Design Basis IMFA

OC No.
Total Sheets
PP 067 M B01 0
Document No.
DDC 067
146
DESIGN BASIS REPORT FOR

MECHANICAL
BB
SRG
PKC/
ABT
BB
C&I
Civil
QA
First Issue
Status
DEC
THERMAX LTD.
INDIAN METAL & FERRO ALLOYS LTD.

OWNER
CHOUDWAR, ODISHA
OWNERS
DEVELOPMENT CONSULTANTS PRIVATE LIMITED
CONSULTANT
KOLKATA
PROJECT
2 X 60 MW THERMAL POWER PLANT

POWER DIVISION
THERMAX LIMITED
PUNE
Appd
Elec.
Description of
Revisions
PKC/
ABT
Mech.
Date
SRG
Ppd
Rev
Client Submission
PM
05.12.09
Approval
Appd
Revised as marked
Ckd
20.01.09
Ppd
POWER DIVISION
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POWER PLANT, IMFA,
ORISSA
DESIGN BASIS REPORT

MECHANICAL
PP 067 M B01 0
DESIGN BASIS REPORT MECHANICAL

INDEX
1.
INTRODUCTION ...............................................................................................9
2.
UNITS OF MEASUREMENT & ABBREVIATIONS .........................................10

2.1.
2.2.
UNITS OF MEASUREMENT .............................................................................10

ABBREVIATIONS............................................................................................10
3.
CODES & STANDARDS .................................................................................11
4.
POWER PLANT CONFIGURATION ...............................................................14

4.1.
4.2.
4.3.
PLANT CONFIGURATION ................................................................................14

PLANT STARTUP, OPERATION AND CONTROL PHILOSOPHY ..............................16
CUSTOMERS DESIGN INPUTS ........................................................................16
4.3.1.
Site Conditions .................................................................................................. 16
4.3.2.
Coal Analysis..................................................................................................... 18
4.3.3.
Ash Analysis :.................................................................................................... 19
4.3.4.
Lime Stone Analysis.......................................................................................... 20
4.3.5.
Bed Material Analysis (As Required by Boiler Design) ..................................... 20
4.3.6.
Raw Water Analysis .......................................................................................... 21
5.
POWER PLANT LAYOUT...............................................................................22

POWER BLOCK AREA ....................................................................................23
5.1.
5.1.1.
Power House..................................................................................................... 24
5.1.2.
Boiler Area......................................................................................................... 25
5.1.3.
Cooling Tower Area........................................................................................... 26
5.2.
5.3.
5.3.1.
Raw Water Reservoir ....................................................................................... 27
5.3.2.
Water Treatment Area....................................................................................... 27
5.4.
5.5.
5.6.
6.
FUEL AREA ..................................................................................................26

WATER SYSTEM AREA ..................................................................................27
SWITCHYARD AREA ......................................................................................28

ASH SILO AREA ............................................................................................28
MISCELLANEOUS ..........................................................................................28
STEAM TURBINE ...........................................................................................28
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MECHANICAL
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6.1.
6.2.
6.3.
6.4.
6.5.
GENERAL .....................................................................................................28
TURBINE ......................................................................................................29
GLAND STEAM SYSTEM.................................................................................30
TURBINE DRAIN SYSTEM ...............................................................................31
TURBINE LUBE OIL SYSTEM...........................................................................32
6.5.1.
Oil Storage Tanks.............................................................................................. 32
6.5.2.
Oil Coolers......................................................................................................... 32
6.5.3.
Oil Pumps.......................................................................................................... 33
6.5.3.1.
Main & Auxiliary Lube Oil Pump...............................................................................33
6.5.3.2.
Emergency Oil Pump ...............................................................................................33
6.5.3.3.
Overhead Tank........................................................................................................33
6.5.4.
Oil Filters ........................................................................................................... 33
6.5.5.
Oil Mist Fan ....................................................................................................... 33
6.5.6.
Lube Oil Purifier................................................................................................. 34
6.6.
JACKING OIL PUMP .......................................................................................34
6.7.
6.8.
6.9.
TURNING GEAR ............................................................................................34

CONDENSER ................................................................................................34
MAIN TECHNICAL PARAMETERS OF STEAM TURBINE .....................................35
7.
BOILER AND AUXILIARIES...........................................................................37

GENERAL .....................................................................................................37
BOILER PRESSURE PARTS ............................................................................40
7.1.
7.2.
7.2.1.
Arrangement of Pressure Parts......................................................................... 40
7.2.2.
Steam Drum ...................................................................................................... 41
7.2.3.
Furnace Walls and Headers.............................................................................. 41
7.2.3.1.
Furnace ....................................................................................................................41
7.2.3.2.
Divisional Wall ..........................................................................................................42
7.2.3.3.
Headers ....................................................................................................................42
7.2.4.
Superheaters..................................................................................................... 42
7.2.5.
De-Superheaters (Attemperators) ..................................................................... 42
7.2.6.
Economiser ....................................................................................................... 43
7.3.
BOILER PERFORMANCE DATA ........................................................................43
7.3.1.
Pressure Part Details ........................................................................................ 43
7.3.2.
Heat Transfer Area............................................................................................ 45
7.3.3.
Temperature Gradient ....................................................................................... 46
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MECHANICAL
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7.3.4.
Pressure Gradient ............................................................................................. 47
7.3.5.
Velocity Profile................................................................................................... 47
7.3.6.
Safety valve details ........................................................................................... 48
7.3.6.1.
Safety Valve Set Pressures .....................................................................................48
7.3.6.2.
Safety Valve Relieving Capacity ..............................................................................48
7.3.7.
7.4.
Fuel, Limestone & Bed Material Consumption .................................................. 48
BOILER MOUNTINGS AND FITTINGS ................................................................49
7.4.1.
Steam Drum ...................................................................................................... 49
7.4.2.
Furnace headers ............................................................................................... 49
7.4.3.
Drain Header ..................................................................................................... 49
7.4.4.
Superheater....................................................................................................... 50
7.4.5.
Spray Water Line............................................................................................... 50
7.4.6.
Economiser ....................................................................................................... 50
7.5.
SOLID FUEL FIRING SYSTEM ..........................................................................50
7.5.1.
Fuel Bunker ....................................................................................................... 51
7.5.2.
Fuel Firing System ............................................................................................ 51
7.5.3.
Fluidized Bed..................................................................................................... 52
7.6.
OIL FIRING SYSTEM ......................................................................................52
7.7.
AIR AND FLUE GAS SYSTEMS ........................................................................52
7.7.1.
Draft System...................................................................................................... 52
7.7.2.
Ductwork and Dampers..................................................................................... 56
7.7.3.
Air Pre-Heater ................................................................................................... 57
7.7.4.
Ash Recycle System ......................................................................................... 57
7.7.5.
Ash Discharge System ...................................................................................... 57
7.8.
BOILER STRUCTURES AND AUXILIARIES ..........................................................58
7.8.1.
Structural Steel.................................................................................................. 58
7.8.2.
Platform, Stairways and Grating........................................................................ 58
7.9.
REFRACTORY AND INSULATION ......................................................................58
7.9.1.
General.............................................................................................................. 58
7.9.2.
Design Temperature Differential - Criteria......................................................... 59
7.9.3.
External Insulation............................................................................................. 59
7.9.4.
Binding and Stitching Wire ................................................................................ 59
7.9.5.
Outer Casing ..................................................................................................... 59
7.10.
7.11.
7.12.
CHEMICAL DOSING SYSTEM ..........................................................................59

SAMPLING LINES ..........................................................................................60
BLOW DOWN TANKS .....................................................................................60
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7.13.
7.14.
ESP DESIGN BASIS .......................................................................................60

CHIMNEY DESIGN BASIS .............................................................................61
7.14.1.
Calculation of Chimney Height....................................................................... 62
7.14.2.
Calculation of Chimney Diameter................................................................... 62
7.14.3.
Sketch of Chimney ......................................................................................... 63
8.
STEAM, FEED WATER AND CONDENSATE SYSTEM ................................63

8.1.
STEAM SYSTEM ............................................................................................63
8.1.1.
8.2.
Control Philosophy ............................................................................................ 66
FEED WATER SYSTEM ..................................................................................66
8.2.1.
Deaerator .......................................................................................................... 66
8.2.2.
Boiler Feed Pumps............................................................................................ 68
8.2.3.
HP Feed Water Heaters .................................................................................... 70
8.2.4.
Feed Water Control Station.............................................................................. 70
8.2.5.
8.3.
CONDENSATE SYSTEM ..................................................................................71
8.3.1.
Surface Condenser ........................................................................................... 72
8.3.2.
Air Evacuation Equipment ................................................................................. 74
8.3.3.
Condensate Extraction Pumps.......................................................................... 75
8.3.4.
LP Feed Water Heaters..................................................................................... 78
8.3.5.
Gland Steam Condenser................................................................................... 78
8.3.6.
Make-up Water................................................................................................. 79
8.3.7.
9.
WATER SYSTEM ............................................................................................80

9.1.
PLANT WATER SYSTEM .................................................................................80
9.1.1.
Raw Water System & Raw Water Reservoir ..................................................... 80
9.1.2.
Raw Water Pre-Treatment Plant & Clarified Water Tank .................................. 81
9.1.3.
Main Cooling Tower Make-up System .............................................................. 82
9.1.4.
DM Feed-cum- Auxiliary Cooling Tower Make-up System................................ 83
9.1.5.
Demineralization Water System ........................................................................ 84
9.1.6.
DM Water Distribution System .......................................................................... 86
9.1.7.
Service Water System....................................................................................... 86
9.1.8.
Potable Water System....................................................................................... 87
9.2.
COOLING WATER SYSTEM .............................................................................88
9.2.1.
Main Cooling Water System For Condenser..................................................... 88
9.2.1.1.
System Description ..................................................................................................88
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MECHANICAL
PP 067 M B01 0
9.2.1.2.
9.2.2.
System Sizing Calculation........................................................................................89
Auxiliary Cooling Water System For Auxiliaries ................................................ 91
9.2.2.1.
System Description ..................................................................................................91
9.2.2.2.
System Sizing Calculation........................................................................................92
9.2.3.
Cooling Water Treatment Scheme .................................................................... 94
10.
FUEL OIL SYSTEM.........................................................................................94
11.
FUEL HANDLING SYSTEM............................................................................94
11.1.
11.2.
12.
LIME STONE HANDLING SYSTEM .............................................................101
12.1.
13.
SYSTEM DESCRIPTION ................................................................................102
13.1.1.
Bed Ash Conveying System ........................................................................ 103
13.1.2.
Fly Ash Conveying System .......................................................................... 103
13.1.3.
Ash Silos ...................................................................................................... 105
13.2.
SYSTEM SIZING .........................................................................................106
13.2.1.
Design Calculation for Intermediate Ash Silo:.............................................. 106
13.2.2.
Design Calculation for Bed Ash Silo: ........................................................... 107
13.2.3.
Design Calculation for Fly Ash Silo:............................................................. 107
COMPRESSED AIR SYSTEM ......................................................................108
14.1.
14.2.
SYSTEM DESCRIPTION .................................................................................108
SYSTEM SIZING ..........................................................................................110
14.2.1.
Instrument Air System.................................................................................. 110
14.2.2.
Service Air System....................................................................................... 110
14.3.
15.
SYSTEM DESCRIPTION & SYSTEM SIZING .....................................................101
ASH HANDLING SYSTEM............................................................................102
13.1.
14.
SYSTEM SIZING ............................................................................................95

SYSTEM DESCRIPTION ..................................................................................96
EQUIPMENT DESCRIPTIONS ................................................................111
AIR CONDITIONING SYSTEM .....................................................................113
15.1.
15.1.1.
Air Conditioning System for Central Control Room & Associated Areas ..... 113
15.1.2.
Air Conditioning System for Other Areas ..................................................... 115
15.2.
SYSTEM SIZING ..........................................................................................116
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MECHANICAL
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16.
VENTILATION SYSTEM ...............................................................................117
16.1.
16.1.1.
Ventilation System for Power House Building & associated Areas.............. 117
16.1.2.
Ventilation System for Auxiliary Buildings in Various Locations .................. 118
16.2.
17.
SYSTEM SIZING ..........................................................................................120
FIRE PROTECTION SYSTEM ......................................................................121
17.1.
17.1.1.
Fire Water System ....................................................................................... 122
17.1.2.
Hydrant System ........................................................................................... 122
17.1.3.
Spray Water System .................................................................................... 123
17.1.4.
Portable & Mobile Fire Extinguishers ........................................................... 124
17.1.5.
Fire Detection & Alarm System .................................................................... 124
18.
CRANES AND HOISTS.................................................................................125
19.
ELEVATORS.................................................................................................127
20.
ENVIRONMENTAL CONSIDERATION.........................................................127
20.1.
GASEOUS EMISSION ...................................................................................127
20.2.
LIQUID EFFLUENT .......................................................................................128
21.
PIPING SYSTEM ...........................................................................................130
21.1.
21.2.
POWER CYCLE PIPING ................................................................................130

LOW PRESSURE UTILITY PIPING ...................................................................131
21.3.
21.4.
21.5.
21.6.
21.7.
COOLING WATER PIPING .............................................................................131

DESIGN BASIS FOR PIPING ...........................................................................132
MAIN STEAM PIPING ....................................................................................134
OTHER STEAM PIPELINES ............................................................................135
BOILER FEEDWATER PIPING .........................................................................136
21.7.1.
Boiler Feed Water Suction & Discharge Lines ............................................. 136
21.7.2.
Boiler Feedwater Recirculation Piping ......................................................... 136
21.7.3.
Boiler Blow Down, Vents, Drains ................................................................. 136
21.8. CONDENSATE PIPING ...................................................................................136

21.9. PIPING FOR RAW WATER .............................................................................137
21.10. AIR PIPE LINE ..........................................................................................137
21.11. DM WATER PIPE LINE ..............................................................................137
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MECHANICAL
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21.12.
21.13.
21.14.
21.15.
21.16.
21.17.
EFFLUENT ...............................................................................................137
SERVICE AND POTABLE WATER PIPE LINE ...................................................138
CONDENSER COOLING WATER PIPING ........................................................138
AUXILIARY COOLING WATER PIPING ...........................................................138
FIRE WATER PIPING .................................................................................138
VALVES...................................................................................................138
21.17.1.
Insulation .................................................................................................. 139
21.17.2.
Pipe Supports and Hangers...................................................................... 139
21.17.2.1. Constant Spring Hangers.......................................................................................139

21.17.2.2. Variable Spring Hangers ........................................................................................140
21.17.2.3. Rod Hangers ..........................................................................................................140
21.17.2.4. Pipe Clamps and Shoe / Saddle supports .............................................................140
21.17.2.5. Materials of Construction .......................................................................................140
21.18.
22.
GENERAL GUIDELINES FOR PIPING ............................................................140
ANNEXURES ................................................................................................142
22.1.
22.2.
22.3.
22.4.
ANNEXURE I : HEAT AND MASS BALANCE DIAGRAM ......................142

ANNEXURE II : WATER BALANCE DIAGRAM .....................................142
ANNEXURE III : FLOW DIAGRAM FOR ASH HANDLING SYSTEM ...................142
ANNEXURE IV : FLOW DIAGRAM FOR FUEL HANDLING SYSTEM .................142
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MECHANICAL
PP 067 M B01 0
INTRODUCTION
This document aims at establishing the criteria for basic and detail
engineering, sizing and specifications of the Power Plant equipment, systems,

components, and piping for the 2 x 60 MW Power Plant at Choudwar in Cuttack
district, Odisha, being set up by M/s. Indian Metals & Ferro Alloys (IMFA) Limited.
The basic design inputs like Fuel analysis, Water analysis, Site conditions,
etc. have been spelt out in various sections of this document, which are as per
IMFA inputs. Details developed in this document is generally in line with the
agreed contract document.
This document is to be read in conjunction with design basis report for
Electrical Systems, Civil Works and Instrumentation systems. For an overall
understanding of the plant and design of auxiliary equipments and system, certain
details of major equipments like boiler, steam turbine etc. have been incorporated
in this document. Further details for such equipment will be available only in O&M
manual of the respective equipment.
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, some changes may have to be accommodated
without compromising the overall plant performance, operability & reliability.
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10
UNITS OF MEASUREMENT & ABBREVIATIONS

2.1. UNITS OF MEASUREMENT
Deg.C
Degree Celsius
kg/cm2 (a) or Ata
Kilograms per Square Centimetre (Absolute)
kg/cm2 (g)
Kilograms per Square Centimetre (Gauge)
kV
Kilo Volt
kW
Kilo Watt
MLC
Meters of Liquid Column
MW
Mega Watt
MWC
Meters of Water Column
No.
Number
Nos.
Numbers
TPH
Tons Per Hour
2.2. ABBREVIATIONS
ACW
Auxiliary Cooling Water System
AHP
Ash Handling Plant
CEP
Condensate Extraction Pump
CHP
Coal Handling Plant
CV
Control Valve
DBR
Design Basis Report
DM
De-Mineralised
HP
High Pressure
IPP
Independent Power Plant
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3.
LP
Low Pressure
MB
Mixed Bed
MCW
Main Cooling Water System (for Condenser)
MOC
Material of Construction
MSL
Mean Sea Level
PRDS
Pressure Reducing & De-superheating Station
PRV
Pressure Reducing Valve
Re
Reynolds Number
RL
Reference Level
RO
Reverse Osmosis
SAC
Strong Acid Cation
SBA
Strong Base Anion
SHP
Superheated High Pressure
STG
Steam Turbine Generator
TDH
Total Dynamic Head
UF
Ultra Filtration
BFP
Boiler feed pump
CODES & STANDARDS

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 & laws
generally to be used in the design and construction is listed below;
International Standard Organization (ISO)
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Bureau of Indian Standards (BIS)
International Electro-technical Commission (IEC)
DIN Standards
British Standards (BS)
American Society of Mechanical Engineers (ASME)
American Society of Testing and Materials (ASTM)
American Welding Society (AWS)
American Institute of Steel Construction (AISC)
American Water Works Association (AWWA)
American National Standard Institute (ANSI)
Architecture Institute of Japan (AIJ)
National Electrical Manufacturers Association (NEMA)
Japanese Electro-technical Committee (JETC)
Power Test Code (PTC)
Electric Power Research Institute (EPRI)
Heat Exchanger Institute (HEI)
Hydraulic Institute Standard (HIS)
Japanese Industrial Standards (JIS)
Tariff Advisory Committee of India (TAC)
National Fire Protection Association (NFPA)
Steel Structures Painting Council (SSPC)
Tubular Exchanger Manufacturer & Association (TEMA)
Indian Boiler Regulation (IBR) Act
American Petroleum Institute (API) codes
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Standards of Manufacturer Standardization Society (MSS)
Indian Electricity Act
Indian Electricity Rule
Indian Factory Act & State Factory Act
Instrument Society of America (ISA)
Federal Occupational Safety and Health Organization (OSHA)
Loss Prevention Association of India (LPA)
Emission regulations of Central Pollution Control Board, India
Central Board of Irrigation and Power (CBIP) publications, India
Pollution Control Regulations of Dept. of Environment, Govt. of India
Permissible limits for pollutants of Orissa Pollution Control Board
Institute of Electrical and Electronic Engineers (IEEE)
National Electric Code (NEC)
Environment (Protection) Act
Environment Protection Agency (EPA) Code
Petroleum Act
Expansion Joints Manufacturers Association (EJMA)
Oil Industry Safety Directorate (OISD)
Indian Explosives Act
Chinese National Standards (GB)

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
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14
reliability.
4.
POWER PLANT CONFIGURATION

4.1. PLANT CONFIGURATION
The power plant consists of the following major Mechanical systems and
equipment:
Two (2) number Boilers: Circulating Fluidized Bed Combustion (CFBC)

type, each generating 240 TPH at 101 kg/cm2 (a) pressure and 540 +
5oC temperature at the Main Steam Stop Valve using fuel as per Coal
Analysis mentioned elsewhere in this document. The boiler envisage desulphuring using lime stone as per lime stone analysis mentioned
elsewhere in this document.
Two (2) number Electro Static Precipitator (ESP), one each per
boiler, each ESP will have single stream of 100% gas path, designed for
dust concentration at ESP outlet of 50 mg/Nm3 with one field out of
operation.
Two (2) number single-flue Steel Chimney one for each boiler. The
height of the chimney will be restricted to 44 m.
Two (2) number STG: Multi-stage, single flow, condensing type Steam
Turbine Generator, with five uncontrolled extraction for regenerative
heating, generating 60 MW at 11 kV voltage level with an inlet steam at
98 kg/cm2 (a) pressure and 535oC temperature before emergency stop
valve and exhausting against condenser pressure of around 0.1 kg/cm2

(a) with necessary auxiliaries like lube oil & control oil system, governor
system, gland sealing system etc. In VWO condition, the steam turbine
generator is capable to generate 63 MW.
STG condensing plant consists of Condenser with air evacuation

system, and condensate extraction pumps.
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Regenerative feed heating system consists of two LP heater, one

Deaerator, two HP heater.
Turbine bypass system Capacity 60% of TMCR.
Boiler feed water pumping system with 3 x 100 % Motor driven boiler
feed water pumps. Out of these three pumps, one will be operating
normally for each boiler unit while the third pump shall remain as a
common standby and will come into operation automatically in case one
of the working pump fails.
One Main Cooling Tower for both units with 7 cells (6 working & 1
standby) induced draft counter flow design and RCC / Pultruded FRP
construction and main cooling water pumping system.
One Auxiliary Cooling Tower for both units with 2 cells (1 working & 1
standby) induced draft counter flow design and FRP / Pultruded FRP
construction and auxiliary cooling water pumping system.
Note : Both for main and auxiliary cooling tower as an alternative to RCC,
pultruded FRP structure as part CTI USA may be used. In either
case, cooling tower basin & fore bay etc. will remain as RCC only.
Fuel handling system consists of fuel feeding, belt conveyors, crushing

and screening system, bunker feeding system, dust extraction and
suppression system etc.
Lime stone handling system consists of lime stone feeding, belt

conveyors, lime stone crushing and pneumatic conveying system etc.
Ash handling system: Dense phase pneumatic handling system for

conveying bed ash and fly ash to bed ash silo and fly ash silos
respectively. The silos shall be designed for storing of ash for 24 hours.
Water system consists of raw water supply pumps pumping raw water
from raw water reservoir, water pre-treatment plant & DM water system,
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CW treatment plant, potable and service water system and effluent

system.
Compressed air system consists of plant air compressors and Air

drying plant for instrument air and service air compressors for service
air.
Air conditioning &Ventilation system.
Fire protection system for the power plant, transformer area, fuel oil
area, switch yard area, coal handling area and ash handling area.
Inter-connecting piping system
EOT crane for TG building and miscellaneous hoists and monorails.
Elevators for Boiler and Power House building.
4.2. PLANT STARTUP, OPERATION AND CONTROL PHILOSOPHY

The complete plant operation and control will be monitored from the Central
Control Room through a dedicated Distributed Controlled System (DCS) terminal.
Individual systems like water treatment plant, coal handling plant, ash
handling plant etc. will have its own PLC, communicating with the central DCS.
Turbovisory control also will have dedicated PLC interconnected to DCS. For
other equipments and systems including the boiler field instruments will be
controlled through DCS where necessary control will be considered.
Overall system architecture has been presented in Dwg. No. PP 067 I 001
3. Further details of control and instrumentation for the total system will covered in
separate DBR of control and instrumentation.
4.3. CUSTOMERS DESIGN INPUTS
4.3.1. SITE CONDITIONS
Sr.
No.
Item
Description
POWER DIVISION
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POWER PLANT, IMFA,
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DESIGN BASIS REPORT

MECHANICAL
PP 067 M B01 0
17
Sr.
No.
Item
Description
1.
Project Title
2 X 60 MW Thermal power project
2.
Location
Choudwar, Distt. Cuttack, State of

Orissa.
Longitude: 8554 E
Latitude: 2031 N
3.
Nearest Town
Choudwar: 0 KMs, Cuttack: 12 KMs
4.
Nearest City
Cuttack 12 KMs.
5.
Nearest Port
Paradeep
6.
Nearest Railway Station
Charbatia 12 km away
7.
Nearest Airport
Bhubaneshwar, at a distance of around

45 kms.
8.
Fuel Availability
Blended coal from Washery Rejects

and F-grade Indian coal.
9.
Coal Transportation
By Coal Conveyors
10.
Water Source
Mahanadi River Water
11.
Meteorological Data
a.
Site elevation
47.38 m above MSL
b.
Ambient Temperature
50 Deg.C.
c.
Average annual rainfall
1475 mm
d.
Average
humidity
relative
62%
e.
Maximum relative humidity
84%
f.
Minimum relative humidity
46%
Mean
POWER DIVISION
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MECHANICAL
PP 067 M B01 0
18
Sr.
No.
Item
Description
g.
Type of atmosphere
Hot and Sultry
h.
Annual
Velocity
i.
Maximum Wind velocity
As per IS 875 Part III
j.
Basic wind speed
As per IS 875 Part III
k.
Design Wind velocity
As per IS code specific to the site

location Choudwar, Cuttack
l.
Wind Direction
South to North.
Seismic Data
As per IS : 1893 (Latest Issue)
m.
Mean
Wind
6.4 Km/hr
4.3.2. COAL ANALYSIS

ULTIMATE ANALYSIS
ELEMENTS
RANGE
BLENDED COAL
(DESIGN BASIS)
ROM coal (%)
Rejects Coal (%)
Performance Coal
(%) (50% ROM 50% Reject)
Carbon
33.73
19.50
26.62
Hydrogen
2.35
1.90
2.13
Oxygen
5.77
4.50
5.14
Sulphur
0.37
0.30
0.34
Nitrogen
0.78
0.80
0.79
Ash
42.00
60.00
51.00
Moisture
15.00
13.00
14.00
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PP 067 M B01 0
19
TOTAL
100.00
100.00
100.00
GCV (Kcal/Kg)
3280.00
2010.00
2645.00
PROXIMATE ANALYSIS
Ash
42.00
60.00
51.00
Volatile matter
21.00
14.00
17.50
Moisture
15.00
13.00
14.00
Fixed carbon
22.00
13.00
17.50
Total
100.00
100.00
100.00
COAL SIZE
Feed Coal size at Grizzly of Ground
90 % below 100 mm.
Hopper by Customer
4.3.3. ASH ANALYSIS :
ELEMENTS
ROM Coal (%)
Rejects Coal (%)
Alumina as Al2O3
28-30
20.65
Calcium as CaO
0.5-0.7
1.44
Chlorides as Cl
0.12
Iron as Fe2O3
3-5
6.21
Magnesium as MgO
0.2-0.4
0.41
Phosphorus as P2O5
0.4-0.5
0.24
Potassium as K2O
0.5-0.7
0.59
Silica sa SiO2
60-65
64.2
Sodium as Na2O
0.05-0.1
0.8
Sulphur as SO3
0.2-0.4
0.18
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PP 067 M B01 0
20
Titanium as TiO2
1-2
2.32
< 0.01
0.02-0.04
0.12
Zinc as ZnO
0.02
Loss on ignition
2.11
Total carbonates as CO3

Manganese
Mn3O4/MnO
oxide
as
4.3.4. LIME STONE ANALYSIS

COMPONENT
% BY WT. (RANGE)
LIME STONE ANALYSIS

CaCO3
90 94% for operability. For

guaranteed
sulphur
capture
on
performance fuel to restrict chimney
height to 44 m, CaCO3 content shall
be 94%.
MgCO3
0.5 1.0
SiO2
1.0 1.5
Inert
3.5 4.5
LIME STONE PROPERTIES

Reactivity
> 3.3
Attrition Index
< 2.6
Nature
Soft, Powdery
LIME STONE PARTICLE SIZE

Feed Lime stone size at Grizzly of
90 % below 20 mm.
Ground Hopper by Customer
4.3.5. BED MATERIAL ANALYSIS (AS REQUIRED BY BOILER DESIGN)
Analysis
Unit
Range
Silica
65 68
Al2O3
25 28
FeO
0.95 1.1
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PP 067 M B01 0
21
TiO2
1.5 1.7
MnO
Traces
CaO
0.5 0.6
MgO
0.2 0.25
P2O5
Less than 0.1
Na2O
Less than 0.22
K2O
Less than 0.45
BED MATERIAL SIZE

Size in Microns
Unit
% Passing
< 500
100
< 400
90
< 300
50
< 250
10
4.3.6. RAW WATER ANALYSIS

Sl.
Description
No.
Unit
Range
1.
Source
Mahanadi River
2.
Calcium
mg/l as CaCO3
31 35
3.
Magnesium
mg/l as CaCO3
13 15
4.
Sodium
mg/l as CaCO3
28 32
5.
Total Cations
mg/l as CaCO3
72 82
6.
Sulphate
mg/l as CaCO3
9 14
7.
Chlorides
mg/l as CaCO3
11 15
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PP 067 M B01 0
22
8.
Bi- Carbonates
mg/l as CaCO3
52 60
9.
Total Anions
mg/l
72 89
10.
Iron as Fe
mg/l as CaCO3
0.8 1.0
11.
Silica (Reactive)
mg/l as SiO2
8.0 10
12.
M- Alkalinity
mg/l as CaCO3
52 60
13.
Turbidity
NTU
184 200
14.
Total Suspended Solids
mg/l
170 190
15.
Total Dissolved Solids
mg/l
70 80
16.
pH value at 25oC
17.
Conductivity at 25oC
18.
Colloidal Silica
19.
COD
mg/l
Traces
20.
BOD
mg/l
Traces
7.6 7.8
S/cm
mg/l as SiO2
137 150
NIL
POWER PLANT LAYOUT

The following factors are considered in developing the Plant Layout;
Adequate clearances 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 minimize the effects of any fire or
explosion. Recommendations of TAC will be followed.
Convenience of power evacuation.
Logistics for road tanker movement
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Convenience of fuel intake.

Convenience of Installation.
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 2 m shall be maintained between floors and over head piping /
cabling.
All road crossing for pipe / cable rack shall be done with minimum 5.5 m
head room from top of road to bottom of rack where only Truck movement
is expected and 7.0 m where crane movement is expected. Minimum 8 m
clearance shall be kept in case of railway track with overhead traction.
Similarly top cover over any underground pipe / cable shall be minimum 1
m.
The power plant is classified in following areas:
Power block area
Fuel handling area
Water system area
Switchyard area
Ash Silo Area
5.1. POWER BLOCK AREA
The following areas, buildings, structures and equipment are located within
the power block:
a) Power house building
b) Boilers, ESPs & Chimney
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PP 067 M B01 0
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c) Cooling tower
d) Compressor room
f) DG room
5.1.1. POWER HOUSE
The Power House will include:
Steam Turbine Generator & auxiliaries which includes condenser, CEPs,
LP & HP heaters, Deaerator, BFPs, steam jet ejectors, gland steam condenser etc.
located in the Steam Turbine Hall.
Power house building size shall be 87 m x 31.5 m devided into AB bay
(20.5 m wide) & BC bay (11 m wide). AB bay shall have 3 floor elevations i.e.
ground floor at 0 m, mezzanine floor at 4.5 m & operating floor at 10 m. BC bay
shall have 4 floor elevations i.e. cable spreader floor at 0 m, swithgear floor at 4.0
1
m, control room floor (false floor) at 10 m & deaerator floor at 15 m.

Technical building of size 12 m x 31.5 m is located adjacent to power house
building on unloading bay side.
The layout of the STG hall shall be designed considering the following:
1.
Two (2) nos. Steam Turbine Generator will be located in the turbine hall of
78 m length and 20.5 m span (width) at operating floor (10 m).
2.
Adequate space for maintenance of Steam Turbine and Generator shall be

provided.
3.
The STG unloading and maintenance area has been provided on the
turbine side of Unit No 1.
4.
The Turbogenerator (TG) deck elevation shall be selected based on:

9 NPSH requirement of Condensate Extraction Pump
9 Surface condenser dimensions
9 Elevation of intermediate floor
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MECHANICAL
PP 067 M B01 0
25
5.
The crane rails elevation of the turbine hall shall be selected based on
turbine height and crane clearance required above turbine.
6.
The vertical can type Condensate Extraction Pump will be located adjacent
to the Condenser on the ground floor.
7.
The Lube Oil System will be located at mezzanine floor (4.5 m) level on
turbine side.
8.
The Deaerator will be mounted on the roof of the control building i.e. at
Deaerator floor level (15 m). The Deaerator foundation design will take into
consideration any possible vibration due to steam chugging.
9.
The boiler feed pumps shall be located within the power house at ground
floor (0 m). Vertical HP & LP heaters are also located on ground floor.
10. A mezzanine floor (4.5 m) would be provided to accommodate STG

auxiliaries like Gland Steam Condenser & Steam Jet Air Ejector.
11. Adequate number of staircases shall be provided for easy access to each
floor and as per applicable norms.
5.1.2. BOILER AREA
The boilers will be semi-outdoor installation.
The boilers shall be provided with canopy and side cladding down to the
canopy level. Side cladding will also be provided up to bunker top in the bunker.
The entire outer casing for the boiler, auxiliaries and piping shall be
designed suitable for semi-outdoor installation.
Distance between the boiler centrelines are maintained such that adequate
space is available for removal of equipment and maintenance. All fans (SA, PA
and ID) are suitably located to provide adequate access for maintenance. ESP is
located between Air Pre-heater outlet & ID fan inlet. ESP control room is located
adjacent to ESP.
The boilers shall be connected to individual single flue steel chimney
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MECHANICAL
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26
provided with necessary aviation lighting, lightning-protection, sampling ports with

platforms etc.
Adequate platform and staircase will be provided for boiler to access
different floor levels and equipment / valves / instruments of boiler for operation
and maintenance.
Both the boiler will be suitably connected through galleries at three different
levels.
5.1.3. COOLING TOWER AREA
Cooling tower area consists of Main Cooling Tower (MCT), Auxiliary
Cooling Tower (ACT), Main & Auxiliary cooling water pump house, MCC & control
room and chlorine dioxide generator room.
The MCT shall be of RCC / Pultruded FRP construction & ACT shall be of
FRP / Pultruded FRP construction. A fore bay shall be provided for cooling water
pumps suction. The dimension of cooling tower basin and the forebay shall be
selected to accommodate the respective cooling tower cells. Main & Auxiliary
cooling water pumps shall be vertical wet pit type and located such that easy
access and maintenance is ensured.
The MCT basin will be suitably partitioned such that equal no. of cells
serves each unit and one common cell serves both the units. A common forebay
will take the cold water to the pump house.
The ACT basin will be partitioned between each cell and a common forebay
will take the cold water to the pump house.
Cooling water piping of the plant will be generally underground except in
power house building.
5.2. FUEL AREA
A grizzly hopper is provided for feeding the fuel in underground tunnel. The
crusher and screen for coal will be located in separate RCC building.
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MECHANICAL
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27
The inclination angle for coal conveyor will be 14 maximum. Central

walkway of 1000 mm and side walkways of 800 mm with 2.7 m clear height will be
provided along the belt conveyor gantry. A separate MCC cum control room for
coal handling plant will be provided near the crusher house.
5.3. WATER SYSTEM AREA
5.3.1. RAW WATER RESERVOIR
Raw Water Reservoir shall be developed in designated area for collection
and storage of raw water. Reservoir shall be a cut and fill arrangement with
suitable embankment around this area upto a height required to build the 10,000
m3 capacity of the reservoir. Reservoir shall have two (2) compartments so that
one half can be emptied and maintained without disturbing the plant operation.
Design and construction of the reservoir shall be done in such a fashion that no
water can escape from the reservoir through seepage.
Raw water pump shed shall be adjacent to this reservoir which will house
raw water pumps to draw required water from the reservoir.
5.3.2. WATER TREATMENT AREA
Water Treatment Plant is located to the north east of the Power Plant. The
raw water from reservoir is fed to the water treatment plant. The water system
consists of raw water pre-treatment plant, Dematerialization plant, CW treatment
system, potable & service water system.
The water pre-treatment plant comprises aerator and tube settler type
clarifier system followed by clarified water storage tank, of required capacity. The
DM water feed pumps, CT make-up pumps, Fire water pumps, Service water
pumps are housed in Clarified Water Pump House.
Demineralization plant consist of 2x100 % capacity complete with dual
medium filter, activated carbon filter, cation, anion and mixed exchanger.
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28
5.4. SWITCHYARD AREA

The 132 kV switchyard & 33 kV switchyard are located on west end side of
the plant so that HT line from the generator transformer can be conveniently
interconnected.
5.5. ASH SILO AREA
Bed & Fly ash silos of RCC construction are provided eastern side of the
plant near to the plant boundary & away form main plant area to avoid the dust
nuisance while discharging to the open truck.
5.6. MISCELLANEOUS
The interconnection pipe work between plant utilities and power block
equipment will be routed through 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, wherever over ground piping would
cause obstruction or hindrance to man or vehicle movement.
6.
STEAM TURBINE
6.1. GENERAL
The steam turbine generator (STG) unit is designed to operate as at a base
load and in parallel with grid. During disturbances in the electrical grid, the unit is
capable of operating in an island mode catering to its own house load (about 10%)
with bypass system in operation. These disturbances will not cause tripping of
steam generator.
The steam turbine has designed to meet the requirements of the latest IEC
Standard Publication No. 45. The steam turbine is designed for quick start-up
rates and to withstand rapid load fluctuations without causing undue thermal
stresses and strains in the components of steam turbine.
The various components of the STG are described below.
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6.2. TURBINE
The Steam Turbine will be of horizontal, single casing impulse-reaction with
axial flow multistage construction. The Turbine will be designed with five bleeds,
for the regenerative heating requirement in LP Heater, Deaerator and HP Heater.
Steam Turbine Casings & Admission Valves
The turbine casing is horizontally split. The upper and lower casing halves
are flanged and assembled by bolts. Steam flow through the turbine is in the axial
direction. After leaving the body of the emergency stop valve, the live steam
enters the valve chest with the control valves which forms an integral casting with
the upper half of the outer casing. The valve chest is designed as a transverse
tube with openings at both ends for assembly.
The turbine casing is divided into an admission and an exhaust section.
Depending on the initial steam conditions, the admission sections of comparable
size are designed with castings of different wall thickness. The admission section
will be completed by an exhaust section of adequate size. The overall length is
adjusted by cylindrical or conical spacer rings.
A hydraulically Operated Emergency stop valve shall be provided for
closing the supply to the Turbine under emergency condition.
Steam Turbine Rotor & Blading
The turbine rotor is integral with the disk of the control-stage wheel and is
forged from a solid blank. Except for the control stage, the blading is of the
reaction type. The moving blades have their root, shaft and shrouding milled from
the same solid forging. Only exception to this rule are the twisted blades of the
low-pressure end rows. Because of their wide spacing and thin shaft section it is
impossible to design them with integrally milled shrouding. The moving blades in
the drum stages have roots of the inverted-T type. Normally, only the roots of the
control-stage blades are forked. But occasionally the last row of low-pressure
blades, depending on the centrifugal stress to which they are subjected, may be
designed with forked roots, too.
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The guide blades are manufactured from drawn bar material and have
pronged roots. The guide blade tips are fitted with riveted shroud strips.
Bearings
By its brackets, the outer casing is supported on the two bearing pedestals
independently from the bearing housings. The vertical position of the outer casing
is determined by adjustable positioning elements located between the brackets
and the supporting plane of the pedestals. The clearance left between the
underside of the assembly-bolt head and the bracket allows for both axial and
lateral expansion of the outer casing with respect to the pedestal. The central
position is ensured by guideways in the bottom half of the casing. They leave the
casing free to expand also in the vertical direction. The fixed reference position of
the casing is at the rear end support brackets. The casing is thus free to yield to
thermal expansion by moving forward on special slide elements between the frontend brackets and the front bearing pedestal. The turbine rotor is supported in the
bearing housings and is radially independent from the outer casing. The radial
journal bearings are of the multi-wedge type. Two or four oil wedges uniformly
spaced on the circumference hold the rotor in a stable position. The bearings are
babbitt-lined.
The correct axial position of the turbine rotor is ensured by a thrust bearing
incorporated in the front bearing housing. It is intended also for taking up the
residual axial thrust. For this reason it is designed as double-acting bearing of the
segment type. The tiltable bearing segments are likewise babbitt-lined. The
heated rotor expands in the direction towards the exhaust hood. As the turbine
casing with its fixed reference position at the rear pedestal expands into the
opposite direction, the resulting differential expansion will be only small on
condition that rotor and casing are heated to approximately the same temperature.
6.3. GLAND STEAM SYSTEM
Shaft outer and interstage glands shall be of the contactless labyrinth type.
The labyrinth rings with the machined sealing collars and recesses shall be split in
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multiple segments that would be pushed in the working position by the flat springs
and by the steam pressure. The stator labyrinth rings segments can be pushed
away from the rotor in case of accidental contact and the rubbing of rotating and
stationary parts can be minimised. The shaft shall have in the gland sections
caulked sheet fins that together with the stator collars form the small chambers of
the labyrinth gland.
During normal operation, the source of sealing steam is from the turbine
itself. During start-up and low loads, an alternative source of sealing steam is
provided from the main steam.The front outer gland shall be fed from a pressurecontrol valve, which shall receive the steam from the main steam line. The rear
outer gland seals during the normal operation permanently face the vacuum inside
of the turbine casing and must be therefore continuously fed by the steam. The
feeding steam shall be taken from the front gland leakage. The leakage steam
from outer labyrinths shall go to the Gland Steam Condenser (GSC). The gland
sealing supply control valve shall be controlled by a pressure transmitter located
on gland steam supply header.
Last sections of both front and rear outer glands shall be slightly below
atmospheric pressure. The gland steam condenser shall keep the pressure in the
last sections lower than atmospheric and to ensure that there is no leak of steam
from the glands in the machine room.
The condensate collected from the Gland steam Condenser shall be sent to
the main condenser and the non-condensable gases shall be vented to the
atmosphere.
6.4. TURBINE DRAIN SYSTEM
During every start-up, it shall be ensured that the drain valves provided on
1
the turbine HP & LP casing, balancing line, gland sealing steam header and
extraction steam line are opened to drain the entrapped condensate to avoid
damage due to high-energy water accumulation or ingress.
Drains are provided at the lowest end of the steam lines. Drains from the
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extraction steam lines before the QCNRV connection are connected to condenser.
The downstream of QCNRV, the drains are connected to atmospheric flash tank
and taken out. Vacuum drains are connected to a manifold in the flash tank whose
top nozzle is connected to steam space of the Condenser and bottom nozzle
connected to the hotwell. The high pressure drain is connected farthest from the
condenser, where as the low pressure drains are connected closer to the
condenser. The drain manifold connection will be above the maximum level in the
condenser hotwell.
6.5. TURBINE LUBE OIL SYSTEM
6.5.1. OIL STORAGE TANKS
Each turbine will have one (1) main oil tank designed considering the
complete drain oil from lube oil system & control oil system. The capacity of the
main oil tank is about 14 m3. The main oil tank will be provided with necessary
level indicator, inlet and outlet oil connections and exhaust fan to evacuate oil
vapour from the tanks. Main oil tank is also provided with necessary connections
for oil centrifuge.
The drain oil tank is provided for handling oil during drain of oil cooler, oil
filter etc. The capacity of the drain oil tank is about 1 m3. The drain oil pump will
deliver the oil back to the main oil tank through oil purifier.
6.5.2. OIL COOLERS
Two (2) oil coolers, each designed with adequate margin, horizontally
mounted will be provided with one (1) running and the other stand-by. The lube oil
coolers shall be interchangeable during service without interruption to oil flow. The
oil cooler tube will be of admiralty brass material. The shell and water boxes will
be made out of carbon steel plates of material specification conforming to IS2062.
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PP 067 M B01 0
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6.5.3. OIL PUMPS

6.5.3.1. Main & Auxiliary Lube Oil Pump
Total three (3) pumps of identical capacity i.e. 3 x 100 % have been
provided, each one capable of meeting the total lube oil requirement. One of these
pumps is designated as Main Oil Pump (MOP) and other two as Auxiliary Oil
Pump (AOP). All the three pumps are AC motor driven.
6.5.3.2. Emergency Oil Pump
The turbine will be provided with an emergency oil pump, mounted on top
of oil tank, driven by an AC & DC motor. It will cater to the needs of bearings of
turbine, gearbox and alternator in case of failure of AC motor driven auxiliary lube
oil pump.
6.5.3.3. Overhead Tank
In the event of a turbine trip when A/C power is not available, the
emergency oil pump, driven by DC power will ensure that necessary lubrication oil
is supplied to the turbine bearings for safe coast down. In the unlikely event of
non-availability of DC power also, the oil pressure in the header may tend to go
down. An overhead tank of adequate capacity is provided for each turbine for
supplying oil to the bearing under such events. The oil from the tank will flow by
gravity. The tank capacity will be suitable for safe coasting down of the turbine.
6.5.4. OIL FILTERS
One (1) duplex lube oil filter and one (1) duplex control oil filter will be
provided each with change over device. The lube oil filter & control oil filter will be
capable of filtering oil to a required quality.
6.5.5. OIL MIST FAN
Two (2x100%) oil mist fan will be provided for evacuating oil vapour from
the oil tank.
The fan will be mounted on top of the tank and the discharge to
atmosphere will be provided with necessary oil catcher arrangement to entrap
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MECHANICAL
PP 067 M B01 0
34
escaping oil.
6.5.6. LUBE OIL PURIFIER
An oil purifier will be provided with necessary filters and heater, including
the pump and motors of the purifier system. The purifier is an off-line equipment
meant to clean the oil in the system by partial recirculation (operated for one shift
per day). Desludging of the purifier shall be done manually periodically. The
system will purify the re-circulating lubricating oil from entrained moisture &
suspended solids. The purifier capacity will be 2000 LPM.
6.6. JACKING OIL PUMP
The turbine will have a 1 x 100 % AC motor driven and 1 x 100 % DC motor
driven jacking oil pump for turbine and generator shaft lifting during starting,
designed so as to lift the rotor from standstill condition.
6.7. TURNING GEAR
When the unit is under shutdown for a long period, due to its inherent
weight, the rotor shaft sags. Rolling of the unit with this condition will result in
contact of the moving parts with the stationary parts. Following tripping of the
machine, due to condensation of the locked up steam, the rotor shaft tends to
hog. In order to prevent sagging and hogging of the rotor shaft, a barring gear
shall be provided. The barring device shall be provided with manual engagement
1
and automatic disengagement facility. The barring gear shall be operated by an

AC motor. In case of AC mains failure, provision for hand barring of the rotor is
provided.
6.8. CONDENSER
Two (2) pass water cooled, horizontal surface condenser with divided water
box design will be provided. The condenser will be designed as per HEI. The
condenser tubes will be of stainless steel (SS 304) construction, tube sheet will of
carbon steel (SA 516 Gr.70) and water box shell / hotwell will be carbon steel (SA
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MECHANICAL
PP 067 M B01 0
35
516 Gr.70) construction. The condenser will be designed with 85% cleanliness
factor. The hot well storage capacity will be minimum 3 minutes between normal
and low level at MCR condition.
6.9. MAIN TECHNICAL PARAMETERS OF STEAM TURBINE
(A) At 100 % TMCR Condition
Parameter
Unit
Value
Power at generator terminal
kW
60,000
Main Steam Pressure at Turbine inlet
Ata
98
Main Steam Temperature at Turbine inlet
535
Main Steam Flow at Turbine inlet
TPH
224
Main steam requirement for auxiliaries
TPH
0.5
Exhaust steam pressure
Ata
0.1
Exhaust flow
TPH
158.27
Unit
Value
kW
63,000
Ata
98
(B) At VWO Condition

Parameter
535
TPH
240
TPH
0.5
Ata
0.1
Exhaust flow
TPH
169.95
Unit
Value
kW
60,000
(C) At Top HP Heater out Condition

Parameter
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MECHANICAL
PP 067 M B01 0
36
Ata
98
535
TPH
219
TPH
0.5
Ata
0.1
Exhaust flow
TPH
166.33
Unit
Value
kW
60,000
Ata
98
(D) At Both HP Heaters out Condition

Parameter
535
TPH
210.6
TPH
0.5
Ata
0.1
Exhaust flow
TPH
172.16
Unit
Value
kW
60,000
Ata
98
(E) At Both LP Heaters out Condition

Parameter
535
TPH
232.7
TPH
0.5
Ata
0.1
Exhaust flow
TPH
166.8
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MECHANICAL
PP 067 M B01 0
37
(F) At 80 % TMCR Condition

Parameter
Unit
Value
kW
48,000
Ata
98
535
TPH
180.8
TPH
0.5
Ata
0.1
Exhaust flow
TPH
132
Unit
Value
kW
30,000
Ata
98
(G) At 50 % TMCR Condition

Parameter
7.
535
TPH
113.6
TPH
0.5
Ata
0.1
Exhaust flow
TPH
87.1
BOILER AND AUXILIARIES

7.1. GENERAL
Boiler is Internal Re-circulation Circulating Fluidised Bed Combustion (IR-
CFBC) type Natural Circulation, Single Drum, Top Supported, Water tube,
Balanced Draft with Over-Bed fuel feeding system, Suitable for semi-outdoor
installation.
The following is the basis for the design of the CFBC Boiler:
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MECHANICAL
PP 067 M B01 0
38
Sl.
No.
Parameters
1.0
Capacity
1.1
Maximum Continuous Rating [BMCR]

at main steam stop valve
2.0
Pressure
2.1
Steam Pressure at main steam Stop

valve outlet
3.0
Temperature
3.1
Steam temperature at main steam

Stop valve outlet.
Unit
Value
TPH
240
Kg/cm2(a)
101
540 5
3.2
Steam temp. control range for design

performance fuel
% MCR
60% MCR -100% MCR
3.3
Feed water temperature at Deaerator

outlet
158
3.4
Feed water temperature at

Economiser inlet
225
4.0
Ambient Conditions
4.1
Ambient temperature
35
4.2
Relative humidity
60
5.0
Fuel
5.1
Main fuel
As mentioned below
5.2
Startup fuel
LDO
The boiler is designed for firing following fuels (Refer to coal analysis as
mentioned elsewhere in this document):
1
1. 50% Washery Rejects + 50% ROM Coal combination on weight basis

(Performance fuel).
2. 100 % ROM Coal.
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MECHANICAL
PP 067 M B01 0
39
3. 100 % Washery rejects.

The boiler is designed and manufactured as per Indian Boiler Regulations
(IBR) codes. All the requirement of IBR will be taken care for safe operation of
boiler. The pressure part materials will be as per IBR codes and standard. Piping
design will be as per IBR / ASME B31.1 (latest addition). The calculations of all
pressure parts will be submitted to the Chief Inspector of Boilers for their approval.
Major boiler parts can be described as Pressure retaining parts (steam and
water circuit), Bunker and fuel feeding equipments, Air-preheater and air ducting
component, Flue gas system, Boiler supporting structure and platforms, Hoppers
and fly ash system.
The complete furnace section will be of fusion welded wall type arranged as
a gas and pressure tight envelope. The circulation system will be complete with
the necessary number of down comers, supply and riser tubes piping. Steam
drum with internals are mainly separating the steam in two stages, first stages
separation done by cyclone-separator and final separation by scrubber.
The convection superheaters (Primary & Secondary SH) will be located at
the furnace exit. De-superheater, for controlling main steam temperature from
boiler within required range, will be provided in two stages. First stage desuperheater is provided between primary superheater 1 & primary superheater
2 and second stage de-superheater between primary - 2 & secondary
superheater. The location, selection and arrangement of the superheater sections
will be chosen so that the rated steam temperature at the superheater outlet is
achieved between 60 to 100 % MCR load. The boiler will be provided with bare
tube economiser fabricated from plain seamless tubes. The boiler will also be
provided with a tubular air heater as the last stage of heat recovery unit. The
complete integral piping, valves, fittings and pipe supports will be provided for
efficient operation of the boiler.
The first pass of boiler and arch is of completely welded membrane panel
construction are well restrained by buck stays and guide to withstand the furnace
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MECHANICAL
PP 067 M B01 0
40
pressure. The boiler is provided with necessary access platform, galleries and
stair case to approach all equipments and pressure part. The boiler top is well
enclosed by canopy with side sheeting / lovers up to drum level. The required
structural supporting steelwork for the boiler, galleries, staircases and outer casing
will be provided for the boiler, auxiliaries, ducting etc.
The boiler has been provided with three storage bunkers for application of
coal (as a main fuel), lime stone (an additive) and bed material.
The fuel feeding system will consist of drag chain feeders and fuel feed
lines. The fluidised bed is located at the bottom most part of the furnace.
The boiler will be provided with two nos. (2 x 60% MCR) ID, SA and PA
fans and the complete air and gas ducting with required dampers and expansion
joints. All the fans will be provided with variable speed fluid coupling.
The feed water system will consist of three (3) nos. (3 x 100 %) motor
driven boiler feed pumps (with variable speed fluid coupling) of which one (1)
1
pump will be working for each boiler unit with third pump as a common standby,
together with complete piping, valves and other fittings.
All required actuators and controls and instrumentation will be supplied.
A brief outline of the various sections of the proposed boiler and auxiliaries
are presented in the following paragraphs.
7.2. BOILER PRESSURE PARTS
7.2.1. ARRANGEMENT OF PRESSURE PARTS
Boiler will have steam drum and be designed for natural circulation with
single pass design. Boiler will be top supported on supporting structure. The
furnace will be formed by fusion welded membrane wall panel on the top of the
furnace & with refractory on bottom of the furnace.
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MECHANICAL
PP 067 M B01 0
41
7.2.2. STEAM DRUM

Steam drum will be of welded construction, completely radiographed to
prove weld soundness, stress relieved and hydraulically tested. The boiler quality
plate for the drums will be fabricated to the appropriate specification and
constructed in accordance with the codes and regulations of Indian Boiler
Regulations.
Drum will be provided with suitable hemispherical dished ends and
manholes, each with a swing type cover opening internally.
The steam drum will be of fusion welded construction, with material
specification conforming to SA 516 Gr. 70. The steam drum will have nozzles for
saturated steam supply pipes to Primary super heater inlet headers, Feed water
inlet piping from economiser, water level gauges, pressure gauges, continuous
blow-down and intermittent blow down, chemical injection, sampling, air vent etc.
Suitable internal piping for feed water distribution, continuous blow down
and chemical dosing will also be provided in the steam drum.
The internals of the steam drums will be designed to provide steam of high
purity. Steam drum will be equipped with girth baffle, cyclone type primary
separators and secondary scrubbers.
7.2.3. FURNACE WALLS AND HEADERS
7.2.3.1.
Furnace
The boiler furnace is in membrane wall construction. The furnace tubes will
be manufactured from carbon steel tubes.
The furnace side wall tubes are
suitably bent for providing peepholes, access doors, and will be welded at top and
bottom to respective side wall top and bottom headers. The furnace tubes will be
suitably sized to allow superheater coils to pass through. The headers shall be
manufactured from seamless pipes. The headers shall be provided with drain
connections, air vent connection and hand holes for inspection as required.
Furnace will have U-Beams for internal primary solid re-circulation. U-
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MECHANICAL
PP 067 M B01 0
42
Beams are supported by bolts through water cooled roof.

7.2.3.2.
Divisional Wall
Divisional wall is placed in the furnace. Divisional wall is of carbon steel

construction and is a water cooled part of the boilers. This is located in the furnace
and helps is achieving / maintaining the combustor temperature.
7.2.3.3.
Headers
The headers will be of adequate size and design in accordance with Indian
Boiler Regulations, and the material specification will conform to SA 106
Gr. B / SA 335 Gr. P11 / SA 335 Gr. P22 depending on the fluid temperature. The
necessary drain connections and hand-holes will be provided as required.
The connections to the steam drum and the connections to the headers will
be designed so as to form an integral circuit providing adequate natural circulation
under all operating conditions.
All headers will be provided with extended pipes and end caps welded.
7.2.4. SUPERHEATERS
The superheaters are provided in three sections i.e. wing wall, primary,
secondary superheater. The wing wall superheater receives saturated steam from
drum and is positioned in the radiation zone of the furnace.
Primary and secondary superheaters are convection zone. The super
heater assembly is designed to meet the steam temperature as specified. The
main outlet is from secondary super heater.
7.2.5. DE-SUPERHEATERS (ATTEMPERATORS)
Two (2) nos. of spray type interstage attemperators are provided. The first
stage is between the Primary 1st stage and 2nd stage of superheater, the second
stage is between the primary superheater and secondary superheater. The final
steam temperature shall be maintained within 5oC over specified load range.
The spray water for the de-superheater will be tapped off from the feed
POWER DIVISION
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MECHANICAL
PP 067 M B01 0
43
water line before the feed water control station.

7.2.6. ECONOMISER
The economiser will be made of bare carbon steel tubes conforming to SA
210 Gr A1 seamless and of continuous inline type with inlet and outlet headers. It
will be supported in a structural steel frame and enclosed within welded steel
casing. Doors will be provided for observation and also access for maintenance.
The economiser will be of non-steaming type. Temperature of economiser shall
always below the saturated steam temperature.
Necessary drains, vents, temperature, pressure gauges, etc. shall be
furnished as per Indian Boiler Regulation requirement.
7.3. BOILER PERFORMANCE DATA
7.3.1. PRESSURE PART DETAILS
Steam Drum
Description
Unit
Value
Inside diameter
mm
1500
Material specification
SA 516 Gr 70
Shell thick
1
mm
90
Dish end type
Hemispherical
Material specification for dish

end
SA 516 Gr 70
Dish end thick

Shell length
Tangent)
(Tangent
to
mm
90
mm
10000
Unit
Value
Primary Superheater
Description
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MECHANICAL
PP 067 M B01 0
44
Tube OD
mm
44.45
Tube thickness
mm
As per IBR calculation.

Min. 4.06
SA213 GR. T22 / SA213
GR. T11 / SA210 GR. A1
Tube material
Header size
NB
200 / 250
Header thickness
mm
As per IBR code

calculation.
SA 106 GR.B / SA 335
GR. P11
Header material
Secondary Superheater
Description
Unit
Value
Tube OD
mm
44.45
Tube thickness
mm

Min. 4.06
SA213 TP304 / SA213
GR. T22 / SA213 GR. T11
Tube material
Header size
NB
200 / 250
Header thickness
mm
As per IBR code

calculation.
SA 335 GR.P11 / SA 335
GR. P22
Header material
Furnace panels / Enclosure panels / Wing walls / Divisional walls

Description
Unit
Value
Tube OD
mm
44.45 / 50.8 / 63.5 / 76.2
Tube thickness
mm

Min. 4.06
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MECHANICAL
PP 067 M B01 0
45
Tube material
SA210 GR. A1
Header size
NB
200
Header thickness
mm
Header material
SA 106 GR.B
Attemperator
Description
Unit
Value
Header size
NB
200 / 250
Header thickness
mm
Header material
SA106 GR.B
Risers
Description
Unit
Value
Riser OD
mm
101.6
Riser thickness
mm
Riser material
SA 210 GR.A1
Main downcomers
Description
Unit
Value
Downcomer size
NB
250
Downcomer thickness
mm
Downcomer material
SA 106 GR.B
7.3.2. HEAT TRANSFER AREA

Sl. No. Description
1
Superehater
Unit
Value
m2
3027
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MECHANICAL
PP 067 M B01 0
46
Economiser
m2
3561
Airpreheater ( PA + SA )
m2
10003
Furnace (water walls +

enclosure walls + divisional
walls etc.)
m2
1441
Unit
Value
7.3.3. TEMPERATURE GRADIENT

Sl. No. Description
1
1.1
Air pre heater In
Deg. C
35
1.2
Air pre heater out
Deg. C
140-150
Combustion air side
Flue gas temperatures
2.1
Super heater In
Deg. C
800-820
2.2
Economizer In
Deg. C
445-465
2.3
Air pre heater In
Deg. C
290-310
2.4
Air pre heater out
Deg. C
140-150
2.5
At Chimney
Deg. C
140-150
Steam temperatures
3.1
Steam drum
Deg. C
315-330
3.2
Wing wall in
Deg. C
330-350
3.3
Pri. Super heater - I In
Deg. C
350-370
3.4
De super heater - I In
Deg. C
400-420
3.5
De super heater - I Out
Deg. C
360-380
3.6
Pri. Super heater II Out
Deg. C
445-465
3.7
De super heater -II Out
Deg. C
420-440
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MECHANICAL
PP 067 M B01 0
47
3.8
Sec. Super heater Out
Deg. C
535-555
3.9
Spray water temperature
Deg. C
220-230
Feed water temperature
4.1
Economizer In
Deg. C
220-230
4.2
Economizer out
Deg. C
290-310
Unit
Value
7.3.4. PRESSURE GRADIENT

Sl. No. Description
1
Steam / water side pressure drop
1.1
Sec superheater
Kg/cm2
4.6
1.2
Pri superheater
Kg/cm2
0.95
1.3
Economiser
Kg/cm2
1.19
Flue gas side pressure drop
2.1
Sec superheater
mmwc
2.2
Pri superheater
mmwc
10
2.3
Economiser
mmwc
20
2.4
Airpreheater
mmwc
40
Unit
Value
7.3.5. VELOCITY PROFILE

Sl. No. Description
1
Flue gas
1.1
Sec. superheater
m/s
6-8
1.2
Pri. superheater
m/s
6-8
1.3
Economiser
m/s
6-8
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MECHANICAL
PP 067 M B01 0
48
1.4
m/s
11-13
m/s
10-12
Unit
Value
1st drum safety valve set

pressure
Kg/cm2 (g)
119
2nd drum safety valve set

pressure
Kg/cm2 (g)
120
Superheater safety valve

set pressure
Kg/cm2 (g)
108
Electromatic relief valve

set pressure
Kg/cm2 (g)
105
2
2.1
Airpreheater
Air
Airpreheater
7.3.6. SAFETY VALVE DETAILS

7.3.6.1.
Safety Valve Set Pressures
Sl. No. Description
7.3.6.2.
Sl. No.
Safety Valve Relieving Capacity
Description
Quantity
(Nos.)
Value (TPH)
Drum safety valve
96
Superheater safety valve
48
Electromatic relief valve
36
7.3.7. FUEL, LIMESTONE & BED MATERIAL CONSUMPTION

Sl.
No.
1
1.1
Description
Unit
Value
Kg/hr
64420
Fuel
Performance fuel (50% ROM coal +
50% Washery rejects)
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MECHANICAL
PP 067 M B01 0
49
1.2
ROM coal
Kg/hr
51564
1.3
Washery rejects
Kg/hr
88746
Limestone
2.1
Performance fuel case
Kg/hr
4030
2.2
ROM coal
Kg/hr
3430
2.3
Washery rejects
Kg/hr
4780
Bed material
Kg/hr
Nil
7.4. BOILER MOUNTINGS AND FITTINGS

The Boiler will be provided with a complete set of mountings and fittings in
accordance with the Indian Boiler Regulations, for the safe operation of the Boiler
and the details of the mountings and fittings including:
7.4.1. STEAM DRUM
-Safety valves
-Continuous blow down (CBD) valve
-Air vent valves
-Pressure gauge with isolation valves
-Chemical dosing valves and check valve
-Sampling valves for CBD and saturated steam
-Isolation valves for pressure transmitters
-Isolation valves for level transmitters
-Direct water level gauges with isolation and drain valves
7.4.2. FURNACE HEADERS
-Drain valves
7.4.3. DRAIN HEADER
-Isolation valves
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MECHANICAL
PP 067 M B01 0
50
7.4.4. SUPERHEATER
-Safety valve (secondary outlet)
-Motor operated main steam stop valve with integral by-pass valve
-Steam outlet check valve
-Start-up vent will be sized for 30% of BMCR capacity.
-Pressure gauges with isolation valves and drain valves
-Sampling valves
-Drain valves
-Air vent valves
-Valves for pressure transmitters and flow transmitters
-Main steam flow nozzle
-Thermocouples
7.4.5. SPRAY WATER LINE
-Spray water regulating valve
-Spray water regulator isolating valves
-Spray water by-pass valve
-Spray water check valve
-Main isolation valve for de-superheater inlet
-Drain valves
7.4.6. ECONOMISER
-Drain valves
-Pressure gauge with isolation valves
-Air vent valves
7.5. SOLID FUEL FIRING SYSTEM
The boiler will adopt circulating fluidised bed combustion system and the
fuel firing system will be designed for `over bed feeding' system. The boiler is
capable of firing the following fuels:
50 % Washery Rejects + 50 % ROM Coal (Performance Fuel).
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MECHANICAL
PP 067 M B01 0
51
100 % ROM Coal.
100 % Washery rejects.
7.5.1. FUEL BUNKER

Each boiler will be provided with following bunker of mild steel construction.
Fuel bunker 1600 m3
Lime stone silo 120 m3
Bed material silo 80 m3
Fuel Bunker sizing basis

Sl.
No.
Description
Basis of
Design
Consumption
of Material per
Boiler, TPH
a)
Fuel bunker
50 % Washery
Rejects + 50
% ROM Coal
(Performance
Fuel) for 16
hrs storage
with 800
kg/m3 fuel
density & 0.9
filling factor
Consumption of
fuel at 100%
BMCR : 64.42
TPH
Bunker
Capacity
Required,
m3
64.42 TPH
x 16 Hrs /
0.8 T/m3 =
1288 m3
(Effective
volume)
Bunker
Volume
Provided,
m3
1600 m3
(Bunker
Capacity
provided
per boiler)
1288 m3 /
0.85 =
1515 m3
(Water
volume)
Note : 1. Bulk density of fuel is 800 kg/m3 & filling factor is considered as 0.85.
2. The bunker will be adequately stiffened and covered at the top, leaving
necessary opening for conveyor chutes.
3. The bunker will be provided with necessary support steelwork from firing floor
level. The design of the bunker should take care of free flow of fuel.
7.5.2. FUEL FIRING SYSTEM
The fuel firing system will be designed to burn maximum particle size of 6
mm with a fine content (less than 1 mm size) not exceeding 35 %.
POWER DIVISION
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MECHANICAL
PP 067 M B01 0
52
For each boiler there are separate bunkers. Fuel is fed into drag chain
feeder. The drag chain feeder speed is controlled through VFD. The outlet of drag
chain feeder is connected to the furnace.
7.5.3. FLUIDIZED BED
The fluidised bed will consist of compartments (sections). Each
compartment will be provided with stainless steel fuel feeding nozzles and
adequate number of stainless steel fluidizing air nozzles fitted on to the distributor
plate.
7.6. OIL FIRING SYSTEM
Three (3) nos. of burners will be installed in the front side of the furnace
panel. Burner will be used for start-up of the boiler. Burner support will be required
till 20% of boiler loading. Each Burner will be 1500 litre capacity and combined
firing capacity will be 25% MCR.
7.7. AIR AND FLUE GAS SYSTEMS
7.7.1. DRAFT SYSTEM
The boiler is designed for balanced draft operation and adequately rated
ID, SA and PA fans are provided. The boiler is equipped with ID, SA and PA fan
along with necessary interconnecting air and gas ducting, dampers etc. Fans
offered will be of simply supported design on bearing pedestal on both sides and
1
will be of back ward-curved / aerofoil blades.

The draft system for the boiler will consist of:
Two (2) Induced Draft (ID) fan of 60% boiler MCR capacity handling
the combustion gas from the outlet of electrostatic precipitator. The fan
will have sufficient head to overcome the draft loss of furnace, primary
& secondary superheater, economiser, air heater, ESP and ducts. The
ID fan shall be of heavy-duty construction radial tip construction, selfaligning spherical roller bearings, inspection door, drain, inlet box and
POWER DIVISION
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MECHANICAL
PP 067 M B01 0
53
guard.
The impeller is provided with tip liners and dynamically
balanced. ID fan will be with inlet damper (multilouver) control. ID fan

shall be with variable speed fluid coupling.
Two (2) Secondary Air (SA) fan of 60% boiler MCR capacity supplying
the necessary amount of combustion air for fluidised bed combustion of
the different fuels with sufficient pressure to overcome the resistance of
ducts, measuring devices, dampers, fluidising air nozzles, air heater
and burners. The SA fan is centrifugal type with suitably sized impeller.
The fan impeller shall be dynamically balanced and is complete with
inspection door, foundation bolts and guard.
The SA fan shall be
provided with silencer to meet the noise level. The control shall be
through Inlet Guide vane. SA fan shall be with variable speed fluid
coupling.
Two (2) Primary Air (PA) fan of 60% boiler MCR capacity, boosting hot
air pressure from air heater outlet. The PA fan is centrifugal type with
suitably sized impeller. The fan impeller shall be dynamically balanced
and is complete with inspection door, foundation bolts and guard. The
PA fan shall be provided with silencer to meet the noise level. The
control shall be through Inlet Guide vane. PA fan shall be with variable
speed fluid coupling.
Sizing of ID, SA & PA fan are as follows:
A) ID Fan ( 2 X 60 % MCR)
Unit
Design
Test
Block
Performa
nce Fuel
100 %
Washery
Rejects
100 %
ROM
Coal
No.
Capacity of each
fan
60
60
60
60
Altitude
47.38
47.38
47.38
47.38
Sl.
No.
Description
I)
Capacity Details
a)
No. of fan
b)
c)
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MECHANICAL
PP 067 M B01 0
54
d)
Ambient temp.
50
35
35
35
e)
Back end temp.
160
140
140
140
f)
ID fan gas Qty
kg/s
56.42
52.27
56.42
49.46
g)
Margin on
Capacity
20
h)
ID fan Capacity
kg/s
67.7
II)
Head Details
a)
dP SH
mmWC
15
12
15
12
b)
dP economiser
mmWC
20
17
20
15
c)
dP APH
mmWC
60
50
60
44
d)
dP ESP + MDC
+ U Beam
mmWC
140
117
140
101
e)
dP Ducts +
Dampers
mmWC
25
21
25
20
f)
Chimney
mmWC
10
10
g)
Total dP
mmWC
270
225
270
200
h)
Margin on head
40
i)
ID fan Head
mmWC
380
Design
Test
Block
Performa
nce Fuel
100 %
Washery
Rejects
100 %
ROM
Coal
No.
B) SA Fan ( 2 X 60 % MCR)
Sl.
No.
Description
Unit
I)
Capacity Details
a)
No. of fan
b)
Capacity of each
fan
60
60
60
60
c)
Altitude
47.38
47.38
47.38
47.38
d)
Ambient temp.
50
35
35
35
e)
Relative humidity
60
60
60
60
f)
SA fan air Qty
kg/s
16.49
16.06
16.49
15.88
g)
Margin on
Capacity
20
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MECHANICAL
PP 067 M B01 0
55
h)
SA fan Capacity
II)
Head Details
a)
kg/s
19.78
dP Bed
mmWC
430
430
388
421
b)
dP flow
measuring +
OFA + Duct and
Damper +
Silencer
mmWC
560
533
560
522
c)
dP APH
mmWC
50
47
50
47
d)
Total dP
mmWC
1040
1010
1000
990
e)
Margin on head
%
45
mmWC
1375
Design
Test
Block
Performa
nce Fuel
100 %
Washery
Rejects
100 %
ROM
Coal
No.
(only on variable
head)
f)
SA fan Head
C) PA Fan ( 2 X 60 % MCR)
Sl.
No.
Description
Unit
I)
Capacity Details
a)
No. of fan
b)
Capacity of each
fan
60
60
60
60
c)
Altitude
47.38
47.38
47.38
47.38
d)
Ambient temp.
50
35
35
35
e)
Relative humidity
60
60
60
60
f)
SA fan air Qty
kg/s
24.76
23.59
24.76
23.20
g)
Margin on
Capacity
20
h)
SA fan Capacity
kg/s
29.71
II)
Head Details
a)
dP Bed
mmWC
1000
912
875
906
b)
dP flow
measuring +
mmWC
125
114
125
110
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MECHANICAL
PP 067 M B01 0
56
Silencer + Duct
and Damper
1
c)
dP APH
mmWC
60
54
60
53
d)
dP bubble cap
mmWC
400
360
400
351
e)
Total dP
mmWC
1585
1440
1460
1420
f)
Margin on head
%
45
mmWC
1920
(only on variable
head)
g)
SA fan Head
7.7.2. DUCTWORK AND DAMPERS

Ducts will be sized considering a maximum velocity of 14 m/sec for air and
1
12 m/sec upto Air Pre-heater & 16 m/sec after Air Pre-heater for flue gas
applications. The ducts will be rectangular in cross section and will be of welded
construction, properly stiffened and reinforced. All ducts handling air and flue gas
will be fabricated with carbon steel plates of thickness not less than 5 mm for air
and for flue gases, 6 mm upto Air Pre-heater & 8 mm from Air Pre-heater outlet to
stack. The carbon steel plates will be as per IS:2062. Alloy steel ducts will be
provided, at regions where flue gas temperature exceeds 450C. Duct corners will
have stitch weld internal and external full weld.
Internal struts will be provided for ducts if required, these will be generally
of tubular truss work, at load transferring points heavier truss work will be
provided. Internal struts will be of ERW tubing. The ducts will be provided with
necessary supporting either from the ground or from the boiler supporting steel
work depending on the locations.
Expansion joints will be provided as applicable and will be made of carbon
steel / alloy steel sheets / fabric (non metallic) as applicable.
Necessary dampers will be provided, complete with actuators, visual
position indicators and means of securing as required by the design.
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MECHANICAL
PP 067 M B01 0
57
7.7.3. AIR PRE-HEATER

A tubular air pre-heater is provided as the last stage of heat recovery unit.
The shell and tube side fluid shall be combustion air and flue gas respectively.
The air pre heater tubes shall be fitted into the tube sheets on both sides. Entire
Air Pre-heater shall be supported in a structural steel frame and enclosed within
welded steel casing. Air Pre-heater shall be provided with BS 6323 / 82 Part V ERW
1
tubes.
The clean air passes through tubes and those tubes are surrounded by hot
flue gases which help to increase the temperature of air. This hot air is used in
boiler to help combustion process.
7.7.4. ASH RECYCLE SYSTEM
Mechanical Dust Collector (MDC) is positioned in the exit of Economiser.
The ash collected in the MDC will be recycled through three
(3) sets of air slides inside the furnace. The ash recycle quantity will be based on
boiler load, operating bed temperature and type of fuel fired.
A fraction of ash will be taken out of the system and disposed by ash
handling system.
7.7.5. ASH DISCHARGE SYSTEM
Bed ash will be periodically drained through the discharge pipes. Bed drain
pipes is provided to drain ash through ash cooler and to maintain the correct bed
height. In addition to this, drain points are provided in the distributor level to drain
out the entire material, if required.
The fly ash collected in the boiler bank / economiser hoppers, air heater
hoppers and ESP hopper shall be delivered to the ash conveying system. One (1)
bypass line will be given in each hopper upto the ground level to discharge the
ash collected, manually.
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MECHANICAL
PP 067 M B01 0
58
7.8. BOILER STRUCTURES AND AUXILIARIES

7.8.1. STRUCTURAL STEEL
The complete structural steel necessary to support/suspend the various
components and equipment, ducts etc. will include all auxiliary columns, duct
supporting columns, bracing, and all equipment structures etc. The structure is of
fully welded construction. Only for erection purpose, erection bolts are provided.
1
All structural steel will be designed for horizontal seismic forces as applicable
under the latest Revision of IS 1893 and wind forces as per latest revision of IS
875, whichever governs the design. All structural steel work will be designed as
per IS 800 and material specification conforming to IS 2062. The structure will
incorporate necessary lifting beams and hoist blocks required for maintenance of
fans, pumps etc.
7.8.2. PLATFORM, STAIRWAYS AND GRATING
A complete system of platforms around boiler at feed water control station,
at fuel feeder floor etc. will be provided and stairways will be provided to enable
access to various parts of the boiler. The stairways will be provided on one side
of the boiler upto drum floor (37.8 m) and other side of boiler upto working
platform floor (5.2 m). Handrails will be provided for all stairways and platforms as
per relevant engineering standard and also as required by Inspector of Factories.
Boiler platform & stair case width will be minimum 900 mm.
7.9. REFRACTORY AND INSULATION
7.9.1. GENERAL
The boiler will be complete with all the necessary castable refractory and
refractory bricks and blocks as required for the furnace and generator bank areas,
together with all the necessary insulating blocks, bricks and mattresses and all the
requisite fixings, holders and other attachments. The refractory and insulation
materials will comply with the relevant Indian standards.
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MECHANICAL
PP 067 M B01 0
59
7.9.2. DESIGN TEMPERATURE DIFFERENTIAL - CRITERIA

The thickness of wool mattress will be calculated such that insulation
surface temperature shall remain within 65OC at an ambient temperature 35OC
with 1 m/s wind velocity. Insulation will be provided for equipment and ducts
where the temperature exceeds 60OC.
7.9.3. EXTERNAL INSULATION
The machine made mineral wool mattresses will be used as external
insulating layer and will have a uniform density of 120 kg/m3. The mineral wool
specifications and thermal conductivity figures will be as per IS: 8183.
The wire netting to be provided on both sides of mattresses will be of GI /
SS material.
7.9.4. BINDING AND STITCHING WIRE
The binding and stitching wire used for fixing the insulation materials will be
of GI material and of diameter (min 1.0 mm) - normal 1.219 mm, stitching wire will
be of 0.711 mm diameter.
7.9.5. OUTER CASING
The main boiler section (furnace and bank tubes) will be enclosed with
corrugated aluminium sheet casing of 0.711 mm (22 SWG) thick. The ducts, boiler
integral piping and vessels etc. will be enclosed with plain aluminium sheet of
0.711 (22 SWG) mm thick.
7.10.CHEMICAL DOSING SYSTEM
HP chemical (Tri-sodium phosphate) dosing system with one (1) number
solution preparation cum metering tank and two (2) numbers dosing pumps (1 W
+ 1 S) will be provided for each unit. LP chemical (Hydrazine) dosing system with
one (1) number solution preparation cum metering tank and two (2) numbers of
dosing pumps (1 W + 1 S) will be provided for each unit. The chemical dosing
system will be provided with all necessary pipe work, valves & fittings, instruments
POWER DIVISION
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MECHANICAL
PP 067 M B01 0
60
etc.
7.11.SAMPLING LINES
The sampling lines and sample coolers will be provided for feed water,
1
drum water, saturated steam and superheated steam.
Sampling lines and
nozzles will be of suitable material to take care of high chloride content in

circulating water.
7.12.BLOW DOWN TANKS
One (1) continuous blow down (CBD) tank and one (1) intermittent blow
down (IBD) tank of appropriate capacity, separate for each boiler, shall be
provided to receive all the continuous and intermittent blow downs and all other
drain discharges from the boilers. Necessary level control station for the
continuous blow down tank along with other fittings shall be provided.
The intermittent blow down tank, together with the internal piping and vent,
is designed to maintain a water-sealed discharge to the effluent drain. It will be
complete with necessary supports and ancillaries including an inspection
manhole. For IBD tank, vent pipe of adequate size will be extended by at least 2
m from the top of the roof and vent pipe of CBD tank will be connected to
deaerator. The CBD tank will work at deaerator pressure and IBD tank will work at
atmospheric pressure.
7.13.ESP DESIGN BASIS
For the purpose of ensuring that the dust concentrations are within the
limits set forth by Local Authorities, an Electrostatic Precipitator (ESP) has been
provided for the plant. All fields shall be on line during normal operation.
The design data for the ESP shall be as per the table below :
Sl. ESP Design
No. Parameters
Unit
Performance
Fuel
Washery
Rejetcs
ROM Coal
POWER DIVISION
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MECHANICAL
PP 067 M B01 0
61
Design flue gas flow
Flue gas temperature
Gas Analysis (wet)
m3/sec
124
134
117
140
140
140
CO2
% v./v.
13.31
12.62
13.70
H2O
% v./v.
14.07
16.16
12.87
N2
% v./v.
69.54
68.20
70.32
O2
% v./v.
3.06
3.00
3.1
SO2
% v./v.
0.0064
0.0074
0.0056
Gas density (wet

basis)
Kg/Nm3
1.2875
1.2732
1.2957
Dust concentration at
ESP inlet (wet)
gm/Nm3
70
70
70
Dust concentration at
ESP outlet with one
field out of service
mg/Nm3
50
50
50
Suction pressure at
MCR
mmWC
- 310
- 310
- 310
Maximum suction
mmWC
- 400
- 400
- 400
Number of fields
10
Number of sections
(flue gas path)
THERMAX LIMITED
7.14.CHIMNEY DESIGN BASIS

Each boiler will be provided with 44 m height steel chimney. Chimney shall
be single-flue self supported type of steel construction suitable to achieve about
1
25 m/sec exit gas velocity at TMCR operation of the plant. The bottom of chimney
will be provided with a manhole for removal of ash and approach to chimney. For
the purpose of maintenance / repair of the chimney, necessary access ladders,
hand rails (with protection cage for cat ladder), platforms, etc will be provided.
POWER DIVISION
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MECHANICAL
PP 067 M B01 0
62
Stack emission shall be monitored to satisfy the requirements of Orissa Pollution

Control Board.
The design data for the chimney shall be as per the table below :
7.14.1.CALCULATION OF CHIMNEY HEIGHT
Sl. No.
Particulars
Units
Value
Coal Consumption per Boiler
Kg/Hr
64420
Sulphur Percentage
0.34
Total Sulphur from Fuel
Kg/Hr
219.0
Percentage Sulphur capture
89.6
Sulphur at Stack
Kg/Hr
22.7
SO2 From Fuel Combustion
Kg/Hr
45.5
Stack height required
44.0
Particulars
Units
Value
Gas Flow Per Boiler
Kg/hr
344400
Gas Temperature
Deg. C
140
7.14.2.CALCULATION OF CHIMNEY DIAMETER

Sl. No.
Gas Specific Volume
m /Kg
1.18
m /hr
407257
Gas Volume Flow rate
Proposed Stack Diameter at Straight

portion
Stack Area at Straight portion
m2
7.1
Calculated
portion
m/s
16
Conical Top Diameter
2.4
Conical Top Area
m2
4.5
10
Velocity
m/s
25.0
Gas
velocity
for
Straight
Note : Height of the Bottom Conical portion & base diameter of chimney will
be decided from Structural Stability
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MECHANICAL
PP 067 M B01 0
63
7.14.3.SKETCH OF CHIMNEY
8.
STEAM, FEED WATER AND CONDENSATE SYSTEM

8.1. STEAM SYSTEM
The steam system is mainly composed of: (A)
Main steam system
Steam from each boiler with steam parameter 101 kg/cm2 (a) pressure
1
and 540C temperature at main steam stop valve is connected to each

steam turbine nozzle. Main steam lines will be interconnected at
suitable location for provision of interchangability of units. Main steam
line will be provided with motor operated main steam stop valve with
integral bypass valve at superheater outlet.
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MECHANICAL
PP 067 M B01 0
64
Following tapping point will be provided in main steam line

a. For steam jet air ejector and turbine gland auxiliary PRDS.
b. For turbine bypass system (sized for 60% TMCR flow).
c. For deaerator pegging steam line.
Suitable drain and vent connections shall be provided between
isolation valves of each boiler in line with IBR requirements. These
drain / vent isolation valves shall be manually operated.
Each boiler superheater outlet would be provided with superheater
safety valve and electromatic relief valve for over-pressure protection
of boiler superheater. Start-up vent valve of 30% BMCR flow capacity
is also provided.
(B) Auxiliary steam system for steam jet air ejector & turbine gland
sealing steam system
From main steam line a tapping will be provided to a PRDS station for
steam jet air ejector & turbine gland sealing steam requirement. The
pressure reducing & de-superheating station will reduce steam
temperature & pressure to 28.5 kg/cm2 (a) & 376C and this steam will
be used as motive steam for ejectors. A tapping will be taken
downstream PRDS and pressure will be further reduced to 1.08 kg/cm2
(a) for turbine gland sealing requirements.
(C) HP steam system for HP heaters
Steam turbine is provided with five (5) numbers of bleeds which are
feeding to the HP heaters, Deaerator and LP heaters for regenerative
feed heating system. Two (2) nos. high pressure bleeds with pressure
at around 30 kg/cm2 (a) & 16.3 kg/cm2 (a) will be taken for HP heaters.
1
These lines will be provided with single pneumatic operated quick

closing non-return valve (QCNRV) and motor operated valve.
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MECHANICAL
PP 067 M B01 0
65
(D) MP steam system for Deaerator

From steam turbine, 3rd bleed with pressure around 6.6 kg/cm2 (a) will
1
be taken for deaerator. This line will be provided with pneumatic

operated quick closing non-return valve (QCNRV), normal non-return
valve and motor operated valve. Pegging steam line from main steam
will also be connected to this bleed line through a PRDS station for
pegging of deaerator during start-up and low load.
(E) LP steam system for LP heater
Two (2) nos. low pressure bleeds with pressure at around 2.5 kg/cm2
(a) & 0.735 kg/cm2 (a) will be taken for LP heaters. These lines will be
provided with pneumatic operated quick closing non-return valve
(QCNRV) and motor operated valve except low pressure line which will
be provided with normal non-return valve.
(F) Steam turbine bypass system
Turbine bypass system will be provided for facilitating the start-up,
shutdown and load throw-off condition of the steam turbine unit.
Turbine bypass system will be sized for 60% of TMCR flow. From main
steam line, a tapping will be provided to PRDS station to reduce main
steam pressure & temperature to about 6 kg/cm2 (a) and 160C
respectively. Then, this low pressure & temperature steam will be

provided to surface condenser steam dumping device. Steam dumping
during sudden load-through off will be initiated by pressure transmitter
on main steam line.
The surface condenser shall be designed to operate under this
condition under a higher exhaust vacuum (higher than normal
operating of 0.1 ata but below allowable / alarm limit) under turbine
bypass condition.
Suitable drain at low points and vents at high points shall be provided as
per the piping layout. All high pressure (40 kg/cm2 (a) and above) drains and
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MECHANICAL
PP 067 M B01 0
66
vents shall be provided with manually operated double isolation valves.

8.1.1. CONTROL PHILOSOPHY
Steam Temperature & pressure will be maintained by combustion control
loop and attemperator in the respective boiler. The control range for temperature,
as indicated earlier, is 60 100 % for the individual boilers for 100% coal firing. In
the event of load throw-off, the main steam line pressure will tend to increase
which will activate turbine bypass control valve and excess steam (maximum 60%
of TMCR) will be bypassed to surface condenser. At the same time the
combustion control loop of boiler will also activate and once the same is stabilised
turbine bypass system will close.
8.2. FEED WATER SYSTEM
The feed water system will supply feed water to each boiler. It will also
supply spray water to the auxiliary PRDS station for ejector & gland sealing
1
system and to the attemperators in between the stages of superheaters.

The feed water system for both the boilers comprise of two (2) nos.
separate deaerator-cum-feed storage tanks, three (3) nos. boiler feed water
pumps for both units with 1 x 100% catering one boiler unit & one common
standby, feed control stations and feed line from the feed pump suction manifold
of deaerator to steam drum through HP heaters separate for each boiler unit.
8.2.1. DEAERATOR
Deaerator will be under sliding pressure control upto 40% of load. Beyond
40% load, deaerator pressure will be constant.
The deaerator will supply deaerated feed water at 158oC at full load.
Necessary piping associated with deaerator will be included. The storage tank will
be sized to meet at least 10 minutes of feed water flow at TMCR between normal
level and low-low level. The storage tank will be mounted at suitable height to
provide the required NPSH for the feed pumps. Deaerator will be located on roof
of power house control room.
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MECHANICAL
PP 067 M B01 0
67
The deaerator-cum-storage tank unit will be complete with necessary

internal trays, water sprays, water level control system, temperature control
system, safety valve, water level indicator and alarm, access ladders and
platforms.
Chemical dosing would be performed inside the deaerator by means of
sparger pipe inside the storage tank.
Steam for heating will be supplied from the extraction of steam turbine.
Provision will also be made for supply of steam from the main steam line through
a system of pressure reducing valve and utilising flash steam from continuous
blow-down tank. The oxygen content on the outlet water will be not more than
0.007 ppm.
Details of Deaerator & Feed water storage tank is as follows.
1)
Deaerator
a)
Type
Vertical, spray cum tray type
b)
Design de-aeration capacity
264 TPH
c)
Operating temperature
158 deg C
d)
Operating pressure
6 ata
e)
Deaerator operation
Sliding pressure
2)
Feed water storage tank
a)
Diameter
During Detailed Engineering
b)
Length
During Detailed Engineering
c)
Storage capacity
44 m3
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MECHANICAL
PP 067 M B01 0
68
8.2.2. BOILER FEED PUMPS

Boiler feed water pumping system with 3 x 100% motor driven boiler feed
water pumps is provided. Out of these three pumps, one will be operating
normally for each boiler unit while the third pump shall remain as a common
standby and will come into operation automatically in case one of the working
pump fails.
Variable speed hydraulic coupling is provided to vary the speed of the feed
pump smoothly and stably over the entire range to minimise the throttling losses in
feed control valves.
Three (3) nos. motor driven boiler feed pumps with all pipe works and
valves will be supplied for the boilers. The pumps will be identical and
interchangeable. The pump will be of multistage centrifugal type, complete with
suction strainer, balance chamber and necessary suction and delivery valves,
1
non-return valves and automatic minimum flow recirculation (ARC) valves to cater
for start-up and low flow conditions, gland sealing and bearing cooling pipe work,
valves, pressure and temperature indicators.
The feed pumps will be provided with minimum flow automatic recirculation
lines and will discharge to deaerator via isolating and non-return valves. The
pumps will be supplied with necessary suction and discharge lines.
Motorised valves will be provided at the discharge of the boiler feed water
pumps. The suction lines for the feed pumps will be tapped from a nozzle of the
deaerator, at a suitable elevation. Isolating valves will be provided at both suction
and discharge ends with pressure gauges. A check valve will be provided at the
discharge line. Inline strainer with facility for removal for cleaning will be provided
on the suction line. The pump and motor will be mounted on a common base
frame and provided with a flexible coupling and guard. Coupling halves will be
properly balanced.
Boiler Feed Pump Sizing
For boiler feed pump sizing, 10% margin will be provided on flow and 5%
POWER DIVISION
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MECHANICAL
PP 067 M B01 0
69
margin will be provided on head calculated based on 2nd drum safety valve set
pressure. With such margin, it shall be checked and ensured that even at 47.5 Hz
frequency the boiler feed water pump is capable of delivering 100 % TMCR flow
rate and required head during TMCR operation of unit. The BFP sizing basis is as
follows.
a) Pump Capacity Calculation
Feed water flow at BMCR
240 TPH
As per boiler data

sheet
Feed water density at 158C

temperature
909.4 kg/m3
As per HBD
MCR volume flow
263.9 m3/hr
MCR volume flow with 3% make-up
271.8 m3/hr
Margin 10%
27.2 m3/hr
Calculated flow
299 m3/hr
Selected Rated flow
300 m3/hr
b) Pump Head Calculation
Boiler design pressure based on 2nd

121 kg/cm2 (a)
drum safety valve set pressure (A)
As per boiler data

sheet
Pressure drop in Piping (B)
2.5 kg/cm2
As per prelim.
piping layout
Pressure drop in HP heaters (C)
1.6 kg/cm2
As per heater data

sheet
Pressure drop across economiser

1.2 kg/cm2
(D)
As per boiler data

sheet
Pressure drop across control valve

3.0 kg/cm2
(E)
As confirmed by
boiler supplier
Vertical static head (F)
As per prelim.
equipment layout
Required
discharge
(G=A+B+C+D+E+F)
3.5 kg/cm2
pressure
132.8 kg/cm2 (a)
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MECHANICAL
PP 067 M B01 0
70
Suction pressure (H)
7.8 kg/cm2 (a)
As per HBD &

prelim. equipment
layout
Required TDH in water column (G-H

1375 mWC
/ density)
Required Rated
Margin 5%)
Head
(including
Selected Rated Head
1444 mWC
1495 mWC
8.2.3. HP FEED WATER HEATERS

Two (2) nos. HP heaters will be located on the down stream side of boiler
feed pumps and will be used for raising the boiler feed water temperature to
230oC. The HP heater shall be mounted vertically in the turbine house. The
heating steam for the HP heaters shall be supplied from the high pressure turbine
bleeds. The normal condensate drain from the HP heater shall cascaded back to
earlier HP heater and then to the deaerator. An emergency condensate drain is
also provided directly to the HP flash tank. The feed water outlet from each the HP
heaters will be connected to respective boiler economiser through feed water
control stations. The feed water side of the HP heater shall be designed to
withstand the boiler feed pump shut-off pressure. The steam side of the HP heater
shall be designed to suit the highest bleed steam pressure obtainable.
8.2.4. FEED WATER CONTROL STATION
Feed water control station is provided with 2 x 100 % capacity
pneumatically operated full load control valves and 1 x 30 % capacity
pneumatically operated low load control valve located upstream of the
economiser. Upstream valves of each of above control stations will be motor
operated isolation valves and downstream will be manual isolation valves.
Each main feed control station is provided with one 100 % capacity
pneumatically operated control valve with a 100 % standby control valve. One 30
POWER DIVISION
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MECHANICAL
PP 067 M B01 0
71
% capacity pneumatically operated control valve is provided to control the feed

water flow at low load. Full load control valve shall be operated through single
element or three element control mode. Low load control valve shall be operated
in single element mode. The upstream isolation valves for the control stations are
motorised for automatic changeover.
In order to avoid excessive throttling and power loss at feed control station,
the differential pressure across feed control valves under steady state shall be
maintained at a constant value by varying hydraulic coupling of boiler feed pump.
HP heater shell side level is maintained by a control station leading the
condensate to the earlier HP heater or deaerator. In case of deaerator high level
or at low load & starting, this condensate will be diverted to the HP flash tank
through another control station.
In case of very high level in the shell, extraction steam line motorised valve
will be closed & the feed water heater is bypassed by means of motorised inlet,
outlet & bypass valves provided for the HP heater.
Condenser hotwell level shall be maintained by regulating condensate flow
in the main condensate line to deaerator. Deaerator level will be maintained by
regulating the DM water make up to hotwell. The condensate excess dump control
valve is also provided to dump the excess condensate to CST in case increase in
deaerator storage tank level.
The above control philosophy will be finalized after receiving the equipment
1
details and P&IDs from the various vendors.

8.3. CONDENSATE SYSTEM
The condensate system will supply condensate from the condenser hotwell
to deaerator. It will also supply de-superheating spray water for HP bypass
system, exhaust hood spray water and auxiliary PRDS station for deaerator
pegging steam etc.
The exhaust steam from the steam turbine is condensed in the water-
POWER DIVISION
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MECHANICAL
PP 067 M B01 0
72
cooled surface condenser. Drain condensate from LP heaters, GSC and interafter ejector condensers are taken to the flash pipe of the condenser.
8.3.1. SURFACE CONDENSER
The condenser shall condense all the steam at the steam turbine exhaust,
and shall receive all the condensate from the steam jet ejector condensers, gland
steam condenser and LP heaters. At an emergency condition of very high level in
HP heater, the condensate drain will be diverted to condenser through HP flash
tank instead of the deaerator.
A flash pipe mounted near the condenser will
receive all the drains. The vent and drain from the HP flash tank and flash pipe will
be connected to the shell and hotwell of the condenser respectively.
The condenser shall be designed as per Heat Exchanger Institute (HEI)
standard for surface condensers.
The condenser shall be of horizontal two-pass type and shall be so
designed that it can operate satisfactorily under normal operating conditions of the
turbine.
The condenser shall be designed such that steam received from the turbine
exhaust during turbine VWO operation with 0% make-up, all heaters in service,
can be condensed along with other heat rejections like all LP heater drains &
vents diverted to the condenser etc. maintaining the condenser pressure of 0.1
ata with inlet cooling water temperature of 33C with all tubes working having a
tube cleanliness factor of 85%. Cooling water temperature rise will be 9C.
The condenser shall also be adequately designed to meet turbine bypass
condition without any problem.
The divided water boxes shall be designed and guaranteed to operate
under shut-off head of the main circulating water pumps. The cover plates of the
water boxes shall have hinged connection in order to enable periodic manual
cleaning of the condenser tubes. A sufficient number of openings shall be
provided at each end of condenser of suitable size and location for inspection and
POWER DIVISION
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MECHANICAL
PP 067 M B01 0
73
maintenance. Condenser (tube side) shall be hydro-statically tested according to

the Heat Exchange Institute Standards.
Condenser water box shell shall be of carbon steel (SA 516 Gr. 70)
1
material. Condenser tube sheet shall be of carbon steel (SA 516 Gr. 70) material.
Suitable drain and vent connections complete with necessary valve shall be
provided for all the water boxes to obtain a smooth flow path in the water boxes
and even water distribution to the tubes and to avoid any unvented air pockets.
The condenser shall be provided with a hotwell made of carbon steel (SA
516 Gr. 70) having a total storage capacity of at least three (3) minutes of the total
design condensate flow (between normal and low level) at maximum steam load
condition. The hotwell shall be provided with suitable access doors. Drain valves
with blind flanges shall be provided on hotwell.
A rupture disc, designed as per manufacturers standard, shall be provided
on the condenser to prevent over-pressurisation of the condenser.
The following are the brief details & design basis of the condenser:
Type
Transverse to turbine axis, twopass, divided water box, shell and

tube type.
Design code
HEI
Service
Continuous
Location
Indoor
Shell Side
Tube Side
Fluid circulated
Exhaust steam Cooling water

from turbine
No. of passes
One
Design pressure
2.04 kg/cm2 (g) 6.0 kg/cm2 (g)

& Full vacuum
Design temperature
150 C
Condenser pressure
0.1 ata
Exhaust steam temperature
45.44 C
Two
60 C
POWER DIVISION
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MECHANICAL
PP 067 M B01 0
74
Cooling water
(inlet / outlet)
temperature 33 C / 42 C
Cleanliness factor
85 %
Plugging margin
3%
Condenser heat load

(corresponding to VWO
operation)
87142367 Kcal/hr
Surface area
4900 m2
Hotwell capacity
3 minutes storage of the total

design condensate flow between
normal level to low level at
maximum steam load condition
Material of Construction :
1
Shell
Carbon steel (SA 516 Gr. 70)
Tube sheet
Hot-well
Tubes
Stainless steel (SS 304)
Method of tube to tube sheet Expansion

joint
8.3.2. AIR EVACUATION EQUIPMENT
Non-condensable gases in the cycle water and air ingress in the condenser
are evacuated by steam jet air ejectors to maintain vacuum in the condenser.
The air evacuation system shall be designed as per HEI. The system shall
comprise service air ejectors for normal operation and a hogger / start up ejector
for initial pulling of vacuum. The start up ejector shall be used to evacuate air from
the condenser and the interconnecting piping. The motive fluid for the start up
ejector shall be tapped from the main steam line. The exhaust of the start up
ejector is let out to the atmosphere through a silencer.
After initial vacuum is pulled, the service air ejectors come into service. The
source of steam for the ejectors is from the downstream of the PRDS tapped from
the main steam line. During normal operation, only the service ejectors will be in
operation. For reliability 2 x 100 % service air ejectors with inter and after
POWER DIVISION
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MECHANICAL
PP 067 M B01 0
75
condenser are provided. Each service air ejector is of two stages with an intercondenser between the Ist and IInd stage and an after-condenser located after
the IInd stage. The condensate from the inter-condenser and after-condenser is
led to the main condenser through a loop seal and trap station respectively.
Condensate from the CEP discharge passes through the tube side of the inter and
after-condensers.
The following are the brief details of the Ejectors: 1
No. of ejectors
Service - Two (1 W + 1 S)
Start up One (1)
Design Calculations
Standard
HEI
Location
Indoor
Medium to be handled
Mixture of air, steam and noncondensable gases
Cooling Medium
Condensate
Material of construction
Body / Diffuser
Carbon Steel
Nozzles
Stainless Steel
Heat Exchanger
Shell
IS 2062 or equivalent
Tubes
Stainless Steel
Tube sheet
IS 2062 or equivalent
8.3.3. CONDENSATE EXTRACTION PUMPS

2 x 100% Condensate Extraction Pumps (CEPs) shall be provided for
condenser. Each pump shall be provided with a suction strainer, a manual
operated suction valve and a motor operated discharge valve. The CEPs shall be
provided with gland packing.
The CEPs shall be operated from the plant DCS.
The CEP will start only if the condenser hotwell is not low.
The pump will trip if:
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MECHANICAL
PP 067 M B01 0
76
Condenser hotwell level is very low.

Motor is overloaded.
The standby pump will come on auto if:
Running pump trips.
Discharge header pressure drops below a predetermined value as sensed
by a pressure switch.
In order to prevent the operation of the CEP on shut off head and to ensure
minimum flow through the inter/after ejector condenser and gland steam
condenser, a minimum flow recirculation facility is provided for the CEP. This
consists of a control valve and CEP discharge flow transmitter. The recirculation
flow is routed back to the condenser hotwell.
The condensate outlet from the CEP is routed to the deaerator after
passing through inter/after ejector condenser, gland steam condenser and LP
heaters. The condensate inlet to each deaerator from the condenser shall be
modulated by a control valve station, located at the inlet of LP Heater.
The following are the sizing details of the Condensate Extraction Pumps:
a) Pump Capacity Calculation
Condensate flow at VWO

(including LP heaters, GSC &
Ejector drains)
196 TPH
As per HBD
Condensate density at 45.5C

temperature
990 kg/m3
As per HBD
Volumetric flow
198 m3/hr
Volume flow with 3% make-up
204 m3/hr
Margin 10%
20.4 m3/hr
Calculated flow
224.4 m3/hr
Selected Rated flow
238 m3/hr
POWER DIVISION
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MECHANICAL
PP 067 M B01 0
77
b) Pump Head Calculation

Deaerator safety
pressure (A)
set
8 kg/cm2 (a)
As per deaerator
data sheet
Pressure drop at deaerator

spray water nozzle (B)
0.75 kg/cm2
As per deaerator
data sheet
Pressure drop in Piping (C)
0.4 kg/cm2
As per prelim.
piping layout
flow
0.2 kg/cm2
Estimated
Pressure drop in LP heaters (E)
1.6 kg/cm2
As per LP heater
data sheet
Pressure drop
condenser (F)
0.5 kg/cm2
As per ejector data

sheet
Pressure drop GSC (G)
0.5 kg/cm2
As per GSC data

sheet
Pressure drop across control

valve (H)
0.5 kg/cm2
Estimated
Vertical static head (I)
2.5 kg/cm2
As per prelim.
equipment layout
Required Discharge Pressure
14.95 kg/cm2 (a)
Pressure drop
nozzle (D)
valve
across
in
ejector
(J=A+B+C+D+E+F+G+H+I)
Suction pressure (K)
0.1 kg/cm2 (a)
Required TDH in water column
150 mWC
(J-K / density)
Required Rated Head (with 5%

margin)
157.5 mWC
Selected Rated Head
159.6 mWC
As per HBD &

prelim. equipment
layout
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MECHANICAL
PP 067 M B01 0
78
8.3.4. LP FEED WATER HEATERS

The LP heaters will be located on the down stream side of condensate
extraction pumps after gland steam condenser and will be used for raising the
condensate water temperature to 123C. The LP heater shall be mounted
vertically in the turbine house. The heating steam for the LP heater shall be
supplied from the low pressure turbine bleeds. The normal condensate drain from
the LP heater shall be cascaded back to earlier LP heater and then to the
condenser. An emergency condensate drain of LP heater 1 is also provided
directly to the condenser flash pipe. The condensate water side of the LP heater
shall be designed to withstand the CEP shut-off pressure. The steam side of the
LP heater shall be designed to suit the highest bleed steam pressure obtainable.
The condensate water outlet from LP heater will be connected to the deaerator
through level control station.
8.3.5. GLAND STEAM CONDENSER
A gland steam condenser sized for full condensate flow and an evacuation
system consisting of two full capacities (2 x 100%) motor driven exhausters
handling gland leak-off steam. The gland steam condenser and exhauster are
sized for condition with severely worn-out labyrinth gland seals of the turbine.
System is designed to ensure the required minimum condensate flow through
gland steam condenser during start-up and other normal/abnormal operating
modes.
The following are the brief details of the GSC :
Location
Indoor
Designed capacity
To suit gland leakage
No. of cooler
One
No. of Gland steam exhaust fans
1 (W) + 1 (S)
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MECHANICAL
PP 067 M B01 0
79
Cooling media
Condensate
8.3.6. MAKE-UP WATER

The normal DM water make up to the power cycle shall account for the loss
of water from the system due to blowdown from the boilers (considered @ 1 %
normal & 3 % maximum), loss of steam from service air ejectors, deaerator losses
and leakage of water from the system. DM water from DM water storage tank will
be transferred to overhead condensate storage tank (CST) by DM water transfer
pumps. Make-up for above losses is provided in condenser hotwell through gravity
from this CST through a control valve. The control valve will be sized for 3 %
make-up water requirement.
Condenser hotwell level shall be maintained by regulating condensate flow
to deaerator by a control valve in the condensate line. Deaerator level will be
maintained by regulating the DM water make up control valve to hotwell. The
condensate excess dump control valve is also provided to dump the excess
condensate to CST in case of increase in deaerator storage tank level.
A minimum flow recirculation control valve is provided to ensure minimum
flow through the CEP, inter/after ejector condenser and gland steam condenser.
LP heater shell side level is controlled by the LP drain control valve station
leading the condensate to the earlier LP heater or condenser. In the event of very
high level in the LP heater shell side, the extraction steam is automatically closed
& the LP heater is bypassed by means of motorised isolation & bypass valves
provided for LP heaters.
The above control philosophy will be finalized after receiving the equipment
1
details and P&IDs from the various vendors.
POWER DIVISION
9.
THERMAX LIMITED
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MECHANICAL
PP 067 M B01 0
80
WATER SYSTEM
9.1. PLANT WATER SYSTEM
9.1.1. RAW WATER SYSTEM & RAW WATER RESERVOIR
Water from Mahanadi river will be pumped by means of raw water intake
pumps to the raw water reservoir. The raw intake pumps and piping upto raw
water reservoir are in Owners scope. The EPC contractors scope starts from the
raw water reservoir.
Raw Water Reservoir, for collection and storage of raw water, of total
capacity 10,000 m3 in two (2) compartments along with gates and accessories
shall be provided. Inside and bottom surface shall be lined with impermeable
HDPE lining of thickness 1 mm. Design and construction of the reservoir shall be
done in such a fashion that no water can escape from the reservoir through
seepage.
The raw water analysis as mentioned elsewhere in this document has been
considered as the design raw water analysis.
Raw water pump house will be adjacent to the raw water reservoir which
will house 2 x 100 % horizontal raw water supply pumps (1 W + 1 S - common for
120 MW) to draw required water from the reservoir. The raw water supply pumps
shall primarily supply water to the water treatment plant through one raw water
header pipe.
Description of Raw water supply pumps is as follows.
Number of pumps: 2 x 100 % for 120 MW (1W + 1S)
Capacity of pumps with 10% Margin: 450 m3/hr
The
water
system
consists
of
raw
water
pre-treatment
Demineralization plant, CW system, Potable & Service water system.
plant,
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MECHANICAL
PP 067 M B01 0
81
9.1.2. RAW WATER PRE-TREATMENT PLANT & CLARIFIED WATER TANK

The water pre-treatment plant mainly comprises of cascade aeration cum
stilling chamber (1 x 100 %), inlet channel with parshall flume (1 x 100 %), flash
mixture (1 x 100 %), flocculation tank (1 x 100 %), Klari-tube settlers (2 x 100 %),
sludge sump (1 x 100 %) and sludge transfer pumps (2 x 100 %).
Various chemical preparation and injection systems in the raw water pretreatment plant shall be designed generally based on the following guidelines:
Alum
Polyelectrolyte
:
:
60 ppm
1 ppm
Sodium
Hypochlorite
Equivalent to 5 ppm chlorine
Chemical house to accommodate chlorination system, storage space for

chemicals, chemical solution preparation tanks, dosing pumps, MCC, Control
Room etc. and all other accessories shall be provided.
Chemical preparation and injection systems mainly consist of alum solution
preparation tank, alum solution dosing pumps, polyelectrolyte solution preparation
tank, polyelectrolyte dosing pumps, sodium hypochlorite solution preparation tank,
sodium hypochlorite dosing pumps etc.
Outlet channels of klari tube settlers will be connected to the clarified water
storage tank, which is of 6,000 m3 capacity with RCC construction in two (2)
compartments. Clarified water pump house shall accommodate following
horizontal centrifugal pumps :
a) Main CT make up pumps
2 x 100 % for 120 MW (1W + 1S).
b) DM feed-cum-Auxiliary CT
make up pumps
3 x 50 % for 120 MW (2W + 1S).
c) Service water pumps
2 x 100 % for 120 MW (1W + 1S).
d) Drinking water pump
2 x 100 % for 120 MW (1W + 1S).
All the pumps will be sized based on system requirement with 10 % margin
on flow and 5 % margin on head.
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MECHANICAL
PP 067 M B01 0
82
Clarified water pump house will also house fire water pumps. A dead
capacity, as per the requirement of TAC, to supply firewater in case of emergency,
will be kept below the minimum submergence level of clarified water storage tank.
The clarified water storage tank shall meet the entire water requirement of
the various power plant consumers like DM water, cooling tower make-up water,
service water, potable water, fire water etc. The water balance diagram showing
the water requirement by various consumers is attached in Annexure-II.
9.1.3. MAIN COOLING TOWER MAKE-UP SYSTEM
Make-up water needs to be supplied to the main cooling tower to recover
1
the water lost in CT blowdown, evaporation & drift losses and SSF backwashing.
This make-up water to main cooling tower is supplied by 2 x 100 % main CT make
up pumps from the clarified water storage tank.
The main cooling water make-up requirement has been calculated as
follows:
:
17,931 m3/hr
Cooling Range (from 42C to 33C)
9 deg C
Cycles of Concentration
Evaporation loss
283 m3/hr
Blowdown + Drift
57 m3/hr
SSF backwash
3 m3/hr
Total make-up to MCT per hour
343 m3/hr
Main cooling water requirement for the

condenser at 100% TMCR
CT make-up pump will be sized based on above flow requirement with 10

% margin on flow and 5 % margin on head.
Description of main CT make up pumps is as follows:
Number of pumps: 2 x 100 % for 120 MW (1W + 1S)
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MECHANICAL
PP 067 M B01 0
83
Capacity of pumps with 10% Margin: 380 m3/hr

9.1.4. DM FEED-CUM- AUXILIARY COOLING TOWER MAKE-UP SYSTEM
Make-up water needs to be supplied to the auxiliary cooling tower to
recover the water lost in CT blowdown and evaporation & drift losses. This make1
up water to auxiliary cooling tower is supplied by 3 x 50 % DM feed-cum-auxiliary

CT make up pumps. A tapping is taken after dual media filter header to supply a
better quality filtered water as a make-up to auxiliary cooling tower.
The auxiliary cooling water make-up requirement has been calculated as
follows:
:
1,976 m3/hr
Cooling Range (from 40C to 33C)
7 deg C
Cycles of Concentration
Evaporation loss
24 m3/hr
Blowdown + Drift
5 m3/hr
Total make-up to ACT per hour
29 m3/hr
Auxiliary cooling water requirement for the

auxiliary coolers
The details of this pump is as follows considering Auxiliary CT mak-up

water, DM feed water, potable water and filter backwashing water requirement.
DM feed-cum-auxiliary CT make up pumps will take suction from the
clarified water storage tank and pump the clarified water to Duel Media Filters
(DMF). This filtered water from DMF outlet header is then sent to the DM plant,
auxiliary cooling tower and filtered water storage tank. The configuration of pumps
& DMF (i.e. 3 x 50%) is selected such that one will be working for DM plant &
1
potable water, one will be working for auxiliary cooling tower make-up and one
common standby. (please refer water balance diagram).
Description of DM feed-cum-auxiliary pumps & DMF is as follows :
Total filtered water required = Make-up to auxiliary CT + DM Plant +
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PP 067 M B01 0
84
potable water + filter backwash water

= 29 + 20.25 + 3 + 1.25
= 53.5 m3/hr
Number of DM feed-cum-auxiliary CT make
pumps & DMF
: 3 x 50 %
Capacity of DM feed-cum-auxiliary CT make

pumps & DMF with 10% Margin
: 30 m3/hr
9.1.5. DEMINERALIZATION WATER SYSTEM

The filtered water from DMF is fed to a DM Plant (2 x 25 m3/hr capacity) to
generate boiler quality water. A tapping is taken after duel media filters to store
1
filtered water in a filtered water storage tank of capacity 40 m3. Potable water (3
m3/hr) and backwashing water for DMF (1.25 m3/hr) will be fed from this filtered
water storage tank.
The capacity of the DM water plant has been arrived as follows:
Individual boiler MCR
240 TPH
Maximum blowdown rate as a percent of boiler

MCR
3%
Blowdown quantity per boiler
7.2 m3/hr
Total blowdown quantity for both boilers
14.4 m3/hr
Deaerator vent loss (estimated)
0.5 m3/hr
Miscellaneous loss as leakage or vent (estimated)
0.5 m3/hr
Total power cycle make-up
15.4 m3/hr
Regeneration water
1.5 m3/hr
Required capacity of DM Plant operation for 18 hrs

a day (operation between regeneration)
22.5 m3/hr
Selected capacity of DM Plant
2 x 25 m3/hr
(1 W + 1 S)
Each stream of the DM Plant shall broadly comprise Activated Carbon Filter
(ACF), Strong Acidic Cation (SAC) exchanger, Degasser tower & storage tank
(common for both the streams), Strong Basic Anion (SBA) exchanger and Mixed
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MECHANICAL
PP 067 M B01 0
85
Bed (MB) exchanger. Acid and alkali measuring tanks (common to both streams)
with ejectors shall form part of the system to provide these chemicals for
regeneration. Hydrochloric acid and sodium hydroxide shall be the chemicals
used for this purpose.
The DM Plant shall be designed to operate continuously for 18 hours
before regeneration of the exhausted resin in the ion exchangers. The
regeneration of the exchangers shall be completed in a maximum period of 6
hours. Regeneration water heater for regeneration of anion resins will be
provided.
The waste from the regenerated waste of DM plant shall be collected in
drain pits near the vessels and routed through acid/alkali proof lined trenches to a
neutralizing pit. Acid or alkali as required shall be dosed in this pit and the effluent
shall be neutralized by recirculation before being pumped to the guard pond.
Bulk acid and alkali storage tanks (one each) shall be provided to store acid
and alkali of commercially available strengths. The capacity of each tank shall be
sufficient to unload one tanker load of chemical. As the standard capacity of a
normal tanker is 10 m3, the tanks shall be sized for 10 m3 capacity. Two (2) nos.
acid unloading pumps and two (2) nos. alkali unloading pumps shall be provided.
The capacity of each pump shall be sufficient to unload each tanker in about one
hour. The acid and alkali shall be transferred to the respective measuring tanks by
gravity.
The operation of the DM Plant will be semi-automatic through a dedicated
1
PLC called water system PLC. DM plant will be located in a RCC building along
with DM plant control cum MCC room.
The DM water generated by the DM plant shall be stored in two (2) nos.
vertical cylindrical MS with epoxy coated DM water storage tanks of capacity 250
m3 each. The tank shall be designed as per IS:803 and provided with inlet, outlet,
drain, overflow, vent and recirculation connections. Tank shall be provided with
suitable access manholes. Level instruments for monitoring the level in the tanks
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MECHANICAL
PP 067 M B01 0
86
shall also be provided.

Design quality of treated water at the DM Plant outlet shall be maintained
with silica content maximum : 0.02 ppm and conductivity not to exceed 0.1
micromho/cm.
9.1.6. DM WATER DISTRIBUTION SYSTEM
DM Water from the DM water storage tanks shall be pumped by 2 x 100%
DM transfer (power cycle make-up) pumps of capacity 17 m/hr (with 10 % margin
on cycle make-up water requirement i.e. 15.4 m/hr). Power cycle make-up pumps
shall be located outdoor near the DM water storage tank. The DM water shall be
stored in the Condensate Storage Tank (CST). The CST tank shall be horizontal
cylindrical steel tank with capacity sufficient to hold 3% make-up water
requirement of two (2) hours i.e. 30 m. The tank shall be designed as per IS:803
and provided with inlet, outlet, drain, overflow and vent connections. Power cycle
make-up water to hotwell shall be supplied from the CST by gravity through a
hotwell level control valve.
One number boiler fill pump (1 x 100%) of capacity 17 m/hr shall be
provided for boiler / system filling during plant start-up. The pump shall be located
beside DM transfer (power cycle make-up) pumps and will take suction from DM
water storage tank.
Power cycle make-up pumps and boiler fill pump will be sized based with
10 % margin on flow and 5 % margin on head.
9.1.7. SERVICE WATER SYSTEM
Two (2) nos. of service water pumps of capacity 100% each will be used to
pump the clarified water from the clarified water tank to cater service water
requirement at various locations of plant. Service water tank of suitable capacity
will be provided in various building as listed below.
The details of the service water system are given below:
Service water pumps
Qty
2 nos.
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MECHANICAL
PP 067 M B01 0
87
Type of pump
Horizontal centrifugal
Location of pumps
Near clarified water tank
Capacity of each service water tank
1 or 2 (as required)
Selected pump capacity with margin
m/hr
Location of tank
STG Building, DM plant

building, Pre-treatment
plant building, ESP
control
room-cumcompressor house, Ash
handling area etc.
Distribution of service water from tank
By gravity
9.1.8. POTABLE WATER SYSTEM

A tapping is taken after Duel media filters to store a filtered water in a
filtered water storage tank of capacity 40 m3. The potable water treatment further
1
comprises of dosing with sodium hypochlorite for chlorination. Two (2) nos. pumps
of capacity 3 m3/hr each shall be provided to cater potable water requirement at
various locations of plant. Potable water tank of suitable capacity will be provided
in various building as listed below. The capacity of the tank shall be sufficient for
one days requirement of potable water.
The capacity of the potable water system has been worked out as below:
Potable water consumption per day per

person
15 litres
No. of persons
(assumed)
Plant
500
Total potable water consumption per day
7500 litres i.e. 7.5 m3
Total potable water consumption per

hour
0.3125 m3
Capacity of Potable water pump
3.0 m3/hr
Capacity of each potable water tank
1-2 m3 (as required)
Location of tank
in
Power
STG Building, DM plant

building, Pre-treatment
plant building, ESP control
room-cum-compressor
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MECHANICAL
PP 067 M B01 0
88
house, Administrative
building, Medical building,
canteen, store, workshop
etc.
1
Distribution of potable water from potable
water tank
By gravity
9.2. COOLING WATER SYSTEM

9.2.1. MAIN COOLING WATER SYSTEM FOR CONDENSER
9.2.1.1.
System Description
The main cooling water system will be used to cool the circulating water
used for condensing steam in the surface condenser.
Main cooling water system for surface condenser will be closed cycle
cooling system employing a cooling tower common for two units, cooling water
pumping system, CW treatment system and associated piping & valves.
The cooling tower will be of mechanical, induced draft, multi-cell, counterflow type. The material of construction of the cooling tower will be of RCC /
Pultruded FRP. Common cooling tower is provided for two units which consist of
seven cells (6 Working + 1 Standby) out of which three (3) cells will be working for
one unit with one (1) common standby. Cooling tower shall cool the hot return
water and discharge it into an RCC fore bay.
The tower will be designed in such a way that any cell can be operated,
repaired or maintained independent of the other cells. Cooling tower basin along
with fore bay shall be provided with storage capacity equivalent to 10 minutes
cooling water flow rate. The make up water will be added in the cooling tower
basin and will be suitably treated. Dosing of chemicals to prevent biological
growth, corrosion and scaling in the cooling water shall be provided on the
forebay. Drains from the sumps located behind the towers shall be provided for
each cell which shall be routed to the storm water drains.
The cold water will be transferred to the condenser water box by means of
MCW pumps and the return will be taken back to the cooling tower. MCW pumps
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MECHANICAL
PP 067 M B01 0
89
will be vertical turbine type pumps located in a pump house at the end of the fore
bay. There will be a total of three (3) number of CW pumps, one will be working
for each unit and the third will remain as common stand by. Overhead EOT crane
of suitable capacity will be provided in the MCW pump house for maintenance of
the pumps.
Motor operated isolation valves will be provided at the discharge of the
main cooling water pumps. Manual isolation valves shall be provided at individual
inlets and outlets to the condenser. Manual isolation valves are provided in the
return line inlet to individual cells of cooling tower. A pneumatically operated
control valve is provided in the CT makeup water line to regulate inflow based on
level in the cooling water sump.
For maintaining the level of TSS in the circulating cooling water a side
stream filter (SSF) has been envisaged. Six (6) numbers of Automatic Valveless
Gravity Filters (AVGF) type SSF are provided. The SSF is designed for 5 % of the
total cooling water flow rate. Considering five (5) nos. of SSF working, the
1
capacity of the each filter works out to be 200 m3/hr. However, each filter of 225
m3/hr capacity will be provided.
9.2.1.2.
System Sizing Calculation
The following criteria are considered for the main cooling water system
sizing.
Design ambient wet bulb temperature : 28C
Design approach temperature : 5C
Cooling water inlet temperature to condenser is 33C
Cooling water outlet temperature from condenser is limited to 42C
Calculation for Main Cooling Water Flow:
Description
Condenser heat load
Unit
Value (100
% TMCR)
Value
(VWO)
Kcal/hr
80,686,468
87,142,366
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MECHANICAL
PP 067 M B01 0
90
Cooling water flow required for

one unit
m/hr
8,965
9,683
Cooling water flow required

for both unit
m/hr
17,930
19,366
10
Minimum CT capacity required
m/hr
19,723
20,334
Selected Main Cooling Tower

Capacity
m/hr
Margin on flow for Main cooling

water pump
10
Minimum required capacity for

each MCW pump (2 W + 1 S)
m/hr
9,862
10,167
Selected Main Cooling Water

Pump Capacity
m/hr
Margin while selecting CT

capacity
20,400
10,200
During steam dump operation also, the selected capacity of the cooling
tower shall suffice with increased cooling water outlet temperature.
Main cooling water flow capacity of each pump shall be 10,200 m3/hr as
1
calculated above. MCW pump head will be established considering Hazen William formula for pressure drop calculation across the pipe line.
The main cooling tower has been sized at 20,400 m3/hr flow rate (total),
3,400 m3/hr per cell. The cooling range of the tower is specified as 9C.
Summary of Main Cooling Tower technical Parameters :
1
Type
: Mechanical,
Flow
Induced
Draft,
Counter
Construction
: RCC / Pultruded FRP
No. of cells
: Seven (7) (6 working & 1 standby)
Flow rate
: 3,400 m3/hr per cell
Design wet bulb temperature
: 28C
Cold water inlet temperature
: 33C
Range
: 9C
POWER DIVISION
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MECHANICAL
PP 067 M B01 0
91
Water quality
: Circulating water
Cycles of concentration
: 6
10
Drift loss (max.)
: 0.05%
9.2.2. AUXILIARY COOLING WATER SYSTEM FOR AUXILIARIES

9.2.2.1.
System Description
The auxiliary cooling water system circulates cooling water through

generator air cooler, STG lube oil cooler, boiler sample coolers, air compressors,
BFP coolers, bed ash coolers, HVAC system and makeup to the air washer units
etc.
Auxiliary cooling water system will be closed cycle cooling system
employing a cooling tower common for two units, auxiliary cooling water pumping
system, ACW treatment system and associated piping & valves.
The auxiliary cooling tower will be of mechanical, induced draft, multi-cell,
counter-flow type. The material of construction of the cooling tower will be of FRP
/ Pultruded FRP. Common cooling tower is provided for two units which consist of
two (2) cells of which one (1) cell will be working for both units and other one (1)
will be standby. Cooling tower shall cool the hot return water from various
auxiliaries and discharge it into a fore bay.
The tower will be designed in such a way that any cell can be operated,
repaired or maintained independent of the other cells. Cooling tower basin along
with fore bay shall be provided with storage capacity equivalent to 10 minutes
1
cooling water flow rate. The make up water (filtered water after duel media filters)
will be added in the cooling tower basin and will be suitably treated. Dosing of
chemicals to prevent biological growth, corrosion and scaling in the cooling water
shall be provided on the forebay. Drains from the sumps located behind the
towers shall be provided for each cell which shall be routed to the storm water
drains.
The cold water will be transferred to various plant auxiliaries of boiler, STG
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MECHANICAL
PP 067 M B01 0
92
and compressors by means of ACW pumps and the return will be taken back to
the cooling tower. ACW pumps will be vertical turbine type pumps located in a
pump house at the end of the fore bay. There will be a total of three (3) number of
ACW pumps, one will be working for each unit and the third will remain as
common stand by. Monorail with manual hoist of suitable capacity will be provided
in the ACW pump house for maintenance of the pumps.
Motor operated isolation valves will be provided at the discharge of the
auxiliary cooling water pumps. Manual isolation valves are provided in the return
line inlet to individual cells of cooling tower. A pneumatically operated control
valve is provided in the CT makeup water line to regulate inflow based on level in
the cooling water sump. Alternatively, an ON-OFF type air operated valve can be
used for make-up.
Auxiliary cooling water system is provided with vertical type pressure sand
filter online for make-up water line to maintain the quality of water.
9.2.2.2.
System Sizing Calculation
The following criteria are considered for the auxiliary cooling water system
sizing.
Design ambient wet bulb temperature : 28C
Design approach temperature : 5C
Cooling water inlet temperature to condenser is 33C
Cooling water outlet temperature from condenser is limited to 42C
Calculation for Auxiliary Cooling Water Flow:
Description
Unit
Value
Generator air cooler
m/hr
350
STG lube oil cooler
m/hr
240
Ash recycle screw feeder cooling
m/hr
80
Water cooled ash cooler
m/hr
100
Fuel feeders
m/hr
48
CBD quenching
m/hr
20
POWER DIVISION
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MECHANICAL
PP 067 M B01 0
93
BFP cooler
m/hr
Sample coolers
m/hr
10
SWAS system
m/hr
15
Plant & ash air compressors
m/hr
50
AC system
m/hr
40
Air washer unit
m/hr
10
Miscellaneous
Total auxiliary cooling water flow
required for one unit
m/hr
20
m/hr
988
Total auxiliary cooling water flow

required for both units
m/hr
1976
Margin while selecting CT capacity
10
Minimum CT capacity required
m/hr
2174
Selected Auxiliary Cooling Tower

Capacity
m/hr
2200
Margin on flow for auxiliary cooling

water pump
10
Minimum required capacity for each

ACW pump (2 W + 1 S)
m/hr
1087
Selected Auxiliary Cooling Water

Pump Capacity
m/hr
1100
Auxiliary cooling water flow capacity of each pump shall be 1,100 m3/hr as
calculated above. ACW pump head will be established considering Hazen William formula for pressure drop calculation across the pipe line.
The auxiliary cooling tower has been sized at 2,200 m3/hr flow rate (total),
2,200 m3/hr per cell. The cooling range of the tower is specified as 7C.
Summary of Auxiliary Cooling Tower technical Parameters :
1
Type
: Mechanical,
Flow
Induced
Draft,
Construction
: FRP / Pultruded FRP
No. of cells
: Two (2) (1 working & 1 standby)
Flow rate
: 2,200 m3/hr per cell
Counter
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MECHANICAL
PP 067 M B01 0
94
Design wet bulb temperature
: 28C
Cold water inlet temperature
: 33C
Range
: 7C
Water quality
: Circulating water
Cycles of concentration
: 6
10
Drift loss (max.)
: 0.05%
9.2.3. COOLING WATER TREATMENT SCHEME

In-situ chlorine dioxide generators system will be provided for dosing in the
cooling tower basin to prevent biological algae growth. In addition, a provision for
scale, corrosion and bio-dispersion inhibitors will be provided along with chemical
storage tank and chemical injection pump to cooling tower forebay.
Cycle of concentration for CW system and cooling tower design is chosen
taking care of the scale formation and corrosion behaviour of the circulating water.
10. FUEL OIL SYSTEM
For start-up of the plant, Light Diesel Oil (LDO) will be used as a start-up
fuel. For storing this fuel oil, LDO tanks (2 nos.) of capacity 250 KL each shall be
provided.
LDO unloading-cum-transfer pumps and pressurizing pumps along with
suction strainer / filters and pipeline extending to the two boilers including the
return lines will also be provided.
11. FUEL HANDLING SYSTEM
The boiler will adopt circulating fluidised bed combustion system and the
1
fuel firing system will be designed for `Over bed feeding system. The circulating
fluidised bed will consist of three (3) feeding points.
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MECHANICAL
PP 067 M B01 0
95
11.1.SYSTEM SIZING
Material Handling System to be supplied will handle ROM Coal, Washery
rejects mixed together or one at a time. Owner will arrange to feed these materials
into specified underground hoppers as per requirement. This system will convey
the material to bunker compartments of boilers after crushing and grading. The
coal handling plant will be controlled by a dedicated PLC located near the coal
handling plant. The PLC will be connected to central DCS for monitoring purpose.
The basic scheme for handling shall be as per the attached scheme
(Drawing No. PP 067 M 132 3).
To arrive at the Coal Handling system sizing, the coal consumption per
Boiler is calculated as indicated in the table below. The Fuel handling plant will be
designed for 12 hrs of operation based on Performance Fuel (50% ROM and 50%
Washery Rejects) as per the specification requirement.
Capacity Calculation for Coal Handling System
Particulars
Calculation
Fuel
Consumption
per
Boiler
(Considering Performance Coal)
64.42 TPH
Fuel Consumption for two boilers
2 x 64.42 = 128.84 TPH
Fuel Handling Plant running hours per

day
12 Hrs.
Down time for Tripper Travel,

Changeover & Establishing capacity
in recirculation line
Hrs.
Hours
of
downtime
operation
excluding
Required Fuel handling plant capacity

Selected
Capacity
Fuel
Handling
Plant
Running Hours with Washery Rejects:
12 - 0.50 = 11.5 hrs

128.84 X 24 / 11.5 = 268.9 TPH
300 TPH
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MECHANICAL
PP 067 M B01 0
96
Particulars
Fuel
Consumption
(Washery Rejects)
Calculation
per
Boiler
88.746 TPH
Fuel Consumption for two boilers
2 x 88.746 = 177.492 TPH
Number of Operating Hours required

per day
177.492 X 24 / 300 = 14.2 Hrs.
Down time for Tripper Travel,

Changeover & Establishing capacity
in recirculation Line
Hrs.
Hours of operation of Fuel Handling

Plant
14.2 + 0.5 = 14.7 Hrs, Say 15 Hrs.
Based on the above and with 12 hours operation the capacity of the
handling system has been sized at 300 TPH.
Each boiler will be provided with fuel bunkers.
Bunker sizing basis is discussed in section covering boilers of this
document.
11.2.SYSTEM DESCRIPTION
1
Coal unloading & storage

Coal unloading & storage is excluded from the scope of EPC. This will be
performed by suitable means by Owner.
Coal loading system
The coal will be loaded by doser to the 2 x 25 T ground flush underground
grizzly hoppers. Each grizzly hopper will be provided with rod gate and motorized
rack and pinion gate, Vibratory feeder, etc. Manual chain pulley block will be
provided in the grizzly hopper area. The grizzly hoppers will be of Steel
construction.
The conveyor below the feeder will run through the tunnel with
required slope to feed the crusher/ screen in the crusher house. The Tunnel will
be provided with 2 x 100% Sump pump.
Coal Crushing, Screening & Bunker Feeding System
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MECHANICAL
PP 067 M B01 0
97
The coal will be available at the terminal point at (-) 100 mm size minimum
90%.
CFBC boilers requires coal at (-) 6 mm. Hence, a coal Crushing and
screening plant will be installed. The coal crushing, screening and boiler feeding
system will be designed for 2 x 300 TPH capacity as per the basis outlined above.
From the grizzly hoppers, the Coal shall be fed to the crushers in the
crusher house. This belt shall be routed through an underground tunnel. All
above ground belts shall be provided central walkway of 1000 mm and both side
walkways of 800 mm. The conveyor will be covered from top as well as from sides
with permanent colour coated zincalume steel sheet.
The RCC crusher house shall house two crushers, one working and one
standby of 300 TPH capacity each. The Crusher will open bottom type non
reversible crushers appropriate for feed and product size of 100 mm and 6 mm
respectively. It shall also house four (4) nos. flip flow type screens for Screening
the Crushed Coal.
Input Coal size distribution and properties has been considered as follows
for sizing screen and Crusher.
Total Moisture - 20 %
Hard Grove Index - 45 - 77
Sieve-analysis:
Maximum lump-size - 100 mm
Sieve-opening size passing through :
100 mm
100 %
50 mm
55 %
25 mm
32 %
12 mm
18 %
6 mm
12 %
1 mm
8%
Bunker feed system:
Two numbers travelling tripper shall be provided in the belt beside the
bunker of the boilers. From the travelling tripper, coal shall be fed to the Coal
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MECHANICAL
PP 067 M B01 0
98
Bunkers.
Dust extraction & ventilation system
Dust extraction systems will be provided for the crusher house and other
dust generation points. Dust Extraction system for material-handling plant will
ensure minimum leakage. Dust Extraction system bag filter outlet will be designed
for 100 mg/Nm3 SPM level.
Grizzly hopper tunnel ventilation system will be provided. Ventilation
system will be provided for all the boiler bunkers.
Dust suppression system with sprinkler nozzles will be provided in coal
storage area and grizzly hopper area. Treated effluent water will be used for the
same purpose.
Other design criteria/ standards followed:
The following is a list of other features that are being followed. However,
this may vary slightly based on manufacturers std.
(a) Conveyor design standards
: IS/CEMA
(b) Bulk density of fuel for volume calculation
: 0.8 T/m3
(c) Bulk density of fuel for weight calculation
: 1.04 T/m3
(d) Conveyor slopes
: 14 to horizontal
Note: Due to layout constraint in few cases, the inclination angle may be
slightly higher to horizontal.
(e) Speed of belt conveyor
: 1.8 m/s (max)
(e) Troughing angle of conveyors
: 35
(f) Deck material
: Nylon Nylon
(h) Cover grade
: Fire resistant as per CAN

/CAS M422-M87
(i) Drive details

(1) Type of drive
: Single snub for all conveyors(at discharge end)
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PP 067 M B01 0
99
(2) Angle of wrap : 210

(3) Surface of drive pulley: Rubber lagged
(j) Belt sag
: 2% of idler spacing
(k) Maximum belt tension corresponding
: Should not exceed 80% of

the design capacity
maximum
during
and
150%
belt
tension
running
should
of
allowable
condition
not
the
belt
exceed
maximum
tension
during starting condition.

(l) Take up arrangement
: Automatic take up, gravity

type
(m) Idlers
(1) Idlers to be Designed as per IS: 8598, IS: 4776, IS:11592 or
Equivalent
(2) Idlers below magnetic separator and metal detectors should be nonmagnetic type. Maximum 3 nos. of such idlers to be provided under
each above mentioned equipment
(3) Minimum 5 impact idlers shall be provided at every feeding point.
1
(4) Suitable no. of adjustable transition idlers at head end and tail end
at slope of maximum 10 shall be provided for all conveyors.
Maximum gap of transmission idler shall be 700mm.
(5) Adequate no. of idler pulley shall be provided for each conveyor
where change of belt direction takes place and for installation of
scrapper.
(6) Minimum bearing life shall be 30000 hours.
(n) Pulley
(1) To be Designed as per IS per IS-8531, IS 4776, Part-1, IS 1891 &
BS 2890 or Equivalent.
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100
(2) Service: For head and drive, head snub, bend take-up, tail and tail
snub pulleys (if required)
(3) Minimum pulley width: As per IS
(4) Pulley construction: Welded steel as per IS 8531.
Pulley below magnetic separators and metal detectors shall be nonmagnetic stainless steel.
(5) Pulley diameter: As per IS 1891 or belt manufacturer standards
(6) Bearing life: 50000 hours
(o) Gear box
(1) Type of high-speed coupling: Pin-Bush
(2) Type of low speed coupling: Gear
(3) Type of gear box: upto 20kW :- Worm type
More than 20kW :- Helical
(4) Type of bearing: Antifriction / Roller
(5) Bearing life: 30000 hours
(6) Hold backs: Hold back will be provided for inclined conveyors
except for reversible ones.
(7) Material of construction: Casing: - Cast Steel, FG -260 of IS -210
Worm, Gear pinion: - Alloy Steel
Shaft: - Forged / Alloy Steel
1
Type of cooling: - Natural / Fan cooler
(p) Magnetic Seperator : Two numbers over-band type magnetic separator
before the belt entering crusher house
(q) Hoppers and chutes
(1) Material: MS IS 2062
In magnetic zone, chutes will be SS 409M / non-magnetic
(2) Chute thickness: 10mm (minimum)
(3) Hopper material; MS
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PP 067 M B01 0
101
(4) Hopper thickness: 10mm (minimum)

(5) Liner: Replaceable, 10mm thick, SAIL HARD
(6) Minimum valley angle: 55-60
(r) Skirt board
(1) Material of main plate: MS IS 2062
(2) Thickness of main plate: 10mm
(3) Minimum length of skirt per feeding point: 3m
(4) Thickness of back plate: 10mm
(5) Thickness of rubber strip: 20mm
(6) Thickness of Top cover: 4mm MS
(For discharge hood skirt cover plate)
(s) Skirt for belt conveyor shall be segmented type.
(t) Zero speed switch one number per conveyor.
(u) Pull chord switch will be provided at spacing of 30 m.
(v) Belt sway switch (auto reset type) in pairs will be provided at spacing of
30m.
12. LIME STONE HANDLING SYSTEM
1
The circulating fluidized bed boiler uses Lime stone to capture the sulphur
present in the fuel. The lime stone quality to be used as per the specification
elsewhere mentioned in the DBR. To restrict the chimney height to 44m, 90%
sulphur capture is required. To achieve this Ca/S ratio of 5.3 is being employed for
performance fuel.
12.1.SYSTEM DESCRIPTION & SYSTEM SIZING
Lime stone less than 20 mm size will be received at ground grizzly hopper
and will be fed to the conveying system through vibratory feeder and conveyor.
Lime stone will be crushed and screened and will be conveyed pneumatically to
the boiler bunkers.
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MECHANICAL
PP 067 M B01 0
102
Capacity Calculation for Lime Stone handling system

Particulars
Lime Stone Consumption Per
(Considering Performance Coal)
Calculation
Boiler
Lime Stone Consumption for Two Boilers
4.03 TPH
2 x 4.03 = 8.06 TPH
Lime stone Handling Plant running Hours

per Day
12 Hrs.
Required
Capacity
Lime
Stone
handling
Plant
8.06 X 24 / 12 = 16.12 TPH
Selected
Capacity
Lime
Stone
Handling
Plant
18 TPH*
* Conveyor has to be designed for 24 TPH as per the specification.

13. ASH HANDLING SYSTEM
1
The ash handling system for two number CFBC boilers operating on
various types of coals as mentioned in Boiler Design Basis Report shall be
designed for the maximum ash generation from Washery Rejects
The ash handling system consists of three basic schemes:
Bed ash handling system - Ash removal from the bed ash coolers.
Fly ash handling system - Ash removal from mechanical dust

collector (MDC), air preheater and ESP hoppers.
Ash silos and ash disposal provisions thereafter.
Ash generation details as worked out from boiler operation with highest ash
content coal are provided in Table-1 below. Ash handling system is designed on
the basis of this data. Details of the system are provided in subsequent sections.
Below each ash hopper outlet, suitable MS surge chutes with 1 no.
expansion joint shall be provided. Level probes will be provided in the surge
hoppers for automatic operation of the system. The ash vessel (transporter) will
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MECHANICAL
PP 067 M B01 0
103
be placed below each surge hopper. The level probe in the hopper senses the
pressure of material to initiate the conveying cycle. The valve will open and allow
the material to gravitate in to the vessel till it is closed automatically by the timer
present as per process parameters. On closure of dome valve, valve seal gets
inflated and signals the conveying air injection into the transporter.
13.1.1.BED ASH CONVEYING SYSTEM
Bed ash from the boilers will be discharged through the bed ash coolers at
about 200 oC. Each boiler will have 3 nos. water cooled type bed ash cooler. Ash
from each bed ash cooler outlet will be transported to a Ash vessel through a
conveyor located below the Boiler.
Though normal ash temperature is expected to be around 200 Deg C ,
design temp for the bed ash conveying system will be 400 Deg C. Bed Ash from
the Ash vessel will be transported to an Intermediate Silo.
1
Bed ash conveying scheme is presented in Flow Diagram for Bed Ash Handling
System, drawing number: - PP 067 M 131 2.
13.1.2.FLY ASH CONVEYING SYSTEM
Dense phase pneumatic handling system shall be used for conveying fly
ash from the MDC at boiler, air preheater and ESP to two fly ash silos.
Ash from six numbers of hoppers at each boiler MDC is transported back to
furnace for recycling. Ash level controllers at the hoppers will discharge excess
ash out of boiler system. This excess fly ash is pneumatically conveyed to ash
silos through one number ash vessels. In addition, two lines of two fly ash
collection points each at air preheater hoppers will also be provided. Ash handling
system at these locations will be designed for 300 Deg C temperatures.
Major fly ash collection is from ESP hoppers. Each boiler ESP has 6 fields
from where fly ash is collected and conveyed pneumatically to ash silos. Ash
collection estimate from various fields under all fields working condition and under
first field failed condition are provided in Table-1 below. Capacities of ash
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MECHANICAL
PP 067 M B01 0
104
conveying lines will be decided based on the worst condition at these locations.
Fly ash conveying scheme is presented in Flow Diagram for Fly Ash
Handling System drawing number: - PP 067 M 131 1.
Table-1 : Ash Generation Details
Sl.
No.
Locatio
n
Number
of Ash
Discharg
e point
Numbe
r of Ash
Vessel
Design
capacity per
Ash vessel
Kg/Hr
Total Design
Ash quantity
Kg/hr
Normal
Operating
Temperatur
e Deg. C
Design
Temperatur
e Deg. C
1.0
Bed Ash
2W + 1S
7500
15000
200
400
2.0
MDC
76570
76570
270
350
3.0
AHP
2960
5920
180
280
4.0
ESP- 1st
field
11970/(1330)
*
23940/(2660)
*
140
160
5.0
ESP2nd field
1200/(10775)
*
2400/(21550)
*
140
160
6.0
ESP3rd field
120/(1080)*
240/(2160)*
140
160
7.0
ESP4th field
12/(110)*
24/(220)*
140
160
8.0
ESP5th field
1.5/(15)*
3.0/(30)*
140
160
9.0
ESP6th field
1/(1.5)*
2/(3.0)*
140
160
Notes :
1.0 Based on specification requirement of 8hrs Ash being evacuated in 5hrs the
conveying Air compressor shall be sized for a total Ash generation of 92660
Kg/Hr per Boiler.
2.0
Figures marked with * is collection of Ash quantity with First field out
condition.
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105
3.0 Design Capacity of vessels have been arrived based on uncertainties of ash
collection rates at different point with adequate margin based on Boiler
Manufacturers experience
13.1.3.ASH SILOS
Ash Silos have designed based on worst fuel i.e. Washery rejects having
maximum Ash content. The maximum fuel consumption has been determined
based on boiler evaporation of 240 TPH. The Ash distribution for sizing Bed Ash
and Fly Ash Silos have been considered as 20% for Bed Ash and 80% for Fly
Ash.
Bed ash from Ash vessels will be transported to one number Intermediate
bed ash Silo located close to the Boiler area. The Ash from the Intermediate Bed
Ash Silo will be transported to one number Bed ash silo, common for two boilers.
Capacity calculation for the Bed Ash intermediate Silo and Bed Ash Silo is
included in subsequent paragraph.
Fly ash from MDC hoppers, AHP Hoppers and ESP hoppers will be
conveyed to Fly Ash silo. Provision will be made for discharging Ash to any one of
the Silo.
1
Each fly ash silo will be provided with RF type level measurement and four
outlets as below.
One for unloading fly ash into closed trucks in dry form through rotary
feeder and retractable telescopic chute.
One for unloading fly ash in conditioned form through rotary feeder and ash
conditioner to open trucks.
Other two with blind flange with plate valves for future use.
The minimum unloading rate of bed ash & fly ash in the open trucks as well
as in the closed trucks shall be 120 TPH.
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MECHANICAL
PP 067 M B01 0
106
13.2.SYSTEM SIZING
For Volume Calculation (Bed Ash)-650 kg/m3
For Volume Calculation (Fly Ash)-750 kg/m3
For Load Calculation (Fly Ash & Bed Ash)-1600 kg/m3
Quality of clean air from bag filter of dust extraction system shall be 50
mg/nm3
Silos will be equipped with Fluidising Air blower and Fluidising Air Heaters.
13.2.1.DESIGN CALCULATION FOR INTERMEDIATE ASH SILO:
Sl. No.
Particulars
Calculation
1.0
Fuel Quantity with Washery rejects
88746 Kg/Hr
2.0
Ash percentage in fuel
60%
3.0
Ash Quantity
53247.6 Kg/Hr
4.0
Lime Stone Contributing to Ash as Calcium

Sulphate
6501 Kg/Hr
5.0
Total Ash Quantity
59748.6 Kg/Hr
6.0
Bed Ash Quantity Per Boiler
0.2 x 59748.6 Kg/hr = 11949.7

Kg/Hr
7.0
Bed Ash Quantity for Two Boilers
2 x 11949.7 Kg/Hr = 23899.4 Kg/Hr
8.0
Storage quantity considering 30mins storage
0.5 x 23899.4 Kg/hr = 11949.7

Kg/Hr
9.0
Selected Storage Capacity of Intermediate Ash

Silo
20 Tons. (Minimum required as per

the specification)
10.0
Bed Ash Density for Volumetric calculation
650 Kg/M3
11.0
Silo Filling Factor*
0.85
12.0
Volumetric Capacity
20000 / (0.85 x 650) M3 = 36.19 M3
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PP 067 M B01 0
107
13.0
Selected Volumetric Capacity of Intermediate Ash

Silo
37 M3
13.2.2.DESIGN CALCULATION FOR BED ASH SILO:
Sl. No.
Particulars
Calculation
1.0
88746 Kg/Hr
2.0
60%
3.0
Ash Quantity
53247.6 Kg/Hr
4.0
Lime Stone Contributing to Ash as Calcium

Sulphate
6501 Kg/Hr
5.0
Total Ash Quantity
59748.6 Kg/Hr
6.0
Bed Ash Quantity Per Boiler
0.2 x 59748.6 Kg/hr = 11949.7

Kg/Hr
7.0
Bed Ash Quantity for Two Boilers
2 x 11949.7 Kg/Hr = 23899.4 Kg/Hr
8.0
Storage quantity considering 24 Hrs. storage
24 x 23899.4 Kg/hr = 573585.6

Kg/Hr
9.0
Selected Storage Capacity of Intermediate Bed

Ash Silo
573585.6 Tons
10.0
Bed Ash Density for Volumetric calculation
650 Kg/M3
11.0
0.88
12.0
Volumetric Capacity
573585.6/(0.88
1002.77 M3
13.0
Selected Volumetric Capacity of Bed Ash Silo
1005 M3
13.2.3.DESIGN CALCULATION FOR FLY ASH SILO:
Sl. No.
Particulars
Calculation
1.0
88746 Kg/Hr
2.0
60%
3.0
Ash Quantity
53247.6 Kg/Hr
650)
M3
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MECHANICAL
PP 067 M B01 0
108
4.0
Lime Stone Quantity
6501 Kg/Hr
5.0
Total Ash Quantity
59748.6 Kg/Hr
6.0
Fly Ash Quantity Per Boiler
0.8 x 59748.6 Kg/hr = 47798.9

Kg/Hr
7.0
Fly Ash Quantity for Two Boilers
2 x 47798.9 Kg/Hr = 95597.8 Kg/Hr
8.0
Storage quantity considering 24 Hrs. storage
24 x 95597.8 Kg/hr = 2294347.2

Kg/Hr
9.0
Number of Fly Ash Silo
10.0
Required Storage capacity per Silo
2294347.2 / 2 Kg/hr = 1147173.6

Kg/hr
11.0
Fly Ash Density for Volumetric calculation
750 Kg/M3
11.0
0.92
12.0
Volumetric Capacity
1147173.6/(0.92
1662.6 M3
13.0
Selected Volumetric Capacity of Bed Ash Silo
1665 M3
750)
M3
* Note : Filling factor have been arrived based on number of feed points in the Silo
and Silo geometry.
14. COMPRESSED AIR SYSTEM
The power plant will require instrument air for operation of I/P converters,
purge instruments, pneumatic actuation of control valves, dampers etc. for
different systems. Service air will be required for cleaning of filters, strainers, fuel
oil atomization, igniters cooling and other general purposes.
Compressed air
system, as detailed in this report, is envisaged to supply both service and

instrument air of required quality and quantity.
Instrument air as required for ash handling plant is also considered in the
plant air compressor sizing. However, separate air compressors will be provided
for conveying air requirement of ash handling system and lime stone handling
system.
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109
The compressed air system shall consist of Instrument Air Compressors &
Air-Drying Plants (ADP), Service Air Compressors, Air Receivers, interconnecting
compressed air piping. It will also include control panels, Instrumentation &
control.
Instrument air is dehumidified & dried to requisite level before use. Oil free
air is required form the compressors for instrument air service. Three (3) nos.
(normally 2 working + 1 standby) oil free screw type instrument air compressors
and two (2) nos. (1 working + 1 standby) driers will be provided to cater for the
instrument air requirement of the entire plant. Instrument air is taken from the
compressed air header after air driers and will be supplied to one (1) no. air
receiver dedicated to instrument air.
Two (2) nos. (1 working + 1 standby) oil filled screw type service air
compressors will be provided to supply service air requirement of the entire plant.
Service air is taken from the compressed air header after service air compressors
& is supplied to one (1) no air receiver dedicated to service air.
The instrument air and service air headers will be connected by a
pneumatic operated on-off valve, so that in case of emergency, the service air
compressors can supply compressed air to the instrument air header.
Compressors shall deliver air at a pressure of 8.0 kg/cm2 (g). Each
compressor to include suction filter, silencer intercooler with moisture separators,
automatic drain traps, instruments, control panel, base plate, coupling guard and
other necessary accessories. Noise level should not exceed 95 dBA when
measured at distance of 1.0 meter from compressor and at a height of 1.5 m
above the floor.
Each air receiver will have a capacity of 10 m3 and will be designed for a
pressure of 10 kg/cm2 (g) and temperature of 50C.
The air drying plant will be drying the air by adsorption method and will be
of Heat of compression type. The quality of instrument air at the outlet of
instrument air receiver shall conform to ISA S7.3 standard (-40C dew point at
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110
atmospheric pressure).
Air piping shall conform to IS: 1239, Heavy Grade, or IS: 3589 Gr. 410.
14.2.SYSTEM SIZING
14.2.1.INSTRUMENT AIR SYSTEM
Instrument air system is sized considering followings consumers:
Steam Turbine Generator
Boiler
Ash Handling Plant
Balance of plant
Basis of instrument air compressor sizing:

a) Continuous air requirement -
b) Intermediate air requirement -
B (based on 0.7 Nm3/hr air requirement

per control valve and 0.4 0.6 Nm3/hr
requirement per ON-OFF valves and
considering 20 % of these valve will
operate simultaneously)
c) Purge loss -
C (15 % additional capacity of

instrument air to meet purge air
requirements of air dryer)
d) Considering margin -
10 % (for spare and leakage losses)
e) Total instrument air required -
1.2 x (A + B + C)
Based on above basis and preliminary calculations, instrument air

compressor is sized for 3 x 10 Nm3/min (2 W + 1 S).
14.2.2.SERVICE AIR SYSTEM
Service air system is sized considering followings service areas:
STG building area
Boiler area
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111
Water treatment area
Ash handling plant
Coal handling plant
LDO tank area
Ash silo area
Based on above areas, total thirty (30) tapping points have been
considered for various applications of service air for the entire plant. Assuming 25
% of the tappings will be in operation simultaneously and considering 0.6 Nm3/
min/tapping, the total service air requirements works out to be 270 Nm3/hr.
Considering spare and leakage losses at 10 %, the total service air quantity
required for service air stations work out to 300 Nm3/hr i.e. 5 Nm3/min.
Based on above calculations, service air compressor is sized for 2 x 5
Nm3/min (1 W + 1 S).
14.3.EQUIPMENT DESCRIPTIONS
Following are salient technical parameters of the equipment selected in the
compressed air system:
Air Compressors:
Parameter
UOM
Value
Fluid to be Compressed
Air
Application
Instrument & Service air
Type of Compressor
IA - Oil free Screw type

SA Oil filled Screw type
Type of drive
Direct driven electric motor
Duty
Continuous
Location
Indoor
Quantity required
Nos.
IA - Three (3) nos. (2 W + 1 S)

SA - Two (2) nos. (1 W + 1 S)
PERFORMANCE DATA
Design
Conditions
Compressors;
- Pressure
for
kg/cm (a)
Atmospheric pressure
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112
Temperature
Humidity
Capacity of each compressor
C
%
Nm3/min
50
62
IA 10 Nm3/min
SA 5 Nm3/min
Discharge pressure required (at

outlet of aftercooler)
kg/cm (g)
8.0
Cooling Water temperature at

inlet
33
Maximum allowable temperature

rise
Deg C
Compressed air temperature at

after-cooler outlet
< 40
Noise at 1 m distance from

compressor
dB(A)
< 95
Oil content in air at the outlet of

oil filter of each compressor
ppm
0.0
Air Driers:
Parameter
UOM
Value
Type of Dryer
Heat of Compression type
Application
Instrument Air
Duty
Continuous
Design Code
IS 2825
Location
Indoor
Design Temperature
Quantity required
Net drier capacity required
C
Nos.
3
Nm /min
Desiccant
Compressed air at Drier inlet:
Pressure
50
Two (2) nos. (1 W + 1 S)
20
Alumina / Silica gel
kg/cm (g)
8 max. (Mechanical design

shall be for 10)
Max. Temperature
45
Compressed air temperature at

Inlet
44
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PP 067 M B01 0
113
Outlet
45 (max)
Dew Point of Instrument Air
(-) 40 (at
pressure)
Maximum
oil
content
exclusive
of
noncondensable
shall
not
exceed 1 ppm
Air quality at Dryer outlet
Noise Level at 1 m distance

from the skid
atmospheric
dB
< 85
Air Receiver:
Parameter
UOM
Value
Design standard
IS 7398 / IS 2825
Type
Vertical, Cylindrical
No. of units
Nos.
IA - One (1)
SA - One (1)
Working pressure
kg/cm2 (g)
8.0
Design pressure
kg/cm2 (g)
10
Hydrostatic test pressure
kg/cm2 (g)
15
m3
10
Capacity
Minimum shell thickness
6 mm
MOC Shell
IS 2062
MOC Dished End
IS 2002
Tolerance / allowance
1.5 mm corrosion allowance,

10 % thinning tolerance for
dished ends
15. AIR CONDITIONING SYSTEM

Following areas of the plant will be provided with Air Conditioning system :
15.1.1.AIR CONDITIONING SYSTEM FOR CENTRAL CONTROL ROOM & ASSOCIATED
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PP 067 M B01 0
114
AREAS
For the Power House Building, one common Central Chilled Water Plant for
both the units shall be provided with individual Air Handling Units and Fan-Coil Units
for the Central Control Room (common for both the units), Control Equipment
Rooms, Computer Room, UPS & Battery Charger Rooms, SWAS Rooms (dry panel
1
area) and Shift Charge Engineers Rooms / Office and Technical Building.
3 x 50% water cooled chilling units will be provided to cater cooling
requirement of Central Control Room & associated areas. Two (2) units will be
working while one (1) unit will be kept as stand-by. The plant will be located on
ground floor of STG Building. Each Chiller unit will have microprocessor based
control panel for operational & safety control of the chiller. Separate Control panel
will be provided in the plant room for automatic operation of the plant. Expansion
tank for the system will be located on B-C bay roof. Cooling water required for the
chiller units will be made available from the Auxiliary Cooling Water system of the
plant.
Air Handling Units (AHUs) with chilled water coil will be provided for Air
Conditioning of Central Control Room & associated areas. Two (2) nos (both
working) AHUs of 50% capacity are provided for this purpose.
The AHUs will be complete with pre filter (90% efficiency down to 10
microns), chilled water coil, 3-way mixing valve in chilled water line, centrifugal
fan, motor operated dampers etc. Dehumidified cool air from AHUs will be
supplied to the air conditioned areas through insulated ducts. The return air from
A/C area will also be taken back to AHUs through insulated ducts. The ducts will
be routed through false ceiling void. High efficiency filters (99 % efficiency down to
5 microns) will be provided in supply air ducts.
Motor operated fire dampers (de-energised to close) shall be provided in
the A/C supply air duct in order to isolate the respective AHU A/C room area in the
event of fire.
Required amount of fresh air will be supplied to AHUs by fresh air supply
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PP 067 M B01 0
115
unit consisting of pre filter, fine filter & Damper. Duct mounted heaters and pan
type humidifier with sensors will be provided to maintain desired DB & RH in A/C
area. Supply air duct up to a distance of 5 m from AHU will be acoustically lined
from in side. Ducts will be fabricated from GI sheets as per IS 277 with Zinc
coating of 120 gsm. Duct thickness & fabrication will be as per IS 655.
Piping for Chilled water, Condenser, cooling water system shall be Heavy
grade-IS: 1239 or equivalent upto150 NB and IS: 3589 or equivalent beyond 200
NB with a minimum thickness of 6 mm.
Chilled water system consisting of refrigerant circuit, chilled water circuit
and cooling water circuit for refrigerant condenser, will have a dedicated
Microprocessor based control system for automatic operation and safety
interlocks.
Air Handling Unit shall take the chilled water for cooling the air which will be
circulated for the air-conditioning system. AHU shall have dedicated control
system for start/stop and automatic control operation of the AHU.
15.1.2.AIR CONDITIONING SYSTEM FOR OTHER AREAS
Following areas will be provided with 2 x 100% or 3 x 50% capacity
(depending on the cooling load) non-ductable air cooled window / split type air
conditioners:
ESP Control Room
CHP Control Room
AHP Control Room
DM Plant Control Room & Chemical Laboratory
33 kV Switchyard Control Room
Administrative Building
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MECHANICAL
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15.2.SYSTEM SIZING
Air conditioning system shall be designed based on parameters described
below :
Sl.
Parameter
No.
1
Design Outdoor Condition
Values
DBT (C)
WBT (C)
Summer
41.5
27.8
Monsoon
35.0
28.3
Winter
13.3
8.3
Relative
Humidity %)
Design Room Condition
For Central Control Room &

Associated Areas
24.4 2
50 5
For Other Areas
24.4 2
< 60 %
A/C units will be sized to

take care of following
Heat load
Equipment load
At actual
Lighting Load
At actual
Occupancy
Fresh air
At actual
1.5 air change / hr or 34 m3/hr per person
whichever is more
Solar Heat gain
As per ASHRAE procedure
Heat gain through Partition
As per ASHRAE procedure
Maximum Air Velocity
Main Duct
8 m/s
Branch Duct
6 m/s
Diffusers
3 m/s
Max. Noise Level @ 1m

from Equipment
85 dB(A)
Cooling Water
From ACW system
CW inlet Temp
33 C
CW outlet Temp
38 C Max.
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16. VENTILATION SYSTEM

The type of ventilation system to be provided for various areas of plant are
as follows:
16.1.1.VENTILATION SYSTEM
FOR
POWER HOUSE BUILDING &
ASSOCIATED
AREAS
The ventilation system will be provided in the following locations within the
Power House :
a) TG bay (Ground, Mezzanine and Operating floor) including HP/LP heater
area, Condenser area, Boiler feed pump area, Oil cooler area etc.
b) Battery Rooms
c)
MCC / Switchgear Rooms
1
d) Cable Spreader Rooms
e) Elevator M/C Rooms
f)
Air Conditioning System Plant Rooms.
g) SWAS Room (Wet Panel area)

Evaporative cooling system by adopting Air Washer Unit (AWU) is provided
for the ventilation of turbine building. Cooled and filtered air from Air Washer Unit
will be distributed by means of ducting to the TG building near various heat
sources like turbo-generator, condenser, boiler feed pump, HP & LP heaters, oil
coolers etc. The hot air from the hall will then be exhausted by means of Roof
Extractors. The quantity of air exhausted shall be kept lower than the quantity of
air supplied (usually 60-65% of the supply air is exhausted) in such a way that a
little overpressure is maintained inside the hall. This will reduce infiltration of
outside hot and dusty air.
The air quantity for each unit is supplied from four (4) AWU - two (2) being
placed on B-C bay at a suitable location and two (2) being placed on A Row side
POWER DIVISION
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of TG building. Such division and location area is decided to achieve effective air
distribution with less amount of duct work and less pressure drop in fans with no
cross-over of ducting across A-B bay.
The Air Washer Units will primarily serve TG hall and the electrical areas
1
like MCC / Switchgear Room, Cable Spreader Room, etc.
The washed air
supplied to MCC / Switchgear / Cable Spreader Rooms will be allowed to return to

TG bay through gravity dampers. Fire dampers (motorized) should be provided in
the supply air ducting / fans leading to all electrical rooms (MCC, Switchgear etc.).
The supplied air in the lower level of TG hall after taking the heat load of
TG bay rises through different openings to the upper floors and is then finally
exhausted by means of roof exhausters placed over the roof of TG Hall. Some
quantity of air leaks out through various leakage areas but still some amount of
over pressure shall be maintained.
Exhaust (pull type) ventilation to be adopted for the battery rooms by
providing bifurcated type axial flow exhaust fans with the motor outside the air
stream. The air from the battery rooms contains acid fumes and therefore it will
be discharged outside the TG hall at a place away from the steel piping or
structures nearby.
Operation of ventilation system is basically manual.
16.1.2.VENTILATION SYSTEM FOR AUXILIARY BUILDINGS IN VARIOUS LOCATIONS
Ventilation provision for Auxiliary Buildings in various locations will be done
as follows :
a)
Non-AC Areas of ESP Control Washed and filtered air supply

Building.
from Unitary Air Filtration Unit
(UAF) and air exhaust through
Back Draft Dampers.
b)
Compressor House including Filtered Air supply by means of

AHP compressors
wall mounted fans and dry panel
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MECHANICAL
PP 067 M B01 0
119
HDPE filter.
c)
Raw Water & Clarified Water Supply air by wall mounted Axial
Pump House
Flow fans (without filter) and
exhaust through louvers.
d)
Gate House Complex
Natural ventilation through open

able windows and wall mounted
axial flow exhaust fans for Toilet
area.
e)
Store Building
Supply air by wall mounted Axial

Wall mounted Axial Flow Exhaust
Fans for Toilet area.
f)
Technical Building (non AC Wall mounted Axial Flow Exhaust

area)
g)
Administrative
AC area)
h)
Non-AC areas of 33 KV Filtered air supply by means of

Switchyard Control Building
wall mounted Fan-Filter Unit/s and
air exhaust through Back Draft
Dampers.
Building
(non Wall mounted Axial Flow Exhaust

Wall mounted Axial Flow Exhaust

i)
DG plant building
Supplying air by Inlet Louver only

and Radiator Fan will effect the
ventilation of the DG Building.
POWER DIVISION
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PP 067 M B01 0
120
j)
CW / ACW Pump House

k)
Non-AC Areas of CHP Control Washed and filtered air supply

Building.
from Unitary Air Filtration Unit
(UAF) and air exhaust through
Back Draft Dampers.
j)
CHP Conveyor Tunnel

exhaust through exhaust fans /
louvers.
Unitary Air Filtration Unit shall consists of Air intake Louvers, HDPE wire
mesh Filter with water spray, PVC moisture eliminator, Centrifugal/ Tube Axial
Fan set, GI casing with water sump.
Dry type Fresh Air Unit shall consists of Wall mounted type Fan Filter Unit.
16.2.SYSTEM SIZING
Ventilation system shall be designed based on parameters described below
:
Sl.
Parameter
No.
1
Design Outdoor Condition
Values
Relative
Humidity (%)
DBT (C)
WBT (C)
Summer
41.5
27.8
Monsoon
35.0
28.3
Winter
13.3
8.3
Design Room Condition
Evaporative Cooled Area
5C lower than maximum design DBT
Dry Air Ventilated Area
3C higher than ambient (outside) DBT
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PP 067 M B01 0
121
Minimum Air Changes Rate
Air changes / Hour
TG hall
Cable Spreader Room
Electrical Room like M.C.C.

Room, Switchgear room in
T.G. Building
15
Electrical Rooms for all

Auxiliary Buildings
20
Non AC areas of ESP control

building
15
Non AC areas of CHP control

building
15
Non AC areas of Compressor

building
20
Switchyard Control Building

(Non AC areas)
15
CHP Conveyor Tunnel
15
Pump Houses
10
Battery Room
20
Toilet
20
17. FIRE PROTECTION SYSTEM

Fire protection system will be provided for entire power plant to provide
reliable means of fighting fire & extinguishment. Following systems will be
provided
a) Fire Water System
b) Hydrant System
c) Spray Water System
d) Portable & Mobile Fire Extinguishers
e) Fire Detection & Alarm System
POWER DIVISION
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PP 067 M B01 0
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The system will be design as per the norms laid down by Tariff Advisory
Committee (TAC), India. NFPA norms will be followed where-ever TAC norms are
not available / not clear. Equipments approved by IS / Statutory Authority / UL
and/or bearing IS mark will be used.
17.1.1.FIRE WATER SYSTEM
The fire water system will consist of:
One (1) no. Motor Driven Fire Water Pump of Capacity 273 Cum/Hr at 88
mWC head for Hydrant System
One (1) no. Motor Driven Fire Water Pump of Capacity 273 Cum/Hr at 88
mWC head for Spray System
One (1) no. Diesel Engine Driven Fire Water Pump of Capacity 273 Cum/Hr
at 88 mWC head. The pump will be connected to Hydrant & Spray system & will
act as Common Stand-by.
One (1) no. Jockey Pump of Capacity 11 Cum/Hr at 88 mwc Head.
One (1) no. Hydro-pneumatic Tank
One (1) no. Air Compressor
All the pumps will be connected to a common ring header which will supply
fire water to both hydrant and spray water system.
17.1.2.HYDRANT SYSTEM
The hydrant system will consist of complete hydrant system, including
hydrant mains in ring, both external and internal hydrant / landing valves, monitors
and hose houses / hose boxes etc with all accessories. Hydrants will be located
through out the plant as per guidelines of TAC. Hydrants will also be provided for
coal conveyors. Monitors will be provided in place of hydrant for protecting tall
structure exceeding 15 m height.
Hydrant Mains will be kept pressurized at all times. Minor leakages will be
POWER DIVISION
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MECHANICAL
PP 067 M B01 0
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taken care of by the Jockey pump. System operation will be automatic. The pump
will also be connected to spray system header to keep the pressurized at all
times.
The fire water piping will be laid in ring mains around all areas to ensure
multidirectional flow. The fire water mains will be buried minimum 1 m below the
FGL and will be coated and wrapped to take care of soil corrosion. Isolation
valves will be provided in the network to enable isolation of any section of the
network without affecting the flow in the rest.
17.1.3.SPRAY WATER SYSTEM
Entire spray water system shall be designed generally as per the guidelines
given in the relevant sections of NFPA / TAC. Spray water supply piping will be
provided up to the spray nozzle of each spray system. Spray water header will be
connected to Hydrant header through NRV & cut-off valve so that Hydrant system
can supply water to spray system as and when required. Spray water header will
1
be kept pressurized at all times. Operation of spray water system will be

automatic. Spray water system will be provided for cable spreader room in STG
building.
The system shall consist of :
Fire signal from detection system
Deluge Valve & accessories
Spray Water distribution piping
MV spray nozzle
The spray system will be designed to provide minimum running water

pressure of 2.8 kg/cm2 at each nozzle. In the event of fire signal, respective
Deluge Valve will open. This will result in starting water spray through MV spray
nozzles in the fire affect zone. Simultaneously audio visual alarm on control panel
will start. Deluge valves of preceding & succeeding zones may be opened
manually depending on actual spread of fire.
POWER DIVISION
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MECHANICAL
PP 067 M B01 0
124
17.1.4.PORTABLE & MOBILE FIRE EXTINGUISHERS

CO2, Dry Chemical Powder (DCP), Foam type Fire Extinguishers will be
provided for entire Plant & Buildings in TL scope as per TAC guide line.
Following Fire Extinguishers will also be provided. Fire Extinguishers will be
installed through-out the plant s per TAC/LPA norms.
Area
Type
TG Building
CO2 Type / DCP Type
Boiler Area
CO2 Type / DCP Type
DG House
CO2 Type / Foam Type
A/C Plant Room
CO2 Type
ESP Control Room
CO2 Type / DCP Type
Pre-Treatment Plant
DCP Type
DM Plant
CO2 Type
CW Pump House
CO2 Type / DCP Type
Fuel Oil Pump House
CO2 Type / Foam Type
Switchgear / MCC Room
CO2 Type / DCP Type
Control Rooms
CO2 Type / DCP Type
Battery Rooms
CO2 Type / DCP Type
Compressor House
CO2 Type / DCP Type
Store / Office
CO2 Type / DCP Type
17.1.5.FIRE DETECTION & ALARM SYSTEM

The Fire alarm system will consist of addressable, combination type smoke
detectors / heat detectors, LHS Cable, sounders, hooters, manual call points,
sirens, isolators.
SWGR/MCC Room, Control Room, Addressable combination type smoke
Control Equipment room, Local detectors, manual call points and
Control Rooms
hooters
1
Cable Galleries
Linear Heat Sensing Cables digital

type, Manual Call points, Hooters
POWER DIVISION
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MECHANICAL
PP 067 M B01 0
125
Battery Rooms, Transformer Yard
Heat Detectors, Manual Call point,

Hooters
Fuel Oil handling Area
Heat Detectors and flame proof manual

call points
Turbine Building,
Boiler Area
Turbine
Floors, Manual Call points
18. CRANES AND HOISTS

Cranes & hoists of different capacity are used to facilitate lifting, moving
and placing of various equipment in various parts of plant. They are mainly put
into use during maintenance of plant equipment.
Following cranes are envisaged for the plant:
E.O.T. crane, cabin operated for TG building A-B Bay
E.O.T. crane, pendant operated for CW Pump House
The design, manufacture, and testing of electric over head travelling crane
mechanical and electrical components shall conform IS 3177-1977. Structural
design of the EOT crane will conform to IS 807-1976.
The crane shall be designed for an estimated life of crane of 20 years and
for maintenance purpose and shall be of class-II duty as per IS 3177.
Turbine Hall EOT Crane
One (1) cabin operated double girder E.O.T. crane of 80/5 T hook capacity
will be provided in the AB bay of the turbine building for handling of the steam
turbine generator components as well as other equipments in TG hall building
such as feed water heaters, boiler feed pumps, condensate extraction pumps,
turbine lube oil tanks etc.
CW Pump House EOT Crane
One (1) pendant operated E.O.T. crane of 10 T hook capacity will be
POWER DIVISION
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provided in the CW Pump House. The same will be adequate to handle the CW
Pump Motor and Pump components.
Miscellaneous Hoists and Trolleys
Miscellaneous Hoists and Trolleys with suitable monorails will be provided,
wherever required, for the handling of equipment and other items of more than
500 Kg weight.
Wherever by the use of a manual hoist the hoisting operation requires an
effort more than 25 Kg, an electrical hoist will be used instead.
Following buildings will be provided with suitable hoist and trolleys. The
capacity of individual hoist will be decided depending on the maximum weight of
component to be handled, once vendor data is received.
Compressor Room
ACW pump house
DM plant building
DG house
EOT Crane Details

Parameter
Unit
Application
Value
STG
CW Pump
Building
House
No. of crane:
Nos.
One (1)
One (1)
Capacity (Main / Auxiliary)
Tons
80 / 5
10
Design Standard for Mechanical
IS 3177-1977
& Electrical Components

Structural design Standard
Duty
IS 807-1976
Class
II
Location
Operation
Indoor
Cabin
Pendant
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operated
operated
Speed
Long Travel
m/min
30
Cross travel
m/min
15
Main Hoist (normal)
m/min
1.5
Aux. Hoist (normal)
m/min
Creep
m/min
10 % of main speed
19. ELEVATORS
Boiler Goods cum Passenger Elevator
One (1) goods cum passenger elevator of capacity ten (10) Tonnes will be
provided common for two boilers. All major boiler floors including the working
platform, fuel feeder floor, fuel bunker floor will be approached by the elevator with
suitable interconnecting platforms at the required levels.
Turbine Building & Service Building Passenger Elevator
One (1) passenger elevator of capacity 650 kg, suitable to carry 8
passengers at a time, will be provided to serve different floors of the TG Building
as well as of the adjacent technical building, which will include major offices of the
plant.
20. ENVIRONMENTAL CONSIDERATION
Both gaseous emission & liquid effluent are discharged from the plant
taking into consideration, the environmental norms & emission standards.
20.1.GASEOUS EMISSION
Being a coal fired plant, the gaseous emission is from the chimney exhaust.
Particulate emission is taken care by providing electrostatic precipitator
(ESP). ESP will be designed to limit dust concentration at ESP outlet to 50
mg/Nm3 with one field out of operation.
POWER DIVISION
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As per the contract requirement, 44 meter high single flue self supported
steel stack is provided to restrict the ground level concentrations within acceptable
limits. Sufficient exit velocity from chimney is considered to limit GLC within limit.
Stack monitoring equipments to measure particulate matter and exhaust
gases has been provided.
20.2.LIQUID EFFLUENT
Liquid effluent from the Power Plant is generated from the following
sources.
Sludge from raw water pre-treatment plant
DM Plant regeneration reject
Cooling Tower blowdown
Side stream filter back wash waste water
Boiler blowdown
Oily waste from fuel oil area, power house area and transformer area
Miscellaneous plant service water waste
All the above streams are of a quality that can be directly discharged to the
guard pond except Sludge from raw water pre-treatment plant and oily waste from
fuel oil area, power house area & transformer area.
The oily water run off during rains and regular washing/cleaning, leakage,
draining from Fuel Oil Unloading Area shall be collected in a Retention Pit. Oily
waste from the Retention Pit shall be directed to a Common Oily Waste Retention
Pit, which also receives oily effluent from Power House area and Transformer
Yard area and. From the Common Oily Waste Retention Pit the oil contaminated
effluent shall be pumped to Oil Water Separator for removal of oil and suspended
solids.
The treated water from OWS may be discharged in another collection pit
POWER DIVISION
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from where treated water shall be sent finally to Guard Pond. Separated oil shall
be collected in a Slope Oil Storage Tank.
Oily effluent from the Transformer Yard Area & Power House Area will be
led to a Retention Pit from where waste shall be transferred to the Common Oily
Waste Retention Pit as addressed above.
For the various effluents in the plant, a guard pond is being provided where
the effluents will be collected. The guard pond is provided with 2 x 100 % pumps
for evacuating the pond. A buffer volume of Guard Pond is provided to allow
containing any sudden upset flow conditions. With this consideration, the pond is
1
provided with a capacity of 2000 m3.

Guard Pond sizing:
The guard pond shall be sized to accommodate 24 hours of the plant
effluent with consideration that 20 m3/hr water will be reused for dust suppression,
horticulture etc. or 16 hrs without considering any reuse, whichever is higher. The
size is based on the following tabulation:
Effluent source
Cooling tower Blowdown
Quantity (m3/hr)
52
Boiler Blowdown
14.4
DM Plant regeneration waste
1.5
SSF Backwash
Miscellaneous plant service water waste
Total effluent generated
79
Effluent reused for dust suppression & ash
20
conditioning
Capacity of the Guard Pond (24 hours basis) = 79 x 24 = 1896 m3.
1
Selected Capacity of the Guard pond = 2000 m3.
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Guard pump sizing:

Following pumps are provided to evacuate the water from the Guard Pond :
1) Guard Pond transfer pumps : 2 x 100 % of capacity 59 m3/hr
2) Dust suppression pumps
: 2 x 100 % of capacity 20 m3/hr for dust

suppression & ash conditioning
21. PIPING SYSTEM

The piping for the power plant is grouped into power cycle piping, lowpressure utility piping and cooling water piping.
The technical and design features of each group are elaborated below.
21.1.POWER CYCLE PIPING
Power cycle piping consists of the following major lines:
Main steam piping line at 101 kg/cm2 (a), 540C (operating parameters
at boiler MSSV outlet) from each boiler to steam turbine nozzle.
1
Extraction steam line (Bleed-1) from the turbine at 30 kg/cm2 (a) for
supply to HP Heater-1.
Extraction steam line (Bleed-2) from the turbine at 16.3 kg/cm2 (a) for
supply to HP Heater-2.
Extraction steam line (Bleed-3) at 6.6 kg/cm2 (a) to deaerator.
supply to LP Heater-1
supply to LP Heater-2
Boiler feed water pump suction piping
Boiler feed water pump discharge piping
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Boiler feed water pump recirculation piping

Condensate extraction pump suction piping
Condensate extraction pump discharge piping
Boiler blowdown, all drains and vents
Spray water lines.
21.2.LOW PRESSURE UTILITY PIPING
The low-pressure utility piping will mainly cover the following services:
DM Makeup water for power cycle
Makeup water for cooling tower
Cooling tower blowdown
Raw water
Potable water
Service water
Instrument air
Service air
Effluent
Vents and drains
Fire fighting system
21.3.COOLING WATER PIPING
This piping consists of the following:
Main cooling water system
Auxiliary cooling water system
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21.4.DESIGN BASIS FOR PIPING

In the design of all pipe lines, the sizing of lines will be based on the
maximum flow through the line and the allowable pressure drop through the lines
including those of control valves, flow elements, strainers, etc., so as to maintain
the required pressure at various consumption points. In all the cases, the velocity
of flow in the lines will be restricted to a maximum value as per the table below.
The thickness calculations for IBR piping will be based on ASME B31.1 or IBR
whichever is more stringent for the design pressure and the allowable stress shall
be as per ASME B31.1 for the selected pipe material at the design temperature.
The thickness calculation for non-IBR pipes shall be as per ASME B31.1 or
IS 1239 / IS 3589 for the design pressure and the allowable stress value for the
selected pipe material at the design temperature. Corrosion allowance (0.75 mm for
steam piping as per IBR) will be added in addition to tolerance on pipe thickness.
Whenever pipe bends are used for larger wall thickness pipes, the wall thinning
factor as per Power Piping design standards ASME B31.1 will be used and the
thickness of pipe bends will be suitably increased.
All piping above 65NB size and carrying fluid more than 100C will be stress
analysed as per ASME B31.1 power piping code.
1.
Steam lines
Average velocity in m/s

Below
50 to 150
200 mm
50 mm
mm NB
NB & up
15-20
20-35
25-45
15-25
20-35
30-50
20-30
25-40
30-50
NB
1.
2.
3.
Saturated steam at 1.1 to 7.0

kg/cm2 (g)
Saturated steam over 7.0 kg/cm2
(g)
Superheated steam at 0 to 7.0
kg/cm2 (g)
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4.
5.
6.
7.
Superheated steam at 7.1 to 35

kg/cm2 (g)
Superheated steam at 35.1 to 70
kg/cm2 (g)
Superheated
steam
over
70
kg/cm2 (g)
Exhaust steam line from turbine to
20-35
30-45
30-55
20-35
30-50
40-60
20-35
35-61
50-75
20
For all line sizes
60
For all line sizes
atmosphere
8.
Vacuum lines
9.
Turbine bypass upstream
75
10. Turbine bypass downstream

2. Water lines
150
Maximum Velocity (m/s)
Feed water suction lines
2.0
Feed water discharge lines
6.0
Auxiliary cooling water suction
1.5
Auxiliary cooling water delivery lines
3.5
Main cooling water lines (discharge)
3.5
Condensate delivery lines
5.0
Condensate suction lines
1.5
Main cooling water lines (suction)
1.2
Service water / potable water
2.2
Cooling water sump blowdown
0.6
Rubber lined piping in DM plant area
2.0
3. Air lines
Pipe Size below 50mm
Maximum Velocity (m/s)

15-20
POWER DIVISION
THERMAX LIMITED
Project
Document Title
Doc. No.
Rev.
Sheet
2 x 60 MW THERMAL
POWER PLANT, IMFA,
ORISSA
DESIGN BASIS REPORT

MECHANICAL
PP 067 M B01 0
134
Pipe Size 50 to 150mm
15-30
Pipe Size 20mm & Up
25-35
21.5.MAIN STEAM PIPING

The design conditions for the main steam line from each boiler shall be
same as superheater safety valve set pressure. The pipe shall be designed for the
MCR conditions of the Boilers. The material of piping will be alloy steel conforming
1
to ASTM A 335 Gr. P91.

Double isolation valves shall be provided in drain and vent of lines with
pressure 40 kg/cm (g) and above.
Sizing calculations of main steam pipe line are as follows:
Line Description
Operating Operating
Pressure
Temp.
Kg/cm2(a) Deg. C
Main steam to STG

from boiler
101
540
Flow
Pipe
TPH Size NB
224
300
Pipe
Thick.
mm
Velocity
m/s.
21.44
38.06
Main steam line pressure drop calculations:

Parameter
Value
Inlet pressure p [kg/cm2]

Inlet temperature t [C]
Enthalpy h [KJ/kg]
DN [ " ]
Schedule
Inner diameter DI [m]
Mass flow m [kg/s]
Spec. Vol. Vs [m3/kg]
Velocity V [m/s]
Kin. Visk. [m2/s]
Re.- number [ - ]
Surface quality k [mm]
D/K
Lambda [ - ]
Total length [m]
101
540
3476
12
100
0.281
62.22
0.03540
35.5
1.0828E-06
9.22E+06
Estimated
0.05
5619
0.01340
100.0
POWER DIVISION
THERMAX LIMITED
Project
Document Title
Doc. No.
Rev.
Sheet
2 x 60 MW THERMAL
POWER PLANT, IMFA,
ORISSA
DESIGN BASIS REPORT

MECHANICAL
PP 067 M B01 0
135
No. of Bendings (=0.18)

No. of Gate Valves (=var.)
No. of hor. Check valves (=1.5)
No. of T-pipes (=0.3)
Add. Resistance:
Zeta overall
10
1
0
1
0.3
7.31
Pressure loss p [kg/cm2]
1.30
Overall
Pressure loss as per 100 % TMCR HBD:
3.00
Margin dp on design dp ( % )
56.5%
21.6.OTHER STEAM PIPELINES

The material for these lines (Extraction steam, LP steam, Aux. Steam shall
be carbon steel conforming to ASTM A106 Gr. B. Steam velocity shall be
maintained in all these pipe lines as indicated in the table elsewhere in this
document.
Sizing calculations of other steam pipe lines are as follows:
Line Description
Operating Operating
Pressure
Temp.
2
Kg/cm (a) Deg. C
Flow
Pipe
TPH Size NB
Pipe
Thick.
mm
Velocity
m/s.
1st extraction to
HPH-1
30
374
15
150
7.11
21.6
2nd extraction to
HPH-2
16.3
301
14.1
150
7.11
33.4
3rd extraction to
Deaerator
6.6
202
12.75
200
6.35
34.6
extraction to
LPH-1
2.5
127.5
12.3
300
6.35
32.9
5th extraction to
LPH-2
0.735
90.7
11.5
450
9.53
49.0
4th
The dumping steam (TG bypass) line will be sized for 60 % of TMCR. The
material for the dumping steam line shall be alloy steel conforming to ASTM A 335
Gr. P22 upstream the TG bypass valve. The material for dumping steam line
downstream of the TG bypass valve shall be carbon steel conforming to ASTM
POWER DIVISION
THERMAX LIMITED
Project
Document Title
Doc. No.
Rev.
Sheet
2 x 60 MW THERMAL
POWER PLANT, IMFA,
ORISSA
DESIGN BASIS REPORT

MECHANICAL
PP 067 M B01 0
136
A106 Gr. B.
21.7.BOILER FEEDWATER PIPING
21.7.1.BOILER FEED WATER SUCTION & DISCHARGE LINES
The piping material shall be carbon steel conforming to ASTM A 106 Gr.B.
For sizing of the lines, the velocity will be maintained as indicated in the table
elsewhere in this document.
Line Description
1
BFP suction
BFP discharge
Operating Operating
Pressure
Temp.
2
Kg/cm (a) Deg. C
6.6
158
110
225
250
Pipe
Thick.
mm
6.35
225
150
14.27
Flow
Pipe
TPH Size NB
160
Velocity
m/s.
1.3
4.9
21.7.2. BOILER FEEDWATER RECIRCULATION PIPING

Separate recirculation line for each boiler feed pump will be provided from the
non return cum modulating recirculation valves, with necessary isolation valves and
will be connected to the deaerator. The material shall conform to ASTM A 106 Gr. B.
Line Description
1
BFP minimum flow
recirculation
Operating Operating
Pressure
Temp.
Kg/cm2(a) Deg. C
10
160
Flow
Pipe
TPH Size NB
67.5
80
Pipe
Thick.
mm
Velocity
m/s.
7.62
4.85
21.7.3. BOILER BLOW DOWN, VENTS, DRAINS

Blow down piping will connect the drains from boiler drums, superheaters,
bottom ring headers, etc., with the blow down tank. Some high pressure drains from
different piping and equipment are also connected to flash tank while others are
quenched and let off to the plant drains. The material shall be carbon steel
confirming to ASTM A106 Gr. B.
21.8.CONDENSATE PIPING
The piping shall be sized for the maximum flow to the condenser under
various modes of operation. The material shall be carbon steel confirming to
POWER DIVISION
THERMAX LIMITED
Project
Document Title
Doc. No.
Rev.
Sheet
2 x 60 MW THERMAL
POWER PLANT, IMFA,
ORISSA
DESIGN BASIS REPORT

MECHANICAL
PP 067 M B01 0
137
ASTM A106 Gr. B.

Line Description
CEP suction
1
Operating Operating
Pressure
Temp.
Kg/cm2(a) Deg. C
0.15
45.5
184
300
Pipe
Thick.
mm
6.35
Flow
Pipe
TPH Size NB
Velocity
m/s.
0.68
CEP discharge
13
46
184
150
7.11
2.77
CEP minimum flow

recirculation
15
46
70
80
5.49
4.16
21.9.PIPING FOR RAW WATER

The material of piping will be carbon steel as per IS:1239 (Class-Heavy) / IS:
3589. The design pressure of the piping will be the shut-off heads of the respective
pumps.
21.10.AIR PIPE LINE
The material for air pipeline will be galvanised carbon steel (IS 1239- Class H)
pipe. Tappings will be made from respective headers at the nearest point. Air lines
shall be provided with globe / ball valves.
21.11.DM WATER PIPE LINE
The DM water pipe from the DM plant to the DM water storage tank and from
the DM water storage tank would be routed through suitably sized pipeline. Pipe
material within DM plant shall be IS 1239 / IS 1239 (rubber lined). Stainless steel
shall be used for sizes of 50 NB and below. The DM water line and valves beyond
DM Plant vendor battery limit if not suitably dosed for pH correction shall be A 106
Gr. B / A 53 Gr. B. In case pH correction of the water is not done the pipeline shall be
of SS 304.
21.12.EFFLUENT
The material will be IS 1239 Class H.
POWER DIVISION
THERMAX LIMITED
Project
Document Title
Doc. No.
Rev.
Sheet
2 x 60 MW THERMAL
POWER PLANT, IMFA,
ORISSA
DESIGN BASIS REPORT

MECHANICAL
PP 067 M B01 0
138
21.13.SERVICE AND POTABLE WATER PIPE LINE

The service and potable water pipe lines shall be routed separately
throughout the power plant. The material of service water shall be carbon steel
conforming to IS 1239 Class H and potable water shall be of carbon steel conforming
to IS 1239 GI.
21.14.CONDENSER COOLING WATER PIPING
The condenser cooling water system shall circulate cooling water through the
condenser of Steam Turbine. The material of piping shall be carbon steel conforming
to IS: 3589 for above 150 NB. For 150 NB & below, the pipe shall conform to IS 1239
(H).
21.15.AUXILIARY COOLING WATER PIPING
The auxiliary cooling water header shall be routed along with the main
cooling water piping. From the header branch lines for lube oil coolers of STG,
Generator air coolers of STG and for other utilities will be tapped. The return
piping shall be routed to cooling tower inlet. The material of construction shall be
same as that of cooling water piping.
21.16.FIRE WATER PIPING
Firewater piping will be routed from the fire pump house of the power plant. It
will be routed around the turbine building, Boiler area, electrical bay, transformer
yard, coal area, etc.
The fire water piping will be buried at 1 m below the ground and the external
hydrant valves will be provided above ground. For above ground pipes of size 150
NB and above the material will be carbon steel as per IS: 3589 and for pipes of sizes
below 150 NB the material will be IS:1239 medium grade as recommended by TAC.
21.17.VALVES
The design, material, construction, manufacture, inspection and testing of
POWER DIVISION
THERMAX LIMITED
Project
Document Title
Doc. No.
Rev.
Sheet
2 x 60 MW THERMAL
POWER PLANT, IMFA,
ORISSA
DESIGN BASIS REPORT

MECHANICAL
PP 067 M B01 0
139
valves and specialities will comply with all currently applicable standards,
regulations and codes.
All drain and vent connections for 40 kg/cm2(a) rating will be made up of
two (2) valves in series, both of isolating type.
All valves and specialities will be located so that they are readily accessible
for both operation and maintenance. Wherever necessary, the valve spindles will
be extended and an approved type of pedestal hand-wheel will be provided at the
next higher floor level or a necessary platform will be provided.
21.17.1.INSULATION
All piping systems having working temperature equal to or more than 60 C
will be normally insulated for conserving enthalpy and for personnel protection.
The insulating material is selected suitably based on the working
temperature of the pipe.
It is essential that the material is free from shots,
chlorides, oil, Sulphur and other impurities and retains its density and thermal
conductivity over a reasonably long period.
Insulation thickness will be so selected that the temperature of its outside
jacket remains 65C with ambient temperature of 35C considering 1 m/s air
velocity, since it is expected that such temperature does not produce burns on
human skin within a contact period of 3 seconds.
21.17.2.PIPE SUPPORTS AND HANGERS
Pipe supports shall be designed according to the layout requirements.
Wherever the load variation is limited, variable spring hangers and constant spring
hangers are used.
In other places, other type of supports like rod hangers,
clamps, saddle supports etc. are used.

21.17.2.1. Constant Spring Hangers
The deviation in supporting effect shall be limited to 8% for constant

spring hangers throughout the total travel.
POWER DIVISION
THERMAX LIMITED
Project
Document Title
Doc. No.
Rev.
Sheet
2 x 60 MW THERMAL
POWER PLANT, IMFA,
ORISSA
DESIGN BASIS REPORT

MECHANICAL
PP 067 M B01 0
140
21.17.2.2. Variable Spring Hangers
The deviation in supporting effect shall be limited to 25% for variable

spring support system.
21.17.2.3. Rod Hangers
Rod hangers are used in those cases where lateral movement is allowable.
21.17.2.4. Pipe Clamps and Shoe / Saddle supports
This shall be used in those cases where restraint supports are used.
Minimum thickness of pipe clamps shall be 5-mm.
21.17.2.5. Materials of Construction
Spring shall be of EN42 / EN45 / EN45A / EN60.

Plates and flats shall be of IS 2062 or equivalent. However, material
of alloy steel shall be of equivalent to A 335 P11 / P22.
Hanger rods shall be of IS 2062 or equivalent.
Spring casings shall be of ERW pipes of IS 3589 / IS 1239.
Turnbuckles shall be of SA 105 or equivalent.
21.18.GENERAL GUIDELINES FOR PIPING
Piping layout is dictated by the relative locations of connecting
equipment and the requirements of stress analysis.
Adequate number of drain and vents shall be provided as per the
system / layout requirements.
Suitable clearances shall be provided with respect to other equipment,
structures, pipe to pipe distances and for ease of access and
maintenance.
Valves shall be located and oriented such a way that these are easily
accessible for operation and maintenance.
POWER DIVISION
THERMAX LIMITED
Project
Document Title
Doc. No.
Rev.
Sheet
2 x 60 MW THERMAL
POWER PLANT, IMFA,
ORISSA
DESIGN BASIS REPORT

MECHANICAL
PP 067 M B01 0
141
While providing openings in floor/walls for pipe crossing due care shall
be taken for the pipe thermal movement and insulation thickness.
POWER DIVISION
THERMAX LIMITED
Project
Document Title
Doc. No.
Rev.
Sheet
2 x 60 MW THERMAL
POWER PLANT, IMFA,
ORISSA
DESIGN BASIS REPORT

MECHANICAL
PP 067 M B01 0
142
22. ANNEXURES
22.1.ANNEXURE I : HEAT AND MASS BALANCE DIAGRAM
22.2.ANNEXURE II : WATER BALANCE DIAGRAM
22.3.ANNEXURE III : FLOW DIAGRAM FOR ASH HANDLING SYSTEM
1
22.4.ANNEXURE IV : FLOW DIAGRAM FOR FUEL HANDLING SYSTEM
PP
PP
PG
PG
PG
TG
TG
PP
PG
TG
PP
TG
BV
BV
PRESSURE RELIEF
VALVE
LEVEL TRANSMITTER
PG
TG
TG
BV
BV
TELESCOPIC
RETRACTABLE
CHUTE WITH
LEVEL SWITCH
PP C
BV
MANUAL CHAIN WHEEL

OPERATED PLATE VALVE
PNEUMATIC
PLATE VALVE
PSL
PNEUMATIC
PLATE VALVE
A
PNEUMATIC
PLATE VALVE
PSL
ASH COND.
MANUAL CHAIN WHEEL

OPERATED PLATE VALVE
PNEUMATIC
PLATE VALVE
ASH COND.
M
M
FROM TREATED WATER
REF.DRG.PP 067 M XXX 1
TO TRUCK
UNLOADING
TO TRUCK
UNLOADING
TELESCOPIC
RETRACTABLE
CHUTE WITH
LEVEL SWITCH
PP C
PP
BV
BV
PP
BV
BAG FILTER WITH REVERSE

PULSE JET CLEANING
PP
RADAR TYPE LEVEL

TRANSMITTER
SCREEN
SURGE HOPPER
WATER JACKET
PP C
PP C
PP C
PP C
BV
PP
PP
PP
PP
BYPASS WITH
GATE
(ONLY FOR BED ASH)
PLATE VALVE
BV
EXPANSION JOINT
PP C
BV
PP C
PP
BV
BV
PP C
PP C
PP C
PP C
BV
PP
PP
PP
PP
PP
TO TRUCK
UNLOADING
SERVICE AIR
PG
COOLING WATER RETURN

INSTRUMENT AIR
COOLING WATER SUPPLY
RADAR TYPE LEVEL

TRANSMITTER
AIR HEATER
2 Nos (1W+ 1S)
RADAR TYPE LEVEL

TRANSMITTER
SURGE HOPPER
SURGE HOPPER
WATER JACKET
M
FLUIDIZING AIR BLOWERS

2 Nos (1W+ 1S)
LEGEND :-
PLATE VALVE
PLATE VALVE
EXPANSION JOINT
DOME VALVE
EXPANSION JOINT
DOME VALVE
TOP PLATE
TOP PLATE
ESP ASH VESSEL (TYP.)

A
PP
TOP PLATE
BV
BV
FROM CONVEYING
AIR COMPRESSOR
DOME VALVE
TELESCOPIC
RETRACTABLE
CHUTE WITH
LEVEL SWITCH
APH ASH VESSEL (TYP.)
BED ASH VESSEL (TYP.)

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OC No.

DESIGN BASIS REPORT FOR

INDIAN METAL & FERRO ALLOYS LTD.

DEVELOPMENT CONSULTANTS PRIVATE LIMITED

2 X 60 MW THERMAL POWER PLANT

DESIGN BASIS REPORT

DESIGN BASIS REPORT MECHANICAL

UNITS OF MEASUREMENT & ABBREVIATIONS .........................................10

UNITS OF MEASUREMENT .............................................................................10

CODES & STANDARDS .................................................................................11

POWER PLANT CONFIGURATION ...............................................................14

PLANT CONFIGURATION ................................................................................14

Site Conditions .................................................................................................. 16

Ash Analysis :.................................................................................................... 19

Lime Stone Analysis.......................................................................................... 20

Bed Material Analysis (As Required by Boiler Design) ..................................... 20

Raw Water Analysis .......................................................................................... 21

POWER PLANT LAYOUT...............................................................................22

Cooling Tower Area........................................................................................... 26

Raw Water Reservoir ....................................................................................... 27

Water Treatment Area....................................................................................... 27

FUEL AREA ..................................................................................................26

SWITCHYARD AREA ......................................................................................28

DESIGN BASIS REPORT

Oil Storage Tanks.............................................................................................. 32

Main & Auxiliary Lube Oil Pump...............................................................................33

Emergency Oil Pump ...............................................................................................33

Oil Filters ........................................................................................................... 33

Oil Mist Fan ....................................................................................................... 33

Lube Oil Purifier................................................................................................. 34

JACKING OIL PUMP .......................................................................................34

TURNING GEAR ............................................................................................34

BOILER AND AUXILIARIES...........................................................................37

Arrangement of Pressure Parts......................................................................... 40

Steam Drum ...................................................................................................... 41

Furnace Walls and Headers.............................................................................. 41

Divisional Wall ..........................................................................................................42

De-Superheaters (Attemperators) ..................................................................... 42

BOILER PERFORMANCE DATA ........................................................................43

Pressure Part Details ........................................................................................ 43

Heat Transfer Area............................................................................................ 45

Temperature Gradient ....................................................................................... 46

DESIGN BASIS REPORT

Pressure Gradient ............................................................................................. 47

Safety valve details ........................................................................................... 48

Safety Valve Set Pressures .....................................................................................48

Safety Valve Relieving Capacity ..............................................................................48

Fuel, Limestone & Bed Material Consumption .................................................. 48

BOILER MOUNTINGS AND FITTINGS ................................................................49

Steam Drum ...................................................................................................... 49

Furnace headers ............................................................................................... 49

Drain Header ..................................................................................................... 49

Spray Water Line............................................................................................... 50

SOLID FUEL FIRING SYSTEM ..........................................................................50

Fuel Bunker ....................................................................................................... 51

Fuel Firing System ............................................................................................ 51

OIL FIRING SYSTEM ......................................................................................52

AIR AND FLUE GAS SYSTEMS ........................................................................52

Ductwork and Dampers..................................................................................... 56

Air Pre-Heater ................................................................................................... 57

Ash Recycle System ......................................................................................... 57

Ash Discharge System ...................................................................................... 57

BOILER STRUCTURES AND AUXILIARIES ..........................................................58

Platform, Stairways and Grating........................................................................ 58