuation. Logistics for road tanker movement. Convenience of fuel intake. Convenience of Installation. Vaastu shasrtra considerations as described in the sketch below. Minimum width of clear access around equipment shall be provided as 1 m. Minimum clear height between two consecutive floors shall be determined considering maintenance, lifting and safety requirements. A clear head room of 2m shall be maintained between floors and overhead piping / cabling. All rail, road crossing for pipe / cable rack shall be done with minimum 6m headroom from top of rail / road to bottom rack. Similarly top cover over any underground pipe/ cable shall be minimum 1 m. Minimum 8 m clearance shall be kept in case of railway track with over head traction. Other Vaastu considerations are as follows. NORTH Coal Area Water Area. Admn. Accounts

Switch Yard

Boiler Chimney

WEST

EAST

SOUTH PLATN PLOT AREA Power plant plot and all the building shapes shall be rectangular or square. Number of entry/exit from Power plant plot area / amy buildings shall be even in number but not ending with zero. For example 10 numbers entry from Power Plant Plot area is not acceptable. Main entrance to Power Plant / any building should be widest. Any slopes to be considered from South to North or from West to East. Highest elevation of the plant will be at South to North or from West to East. Highest elevation of the plant will be at South-West corner. In this case chimney (highest elevation structure) is placed at South-West corner. Major plant roads (i.e. subject to heavy vehicle movements) and Power Plant approach roads will be 6 m wide and other with power plant will be 4 m wide.

The Power plant is classified in following areas. a) b) c) d) 5.1 Power block area Water System area Coal handling area Switch yard area

POWER BLOCK AREA The following areas, building, structures and equipment are located within the power block: a) b) c) d) e) f) 5.1.1. Power house building Boilers, ESPs & Chimney Cooling Tower Ash Silos ESP control room Compressor room POWER HOUSE The Power House will include. Steam Turbine Generator & Auxiliaries, LP & HP heaters located in the Steam Turbine Hall. The One (1) no Steam Turbine generators will be located in the turbine hall of 45 M span The layout of the STG hall shall be designed considering the following. 1. Adequate space for maintenance of Steam Turbine and generator shall be provided. 2. The STG unloading and maintenance are has been provided on the turbine side. 3. The Turbo-Generator (TG) deck elevation shall be selected based on NPSH requirement of Condensate Extraction Pump.

4. 5. 6. 7. 8. 9.

Surface condenser dimensions Elevation of intermediate floor. The crane rails elevation of the turbine hall shall be selected based on turbine height and crane clearance required above turbine. The vertical can type Condensate Extraction Pump will be located adjacent to the condenser, on the ground floor in a depressed floor at (-) 0.35 m elevation. The Lube Oil System will be located ground floor at turbine side. The Deaerator will be mounted on the roof of the control building. The Deaerator foundation design will take into consideration any possible vibration due to steam chugging. The boiler feed pumps shall be located within the Power House. A mezzanine floor would be provided to accommodate STG auxiliaries like Gland Steam Condenser & Steam Jet Air Ejector, the HP & LP Heaters, etc. Adequate number of staircases shall be provided for easy access to each floor and as per applicable norms and Vaastu considerations as described above.

Control & Switchgear room The main control room, electrical switchgear room, the cable spreader rooms, battery rooms, UPS room, Air Conditioner room and Service Engineer room toilet shall be housed within this bay of the Powerhouse. The cable spreader room shall be provided on the ground floor below the Switchgear and MCC room. The electrical switchgear will be located in the control building at about 4.0 m above the cable spreader room. All MCCs except the Water & Fire MCC (which shall be kept in the Water Treatment area) and coal handling MCC (which shall be located in local handling electrical room) and ESP auxiliary control panels (which will be located in ESP control room / Main control building) will be located the Switchgear room. 5.2 BOILER AREA The boilers will be semi-outdoor installation The boilers shall be provided with roof and side cladding above steam drum floor and bunker floor areas. The entire outer casing for the boiler, auxiliaries and piping shall be designed suitable for outdoor installation. Distance between the boiler centerlines is maintained such that adequate space is available for removal of equipment and maintenance. All fans (FD/ID/PA) are suitably located to provide adequate access for maintenance.

The boilers shall be connected to a common RCC chimney provided with necessary aviation lighting, lighting-protection, sampling ports with platforms etc. Adequate platform and staircase will be provided for boiler to access difference floor levels and equipment / valves / instruments of boiler for operation and maintenance.

5.3.

COOLING TOWER AREA The Cooling tower shall be of RCC construction. A foreby shall be provided for cooling water pumps suction. The dimension of cooling tower basin and the forebay shall be selected to accommodate four (4) cells. Cooling water pumps shall be horizontal and located such the easy access and maintenance is ensured. Each cell of the towers shall be provided with a drain sump. Cooling water piping to the plant will be buried, wherever over ground piping would cause obstruction or hindrance to main or vehicle movement.

5.4

FUEL AREA Coal storage of 10 days will be provided (8 days open storage and 2 days covered storage). The primary crusher and primary screen for local will be located in RCC building (Primary crusher house). Secondary crusher and secondary screen will be located in another RCC building (Secondary crusher house). The inclination angle for coal conveyor will be restricted to maximum 16 and two sides walk way of 750 mm & 450 mm width will be provided along the belt conveyor gantry. A separate Electrical cum control room for local handling plant will be provided near the crusher house.

5.5 5.5.1

WATER TREATMENT AREA RAW WATER RESERVOIR Raw water reservoir will be of open earthen bound construction with Pre cast stab lining The capacity of the reservoir will be 11.00 m3 to cater to the water requirement of Power Plant and fire water requirement for Power Plant. Two (2) numbers Raw Water transfer pumps and 3 numbers Fire Water Pumps will draw suction from this sump. These pumps will be housed in Raw Water cum Fire Water pump house, located adjacent to raw water reservoir.

5.5.2

WATER TREATMENT AREA

Water Treatment plant is located to the north east of the Power Plant. The DM & Ultra-filtration plant & RO plant will be located in a shed and DM Plant control cum MCC cum Laboratory room will be provided near the DM plant area. 5.6 MISCELLANEOUS The interconnection pipe work between plant utilities and power block equipment will be routed through under ground/pipe racks/sleepers and pipe trenches depending on the layout. The Main Cooling water and Auxiliary Cooling Water Piping will be laid below ground and buried, whenever over ground piping would cause obstruction or hindrance to man or vehicle movement. 6.0. BOILER SYSTEM The CETHAT FLUIDIX is of single drum, natural recirculation, semi outdoor type, fluidized bed combustion with under bed fuel feeding system boiler designed for maximum continuous rating of 90,000 kg/hr, pressure of 89 ATA at main steam stop valve of boiler and a steam temperature of 515 +5 C with feed water temperature at economizer inlet in 205 Deg. C firing with 100% Imported coal and 100% Indian coal having the GCV of 6000 Kcal/kg and 4115 Kcal/kg respectively. 6.1. FUEL ANALYSIS PERFORMANCE FUEL IMPORTED COAL INDIAN COAL ULTIMATE ANALYSIS (BY % WEIGHT) CARBON HYDRAGEN NITRAGEN SULPHUR MOISTURE ASH OXYGEN GCV (Kcal / Kg) 64.67 3.98 1.36 1.20 10.00 12.00 6.79 6000 42.10 2.58 0.78 0.99 5.00 37.30 11.20 4115 WORST FUEL INDIAN COAL 37.25 2.20 0.73 0.42 8.00 46.00 5.40 3600

The boiler consisting of steam drum, membrane water wall panels, bed evaporator coils, convection superheater, radiant superheater, bed superheater, Economiser. Air heater, Inter connecting pipings, air and gas ducting, fuel feeding system, supporting structure with roof and side cladding, platforms and staircases etc. The other equipments like bunker, fans, ESP, HP dosing systems, blow down tanks, start up oil firing, are also supplied along with boiler.

The deaerator, LP dosing system and feed pumps are also supplied with boiler package to supply the required quantity an quality of feed water to boiler. 6.2 GENERAL All the water required to produce steam is supplied by the two boiler feed water pumps. The feed water passes through the economizer adds only sensible heat to the feed water. From the drum, water is circulated through the natural circulation circuit. This circuit add latent heat to the water and thus this circuit, may be termed as evaporator circuit. As the steam and water mixture enters the drum from this circuit, the drum internals, separate the steam, from the mixture. The separated water along with the incoming feed water is continuously circulated through this circuit. The natural circulation circuit is formed by the drum down comers, bed evaporator headers, bed evaporator, water walls, roof tubes, outlet headers and riser pipes. The saturated steam from the drum is superheated in the superheater coils, in three stages. The steam passes through the connecting links, convection super heater inlet header, Convection superheater coils, convection superheater outlet header connecting link between convection superheater outlet and radiant superheater inlet header, radiant superheater inlet header, radiant superheater coils, radiant superheater outlet header, connecting link between radiant superheater outlet header and De-superheater, De-superheater, connecting ling between De-superheater 1 outlet header, connecting links, bed superheater-2 inlet heater, bed superheater-2 coils, bed superheater-2 outlet header. De-superheater is located in-between radiant and bed superheater-1, it serves to control the boiler outlet steam temperature. 6.3 STEAM DRUM The steam drum is of fusion welded type, liberally sized and fitted with high efficiency internals. The steam drum provided with 2 nos manhole door to open inwards. The following nozzles are provided in the steam drum. 01. 02. 03. 04. 05. 06. LOCAL PRESSURE GAUGE REMOTE PRESSURE GAUGE AIR VENT SAFETY VALVE AUXILIARY/N2 CAPPING STUB DIRECT LEVEL GAUGES - 1 NO - 1 NO - 1 NO - 2 NOS - 1 NO - 2 NOS

07. 08. 09. 10. 11. 12. 13. 14. 15.

LEVEL TRANSMITTER PRESSURE TRANSMITTER CONTINUOUS BLOWDOWN CONNECTION INTERMI9TTENT BLOWDOWN CONNECTION HP DOSING CONNECTION DOWNCOMER RISER FEED PIPE STEAM OUTLET

- 3 NOS - 1 NO - 1 NO - 1NO - 1 NO - 6 NOS - 10 NOS - 1 NO - 3 NOS

The thickness of the drum is arrived based on the requirements as specified under IBR 1950 with latest amendments. 6.3.1 DRUM INTERNALS The boiler drum forms a part of the circulation system of the boiler. Its main functions are a) Providing the necessary space for separation of steam from mixture of steam and water. b) Housing the equipment needed for purification of steam c) Meeting the steam demand fluctuation by its steam storage capacity. The drum internals combine simplicity and efficiency to provide low maintenance cost and high steam quality. The drum is positioned horizontally in front of the boiler. It is fixed on boiler supporting structure. The steam-water mixture, entering the drum from side water wall top headers and roof panel top headers, is collected in the separating chamber formed by the vertical baffle panels through risers. The primary separation of steam and water takes place in the separating chamber. Most of the water drops down after impact and passes around the ends of the panels to mix with the incoming feed water. A portion of the water is drained off through the perforated continuous blow down pipes at this point of high solids concentration. The blow down line is provided with an motor operated angel type blow down with isolation valve. The steam and some water is released over the top end of the panel and cascades into the top part of the drum Here the wet steam rises and passes through the drier screens. The water, as it undergoes the tortous path provided by the screens, gets collected and this water is drained to the waterside of the drum through the four drain pipes. Dry steam leaves the drum through the top four steam outlet nozzles. Drum safety valves are set to open when the drum gets pressurized above limits. Drum level is sensed to control the feed water flow. Drum level is indicated by the local drum water level gauge and by the remote water level indicator. The motorized operated emergency drain (Intermittent blow down) with isolation valves, is to be used when the drum level shoots up abnormally.

6.3.2

DATA SHEET DRUM INTERNATIONAL DIAMETER THICKNESS OF THE DRUM THICKNESS OF THE DISHED HEAD LENGTH OF THE DRUM MATERIAL OF DRUM PLATE MATERIAL OF DISHED HEAD DESIGN PRESSURE DESIGN TEMPERATURE : : : : : : : : 1371 MM 90 MM 90 MM (MIN. 76 MM) 7100 MM (TAN TO TAN) SA515 GR. 70 SA515 GR. 70 105 KG/CM2 (G) 314C

INTERNALS A) TURBO SEPERATOR: NO. OFF SIZE B) SCREEN BOX: NO.OFF SIZE 6.4. DOWN COMER & BED EVAPORATOR The water from drum flows through four down comers to the bottom bed evaporator headers. Form this bottom bed evaporator header water flows through the bed evaporator tubes to water wall bottom ring headers. Bed evaporator consists of 210 coils assemblies arranged in a inline manner. The inlet headers are located horizontally both left and right side of the boiler. The bed evaporator is completely immersed within the fluidized bed. The bed evaporator is provided to extract heat from fluidized bed and to keep the bed temperature will below the ash fusion temperature. MS studs are welded on to the bed evaporator tubes to minimize the erosion of the tubes. The bed evaporators outlet headers are connected with front and rear water wall bottom headers and formed as bottom rind headers for water wall. 6.4.1 DATA SHEET : : : : 19 220 MM 16 570 X 303 MM

DOWNCOMER: NO. OFF PIPE SIZE PIPE MATERIAL : : : SIX D219.1 X 12.70 THK SA 106 GR.B

BED EVAPORATOR: TOP & BOTTOM HEADER PIPE SIZE PIPE MATERIAL BED TUBES NO. OFF TUBE SIZE THK TUBE MATERIAL : STUD SIZE : MATERIAL SPECN : 6.5 WATER WALL: The waterwall, walls and roofs are formed by the tubes rising from the bottom ring headers. The waterwall are made of fin welded tube panels. The front waterwall consists of tubes that rise from the bottom ring header and end in the front roof panels and front roof panels end in the top roof header. The rear wall panel is formed by the tubes that originate from the rear portion of the bottom ring header and rise upto the rear roof tubes and the rear roof tubes end in the roof top header. The rear wall panels are extended into the furnace to form as nose to facilitate to provide convection super heater tubes. Inbetween roof tubes and end of the rear wall nose the tubes are formed without find to exit the flue gas from furnace. The two side wall are formed from the tubes that rise from the bottom ring headers and they are crowned by the two side water wall outlet headers. Entire water wall and bed evaporator assembly is suspended from the top using hangers and rockers. From the side water wall top headers there are fiver riser pipes, from each header, to carry the steam water mixture to the drum. From the roof panel top header there are two riser pipe to carry the steam water mixture to the drum. The water wall are provided with openings and seal boxes for the coil penetration, Bed material feed chutes, view ports, man hole doors etc., To protect the boiler from the effect of explosions buckstays are used. Waterwalls serve two functions mainly. They form a gas tight enclosure to contain the hot flue gases. They form the evaporator circuit which generations steam Natural circulation is established by the density difference between the water in downcomers and water steam mixtures in waterwalls. The rate of the SA 210 GR. A1 DIA 10 mm IS 2062 Gr. A SA 210 GR. A1 DIA 10 mm IS 2062 Gr. A : : : : : D273.1 X 25.40 THK SA 106 GR. B TYPE 1 150 D 51 X 6.35 THK TYPE -2 60 D 51 X 6.35

circulation adjusts itself until an equilibrium is reached such that the difference between the hydrostatic head at the feet of downcomers and the water walls is equal to the sum of pressure drops due to friction and acceleration of the flow medium in the circuit. Circulation will be high at lower pressure and at lower loads. Circulation will be reduced when feed water temperature increases and when drum level is low. 6.5.1. DATA SHEET WATER WALL SIZES FRONT AND REAR WALL SIDE WALLS HEIGHT TUBES PITCH FIN WIDTH SIDE WALL BOTTOM RING HEADERS PIPE SIZE PIPE MATERIAL SIDE WALL TOP HEADERS PIPE SIZE PIPE MATERIAL ROOF PANEL TOP HEADER PIPE SIZE PIPE MATERIAL WATER WALL TUBES TUBE SIZE TUBE MATERIAL 6.6 ECONOMISER The purpose of economizer is to preheat the boiler feed water before it enters the steam drum and to recover some heat from the flue gas leaving the boiler. The inlet and outlet headers are positioned horizontally. It is fed with feed water by a pipe from the feed water control station. There are 39 parallel paths of economizer coils connecting the inlet header to the outlet header. The economizer coils are horizontally arranged and are split into two banks with a gap of 900 mm in between them. The economizer coils are suspended from the economizer casing top frame through lugs and pins. There is a link connecting the economizer outlet header to the drum. The feed water flow is upward through the economizer, that is, in counterflow to the hot flue gases. Most efficient heat transfer is hereby accomplished. 6.6.1 DATA SHEET : : : : : : : : : : : : : 9292 mm 5555 mm 13000 mm 101 mm 50 mm D 219.1 X 25.4 THK. SA 106 GR.B D 219.1 X 25.4 THK. SA 106 GR. B D 273.1 X 25.4 THK SA 106 GR. B D 51 X 4.5 THK SA 210 GR. A1

ECONOMISER ECONOMISER FEED INLET PIPE: SIZE : 114.3 x 8.56 THK MATERIAL : SA 106 GR. B NO. OFF : ONE ECONOMISER INLET HEADER: SIZE MATERIAL NO. OFF ECONOMISER COILS: TUBE SIZE TUBE MATERIAL LONGITUDINAL PITCH TRANSVERSE PITCH FLOW ARRANGEMENT COIL ARRANGEMENT TYPE OF SUPPORT TYPE OF SPACER : : : : : : : : 51 X 4.5 THK SA 210 GR. A1 153 85 COUTER FLOW INLINE CLAMP, SUSPENDED FROM ECONOMISER CASING TOP FRAME SCALLOPED U PLATE : : : 219.1 X 18.26 THK SA 106 GR. B ONE

ECONOMISER OUTLET HEADER: SIZE MATERIAL NO. OFF : : : 219.1 X 18.26 THK SA 106 GR. B ONE

ECONOMISER OUTLET LINK: SIZE MATERIAL NO. OFF 6.7 : : : 168.3 X 10.97 THK SA 106 GR. B ONE

SUPERHEATER SYSTEM In superheater system, the superheaters are provided in three stages termed as Convection superheater, Radiant superheater and Bed superheater. CONVECTION SUPER HEATER The dry saturated steam from drum is let into the convection super heater inlet header by means of 3 nos of connecting links. The super heater inlet and outlet headers are located horizontally in top of the water wall headers perpendicular to the boiler axis. The convection super heater consists of 90 parallel paths. The super heater is located above rear wall nose portion. The super heater is vertically

6.7.1

placed, spaced and cross flow arrangement. The super heater coils with headers are suspended from top using hangers and rockers. 6.7.2 RADIANT SUPERHEATER The superheated steam from convection super heater outlet header is let into the radiant super heater inlet header by of connecting link. The super heater provided as pentant type and the inlet and outlet headers are placed above water wall top headers and suspended from top hangers and rockers coils are placed vertically at the direct radiant zone of furnace just away from rear wall nose construction. The super heater consists 90 numbers parallel paths. This superheated steam heated upto 490C. 6.7.3 BED SUPERHEATER The superheated steam from radiant super heater outlet is let into the bed super heater inlet header for further temperature raising to the required level through inlet link. The bed super heater arranged are splited as two stages and placed in between bed evaporator tubes in both left and right side by providing individual inlet and outlet headers. Inlet and outlet headers are placed horizontally, parallel to the boiler axis and supported with bed tube bottom headers. The bed super heater tubes are horizontally placed perpendicular to the boiler axis. The bed super heater consists of 22 parallel paths in stage-1 and 22 parallel paths in stage-II. The bed super heater stage-I and stage-II are connected through link. In bed the super heater coils located away from startup compartment to avoid tube failure due to high tube metal temperature while stating of the boiler. The De-super heater is provided on the link that connects the radiant super heater and bed super heater stage I. De-superheating is done by spraying feed water and mixing it with steam so that the required outlet steam temperature is obtained. Spray control valve is actuated by the signal generated by the temperature sensing element which is mounted on the bed super heater stage-2 outlet steam pipe. BED SUPERHEATER OUTLET LINK The main steam pipe is provided from bed super heater stage-2 outlet heater upto main steam stop valve. The main steam pipe accommodates, the following stubs. 01. 02. 03. 04. 05. 06. SAFETY VALVE STARTUP STEAM VENT (MOTORISED) PRESSURE TRANSMITTER PRESSURE GAUGE (LOCAL) PRESSURE GAUGE (REMOTE) SAMPLING - 1 NO - 1 NO - 1 NO - 1 NO - 1 NO - 1 NO

6.7.4

07. 08. 09. 10. 11.

TEMPERATURE GAUGE (LOCAL) TEMPERATURE ELEMENT DRAIN AIR VENT AUXILIARY : :

- 1 NO - 1 NO - 1 NO - 1 NO - 1 NO

PIPE SIZE PIPE MATERIAL 6.7.5

D 219.1 X 25.4 mm SA 335 P22

6.7.6

MAIN STEAM PIPE From main steam stop valve outlet steam let to the turbine through main steam pipes Steam flow measuring nozzle is provided in the main steam pipe with maintaining adequate upstream and down stream pipe length. The adequate no off steam traps provided in the bottom most of the pipes and airvent provided in the top most of the pipes. PROTECTION AND CONTROL As long as there is fire in the furnace adequate protection must be provided for superheater elements. This is especially important during periods when there is no demand for steam, such as start-up and shut down. During these periods, adequate flow through the superheater is assured by means of drains and vents in the headers, links and main steam piping. Superheater is provided with a safety valve. It is set to pop at a lower pressure compared to the low set drum safety valve. Hence when there is load fluctuation or when the steam demand drops suddenly, the flow is established by the lifting of safety valve. During all state ups, care must be taken not to overheat the superheater elements by limiting the inlet gas temperature.

6.7.7

DATA SHEET CONVECTION SUPERHEATER INLET LINK NO. OFF PIPE SIZE MATERIAL THREE D 168.3 X 10.97 mm SA 106 GR. B

CONVECTION SUPERHEATER INLET HEADER NO. OFF SIZE MATERIAL ONE D 273.1 X 25.4 mm SA 106 Gr. B : : 90 ONE

CONVECTION SUPERHEATER COILS NUMBER OF PARALLEL PATHS NUMBER OF BANKS

DISPOSITION TYPE OF HEAT FLOW TUBE SIZE TUBE MATERIAL COIL TYPE TRANSVERSE PITCH LONGITUDINAL PITCH ARRANGEMENT TUPE OF SUPPORT :

: : : : : : : :

VERTICAL CROSS D 44.5 X 4.5 MM A SA 210 Gr. A1 PENDANT 101 MM 130 MM INLINE ARRANGEMENT

TYPE OF SPACER

U ROD ATTACHED WITH BATTEND CHANNEL AND SUSPENDED FROM TOP HANGERS AND ROCKERS : SCALLOPED BAR

CONVECTION SUPERHEATER OUTLET HEADER NO.OFF SIZE MATERIAL 6.7.8 DATA SHEET RADIANT SUPERHEATER INLET LINK NO.OFF PIPE SIZE MATERIAL : : : ONE D 168.3 X 14.27 mm SA 106 Gr. B : : : ONE D 273.1 X 25.4 mm SA 106 Gr. B

RADIANT SUPERHEATER INLET HEADER NO.OFF SIZE MATERIAL : : : ONE D 273.1 X 25.4 mm SA 106 Gr. B 90 ONE VERTICAL CROSS D 44.5 X 4.5 mm D44.5x 4.5 SA 213 T11 SA 213 T22 PENDANT 101 MM 130 MM

RADIANT SUPERHEATER INLET HEADER NUMBER OF PARALLEL PATHS : NUMBER OF BANKS : DISPOSITION : TYPE OF HEAT FLOW : TUBE SIZE : TUBE MATERIAL : COIL TYPE : TRANSVERSE PITCH : LONGITUDINAL PITCH :

ARRANGEMENT TUPE OF SUPPORT

: :

TYPE OF SPACER

INLINE ARRANGEMENT U ROD ATTACHED WITH BATTEND CHANNEL AND SUSPENDED FROM TOP HANGERS AND ROCKERS PLATE AND ROD CLEVIS

RADIANT SUPERHEATER OUTLET HEADER NO.OFF SIZE MATERIAL BED SUPERHEATER INLET LINK NO. OFF : PIPE SIZE : MATERIAL : BED SUPERHEATER INLET HEADER NO.OFF : SIZE : MATERIAL : : : : ONE D 273.1 X 25.4 mm SA 335 P11 STAGE-2 ONE D219.1X20.62 SA 335 P22 LEFT SIDE ONE D273.1X32.0 SA 335 P22

STAGE-1 ONE D 219.1 X 20.62 mm SA 335 P22 RIGHT SIDE ONE D 273.1X32.0 mm SA 335 P22

BED SUPERHEATR COILS NUMBER OF PARALLEL PATHS : 22 22 NUMBER OF BANKS : ONE ONE DISPOSITION :HORIZONTAL HORIZONTAL TYPE OF HEAT FLOW : CROSS CROSS TUBE SIZE : D 44.5X6 mm D 44.5X6mm TUBE MATERIAL : SA 213 T91 SA 213 t91 COIL TYPE : U-BEND U-BEND TRANSVERSE PITCH : 119 MM 119 MM ARRANGEMENT : INLINE INLINE ARRANGEMENT ARRANGEMENT BED SUPERHEATER OUTLET HEADER NO.OFF SIZE MATERIAL MAIN STEAM PIPE SIZE MATERIAL : : D 273.1 X 32.0 mm SA 335 P22 : : : ONE D 273.1 X 32.0 mm SA 335 P22

6.7.9

DE-SUPERHEATER Desuperheater is provided in the link connecting the radiant superheater outlet header and bed superheater stage-1 inlet header. This is used to maintain the steam temperature at design valve. Temperature reduction is accomplished by injecting spray water into the path of the steam, through a nozzles at the entering end of the desuperheater. The spray water is drawn from the feed pump discharge line but before the feed control station. It is essential that the spray water be chemically pure and free of suspended and dissolved solids. CONTROL A spray control valve linked to an automatic temperature control one number temperature control valve will be provided to regulate the flow of spray water supplied to de-superheater. A manual operated isolation valve is installed on upstream and downstream of control valve to permit isolation when required. A motor operated regulating valve is provided in the by pass line to take care of the spray during maintenance of spray control valve.

6.7.10. DATA SHEET NO. OFF : ONE SIZE : D 273.1 X 25.4 mm MATERIAL : SA 335 P11 LINER SIZE : D 180 X 1.5 mm LINER MATERIAL : SA 240 GR. 304 NO.OF SPRAY NOZZLES : ONE SPRAY NOZZLE MATERIAL : SPRAY NOZZLE BODY MATERIAL : NUMBER OF HOLES IN SPRAY NOZZLE : HOLE SIZE : DESH INLET LINK SIZE : DESH INLET LINK MATERIAL : DESH OUTLET LINE SIZE : DESH OUTLET LINK MATERIAL : 6.8

SA 479 GR. 304 SA 479 GR. 304 ONE D 11 MM D 219.1 x 25.4 mm SA 335 P11 D 219.1 X 25.4 mm SA 335 P11

FEED WATER SYSTEM The feed water system for both comprises one common deaerator deaerator-cumfeed water storage tank, three numbers of Feed water pumps of 100% MCR capacity of each boiler. DEAERATOR The deaerator will be common for two boilers to supply feed water at 157 Deg.C at BMCR.

6.8.1

The steam for deaerator will be supplied by Turbine 2nd extraction. At low load to maintain minimum deaerator outlet temperature, pegging steam will be supplied from main steam line through PRDS station. The deaeration capacity will be provided for 120% of BMCR (216 TPH) The deaerator is placed before boiler feed pump in the feed water cycle to remove the dissolved corrosive gases from the feed water which goes to the boiler. The oxygen is reduced to 0.005 cc/litre and carbon di-oxide is reduced to untraceable limits. In the condensate leaving deaerator. It is a direct intimate contact type heat exchanger and is located before suction side of boiler feed pump in thermal cycle. The steam is drawn to heat the condensate which is broken into fine droplets for effective heat and mass transfer of non condensable gases. The deaerator consists of vertical deaerating chamber called header and horizontal feed storage link. The condensate and make up water enters the deaerating chamber and is sprayed by spray valves. The sprayed water falls through tray stack for heat and mass transfer. The condensate is divided into fine droplets and comes in contact with the steam resulting in release of non condensate gases which are carried by the steam moving upwards. The condensate after leaving deaerating header enters into feed storage tank from where it goes out to boiler feed pumps. Steam enters the feed storage tank and then goes into deaerating header where it gets condensed, some steam along with non condensate gases goes out of the equipment. 6.6.2 DESIGN AND CONSTRUCTION Steam admitted in storage tank provides a steam blanket over stored condensate and thus eliminates under cooling of condensate and reabsorption of gases bythe condensate. The deaerator, feed water storage tank is designed and constructed to international standard like, HEI, ASME Section VII Division-1 etc. The deaerating header is mounted on the feed storage tank from simplified layout and compact arrangement. 6.8.3. FEED WATER STORAGE TANK The feed water storage tank will be sized to meet 10 minutes requirement (between normal water level and low-low water level) of two boiler running at BMCR. The storage vessel will be mounted at suitable height to provide the required NPSH for the feed water pumps.

The shell of the storage tank is fabricated from boiler quality steel plates. The ends are closed with dished ends. Various connectors like condensate outlet, steam inlet, drain outlet, dosing inlet, relief valve, thermometer pockets, level gauges, high and low level alarms, manhole etc., are provided. 6.8.4 DEAERATING HEADER The main parts of the deaerating header are a) Shell and dished ends. b) Tray plates and spray valves. SHELL The shell of the deaerating header is fabricated from boiler quality steel plates, and is closed with dished end. The shell mounted directly over the feed storage tank. It houses stainless steel trays. Stainless steel spray valves are provided for spraying condensate. It is provided with connections such as condensate inlet, make up water inlet, inspection opening, air vent outlet. TRAY AND SPRAY VALVES The trays and spray valves are fabricated from SS 304. DATA SHEET 01. 02. TYPE DESIGN DATA DESIGN PRESSURE DESIGN TEMPERATURE TEST PRESSURE TEST TEMPERATURE RADIOGRAPHY CORROSION ALLOWANCE DEAERATOR HEADER : SPRAY CUM TRAY : 7.0 Kg/Cm2(g) & F.V : 250C (DEAERATOR & FST) : 10.5 Kg/cm2(g) : AMBIENT : SPOT : 1.5 MM (DEAERATOR&FST) VERTICAL

6.8.5

6.8.6 6.8.7

03.

04.

05.

INSIDE DIA X THK : 1900 MM X 10 MM THK OVERALL LENGTH : 3390 MM NUMBER OF TRAYS :7 NUMBER OF SPRAY VALVES : 16 SPRAY VALVE CAPACITY : 15 TPH FEED WATER STORAGE TANK HORIZONTAL INSIDE DIA X THK : 2476 MM X 12 MM THK OVERALL LENGTH : 10500 MM STORAGE CAPACITY/VOLUME : 10 MIN / 30 M^3 BETWEEN LOW LOW LEVEL & NORMAL LEVEL MATERIALS DEAERATOR HEADER SHELL AND DISH : SA 515 GR.70 FEED STORAGE TANK SHELL AND DISH : SA 515 GR. 70

TRAYS NOZZLES FASTENERS FLANGES SPRAY NOZZLE NOZZLES CONDENSATE INLET STEAM INLET FEED WATER OUTLET SAFETY RELIEF VALVE (INLET / OUTLET) HEATING STEAM INLET 6.8.8

: SS 240 GR. 304 : SA 106 GR. B : SA 193 GR. B7 / SA 194 GR.2H : SA 515 GR.70 : SS TP 304 / 316 : 1 NO 8 NB ANSI # 150 RF : 1 NO 10 OD Dia 273.1 x 12.7 : 1 NO 10 NB OD Dia 273.1 x 12.7 : 1 NO INLET 3/ OUTLET 4 ANSI # 150 RF : 1 NO 6 NB OD Dia 168.3 x 10.97 ANSI # 150 RF

06.

FEED WATER PUMP Three number electrically driven feed pumps will be provided with motor operated Isolation valves provided at the outlet of each feed pump. The pumps will be of multistage, rind section, centrifugal type. Complete with suction strainer, balancing chamber and necessary valve and instruments A suction strainer is provided after the inlet manual isolation valve of each pump, to protect the pump against the damage due to debris in feed water. Balancing leak off line is connected to the deaerator storage tank. The delivery of the pump is split into two branches. One goes to the economizer through Common feed water discharge header to supply the water to economizer through feed control station. And the other branch is recirculation branch going to deaerator storage tank through the Auto recirculation valve and inbuilt energy absorber (i.e. the break-down orifice). This arrangement prevents the abnormal temperature rise within the pump by establishing a minimum flow through the pump, whenever the feed water drawn by the boiler is less than the permissible minimum flow through the pump. PUMP CAPACITY CALCULATION Boiler MCR flow rate Feed water flow at MCR Blowdown 2% Feed Water density at 157 Deg.C MCR volume flow Margin 5% (as per DCBLS tender) Calculated toral volume flow PROVIDED : : : : : : : : : : 90 tph 90 tph 1.8 tph 910.2 Kg/cu.m 100.85 Cu.m/hr 5.04 Cu.m hr 105.89 Cu.m/hr 108.77 Cu.M/HR 105 kg/cm2(g) 1.2 kg/cm2(g)

6.8.9

6.8.10 PUMP HEAD CALCULATION Drum 2nd safety valve set pressure Pressure drop in piping

Pressure drop in HP heater Pressure drop across control valve & orifice Pressure drop in Economiser Static head Calculated total pressure Margin 5% Calculated Total head PROVIDED

: : : : : : : :

1.0 kg/cm2(g) 3.0 kg/cm2(g) 1.0 kg/cm2 2.3 kg/cm2 113.5 kg/cm2(g) 5.675 kg/cm2(g) 119.18 kg/cm2 (g) 1309 m/c

6.8.11 FEED WATER CONTROL The tow numbers 1 x 100% feed control valve and 1 x 30% feed control valve provided to regulate the flow of feed water supplied to the boiler. Whenever boiler load less than 30% the water flows through 30% feed control valve and above 30% water flows through 100% feed control valve. A motor operated isolation valves are installed on upstream side of each feed control valve and a manually operated regulating valve is provided in the bypass line to take care of feed water regulation during the maintenance of feed control valve. 6.9 6.9.1 AIR AND GAS CIRCUIT FD AIR SYSTEM All the required air for the boiler operation is supplied by one number FD fan. FD fan is provided with pneumatically operated inlet regulating damper. The cold air from the FD fan is let into the tubular air heater. The hot air from the air heater is distributed to the five compartments by means of the air distributor (FD header). This is the air which keeps bed fluidized. This FD header also serves as the suction for primary air fans. The fluidizing air to the five compartments can be cut off using the pneumatically operated shut-off dampers provided in the respective compartment air inlet ducts. TUBULAR AIR HEATER Air heater of multi tubular recuperative type is provided for the boiler at the downstream of economizer with air flow through the tubes and gas flow over the tubes. Cold air from FD fan let into the air heater in two passes. Ten rows corton steel tubes will be provided at cold junction of air and gas to avoid cold end corrosion on tubes. DUCTING SYSTEM The ducting system will be provided with 5 mm thickness and 6 mm thichness for air and gas ducting respectively. All ducts are of Mild steel suitably stiffened on the outside and designed to withstand the pressures encountered. The ducting system is complete with all required expansion joints, mating flanges, dampers, supports, access doors, platforms insulation etc. All ducts are of welded construction. PRIMARY AIR SYSTEM

6.9.2

6.9.3

6.9.4

One number of PA fan will be provided with pneumic operated regulation damper at inlert. Suction line of PA fan is from the FD header. The PA fan bootsup the pressure of incoming hot air so that coal can be pneumatically transported in the bed. The PA fan outlet is connected with PA distribution header. From this PA header 5 nos of ducts connected with branch header with pneumatic operated shutoff dampers. Each branch header has four coal transport air pipes feeding a compartment. The coal transport air to any compartment can be cut-off using pneumatic operated shutt off dampers. Each fuel transportation line has manual operated shutt off dampers to facilitate to take individual line maintenance. 6.9.5 FLUE GAS SYSTEM The hot gas generated in bed exchanges the heat with the heat transfer surfaces with in the boiler. The heat is transferred from the flue gases to the water walls, radiant super heater coils and convection super heater coils places in side of the furnace the flue gas temperature further drops which passes through economizer coils placed in the outside of furnace. The economizer to air heater gas ducting provides a change in flow direction of the flue gas. The separated un-burnt combustibles and ash are collected in the two hoppers provided below the economizer and one hopper provided below air pre heater and are disposed through suitable ash removal system. The temperature of the flue gas further reduces it passes through the air heater. The combustion air is preheated in the air heater by the flue gas. ELECTROSTATIC PRECIPITATOR Electrostatic Precipitator is the most effective method for removal of solid particles from the gases. The Electrostatic Precipitator basically consists of a large steel chamber and the electrodes. High voltage DC supply is applied between the emitting electrode and the collecting electrode. The emitting electrode is connected to the negative terminal. The collecting electrode is connected to the positive terminal and earthed. When flue gases pass through the chamber, because of the high DC voltage applied across the emitting and the collecting electrodes, the solid particulars get ionized and are attracted to the collecting electrode Ash drops down in the hoppers, which is then removed and disposed off.

6.10

6.10.1 ESP DESIGN BASIS 1. 2. 3. FUEL FUEL QUANTITY FOR 100% MCR GAS QUANTITY PER BOILER Kg/hr Kg/hr INDIAN COAL 4115 KCAL/KG 16652 110244 IMPORTED COAL 6000 KCAL/KG 10993 123959 WORST COAL 3600 KCAL/KG 18322 117195

4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

GAS DENSITY GAS TEMPERATURE (T) GAS DENSITY @ T Temperature GAS VOLUME ASH CONTENT IN FUEL ASH QUANTITY % OF DUST COLLECTION BEFOR ESP % OF DUST LOADING AT EST DUST LOADING @ ESP I/L DUST LOAST @ ESPO/L (one field out) DUST LOAST @ ESPO/L (all field working)

Kg/Nm3 Deg.C Kg/Nm3 M3/Sec % Kg/hr % % Gm/Nm3 Mgm/Nm3 Mgm/Nm3

1.323 140 0.875 35.02 37.30 5838.28 30 70 49.0 <100 <60

1.318 140 0.871 39.52 12.00 1319.15 30 70 9.8 <100 <50

1.317 140 0.871 37.39 46.00 8428.12 30 70 66.3 <100 <60

The dust concertration in the flue gas is reduced to the requirement by use of the electrostatic precipitator placed after the air heater. The outlet duct of the electrostatic precipitator connected to the inlet of the ID fan. ID fan will be provided with power cylinder operated regulation damper at inlet. Manhole doors are provided inlet and outlet duct of economizer and air heater ducts. Space will be provided for 5th field in ESP so that additional field can be incorporated at a later date by M/s. SPL. 6.11 FANS Each one number FD, ID and PA fans will be provide and each designed for 100% MCR capacity with adequate margin. The fans supplied are complete with coupling, base plates etc. All control vanes/dampers will be supplied complete with the pneumatic actuators and connecting mechanism etc., The ID fan will be provided with variable frequency drive arrangement for speed control and FD and PA fans will be of constant speed drivers. All the fan impellers are dynamically balanced at works, before dispatch. 6.11.1 DESIGN BASIS FD FAN 1. CAPACITY CALCULATION

1. 2. 3. 4 5 6. 7. 8. 9. II 1 2 3 4 5 6 7 8 9 10

FUEL FUEL FLOW RATE DESIGN TEMPERATURE EXCESS AIR MCR AIR FLOW (WET) AIR FLOW FOR FAN DENSITY OF AIR CORRECTED FOR TEMP. Alt. FAN FLOW (MCR) MARGIN ON MCR Kg/hr Deg./C % Kg/hr Kg/sec Kg/m3 m3/sec %

100% COAL 15652 40 20 100817 28.0 1.128 24.82 42.22

IMPORTED COAL 10993 40 20 114676 31.85 1.128 28.24 25.0

WORST COAL 18322 40 20 10767 29.91 1.128 26.52 33.10

HEAD CALCULATION dp BED dp FLOW MEASURING DEVICE dp SILENCER dp AIR HEATER dp D.B PLATE dp DUCT AND DAMPERS dp TOTAL HEAD DEVELOPED ON MCR FLOW MARGIN ON HEAD AT MCR TEST BLOCK HEAD mmwc mmwc mmwc mmwc mmwc mmwc mmwc % % mmwc 510 25 30 37 111 30 743 963 29.6 510 25 30 38 112 30 745 932 25.1 1800 510 25 30 38 112 30 745 952 27.7

The dust concentration in the flue gas is reduced to the requirement by use of the electrostatic precipitator placed after the air heater. The outlet duct of the electrostatic precipitator connected to the inlet of the ID fan. ID fan will be provided with power cylinder operated regulation damper at inlet. Manhole doors are provided inlet and outlet duct of economizer and air heater ducts.