Boiler Operation Hand Book.pdf

PLANT HAND BOOK SIPAT STPP STAGE-I (3 x 660 MW) UNITS 1, 2 & 3

CONTRACT NO. T04019 SUPPLIED BY :

DOOSAN HEAVY INDUSTRIES & CONSTRUCTION CO., LTD Proprietary Notice: This hand book contains proprietary data of Doosan Heavy Industries & Construction Co., LTD. No disclosure, reproduction, or use of any part may be made without written permission of Doosan Heavy Industries & Construction Co., LTD. Date of Issue: June, 2006

PLANT HAND BOOK-SIPAT STAGE 1 (3x660MW) STPP VOLUME- I TABLE OF CONTENTS

TITLE

PAGE NO.

I.

COAL ANALYSIS

II.

ASH ANALYSIS

III.

BOILER PARAMETERS

IV.

DESIGN AND PERFORMANCE DATA

1.

STEAM GENERATOR DESCRIPTION DESIGN ASPECTS …………………………………………………………………………. 1 General …………………………………………………………………………………………1 Mechanical Design Aspects ………………………………. …………………………………1 FURNACE DIMENSIONS…………………………………………………………………… .2 BOILER ARRANGEMENT………………………………………………………………….. .2 General…………………………………………………………………………………………. 2 Arrangement of Tube Banks…………………………………………………………………. 3 Fuels and Fuel Firing Requirements………………………………………………………...3 Boiler Start-up and Bypass System………………………………………………………… 3 The Water Separation System………………………………………………………………. 4 Control of Superheat and Reheat Temperatures…………………………………………… 4 Turbine Operation…………………………………………………………………………….. 4 BOILER LOAD CONDITIONS………………………………………………………………. 5 Boiler Maximum Continuous Rating (BMCR).. ……………………………………………5 Turbine Maximum Continuous Rating (TMCR) …………………………………………… 5 Normal Operation………………………………………………………………………………5 Minimum Once-Through Load……………………………………………………………….. 5 Allowable Steam Temperature Variations…………………………………………………… 5 CONDITIONS OF SERVICE…………………………………………………………………. 6 Description of Service………………………………………………………………………… 6 Operational Mode…………………………………………………………………………… 6 Operation Capability…………………………………………………………………………6 Operation Features…………………………………………………………………………….6 SAFETY VALVES …………………………………………………………………………… 6 SH Safety Valves …………………………………………………………………………….. 6 RH Safety Valves………………………………………………………………………………7

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01 PLANT HAND BOOK-contents.doc

PLANT HAND BOOK-SIPAT STAGE 1 (3x660MW) STPP 2.

STEAM AND WATER FLOW SYSTEM SUPERHEATER ………………………………………………………………………...1 DESCRIPTION………………………………………………………………………………… 1 Superheater……………………………………………………………………………………. 1 Steam Flow…………………………………………………………………………………….. 1 Protection and Control…………………………………………………………………………2 OPERATION…………………………………………………………………………………... 3 General………………………………………………………………………………………….3 Superheater …………………………………………………………………………………….4 SUPERHEATER DESUPERHEATERS ……………………………………………….5 DESCRIPTION………………………………………………………………………………... 5 CONTROL STATIONS………………………………………………………………………. 5 BLOWOUT PROCEDURE FOR DESUPERHEATER SPRAY WATER LINES ………6 MAINTENANCE………………………………………………………………………………. 6 REHEATER …………………………………………………………………………... 8 DESCRIPTION………………………………………………………………………………. 8 REHEATER……………………………………….. …………………………………………8 Steam Flow…………………………………………………………………………………. 8 Protection and Contro……………………………………………………………………….. 9 OPERATION………………………………………………………………………………….. 9 General ………………………………………………………………………………………9 Reheater…………………………………………………………………………………….. 10 REHEATER DESUPERHEATERS ………………………………………………….11 DESCRIPTION ……………………………………………………………………….11 CONTROL STATIONS ……………………………………………………………………11 MAINTENANCE ………………………………………………………………………12 BLOWOUT PROCEDURE FOR DESUPERHEATER SPRAY WATER LINES ……12 WATER WALL SYSTEM ………………………………………………………………14 FURNACE WALL WATER CIRCUIT………. …………………….……………………14 ECONOMIZER SYSTEM…………………………………………………………….. 15

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01 PLANT HAND BOOK-contents.doc

PLANT HAND BOOK-SIPAT STAGE 1 (3x660MW) STPP 3.

AIR AND FLUE GAS FLOW SYSTEM AIR AND FLUE GAS SYSTEMS ……………………………………………………….. 1 AIR/GAS FLOW ……………………………………………………………………………...1 Secondary Air and Overfire Air - Combustion…………. …………………………………1 Flame Scanner Cooling Air………………….. ………………………………………………1 Primary Air - Conveying and Drying of Pulverized Coal…….. …………………………2 Seal Air - Pulverizers and Coal Pipes…….. ………………………………………………2 Seal Air - Feeders…………………………. …………………………………………………2 FLUE GAS FLOW………………………. …………………………………………………3 OPERATIONAL PROCEDURES… ……..…………………………………………………3 SCANNER AIR SYSTEM……… …………………………………………………………3 DESCRIPTION…………………………………. ……………………………………………3 SCANNER AIR…………………………………. ……………………………………………3 PULVERIZER SEAL AIR SYSTEM ….……………………………………………………4 INTRODUCTION ……………………………………………………………………………..4 SEAL AIR TO PULVERIZERS………. ……………………………………………………5 SEAL AIR FOR FEEDERS………………. …………………………………………………6 SOOT BLOWING PHILOSOPHY ………………………………………………………. 7 INTRODUCTION………………………….. …………………………………………………7 OPERATIONS ……………………………………………………………………………7 TYPES OF ASH DEPOSITS……………….. ………………………………………………7 BLOWER LOCATIONS…………………… …………………………………………………8 Furnace Walls……………………………… …………………………………………………8 Superheater and Reheater Areas……….. …………………………………………………8 Economizer and Air Preheaters…………….. ………………………………………………8 LIST OF REFERENCE ENGINEERING DRAWINGS………………………………………… 9 P&ID Diagram - Windbox & Burner Unit P&ID Diagram - Windbox Detail P&ID Diagram – Primary Air, Sealing & Cooling Air System Scanner Air System Piping Arrangement Scanner Air System Piping Arrangement Suggested Pipe Supports

iii

T04019-PI-D0019 T04019-PI-D0020 T04019-PI-D0021 T04019-SP-A001 T04019-SP-A002 T04019-SP-A003

01 PLANT HAND BOOK-contents.doc

PLANT HAND BOOK-SIPAT STAGE 1 (3x660MW) STPP

4.

TILTING TANGENTIAL FIRING SYSTEM DESIGN FEATURES………………………………………………………………..……… 1 SYSTEM DESCRIPTION…………………………………………………………………... 2 MAIN WINDBOX COMPONENTS…………………………………………………………. 2 AIRFLOW CONTROL AND DISTRIBUTION……………………………………………… 4 CONTROL SYSTEM PHILOSOPHY……………………………………………………….. 7 WINDBOX MAINTENANCE……………………………………………………………….. 7 LIST OF FIGURES FIGURE 1. WINDBOX AND CCOFA ELEVATION DESIGNATIONS…………………..11 FIGURE 2. COAL COMPARTMENT-FUEL AIR DAMPER RAMP F(X) ……………….12 FIGURE 3. AUXILIARY AIR DAMPERS CHARACTERISTICS………………………… 13 FIGURE 4. CCOFA DAMPERS CHARACTERISTICS………………………………… 14 FIGURE 5. COAL COMPARTMENT ASSEMBLY…….. …………………………………15 FIGURE 6. EXPLODED VIEW EXTERNAL TILT DRIVE SHEAR PIN FAILURE MECHANISM…………………………………………………………… 16

LIST OF REFERENCE ENGINEERING DRAWINGS WINDBOX ARRANGEMENT SHEET 1 (T04019-WB-A001) ……………………………17 WINDBOX ARRANGEMENT SHEET 2 (T04019-WB-A002) …………………………18 WINDBOX ARRANGEMENT SHEET 3 (T04019-WB-A003)…………………………… 19 COAL NOZZLE TIP…………………………………………………………………………. 20 OIL NOZZLE TIP……………………………………………………………………………. 21 STRAIGHT AIR NOZZLE TIP(TOP, END) ………………………………………………. 22 STRAIGHT AIR NOZZLE TIP(AUX. AIR) ………………………………………………… 24 STRAIGHT AIR NOZZLE TIP(CCOFA) ………………………………………………….. 25 5.

DESIGN DATA AND CONTRACT DATA SHEET……………………… …………………1 Predicted Performance Data (BMCR, TMCR, 80% TMCR & 60% TMCR) ................ 2 Predicted Performance Data (50%TMCR, 30% TMCR & Both HP Heaters Out) ...... 3

6.

PRESSURE PARTS SKETCH

7.

PRESSURE PARTS SCHEDULE-UNIT MATERIAL DIAGRAM Back pass Economiser Tubes Economiser Hanger Tubes

Page 1 of 12 Page 2 of 12

iv

01 PLANT HAND BOOK-contents.doc

PLANT HAND BOOK-SIPAT STAGE 1 (3x660MW) STPP Lower Furnace Furnace Vertical Wall Furnace Rear Wall Extended Wall Back Pass Wall SH Division Panel SH Platen SH Final Low Temperature Reheater Reheater Final 8.

Page 3 of 12 Page 4 of 12 Page 5 of 12 Page 6 of 12 Page 7 of 12 Page 8 of 12 Page 9 of 12 Page 10 of 12 Page 11 of 12 Page 12 of 12

SAFETY VALVES DATA Design Basis for Safety Valves …………………………………………………………..1 Separator Outlet and Superheater Safety Valve …………………………………………2 Cold RH and Hot RH Safety Valve…………………………………………………………3 Soot Blowing Pipe Safety Valve ……………………………………………………………4 Safety Valve Setting Diagram at Superheate r……………………………………………5 Safety Valve Setting Diagram at Reheater System ……………………………………6 Safety Valve Setting Diagram at Soot Blowing System …………………………………7 Design Basis for Power Operated Impulse Safety Valves……………………………… 8 SH Power Operated Impulse type SV Setting Diagram…………………………………9 Hot RH Pipe Power Operated Impulse type SV Setting Diagram ……………………10 SV Setting for High Capacity PRDS Downstream. ………………………………… 11 Safety Valve Setting Table for HT Unit Aux. Steam Header…………………………..12

9.

SOOTBLOWER SELECTION DATA AND PHILOSOPHY Soot Blower Selection Data and Philosophy ……………………………………………1 Wall Blowers…………………………………………………………………………………..1 Retract Blowers, Furnace Probe & Half Retracts ………………………………………..2 Air Pre-Heaters ……………………………………………………………………………….2 Soot Blower Selection Data…………………………………………………………………3 Retractable Soot Blower Locations….. ……………………………………………………3 Wall Blower Locations……. …………………………………………………………………4

10.

DUCT DESIGN DATA AND SCHEMATIC

11.

PREDICTED PERFORMANCE DATA Design coal……………………………………………………………………………………1 Worst coal……………………………………………………………………………………40 Best coal……………………………………………………………………………………..79

V.

PERFORMANCE CURVES Load Load Load Load Load

Vs Vs Vs Vs Vs

Water/Steam Temperature Reheat Steam Temperature Burner Tilt Excess Air Spray Water Flow

T04019-CV-01 T04019-CV-02 T04019-CV-03 T04019-CV-04 T04019-CV-05

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01 PLANT HAND BOOK-contents.doc

PLANT HAND BOOK-SIPAT STAGE 1 (3x660MW) STPP Moisture in Coal Vs Pulveriser Capacity Moisture in Coal Vs Inlet Air Temperature Pulveriser Capacity Vs Hardgroove Grindability Pulveriser Power Consumption Vs Coal Capacity Pulveriser Power Consumption Vs Coal Fineness

VI.

T04019-CV-09 T04019-CV-10 T04019-CV-11 T04019-CV-12 T04019-CV-13

START-UP CURVES Cold start-up…………………………………………………………………. T04019-CV-06 Warm start-up……………………………………………………………….. T04019-CV-07 Hot start-up……………………………………………………. ……………. T04019-CV-08

VII.

GENERAL ARRANGEMENT OF BOILER-DRAWINGS GA of GA of GA of GA of GA of GA of GA of GA of GA of GA of GA of GA of

VIII.

Boiler Boiler Boiler Boiler Boiler Boiler Boiler Boiler Boiler Boiler Boiler Boiler

Key Plan & General Notes………………. T04019-GA-A0001-Rev.F1 Sect. Boiler Side Elev. View “01-01”…… T04019-GA-A0002-Rev.F1 Mill Side Elev. View “02-02/02a-02a”…… T04019-GA-A0003-Rev.F1 Boiler Front Elev. View “03-03”…………. T04019-GA-A0004-Rev.F1 El. 00 Plan View “04-04”………………… T04019-GA-A0005-Rev.F1 El. 22600 Plan Sect. View “05-05”……… T04019-GA-A0006-Rev.F1 El. 38000 Plan Sect. View “06-06”……… T04019-GA-A0007-Rev.F1 El. 58800 Plan Sect. View “07-07”……… T04019-GA-A0008-Rev.F1 El. 92132 Plan Sect. View “08-08”……… T04019-GA-A0009-Rev.F1 Boiler Rear Elev. View “09-09”………….. T04019-GA-A0010-Rev.F1 Gas A/H Center Elev. View “10-10”……. T04019-GA-A0011-Rev.F1 Gas A/H Rear Elev. View “11-11”……… T04019-GA-A0012-Rev.F1

PROCESS & INSTRUMENTATION DRAWINGS BOILER & DUCT INSTRUMENT INSERT LOCATION CONNECTION LIST CONNECTION DETAIL P&ID P&ID P&ID P&ID P&ID P&ID P&ID P&ID P&ID P&ID P&ID P&ID P&ID P&ID P&ID P&ID P&ID P&ID

– SYMBOLS AND LEGENDS – SYMBOLS AND LEGENDS – SYMBOLS AND LEGENDS – SYMBOLS AND LEGENDS – ECONOMIZER SYSTEM – EVAPORATOR SYSTEM – WATER SEPARATOR SYSTEM – SUPERHEATER SYSTEM(1/3) – SUPERHEATER SYSTEM(2/3) – SUPERHEATER SYSTEM(3/3) – REHEATER SYSTEM – CIRCULATION & START-UP SYSTEM – BOILER DRAIN & VENT SYSTEM – COMB. AIR&FLUE GAS SYSTEM(1/3) – COMB. AIR&FLUE GAS SYSTEM(2/3) – COMB. AIR&FLUE GAS SYSTEM(3/3) – FUEL SYSTEN(1/3) – FUEL SYSTEN(2/3)

vi

T04019-GA-A0018-Rev.A T04019-GA-A0019-Rev.A T04019-PI-D0001-Rev.0 T04019-PI-D0002-Rev.0 T04019-PI-D0003-Rev.0 T04019-PI-D0004-Rev.0 T04019-PI-D0005-Rev.0 T04019-PI-D0006-Rev.0 T04019-PI-D0007-Rev.0 T04019-PI-D0008-Rev.0 T04019-PI-D0009-Rev.0 T04019-PI-D0010-Rev.0 T04019-PI-D0011-Rev.0 T04019-PI-D0012-Rev.0 T04019-PI-D0013-Rev.0 T04019-PI-D0014-Rev.0 T04019-PI-D0015-Rev.0 T04019-PI-D0016-Rev.0 T04019-PI-D0017-Rev.0 T04019-PI-D0018-Rev.0

01 PLANT HAND BOOK-contents.doc

PLANT HAND BOOK-SIPAT STAGE 1 (3x660MW) STPP P&ID P&ID P&ID P&ID P&ID P&ID P&ID P&ID P&ID P&ID P&ID P&ID P&ID P&ID

– FUEL SYSTEN(3/3) – OIL BURNER DETAIL – PRIMARY AIR, SEALING&COOLING AIR SYSTEM – COAL FEEDER & PULVERIZER SYSTEM – SCANNER COOLING & DAMPER SEAL SYSTEM – STEAM COIL AIR HEATER SYSTEM – BOILER WATER CIRCULATION PUMP SYSTEM – SOOT BLOWING SYSTEM – CLOSED COOLING WATER SYSTEM – SERVICE AIR SYSTEM – BOILER START-UP FLASH TANK SYSTEM – SAMPLING SYSTEM – INSTRUMENT AIR SYSTEM – SERVICE WATER SYSTEM

T04019-PI-D0019-Rev.0 T04019-PI-D0020-Rev.0 T04019-PI-D0021-Rev.0 T04019-PI-D0022-Rev.0 T04019-PI-D0023-Rev.0 T04019-PI-D0024-Rev.0 T04019-PI-D0025-Rev.0 T04019-PI-D0026-Rev.0 T04019-PI-D0027-Rev.0 T04019-PI-D0028-Rev.F T04019-PI-D0029-Rev.0 T04019-PI-D0030-Rev.0 T04019-PI-D0031-Rev.F T04019-PI-D0032-Rev.0

P&ID P&ID P&ID P&ID P&ID P&ID P&ID

– MAIN & REHEAT STEAM SYSTEM(1/2) ................ T04019-PI-D0501-Rev.G – MAIN & REHEAT STEAM SYSTEM(2/2) ................. T04019-PI-D0501-Rev.0 – FUEL OIL SYSTEM(1/5) .......................................... T04019-PI-D0502-Rev.0 – FUEL OIL SYSTEM(2/5) .......................................... T04019-PI-D0502-Rev.0 – FUEL OIL SYSTEM(3/5) .......................................... T04019-PI-D0502-Rev.0 – FUEL OIL SYSTEM(4/5) .......................................... T04019-PI-D0502-Rev.0 – FUEL OIL SYSTEM(5/5) .......................................... T04019-PI-D0502-Rev.0

P&ID – EQUIPMENT COOLING WATER SYSTEM(1/2)…… T04019-PI-D0503-Rev.0 P&ID – EQUIPMENT COOLING WATER SYSTEM(2/2)…… T04019-PI-D0503-Rev.0 P&ID – LP DOSING & OXYGENATED TREATMENT SYSTEM(1/2)………........................................... …..T04019-PI-D0504-Rev.0 P&ID – LP DOSING & OXYGENATED TREATMENT SYSTEM(2/2)……….................................................T04019-PI-D0504-Rev.0 P&ID – AUXILIARY STEAM SYSTEM………………………… T04019-PI-D0505-Rev.0 P&ID – NITROGEN GAS SUPPLY SYSTEM………………… T04019-PI-D0506-Rev.0

IX.

IMPORTANT DO’s & DON’Ts

VOLUME-II X.

SEQUENCE AND PROTECTION INTERLOCK SCHEMES

XI.

ALARM AND TRIP VALUES

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01 PLANT HAND BOOK-contents.doc

I. COAL ANALYSIS TABLE OF CONTENTS

PAGE NO.

TITLE

COAL ANALYSIS………………………………………………………………………………………………... 1

i

I. Coal Analysis.doc

I. COAL ANALYSIS

COAL ANALYSIS

Unit

Design Coal

Worst Coal

Best Coal

kcal/kg

3,300

3,000

3,750

Total Moisture

%

12.0

15.0

11.0

Proximate Volatile Matter Analysis Fixed Carbon

%

21.0

20.0

24.0

%

24.0

20.0

29.0

%

43.0

45.0

36.0

Fuel Ratio (FC/VM)

-

1.14

1.00

1.21

Combustibility Index

-

2,067

2,353

2,476

Carbon

%

34.46

30.72

39.7

Hydrogen

%

2.43

2.30

2.68

Nitrogen

%

0.69

0.60

0.83

Oxygen

%

6.64

5.35

8.65

Sulfur

%

0.45

0.40

0.60

Ash

%

43.00

45.00

36.00

Moisture

%

12.00

15.00

11.00

HGI

50

47

52

Parameter High Heating Value

Ash

Ultimate Analysis

Grindability

Note) Proximate Analysis and Ultimate analysis are based on as received coal basis.

1

I. Coal Analysis.doc

II. ASH ANALYSIS

TABLE OF CONTENTS

PAGE NO.

TITLE

ASH ANALYSIS………………………………………………………………………………………………... 1

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II. Ash analysis.doc

II. ASH ANALYSIS

ASH ANALYSIS

Parame

Unit

Design Coal

Worst Coal

Best Coal

ter

Ash Analysis

Silica

SiO2

%

61.85

62.40

61.20

Alumina

Al2O3

%

27.36

27.31

27.32

Iron Oxide

Fe2O3

%

5.18

4.96

5.40

Lime

CaO

%

1.47

1.42

1.52

Magnesia

MgO

%

1.00

1.03

0.97

Sodium Oxide

Na2O

%

0.08

0.08

0.08

Potasium Oxide

K2O

%

0.63

0.32

1.22

Titania

TiO2

%

1.84

1.88

1.80

Phosphoric Anhydride

P2O5

%

0.54

0.55

0.44

Sulphuric Anhydride

SO3

%

0.05

0.05

0.05

Others

%

-

-

-

Initial Deformation

o

C

1150

1100

1250

Softening

o

C

-

-

-

Hemispheric

o

C

1400

1280

1400

Flow

o

C

1400

1280

1400

Ash Content

Kg /Gcal

130.3

150.0

96.0

Basic / Acid

B/A

0.09

0.09

0.10

Ash Fusion Temp. (oC) (Reducing Atmos.)

1

II. Ash analysis.doc

III. BOILER PARAMETERS

TABLE OF CONTENTS

TITLE

PAGE NO.

Boiler parameters……………………………………………………………………………………1

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III. Boiler Parameters.doc

III. BOILER PARAMETERS

BOILER PARAMETERS (Modified Sliding Pressure Operation)

100% BMCR

100% TMCR

80% TMCR

50% TMCR

Both HP Htrs out of oprn.

1839.5 252.92 540

60% BMCR (One stream)

SH SYSTEM Steam Flow at SHO T/Hr Steam Pressure at SHO Kg/cm2(a) Steam temp. at SHO deg. C

2225 256 540

2023.75 254.45 540

1572.47 238.01 540

963.76 151.25 540

1741.82 48.3 568 299 1.69

1678.37 46.7 568 296 1.62

1328.96 37.2 568 281 1.30

836.41 23.6 568 289 0.88

289.64

286.23

270.35

244.34

1335 204.4 540

RH SYSTEM Steam Flow Steam Pressure at RHI Steam temp. at RHO Steam temp. at RHI Pr. Drop across RH

T/Hr Kg/cm2(a) deg. C deg. C Kg/cm2

FEED WATER TEMP. deg. C

STEAM TEMPERATURE CONTROL RANGE %

1784.2 50.5 568 309 1.70

196.15

1138 32.2 568 284 1.16

261

---------------100% BMCR to 50% TMCR-----------

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III. Boiler Parameters.doc

IV. 1. STEAM GENERATOR DESCRIPTION TABLE OF CONTENTS

TITLE

PAGE NO.

DESIGN ASPECTS......................................................................................................................... １ General.............................................................................................................................................１ Mechanical Design Aspects .............................................................................................................１ FURNACE DIMENSIONS………………………………………………………………………………….２ BOILER ARRANGEMENT ............................................................................................................... 2 General.............................................................................................................................................. 2 Arrangement of Tube Banks… .......................................................................................……… ３ Fuels and Fuel Firing Requirements................................................................................................. 3 Boiler Start-up and Bypass System .................................................................................................. 3 The Water Separation System .......................................................................................................... 4 Control of Superheat and Reheat Temperatures ................................................................................ 4 Turbine Operation ............................................................................................................................. 4 BOILER LOAD CONDITIONS .......................................................................................................... 5 Boiler Maximum Continuous Rating (BMCR).................................................................................... 5 Turbine Maximum Continuous Rating (TMCR)................................................................................. 5 Normal Operation .............................................................................................................................. 5 Minimum Once-Through Load........................................................................................................... 5 Allowable Steam Temperature Variations..........................................................................................５ CONDITIONS OF SERVICE.............................................................................................................. 6 Description of Service ....................................................................................................................... 6 Operational Mode.............................................................................................................................. 6 Operation Capability.......................................................................................................................... 6 Operation Features ........................................................................................................................... 6 SAFETY VALVES ........................................................................................................................... 6 SH Safety Valves ............................................................................................................................. 6 RH Safety Valves ......................................................................................................... …………… 7

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IV.1 Steam Generator description.doc

IV. 1. STEAM GENERATOR DESCRIPTION

DESIGN ASPECTS General The steam generator is a Doosan Heavy Industries & Construction Co., Ltd., balanced-draft, once-through, supercritical, single reheat, dry bottom, indoor type. It is designed for sliding pressure operation, with a balanced draft furnace capable of firing pulverized coal. The steam generator will produce steam flow to a turbine generator with boiler outlet conditions of main steam flow of 2023.75 t/h,(660 MW) SH Steam Temperature 540°C @ 255 kg/cm2(g) and RH outlet steam flow of 1678.37 t/h, RH Steam Temperature 568°C @ 44.08 kg/cm2(g). The once-through system is characterized by the unique arrangement of the evaporator sections with the water separator placed at the end of the sections. In a once-through system, the water and steam flows only once through the evaporator circuit with no re-circulation. The steam is slightly superheated as it exits the evaporator section, or waterwalls, between minimum once-through load and maximum load. In this load range, the water separator operates in a dry mode. The fluid pressure in the evaporator changes from supercritical to subcritical over the boiler load range due to the sliding pressure mode of operation. However the once-through circuitry is always the same above the minimum once-through load. Below about 75% load the water walls are in subcritical region of flow, and part of the waterwalls will have two phase flow. Below the minimum once-through load the flow through the evaporator must be maintained at a constant value to ensure adequate cooling of the evaporator tubes. This flow is ensured by the Boiler Circulation Pump, which is in service only below the minimum once-through load. Therefore at low loads a mixture of water and steam leaves the waterwalls, and the water separator operates in a wet mode with a controlled water level. A major advantage of the once-through system is that there is no fixed point at which the waterwall system ends and the superheater system starts. This means that the system can operate with a very wide range of fuels and different states of furnace cleanliness. The water separators have been located in the system to ensure a smooth transition from the constant waterwall flow mode to the once-through flow mode. This also ensures that no significant steam temperature excursions occur at the superheater outlet. During startup and at low load, the steam-water mixture generated in the water walls flows to the separators. In the separator, the steam is separated from the steam water mixture. The steam passes to the superheaters and the water is recirculated through the Economizer and Evaporator by the Boiler Recirculation Pump. The furnace is made up of two sections-the lower spiral wall section and the upper vertical wall section. The lower furnace spiral wound parallel tube construction results in uniform heat absorption in all tube circuits, thus avoiding potentially damaging temperature differentials in the tube panels.

Mechanical Design Aspects The mechanical design of this boiler meets the demands of the specified pressure, temperature and transients during load changes. A transient design pressure of ± 889 mmWC the furnace chamber covers extreme conditions of puffs and implosion.

１

IV.1 Steam Generator description.doc

IV. 1. STEAM GENERATOR DESCRIPTION

The furnace chamber is formed of spiral wound parallel tubing welded to form water wall panels The furnace weight is supported by tension strips and distributed into the upper vertical waterwalls. A wrap-around buckstay system is installed over the whole height of the boiler. The upper vertical walls are reinforced by an internal buckstay system attached perpendicular to the tubes. This arrangement is capable of sustaining the ± 889 mm WC furnace transient design pressure. Again, careful attention has been taken by designing the boiler suspension with an even load distribution over a multitude of links to the steel structure. High strength materials are used for the waterwall, the superheater and the reheater outlet headers. These materials make it possible to use smaller wall thickness tubes and reduce thermal stresses. FURNACE DIMENSIONS The complex properties of coal and its ash have a major impact upon the unit. The combustibility of the coal, the ash content and the ash chemistry determine the slagging and fouling properties. Furnace dimensions and the burner arrangement must reflect the resulting fuel ash slagging characteristics. While the ignition of coal particles and the complete combustion must be allowed, sufficient radiant surfaces must be provided within the furnace to lower the gas temperature at the inlet to the convection heating surfaces to eliminate sticky deposits from forming on these surfaces. BOILER ARRANGEMENT General The boiler is a two-pass boiler of gas tight welded wall construction. The furnace is of dry bottom type with continuous spiral wound tubes that run from the furnace hopper up to the bottom of the furnace arch. The tubes connect to intermediate headers and from these headers, vertical tubes are attached to form the upper vertical evaporator walls. From the outlet headers of the vertical walls, the steam/steam & water mixture is fed to the water separators. The subsequent steam path is through the steam-cooled roof, the back pass wall, into the superheater extended sidewall panels, into the superheater division panels, to the superheater platens and finally to the finishing superheater located above the furnace arch. Two stages of Superheater desuperheaters are located in the steam circuitry. The first stage is between the SH Division panels and the superheater platens, and the second stage is between the superheater platens and the finishing superheater. There are two parallel desuperheater stations in each stage of the superheater desuperheater. The Reheater section consists of two stages-the Low Temperature Reheater arranged horizontally in the rear pass of the boiler and the High Temperature Finishing Reheater arranged pendant above the furnace arch in the high gas temperature zone. A single stage Reheater desuperheater is located at the cold reheat line, that is the upstream of horizontal reheater section. Feedwater enters the economizer through the lower inlet header and flows through the horizontal bare tube, in-line tubing comprising the heating surface. Return bends at the ends of the tube banks provide continuous tube elements, whose upper ends connect to junction headers. The economizer terminal tubes act as hanger tubes for the horizontal primary reheater ２

IV.1 Steam Generator description.doc

IV. 1. STEAM GENERATOR DESCRIPTION and terminate at the economizer outlet header. The outlet header is linked with the lower waterwall headers through connecting links. The economizer is designed for counterflow of gas and water, which results in a maximum log mean temperature difference for heat transfer. Upward flow of water helps avoid water hammer. Arrangement of Tube Banks The location and sequence of superheat and reheat heating surfaces in the flue gas path is dictated by: The temperature difference between the gas and the internal fluid. The method of reheat temperature control. The metal temperature limits. The reheat temperature is controlled by burner tilt, which assures reliable and maintenance free operation. Because of this, the final reheater is located before the final superheater. In this way the burner tilt has a maximum effect on the finishing reheat platen surface. The first stage of reheater, the Low Temperature Reheater, is placed in the second pass to take advantage of the convection heat transfer. All heating surfaces are bare tubes and are arranged in line. The convection bundle suspension and tube penetrations are designed for easy access and effective cleaning.

Fuels and Fuel Firing Requirements 1. Ignition and Warm-up Fuel Light Diesel Oil. 2. Start-up. Low Load and Flame Stabilization Fuel HFO/HPS/LSHS 3. Fuel for Rating and Performance The steam generating unit and fuel preparation system is designed for continuous operation at maximum continuous output with the Design/Worst/Best Coal and the range of Coal as specified. The Performance Guarantees are based on the Design coal.

Boiler Start-up and Bypass System The start-up and re-circulation system is designed to provide the necessary mass flow for adequate cooling of the evaporator during start-up and low load operation. A minimum of 30% of TMCR flow is maintained up to a boiler load of 30% TMCR. In this re-circulation system the feedwater flows through the boiler feedwater line to the economizer, to the evaporator, and then to the water separator. From the separator the recirculated water returns through the Boiler Recirculation Pump to the boiler feedwater line, where it is mixed with feedwater. The UG valve, located downstream of the BCP, controls the amount of flow. ３

IV.1 Steam Generator description.doc

IV. 1. STEAM GENERATOR DESCRIPTION

During a cold start-up, as the water swells, the excess re-circulated water is drained from the water separator (at or near ambient pressure) through the WR and ZR control valves into the boiler flash tank and thereafter the condenser. As the pressure in the water separator increases and the water swell reduces, the amount of excess water decreases. The WR and ZR control valves automatically maintain the water level in the separator. As the water level increases the WR valve opens, followed by the ZR valve. When water level drops, the ZR valve closes first followed by the WR valve. Both the WR and ZR control valves are closed when water level is normal or below normal level. During shutdown, the return water may become more or less contaminated, depending on the amount of time the unit is shutdown. The contamination must be removed from the circuit. If this happens, the return water can be routed through the atmospheric flash tank and then to the condenser. From the condenser the water will pass through the condensate polishing plant before returning to the feedwater tank. This will provide the required feedwater quality relatively quickly.

The Water Separation System The water separator system consists of 2 vertical separators with tangentially attached inlet branches. Steam outlet branches are located on the top and the drain discharges are located on the bottom. The drain discharge lines of the separators are connected to another vertical water storage tank. The storage tank is provided with water level indicators for indicating water level during start-up, low load and shut down operation. Control of Superheat and Reheat Steam Temperatures The superheater outlet steam temperature is controlled by two stages of spray water attemperation. The reheater outlet temperature is controlled by modulation of burner tilt. A single stage spray water attemperation system acts as an emergency control measure for reheater outlet steam temperature. There are many methods of steam temperature control such as gas circulation, spray water, selective sootblowing and burner tilt. Experience has shown that for coal firing, gas recirculation is less reliable, more expensive to maintain, and is also very vulnerable to erosion problems. The burner tilt method has been chosen for primary control of the reheat temperature. The burner tilt characteristics give a wide range within which the reheat temperature can be kept constant. A spray water attemperation system is also provided to keep the temperature excursions within allowable limits during fast load changes and upset conditions. Turbine Operation Today's power station practice requires increasing operational flexibility. This in turn requires a mode of operation which is not only economical but also suitable to avoid undue thermal stresses in thick walled components. For the turbine the best solution is sliding pressure and temperature during start up and sliding pressure during normal operation. The advantages of sliding pressure operation are: Minimal temperature variation for first stage turbine shell under varying load conditions. Lower thermal stress levels during start-up. Reduced pressure levels at lower loads enhances component life span. ４

IV.1 Steam Generator description.doc

IV. 1. STEAM GENERATOR DESCRIPTION

Improved overall power plant heat rates. Extended control range of main and reheat steam temperatures. Natural sliding pressure operation has an inherent disadvantage. Compared to the turbine, the boiler has a large energy storage capacity, which seriously retards fast load changes. As a result, modified sliding pressure is recommended, where the turbine admission valves are modulated briefly with load variation. BOILER LOAD CONDITIONS Boiler Maximum Continuous Rating (BMCR) Boiler Maximum Continuous Rating (BMCR) is the maximum rating specified for the boiler. This corresponds to 109.94% of Turbine maximum continuous rating. Turbine Maximum Continuous Rating (TMCR) Turbine Maximum Continuous Rating (TMCR) is the basis of steam generator output and is equal to the turbine generator maximum guaranteed rating. Normal Operation The steam generator is designed to be operated as follows: Constant Pressure Operation. Above 90% TMCR, the main steam pressure remains constant at the rated value, condition, while the load is controlled by throttling main steam flow with the designated partial arc control valve. Below 30% TMCR, the main steam pressure remains constant at the minimum. The minimum constant pressure is 93.84 kg/cm2 (g). Sliding Pressure Operation. Between 30% and 90% TMCR, the steam pressure and steam flow rate is controlled by the load directly. Governor Regulating Operation. Load is regulated in response to the network frequency fluctuation. Minimum Once-Through Load The minimum once-through load is designed for 30% TMCR and is where the transition is made from wet to dry operation. Below 30% TMCR, waterwall flow must be kept constant to ensure adequate waterwall tube cooling. Accordingly, the start-up and re-circulation system is designed for 30% TMCR. Allowable Steam Temperature Variations The control system is designed to meet the performance objectives tabulated below. Description Steady state condition Load changing rate of 5% TMCR/min. above 50% TMCR

SH Steam Temp. ±5°C ±8°C

５

RH Steam Temp. ±5°C ±8°C

IV.1 Steam Generator description.doc

IV. 1. STEAM GENERATOR DESCRIPTION CONDITIONS OF SERVICE Description of Service The steam generator supplies steam to the reheat, condensing type turbine generator for the generation of electric power. Each unit may be operated in parallel with other station generating units within the power system. The steam generator may be subjected to sudden load rejection or rapid load pickup, and also to adverse conditions of maladjusted unit controls. Operational Mode The steam generator is suitable for base load operation and load cycling operation. Operation Capability The steam generator will be capable of: Achieving the maximum continuous load of BMCR at rated steam temperatures of 540°C/568°C. Supplying steam within the allowable variation for the following load variations: At a rate of 5% minimum of nominal rating per minute between 50% and 100% TMCR. At a rate of 3% minimum of nominal rating per minute between 30% and 50% TMCR. Sustaining the minimum stable load by full automation not more than 30% TMCR without supporting oil and bypass operation. Operation Features This unit is associated supplied with a High Pressure Bypass system with safety function, and a low pressure bypass system (by others). These systems are used to assist matching steam and turbine metal temperatures during start-up by bypassing main steam directly to the reheater and into the condenser.

SAFETY VALVES This unit is supplied with spring loaded safety valves, power operated impulse type safety valves and power operated impulse type relief valves located on Separator, Separator outlet links, Main Steam line, Cold Reheat and Hot reheat lines for protection of the boiler components against over pressurization. SH Safety Valves SH safety valves are located on Separator, Separator outlet links and Main Steam line. Ten nos. of spring loaded safety valves-one each on separator, two each on separator outlet links, two each on main steam line are provided having a total relieving capacity of 107.2% of BMCR flow. Two nos. of power operated impulse type safety valves-one each on main steam line, two nos. of power operated impulse type relief valves-one each on main steam line are provided having a total relieving capacity of 41.5%. The combined total relieving capacity of the spring loaded safety valves and power operated safety and relief valves is 148.7% of BMCR flow.

６

IV.1 Steam Generator description.doc

IV. 1. STEAM GENERATOR DESCRIPTION RH Safety Valves RH safety valves are located on the cold reheat lines and the hot reheat lines near the boiler. These valves discharge to atmosphere. There are two hot RH spring loaded safety valves-one each on hot reheat line, two hot RH power operated impulse type safety valves-one each on hot reheat line, two hot RH power operated impulse type relief valves-one each on hot reheat line that operate simultaneously, and eight cold RH spring loaded safety valves-four each on cold reheat line, that operate simultaneously. The maximum capacity of the RH spring loaded safety valves is based on the maximum reheat steam flow at BMCR load. The spring loaded safety valves are sized with a relieving capacity of 107.3% of BMCR reheat flow. The relieving capacity of power operated impulse type valves is 61.4%. The combined capacity of spring loaded safety valves and power operated safety valves is 168.7.

７

IV.1 Steam Generator description.doc

IV. 2. STEAM AND WATER FLOW SYSTEMS

TABLE OF CONTENTS

TITLE

PAGE

1. SUPERHEATER...................................................................................................................1 DESCRIPTION.............................................................................................................................1 Superheater .............................................................................................................................1 Steam Flow ..............................................................................................................................1 Protection and Control .............................................................................................................2 OPERATION................................................................................................................................3 General ....................................................................................................................................3 Superheater .............................................................................................................................4 2. SUPERHEATER DESUPERHEATERS ................................................................................5 DESCRIPTION.............................................................................................................................5 CONTROL STATIONS.................................................................................................................5 BLOWOUT PROCEDURE FOR DESUPERHEATER SPRAY WATER LINES ...........................6 MAINTENANCE ...........................................................................................................................6 3. REHEATER ..........................................................................................................................8 DESCRIPTION ............................................................................................................................. 8 Reheater ..................................................................................................................................8 Steam Flow ..............................................................................................................................8 Protection and Control ............................................................................................................ 9 OPERATION................................................................................................................................. 9 General ................................................................................................................................... 9 Reheater ............................................................................................................................... 10 4. REHEATER DESUPERHEATERS ....................................................................................... 11 DESCRIPTION............................................................................................................................ 11 CONTROL STATIONS................................................................................................................ 11 MAINTENANCE .......................................................................................................................... 11 BLOWOUT PROCEDURE FOR DESUPERHEATER SPRAY WATER LINES.......................... 12 5. WATER WALL SYSTEM......................................................................................................14 FURNACE WALL WATER CIRCUIT .....................................................................................14 ECONOMIZER SYSTEM......................................................................................................15

i IV.2,3,4 Boiler operation description.doc

IV. 2. STEAM AND WATER FLOW SYSTEMS

1. SUPERHEATER DESCRIPTION The flow path and arrangement of the superheat circuits is shown on P&ID drawings T04019-PI-D0008, D0009, and D0010 and the Pressure Part Arrangement drawings T04019-PA-A0100, A0101 and A0102.

Superheater The superheater (SH) is composed of four basic stages or sections; namely the vertical SH finishing section, the SH vertical platen section, the SH division panel section, and the back pass wall and roof and extended back pass floor and wall sections. The SH vertical finishing section (S-35) is located in the back pass extended side. It is composed of 55 (42.2 mm O.D. tube) assemblies spaced on 336 mm centers across the width of the furnace, with 336 mm end spaces. The SH vertical platen section (S-29A) is located directly above the furnace in front of the furnace arch. It is composed of 20 (50.8 mm O.D. tube) assemblies spaced on 896, 924mm centers across the width of the furnace, with 896 mm end spaces. The SH division panel section (S-22) is located directly above the furnace between the front wall and the SH vertical platen section. It consists of six front and six rear division panel (44.5 mm O.D. tube) assemblies spaced on 2688, 2632 mm centers across the furnace width, with 2716 mm end spaces. The back pass wall and roof section forms the back pass roof tubes (S-3), back pass rear wall tubes (S-4), back pass front wall screen tubes (S-12), back pass front wall tubes (S-13), and back pass side wall tubes (S-10) of the vertical gas pass. The extended back pass wall and floor area forms the floor (S-17) and side wall tubes (S-18) of the extended back pass. The back pass at furnace front roof (S-3) and rear (S-4) tubes form the roof above the furnace, arch, and extended back pass.

Steam Flow The steam flow from the water separators to the superheater finishing outlet header can be followed on the Process (Refer to the attached Superheater System Schematic diagram). The elements which make up the flow path are essentially listed consecutively. Where parallel paths exist, first one and then the other circuit is listed. From the water separators (F-31), the main steam flow is through the back pass connecting pipes (S-1) to the back pass at roof inlet header (S-2). From the back pass roof inlet header, the steam flows through the back pass at furnace front roof tubes (S-3) and back pass at furnace rear roof tubes (S-4) to the back pass at roof outlet header (S-5). Steam from the back pass at roof outlet header (S-5) takes two paths. One path flows through the back pass roof tubes (S-6), down the back pass rear wall tubes (S-7), into the back pass lower rear header (S-8), and into the rear of the two back pass lower side headers (S-9). The other path from the back pass at roof outlet header (S-5) flows down １ IV.2,3,4 Boiler operation description.doc

IV. 2. STEAM AND WATER FLOW SYSTEMS the back pass front wall screen tubes (S-12), through the back pass front wall tubes (S-13), into the back pass lower front header (S-14), and into the front of the two back pass lower side headers (S-9). From the back pass lower side headers (S-9), steam flows upward through the back pass side walls (S-10) and into the two back pass upper side headers (S-11). Steam from the back pass lower front header (S-14) also flows through the back pass lower extended side inlet pipe (S-15), to the back pass extended side inlet header (S-16), through the back pass extended side floor tubes (S-17) and side wall tubes (S-18), and into the two back pass upper side headers (S-11). Steam from the two back pass upper side headers (S-11) continues to the two division panel inlet headers (S-20) via four links (S-19). The SH division inlet headers (S-20) supply steam through the SH division panels (S-22) to the two SH division outlet headers (S-24). From the SH division outlet headers, the steam is carried to the No. 1 SH desuperheaters (S-26) by the SH links to the No. 1 SH desuperheaters (S-25). The SH links from the No. 1 SH desuperheaters (S-27) carry steam from the No. 1 SH desuperheaters to the SH vertical platen inlet header (S-28). This header supplies steam through the SH vertical platen assemblies (S-29) to the SH vertical platen outlet header (S-30).

Steam continues from the SH vertical platen outlet header (S-30) through the two outlet links (S-31) to the No. 2 SH desuperheaters (S-32). The SH links from the No. 2 SH desuperheaters (S-33) cross and carry steam from the No. 2 SH desuperheaters to the SH vertical finishing inlet header (S-34). This header supplies steam through the SH vertical finishing assemblies (S-35) to the two SH vertical finishing outlet headers (S-36) and the four SH outlet leads (S-37) to the main steam lines. NOTE: Fluid (steam) cooled spacer supply tubes, originating at the SH division inlet headers (S-20) and discharging into the SH vertical platen outlet header (S-30), maintain the alignment of the division panels (S-22) and SH vertical platen assemblies (S-29) and prevent them from swaying excessively. NOTE: Additional fluid (steam) cooled spacer tubes, originating from the extended side inlet header (S-16) and discharging into the SH vertical platen outlet header (S-30), maintain alignment of the SH vertical platen assemblies (S-29) and the reheater finishing assemblies (R-11). Superheated steam from the SH finishing outlet headers goes to the high pressure stages of the turbine via the main steam lines. After passing through the high pressure stages of the turbine, steam is returned to the reheater via the cold reheat lines.

Protection and Control As long as there is a fire in the furnace, adequate protection must be provided for the superheater elements. This is especially important during periods when there is no demand for steam, such as when starting up or shutting down the unit. During these periods of no steam flow through the turbine, adequate flow through the superheater is assured by means of the HP by-pass drain system. ２ IV.2,3,4 Boiler operation description.doc

IV. 2. STEAM AND WATER FLOW SYSTEMS

Superheater safety valves, spring loaded safety valves, are located on the separator outlet connection pipes (S-1) and main steam pipes and power operated impulse safety valves located on the main steam pipes. These safety valves serve to protect the superheater from being over-pressurized by sudden interruption. During all start-ups, care must be taken not to overheat the superheater elements. The firing rate must be controlled to prevent the furnace exit gas temperature from exceeding 1000°F (538°C). The temperature probe located in the upper furnace side wall should be used to measure the furnace exit gas temperatures (Refer to the General Arrangement Drawings for temperature probe location). NOTE: Gas temperature measurements will be accurate only if a shielded, aspirated probe is used. If the probe consists of a simple bare thermocouple, there will be an error due to radiation resulting in a low temperature indication. At 1000°F (538°C) actual gas temperature, the thermocouple reading will be approximately 50°F (28°C) low. Unless very careful traverses are made to locate the point of maximum temperature, it is advisable to allow another 50°F (28°C) tolerance, regardless of what type of thermocouple is used. NOTE: The 1000°F (538°C) gas temperature limitation is based on normal start-up conditions where steam is admitted to the turbine at the minimum allowable pressure prescribed by the turbine manufacturer. Should turbine rolling be delayed and the steam pressure be permitted to build up, the gas temperature limitation should be reduced to 950°F (510°C) when the steam pressure exceeds two-thirds of the design pressure before steam flow through the turbine is established. Thermocouples installed on various superheater terminal tubes above the furnace roof serve to provide a continuous indication of element metal temperatures during start-up and when the unit is carrying load. Refer to the Thermocouple Arrangement Drawings for location. ( P&ID drawing, T04019-PI-D0009, D0010, D0011) Steam temperature control is provided by means of windbox nozzle tilts and desuperheaters. Refer to appropriate sections elsewhere in the manual for details.

OPERATION Operation of the superheater is not independent of the rest of the steam generator. Therefore, operating procedures for this component are discussed in detail under startup procedure for Sipat Project. However, the basic rules in the following paragraphs must always be followed.

General It is essential that suitable arrangements are made to assure cleanliness of the external and internal surfaces of the superheater at all times. Fly ash and/or slag accumulations result in unequal gas distribution, inefficient heat transfer, and possible localized overheating. Suitably located soot blowers, operated in the proper cycle, normally provide adequate means of keeping surfaces clean.

３ IV.2,3,4 Boiler operation description.doc

IV. 2. STEAM AND WATER FLOW SYSTEMS The external surfaces of the superheater should be inspected regularly for cleanliness. Slagging must be kept to a minimum by proper use of soot blowers. Extreme buildups must be removed immediately. Lancing with compressed air is often effective in slag removal. Local slagging may become a cause of overheating of element tubes, possibly resulting in tube failures. Furthermore, it may restrict the gas flow causing uneven heat transfer and creating further operating difficulties. Proper feedwater treatment, and control of steam quality and carry-over are essential to assure cleanliness of interior surfaces of superheaters. Overloads, fluctuating load, high water level, foaming, high concentrations, etc., all contribute to deposits on interior surfaces. Accumulation of these deposits inside the tubes will lead to unit failure. Care must be taken to assure that condensate quality spray water is used for the desuperheaters to avoid carry-over of solids into the superheater and the turbine blades. Periodic checks of steam pressure drops across the superheater under identical load conditions usually indicate whether or not solid deposits are present within the elements. In the event of failure of one or more superheater elements, check carefully to determine the cause. Doosan Heavy Industries & Construction Co., LTD. may be consulted for repair procedures and proper means to prevent recurrence.

Superheater Make sure the superheater back pass walls and main steam lines are completely drained (especially after a hydrostatic test) by opening the inlet and outlet header drains before lighting off. Close the back pass header drains immediately after rolling the turbine. The main steam line vents and drains, which serve as starting vents, are kept open until the turbine is under light load. The drain valves near the turbine should be operated in conjunction with the start-up vents to provide additional steam flow and to drain and warm the main steam line prior to turbine rolling.

４ IV.2,3,4 Boiler operation description.doc

IV. 2. STEAM AND WATER FLOW SYSTEMS 2. SUPERHEATER DESUPERHEATERS DESCRIPTION Two spray-type superheater (SH) desuperheaters (No. 1) are installed in the connecting links between the superheater division panel outlet headers and the SH vertical platen inlet header, and two additional spray-type superheater (SH) desuperheaters (No. 2) are installed in the connecting links between the SH vertical platen outlet header and the SH finishing inlet header to permit reduction of steam temperature, when necessary, and to maintain the temperatures at design values, within the limits of the nozzle capacity. Temperature reduction is accomplished by spraying water into the path of the steam through a nozzle at the inlet end of the desuperheater. It is essential that the spray water be chemically pure and free of suspended and dissolved solids, containing only approved volatile organic treatment material, in order to prevent chemical deposition in the superheater and carry-over of solids to the turbine. CAUTION: During start-up of the unit, if desuperheating is used to match the outlet steam temperature to the turbine metal temperatures, care must be exercised so as not to spray down below a minimum of 20°F (11°C) above the saturation temperature at the existing operating pressure. Desuperheating spray is not particularly effective at the low steam flows of start-up. Spray water may not be completely evaporated but be carried through the heat absorbing sections to the turbine where it can be the source of considerable damage. During start-up, alternate methods of steam temperature control should be considered. The locations of the desuperheaters, between the SH division panel section and the SH vertical platen section and between the SH vertical platen section and the SH finishing section, help to ensure that water carry-over to the turbine does not occur. It also eliminates the necessity for high temperature resisting materials in the desuperheater construction.

CONTROL STATIONS NOTE: For desuperheater piping and valves, refer to the Process and Instrumentation Diagrams T04019-PI-D0009 and D0010. One pneumatically operated control valves linked to an automatic control drive regulates the flow of spray water on the main line supplied to each desuperheater. A manually operated isolation valve is located downstream of each control valve and pneumatic diaphragm type isolation valve is upstream of each control valve to permit isolation when required. There is spray water bypass line which is consisting of the same system as in the main line. These one manual and one pneumatic isolating valves around the automatic control valve should be used only in an emergency, or when the automatic control valve may require maintenance. A motor operated block valve is installed in the main supply line to the superheater desuperheater control stations as an additional shutoff valve. These block valves must be interlocked to close when the superheater desuperheater control valves are closed. ５ IV.2,3,4 Boiler operation description.doc

IV. 2. STEAM AND WATER FLOW SYSTEMS The spray water control valves must be interlocked to close upon a turbine trip. Closing the block valve will prevent water from entering the superheater elements if a superheater spray water control valve should leak. Spray water for the superheater desuperheaters is normally taken from the boiler feed pump discharge line.

BLOWOUT PROCEDURE FOR DESUPERHEATER SPRAY WATER LINES Each desuperheater is fitted with a renewable liner to take the wear of erosion from the spray water stream, thus protecting the main desuperheater shell. Excessive noise from within a desuperheater usually indicates a worn liner and the Service Department of this Company should be contacted when this or any such abnormal conditions may arise. Sufficient clearances should be provided around the desuperheaters for replacing liners.

MAINTENANCE The spray water lines should be blown out before using the desuperheaters on a new unit and after repairs on the spray water lines have been made. They may also be blown when there appears to be any indication of plugging. Always have full pressure on the boiler when blowing out the desuperheaters. Each desuperheater should be blown out in the following sequence: 1. With the isolating valves closed, open the valves in the blowoff connection and then open the bypass valve for 1 minute. 2. With the bypass valve closed and the blowoff valves open, open the isolating valves and then open the control valve for 1 minute (from the control station). Close the isolating valves and the control valve but leave the blowoff valves open for another minute to clear the waste line before restoring the system to its operating status. NOTE: The blowoff valves should be installed close to the spray water piping and with no bends intervening, if possible.

６ IV.2,3,4 Boiler operation description.doc

IV. 2. STEAM AND WATER FLOW SYSTEMS

SUPERHEATER SYSTEM SCHEMATIC DIAGRAM

S-19 S-27

S-25

S-37

S-26 S-31

S-1 S-24

S-32

S-30

S-28

S-33 S-11 S-34

S-36 S-29B S-35B

S-29A

S-35A

S-20 S-2

S-21

S-23

S-3

S-6

S-4

S-22

S-18

S-5

S-29 S-35

S-12

S-17 S-22A

S-17A

S-7

S-16 S-13

S-10A

S-15

S-10

S-9

S-14

S-8

S-17,18 S-2

S-5

S-9

S-8

S-11

S-6,7

S-1

S-20 S-24

S-28

S-30

S-3,4

S-34

S-31

S-25

S-36

S-32

S-10

S-26

S-14 S-15 S-12,13

S-9

S-27 S-19 S-29,29A,29B S-21,22,23

S-16

S-33

S-37 S-35,35A,35B

７ IV.2,3,4 Boiler operation description.doc

IV. 2. STEAM AND WATER FLOW SYSTEMS 3. REHEATER DESCRIPTION The flow path and arrangement of the reheat circuits is shown on the P&ID drawing T04019-PI-D0011 and on the Pressure Parts Arrangement Drawings T04019-PA-A0100, A0101 and A0102.

Reheater The reheater (RH) is composed of two stages, or sections; namely, the reheater low temperature (RHLT) section, and the RH finishing section. The vertical RH (finishing) assemblies (R-11) are located above the furnace arch between the furnace rear hanger tubes and the SH vertical platen section. This portion of the RH consists of 41 (50.8, 57.0, 63.5, 70.0 and 76.2 mm O.D. tube) assemblies on 448 mm centers across the furnace width, with 448 mm end spaces. The RHLT horizontal rear assemblies (R-4) (R-5) (R-6) and RHLT vertical rear pendant assemblies (R-7) are located in the upper back pass above the economizer. There are 111 (63.5 mm O.D. tube) RHLT horizontal rear assemblies on 168 mm centers across the furnace width, with 168 mm end spaces. There are 56/55 (63.5 mm O.D. tube) RHLT vertical rear pendant (front) assemblies on 336 mm centers across the furnace width, with 168/336 mm end spaces.

Steam Flow The steam flow course from the cold RH inlet to the hot RH outlet leads can be followed on the Process which is attached diagram as a Reheater System Schematic diagram. Section 8. The elements which make up the flow path are essentially listed consecutively. Where parallel paths exist, first one, and then the other circuit is listed. The reheat steam flow is as follows: After passing through the high pressure stages of the turbine, steam is returned to the reheater via the two cold reheat steam lines (R-1A). From the cold reheat steam lines, the steam is carried to the RH desuperheaters (R-1). Steam from the cold reheat steam lines (R-2) enters the reheater through the RHLT rear horizontal inlet header (R-3), located in the back pass. From the RH inlet header, the steam flows upward through the back pass RHLT rear horizontal lower (R-4), intermediate (R-5), and upper (R-6) tube assemblies to the rear RHLT pendant assemblies (R-7) before discharging into the RHLT outlet header (R-8). Reheat steam continues from the RHLT outlet header (R-8) through the two outlet links (R-9) that cross and carry reheat steam to the RH finishing assemblies inlet header (R-10). This header supplies reheat steam through the vertical RH finishing assemblies (R-11, 11A and 11B) to the two RH finishing outlet headers (R-12) and the two RH outlet leads (R-13) to the hot reheat steam lines. The reheated steam from the reheat finishing section, now at design temperature, is returned to the intermediate pressure section of the turbine via the two hot reheat steam lines.

８ IV.2,3,4 Boiler operation description.doc

IV. 2. STEAM AND WATER FLOW SYSTEMS

Protection and Control As long as there is a fire in the furnace, adequate protection must be provided for the reheater elements. This is especially important during periods when there is no demand for steam, such as when starting up or shutting down the unit. Reheater drains and vents provide the means to boil off residual water in the reheater elements during initial firing of the boiler. Reheater safety valves, located on the cold and hot reheat piping, serve to protect the reheater should steam flow through the reheater be suddenly interrupted. During all start-ups, care must be taken not to overheat the reheater elements. The firing rate must be controlled to keep the furnace exit gas temperature from exceeding 1000°F (538°C). The temperature probe, located in the upper furnace side wall, should be used to measure the furnace exit gas temperatures (Refer to the General Arrangement Drawings for the temperature probe location). NOTE: Gas temperature measurements will be accurate only if a shielded, aspirated probe is used. If the probe consists of a simple bare thermocouple, there will be an error due to radiation resulting in a low temperature indication. At 1000°F (538°C) actual gas temperature, the thermocouple reading will be approximately 50°F (28°C) low. Unless very careful traverses are made to locate the point of maximum temperature, it is advisable to allow another 50°F (28°C) tolerance, regardless what type of thermocouple is used. NOTE: The 1000°F (538°C) gas temperature limitation is based on normal start-up conditions, where steam is admitted to the turbine at the minimum allowable pressure prescribed by the turbine manufacturer. Should turbine rolling be delayed and the steam pressure be permitted to build up, the gas temperature limitation should be reduced to 950°F (510°C) when the steam pressure exceeds two-thirds of the design pressure before steam flow through the turbine is established. Thermocouples installed on various reheater terminal tubes above the furnace roof serve to provide a continuous indication of element metal temperatures during start-up, and when the unit is carrying load. Refer to the Thermocouple Arrangement Drawings for location of permanent thermocouples. Steam temperature control is provided by means of windbox nozzle tilts and desuperheaters. Refer to appropriate sections elsewhere in the manual for details.

OPERATION

General Operation of the reheater is not independent of the rest of the boiler. Therefore, for detail ed operating procedures for this component, see Start-up procedure for Sipat project. However, the basic rules in the following paragraphs must always be followed.

９ IV.2,3,4 Boiler operation description.doc

IV. 2. STEAM AND WATER FLOW SYSTEMS Reheater It is essential that suitable arrangements are made to assure cleanliness of the external and internal surfaces of the reheater at all times. Fly ash and/or slag accumulations result in unequal gas distribution, inefficient heat transfer, and possible localized overheating. Suitably located soot blowers, operated in the proper cycle, normally provide adequate means of keeping surfaces clean. The external surfaces of the reheater should be inspected regularly for cleanliness. Slagging must be kept to a minimum by proper use of soot blowers. Extreme buildups must be removed immediately. Lancing with compressed air is often effective in slag removal. Local slagging may become a cause of overheating of element tubes possibly resulting in tube failures. Furthermore, it may restrict the gas flow causing uneven heat transfer and creating further operating difficulties. Proper feedwater treatment, and control of steam quality and carry-over are essential to assure cleanliness of interior surfaces of reheaters. Overloads, fluctuating load, high water level, foaming, high concentrations, etc., all contribute to deposits on interior surfaces. Accumulation of these deposits inside the tubes will lead to unit failure. Care must be taken to assure that condensate quality spray water is used for the desuperheaters to avoid carry-over of solids into the reheater and the turbine blades. Periodic checks of steam pressure drops across the reheater under identical load conditions usually indicate whether or not solid deposits are present within the elements. In the event of failure of one or more reheater elements, check carefully to determine the cause. Doosan Heavy Industries & Construction Co., LTD. may be consulted for repair procedures and proper means to prevent recurrence. All reheater drains and vents should be opened before lighting off. The vents and drains to the atmosphere must be closed prior to raising a vacuum in the condenser. Drains connecting with the condenser may be left open until the turbine is under light load.

１０ IV.2,3,4 Boiler operation description.doc

IV. 2. STEAM AND WATER FLOW SYSTEMS 4. REHEATER DESUPERHEATERS

DESCRIPTION Two spray-type reheater (RH) desuperheaters are installed in the connecting links R1 & R2 to permit reduction of steam temperature, when necessary, and to maintain the temperatures at design values, within the limits of the nozzle capacity. Temperature reduction is accomplished by spraying water into the path of the steam through a nozzle at the inlet end of the desuperheater. It is essential that the spray water be chemically pure and free of suspended and dissolved solids, containing only approved volatile organic treatment material, in order to prevent chemical deposition in the reheater and carry-over of solids to the turbine. CAUTION: During start-up of the unit, if desuperheating is used to match the outlet steam temperature to the turbine metal temperatures, care must be exercised so as not to spray down below a minimum of 20°F (11 °C) above the saturation temperature at the existing operating pressure. Desuperheating spray is not particularly effective at the low steam flows of start-up. Spray water may not be completely evaporated but be carried through the heat absorbing sections to the turbine where it can be the source of considerable damage. During start-up, alternate methods of steam temperature control should be considered. The location of the desuperheaters, at inlet of RH low temperature inlet header, help to ensure that water carry-over to the turbine does not occur. It also eliminates the necessity for high temperature resisting materials in the desuperheater construction.

CONTROL STATIONS NOTE: For desuperheater piping and valves, refer to the Process and Instrumentat ion Diagram T04019-PI-D0011. A pneumatically operated control valve linked to an automatic control drive regulates the flow of spray water on the main line supplied to each desuperheater. A manually operated isolation valve is located downstream of each control valve and pneumatic diaphragm type isolation valve is upstream of each control valve to permit isolation when required. There is spray water bypass line which is consisting of the same system as in the main line. These one manual and one pneumatic isolating valves around the automatic control valve should be used only in an emergency, or when the automatic control valve may require maintenance. A motor operated block valve is installed in the main supply line to the reheater desuperheater control stations as an additional shutoff valve. These block valves must be interlocked to close when the reheater desuperheater control valves are closed. The spray water control valves must be interlocked to close upon a turbine trip. Closing the block valve will prevent water from entering the reheater elements if a reheater spray water control valve should leak. Spray water for the reheater desuperheaters is normally taken from the boiler feed pump interstage manifold.

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IV. 2. STEAM AND WATER FLOW SYSTEMS

MAINTENANCE Each desuperheater is fitted with a renewable liner to take the wear of erosion from the spray water stream, thus protecting the main desuperheater shell. Excessive noise from within a desuperheater usually indicates a worn liner and the Service Department of this Company should be contacted when this or any such abnormal conditions may arise. Sufficient clearances should be provided around the desuperheaters for replacing liners.

BLOWOUT PROCEDURE FOR DESUPERHEATER SPRAY WATER LINES The spray water lines should be blown out before using the desuperheaters on a new unit and after repairs on the spray water lines have been made. They may also be blown when there appears to be any indication of plugging. Always have full pressure on the boiler when blowing out the desuperheaters. Each desuperheater should be blown out in the following sequence: 1. With the isolating valves closed, open the valves in the blowoff connection and then open the bypass valve for 1 minute. 2. With the bypass valve closed and the blowoff valves open, open the isolating valves and then open the control valve for 1 minute (from the control station). Close the isolating valves a nd the control valve but leave the blowoff valves open for another minute to clear the waste line before restoring the system to its operating status. NOTE: The blowoff valves should be installed close to the spray water piping and with no bends intervening, if possible.

１２ IV.2,3,4 Boiler operation description.doc

IV. 2. STEAM AND WATER FLOW SYSTEMS

REHEATER SCHEMATIC DIAGRAM R-13 R-9

R-12

R-10

R-8 R-11A

R-11B

R-7A

R-7

R-11

R-4,5,6

R-3

R-1 R-2

R-1A

R-1 R-2

R-1A R-10 R-13 R-4, 5, 6, 7, 7A

R-11,11A, 11B R-9

R-12

R-3

R-8

１３ IV.2,3,4 Boiler operation description.doc

IV. 2. STEAM AND WATER FLOW SYSTEMS 5. WATER WALL SYSTEM

FURNACE WALL WATER CIRCUIT In Once Through Supercritical Units, the boiler feed pumps ensure proper circulation of supercritical fluid through the furnace wall system. The flow path can be followed on P&ID Drawings T04019-PI-D0005, D0006 and D0007 for the economizer, evaporator, and water separator systems. The elements which make up the flow path are essentially numbered consecutively. Where parallel flow paths exist, first one and then the other circuits are numbered. Per Drawing T04019-PI-D0005, the supercritical fluid from the boiler feed water line (E-1) and inlet links (E-2) enters the unit through the economizer inlet header (E-3), flows through the economizer elements (E-4), to the four economizer junction headers (E-5) that are connected with the economizer outlet header (E-7) by four rows of 56 economizer hanger tubes (E-6). Two economizer outlet links (E-8) feed the economizer mixing link (E-9) and two economizer waterwall inlet links (E-10) to the furnace lower side wall headers (F-21). The furnace lower side wall headers (F-21) feed the furnace lower front wall (F-1) and rear wall (F-10) headers. From the furnace lower front, rear and side wall headers, the fluid rises through furnace spiral waterwall tubes where it absorbs heat and exits into the front, rear, and side wall intermediate headers (F-5, F-14, F-25). From the intermediate wall headers, the fluid enters the vertical wall circuitry where additional heat is absorbed. The front wall spiral tubes (F-3), rear wall spiral tubes (F-12), and side wall spiral tubes (F-23) form parallel flow paths between the furnace lower wall headers (F-1, F-10, F-21) and the furnace intermediate front, rear, and side headers (F-5, F-14, F-25) as does the front vertical wall tubes (F-7), rear wall vertical tubes (F-16) and side wall vertical tubes (F-27) between the intermediate wall headers and the upper outlet headers (F-8, F-19, F-28). The fluid collects in the upper outlet headers and is discharged through the front, rear, and side wall riser pipes (F-9, F-20, F-29) to the water separators (F-31). At loads above minimum once through load, the fluid then goes to the superheater system.

１４ IV.2,3,4 Boiler operation description.doc

IV. 2. STEAM AND WATER FLOW SYSTEMS

ECONOMIZER SYSTEM The function of the economizer is to preheat the boiler feedwater before it is introduced into the furnace waterwalls by recovering some of the heat of the flue gases leaving the boiler. The economizer is comprised of one section. The flow path and arrangement of the economizer circuits is shown on P&ID drawing T0419-PI-D0005 and the Pressure Part Arrangement drawings T04019-PA-A0100, A0101 and A0102. The economizer is located below the rear horizontal reheater assemblies in the lower section of the boiler back pass. It is composed of three banks of 163 parallel bare tube (50.8 mm O.D.) elements on 114.3 mm centers, arranged in horizontal rows in such a manner that each row is in line in relation to the row above and below. All tube circuits originate from the economizer inlet header, and discharge into four economizer junction headers that are connected with the economizer outlet header by economizer hanger tubes(70.0 mm O.D.). Per Drawing T04019-PI-D0005, the supercritical fluid from the boiler feed water line (E-1) and inlet links (E-2) enters the unit through the economizer inlet headers (E-3), flows through the economizer elements (E-4), to the four economizer junction headers (E-5) that are connected with the economizer outlet header (E-7) by four rows of 56 economizer hanger tubes (E-6). Two economizer outlet links (E-8) feed the economizer mixing link (E-9) and two economizer waterwall inlet links (E-10) to the furnace lower side wall headers (F-21). Feedwater is supplied to the economizer system via feed stop and check valves. The feedwater flow is upward through the economizer sections, that is, in counterflow to the hot flue gases. Most efficient heat transfer is thereby accomplished, while the possibility of steam generation within the economizer is minimized by the upward water flow.

OPERATION Operation of the economizer is not independent of the rest of the boiler. Therefore, operating procedures for the economizer are discussed in general under the Start-up procedure for Sipat project. The frequency with which soot blowers are used depends entirely on local conditions. When the economizer is first placed in operation, the economizer soot blowers should be blown about once every shift. Observation of the increase in draft loss between blowings will determine how long an interval may be set as a standard. In many cases, it has been found that blowing the economizer soot blowers once a day or less is sufficient. For further details, refer to the Soot Blowing Philosophy section located in the Steam and water flow system.

１５ IV.2,3,4 Boiler operation description.doc

IV. 3. AIR AND FLUE GAS FLOW SYSTEMS

TABLE OF CONTENTS TITLE

SECTION

1. AIR AND FLUE GAS SYSTEMS ......................................................................................................................1 AIR/GAS FLOW............................................................................................................................. 1 Secondary Air and Overfire Air - Combustion .......................................................................... 1 Flame Scanner Cooling Air ...................................................................................................... 1 Primary Air - Conveying and Drying of Pulverized Coal ......................................................... 2 Seal Air - Pulverizers and Coal Pipes...................................................................................... 2 Seal Air - Feeders..................................................................................................................... 2 FLUE GAS FLOW.......................................................................................................................... 3 OPERATIONAL PROCEDURES................................................................................................... 3 2. SCANNER AIR SYSTEM ...................................................................................................................................3 DESCRIPTION .............................................................................................................................. 3 SCANNER AIR .............................................................................................................................. 3 3. PULVERIZER SEAL AIR SYSTEM ..................................................................................................................4 INTRODUCTION ........................................................................................................................... 4 SEAL AIR TO PULVERIZERS....................................................................................................... 5 SEAL AIR FOR FEEDERS ............................................................................................................ 6 4. SOOT BLOWING PHILOSOPHY ....................................................................................................................7 INTRODUCTION ........................................................................................................................... 7 OPERATIONS ............................................................................................................................... 7 TYPES OF ASH DEPOSITS ......................................................................................................... 7 BLOWER LOCATIONS ................................................................................................................. 8 Furnace Walls .......................................................................................................................... 8 Superheater and Reheater Areas ............................................................................................ 8 Economizer and Air Preheaters ............................................................................................... 8

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IV. 3. AIR AND FLUE GAS FLOW SYSTEMS

5. LIST OF REFERENCE ENGINEERING DRAWINGS P&ID Diagram - Windbox & Burner Unit .............................................................................. T04019-PI-D0019 P&ID Diagram - Windbox Detail............................................................................................ T04019-PI-D0020 P&ID Diagram – Primary Air, Sealing & Cooling Air System ............................................... T04019-PI-D0021 Scanner Air System Piping Arrangement....................................................................T04019-SP-A001, A002 Suggested Pipe Supports .......................................................................................................T04019-SP-A003

ii IV.2,3,4 Boiler operation description.doc

IV. 3. AIR AND FLUE GAS FLOW SYSTEMS

1. AIR AND FLUE GAS SYSTEMS AIR/GAS FLOW Air and gas flow through the unit is handled by the two forced draft (FD) fans, two induced draft (ID) fans, and two primary air (PA) fans. Two scanner cooling air booster fans and two pulverizer seal air booster fans assure that air pressures are adequate to overcome resistance in their respective systems. The air is utilized for: 1.

Combustion - Secondary Air and Overfire Air.

2.

Cooling - Flame Scanners (Two Fans).

3.

Conveying and Drying of Pulverized Coal - Primary Air.

4.

Sealing - Pulverizers and Coal Pipes (Two Booster Fans).

5.

Sealing - Feeders.

Secondary Air and Overfire Air - Combustion The secondary air for combustion is preheated by means of two Ljungstrom bi-sector gas air preheaters, one for each set of FD and ID fans. The gas air preheater air inlet and outlet ducts are interconnected to provide an airflow to the furnace and to make it possible to operate the unit at reduced rating with only one set of fans and one gas air preheater in service. To assist in reducing the amount of NOx formed in the furnace, overfire air can be admitted to the furnace through the two upper levels of furnace main windbox Close Coupled Overfire Air (CCOFA) nozzles. Control of unit air flow is obtained by positioning the FD fan blade pitch and the ID fan blade pitch, while the distribution of secondary air to the windbox compartments is controlled by secondary air dampers. These are positioned by a sub-loop control system associated with the burner management system. Refer to the BMS supplier's instructions for details. The steam coil air heaters at the gas air preheater air inlets are used to control the gas air heater cold end temperature for corrosion control. Refer to the manufacturer's instructions.

Flame Scanner Cooling Air Flame scanner cooling air is supplied from atmosphere. Two numbers of scanner cooling air fan are supplied, one with AC motor and the other with DC motor. Either of two 100% fans serving the flame scanner air manifold can be used to supply the cooling air pressure required. A filter upstream of each of the fans helps to assure clean air for cooling. An alarm system should indicate when a filter requires service. Refer to Scanner Air System, at Air and Flue Gas System for details. A scanner fan should be in service whenever a fire is in the furnace and should be kept in service until the unit is shut down and the flame scanners are cooled to their acceptable high temperature limit.

1 IV.2,3,4 Boiler operation description.doc

IV. 3. AIR AND FLUE GAS FLOW SYSTEMS

Primary Air - Conveying and Drying of Pulverized Coal The air used to convey and dry the pulverized coal is referred to as primary air. Two primary air (PA) fans supply the air to the pulverizer primary air system. To assure proper drying in the pulverizers, both hot and cold air must be available; therefore, a portion of the air from the primary air fans passes through the bi-sector gas air heaters. Control of unit air flow is obtained by positioning the PA fan blade pitch, which is controlled to maintain a predetermined pressure in the pulverizer primary air ducts. The flow of air from the hot and cold air ducts is controlled by the hot and cold air control dampers at each pulverizer to deliver the necessary total primary air flow requirement for the pulverizer and also to maintain a predetermined outlet temperature. Refer to Pulverized Coal System, at Tilting Tangential Firing System and the BMS supplier's instructions for additional details.

If a PA fan is not available for service and the other fan is operating, it must be isolated from the system by closing its outlet shutoff dampers. The number of pulverizers in service is then limited. Refer to Operating Procedures, Start-up procedure, and the BMS supplier's instructions.

Seal Air - Pulverizers and Coal Pipes Seal air for the pulverizer bowl hub, journal assemblies, journal springs, and pulverizer discharge dampers is taken from the cold primary air duct to the pulverizers. Either of two 100% booster fans in the supply duct can be used to ensure a flow of air into the pulverizer openings under all normal operating conditions. A shutoff valve in the seal air duct at each pulverizer inlet can be closed when the pulverizer is out of service for maintenance. A mechanical filter upstream of the booster fans is used to remove dust, etc. from the air supply, thus assuring a clean air supply for the pulverizer bowl hub and journals. Refer to Pulverizer Seal Air System, Air and Flue Gas System for details.

A power operated valve in each purge air duct to the coal pipes operates in conjunction with the pulverizer discharge valves to provide a positive seal air pressure in the coal pipes when the discharge valves are closed.

Seal Air - Feeders Seal air for the feeders is taken direct from the cold air duct to the pulverizers. Feeder seal air prevents hot gases from the pulverizer from entering the feeder. A pneumatic operation shutoff valve in each feeder seal air duct makes it possible to isolate the feeders for maintenance.

2 IV.2,3,4 Boiler operation description.doc

IV. 3. AIR AND FLUE GAS FLOW SYSTEMS FLUE GAS FLOW Flue gases travel upward in the furnace and downward through the rear gas pass and separated with four gas ducts, two gas ducts lead to bi-sector primary gas air preheaters and the other two gas ducts lead to bi-sector secondary gas air preheaters. In the gas air preheaters, the residual heat of the flue gases is utilized to preheat the combustion and pulverizer primary air. From the bi-sector gas air preheaters, the gases pass through the precipitators, the ID fans, and to the stack.(Reference P&ID drawings : T-04019-PI-D0015, D0016)

OPERATIONAL PROCEDURES Shutoff dampers at each FD, PA fan outlet and ID fan inlet and outlet may be used to isolate the fans for maintenance. An gas air preheater may be isolated by closing the associated duct dampers. For operational procedures refer to Start-up procedure of this manual.

2. SCANNER AIR SYSTEM

DESCRIPTION The scanner air system is designed to provide adequate cooling air to the flame scanners under all normal operating conditions and to initiate corrective action or alarms under adverse operating conditions. The scanner air system consists of a series of ducts which supply air taken from cold secondary air crossover duct, boosted to the required pressure by either of two 100% scanner air fans, to the scanner cooling air manifolds at the tangential windboxes.

SCANNER AIR Either of the two 100% booster fans in the scanner cooling air system ensures an adequate supply of cooling air to the scanners during normal unit operating conditions. Two kinds of scanner air fan drives are installed, one is AC motor type and the other DC motor type. A supply of clean, cool air must be available to the flame scanners whenever the furnace temperature is above 140°F (60°C). CAUTION: With the furnace hot, all flame scanners must be removed from the furnace with loss of the scanner cooling air fans. An example could be a plant electrical power failure, with the boiler on line. A filter located upstream common duct for the scanner booster fans removes dust and dirt which may be introduced into the system from cold secondary air cross over duct. Differential pressure switches across the filters may be used to initiate "plugged" or "no filter" alarms. A differential pressure gauge may provide the operator with a local indication of the filter condition. It is recommended that pressure readings be taken and recorded immediately after a new filter is installed, and that periodic readings (at least once per shift) be taken 3 IV.2,3,4 Boiler operation description.doc

IV. 3. AIR AND FLUE GAS FLOW SYSTEMS thereafter to assist in establishing a filter cleaning schedule. The scanner fans must be powered from a reliable power source. As soon as the BMS is engaged, an alarm will appear and the primary scanner air fan will automatically receive a start command. This start command is initiated whenever the scanner air duct-to-furnace differential pressure is below the setting of the scanner fan control pressure switch [approximately 6 in. w.g. (152 mm H2O) pressure drop across the most remote scanners]. Once the minimum pressure is satisfied, the alarm will automatically reset and not activate unless the differential pressure drops below the set point. The initial low differential pressure will activate an additional alarm after a time delay of approximately 10 seconds, if the minimum differential pressure is not reached. After a start command, the primary fan must satisfy the minimum differential pressure within five seconds or the secondary fan is given a start command. If the secondary scanner fan satisfies the pressure requirement before the 10 seconds expires, the delayed alarm will not be activated. CAUTION: Scanner cooling air is very important. Should the secondary scanner air fan automatically start, it is important to quickly find the reason and resolve the problem. Either scanner fan can be started manually at the operator's discretion. The operator can also change which fan is the primary and which is secondary. The shutoff valve at each scanner fan inlet in conjunction with the closed flapper transfer damper isolates an idle fan. Scanner fan interlocks are described in the BMS instructions. Control panel indicators should provide scanner fan status.

3. PULVERIZER SEAL AIR SYSTEM INTRODUCTION Seal air for the pulverizer bowl hub, journal assemblies, journal springs and pulverizer discharge dampers is taken from the cold primary air duct to the pulverizers. Either of two booster fans in the supply duct can ensure a flow of air into the pulverizer openings under all normal operating conditions. A power operated shutoff valve in the seal air duct at each pulverizer can be closed when the pulverizer is out of service for maintenance. A power operated shutoff damper in the seal air line to the coal pipes is utilized to admit seal air to the coal pipes for cooling when the pulverizer is isolated. The seal air damper is open whenever the pulverizer discharge valves are closed and is closed whenever the pulverizer discharge valves are open. A mechanical filter upstream of the booster fans removes dirt and dust from the air, ensuring a clean air supply for the pulverizer. The pulverizer seal air shutoff valves are always kept wide open. They are closed only when a pulverizer is isolated for maintenance.

4 IV.2,3,4 Boiler operation description.doc

IV. 3. AIR AND FLUE GAS FLOW SYSTEMS

SEAL AIR TO PULVERIZERS An adequate supply of clean seal air for the pulverizer is provided by the two booster fans and the filter in the seal air system. One fan normally runs continuously, with the self-positioning, transfer damper directing flow from the operating fan. The non-operating fan may be isolated for maintenance by closing the associated manual inlet shutoff damper. The filter in this system is an inertial, separator-type which discharges approximately 90% of its input as clean air. A bleed-off system, with a control damper, returns the accumulated dirt and dust to the windbox hot secondary air connecting duct. The control damper regulates the amount of air being bled from the filter, so that the differential pressure between the filter air outlet and the filter bleed outlet is zero. Refer to Figure 1. The control damper should be installed so that the damper fails open with a loss of instrument air. Figure 1: Suggested Hook Up for Bleed Off Control Valve for Mechanical Filter

5 IV.2,3,4 Boiler operation description.doc

IV. 3. AIR AND FLUE GAS FLOW SYSTEMS SEAL AIR FOR FEEDERS Seal air for the feeders is also taken from the cold primary air duct to the pulverizers. A manually operated shutoff damper in each feeder purge air duct makes it possible to isolate a feeder for maintenance.

6 IV.2,3,4 Boiler operation description.doc

IV. 3. AIR AND FLUE GAS FLOW SYSTEMS

4. SOOT BLOWING PHILOSOPHY INTRODUCTION The soot blowing system for this unit has been designed on the basis of specific parameters. That is, in determining the number and type of blowers, blower location and operating sequences, the characteristics of the coal to be burned, the configuration of the heat-absorbing surfaces of the boiler and past experience with slagging tendencies in this type of unit, were taken into account. However, it is impossible to predict the performance of the soot blowing equipment for all operating conditions and for each individual unit. Factors such as variation in coal characteristics, load changes, fluctuations in furnace temperatures and air flow conditions can greatly affect the soot blowing requirements. Therefore, operation of the soot blowers must be continuously evaluated and reviewed on the basis of changing operating conditions. OPERATIONS Soot blowers are provided to fulfill a need. Operating practices should be modified as the needs change. For this reason, ample flexibility is provided in the system to enable manual selective operation in addition to fully automatic control. Intelligent use of the soot blower system offers the following advantages: 1. It can prevent troublesome accumulations of slag and ash deposits that, in turn, may cause additional unit operating problems. 2. It provides for maximum cleaning of the heat absorbing surfaces. In addition, minimizing the number of blowing cycles will save valuable blowing medium. More efficient, selective use of the equipment will result in reduced maintenance. There are several indicators of ineffective use of the soot blowing equipment, such as response of steam temperature control, changes in draft loss, etc. The best way to monitor the effectiveness of soot blowing is by frequent furnace observation. If operation of a blower or a series of blowers does not produce the expected results, the furnace area involved should be observed and the blower(s) in question checked. Blowing pressures should be checked periodically (approximately every six months) to determine whether they have changed from their initial effective settings.

TYPES OF ASH DEPOSITS To determine if proper cleaning is taking place, the operator should have a basic knowledge of the types of ash deposits that can build up in the various parts of the unit. Sintered or dust-like ash deposits or buildups are prevalent on convection surfaces, such as superheater and reheater elements, and in the back pass. Ash deposits can also form on the furnace walls if the furnace temperature is low, such as during low load operation. When an ash deposit fuses it is called "slag". Slag deposits usually

7

IV.2,3,4 Boiler operation description.doc

IV. 3. AIR AND FLUE GAS FLOW SYSTEMS occur on the furnace walls and other surfaces exposed predominantly to radiant heat and high furnace gas temperatures. Slag can appear in a variety of formations, depending on the composition of the ash and the temperature in the furnace. A change in the type of slag is usually an indication that either the coal has changed or that furnace conditions have changed. A reduction in excess air, for instance, or increased unit loads, will result in higher furnace temperatures; this will produce a more troublesome wet slag, or slag more difficult to control. Usually, dry slag can easily be removed by soot blowing. Molten slag is much more difficult to remove. Thin layers of molten slag are the most difficult to remove and often cannot be removed by conventional soot blowing. In order to remove thin layers of molten slag, it may be necessary to increase the excess air or lower the unit load in order to make the soot blowers effective. "Wet" or molten slag can be dangerous; it will drip down to the furnace bottom and accumulate. The accumulations can bridge and plug the furnace bottom.

BLOWER LOCATIONS Furnace Walls Blowing wall blowers in the furnace should remove accumulated slag from the walls. This will improve the furnace heat absorption and lower the gas temperature to the superheater and reheater. If the steam temperature controls are on automatic, the cleaning of the walls should cause the tilts to rise and/or spray water flow to decrease. Consequently, if blowing wall blowers has no effect, either the furnace is already clean or the soot blowers are only keeping pace with the slag formation.

Superheater and Reheater Areas Using the long retractable blowers in the convection superheater and reheater areas should remove accumulated surface deposits. This will improve heat absorption in these sections. If the steam temperature controls are on automatic, this should cause the tilts to lower and/or spray water flow to increase. Selective blowing of long, retractable blowers in the superheater and reheater zones can also be utilized to balance superheater and reheater outlet temperatures. In any case, draft loss across convection surfaces should be closely observed. Increased draft loss indicates an advanced plugging condition. If a plugging condition is allowed to progress too far, it may be impossible to clean the convection surfaces except by removing the unit from service for water washing.

Economizer and Gas Air Preheaters The economizer blowers and gas air preheater soot blowers should be blown to provide maximum unit efficiency consistent with reasonable blowing medium consumption. Constant blowing of the economizer and the gas air preheaters would assure that these surfaces stay clean, but the economics of blowing medium consumption, maintenance of equipment, and metal erosion rates must be considered. An "optimum medium" should be determined by observing the fouling rate, cost of blowing medium, and blowing effectiveness. Efficient use of soot blowers can help counter other operational problems with the unit. For instance, to increase the primary air temperature leaving the bi-sector primary air preheater (to improve drying of wet coal), it may be desirable to reduce soot blowing of the economizer in order to cause an increase of the flue gas temperature to the primary air preheater.

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IV.2,3,4 Boiler operation description.doc

IV. 3. AIR AND FLUE GAS FLOW SYSTEMS

Doosan Heavy Industries & Construction Co., LTD. Service Engineers may be consulted in determining which blowers should be blown, how often, and why. Generally, the best soot blowing policy is to determine the minimum amount of soot blowing required to keep the unit clean enough to avoid operational problems.

5. LIST OF REFERENCE ENGINEERING DRAWINGS Reference Drawing: P&ID Diagram - Windbox & Burner Unit ............................................... T04019-PI-D0019 Reference Drawing: P&ID Diagram - Windbox Detail............................................................. T04019-PI-D0020 Reference Drawing: P&ID Diagram – Primary Air, Sealing & Cooling Air System ................ T04019-PI-D0021 Reference Drawing: Scanner Air System Piping Arrangement.....................................T04019-SP-A001, A002 Reference Drawing: Suggested Pipe Supports ........................................................................T04019-SP-A003

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IV.2,3,4 Boiler operation description.doc

IV. 4. Tilting Tangential Firing System

TABLE OF CONTENTS

TITLE

Page No

DESIGN FEATURES ........................................................................................................................ 1 SYSTEM DESCRIPTION .................................................................................................................. 2 MAIN WINDBOX COMPONENTS.................................................................................................... 2 AIRFLOW CONTROL AND DISTRIBUTION ................................................................................... 4 CONTROL SYSTEM PHILOSOPHY ................................................................................................ 7 WINDBOX MAINTENANCE ............................................................................................................. 7

LIST OF FIGURE TITLE

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FIGURE 1. WINDBOX AND CCOFA ELEVATION DESIGNATIONS ............................................ 11 FIGURE 2. COAL COMPARTMENT-FUEL AIR DAMPER RAMP F(X) ........................................ 12 FIGURE 3. AUXILIARY AIR DAMPERS CHARACTERISTICS ..................................................... 13 FIGURE 4. CCOFA DAMPERS CHARACTERISTICS................................................................... 14 FIGURE 5. COAL COMPARTMENT ASSEMBLY ....................................................................... 15 FIGURE 6. EXPLODED VIEW EXTERNAL TILT DRIVE SHEAR PIN FAILURE MECHANISM ................................................................................................................................. 16

LIST OF REFERENCE ENGINEERING DRAWINGS TITLE (DRAWING NO.)

Page No

WINDBOX ARRANGEMENT SHEET 1 (T04019-WB-A001) ......................................................... 17 WINDBOX ARRANGEMENT SHEET 2 (T04019-WB-A002) ......................................................... 18 WINDBOX ARRANGEMENT SHEET 3 (T04019-WB-A003) ......................................................... 19 COAL NOZZLE TIP ........................................................................................................................ 20 OIL NOZZLE TIP ............................................................................................................................ 21 STRAIGHT AIR NOZZLE TIP(TOP, END) ..................................................................................... 22 STRAIGHT AIR NOZZLE TIP(AUX. AIR)....................................................................................... 24 STRAIGHT AIR NOZZLE TIP(CCOFA).......................................................................................... 25

i IV.2,3,4 Boiler operation description.doc

IV. 4. Tilting Tangential Firing System

DESIGN FEATURES The integrated firing system incorporates the following design features to reduce the total emissions: 1.

Secondary air staging

2.

Bulk furnace staging

3.

Early controlled coal devolatization

4.

Active Zone Stoichiometry Controls

Secondary Air Staging is accomplished by aux air nozzles incorporated into the integrated system. This local air staging technique is accomplished by re-directing a portion of the main windbox secondary air, horizontally away from the coal stream towards the waterwall, with offset auxiliary air nozzles, tangent to a larger diameter firing circle. With this arrangement, near burner stoichiometry is reduced as compared with non-concentric firing, minimizing the generated prompt NOx, while at the same time maintaining appropriate oxidizing conditions along the waterwall. Bulk Furnace Staging takes a portion of the combustion air, and injects this secondaryair above the main firing zone, diverting air away from the initial devolatization zone, retarding air and fuel mixing. Staged combustion minimizes NOx emissions with an initial fuel rich ignition zone, promoting the formation of N2 from volatile nitrogen species. In addition significantly staged combustion reduces the peak flame temperatures, resulting in lower thermal NOx. The firing system specifically incorporates two CCOFA compartments strategically located at the top of each main windbox. The CCOFA secondary airflow improves carbon burnout while assisting with the global NOx emission control. Early Controlled Coal devolatization is another important feature of the firing system which promotes early ignition of the coal at the nozzle tip. Initiating combustion early, at a point close to the coal nozzle tip produces a stable volatile matter flame, where the local stoichiometry and resultant "prompt NOx" can be better controlled. Specifically, the windbox fuel air dampers behind the coal compartments can be adjusted regulating the surrounding secondary air flow, matching the volatile matter local requirements while shaping and positioning the ignition point. These fuel air dampers will be fine tuned during unit commissioning to maintain the proper ignition points over the pulverizer load range. An initial curve for coal air damper position versus pulverizer feeder speed will be programmed into the secondary air damper control system (SADCS), and will either be confirmed or modified during initial commissioning of this unit. NOTE: It is important to be aware that siqnificant changes in the coal can change the ignition point location. When changing coals the operator must observe these ignition points and reposition the fuel air dampers accordingly.

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IV. 4. Tilting Tangential Firing System

SYSTEM DESCRIPTION In the tangential firing system, the furnace is considered to be the burner. Fuel and air are introduced into the furnace through windbox assemblies located in the furnace corners. The fuel and air streams from the windbox nozzles are directed toward concentric firing circles, swirling clockwise as viewed from above, in the center of the furnace. The cyclonic action that is characteristic of this type of firing is most effective in mixing the fuel and air through turbulence and diffusion, thereby completing combustion of the fuel within the prescribed furnace gas flow path. The windboxes are designed to distribute all of the supporting combustion air into the furnace through distinct zones: 1.

Primary air, which is the portion used to dry and transport pulverized coal from the pulverizers to the furnace.

2.

Fuel air, which is the portion of secondary air admitted to the furnace through air annulus around the fuel nozzles.

3.

Auxiliary air, which is the balance of the secondary air required to complete combustion. It is injected into the furnace through the air nozzles located between fuel elevations.

4.

Overfire air, which is a portion of secondary air admitted to the furnace through CloseCoupled Overfire Air (CCOFA) nozzles located in the main windbox above the top coal elevation. This technique produces staged combustion by introducing a portion of the secondary air above the primary firing zone, which in turn reduces the amount of available oxygen in the main combustion zone where NOx is generated. It is important to understand that the total quantity of combustion air being introduced to the furnace is not being changed; it is the distribution of the air that is changing.

MAIN WINDBOX COMPONENTS There are four main windboxes, one in each corner of the furnace. Each main windbox is 17,743 mm tall by 813 mm wide. Each main windbox assembly contains five oil elevations situated between six coal elevations. Refer to Figure 1 and Drawings T04019-WB-A001 thru T04019-WB-A003. Each main windbox is divided into 23 compartments. Partition plates form the top and bottom of each main windbox compartment, labeled alphabetically from bottom to top. Each of the 23 main windbox elevations has independent, secondary airflow damper controls. All main windbox nozzles are tied to a common tilt drive. The windbox nozzle tips tilt ± 30° from horizontal.

Bottom End Air Nozzles The bottom end air nozzle, designated as elevation AA, is located below the coal A nozzle. The bottom end air nozzle is a straight nozzle design. Refer to Drawing (Later).

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IV. 4. Tilting Tangential Firing System

Coal Nozzles Coal nozzles are located at elevations A, B, C, D, E, F, G, H, J and K. The coal nozzles are designed to promote early ignition at the nozzle tip. Refer to Drawing (Later).

Auxiliary Air Nozzles The auxiliary air nozzles are located between the coal elevations. Three different designs of auxiliary air nozzles are incorporated in the main windbox. Elevations AB, CD, EF, GH and JK contain straight air nozzles that also house the oil guns. Refer to Drawing (Later). Elevations BU, DU, FU and HU are also a straight air nozzle design. Refer to Drawing (Later).

Top End Air Nozzles The top end air nozzle, designated as elevation KU, is located above the coal K nozzle. This nozzle is a straight nozzle design. Refer to Drawing (Later).

Close-Coupled Overfire Air (CCOFA) The CCOFA nozzles, designated as elevations CCOFA-A and CCOFA-B, are straight nozzle design and are located on top of the main windbox. Refer to Drawing (Later).

Flame Scanners The flame scanners for coal or oil flame respectively are provided for flame supervision and supply "Flame" or "No flame" logic signals to the BMS. Flame scanners are located in the auxiliary air compartments at elevations AA, AB, BU, CD, DU, EF, FU, GH, HU, JK and KU.

High Energy Arc Ignitors The High Energy Arc (HEA) igniters provide the ignition source for the oil guns. The HEA igniters are located at elevations AB, CD, EF, GH and JK.

Oil Guns Steam atomized heavy oil guns are located at elevations AB, CD, EF, GH and IJ. The

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IV. 4. Tilting Tangential Firing System oil guns provide for warm-up and low load stabilization. The firing system for light oil with air atomized is designed to be used common at elevations AB only, which provide for cold start-up.

Air and Fuel Nozzle Tilts The air and fuel streams are vertically adjustable by means of the movable nozzle tips in each windbox compartment. The coal, oil, auxiliary air and CCOFA compartment nozzle tips can be positioned upward or downward through a total angle of 60 degrees (30 degrees up, 30 degrees down) tilt. The nozzle tip tilt position is the same in all four corners and within each windbox. The main windbox drive unit normally responds automatically to signals from the steam temperature control system, but may be positioned manually.

Tilt Stroking Recommendations The windbox tilt drive mechanism is subjected to harsh operating conditions that can adversely affect the operation of the system. In particular, dry or slogged ash may accumulate on or in the tilting nozzle tip, and can impede the tilting motion. Each tilt indicator is equipped with a shear pin and a locking pin. If tilt linkage movement is obstructed, the shear pin will break and the spring-loaded locking pin will be released, keeping the tilt angle at its present position. All tilt linkages should be kept in an unobstructed condition to prevent failure. Accumulations usually occur at compartments taken out of service for extended periods of time. With only minimal leakage airflow through these out-of-service, closed damper compartments, fly ash can build up around the nozzle. Therefore, it is strongly recommended the tilt drive mechanism of each windbox be manually stroked at least once per day. This should be accomplished one corner at a time. After noting the current tilt position, the operator should stroke the nozzle tips down to at least -20°, then reverse the stroke and tilt up to at least +20°. The tilts should then be returned to the starting position and released to automatic control. The same procedure should be followed for each successive corner. During the stroking procedure, the tilt action at each corner should be observed to note any erratic motion, unusual noise, or shear pin breakage. In the event of shear pin failure, an identical replacement pin should be installed and the tilts stroked again.

AIRFLOW CONTROL AND DISTRIBUTION Total airflow control to the boiler is accomplished by regulating the forced draft fan dampers. Combustion air distribution is accomplished by means of the individual windbox compartment secondary air dampers. This secondary airflow is labeled as fuel air, auxiliary air, or OFA. In order to ensure safe light-off conditions, the pre-operational purge airflow (at least

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IV. 4. Tilting Tangential Firing System 30% of full load airflow) is maintained during the entire warm-up period until the unit is on the line and the boiler load has reached the point where the airflow must be increased to accommodate further load increase. To provide proper air distribution for purging and suitable air velocities for lighting off, all auxiliary air dampers should be open during the purge, light-off and warm-up periods. After the unit is on the line, the total required amount of air (total airflow) is a function of the unit load. Proper airflow at a given load depends on the characteristics of the fuel fired and the amount of excess air required to satisfactorily burn the fuel. Excess air can best be determined through flue gas analysis. NOTE: The excess air values indicated on the predicted performance data sheet is theoretical, and used as a basis for performance calculations. These figures should be used as an initial guide. The optimum amount of excess air for a particular unit, at a given load and with a given fuel must be determined by experience. This is best accomplished by observing furnace slagging conditions. Slagging tendency of a particular fuel may dictate an increase of operating excess air. Windbox Airflow Distribution Total airflow control to the boiler is accomplished by regulating the forced draft fan blade pitch. Combustion air distribution is accomplished by means of the individual windbox compartment secondary air dampers. This secondary airflow is labeled as fuel air, auxiliary air or overfire air. Fuel air is admitted through operating coal or oil elevations compartment dampers, while auxiliary air is admitted between, below and above these operating coal elevations. Auxiliary air flows through eleven(11) elevations, when adjacent or between an operating fuel elevation. There are 3 groups distinctly different types of windbox compartment dampers as below : 1. Coal Fuel Air Dampers

A, B, C, D, E, F, G, H, J, K

* Oil Fuel Air Dampers

AB, CD, EF, GH, JK (Oil firing only)

2. Aux. Air Dampers

AA, AB, BU, CD, DU, EF, FU, GH, HU, JK, KU

3. Overfire Air Dampers

CCOFA-A, CCOFA-B

Proper secondary air distribution is important for ignition stability when lighting off individual fuel nozzles, firing at low loads, maintaining the furnace O2 balance, and achieving optimum low NOx combustion conditions. Secondary air is admitted to the fuel air, auxiliary air and overfire air compartments through sets of opposed blade – louvered dampers. These windbox compartment dampers are used to proportion the amount of secondary air admitted to fuel, auxiliary and OFA elevations. By varying the windbox compartment damper position, the air distribution is affected as

5

IV.2,3,4 Boiler operation description.doc

IV. 4. Tilting Tangential Firing System follows. z Opening the fuel air dampers or closing the auxiliary air dampers increases the airflow around the fuel nozzle z Closing the fuel air dampers or opening the auxiliary air dampers decreases the airflow directly around the fuel stream

Coal Elevation Dampers When firing coal, initially the fuel air damper positions are closed when placing the feeder in service, and are released to the control system after 50 seconds. Under normal operation, the SADCS controls these fuel air dampers based on the associated mill feeder speed. Initially, these field fine tuned set positions are set-up with 30% open at minimum (25%) feeder speed and linearly ramped to 80% open at 60% feeder speed. Between 60% feeder speed and 100% feeder speed, the fuel air dampers remain wide, 80% open. Refer to Figure 2. These fuel air dampers will be fine-tuned during unit commissioning to maintain the proper ignition points over the pulverizer load range.

NOTE : It is important to be aware that significant changes in the coal can change the ignition point location. When changing coals the operator must observe these ignition points and reposition the fuel air dampers accordingly.

Auxiliary Elevation Dampers During start-up and low load operation (below 30%), all auxiliary air dampers are released to maintain the windbox-to-furnace differential pressure, at 1.5" wg whether or not they are adjacent to an in service fuel elevation. Above 30% load, the windbox-tofurnace differential pressure is linearly ramped to 2.5" wg at 50% load, and then linearly ramped to 4" wg at 60% load. At unit loadings above 60%, the differential pressure is normally maintained at 4" wg. Refer to Figure 3.

Oil Elevation Dampers When an oil elevation is in service for warm-up or stabilizing the adjacent coal compartment, the center oil compartment fuel air damper is opened to a pre-set, 50% open fixed position after the third oil gun is placed in service. Like the coal fuel air dampers, these oil fuel air damper set points are field fine tuned as needed. NOTE: When lighting off an elevation on manual control, the auxiliary air dampers should be opened 20% to 40% prior to light off and kept at this position until the fuel air dampers are open. The fuel air dampers should be closed when lighting off an elevation. Once ignition of the main fuel is established, the fuel air dampers should be opened in proportion to the fuel elevation firing rate. When the fuel air dampers are fully open, further damper adjustments should be made, if necessary, with the auxiliary air dampers only. When changing damper

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IV.2,3,4 Boiler operation description.doc

IV. 4. Tilting Tangential Firing System positioning, an entire elevation should be treated simultaneously (damper positioning at the same elevation should be identical in all windboxes).

Overfire Airflow Control OFA flow control is key to minimizing NOx emissions. The OFA flow control system consists of two CCOFA elevations located at the top of the main windbox. The secondary airflow through all OFA elevations are independently controlled with pneumatically operated opposed blade dampers. CCOFA flow control is key to minimizing NOx emissions. The secondary airflow through all CCOFA elevations is independently controlled with pneumatically operated dampers. The CCOFA flows through the top two main windbox elevations and the CCOFA air dampers ramp open with total unit airflow. The lower CCOFA-A elevation dampers will step from 0% to 20% open at 30% unit airflow, linearly ramp to 80% open at 40% unit airflow, and continue along the same ramp till the actuator reaches 100% open. Likewise the upper CCOFA-B elevation dampers will step from 0% to 20% open at 43% unit airflow, ramp to 100% open at 60% unit airflow, and unit air flow at 60% above, the damper is normally maintained 100% open, as shown below. Refer to Figure 4.

CONTROL SYSTEM PHILOSOPHY The typical SADCS OFA damper logic is typically indexed on total unit airflow. Under this scheme, preset, fixed CC-OFA compartment damper ramps were assigned, field fine tuned as necessary, and implemented. This control philosophy was usually more than adequate to meet steady state, full load NOx requirements. Overfire air damper control is key to maintaining consistent NOx emissions. But, with existing, typical OFA damper control logic, the quantity of in-furnace produced NOx changes significantly throughout the entire boiler operating envelope. Specifically, at full load, the unit airflow would be at 100% capacity, and OFA compartments would be in service. As total unit airflow diminished, these OFA dampers would be sequentially closed from the top down, until at 40% or 50% unit airflow, OFA dampers would be typically closed. In other words, as the unit total airflow followed a reduction in boiler load, the OFA flow diminishes, resulting in an increase in NOx emissions. Simultaneous with this reduction in total OFA flow, as boiler load is reduced other operational factors also influence the NOx emissions.

WINDBOX MAINTENANCE Maintenance on windbox assemblies consists mainly of replacement of adjustable nozzle tips and adjustment of tilting mechanism.

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IV. 4. Tilting Tangential Firing System

Auxiliary Air Nozzle Tips

The auxiliary air nozzle tips are replaced from the furnace side as follows:

1.

Remove the side windbox access panels.

2.

Ensure that the tilt mechanism is in the horizontal position and locked in place with the maintenance pin.

3.

From the furnace side, secure the nozzle do in place utilizing blocks and rope.

4.

Disconnect the nozzle adjusting link at the internal bell crank from the side access panel.

5.

Grind away the tack welds on the clamping bolts and remove the two clamping bolts and the nozzle pivot pin support block retainer caps.

6.

The old nozzle can now be removed with the adjusting link attached. The nozzle adjusting link is removed from the nozzle by grinding away the pin weld.

7.

Reinstall the nozzle adjusting link on the new nozzle and weld the pivot pin to the nozzle body.

8.

Install the nozzle in the windbox, positioning the nozzle pins in the support blocks. Install the pivot pin retainer caps and bolts and nuts. Tack weld the clamping bolt to the retainer cap and to the nut.

9.

Check the nozzle tip clearances. Clearances around the adjustable nozzle tips should be 38mm between the tips and compartment plates, and 1/2" (13 mm) on the sides between the tips and channels.

10.

Reconnect the nozzle adjusting link and install the windbox access doors.

11.

Remove the maintenance pin.

Coal Nozzle and Nozzle Tip The coal nozzle tips can be replaced from the windbox front as follows:

1.

Provide support to the coal piping and remove the coal pipe elbow.

2.

Remove the stud nuts from around the rectangular panel at the front of the windbox and side the access panels. Refer to Figure 5.

3.

Ensure that the tilt mechanism is in the horizontal position and locked in place with the maintenance pin.

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IV. 4. Tilting Tangential Firing System

4.

From outside the windbox, remove the pin "C" clip from between the vertical tilt link and the horizontal positioning plate. Refer to Figure 6.

5.

Temporarily wedge a wooden block between the stationary nozzle and nozzle tip.

6.

Loosen the two alien set screws and slide the bell crank and adjusting lever off the drive shaft. Refer to Figure 6. Wire the bell crank and lever to the stationary coal pipe.

7.

Slide the drive shaft outward until flush with the windbox plate. Refer to Figure 6.

8.

Loosen upper or lower jacking bolts on front coal nozzle supports (left and right). Refer to Figure 5.

9.

The complete coal nozzle assembly may now be pulled out through the front of the windbox.

10.

Inspect both the stationary nozzle and nozzle tip.

11.

The nozzle tip can be replaced by removing the nozzle tip pivot pins.

12.

Upon completion of maintenance, reinstall the nozzle assembly and using the jacking bolts, center the nozzle assembly. Make sure that a 1/2" (13 mm) minimum clearance is maintained between the nozzle tip and the compartment partition plate at the top and bottom and a 1/2" (13 mm) minimum is maintained on each side. Refer to Figure 5.

13.

Reinstall the drive shaft and install the "C" clip on the pin between the vertical tilt link and the horizontal positioning plate. Refer to Figure 6.

14.

Reinstall the bell crank with adjusting lever attached. Using two shims, set a 1/16" (1.58 mm) gap between the bell cranks and frame inside and outside the windbox. Refer to Figure 6.

15.

Tighten the two allen-set screws and remove the shims.

16.

Remove any wedge from between the stationary nozzle and nozzle tip.

17.

Tighten the jack bolt jam nuts.

18.

Reinstall the access plates, stud nuts, and coal pipe elbow.

19.

Remove the maintenance pin.

Adjustment of Tilt Linkage 1.

Inspect the tilt linkage to ensure components are in good condition. Run the tilts through the full range and check that there is no interference with other components, such as the building steel, platforms, and piping.

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IV.2,3,4 Boiler operation description.doc

IV. 4. Tilting Tangential Firing System 2.

Check the tilt positions at +30, -30, and return to horizontal position. Using the maintenance pin, lock the tilts in place.

3.

Inspect the tilt indicator and pointer for proper relationship with the tilting nozzles.

4.

Inspect the locking pin mechanism.

5.

Inspect the shear pin for deformation. Make sure to install the correct shear pin.

6.

Inspect the tilt drive lever.

7.

Check the adjustable nozzle tip angles from inside the furnace to ensure they are in the horizontal position (±1-1/2°).

8.

Adjustment of the individual nozzle tilt position is achieved by turning both the upper and lower jacking bolts on the external drive levers. Tighten the jam nuts upon final adjustment.

9.

When all compartments have been adjusted for horizontal position, run tilts through full range again.

10.

Check the tilt position at extreme angles and return to horizontal.

11.

Remove the maintenance pin.

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IV. 4. Tilting Tangential Firing System

OVERFIRE AIR CCOFA-B OVERFIRE AIR CCOFA-A TOP END AIR-KU COAL NOZZLE TIP-K AUXILIARY AIR / OIL-JK COAL NOZZLE TIP-J

AUXILIARY AIR-HU COAL NOZZLE TIP-H AUXILIARY AIR / OIL-GH COAL NOZZLE TIP-G

AUXILIARY AIR-FU COAL NOZZLE TIP-F AUXILIARY AIR / OIL-EF COAL NOZZLE TIP-E AUXILIARY AIR-DU COAL NOZZLE TIP-D AUXILIARY AIR / OIL-CD

COAL NOZZLE TIP-C AUXILIARY AIR-BU COAL NOZZLE TIP-B AUXILIARY AIR / OIL-AB

COAL NOZZLE TIP-A BOTTOM END AIR-AA

Figure 1. Windbox Elevation Designations

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IV. 4. Tilting Tangential Firing System

80

DAMPERS % OPEN

30

25

100

60 COAL FEEDER SPEED RATE(%)

Figure 2. Coal Compartment-Fuel Air Damper Ramp f(x)

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IV. 4. Tilting Tangential Firing System

100 WINDBOX TO FURNACE ^P

63

(mm WG) 37

30

50

60

100

UNIT LOAD (%)

Figure 3. Auxiliary Air Dampers Characteristics

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IV. 4. Tilting Tangential Firing System

100

OVERFIRE

80

AIR

CCOFA-A

DAMPER OPENING (%)

CCOFA-B

20

30

35

40

43

60

100

UNIT AIR FLOW (%)

Figure 4. CCOFA Dampers Characteristics

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IV. 4. Tilting Tangential Firing System

Figure 5. Coal Compartment Assembly 15

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IV. 4. Tilting Tangential Firing System

Figure 6. Exploded View External Tilt Drive Shear Pin Failure Mechanism 16

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IV. 4. Tilting Tangential Firing System

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IV. 4. Tilting Tangential Firing System

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IV. 4. Tilting Tangential Firing System

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IV. 5. DESIGN DATA AND CONTRACT DATA SHEET

LIST OF DATA SHEETS

TITLE

SHEET NO.

Design Data And Contract Data Sheet.............................................................................................. 1 Predicted Performance Data (BMCR, TMCR, 80% TMCR & 60% TMCR) .................................. 2 Predicted Performance Data (50%TMCR, 30% TMCR & Both HP Heaters Out) ........................ 3

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IV.5 Design and Contract Data Sheet.doc

IV. 5. DESIGN DATA AND CONTRACT DATA SHEET

Doosan Heavy Industries & Construction Co., LTD. Boiler Basic Design Department TO:

CONTRACT DATA SHEET CONTRACT DATA SHEET Contract No. T04019

Page 1 of 1

File alphabetically Destroy sheet dated: Contract Date : 2004.04.15

NTPC Limited PURCHASER NTPC Limited USER PLANT NAME : Sipat Stage-I Super CONS. ENGR: NTPC Limited Thermal Power Plant Units 1, 2 & 3 272.9 kg/cm2 (g) BOILER P DESIGN: R OPER @ SHO: 255 kg/cm2 (g) DESIGNATION: Once-Thru Super-critical, Two-pass, E Balanced draft, Outdoor S TURB. THROTTLE: 246 kg/cm2 (g) 440 Spiral Wall Tubes of 38.0 mm OD @ 50 mm spacing S 1,320 Vertical Wall Tubes of 34.0 mm OD @ 56 mm spacing TYPE OF BOTTOM: WIDTH 18,816 mm DEPTH 18,144 mm. FURNACE VOL.: m³, 21,462 Coutant TYPE: Multi-stage SUPERHEATER TYPE: Multi-stage with panel, Platen and REHEATER pendant sections TYPE Bare tube, Inline, Counter flow; 4 banks; 163 Asslys; Tube O.D 50.8 mm ECONOMIZER M A K E : Doosan Heavy Industries & TYPE: Regener PRI: 2 Nos. 26-VI-1800 AIR HEATER Construction Co, Ltd ative, Bi-Sector SEC: 2 Nos. 31.5-VI-1900 FUEL BURNING Vertical Bowl Mills 10 Nos. XHPS 1103; 10 Nos. 36 inch Gravimetric Feeders; Tilting tangential, Corner Windbox with CCOFA EQUIPMENT Design Coal ASH FUSION GRINDABILITY HHV FUEL TEMP., °C HGI Kcal/Kg C=34.46%, H2=2.43%, N2=0.69%, 02=6.64%, S=0.45% I.D.T – 1,150 50 3300 Ash=43.00%, Moisture=12.00%, VM 21.00% OPERATINGCONDITIONS BMCR

SH CONTROL POINT 50%TMCR

STEAM FLOW

SUPERHEATER, kg/hr 2225,000 963,760 REHEAT, kg/hr 1741,820 836,410 STEAM TEMP. SUPERHEATER, °C 540 540 REHEATER, °C 568 568 REHEAT ENTERING TEMP, °C 299 289 2 DATA 46.3 22.6 ENTERING PRESS Kg/cm (g) FEED WATER TEMPERATURE, °C 289.64 244.34 TEMP. AIR TO AIR HEATER Pri / Sec, °C 34.7/30.9 42/41.6 TEMP GAS LVG AIR HEATER (Uncorr.) Pri / Sec, °C 144/137 124/118 BOILER EFFICIENCY, % 86.28 86.85 SUPPLEMENTARY DATA DRAFT SYSTEM: 2 Nos. Two stage, Const. Speed, GENERATOR Variable pitch, Axial PA Fans; 2 Nos. Const. Speed, Axial FD KW and 2 Nos Const. Speed, Axial ID Fans with Motor Drives. 660,000 BCP: 1 No. Glandless pump with Motor Drive

1

PLANT 282.5 m Above MSL.

IV.5 Design and Contract Data Sheet.doc

IV. 5. DESIGN DATA AND CONTRACT DATA SHEET

Doosan Heavy Industries & Construction Co., LTD

Predicted Performance Sheet For Instruction Manual

Page 1 of 2

Customer: NTPC Limited Station : Sipat Stage-I, 3x 660 MW STPP

PREDICTED PERFORMANCE Load Fuel Main Steam Flow Feedwater Temperature Superheater Outlet Temp.

kg/hr °C °C

Superheater Outlet Press. kg/cm2(g) ( 2 Press. Drop Econ Inlet Conn. To SHO Conn. kg/cm Reheater Flow kg/hr Reheater Inlet Temp. °C Reheater Inlet Press. kg/cm2(g) Reheater Outlet Temp. °C Reheater Outlet Press. kg/cm2(g) Reheater Press. Drop kg/cm2 Gas Drop, Furnace to Econ. Outlet mm. w.g. Gas Drop, Econ. Outlet to A.H. Outlet mm. w.g. Gas Temp. Ent. Air Heater °C Gas Temp. Lvg. Air Heater, Uncorr. - Pri/Sec °C Gas Temp. Lvg. Air Heater, Corr. - Pri/Sec °C Air Temp. Ent Air Heater - Pri/Sec °C Air Temp. Lvg. Air Heater - Pri/Sec °C Air Press. Ent. Air Heater Pri/Sec mm. w.g. Ambient Air Temp. °C Excess Air Lvg. Econ. %

Cont. No. : T04019

BMCR

TMCR

80%TMCR 60%TMCR

Design Coal

Design Coal

Design Coal

Design Coal

2,225,000 289.64 540 255 49.2 1,741,820 299 47.3 568 45.61 1.69 94 84 322 144/137 133/131 34.7/30.9 295/296 874/200 27 20

2,023,750 286.23 540 253.45 39.45 1,678,370 296 45.7 568 44.08 1.62 85 80 317 143/136 132/130 34.4/30.6 291/293 851/182 27 20

1,572,470 270.35 540 237.01 24.09 1,328,960 281 36.2 568 34.9 1.30 69 62 298 134/127 122/120 34/30.3 275/277 828/152 27 20

1,158,410 254.09 540 178.42 16.48 996,950 286 27.10 568 26.08 1.02 57 45 279 124/118 111/111 33.9/33.0 258/261 798/131 27 23.4

Fuel Fired

kg/hr

471,800

438,100

354,900

272,400

Efficiency

%

86.28

86.29

86.69

86.88

* NOTES: • These performance figures are predicted only and are not to be construed as being guaranteed except where the points coincide with the guarantees. • Operation of this unit in excess of the above specified Maximum Continuous Rating (MCR) may result in damage to the equipment and/or increased maintenance. • Superheat steam temperature control range is from 2,225,000 (BMCR) to 963,760 (50%TMCR) kg/hr. • Reheat steam temperature control range is from 1,741,820 (BMCR) to 836,410 (50%TMCR) kg/hr. • The fuel specifications on which the guarantees are based are as follows: Design Coal: C=34.46%, H2=2.43%, N2=0.69%, 02=6.64%, S=0.45%, Ash=43.00%, Moisture=12.0%, VM= 21.00%

2

IV.5 Design and Contract Data Sheet.doc

IV. 5. DESIGN DATA AND CONTRACT DATA SHEET

Doosan Heavy Industries & Construction Co., LTD Customer: NTPC Limited

Predicted Performance Sheet For Instruction Manual Station : Sipat Stage-I, 3 x 660 MW STPP

PREDICTED PERFORMANCE Load

Cont.No. : T04019

BOTH HP HEATE 50% TMCR 30% TMC RS OUT R Design Coal Design Co Design Coal

Fuel Main Steam Flow Feedwater Temperature Superheater Outlet Temp.

Page 2 of 2

kg/hr °C °C

Reheater Inlet Press. kg/cm2(g) Reheater Outlet Temp. °C Reheater Outlet Press. kg/cm2(g) Reheater Press. Drop kg/cm2 Gas Drop, Furnace to Econ. Outlet mm. w.g. Gas Drop, Econ. Outlet to A.H. Outlet mm. w.g. Gas Temp. Ent. Air Heater °C Gas Temp. Lvg. Air Heater, Uncorr. – Pri / Sec °C Gas Temp. Lvg. Air Heater, Corr. – Pri / Sec °C Air Temp. Ent Air Heater – Pri / Sec °C Air Temp. Lvg. Air Heater – Pri / Sec °C Air Press. Ent. Air Heater-- Pri / Sec mm. w.g. Ambient Air Temp. °C Excess Air Lvg. Econ. %

963,760 244.34 540 150.25 15.25 836,410 289 22.6 568 21.72 0.88 50 35 265 124/119 111/111 42/41.6 249/249 821/146 27 24

596,100 219 540 92.9 7.2 517,200 294 13.6 540 13.03 0.57 41 22 234 125/121 110/111 57/55.5 222/222 772/119 27 26.7

1,839,500 196.15 540 251.92 29.68 1,784,200 309 49.5 568 47.8 1.70 88 103 251 118/115 111/110 51/49.6 223/229 972/275 27 20

Fuel Fired

kg/hr

231,100

147,300

463,100

Efficiency

%

86.85

86.24

87.31

Superheater Outlet Press. kg/cm2(g) Press. Drop Econ Inlet Conn. To SHO Conn. kg/cm2 Reheater Flow kg/hr Reheater Inlet Temp. °C

* NOTES: • These performance figures are predicted only and are not to be construed as being guaranteed except where the points coincide with the guarantees. • Operation of this unit in excess of the above specified Maximum Continuous Rating (MCR) may result in damage to the equipment and/or increased maintenance. • Superheat steam temperature control range is from 2,225,000 (BMCR) to 963,760 (50%TMCR) kg/hr. • Reheat steam temperature control range is from 1,741,820 (BMCR) to 836,410 (50%TMCR) kg/hr. • The fuel specifications on which the guarantees are based are as follows: Design Coal: C=34.46%, H2=2.43%, N2=0.69%, 02=6.64%, S=0.45%, Ash=43.00%, Moisture=12.0%, VM= 21.00%

3

IV.5 Design and Contract Data Sheet.doc

IV. 6. PRESSURE PARTS ARRANGEMENT SKETCH

TABLE OF CONTENTS

PAGE NO.

TITLE

Pressure Part Schedule and data ……..……………………………………………………………………... 1 Pressure Part flow diagram………………………………………………………………………………2

i

IV.6 Pressure parts Arrangement and flow diagram-cover.doc

Pressure Part Sketch and Performance Data Superheater Platen Tube Material

Reheater Final Tube

SA213-T12

Material

SA213-T23 50.8 x 6.6, 50.8 x 7.3 60 / 896

Bank Depth, mm

2,460.

Gas Temp.(Inlet/Outlet), ℃ Max. Avg. Gas Velocity, m/s

Tube Spec.

42.2 x 5.5, 42.2 x 5.8

70.0 x 4.0 SL/ST, mm

127 / 448

Bank Depth, mm

3,683.

42.2 x 6.4, 42.2 x 6.6 SL/ST, mm

85 / 336

Bank Depth, mm

2,805 x 2 Bank

Gas Temp.(Inlet/Outlet), ℃ Max. Avg. Gas Velocity, m/s

988 / 874 8.7

Gas Temp.(Inlet/Outlet), ℃ Max. Avg. Gas Velocity, m/s

100.3

Heat Absortion, x106 kcal/h

106.4

Heat Absortion, x106 kcal/h

855 / 727 8.7 107.1

18,256

26,144

Superheater Division Panel Tube Material

SA213-T92

63.5 x 4.4, 63.5 x 4.6

8

1,078 / 988

6 Heat Absortion, x10 kcal/h

SA213T-23 SA213-T91

Super304H Tube Spec.

50.8 x 8.5, 50.8 x 10.0 SL/ST, mm

Material

SA213-T91

SA213-T91 Tube Spec.

Superheater Final Tube SA213-T23

Low Temperature Reheater Tube

SH Fin.

SA213-T23

Material

SA210-C

SA213-T91 Tube Spec.

SA213-T12

44.5 x 5.4, 44.5 x 5.9

SH Div. Panel

44.5 x 6.1, 44.5 x 7.0 SL/ST, mm Bank Depth, mm

SH Platen

Tube Spec. SL/ST, mm

54 / 2688 4,266 x 2 Bank

Gas Temp.(Inlet/Outlet), ℃

1,333 / 1,078

Heat Absortion, x106 kcal/h

149.2

SA213-T23 63.5 x 3.4

RH Fin

127 / 168

Bank Depth, mm Low Temp. RH

73,885

2,222.5 x 3 Bank

Gas Temp.(Inlet/Outlet), ℃ Max. Avg. Gas Velocity, m/s

721 / 489

Heat Absortion, x106 kcal/h

168.7

Economizer

Economizer Tube Material

SA210-C

Tube Spec. SL/ST, mm

50.8 x 6.5

Bank Depth, mm 18,144

10,356 55

o

9.2

102 / 114.3 1734 x 4 Bank

Gas Temp.(Inlet/Outlet), ℃ Max. Avg. Gas Velocity, m/s

489 / 322

Heat Absortion, x106 kcal/h

140.9

7.9

SH/RH/ECO Performance & Arrangement Sketch along with Material Data R-13

Reheater Outlet Leads

2

660.4

21.5

SA335-P91

53.4

573.0

R-12

Reheater Final Outlet Header

2

812.8

42.4

SA335-P91

53.4

573.0

76.2

4.0

SUPER304H

53.4

615.6

70.0

4.0

SUPER304H

53.4

606.1

63.5

3.4

SUPER304H

53.4

602.2

63.5

3.6

SA213-T91

53.4

582.2

57.0

3.6

SA213-T91

53.4

562.8

70.0

4.0

SUPER304H

53.4

642.9

63.5

3.4

SUPER304H

53.4

634.0

63.5

3.6

SA213-T91

53.4

591.2

63.5

3.4

SA213-T23

53.4

537.9

76.2

4.0

SA213-T23

53.4

456.7

70.0

4.0

SA213-T23

53.4

456.7

63.5

3.4

SA213-T23

53.4

456.7

50.8

3.4

SA213-T23

53.4

456.7

R-11B

Reheater Final Outlet Term. Tubes

R-11

Reheater Final Tubes

R-11A

Reheater Final Inlet Term. Tubes

615

615

615

R-10

Reheater Final Inlet Header

1

609.6

29.3

SA335-P12

53.4

462.1

R-9

Links to Reheater Final Inlet Header

2

711.2

18.8

SA335-P12

53.4

462.1

R-8

Low Temperature Reheater Outlet Header

1

711.2

31.1

SA335-P12

53.4

462.1

R-7A

Low Temperature Reheater Outlet Term. Tubes

111

63.5

3.4

SA213-T12

53.4

514.4

63.5

3.4

SA213-T23

53.4

536.2

R-4,5,6,7

Low Temperature Reheater Tubes

111

63.5

3.4

SA213-T12

53.4

504.6

63.5

3.4

SA210-C

53.4

404.6

R-3

Low Temperature Reheater Inlet Header

1

508.0

21.0

SA106-C

53.4

327.3

R-2

Reheater Inlet Leads

2

660.4

16.5

SA106-C

53.4

304.3

R-1

Reheater Desuperheater

2

660.4

22.8

SA106-C

53.4

304.3

R-1A

Reheater Inlet Leads

2

660.4

16.5

SA106-C

53.4

304.3

S-37

Superheater Final Outlet Leads

2

457.2

57.0

SA335-P91

272.9

545.0

S-36

Superheater Final Outlet Header

2

457.2

64.8

SA335-P91

272.9

545.0

42.2

6.6

SA213-T91

276.2

561.7

42.2

6.4

SA213-T23

276.2

557.8

42.2

6.4

SA213-T92

276.2

594.0

42.2

6.6

SA213-T91

276.2

580.1

42.2

5.8

SA213-T91

276.2

560.7

42.2

6.4

SA213-T23

276.2

550.1

42.2

5.5

SA213-T23

276.2

531.8

42.2

5.5

SA213-T23

276.2

557.8

S-35B

Superheater Final Outlet Term. Tubes

S-35

Superheater Final Tubes

935

935

S-35A

Superheater Final Inlet Term. Tubes

S-34

Superheater Final Inlet Header

1

355.6

45.5

SA335-P23

276.2

490.2

S-33

Links to Superheater Final Inlet Header

2

457.2

46.8

SA335-P23

277.1

490.2

S-32

Superheater Desuperheater #2

2

457.2

48.6

SA335-P23

277.7

497.3

S-31

Links to Superheater Desuperheater #2

2

457.2

48.6

SA335-P23

278.2

497.3

S-30

Superheater Platen Outlet Header

1

406.4

52.5

SA335-P23

278.2

497.3

50.8

6.6

SA213-T23

282.4

520.0

50.8

8.5

SA213-T12

282.4

513.3

50.8

6.6

SA213-T91

282.4

552.8

50.8

7.3

SA213-T23

282.4

546.7

50.8

6.6

SA213-T23

282.4

528.3

50.8

10.0

SA213-T12

282.4

526.1

S-29B

Superheater Platen Outlet Term. Tubes

S-29

Superheater Platen Tubes

935

420

420

420

50.8

8.5

SA213-T12

282.4

511.1

50.8

6.4

SA213-T12

282.4

467.2

S-29A

Superheater Platen Inlet Term. Tubes

S-28

Superheater Platen Inlet Header

1

355.6

52.9

SA335-P12

282.4

456.2

S-27

Links to Superheater Platen Inlet Header

2

406.4

58.6

SA335-P12

283.1

456.2

S-26

Superheater Desuperheater #1

2

406.4

58.6

SA335-P12

284.7

501.6

S-25

Links to Superheater Desuperheater #1

2

406.4

58.6

SA335-P12

285.5

501.6

S-24

Superheater Division Panel Outlet Headers

2

508.0

72.6

SA335-P23

285.5

501.6

S-23

Superheater Division Panel Outlet Term. Tubes

480

44.5

5.4

SA213-T23

289.2

480.0

44.5

5.9

SA213-T91

289.2

546.1

S-22

Superheater Division Panel Tubes

480

44.5

7.0

SA213-T23

289.2

555.6

44.5

6.1

SA213-T23

289.2

533.9

44.5

5.4

SA213-T23

289.2

515.0

480

44.5

5.9

SA213-T12

289.2

430.6

46.0

568.0

46.8

456.9

47.2

457.1

47.7

299.3

255.0

540.0

258.2

485.2

260.1

492.3

264.5

451.2

267.5

461.6

270.8

417.4

272.8

415.1

272.8

415.1

272.0

417.5

S-21

Superheater Division Panel Inlet Term. Tubes

S-20

Superheater Division Panel Inlet Headers

2

355.6

60.8

SA335-P12

289.2

457.4

S-19

Links to Superheater Panel Inlet Header

4

323.9

40.7

SA335-P12

290.3

457.5

S-18

Extended Wall Side Tubes

142

50.8

7.1

SA213-T12

290.9

496.5

S-17

Extended Wall Floor Tubes

142

50.8

7.1

SA213-T12

290.9

496.5

S-16

Extended Wall Inlet Header

1

355.6

60.8

SA335-P12

290.9

483.1

S-15

Link to Extended Wall Inlet Header

1

355.6

44.2

SA335-P12

290.9

455.1

S-14

Backpass Lower Front Header

1

406.4

73.9

SA335-P12

290.9

483.1

S-13

Backpass Front Wall Tubes

167

57.0

10.5

SA213-T12

291.8

494.1

S-12

Backpass Screen Tubes

167

57.0

10.5

SA213-T12

291.8

494.1

S-11

Backpass Outlet Headers

2

406.4

71.3

SA335-P12

290.3

457.5

S-10

Backpass Side Wall Tubes

328

57.0

7.9

SA213-T12

290.9

496.5

S-9

Backpass Lower Side Header

2

406.4

73.9

SA335-P12

290.9

483.1

272.8

415.1

S-8

Backpass Lower Rear Header

1

406.4

68.7

SA335-P12

290.9

483.1

272.8

415.1

S-7

Backpass Rear Wall Tubes

111

70.0

9.6

SA213-T12

291.8

494.1

S-6

Backpass Roof Tubes

111

70.0

9.6

SA213-T12

291.8

494.1

S-5

Furnace Roof Outlet Header

1

219.1

44.6

SA335-P12

291.8

480.3

273.9

412.3

S-4

Furnace Rear Roof Tubes

168

70.0

9.6

SA213-T12

293.2

491.3

S-3

Furnace Front Roof Tubes

168

70.0

9.6

SA213-T12

293.2

491.3

S-2

Furnace Roof Inlet Header

1

273.1

42.9

SA335-P12

293.2

451.2

275.3

411.2

S-1

Links to Roof Inlet Header

4

323.9

40.7

SA335-P12

293.8

451.2

F-33 F-32 F-31

Storage Tank Link to Storage Tank Separator

1 2 2

650.0 323.9 650.0

80.0 41.4 80.0

SA302-C SA335-P12 SA302-C

295.3 295.2 302.6

422.9 422.9 452.7

276.9

382.9 382.9 412.7

F-9, F-20, F-29 F-8, F19, F-28 F-18B F-18A F-17 F-16 F-27 F-7

8 4 56 280 336 336 648 336

273.1 273.1 48.3 48.3 38.0 38.0 34.0 34.0

35.9 41.6 11.5 8.5 6.7 5.4 5.4 5.4

SA335-P12 SA335-P12 SA213-T22 SA213-T22 SA213-T22 SA213-T22 SA213-T22 SA213-T22

306.1 306.1 307.7 307.7 307.7 307.7 307.7 307.7

464.1 464.1 492.1 484.5 477.0 465.9 485.0 485.0

277.2 277.2

424.1 424.1

F-5, F-14, F-25 F-3, F12, F-23 F-21 F-1, F10

Furnace wall Riser Pipe Outlet Front/Rear/Side Header - Rear Wall Hanger Tubes - Rear Wall Screen Tubes - Rear Wall Arch Tubes - Rear Wall Tubes - Side Wall Tubes - Front Wall Tubes Vertical wall Tube Intermediate Header Spiral wall Tube Inlet Side Header Inlet Front/Rear Header

4 440 2 1/1

273.1 38.0 406.4 406.4

42.4 6.6 49.9 60.4

SA335-P12 SA213-T22 SA106-C SA106-C

307.7 327.0 327.0 327.0

437.6 466.0 380.6 380.6

278.7

397.6

297.2 297.2

340.6 340.6

E-10

Economizer Waterwall Inlet Links

2

355.6

39.8

SA106-C

327.3

340.7

E-9

Economizer Mixing Line

1

457.2

50.8

SA106-C

325.5

340.7

E-8

Economizer Outlet Links

2

355.6

39.8

SA106-C

323.7

340.7

E-7

Economizer Hanger Tube Outlet Header

1

457.2

63.4

SA106-C

323.7

340.7

293.9

340.7

E-6

Economizer Hanger Tubes

224

70.0

13.0

SA210-C

326.2

351.7

E-5

Economizer Junction Headers

4

219.1

34.1

SA106-C

326.2

366.9

296.4

338.9

E-4

Backpass Economizer Tubes

489

50.8

6.5

SA210-C

330.1

349.9

E-3

Backpass Economizer Inlet Header

1

406.4

62.6

SA106-C

330.1

317.7

300.1

289.7

E-2

Economizer Inlet Leads

2

DN 400

46.0

SA106-C

331.4

289.7

E-1

Feedwater Line

1

DN 600

76.1

SA106-C

333.2

289.7

Pressure kg/cm2g

Temp. o C

Pressure kg/cm2g

Temp. o C

No.

Description of Heating Surface

No of Tubes per Boiler

Outside Diameter (mm)

Minimum Thickness (mm)

Materials

Design Data

Operating Data @ BMCR

IV. 7. PRESSURE PARTS SCHEDULE-UNIT MATERIAL DIAGRAM

TABLE OF CONTENTS

PAGE NO.

TITLE

Pressure Parts Schedule-Unit Material Diagram Back pass Economiser Tubes

Page 1 of 12

Economiser Hanger Tubes

Page 2 of 12

Lower Furnace

Page 3 of 12

Furnace Vertical Wall

Page 4 of 12

Furnace Rear Wall

Page 5 of 12

Extended Wall

Page 6 of 12

Back Pass Wall

Page 7 of 12

SH Division Panel

Page 8 of 12

SH Platen

Page 9 of 12

SH Final

Page 10 of 12

Low Temperature Reheater

Page 11 of 12

Reheater Final

Page 12 of 12

i

IV.7 Pressure parts schedule-Unit Material Diagram-cover.doc

VI. 8. SAFETY VALVE DATA

TABLE OF CONTENTS

PAGE NO.

TITLE

SAFETY VALVES DATA Design Basis for Safety Valves

…………………………………………………………..1

Separator Outlet and Superheater Safety Valve

…………………………………………2

Cold RH and Hot RH Safety Valve………………………………………………………………… 3 Soot Blowing Pipe Safety Valve

……………………………………………………………4

Safety Valve Setting Diagram at Superheater……………………………………………………. 5 Safety Valve Setting Diagram at Reheater System………… ……………………………………6 Safety Valve Setting Diagram at Soot Blowing System………. …………………………………7 SH Power Operated Impulse type SV Setting Diagram…………………………………………. 8 Hot RH Pipe Power Operated Impulse type SV Setting Diagram………… ……………………9 Design Basis for Power Operated Impulse Safety Valves…………………………………….. 10 SV Setting for High Capacity PRDS Downstream. …………………………………………….11 Safety Valve Setting Table for HT Unit Aux. Steam Header…………………………………..12

i

IV.8 Safety valve-cover.doc

DESIGN BASIS FOR SAFETY VALVES : Per Technical Specification Section VI-A(Part A), Part B / Sub-section-II-M1 (SG AND AUX.), Clause No. 16.02.01 & Sub-section-II-M4 (PCP), Clause No.8.03.00 1. Minimum Discharge Capacities. A. Safety valves on Separator and Superheater (excluding power operated impulse safety valve)

Combined capacity 105%BMCR

B. Safety valves on Reheater system (excluding power operated impulse safety valve)

Combined capacity 105% of Reheat flow at BMCR

C. Power operated impulse safety valve

40%BMCR at superheater outlet 60% of Reheat flow at BMCR at reheater outlet

2. Blow down

4% (max.)

1

SEPARATOR OUTLET AND SUPERHEATER SAFETY VALVE SETTING DIAGRAM Main Steam Parameters : - Boiler Maximum Continuous Rating Steam Flow - Superheater Header Outlet Steam Pressure - Separator Outlet Steam Pressure System Design Pressure : - Superheater Header Outlet Piping Design Pressure - Separator Design Pressure

Description

No. of Safety Valve

Set Pressure Open Close kg/cm2(g)

Steam Temp.

Blowdown Ratio

℃

(%)

412.7 412.7

4.0 4.0

kg/cm2(g)

2,225,000 255 276

kg/hr kg/cm2(g) kg/cm2(g)

272.9 294.9

kg/cm2(g) kg/cm2(g)

Type

Relieving Capacity

Relieving Capa. of each valve type

Percent of BMCR flow

(kg/hr)

(kg/hr)

(%)

1992190

89.5

195550 197710

393260

17.7

667500

667500

30.0

255200

255200

11.5

Separator Outlet 1st Safety Valve 2nd Safety Valve

2 4

294.9 302.6

283.1 290.5

Spring loaded Spring loaded

337770 1654420

Superheater Outlet 1st Safety Valve 2nd Safety Valve

2 2

272.9 275.6

262.0 264.6

540.0 540.0

4.0 4.0

3rd Safety Valve

2

270.2

262.1

540.0

3.0

4th Safety Valve

2

267.4

262.1

540.0

2.0

Spring loaded Spring loaded Power actuated impulse type Hydraulic Power actuated impulse type Relief valve

Spring loaded Safety Valves Total Capacity

2,385,450

107.2

Power actuated impulse type Safety valves Total Capacity

667,500

30.0

Power actuated impulse type Relief valves Total Capacity

255,200

11.5

GRAND TOTAL

148.7 2

COLD REHEAT PIPE AND HOT REHEAT PIPE SAFETY VALVE SETTING DIAGRAM Reheater Steam Parameters : - Boiler Maximum Continuous Rating Reheater Flow

1,741,800

kg/hr

- Cold Reheat Pipe Pressure(at Reheater inlet Header)

45.63

kg/cm2(g)

- Hot Reheat Pipe Pressure(at Reheater outlet Header) System Design Pressure :

43.94

kg/cm2(g)

53.0

kg/cm2(g)

- Cold / Hot Reheat Pipe Design Pressure

Description

No. of S/V

Set Pressure Open Close kg/cm2(g)

Steam Temp.

Blowdown Ratio

℃

(%)

299.3 299.3 299.3 299.3

4.0 4.0 4.0 4.0

kg/cm2(g)

Type

Relieving Capacity

Relieving Capa. of each valve type

Percent of BMCR flow

(kg/hr)

(kg/hr)

(%)

1580190

90.7

288020

288020

16.5

992830

992830

57.0

77500

77500

4.4

Cold Reheat Pipe 1st Safety Valve 2nd Safety Valve 3rd Safety Valve 4th Safety Valve

2 2 2 2

53.0 53.5 54.1 54.6

50.88 51.36 51.94 52.42

Spring loaded Spring loaded Spring loaded Spring loaded

340750 343850 445800 449790

Hot Reheat Pipe 1st Safety Valve

2

50.3

48.3

568.0

4.0

2nd Safety Valve

2

49.8

48.3

568.0

3.0

3rd Safety Valve

2

49.3

48.3

568.0

2.0

Spring loaded Power actuated impulse type Hydraulic Power actuated impulse type Relief valve

Spring loaded Safety Valves Total Capacity

1,868,210

107.3

Power actuated impulse type Safety valves Total Capacity

992,830

57.0

Power actuated impulse type Relief valves Total Capacity

77,500

4.4

GRAND TOTAL

168.7 3

SOOT BLOWING PIPE SAFETY VALVE SETTING DIAGRAM Sootblower Steam Parameters : - Sootblowing steam pressure (at downstream of PRV) - Maximum sootblowing steam flow System Design Pressure : - Sootblowing design steam flow for Safety Valve - Sootblowing steam Design Pressure

Description

No. of S/V

Set Pressure Open Close kg/cm2(g)

kg/cm2(g)

Steam Temp.

Blowdown Ratio

℃

(%)

350.0

4.0

25 18720

kg/cm2(g) kg/hr

30000

kg/hr

35.0

kg/cm2(g)

Type

Relieving Capacity

Percent of Relieving Capa. steam Capa. of of each valve sootblowing type flow

(kg/hr)

(kg/hr)

(%)

30000

30,000

100.00

Soot Blowing Pipe Safety Valve

1

35

33.60

Spring loaded

4

SAFETY VALVE SETTING DIAGRAM AT SUPERHEATER SYSTEM Pressure (Kg/cm2(g)) 310

Design Press. : 294.9 at Separator area Design Press. : 293.8 302.6

at Separator outlet conn. pipe

300 4%

294.9

290

280

4%

②

①

Design Press. : 272.9 275.6

270

Separator Operating Pressure : 277.0 kg/cm2g

272.9

Separator outlet conn. pipe Operating Pressure : 275.9 kg/cm2g

270.2 4%

267.4

4%

3% 2%

⑥

260

⑤

④ ③

PRESSURE DROP at Superheater System : 20.9 kg/cm2

250 SEPARATOR

SEPARATOR outlet conn.

SYSTEM PRESSURE DROP

Superheater Outlet Operating Pressure : 255 kg/cm2g

SUPERHEATER OUTLET PIPE

Note 1. ①,②,③,④ : Spring Loaded type Safety Valve 2. ⑤ : Power operated impulse type Safety Valve 3. ⑥ : Power operated impulse type relief valve ② ③④⑤⑥

① ②

② ③④⑤⑥

① ②

SEPARATOR & SH SYSTEM FLOW SCHEME 5

SAFETY VALVE SETTING DIAGRAM AT REHEATER SYSTEM Pressure (Kg/cm2(g)) 55

54.6 54.1

53.5 53

4%

53.0 4%

4%

④

4%

50

②

①

Design Pressure : 53.0

③

3%

2%

⑦

48

50.3

49.8

49.3

4%

⑥ ⑤

Reheater Inlet Operating Pressre : 45.63 kg/cm2g

PRESSURE DROP at Reheater Tube : 1.69 kg/cm 2

45

Reheater Outlet Operating Pressure : 43.94 kg/cm2g

43 COLD REHEAT PIPE

SYSTEM PRESSURE DROP

HOT REHEAT PIPE

Note 1. ①,②,③,④,⑤ : Spring Loaded type Safety Valve 2. ⑥ : Power Operated Impulse type Safety Valve 3. ⑦ : Power Operated Impulse type Relief Valve

⑦ ⑥ ⑤

①③ ②④

⑤ ⑥ ⑦

① ③ ②④

REHEATER SYSTEM FLOW SCHEME

6

SAFETY VALVE SETTING DIAGRAM AT SOOTBLOWING SYSTEM

Pressure (Kg/cm2(g))

40

35.0

Design Pressure : 35.0

35 4%

30

25 Sootblowing system Operating Pressre : 25 kg/cm2g

SOOTBLOWING PIPE AT DOWNSTREAM OF PRV

7

VI. 8. SAFETY VALVE DATA

DESIGN BASIS FOR POWER OPERATED IMPULSE SAFETY VALVES : Per Technical Specification Section VI-A(Part A), Part B / Sub-section-II-M1 (SG AND AUX.), Clause No. 16.02.01 & Sub-section-II-M4 (PCP), Clause No.8.03.00

1. Minimum Discharge Capacities. A. Power operated impulse safety valve

40%BMCR at superheater outlet 60% of Reheat flow at BMCR at reheater outlet

2. Blow down

10% to 15%

8

IV.8 Safety valve-cover.doc

SUPERHEATER POWER ACTUATED IMPULSE TYPE SAFETY VALVE SETTING DIAGRAM Main Steam Parameters : - Boiler Maximum Continuous Rating Steam Flow

2,225,000

kg/hr

- Superheater Header Outlet Steam Pressure

255

kg/cm2(g)

272.9

kg/cm2(g)

System Design Pressure : - Superheater Header Outlet Piping Design Pressure

Description

No. of Safety Valve

Set Pressure Open Close kg/cm2(g)

Steam Temp.

Blowdown Ratio

℃

(%)

540.0

3.0 2.0

kg/cm2(g)

Relieving Capacity

Relieving Capa. of each valve type

Percent of BMCR flow

(kg/hr)

(kg/hr)

(%)

Power actuated impulse type Hydraulic

667500

667500

30.0

Power actuated impulse type Relief valve

255200

255200

11.5

Type

Superheater Outlet 3rd Safety Valve 4th Safety Valve

2 2

270.2 267.4

262.1 262.1

540.0

Power actuated impulse type Safety valves Total Capacity

667,500

30.0

Power actuated impulse type Relief valves Total Capacity

255,200

11.5

GRAND TOTAL

41.5

9

HOT REHEAT PIPE POWER ACTUATED IMPULSE TYPE SAFETY VALVE SETTING DIAGRAM Reheater Steam Parameters : - Boiler Maximum Continuous Rating Reheater Flow

1,741,800

kg/hr

- Hot Reheat Pipe Pressure(at Reheater outlet Header)

43.94

kg/cm2(g)

53.0

kg/cm2(g)

System Design Pressure : - Cold / Hot Reheat Pipe Design Pressure

Description

No. of S/V

Set Pressure Open Close kg/cm2(g)

Steam Temp.

Blowdown Ratio

℃

(%)

568.0

3.0 2.0

kg/cm2(g)

Relieving Capacity

Relieving Capa. of each valve type

Percent of BMCR flow

(kg/hr)

(kg/hr)

(%)

Power actuated impulse type Hydraulic

992830

992830

57.0

Power actuated impulse type Relief valve

77500

77500

4.4

Type

Hot Reheat Pipe 2nd Safety Valve 3rd Safety Valve

2 2

49.8 49.3

48.3 48.3

568.0

Power actuated impulse type Safety valves Total Capacity

992,830

57.0

Power actuated impulse type Relief valves Total Capacity

77,500

4.4

GRAND TOTAL

61.4

10

SAFETY VALVES SETTING FOR HIGH CAPACITY PRDS DOWNSTREAM Service Safery Valves Tag. No. Location Relieving Capacity

Safety valves for High Capacity PRDS 10LBG11-AA191, 10LBG11-AA192, 10LBG11-AA193(Total 3ea/per boiler) Downstream piping of HC PRDS The relieving capacity of safety valves shall not be less than the full capacity of HC PRDS(including the spray quantity).(As the MOM of 5th TCM)

High Capacity PRDS Parameters : - Full Capacity of HC PRDS(Refer to Attachment #1) System Operating & Design Pressure : - Operating Pressure of High Capacity PRDS downstream - Design Pressure of High Capacity PRDS downstream

Description

Tag. No.

Set Pressure Open Close kg/cm 2(g)

1st Safety Valve 2nd Safety Valve 3rd Safety Valve

10LBG11-AA191 10LBG11-AA192 10LBG11-AA193

20 21 22

kg/cm 2(g) 18.0 18.9 19.8

Blowdown Ratio

172,754

kg/hr

15 20

kg/cm 2(g) kg/cm 2(g)

Type

(%) 10.0 10.0 10.0

11

Spring loaded Spring loaded Spring loaded

Relieving Capacity per each valve

Percent of Full Capacity

(kg/hr)

(%)

57,585 57,585 57,585

33.3 33.3 33.3

Total

100

SAFETY VALVE SETTING TABLE FOR HT UNIT AUX. STEAM HEADER Service Safery Valves Tag. No. Location Relieving Capacity

Safety valves for HT AUX. STEAM HEADER LBG11-AA194, LBG11-AA195(Total 2ea/per boiler) HT Unit Aux. Steam Header The relieving capacity of safety valves shall not be less than the full capacity of LC PRDS. (As the MOM of 5th TCM)

Low Capacity PRDS Parameters : - Full Capacity of LC PRDS(Refer to Attachment #2) System Operating & Design Pressure : - Operating Pressure of Low Capacity PRDS downstream - Design Pressure of Low Capacity PRDS downstream

Description

Tag. No.

Set Pressure Open Close kg/cm 2(g)

Safety Valve Safety Valve

10LBG11-AA194 10LBG11-AA195

20 21

Blowdown Ratio

kg/cm 2(g) 18.0 18.9

40,000

kg/hr

15 20

kg/cm 2(g) kg/cm 2(g)

Type

(%) 10.0 10.0

12

Spring loaded Spring loaded

Relieving Capacity per each valve

Percent of Full Capacity

(kg/hr)

(%)

8,000 32,000

20.0 80.0

Total

100

IV. 9. SOOT BLOWER PHILOSOPHY

TABLE OF CONTENTS

TITLE

PAGE NO.

SOOTBLOWER SELECTION DATA AND PHILOSOPHY Soot Blower Selection Data and Philosophy…….. …………………………………………… 1 Wall Blowers………….. …………………………………………………………………………….. 1 Retract Blowers, Furnace Probe & Half Retracts…… ………………………………………. 2 Air Pre-Heaters……… ………………………………………………………………………………. 2 Soot Blower Selection Data………………………………………………………………………… 3 Retractable Soot Blower Locations………… …………………………………………………… 3 Wall Blower Locations…………… ………………………………………………………………… 4

i

IV.9 Soot blower selection data and philosphy.doc

IV. 9. SOOT BLOWER PHILOSOPHY Soot blower selection data and philosophy

1. Soot blower selection philosophy The sootblower selection is dependent on the expected slagging and fouling potential of the ash of coals. Sipat coals range in higher heating value from 3000 ~ 4000 kcal/kg. The ash content varies from 32% to 48% with silica and alumina forming 88% to 92 % in the ash and the ash fusion temperature (initial deformation) ranges between 1100℃ and 1450℃.

The sulphur content

is less than 0.6%. As a result of these and characteristic of slagging, fouling potential of ash analysis forwarded to Doc. No.: T04019-PE-C0001, Sipat coal is generally of the non-slagging, fouling type which are normal property for indian coal as described below.

Note : Characteristics of Indian Coals Coal being the major fossil fuel for centuries to come, a brief look at its characteristics is relevant here.

Considering the type of coal formation, the major part of the Indian coals

theses coals presently range in higher heating value from about 3000 to 4000 Kcal/Kg. The ash content varies from 35 to 50 percent with silica and alumina forming 80 to 90 percent in the ash, thus making the pulverized coal as well as the ash highly abrasive.

The sulphur

content is generally less than 0.5 percent in most of the areas leading to a fairly high resistivity of the ash.

The ash fusion temperature ranges between 1100 and 1500℃ and the coals are

generally of the non-slagging type.

For the non-slagging, fouling type, the sootblower blowers are selected as basic guide below; WALL BLOWERS Futures only at elevation below burners -no openings. Two rows of openings above burners, each row has: Blowers in the two openings closest to hot comers. Blower in every other opening, after the two with blowers, going toward cold comers. Third row above burners -futures only, no openings. Note: "Futures" means space allowed for future wallblowers but no bent tube openings or

1

IV.9 Soot blower selection data and philosphy.doc

IV. 9. SOOT BLOWER PHILOSOPHY sealboxes are supplied. "Openings only" means bent tube inserts with blanked off seal boxes packed with refractory

RETRACT BLOWERS, FURNACE PROBE & HALF TRACKS Retract Blowers are located on the ash deposits area of superheater and reheater area. For same objects, half tracks are located on economizer area. Furnace temperature probes are monitoring flue gas temperature at the top of furnace during the lighting-off period and remains in the furnace until reheater steam flow has been established.

These are usually located below the platen 'midway between the front and

rear of the platen.

AIR PREHEATERS The sootblower is normally located at the cold end of the air preheater where deposit formation usually occurs. Generally, the gas side is the preferred location for this equipment in order to eliminate fly ash being carried into the burner wind boxes.

In addition to the design concepts mentioned above, the results of investigation about the existing sootblowing systems were sufficiently taken into consideration for Sipat project after the site survey of Korba and Talcher Power Plants.

If the actual performance of steam generators requires provision of additional sootblowers/ Retractable soot blowers, the same shall be installed by DOOSAN free of charges.

2

IV.9 Soot blower selection data and philosphy.doc

IV. 9. SOOT BLOWER PHILOSOPHY 2. Sootblower selection data (1) Retractable sootblower locations 1020 oC

877 oC

800 oC

730 oC

15860 mm

◎ ◎ 3658mm (Typ.)

◎

◎

◎

3658mm (Typ.)

3658mm (Typ.)

●

●

● 610 mm

●

LTRH

1075 oC

● ● ● LTRH

1220 mm (Typ.) 914 mm

● LTRH

●

610 oC

◎

◎

550 oC

18256 mm

▲ 914 mm

Future Econ. ◎ o

1538 C

FW = 18816 mm FD = 18144 mm

◆ Economizer

490 oC

◆ Economizer

450 oC

◆ Economizer ◆ Economizer

Fuels: Coal ■

Heavy Oil □

Blowing Medium: Steam ■

Sootblowers

Air □

High Vol. C , Ash Softening Temp. Min. 1100 (IDT) °C

, Location of Steam Take-off: Single Side

Double Side

Total No.

● (B)

-

9

18

Opening ◎ (O)

-

8

16

○ (F)

-

-

-

Present Retractable

Coal Type:

Future

◆ (B)

-

4

8

(O)

-

7

14

Future

◇ (F)

-

-

-

Temp. Probe

Present

▲

-

1

2

AH Blowers :

Cold End *

* = per AH

Hot End *

Total = per BLR

Fut. H.E. *

Half Track Sootblowers

Present Opening

1

Division SH Outlet

KEY F = Future - Allow space for future blower only no bent tubes O = Opening Only - Bent tubes B = Opening with blower - Complete installation

4

Location/Conditions of AH steam take-off

1

:

4

3

IV.9 Soot blower selection data and philosphy.doc

IV. 9. SOOT BLOWER PHILOSOPHY (2) Wall blower locations

2438 mm (Typ.)

Row 4

2438 mm (Typ.)

O B O B O O O

2438 mm (Typ.)

O O O B O B O 3048 mm

Row 3

B B O B O B B

Row 2

B B B B B B B

3048 mm

B B B B B B B

2438 mm

2438 mm

F F F F F F F

H

Front Wall

CL Bot. Fuel Nozzle

C

CL Top Fuel Nozzle Width = 18144 mm

CL Bot. Fuel Nozzle

2438 mm

Rear Wall

2438 mm

CL Top Fuel Nozzle Width = 18144 mm

F F F F F F F

C

3048 mm

B B B B B B B 2438 mm

CL Top Fuel Nozzle Width = 18816 mm

2438 mm

3048 mm

B B O B O B B 3048 mm

B B B B B B B

CL Top Fuel Nozzle Width = 18816 mm

O O O B O B O 3048 mm

B B O B O B B

3048 mm

Row 1

O B O B O O O 3048 mm

B B O B O B B

CL Bot. Fuel Nozzle

2438 mm (Typ.)

F F F F F F F

H

H

CL Bot. Fuel Nozzle

2438 mm

Right Side

2438 mm

F F F F F F F

C

C

Left Side

H

View from outside right side wall

View from outside front wall

C

KEY

H

H

F = Future - Allow space for future blower only no bent tubes

C H = Hot

O = Opening Only - Bent tubes B = Opening with wall blower - Complete installation

C = Cold C

H C

H Front

Wall blowers

B

O

F

Location : Row 1

-

-

28

Row 2

28

-

-

Row 3

20

8

-

Row 4

8

20

-

56

28

28

Total

4

IV.9 Soot blower selection data and philosphy.doc

IV. 10. DUCT DESIGN DATA AND SCHEMATIC

TABLE OF CONTENTS

PAGE NO.

TITLE

Duct Design Data and Schematic……………….…………………………………………………………... 1

i

IV.10 Duct Design Data and Schematic-cover.doc

5. Duct schematic and design data

PA FAN "B"

Ci

C

PRI. AH (AIR) "B"

D1 D

Pluv.

Pluv.

Pluv.

Pluv.

Pluv.

K

K

K

K

K

H1

J1

H1

J1

H1

J1

H1

J1

H1

J1

H1

J1

H1

J1

H1

J1

H1

J1

H1

J1

J

H H2

J2

PA FAN "A"

Ci

C

PRI. AH (AIR) "A"

H D

J

D1 K

K

K

K

Pluv.

Pluv.

Pluv.

Pluv.

Pluv.

E F1 E1

B B1

FD FAN "B"

F2 FURNACE

G1 M' G G2 G'

N

B

F1 F

B1

E1

WINDBOX

F2

E

PRI. AH SEC. AH (GAS) "B" (GAS) "B"

L Bi

SEC. AH (AIR) "A"

FD FAN "B"

F

SEC. AH (AIR) "B"

Bi

WINDBOX

PRI. AH SEC. AH (GAS) "A" (GAS) "A"

K

EP

O

ID FAN "B"

M

O

ID FAN "B"

M

O'

G1 G G2

Schematic for Draft System Excess air, %

25% (STOICH)

20% (STOICH)

Air &

Worst

Worst

Gas Side

Coal Firng I t Description

100% BMCR Mass

1)

Duct Size

60%BMCR (Rev.)

Opera. Density Volume

Max.

Mass

1)

Opera. Density Volume

Max.

Total

Duct

Design

Duct

One Duct

Duct

Design

Pressure

Q'ty

Area

Temp.

m2

℃

Pos.

Neg. -660

e

Flow

Temp.

Flow

Vel.

Flow

Temp.

Flow

Vel.

Width

Depth

Area

m

kg/hr

℃

kg/m

m3/sec

m/sec

kg/hr

℃

kg/m3

m3/sec

m/sec

m

m

m2

Sec. Air Fan Inlet

Bi

885,912

27

1.127

218

14.2

1,005,673

27

1.127

248

16.0

3.21

4.80

15.4

2

30.8

50

+660

Sec. Air to AH

B

885,912

31

1.112

221

14.2

1,005,673

31

1.112

251

16.0

3.95

3.95

15.6

2

31.2

50

+660

-660

Bypass Duct to Sec. AH

B1

885,912

31

1.112

221

12.7

1,005,673

31

1.112

251

14.5

4.40

3.95

17.4

2

34.8

50

+660

-660

Cold Sec. Air Xover

L

885,912

31

1.112

221

14.2

1,005,673

31

1.112

251

16.0

3.95

3.95

15.6

1

15.6

50

+660

-660

Hot Sec. Air to WB

E

821,012

300

0.590

386

15.7

469,937

257

0.638

205

8.3

5.95

4.14

24.6

2

49.3

304

+660

-660

WB to WB Conn. Duct

E1

821,012

300

0.590

386

15.7

469,937

257

0.638

205

8.3

5.95

4.14

24.6

2

49.3

304

+660

-660

Hot Sec. Air Xover

N

410,506

300

0.590

193

13.0

469,937

257

0.638

205

13.7

4.14

3.60

14.9

1

14.9

304

+660

-660

PA Fan Inlet

Ci

586,499

27

1.127

145

14.0

674,324

27

1.127

166

16.0

3.21

3.21

10.3

2

20.6

50

+660

-660

Air from PA Fan

C

586,499

34

1.101

148

13.9

674,324

34

1.101

170

16.0

3.54

3.00

10.6

2

21.2

50

+1425

-660

3

mm wg

Air to Pri. AH

D

466,547

34

1.101

118

11.3

660,188

34

1.101

167

16.0

3.46

3.00

10.4

2

20.8

50

+1425

-660

Bypass Duct to Pri. AH

D1

466,547

34

1.101

118

11.3

660,188

34

1.101

167

16.0

3.46

3.00

10.4

2

20.8

50

+1425

-660

Cold Air to Mills

H

119,952

34

1.101

30

6.7

14,136

34

1.101

4

0.8

2.12

2.12

4.5

2

9.0

50

+1425

-660

Cold Air per Mill

H1

26,656

34

1.101

7

5.1

2,827

34

1.101

1

0.5

1.15

1.15

1.3

10

13.2

50

+1425

-660

PA Air Xover

H2

586,499

34

1.101

148

13.9

674,324

34

1.101

170

16.0

3.54

3.00

10.6

1

10.6

50

+1425

-660

Hot Air to Mills

J

417,947

290

0.601

193

12.0

604,788

243

0.656

256

15.9

6.05

2.665

16.1

2

32.2

304

+1003

-660

Hot Air per Mill

J1

92,877

293

0.598

43

13.5

120,958

243

0.659

51

15.9

1.19

2.69

3.2

10

32.0

304

+1003

-660

Hot Pri. Air Xover

J2

278,632

293

0.598

129

13.5

362,874

243

0.655

154

16.0

3.60

2.665

9.6

1

9.6

304

+1003

-660

Total Air per Mill

K

130,771

2)

258

0.637

57

15.7

130,771

2)

239

0.661

55

15.2

3.048

1.19

3.6

10

36.3

271

+876

-660

Gas Leaving Econ.

F

1,543,482

327

0.576

744

11.9

1,813,486

285

0.619

13.0

6.25

10.00

62.5

2

125.0

332

+660

-660

Gas to Sec. AH

F1

1,032,188

327

0.576

498

12.8

1,129,774

285

0.619

507

13.0

4.09

9.50

38.9

2

77.7

332

+660

-660

Gas to Pri. AH

F2

511,294

327

0.576

247

10.4

683,712

285

0.619

307

13.0

5.75

4.12

23.7

2

47.4

332

+660

-660

814

Gas from Sec. AH

G1

1,097,088

132

0.854

357

12.6

1,195,574

113

0.893

372

13.0

4.66

6.08

28.3

2

56.7

138

+660

-660

Gas from Pri. AH

G2

559,894

132

182

10.2

739,112

114

13.0

6.80

2.62

17.8

2

35.6

138

+660

-660

G

1,656,982

132

539

11.5

1,934,686

113

0.886 0.890

232

Gas from Sec.& Pri. AH

0.854 0.854

604

12.9

6.42

7.30

46.9

2

93.7

138

+660

-660

Gas Xover before EP

G'

828,491

132

0.854

269

6.5

967,343

113

0.890

302

7.3

6.42

6.42

41.2

1

41.2

138

+660

-660

Gas Xover from EP

O'

828,491

130

0.858

268

6.5

967,343

111

0.895

300

7.3

6.42

6.42

41.2

1

41.2

138

+660

-660

Gas to ID Fan

O

1,656,982

130

0.858

536

11.2

1,934,686

111

0.895

600

12.5

6.42

7.47

48.0

2

95.9

138

+660

-660

ID Fan Outlet

M

1,656,982

130

0.858

536

11.7

1,934,686

111

0.895

600

13.0

6.11

7.50

45.8

2

91.7

138

+660

-660

Gas to Common Stack

M'

3,313,964

130

0.858

1073

12.7

1,934,686

111

0.895

600

7.1

7.70

11.00

84.7

1

84.7

138

+660

-660

Note : 1) Refer to attachment for air & gas weight calculation 2) Maximum Mill Air Flow

IV. 11. PREDICTED PERFORMANCE DATA

TABLE OF CONTENTS

PAGE NO.

TITLE

Predicted Performance Data Design coal……………………………………………………………………………………………. 1 Worst coal…………………………………………………………………………………………..…40 Best coal………………………………………………………………………………………………79

i

IV.11 Predicted performance data-cover.doc

3.00.00

ANTICIPATED PERFORMANCE DATA OF STEAM GENERATOR FOR DESIGN/WORST/BEST COALS BASED ON DESIGN AMBIENT AIR CONDITION OF 27℃ & 60%RH A) DESIGN COAL Modified Sliding Pressure Operation

3.01.00

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Steam flow at superheater outlet (Tonnes/hr)

2225

2160

2023.75

1572.47

1158.41

963.76

2035.24

1592.96

1178.13

982.34

1839.5

1960.0

1335.0

596.1

Steam pressure at superheater outlet (kg/cm2) abs

256

255

254.45

238.01

179.42

151.25

242.89

193.27

145.52

122.33

252.92

254.98

204.40

93.9

Steam temperature at superheater outlet (degC)

540

540

540

540

540

540

540

540

540

540

540

540

540

540

1741.82

1753.03

1678.37

1328.96

996.95

836.41

1686.33

1343.65

1012.39

851.48

1784.2

1784.34

1138

517.2

Steam pressure at reheater inlet (kg/cm2)(abs)

48.3

48.7

46.7

37.2

28.1

23.6

47.0

37.6

28.5

24.0

50.5

50.1

32.2

14.6

Steam temperature at reheater outlet (degC)

568

568

568

568

568

568

568

568

568

568

568

568

568

540

Steam temperature at reheater inlet (degC)

299

300

296

281

286

289

303

306

310

313

309

306

284

294

Pressure drop across reheater (kg/cm2)

1.69

1.70

1.62

1.30

1.02

0.88

1.64

1.34

1.05

0.91

1.70

1.70

1.16

0.57

General i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

Reheater steam flow (Tonnes/hr)

ix)

Control point (% TMCR)

50

50

50

50

50

50

50

50

50

50

50

50

50

50

x)

Feed water temperature (degC)

289.64

290

286.23

270.35

254.09

244.34

287.28

273.24

256.75

246.95

196.15

243.54

261

219

Steam generator efficiency based on the HHV of design coal

86.28

86.26

86.29

86.69

86.88

86.85

86.29

86.61

86.85

86.91

87.31

87.17

86.86

86.24

xi)

xii)

Heat liberated by fuel per

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 1 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

unit furnace volume (x106kal/m3/hr)

0.073

0.071

0.067

0.055

0.042

0.036

0.068

0.055

0.042

0.036

0.071

0.071

0.047

0.023

Furnace cooling factor (x106kcal/m2/hr)

0.174

0.169

0.161

0.129

0.099

0.084

0.161

0.130

0.099

0.085

0.168

0.167

0.112

0.053

Burner zone heat release rate (x106kcal/m2/hr)

1.192

1.165

1.107

0.897

0.688

0.584

1.110

0.902

0.694

0.589

1.170

1.159

0.780

0.372

Plan area heat release rate (x106kcal/m2/hr)

4.60

4.49

4.26

3.43

2.62

2.22

4.27

3.45

2.64

2.24

4.44

4.43

2.97

1.40

Total number of coal pulverisers

10

10

10

10

10

10

10

10

10

10

10

10

10

10

xvii) Number of coal pulverisers working with design coal

7

7

7

6

5

4

7

6

5

4

7

7

5

3

471.8

461.1

438.1

354.9

272.4

231.1

439.3

356.8

274.4

233.2

463.1

458.6

308.5

147.3

Furnace exit gas temperature (degC)

988

1003

1004

977

910

880

994

943

894

864

1000

1007

943

754

Dryness fraction of steam at drum outlet (%)

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

xiii)

xiv)

xv)

xvi)

xviii) Weight of coal fired (tonnes/hr) xix)

xx)

xxi)

Steam Purity at SH outlet (ppm) a)

Total dissolved solids

b)

Silica

c)

Sodium

d)

Chlorides

e)

Copper

f)

Iron

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

Max 0.002 Max 0.002 Max 0.002 0.002 Max 0.001 Max 0.005

PAGE 2 OF 117

Modified Sliding Pressure Operation 100% BMCR

VWO

100% TMCR

80% TMCR

xxii) Furnish calculations for plan area heat release rate, burner zone heat release rate, volumetric heat release rate furnace cooling factor & heat input per burner alongwith details of EPRS calculation, basis for the fouling factor/surface adjustment factor considered

3.02.00

Temperature ( degC)

3.02.01

Air

60% TMCR

50% TMCR

Pure Sliding Pressure Operation 100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Refer to Furnace Performance and Sizing Calculation (T04019-SY-C0003)

A) Bottom Burner Elevations in Service i)

Identify Mills/Elevations in service

B~H

B~H

B~H

B~G

B~F

C~F

B~H

B~G

B~F

C~F

B~H

B~H

B~F

C~E

Burner Tilts (if appli cable( deg)

8

25

25

25

25

25

25

25

25

25

25

25

25

0

iii)

Design Ambient

27

27

27

27

27

27

27

27

27

27

27

27

27

27

iv)

Inlet to the RAPH (Primary air)

34.7

34.7

34.4

34.0

33.9

42.0

34.4

34.0

33.9

39.0

51.0

34.8

33.9

57.0

Outlet of RAPH (Primary air)

295

295

293

276

258

250

295

279

262

255

223

258

254

222

Inlet to the RAPH (Secondary air)

30.9

30.9

30.6

30.3

33.0

41.6

30.6

30.3

30.1

35.6

49.6

30.9

30.1

55.5

Outlet of the RAPH (Secondary air)

296

296

294

277

261

251

296

282

265

256

229

262

259

222

Secondary air at Inlet to burners

296

296

294

277

261

251

296

282

265

256

229

262

259

222

ii)

v)

vi)

vii)

viii)

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 3 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Hot Primary air in the common duct before pulverisers

295

295

293

276

258

250

295

279

262

255

223

258

254

222

Hot primary air at the inlet to pulverisers

208

206

202

198

191

196

202

198

191

196

206

206

201

184

Identify Mills/Elevations in service

C~I

C~I

C~I

C~H

D~H

D~G

C~I

C~H

D~H

D~G

C~I

C~I

D~H

N/A

Burner Tilts (if appli cable (deg)

-30

0

20

25

25

13

7

-5

0

-25

-1

10

25

N/A

iii)

Design Ambient

27

27

27

27

27

27

27

27

27

27

27

27

27

N/A

iv)

Inlet to the RAPH (Primary air)

34.7

34.7

34.4

34.0

33.9

42.0

34.4

34.0

33.9

39.0

51.0

34.7

33.9

N/A

Outlet of RAPH (Primary air)

295

295

291

275

258

249

292

277

261

251

223

256

254

N/A

Inlet to the RAPH (Secondary air)

30.9

30.9

30.6

30.3

30.1

40.6

30.6

30.3

30.1

35.6

50.6

30.9

30.1

N/A

Outlet of the RAPH (Secondary air)

296

296

293

277

260

249

294

281

263

252

229

262

259

N/A

Secondary air at Inlet to burners

296

296

293

277

260

249

294

281

263

252

229

262

259

N/A

Hot Primary air in the common duct before pulverisers

295

295

291

275

258

249

292

277

261

251

223

256

254

N/A

Hot primary air at the inlet to pulverisers

208

206

202

197

191

196

202

198

192

196

206

205

202

N/A

ix)

x)

B) Middle Burner Elevations in Service i)

ii)

v)

vi)

vii)

viii)

ix)

x)

C) Top Burner Elevations SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 4 OF 117

Modified Sliding Pressure Operation 100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

D~J

D~J

D~J

E~J

F~J

G~J

D~J

E~J

F~J

G~J

D~J

D~J

F~J

N/A

Burner Tilts (if appli cable( deg)

-30

-30

-8

12

0

-15

-25

-25

-25

-25

-25

-25

10

N/A

iii)

Design Ambient

27

27

27

27

27

27

27

27

27

27

27

27

27

N/A

iv)

Inlet to the RAPH (Primary air)

34.7

34.7

34.4

34.0

33.9

42.0

34.4

34.0

33.9

41.0

51.0

34.7

33.9

N/A

Outlet of RAPH (Primary air)

295

295

291

274

257

248

293

277

260

250

222

257

252

N/A

Inlet to the RAPH (Secondary air)

30.9

30.9

30.6

30.3

30.1

40.6

30.6

30.3

30.1

35.6

50.6

30.9

30.1

N/A

Outlet of the RAPH (Secondary air)

296

296

293

278

259

249

295

280

262

251

229

262

259

N/A

Secondary air at Inlet to burners

296

296

293

278

259

249

295

280

262

251

229

262

259

N/A

Hot Primary air in the common duct before pulverisers

295

295

291

274

257

248

293

277

260

250

222

257

252

N/A

Hot primary air at the inlet to pulverisers

209

206

202

198

191

196

202

198

191

197

207

205

201

N/A

Fuel and air mixture leaving the p!ulveriser

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

Fuel & air mixture entering the burner

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

in Service i) Identify Mills/Elevations in service ii)

v)

vi)

vii)

viii)

ix)

x)

3.02.02

Fuel & air mixture i)

ii)

3.02.03

Pure Sliding Pressure Operation

Flue Gases (Actual Temperatures) SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 5 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

B~H

B~H

B~H

B~G

B~F

C~F

B~H

B~G

B~F

C~F

B~H

B~H

B~F

C~E

8

25

25

25

25

25

25

25

25

25

25

25

25

0

Theoretical combustion temperature in the combustion zone

1579

1565

1531

1457

1382

1345

1543

1491

1404

1359

1539

1538

1386

1224

At furnace arch level (Furnace arch level is defined as the level at the entrance to radiant super heater)

1324

1339

1328

1293

1243

1213

1332

1305

1248

1215

1338

1334

1266

1080

At Furnace arch exit (as defined in the specification for FEGT)

988

999

986

946

888

868

986

939

882

862

996

996

916

754

Stage I

1324

1339

1328

1293

1243

1213

1332

1305

1248

1215

1338

1334

1266

1080

Stage II

1078

1093

1078

1041

987

978

1080

1040

984

975

1091

1089

1013

858

Stage III

855

862

854

815

759

734

852

804

751

727

860

862

784

631

Stage I

1078

1093

1078

1041

987

978

1080

1040

984

975

1091

1089

1013

858

Stage II

988

999

986

946

888

868

986

939

882

862

996

996

916

754

Stage III

727

731

725

693

648

625

722

682

640

619

727

730

667

565

A) Bottom Burner Elevations in Service i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

Identify Mills/elevations in service Burner Tilts (if applicable) (deg)

Entrance to superheater

Exit of Superheater

Entrance to reheater

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 6 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Stage I

721

723

718

686

642

618

715

674

633

612

720

723

660

557

Stage II

988

999

986

946

888

868

986

939

882

862

996

996

916

754

Stage I

489

490

487

461

436

420

487

462

439

427

491

493

446

383

Stage II

874

882

873

834

779

754

871

824

771

748

879

881

804

652

Entrance of economizer

489

490

487

461

436

420

487

462

439

427

491

493

446

383

xi)

Exit of economizer

322

322

319

300

279

267

319

301

281

268

251

288

288

234

xii)

Entrance to primary air heater

322

322

319

300

279

267

319

301

281

268

251

288

288

234

Entrance to secondary air heater

322

322

319

300

279

267

319

301

281

268

251

288

288

234

Exit of primary air heater (corrected)

133

133

130

120

111

110

132

123

113

111

111

113

119

110

Exit of secondary air heater (corrected)

131

131

130

120

111

110

131

123

114

110

110

114

119

111

xvii) Exit of primary air heater (Uncorrected)

144

144

142

132

124

124

144

136

126

125

118

123

127

125

xviii) Exit of secondary air heater (Uncorrected)

137

137

135

126

118

118

136

130

122

118

115

119

123

121

Exit of air preheater (average considered)

132

132

130

120

111

110

131

123

114

110

110

114

119

110

Entrance of electrostatic precipitator

132

132

130

120

111

110

131

123

114

110

110

114

119

110

Exit of electrostatic precipitator

130

130

128

118

109

108

129

121

112

108

108

112

117

108

ix) Exit of reheater

x)

xiii)

xv)

xvi)

xix)

xx)

xxi)

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 7 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

xxii) Entrance of ID fans

130

130

128

118

109

108

129

121

112

108

108

112

117

108

xxiii) Entrance to Chimney

134

134

132

121

112

111

133

124

115

111

111

115

120

111

Identify Mills/elevations in service

C~I

C~I

C~I

C~H

D~H

D~G

C~I

C~H

D~H

D~G

C~I

C~I

D~H

N/A

Burner Tilts (if applicable ) (deg)

-30

0

20

25

25

13

7

-5

0

-25

-1

10

25

N/A

Theoretical combustion temperature in the combustion zone (deg C)

1579

1573

1558

1485

1404

1359

1559

1499

1412

1362

1545

1557

1410

N/A

At furnace arch level (Furnace arch level is defined as the level at the entrance to radiant super heater)

1324

1347

1361

1342

1313

1254

1348

1313

1266

1197

1345

1355

1327

N/A

At furnace arch exit (as defined in the specification for FEGT)

988

1003

1004

968

907

880

994

943

889

864

1000

1007

936

N/A

Stage I

1324

1347

1361

1342

1313

1254

1348

1313

1266

1197

1345

1355

1327

N/A

Stage II

1078

1099

1106

1076

1018

1000

1093

1046

996

977

1097

1106

1046

N/A

Stage III

855

863

861

823

764

736

854

805

753

728

862

866

791

N/A

Stage I

1078

1099

1106

1076

1018

1000

1093

1046

996

977

1097

1106

1046

N/A

Stage II

988

1003

1004

968

907

880

994

943

889

864

1000

1007

936

N/A

B) Middle Burner Elevations in Service i)

ii)

iii)

iv)

v)

vi)

vii)

Entrance to superheater

Exit of Superheater

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 8 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

727

730

724

692

647

623

721

681

641

619

727

729

666

N/A

Stage I

721

723

718

686

639

616

714

674

633

612

720

722

659

N/A

Stage II

988

1003

1004

968

907

880

994

943

889

864

1000

1007

936

N/A

Stage I

489

488

481

454

429

416

483

461

438

427

491

489

439

N/A

Stage II

874

883

881

843

786

757

874

825

774

749

881

886

812

N/A

Entrance of economizer

489

488

481

454

429

416

483

461

438

427

491

489

439

N/A

xi)

Exit of economizer

322

322

317

298

277

265

318

300

281

268

251

286

286

N/A

xii)

Entrance to primary air heater

322

322

317

298

277

265

318

300

281

268

251

286

286

N/A

Entrance to secondary air heater

322

322

317

298

277

265

318

300

281

268

251

286

286

N/A

Exit of primary air heater (corrected)

133

133

132

122

112

111

133

123

113

108

110

114

120

N/A

Exit of secondary air heater (corrected)

131

131

130

120

112

111

131

123

114

109

111

114

120

N/A

xvii) Exit of primary air heater (Uncorrected)

144

144

143

134

125

124

144

135

126

122

117

123

127

N/A

xviii) Exit of secondary air heater (Uncorrected)

137

137

136

127

119

119

136

129

122

118

115

120

124

N/A

Exit of air preheater (average considered)

132

132

131

121

112

110

131

123

114

108

110

114

120

N/A

Entrance of electrostatic precipitator

132

132

131

121

112

110

131

123

114

108

110

114

120

N/A

Stage III viii)

ix)

x)

xiii)

xv)

xvi)

xix)

xx)

Entrance to reheater

Exit of reheater

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 9 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Exit of electrostatic precipitator

130

130

129

119

110

108

129

121

112

106

108

112

118

N/A

xxii) Entrance of ID fans

130

130

129

119

110

108

129

121

112

106

108

112

118

N/A

xxiii) Entrance to Chimney

134

134

133

122

113

111

133

124

115

109

111

115

121

N/A

Identify Mills/elevations in service

D~J

D~J

D~J

E~J

F~J

G~J

D~J

E~J

F~J

G~J

D~J

D~J

F~J

N/A

Burner Tilts (if applicable ) (deg)

-30

-30

-8

12

0

-15

-25

-25

-25

-25

-25

-25

10

N/A

Theoretical combustion temperature in the combustion zone (deg C)

1582

1573

1558

1496

1407

1371

1559

1500

1417

1371

1546

1556

1426

N/A

At furnace arch level (Furnace arch level is defined as the level at the entrance to radiant super heater)

1353

1349

1362

1356

1318

1267

1348

1326

1282

1241

1353

1352

1339

N/A

At furnace arch exit (as defined in the specification for FEGT)

1015

1005

1006

977

910

886

996

957

894

877

1008

1006

943

N/A

Stage I

1353

1349

1362

1356

1318

1267

1348

1326

1282

1241

1353

1352

1339

N/A

Stage II

1112

1102

1108

1090

1024

1012

1094

1063

1005

999

1107

1104

1058

N/A

Stage III

874

865

862

825

765

736

854

814

755

732

867

865

792

N/A

xxi)

C) Top Burner Elevations in Service i)

ii)

iii)

iv)

v)

vi)

vii)

Entrance to superheater

Exit of Superheater

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 10 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Stage I

1112

1102

1108

1090

1024

1012

1094

1063

1005

999

1107

1104

1058

N/A

Stage II

1015

1005

1006

977

910

886

996

957

894

877

1008

1006

943

N/A

Stage III

738

731

725

692

646

622

722

686

640

619

731

729

665

N/A

Stage I

731

724

718

684

639

614

714

678

633

612

723

722

658

N/A

Stage II

1015

1005

1006

977

910

886

996

957

894

877

1008

1006

943

N/A

Stage I

488

488

481

452

428

413

483

459

437

422

489

489

437

N/A

Stage II

893

884

882

846

786

758

874

834

776

753

887

885

813

N/A

Entrance of economizer

488

488

481

452

428

413

483

459

437

422

489

489

437

N/A

xi)

Exit of economizer

322

322

317

297

277

264

318

300

280

267

251

286

285

N/A

xii)

Entrance to primary air heater

322

322

317

297

277

264

318

300

280

267

251

286

285

N/A

Entrance to secondary air heater

322

322

317

297

277

264

318

300

280

267

251

286

285

N/A

Exit of primary air heater (corrected)

132

133

132

121

110

111

133

122

113

110

110

114

120

N/A

Exit of secondary air heater (corrected)

131

131

130

121

113

111

131

123

115

110

111

114

120

N/A

xvii) Exit of primary air heater (Uncorrected)

143

144

143

133

123

124

145

134

126

124

117

123

127

N/A

xviii) Exit of secondary air heater (Uncorrected)

136

137

136

128

120

119

137

129

123

118

115

120

124

N/A

viii)

ix)

x)

xiii)

xv)

xvi)

xix)

Entrance to reheater

Exit of reheater

Exit of air preheater

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 11 OF 117

Modified Sliding Pressure Operation 100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

(average considered)

131

132

131

121

112

111

131

122

114

110

111

114

120

N/A

Entrance of electrostatic precipitator

131

132

131

121

112

111

131

122

114

110

111

114

120

N/A

Exit of electrostatic precipitator

129

130

129

119

110

109

129

120

112

108

109

112

118

N/A

xxii) Entrance of ID fans

129

130

129

119

110

109

129

120

112

108

109

112

118

N/A

xxiii) Entrance to Chimney

133

134

133

122

113

112

133

123

115

111

112

115

121

N/A

B~H

B~H

B~H

B~G

B~F

C~F

B~H

B~G

B~F

C~F

B~H

B~H

B~F

C~E

8

25

25

25

25

25

25

25

25

25

25

25

25

0

Water entering economizer

290

290

286

270

254

244

287

273

257

247

196

244

261

219

Water leaving economizer

341

342

341

329

315

306

340

326

316

307

297

321

319

280

a) Superheater

290

290

286

270

254

244

287

273

257

247

196

244

261

219

b) Reheater

191

191

191

181

169

161

191

181

169

161

196

195

169

144

C~I

C~I

C~I

C~H

D~H

D~G

C~I

C~H

D~H

D~G

C~I

C~I

D~H

N/A

xx)

xxi)

3.02.04

Pure Sliding Pressure Operation

Feed Water A) Bottom Burner Elevations in Service i)

ii)

iii)

iv)

v)

Identify Mills/elevations in service

Burner Tilts (if applicable ) (deg)

Desuperheating spray water temperature

B) Middle Burner Elevations in Service i)

Identify Mills/elevations in service

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 12 OF 117

Modified Sliding Pressure Operation

ii)

iii)

iv)

v)

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Burner Tilts (if applicable ) (deg)

-30

0

20

25

25

13

7

-5

0

-25

-1

10

25

N/A

Water entering economizer

290

290

286

270

254

244

287

273

257

247

196

244

244

N/A

Water leaving economizer

341

341

338

325

312

303

339

326

315

306

296

318

317

N/A

a) Superheater

290

290

286

270

254

244

287

273

257

247

196

244

244

N/A

b) Reheater

191

191

191

181

169

161

191

181

169

161

196

195

169

N/A

Identify Mills/elevations in service

D~J

D~J

D~J

E~J

F~J

G~J

D~J

E~J

F~J

G~J

D~J

D~J

F~J

N/A

Burner Tilts (if applicable ) (deg)

-30

-30

-8

12

0

-15

-25

-25

-25

-25

-25

-25

10

N/A

Water entering economizer

290

290

286

270

254

244

287

273

257

247

196

244

244

N/A

Water leaving economizer

341

341

338

323

311

302

339

326

314

304

297

318

315

N/A

a) Superheater

290

290

286

270

254

244

287

273

257

247

196

244

244

N/A

b) Reheater

191

191

191

181

169

161

191

181

169

161

196

195

169

N/A

Desuperheating spray water temperature

C) Top Burner Elevations in Service i)

ii)

iii)

iv)

v)

3.02.05

Desuperheating spray water temperature

Steam

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 13 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

B~H

B~H

B~H

B~G

B~F

C~F

B~H

B~G

B~F

C~F

B~H

B~H

B~F

C~E

8

25

25

25

25

25

25

25

25

25

25

25

25

0

1st Stage

418

413

410

399

371

362

406

383

363

351

401

405

382

338

2nd Stage

451

447

444

435

423

411

442

427

417

406

433

439

430

421

3rd Stage

485

483

480

477

472

469

480

475

472

469

473

476

473

491

1st Stage

462

457

454

445

430

431

453

439

443

434

444

449

430

432

2nd Stage

492

489

487

485

490

490

487

484

492

492

480

483

490

518

3rd Stage

540

540

540

540

540

540

540

540

540

540

540

540

540

540

1st Stage

299

300

296

281

286

289

303

306

310

313

309

306

284

294

2nd Stage

457

456

456

450

448

445

457

455

453

450

458

459

448

428

1st Stage

457

457

457

450

449

445

458

455

453

450

459

459

448

429

2nd Stage

568

568

568

568

568

568

568

568

568

568

568

568

568

540

Outlet of seperator

412

407

404

394

362

349

401

376

349

334

397

401

375

315

A) Bottom Burner Elevations in Service i)

ii)

iii)

iv)

v)

vi)

vii)

Identify Mills/elevations in service Burner Tilts (if applicable ) (deg) Inlet of superheater

Outlet of superheater

Inlet to reheater

Outlet to reheater

B) Middle Burner Elevations in Service SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 14 OF 117

Modified Sliding Pressure Operation

i)

ii)

iii)

iv)

v)

vi)

vii)

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Identify Mills/elevations in service

C~I

C~I

C~I

C~H

D~H

D~G

C~I

C~H

D~H

D~G

C~I

C~I

D~H

N/A

Burner Tilts (if applicable ) (deg)

-30

0

20

25

25

13

7

-5

0

-25

-1

10

25

N/A

1st Stage

417

412

406

395

371

362

405

383

363

351

400

404

383

N/A

2nd Stage

451

447

442

432

419

408

442

426

416

406

433

437

427

N/A

3rd Stage

485

483

480

477

472

470

480

475

471

469

472

476

474

N/A

1st Stage

462

456

451

441

441

436

452

438

445

425

443

447

439

N/A

2nd Stage

492

490

487

484

490

491

488

484

492

491

480

483

491

N/A

3rd Stage

540

540

540

540

540

540

540

540

540

540

540

540

540

N/A

1st Stage

299

300

296

281

286

289

303

306

310

313

309

306

284

N/A

2nd Stage

457

455

450

443

442

440

454

453

452

450

457

455

442

N/A

1st Stage

457

455

451

443

442

440

455

454

452

450

458

456

442

N/A

2nd Stage

568

568

568

568

568

568

568

568

568

568

568

568

568

N/A

Outlet of seperator

412

407

402

391

362

349

400

376

349

334

396

399

375

N/A

Inlet of superheater

Outlet of superheater

Inlet to reheater

Outlet to reheater

C) Top Burner Elevations in Service SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 15 OF 117

Modified Sliding Pressure Operation

i)

ii)

iii)

iv)

v)

vi)

vii)

3.03.00

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Identify Mills/elevations in service

D~J

D~J

D~J

E~J

F~J

G~J

D~J

E~J

F~J

G~J

D~J

D~J

F~J

N/A

Burner Tilts (if applicable ) (deg)

-30

-30

-8

12

0

-15

-25

-25

-25

-25

-25

-25

10

N/A

1st Stage

411

411

406

394

371

362

405

380

363

351

399

406

383

N/A

2nd Stage

445

446

442

431

418

407

441

423

414

401

432

441

426

N/A

3rd Stage

481

482

480

477

472

470

480

473

471

468

471

476

474

N/A

1st Stage

455

456

451

440

441

436

451

435

447

435

442

452

441

N/A

2nd Stage

488

489

487

484

490

491

487

482

491

490

480

489

491

N/A

3rd Stage

540

540

540

540

540

540

540

540

540

540

540

540

540

N/A

1st Stage

289

299

296

281

286

289

303

300

310

309

305

306

284

N/A

2nd Stage

450

454

450

440

441

437

454

450

450

445

455

455

439

N/A

1st Stage

450

455

451

440

441

437

455

451

450

445

455

456

440

N/A

2nd Stage

568

568

568

568

568

568

568

568

568

568

568

568

568

N/A

Outlet of seperator

407

406

402

390

362

349

399

374

349

334

395

401

375

N/A

Inlet of superheater

Outlet of superheater

Inlet to reheater

Outlet to reheater

Pressure

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 16 OF 117

Modified Sliding Pressure Operation

3.03.01

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Air (mmwc) i)

ii) iii)

iv)

v)

vi)

3.03.02

Pure Sliding Pressure Operation

Forced draft fan inlet (with air duct, air foil and silencer) Forced draft fan discharge

-36

-34

-30

-18

-12

-8

-30

-20

-10

-10

-36

-34

-14

-4

228

220

205

167

140

153

206

168

140

154

303

217

194

122

Air heater inlet (Secondary air )

200

194

182

152

131

146

183

153

131

147

275

191

184

119

Air heater outlet (Secondary air)

155

152

145

128

117

135

146

129

117

135

235

151

122

114

In burner windbox (Secondary air)

102

102

102

102

102

102

102

102

102

102

102

102

102

102

-24

-24

-24

-17

-12

-9

-24

-17

-12

-9

-25

-24

-11

-5

vii)

Primary air fan inlet (with air duct, air foil and silencer) Primary air fan discharge

884

877

861

835

803

825

861

835

804

826

982

890

904

774

viii)

Air heater inlet (Primary air)

874

867

851

828

798

821

851

828

799

822

972

880

899

772

ix)

Air heater outlet (Primary air)

831

825

811

797

775

803

811

797

776

804

902

827

805

761

x)

Hot primary air in the common duct before pulverisers

808

802

790

781

764

778

790

781

765

779

793

797

790

746

xi)

Cold primary air header

786

781

769

761

745

758

769

766

755

773

772

776

770

728

xii)

Hot primary air at the inlet to pulverisers

658

688

620

596

561

584

620

596

563

586

648

643

613

496

Fuel Side (mmwc) i)

In the pulveriser

658

688

620

596

561

584

620

596

563

586

648

643

613

496

ii)

At the pulveriser outlet

299

335

279

267

249

261

279

267

250

262

294

291

276

203

iii)

At the burners inlet

25

25

25

25

25

25

25

25

25

25

25

25

25

25

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 17 OF 117

Modified Sliding Pressure Operation

3.03.03

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Inlet to economizer (at the specified terminal point)

304.2

300.4

292.9

261.1

195.9

165.5

283.0

220.6

165.3

139.2

282.6

289.2

224.4

101.1

ii)

At economizer inlet

301.2

297.6

290.3

259.1

194.3

164.0

280.4

218.6

163.7

137.7

280.3

286.7

222.7

99.8

iii)

Outlet of economizer

295.0

291.6

284.6

254.4

190.1

160.0

274.7

213.8

159.5

133.8

274.8

281.1

218.3

96.0

iv)

Attemperation water for superheater

304.2

300.4

292.9

261.1

195.9

165.5

283.0

220.6

165.3

139.2

282.6

289.2

224.4

101.1

Attemperation water for reheater

91.5

91.9

89.9

80.4

71.3

66.8

90.2

80.7

71.7

67.2

93.7

93.3

75.4

57.8

278.0

274.8

271.0

248.2

187.7

158.3

260.8

207.2

156.7

131.7

266.2

270.2

213.5

99.4

2

Feed Water (kg/cm ) abs i)

v)

3.03.04

3.03.05

Pure Sliding Pressure Operation

Separator Pressure ( Kg/cm2) abs Steam (kg/cm2)(abs) i)

Inlet of superheater

271.9

270.3

267.3

245.9

185.7

156.5

256.7

203.8

154.0

129.3

263.3

266.8

211.4

97.9

ii)

Outlet of superheater

256.0

255.5

254.5

238.0

179.4

151.2

242.9

193.3

145.6

122.3

252.9

255.0

204.4

93.9

iii)

Inlet to reheater

48.3

48.7

46.7

37.2

28.1

23.6

47.0

37.6

28.5

24.0

50.5

50.1

32.2

14.6

iv)

Outlet of reheater

46.6

47.0

45.1

35.9

27.1

22.7

45.3

36.2

27.4

23.1

48.8

48.4

31.1

14.0

v)

Inlet of seperator

278.0

275.8

271.8

248.7

188.0

158.7

261.7

207.7

157.1

132.1

266.8

270.9

213.9

99.5

vi)

Outlet of seperator

277.0

274.8

271.0

248.2

187.7

158.3

260.8

207.2

156.7

131.7

266.2

270.2

213.5

99.4

3.04.00

Pressure Drop

3.04.01

Air Path: (mmwc) SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 18 OF 117

Modified Sliding Pressure Operation

i)

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

In air ducts including bends dampers, vanes etc

150

115

169

180

195

199

169

185

203

212

232

162

172

247

Across aerofoil (flow measuring device)

33

32

32

28

24

24

32

23

15

10

32

32

25

20

c)

Across RAPH

43

42

40

31

23

18

40

31

23

18

70

53

94

11

d)

Total loss through the system

226

189

241

239

242

241

241

239

241

240

334

247

291

278

Primary air circuit a)

b)

3.04.02

3.04.03

Pure Sliding Pressure Operation

Fuel Path (mmwc) i)

Across the pulverisers

359

353

341

329

312

323

341

329

313

324

354

352

337

293

ii)

In the fuel piping from pulveriser outlet to burners

299

335

279

267

249

261

279

267

250

262

294

291

276

203

Furnace pressure (back draught)

3

3

3

3

3

3

3

3

3

3

3

3

3

3

Across SH/RH convection path

65

65

60

52

46

41

60

52

46

41

62

62

31

14

iii)

Across economizers

26

24

22

14

8

6

22

14

8

6

23

24

24

24

iv)

Across air heaters

84

82

80

62

45

35

80

62

45

35

103

89

157

22

v)

In gas ducts

43

41

37

25

17

13

38

26

16

13

43

41

18

6

Flue Gas Path (mmwc) i)

ii)

a)

Between air heater outlet and electrostatic precipitator funnel inlet

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 19 OF 117

Modified Sliding Pressure Operation 100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Between outlet of electrostatic precipitator funnels & inlet of ID fan

23

22

20

14

9

7

20

14

9

7

23

22

10

3

Between ID fan outlet and chimney inlet

13

12

11

8

5

4

11

8

5

4

13

13

5

2

289

286

262

197

145

119

263

198

142

119

302

283

260

77

Saturated steam connections including horizontal and vertical hangers

5.1

4.5

3.7

2.3

2.0

1.8

4.1

3.4

2.7

2.4

2.9

3.4

2.1

1.5

Superheater Stage I

3.3

3.0

2.6

1.4

1.3

1.1

2.8

2.0

1.7

1.4

2.1

2.4

2.4

2.4

Superheater Stage II

4.3

4.0

3.5

2.1

1.7

1.4

3.8

2.8

2.2

1.9

2.8

3.2

1.9

1.1

Superheater Stage III

3.2

3.0

2.7

1.6

1.3

1.1

2.9

2.2

1.7

1.5

2.2

2.5

1.5

0.8

Superheater desuperheater

2.3

2.2

1.9

1.2

0.9

0.8

2.0

1.6

1.2

1.0

1.5

1.7

1.7

1.7

Reheater Stage I

0.5

0.5

0.4

0.4

0.3

0.2

0.4

0.4

0.3

0.3

0.5

0.5

0.3

0.2

Reheater Stage II

0.8

0.8

0.8

0.6

0.5

0.4

0.8

0.6

0.5

0.4

0.8

0.8

0.6

0.3

Reheater desuperheater

0.06

0.06

0.05

0.03

0.02

0.01

0.05

0.03

0.02

0.01

0.04

0.06

0.02

0.00

-0.3

-0.5

-1.0

-2.4

-3.3

-3.6

-0.9

-2.2

-3.1

-3.5

-2.3

-1.6

-3.0

-4.2

b)

c)

vi) 3.04.04

Total loss through the system

Steam Path (kg/cm2) i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

3.04.05

Pure Sliding Pressure Operation

Feed Water Path (kg/cm2) i)

Valves and connected piping

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 20 OF 117

Modified Sliding Pressure Operation

ii) 3.05.00

economizer

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

6.2

6.0

5.7

4.7

4.2

4.0

5.7

4.8

4.2

3.9

5.5

5.6

4.4

3.8

8.2

8.1

7.7

6.2

4.6

3.9

7.7

6

4.6

3.8

8.1

8.1

5.3

2.2

Velocities (m/sec) i)

Furnace throat gas velocity

ii)

Maximum gas velocity through tube banks of TSH

9

8.9

8.4

6.6

4.9

4.1

8.4

6.5

4.9

4

8.9

8.8

5.6

2.4

Maximum gas velocity through tube banks of economizer

9

8.8

8.3

6.5

4.9

4.1

8.3

6.6

5

4.2

8.9

8.8

5.5

2.6

Stage I

-

-

-

-

-

-

-

-

-

-

-

-

-

-

Stage II

7.9

7.8

7.5

5.9

4.4

3.7

7.4

5.8

4.4

3.6

7.8

7.8

5

2.1

Stage III

8.7

8.6

8.1

6.4

4.8

3.9

8.1

6.3

4.7

3.9

8.6

8.5

5.4

2.3

Stage I

9

8.8

8.3

6.5

4.9

4.1

8.3

6.5

4.9

4.1

8.9

8.8

5.5

2.5

Stage II

8.7

8.6

8.1

6.4

4.8

4

8.1

6.3

4.7

3.9

8.6

8.5

5.4

2.3

Stage I

8

7.9

7.4

5.8

4.4

3.7

7.4

5.9

4.5

3.7

7.5

7.6

4.9

2.3

Stage II

-

-

-

-

-

-

-

-

-

-

-

-

-

-

iii)

Note : In case gas biasing in the convective pass is being used for RH temperature control the details of gas flow and velocity through both the passes shall be indicated a)

b)

c)

iii)

Superheater

Reheater

economizer

Gas/air velocities through

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 21 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

- Secondary RAPH

8.3

8.1

7.6

5.8

4.3

3.6

7.6

5.9

4.3

3.7

6.8

7.4

9.8

2.1

- Primary RAPH

8.7

8.6

8.4

7.1

5.7

4.9

8.4

7.1

5.8

4.9

9.4

8.8

12.4

3.7

- Secondary RAPH

5.6

5.4

5.0

3.9

2.9

2.5

5.1

3.9

2.9

2.6

5.2

5.2

6.6

1.5

- Primary RAPH

5.4

5.3

5.1

4.4

3.7

3.2

5.1

4.4

3.6

3.2

6.8

5.9

8.1

2.3

the air heater heating elements a)

b)

iv)

v)

vi)

3.06.00

Gas

Air

Air velocities a)

Cold air ducts

13.9

13.5

12.6

10.1

7.9

6.9

12.6

10.1

7.7

7

13.8

13.5

8.5

4.4

b)

Hot air ducts

15.3

14.6

13.5

10.4

7.8

6.7

13.6

10.6

7.7

6.9

13.1

13.7

8.5

3.9

Gas velocities in gas ducting sections a)

Eco to AH

10.4

10.2

9.6

7.5

5.7

4.7

9.6

7.5

5.6

4.8

9.1

9.5

6.1

2.9

b)

Eco gas bypass ducts

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

c)

AH to ESP

11.6

11.4

10.8

8.6

6.8

5.9

10.8

8.7

6.7

5.9

11

10.9

7.3

4.1

d)

ESP to ID fan

12.3

12

11.4

9.1

7.2

6.2

11.5

9.2

7.1

6.2

11.7

11.5

7.7

4.3

e)

ID fan to stack

11.9

11.7

11

8.8

6.9

6

11.1

8.9

6.9

6

11.3

11.2

7.4

4.2

27.6

27.2

26.7

26.2

25.5

26.0

26.7

25.5

25.5

26.0

27.3

27.2

26.6

24.6

Air-fuel mixture velocity in the fuel pipe line

Percentage of Oxygen in flue gas

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 22 OF 117

Modified Sliding Pressure Operation 100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

i)

At furnace exit

3.45

3.45

3.45

3.45

3.94

4.02

3.45

3.45

3.55

4.02

3.45

3.45

3.45

4.38

ii)

At economizer outlet

3.45

3.45

3.45

3.45

3.94

4.02

3.45

3.45

3.55

4.02

3.45

3.45

3.45

4.38

iii)

At air heater outlet (primary)

5.60

5.62

5.66

6.00

6.87

7.35

5.64

5.99

6.53

7.38

5.62

5.60

5.09

8.58

iv)

At air heater outlet (secondary)

4.55

4.57

4.62

4.88

5.69

6.06

4.62

4.86

5.35

6.01

4.91

4.73

4.40

7.51

In the common duct before ESP

4.84

4.86

4.92

5.23

6.08

6.50

4.91

5.20

5.74

6.47

5.15

4.99

4.62

7.93

vi)

At ESP outlet

4.84

4.86

4.92

5.23

6.08

6.50

4.91

5.20

5.74

6.47

5.15

4.99

4.62

7.93

vii)

At ID fan inlet

4.84

4.86

4.92

5.23

6.08

6.50

4.91

5.20

5.74

6.47

5.15

4.99

4.62

7.93

v)

3.07.00

Pure Sliding Pressure Operation

Flow rate of air (kg/hr) i)

FD fan outlet

1,732,318

1,681,102

1,570,672

1,252,816

980,482

863,822

1,575,972

1,260,852

955,412

873,054

1,720,416

1,682,782

1,058,293

548,946

ii)

PA fan outlet

946,376

939,530

924,792

794,714

665,082

561,960

924,712

795,138

665,594

563,298

960,794

945,314

642,986

434,342

iii)

Air heater inlet 661,390

650,496

635,816

572,586

497,226

443,646

633,822

565,624

491,666

443,622

879,964

752,148

502,852

358,342

1,732,318

1,681,102

1,570,672

1,252,816

980,482

863,822

1,575,972

1,260,852

955,412

873,054

1,720,416

1,682,782

1,058,293

548,946

566,990

556,096

541,416

476,386

399,226

343,846

540,222

470,224

394,466

343,822

765,564

650,348

450,152

253,942

1,606,118

1,555,902

1,447,272

1,132,016

861,482

744,822

1,452,572

1,141,052

838,212

755,054

1,565,216

1,543,982

991,093

429,946

Tempering air for each pulveriser

40,712

41,291

41,282

37,021

33,571

29,579

41,556

38,252

34,786

29,919

11,547

27,595

28,027

25,333

vi)

Total air to each pulveriser

121,711

120,733

118,627

116,419

113,416

115,540

118,730

116,623

113,679

115,875

120,913

120,502

118,057

109,981

vii)

Total combustion air (included furnace leakage)

2,534,117

2,477,055

2,353,687

1,906,553

1,504,587

1,283,005

2,359,707

1,916,813

1,482,629

1,294,575

2,487,633

2,463,519

1,657,402

835,911

iv)

v)

a)

Primary air

b)

Secondary air

Air heater outlet a)

Primary air

b)

Secondary air

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 23 OF 117

Modified Sliding Pressure Operation

3.08.00

3.09.00

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

741,312

731,628

716,986

622,238

521,538

454,480

718,156

620,380

521,840

449,248

889,340

798,468

560,000

346,860

2,058,744

2,005,122

1,883,450

1,484,138

1,136,344

958,576

1,888,932

1,497,334

1,115,400

976,552

1,859,100

1,923,326

1,271,079

571,880

835,712

826,028

811,386

718,438

619,538

554,280

811,756

715,780

619,040

549,048

1,003,740

900,268

612,700

451,260

Flow rate of flue gases (kg/hr) i)

Primary Airheater inlet

ii)

Secondary Airheater inlet

iii)

Primary airheater outlet

iv)

Secondary airheater outlet

2,184,944

2,130,322

2,006,850

1,604,938

1,255,344

1,077,576

2,012,332

1,617,134

1,232,600

1,094,552

2,014,300

2,062,126

1,338,279

690,880

v)

ESP inlet

3,020,656

2,956,350

2,818,236

2,323,376

1,874,882

1,631,856

2,824,088

2,332,914

1,851,640

1,643,600

3,018,040

2,962,394

1,950,979

1,142,140

vi)

ESP outlet

3,020,656

2,956,350

2,818,236

2,323,376

1,874,882

1,631,856

2,824,088

2,332,914

1,851,640

1,643,600

3,018,040

2,962,394

1,950,979

1,142,140

vii)

ID fan inlet

3,020,656

2,956,350

2,818,236

2,323,376

1,874,882

1,631,856

2,824,088

2,332,914

1,851,640

1,643,600

3,018,040

2,962,394

1,950,979

1,142,140

viii)

Recirculation gas flow (Applicable for the cases where gas recirculation is being used to control RH steam temperature)

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Excess Air (%) i)

At burner

20.0

20.0

20.0

20.0

23.4

24.0

20.0

20.0

20.7

24.0

20.0

20.0

20.0

26.7

ii)

At furnace exit

20.0

20.0

20.0

20.0

23.4

24.0

20.0

20.0

20.7

24.0

20.0

20.0

20.0

26.7

iii)

At economizer outlet

20.0

20.0

20.0

20.0

23.4

24.0

20.0

20.0

20.7

24.0

20.0

20.0

20.0

26.7

iv)

At the air heater exit (primary)

36.40

36.62

36.96

39.93

48.24

53.17

36.79

39.82

44.84

53.51

36.57

36.42

32.11

67.50

At the airheater exit (secondary)

27.87

28.02

28.42

30.47

37.22

40.46

28.39

30.29

34.30

40.02

30.74

29.28

26.78

54.88

vi)

At ESP inlet

30.13

30.32

30.77

33.26

40.69

44.55

30.71

33.08

37.66

44.28

32.63

31.37

28.41

59.65

vii)

At ID fan inlet

30.13

30.32

30.77

33.26

40.69

44.55

30.71

33.08

37.66

44.28

32.63

31.37

28.41

59.65

v)

3.10.00

Pure Sliding Pressure Operation

Leakages (Tonnes per hour)

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 24 OF 117

Modified Sliding Pressure Operation

i)

Primary air a) Regenerative air preheater b)

ii)

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

94.4

94.4

94.4

96.2

98.0

99.8

93.6

95.4

97.2

99.8

114.4

101.8

52.7

104.4

0

0

0

0

0

0

0

0

0

0

0

0

0

0

126.2

125.2

123.4

120.8

119.0

119.0

123.4

119.8

117.2

118.0

155.2

138.8

67.2

119.0

Secondary air a)

3.11.00

Ducts/Dampers

Pure Sliding Pressure Operation

Regenerative air heater

b)

Wind box

0

0

0

0

0

0

0

0

0

0

0

0

0

0

c)

Ducts/Dampers

0

0

0

0

0

0

0

0

0

0

0

0

0

0

Heat Balance (based on GCV of design coal fired) i)

Total coal fired (tonnes/hr)

471.8

461.1

438.1

354.9

272.4

231.1

439.3

356.8

274.4

233.2

463.1

458.6

308.5

147.3

ii)

Gross Calorific value of coal (Kcal/kg)

3300

3300

3300

3300

3300

3300

3300

3300

3300

3300

3300

3300

3300

3300

- Primary

77.3

77.6

78.3

79.5

80.8

79.1

78.4

79.1

80.5

79.2

77.7

78.0

78.9

80.5

- Secondary

219.9

218.2

211.1

192.0

176.5

171.9

212.0

194.8

172.6

174.9

163.7

189.6

179.2

136.4

b)

economizer (kcal)

298.8

297.1

293.2

276.1

274.2

272.5

292.5

284.2

277.2

279.5

422.0

360.2

263.1

360.2

c)

Superheater (kcal) Stage I

316.2

342.0

364.7

370.9

362.8

319.6

352.1

332.4

339.5

289.4

338.4

350.6

381.9

350.6

Stage II

212.6

225.7

236.4

257.1

261.8

268.1

230.8

237.6

251.2

253.9

224.8

230.2

270.2

230.2

Stage III

227.0

236.8

240.6

234.6

211.6

200.0

235.7

219.5

200.6

191.5

238.2

241.1

216.7

241.1

iii)

Heat absorbed per kg of coal in a)

Air preheaters (kcal)

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 25 OF 117

Modified Sliding Pressure Operation 100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Roof tubes

6.5

6.7

6.7

6.6

6.0

5.9

6.6

6.2

5.6

5.8

6.7

6.8

6.1

6.8

Convective pass

52.7

55.0

56.5

57.8

60.3

62.3

55.6

57.6

60.4

63.9

55.7

56.4

59.7

56.4

Enclosure

d)

e)

3.12.00

(Included in steam cooled)

Steam cooled

29.1

30.4

31.1

31.4

29.3

28.6

30.4

28.9

27.5

27.0

30.2

30.8

30.0

30.8

Hanger tubes

12.2

12.7

12.9

12.9

13.2

13.4

12.3

12.8

13.2

13.7

12.6

13.0

13.0

13.0

Stage I

357.6

362.0

363.6

352.6

316.1

295.8

353.8

320.3

284.6

269.2

350.8

357.3

320.2

357.3

Stage II

225.6

237.6

246.1

257.1

246.7

243.7

240.1

234.2

232.0

229.1

234.8

241.1

254.9

241.1

1095.7

1042.5

978.8

1102.5

1065.4

1146.8

1020.2

1115.3

1138.2

1137.6

970.7

986.1

1039.6

986.1

Screen tubes

35.5

37.2

38.3

39.8

40.3

41.0

37.8

37.7

39.8

39.9

37.6

38.1

40.7

38.1

Any other

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

3166.8

3181.5

3158.3

3270.8

3145.0

3148.7

3158.2

3160.6

3123.0

3054.5

3163.9

3179.3

3154.2

3128.6

Reheater (kcal)

Water walls Wall tubing

iv)

Pure Sliding Pressure Operation

Total heat absorbed effectively by the unit (per kg of coal (kcal) be)

Heat losses in the Steam Generator Heat losses in the Steam Generator shall be quoted for guarantee conditions also: i)

Heat loss due to flue gasses (%) -

Dry gas loss

4.69

4.70

4.67

4.30

4.10

4.11

4.67

4.38

4.11

4.05

3.82

3.92

4.10

4.52

-

Hydrogen in the fuel

4.17

4.17

4.17

4.14

4.11

4.11

4.17

4.14

4.12

4.10

4.11

4.12

4.14

4.11

-

Moisture in the fuel

2.29

2.29

2.29

2.27

2.26

2.25

2.29

2.27

2.26

2.25

2.25

2.26

2.27

2.25

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 26 OF 117

Modified Sliding Pressure Operation

ii)

iii)

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

-

Moisture in the air

0.11

0.11

0.11

0.10

0.10

0.10

0.11

0.10

0.10

0.10

0.09

0.09

0.10

0.11

-

Total heat loss due to flue gases

11.26

11.27

11.24

10.81

10.57

10.57

11.24

10.89

10.59

10.50

10.27

10.39

10.61

10.99

Heat loss due to unburnt carbon (%) in: -

Furnace bottom ash

0.58

0.58

0.58

0.58

0.58

0.58

0.58

0.58

0.58

0.58

0.58

0.58

0.58

0.58

-

Fly ash

0.92

0.92

0.92

0.92

0.92

0.92

0.92

0.92

0.92

0.92

0.92

0.92

0.92

0.92

-

Total heat loss due to unburnt carbon

1.50

1.50

1.50

1.50

1.50

1.50

1.50

1.50

1.50

1.50

1.50

1.50

1.50

1.50

Sensible heat loss (%) in: -

Furnace bottom ash

0.42

0.42

0.42

0.42

0.42

0.42

0.42

0.42

0.42

0.42

0.42

0.42

0.42

0.42

-

economizer hopper ash

0.03

0.03

0.03

0.03

0.03

0.02

0.03

0.03

0.03

0.03

0.02

0.03

0.03

0.02

Air heater hopper ash

0.01

0.01

0.01

0.01

0.01

0.01

0.01

0.01

0.01

0.01

0.01

0.01

0.01

0.01

Any other hopper ash

0.15

0.15

0.15

0.14

0.12

0.12

0.15

0.14

0.13

0.12

0.12

0.13

0.14

0.12

Total sensible heat loss

0.61

0.61

0.61

0.60

0.58

0.57

0.61

0.60

0.59

0.58

0.57

0.59

0.60

0.57

iv) Heat loss due to Mill Rejects (%)

0.07

0.07

0.07

0.07

0.07

0.07

0.07

0.07

0.07

0.07

0.07

0.07

0.07

0.07

v)

Heat loss due to radiation (%)

0.18

0.19

0.19

0.23

0.30

0.34

0.19

0.23

0.30

0.34

0.18

0.18

0.26

0.53

vi)

Unaccounted heat loss (%) (give details)

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

Total heat losses {sum of the (i) to (v)}

13.62

13.64

13.61

13.21

13.02

13.05

13.61

13.29

13.05

12.99

12.59

12.73

13.04

13.66

-

-

-

vii)

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 27 OF 117

Modified Sliding Pressure Operation 100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Heat credits (give details of equipment and breakup)

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

ix)

Manufacturer’s margin(%)

0.10

0.10

0.10

0.10

0.10

0.10

0.10

0.10

0.10

0.10

0.10

0.10

0.10

0.10

x)

Steam generator efficiency (%)

86.28

86.26

86.29

86.69

86.88

86.85

86.29

86.61

86.85

86.91

87.31

87.17

86.86

86.24

Furnace bottom hopper (kg/hr)

40572

39655

37680

30521

23422

19876

37776

30685

23598

20055

39824

39438

26532

12672

economizer hopper (kg/hr)

10143

9914

9420

7630

5856

4969

9444

7671

5899

5014

9956

9859

6633

3168

iii)

Air heater hopper (kg/hr)

6086

5948

5652

4578

3513

2981

5666

4603

3540

3008

5974

5916

3980

1901

iv)

Any other hoppers (kg/hr)

146059

142757

135646

109875

84320

71554

135993

110466

84953

72199

143367

141977

95514

45619

1592.6

1534.3

1453.8

1170.8

894.2

765.4

1458.0

1185.9

899.7

764.4

1523.4

1512.1

1013.2

N/A

Identify mills/elevations in services

D~J

D~J

D~J

E~J

F~J

G~J

D~J

E~J

F~J

G~J

D~J

D~J

F~J

N/A

Burner tilt (deg)

-30

-30

-8

12

0

-15

-25

-25

-25

-25

-25

-25

10

N/A

With Middle mills /elevations in operation

1569.2

1532.9

1453.8

1175.2

895.6

757.1

1457.9

1178.0

901.8

764.6

1515.0

1512.1

1016.4

N/A

Identify mills/elevations in services

C~I

C~I

C~I

C~H

D~H

D~G

C~I

C~H

D~H

D~G

C~I

C~I

D~H

N/A

Burner tilt (deg)

-30

0

20

25

25

13

7

-5

0

-25

-1

10

25

N/A

viii)

3.13.00

Pure Sliding Pressure Operation

Weight and Distribution of Ash collected i)

ii)

3.14.00

Furnace Design Data

3.14.01

Net Heat Input (x106kal/hr) a)

With top mills /elevations in operation i)

ii) b)

i)

ii)

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 28 OF 117

Modified Sliding Pressure Operation

c)

ii)

3.14.02

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

1569.2

1536.4

1466.4

1186.2

903.2

761.7

1464.6

1180.8

904.8

765.4

1516.9

1519.5

1024.7

476.8

B~H

B~H

B~H

B~G

B~F

C~F

B~H

B~G

B~F

C~F

B~H

B~H

B~F

C~E

8

25

25

25

25

25

25

25

25

25

25

25

25

0

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

161.0

157.5

125.1

69.2

53.1

54.8

136.3

94.6

69.8

65.2

141.6

107.3

39.3

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

166.2

129.6

88.6

59.6

45.9

50.4

108.8

100.5

74.1

50.4

124.1

91.7

45.0

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

128.5

86.1

80.1

74.2

57.6

51.5

82.6

83.6

61.8

51.5

92.6

33.4

63.5

41.3

207.5

203.2

165.3

120.1

90.4

90.0

177.5

157.0

116.7

106.1

183.6

158.7

66.2

N/A

With bottom mills /elevations in operation i)

Pure Sliding Pressure Operation

Identify mills/elevations in services Burner tilt (deg)

Cumulative Heat Absorption in Furnace i)

Passive Heat Absorption (Heat Absorption in furnace from bottom upto mean firing Zone level) a)

b)

c)

ii)

Upto exit of Burner Basket a)

b)

With top mills/elevations in operation and conditions as identified in Clause 3.14.01 With middle mills/elevations in operation and conditions as identified

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 29 OF 117

Modified Sliding Pressure Operation

c)

iii)

b)

c)

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

in Clause 3.14.01

233.9

187.7

135.5

101.3

76.6

86.5

161.0

155.8

113.6

86.5

179.4

143.4

71.1

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

207.7

150.8

142.5

114.3

95.5

83.1

157.1

129.0

102.5

83.1

144.8

60.7

105.6

76.2

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

365.0

358.1

315.7

283.0

208.8

200.3

330.5

295.3

235.2

218.6

328.1

325.9

201.0

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

405.4

364.2

308.8

248.5

204.6

198.9

330.0

301.2

234.8

198.9

336.8

328.2

206.9

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

400.0

344.1

321.0

262.6

218.5

199.7

333.4

295.7

233.4

199.7

331.0

132.5

226.3

164.9

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

410.5

403.4

360.4

335.2

247.7

233.5

374.8

336.3

270.3

251.2

370.7

376.7

245.7

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

453.8

414.3

361.6

295.3

246.4

232.6

381.3

344.5

271.0

232.6

383.3

384.4

252.9

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

455.0

402.3

375.3

308.3

255.7

233.8

387.5

345.4

271.9

233.8

386.8

152.5

261.9

188.0

Upto Furnace Arch Exit a)

b)

c)

v)

100% BMCR

Upto Furnace Arch level a)

iv)

Pure Sliding Pressure Operation

Upto platen superheater Exit

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 30 OF 117

Modified Sliding Pressure Operation

a)

b)

c)

vi)

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

758

739

697

619

464

406

700

602

475

417

712

714

478

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

772

748

698

572

462

404

707

603

474

392

716

724

473

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

772

730

688

564

457

399

700

600

471

398

714

477

466

285

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

1026

995

946

822

611

528

942

796

615

534

973

971

633

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

1020

1002

946

774

608

525

949

792

613

508

971

981

625

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

1020

984

932

760

599

518

941

787

608

514

914

731

614

343

1230

1185

1127

965

711

608

1119

931

707

608

1163

1158

737

N/A

Upto final super heater Exit a)

b)

c)

vii)

Pure Sliding Pressure Operation

Upto primary reheater exit a)

b)

With top mills/elevations in operation and conditions as identified in Clause 3.14.01 With middle mills/elevations in operation and

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PAGE 31 OF 117

Modified Sliding Pressure Operation

c)

viii)

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

conditions as identified in Clause 3.14.01

1211

1191

1127

920

709

606

1126

924

706

583

1156

1168

732

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

1211

1175

1118

911

704

601

1121

920

702

589

1100

921

725

388

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

1372

1322

1256

1022

786

669

1259

1033

792

677

1360

1326

889

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

1352

1321

1256

1022

786

669

1259

1026

792

675

1352

1326

889

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

1352

1321

1256

1022

786

669

1259

1026

792

675

1352

1326

889

428

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

1508

1452

1377

1155

852

720

1368

1120

849

723

1454

1438

881

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

1485

1458

1375

1117

853

721

1375

1118

852

702

1446

1449

886

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

1485

1447

1387

1125

860

723

1382

1118

851

709

1394

1215

892

454

Upto economizer exit a)

b)

c)

ix)

Pure Sliding Pressure Operation

Upto air preheater exit a)

b)

c)

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PAGE 32 OF 117

Modified Sliding Pressure Operation

x)

b)

c)

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

48

49

49

51

52

53

50

53

54

55

47

48

52

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

50

50

49

49

52

53

50

52

54

54

48

48

51

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

50

49

48

48

51

53

49

52

54

54

49

37

50

61

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

89.0

86.4

81.0

62.9

83.4

75.2

81.4

63.7

94.3

76.6

73.6

78.4

82.8

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

89.0

86.4

81.0

62.9

82.2

72.3

81.4

63.7

88.4

56.0

73.6

78.4

72.1

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

89.0

86.4

81.0

62.9

47.5

59.8

81.4

63.7

80.1

67.8

73.6

78.4

36.0

24.4

Superheater Spray Quantity in T/hr a)

b)

c)

3.14.04

100% BMCR

Furnace heat absorption as percentage of total heat absorption (upto Arch exit) a)

3.14.03

Pure Sliding Pressure Operation

Reheater Spray Quantity in T/hr a)

With top mills/elevations in operation and conditions as identified

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PAGE 33 OF 117

Modified Sliding Pressure Operation

b)

c)

3.15.00

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

in Clause 3.14.01

36.6

1.8

0.0

0.0

0.0

0.0

0.0

12.1

0.0

4.3

10.7

0.0

0.0

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

Furnace Performance Data Description (As per Clause 5.00.00 Section-VIA, PartBSub-section-MI) i)

Total heat duty (106 Kcal/hr)

1352.0

1321.2

1255.8

1021.5

786.2

669.2

1258.4

1026.2

791.8

674.8

1352.2

1326.4

889.3

427.9

ii)

Efficiency (%)

86.85

86.83

86.86

87.22

87.47

87.74

86.81

87.16

87.44

87.68

88.49

87.65

87.35

88.00

iii)

Total heat generated 6 (10 Kcal/hr)

1556.8

1521.6

1445.8

1171.1

898.8

762.7

1449.5

1177.4

905.5

769.6

1528.1

1513.3

1018.1

486.2

Net heat input (106 Kcal/hr) (Unburnt)

1569.2

1532.9

1453.8

1170.8

894.2

757.1

1457.9

1178.0

899.7

764.6

1515.0

1512.1

1013.2

476.8

v)

Furnace Plan area (m2)

341.4

341.4

341.4

341.4

341.4

341.4

341.4

341.4

341.4

341.4

341.4

341.4

341.4

341.4

vi)

Furnace EPRS (m2)

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

vii)

Furnace Volume (m3)

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

viii)

Net heat input/plan area (106 Kcal/m2/hr)

4.60

4.49

4.26

3.43

2.62

2.22

4.27

3.45

2.64

2.24

4.44

4.43

2.97

1.40

Net heat input /EPRS (106 Kcal/m2/hr)

0.174

0.169

0.161

0.129

0.099

0.084

0.161

0.130

0.099

0.085

0.168

0.167

0.112

0.053

Volumetric Heat Release rate (106 Kcal/m3/hr)

0.073

0.071

0.067

0.055

0.042

0.036

0.068

0.055

0.042

0.036

0.071

0.071

0.047

0.023

iv)

ix)

x)

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PAGE 34 OF 117

Modified Sliding Pressure Operation

xi) 3.16.00

3.17.00

3.18.00

Furnace exit gas temp (DegC)

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

988

1003

1004

977

910

880

994

943

894

864

1000

1007

943

754

Mass velocity in evaporator tubes (Kg/m2 sec) i)

Maximum

3150

3058

2865

2226

1640

1365

2881

2255

1672

1391

2605

2775

1314

669

ii)

Minimum

2495

2422

2270

1764

1299

1081

2282

1787

1325

1102

2064

2198

1659

844

Tube Mass Velocity (Kg/m2sec) (Vertical Wall) i)

Front water walls

1183

1148

1075

838

615

512

1081

849

627

522

977

1041

623

317

ii)

Rear water walls

1085

1054

987

771

567

472

992

781

577

481

899

957

618

314

iii)

Side Walls

1173

1138

1067

826

611

508

1073

836

623

517

970

1033

572

291

Auxiliary Steam Consumption i)

Steam conditions a)

b)

Pressure range (kg/cm2) (abs) Temperature range (degC)

16

210 ~ 310

ii)

Fuel oil heating (kg/hr) Max

N/A

iii)

Fuel oil line tracing (kg/hr) Max

N/A

iv)

Steam coil air pre-heater (kg/hr)Max a)

Primary

7406

b)

Secondary

17490

v) Total auxiliary steam consumSIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 35 OF 117

Modified Sliding Pressure Operation 100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Pure Sliding Pressure Operation 100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

ed from startup to full load a)

b)

c)

d)

e)

After eight hours shutdown (kg/hr)

Later

After four hours shutdown (kg/hr)

Later

Hot restart after trip out (Less than 1 hr shut down) (kg/hr)

Later

After thirty six hours shutdown (Kg/hour)

Later

Cold start, After seventy two hours(kg/hr

Later

3.19.00

Start ups

3.19.01

Recommended Startup time periods to bring steam Generator to full load from ignition (with HP-LP bypass system) i)

ii)

iii)

iv)

v)

vi)

Cold start, (hours), after (72) hours

9.34

After thirty six (36) hours shut down (hours)

4.6

After twenty four (24) hours shut down (hours)

4.3

After twelve (12) hours shutdown (hours) After eight (8) hours shutdown (hours)

4

3.5

After four (4) hours

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 36 OF 117

Modified Sliding Pressure Operation 100% BMCR

vii)

3.19.02

3.20.00

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Pure Sliding Pressure Operation 100% TMCR

80% TMCR

shutdown (hours)

3.3

Hot restart after trip out with less than one hour shut down

2.5

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Number of start ups/life (Nos) of following type for which the unit has been designed a)

Cold startup (after 72 hours)

455

b)

Warm startup (after 36 hours)

910

c)

Hot startups (after 8 hours)

4550

d)

Daily load cycling between 40% to 100%

No limit provided recommended heat-up ratesAre adhered to.

Quantity of expected steam to be vented out in raising full pressure when starting without HP-LP bypass (Kg) i)

ii)

iii)

iv)

v)

vi)

vii)

From cold start up after (72) hours

Later

After thirty six (36) hours shut down

Later

After twenty four (24) hours shut down

Later

After twelve (12) hours shutdown

Later

After eight (8) hours shutdown

Later

After four (4) hours shutdown

Later

Hot restart after trip out

Later

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 37 OF 117

Modified Sliding Pressure Operation 100% BMCR

3.21.00

b)

c)

3.23.00

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

SH drains during starting a)

3.22.00

VWO

Pure Sliding Pressure Operation

Flow rate of drain water from primary superheater header (kg/hr)

N/A

Flow rate of drain water from SH final header (kg/hr)

N/A

Flow rate of drain water from SH final header (kg/hr)

N/A

Wind box performance i)

Free air area (m2)

3.49

3.49

3.49

2.99

2.49

1.99

3.49

2.99

2.49

1.99

3.49

3.49

2.49

1.49

ii)

Secondary air flow into the 3 wind box (m /sec)

754

731

676

514

379

321

680

521

370

327

648

681

435

176

0.591

0.591

0.594

0.611

0.632

0.645

0.594

0.608

0.629

0.641

0.671

0.630

0.632

0.680

iii)

Secondary air density (kg/m3)

iv)

Secondary air temperature in the wind box (degC)

296

296

293

278

259

249

294

281

262

252

229

262

259

222

v)

Secondary air velocity (m/sec)

54.1

52.4

48.5

43.0

38.0

40.3

48.7

43.6

37.2

41.1

46.5

48.9

43.7

29.4

vi)

Differential pressure with respect to the furnace (mmwc)

102

Combustion Data i)

ii)

iii)

Stoichiometric dry air required kg/kg fuel

4.539

Stoichiometric wet air required kg/kg fuel

4.602

Volume of flue gas at Eco outlet per Kg of Coal (NM3)

4.338

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PAGE 38 OF 117

Modified Sliding Pressure Operation 100% BMCR

iv)

v)

vi)

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Pure Sliding Pressure Operation 100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Emissivity at mean firing zone (Correct upto fifth place of decimal) a) Flame Emissivity (Luminous emissivity) b) Gas Emissivity (Non-luminous emissivity) c) Total Emissivity (Luminous+Non-luminous emissivity) Specific heat of flue gases at mean firing zone (correct upto fifth place of decimal) Weight of flue gas produced by burning 1 kg of fuel (kg) at Eco outlet

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

0.1516 0.3431 0.4947

0.33062 kcal/kg-k

5.935

PAGE 39 OF 117

4.00.00

ANTICIPATED PERFORMANCE DATA OF STEAM GENERATOR FOR DESIGN/WORST/BEST COALS BASED ON DESIGN AMBIENT AIR CONDITION OF 27℃ & 60%RH B) WORST COAL Modified Sliding Pressure Operation

4.01.00

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Steam flow at superheater outlet (Tonnes/hr)

2225

2160

2023.75

1572.47

1158.41

963.76

2035.24

1592.96

1178.13

982.34

1839.5

1960.0

1335.0

596.1

Steam pressure at superheater outlet (kg/cm2) abs

256

255

254.45

238.01

179.42

151.25

242.89

193.27

145.52

122.33

252.92

254.98

204.40

93.9

Steam temperature at superheater outlet (degC)

540

540

540

540

540

540

540

540

540

540

540

540

540

540

1741.82

1753.03

1678.37

1328.96

996.95

836.41

1686.33

1343.65

1012.39

851.48

1784.2

1784.34

1138

517.2

Steam pressure at reheater inlet (kg/cm2)(abs)

48.3

48.7

46.7

37.2

28.1

23.6

47.0

37.6

28.5

24.0

50.5

50.1

32.2

14.6

Steam temperature at reheater outlet (degC)

568

568

568

568

568

568

568

568

568

568

568

568

568

540

Steam temperature at reheater inlet (degC)

299

300

296

281

286

289

303

306

310

313

309

306

284

285

Pressure drop across reheater (kg/cm2)

1.69

1.69

1.62

1.30

1.02

0.88

1.63

1.34

1.05

0.90

1.70

1.70

1.13

0.57

General i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

Reheater steam flow (Tonnes/hr)

ix)

Control point (% TMCR)

50

50

50

50

50

50

50

50

50

50

50

50

50

50

x)

Feed water temperature (degC)

289.64

290

286.23

270.35

254.09

244.34

287.28

273.24

256.75

246.95

196.15

243.54

261

219

Steam generator efficiency based on the HHV of design coal

84.89

85.13

85.17

85.56

85.76

85.35

85.06

85.38

85.84

85.71

86.08

86.05

85.89

84.91

xi)

xii)

Heat liberated by fuel per

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 40 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

unit furnace volume (x106kal/m3/hr)

0.073

0.072

0.068

0.055

0.042

0.036

0.068

0.055

0.043

0.036

0.072

0.071

0.048

0.023

Furnace cooling factor (x106kcal/m2/hr)

0.174

0.170

0.161

0.130

0.099

0.084

0.162

0.131

0.100

0.084

0.168

0.168

0.113

0.053

Burner zone heat release rate (x106kcal/m2/hr)

1.208

1.176

1.119

0.906

0.693

0.589

1.122

0.911

0.699

0.593

1.185

1.170

0.788

0.375

Plan area heat release rate (x106kcal/m2/hr)

4.61

4.50

4.27

3.44

2.62

2.23

4.28

3.46

2.64

2.24

4.45

4.44

2.98

1.41

Total number of coal pulverisers

10

10

10

10

10

10

10

10

10

10

10

10

10

10

xvii) Number of coal pulverisers working with design coal

9

8

8

7

5

4

8

7

5

4

9

8

5

3

525.5

511.8

487.0

394.5

301.7

256.2

488.2

396.6

304.1

258.2

515.7

509.2

342.9

163.3

Furnace exit gas temperature (degC)

976

986

992

962

901

867

981

931

883

861

985

994

932

743

Dryness fraction of steam at drum outlet (%)

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

xiii)

xiv)

xv)

xvi)

xviii) Weight of coal fired (tonnes/hr) xix)

xx)

xxi)

Steam Purity at SH outlet (ppm) a)

Total dissolved solids

b)

Silica

c)

Sodium

d)

Chlorides

e)

Copper

f)

Iron

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

Max 0.002 Max 0.002 Max 0.002 0.002 Max 0.001 Max 0.005

PAGE 41 OF 117

Modified Sliding Pressure Operation 100% BMCR

VWO

100% TMCR

80% TMCR

xxii) Furnish calculations for plan area heat release rate, burner zone heat release rate, volumetric heat release rate furnace cooling factor & heat input per burner alongwith details of EPRS calculation, basis for the fouling factor/surface adjustment factor considered

4.02.00

Temperature ( degC)

4.02.01

Air

60% TMCR

50% TMCR

Pure Sliding Pressure Operation 100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Refer to Furnace Performance and Sizing Calculation (T04019-SY-C0003)

A) Bottom Burner Elevations in Service i)

Identify Mills/Elevations in service

A~I

A~H

A~H

B~H

B~F

C~F

A~H

B~H

B~F

C~F

A~I

A~H

B~F

C~E

Burner Tilts (if appli cable( deg)

-8

16

25

25

25

25

20

25

25

0

15

25

25

0

iii)

Design Ambient

27

27

27

27

27

27

27

27

27

27

27

27

27

27

iv)

Inlet to the RAPH (Primary air)

34.7

34.7

34.4

34.0

41.0

51.0

34.4

34.0

38.4

47.4

48.5

34.8

33.9

67.0

Outlet of RAPH (Primary air)

289

280

283

269

252

243

287

272

255

249

219

248

243

220

Inlet to the RAPH (Secondary air)

30.9

30.9

30.6

30.3

39.0

51.0

30.6

30.3

36.0

45.6

48.0

30.9

30.1

63.0

Outlet of the RAPH (Secondary air)

301

300

295

279

262

252

298

284

266

258

235

263

257

224

Secondary air at Inlet to burners

301

300

295

279

262

252

298

284

266

258

235

263

257

224

ii)

v)

vi)

vii)

viii)

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 42 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Hot Primary air in the common duct before pulverisers

289

280

283

269

252

243

287

272

255

249

219

248

243

220

Hot primary air at the inlet to pulverisers

231

240

235

228

234

240

235

228

235

241

215

239

239

216

Identify Mills/Elevations in service

A~I

B~I

B~I

C~I

D~H

D~G

B~I

C~I

D~H

D~G

A~I

B~I

B~I

N/A

Burner Tilts (if appli cable (deg)

-30

-23

4

25

25

-16

-13

-5

3

-25

-21

-7

25

N/A

iii)

Design Ambient

27

27

27

27

27

27

27

27

27

27

27

27

27

N/A

iv)

Inlet to the RAPH (Primary air)

34.7

34.7

34.4

34.0

42.0

52.0

34.4

34.0

38.4

47.4

48.5

34.7

33.9

N/A

Outlet of RAPH (Primary air)

289

280

283

268

250

242

287

272

254

249

219

248

243

N/A

Inlet to the RAPH (Secondary air)

30.9

30.9

30.6

30.3

38.0

51.0

30.6

30.3

35.0

45.6

48.0

30.9

30.1

N/A

Outlet of the RAPH (Secondary air)

301

300

295

279

261

252

298

283

265

258

233

263

258

N/A

Secondary air at Inlet to burners

301

300

295

279

261

252

298

283

265

258

233

263

258

N/A

Hot Primary air in the common duct before pulverisers

289

280

283

268

250

242

287

272

254

249

219

248

243

N/A

Hot primary air at the inlet to pulverisers

231

240

235

228

234

240

235

228

235

240

215

239

239

N/A

ix)

x)

B) Middle Burner Elevations in Service i)

ii)

v)

vi)

vii)

viii)

ix)

x)

C) Top Burner Elevations SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 43 OF 117

Modified Sliding Pressure Operation 100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

B~J

C~J

C~J

D~J

F~J

G~J

C~J

D~J

F~J

G~J

B~J

C~J

C~J

N/A

Burner Tilts (if appli cable( deg)

-30

-25

-19

11

-5

-25

-25

-25

-25

-25

-25

-25

-1

N/A

iii)

Design Ambient

27

27

27

27

27

27

27

27

27

27

27

27

27

N/A

iv)

Inlet to the RAPH (Primary air)

34.7

34.7

34.4

34.0

42.0

52.0

34.4

34.0

39.0

47.4

49.5

35.7

33.9

N/A

Outlet of RAPH (Primary air)

288

280

283

267

250

241

286

272

254

248

220

248

243

N/A

Inlet to the RAPH (Secondary air)

30.9

30.9

30.6

30.3

37.0

50.0

30.6

30.3

35.0

43.6

48.0

30.9

30.1

N/A

Outlet of the RAPH (Secondary air)

300

300

295

279

261

252

298

283

265

257

233

263

258

N/A

Secondary air at Inlet to burners

300

300

295

279

261

252

298

283

265

257

233

263

258

N/A

Hot Primary air in the common duct before pulverisers

288

280

283

267

250

241

286

272

254

248

220

248

243

N/A

Hot primary air at the inlet to pulverisers

233

241

235

227

234

240

235

228

235

240

216

240

239

N/A

Fuel and air mixture leaving the p!ulveriser

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

Fuel & air mixture entering the burner

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

in Service i) Identify Mills/Elevations in service ii)

v)

vi)

vii)

viii)

ix)

x)

4.02.02

Fuel & air mixture i)

ii)

4.02.03

Pure Sliding Pressure Operation

Flue Gases (Actual Temperatures) SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 44 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

A~I

A~H

A~H

B~H

B~F

C~F

A~H

B~H

B~F

C~F

A~I

A~H

B~F

C~E

-8

16

25

25

25

25

20

25

25

0

15

25

25

0

Theoretical combustion temperature in the combustion zone

1562

1555

1540

1447

1372

1325

1542

1480

1396

1332

1527

1537

1371

1208

At furnace arch level (Furnace arch level is defined as the level at the entrance to radiant super heater)

1297

1326

1331

1289

1237

1204

1325

1301

1242

1161

1324

1336

1262

1074

At Furnace arch exit (as defined in the specification for FEGT)

976

988

983

936

883

854

979

929

877

839

985

994

910

743

Stage I

1297

1326

1331

1289

1237

1204

1325

1301

1242

1161

1324

1336

1262

1074

Stage II

1062

1080

1078

1028

981

956

1073

1027

979

936

1077

1089

1007

840

Stage III

848

854

847

808

756

727

844

797

748

718

853

858

779

627

Stage I

1062

1080

1078

1028

981

956

1073

1027

979

936

1077

1089

1007

840

Stage II

976

988

983

936

883

854

979

929

877

839

985

994

910

743

Stage III

724

726

718

689

646

623

717

678

638

619

723

726

664

564

A) Bottom Burner Elevations in Service i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

Identify Mills/elevations in service Burner Tilts (if applicable) (deg)

Entrance to superheater

Exit of Superheater

Entrance to reheater

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 45 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Stage I

717

719

711

682

639

617

710

671

632

612

717

719

657

557

Stage II

976

988

983

936

883

854

979

929

877

839

985

994

910

743

Stage I

491

489

481

461

436

423

484

461

440

432

492

491

445

385

Stage II

866

873

866

826

774

747

864

817

768

738

872

878

799

648

Entrance of economizer

491

489

481

461

436

423

484

461

440

432

492

491

445

385

xi)

Exit of economizer

324

323

318

301

280

268

319

301

282

271

253

288

288

236

xii)

Entrance to primary air heater

324

323

318

301

280

268

319

301

282

271

253

288

288

236

Entrance to secondary air heater

324

323

318

301

280

268

319

301

282

271

253

288

288

236

Exit of primary air heater (corrected)

133

118

127

118

110

111

130

122

110

110

110

110

112

110

Exit of secondary air heater (corrected)

134

135

129

118

110

110

130

121

110

110

111

112

115

110

xvii) Exit of primary air heater (Uncorrected)

141

126

136

127

119

120

139

131

120

120

116

117

118

120

xviii) Exit of secondary air heater (Uncorrected)

140

141

135

124

117

117

137

128

118

117

116

117

119

120

Exit of air preheater (average considered)

134

129

128

118

110

110

130

121

110

110

110

111

114

110

Entrance of electrostatic precipitator

134

129

128

118

110

110

130

121

110

110

110

111

114

110

Exit of electrostatic precipitator

132

127

126

116

108

108

128

119

108

108

108

109

112

108

ix) Exit of reheater

x)

xiii)

xv)

xvi)

xix)

xx)

xxi)

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 46 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

xxii) Entrance of ID fans

132

127

126

116

108

108

128

119

108

108

108

109

112

108

xxiii) Entrance to Chimney

136

131

130

119

111

111

132

122

111

111

111

112

115

111

Identify Mills/elevations in service

A~I

B~I

B~I

C~I

D~H

D~G

B~I

C~I

D~H

D~G

A~I

B~I

B~I

N/A

Burner Tilts (if applicable ) (deg)

-30

-23

4

25

25

-16

-13

-5

3

-25

-21

-7

25

N/A

Theoretical combustion temperature in the combustion zone (deg C)

1563

1555

1541

1470

1394

1329

1542

1482

1404

1340

1527

1537

1413

N/A

At furnace arch level (Furnace arch level is defined as the level at the entrance to radiant super heater)

1321

1324

1342

1339

1306

1203

1328

1307

1263

1191

1325

1336

1324

N/A

At furnace arch exit (as defined in the specification for FEGT)

979

986

992

956

901

856

981

931

883

848

986

994

930

N/A

Stage I

1321

1324

1342

1339

1306

1203

1328

1307

1263

1191

1325

1336

1324

N/A

Stage II

1067

1078

1089

1059

1011

961

1074

1029

990

953

1078

1089

1040

N/A

Stage III

851

853

853

815

760

727

846

798

748

721

853

858

786

N/A

Stage I

1067

1078

1089

1059

1011

961

1074

1029

990

953

1078

1089

1040

N/A

Stage II

979

986

992

956

901

856

981

931

883

848

986

994

930

N/A

B) Middle Burner Elevations in Service i)

ii)

iii)

iv)

v)

vi)

vii)

Entrance to superheater

Exit of Superheater

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 47 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

726

725

722

689

644

623

717

678

637

618

723

726

663

N/A

Stage I

719

718

714

682

637

616

711

672

630

611

717

719

656

N/A

Stage II

979

986

992

956

901

856

981

931

883

848

986

994

930

N/A

Stage I

490

489

482

455

429

422

484

462

437

429

492

491

439

N/A

Stage II

869

872

872

835

781

747

865

818

769

741

872

878

807

N/A

Entrance of economizer

490

489

482

455

429

422

484

462

437

429

492

491

439

N/A

xi)

Exit of economizer

324

323

318

299

278

268

319

301

281

270

253

288

286

N/A

xii)

Entrance to primary air heater

324

323

318

299

278

268

319

301

281

270

253

288

286

N/A

Entrance to secondary air heater

324

323

318

299

278

268

319

301

281

270

253

288

286

N/A

Exit of primary air heater (corrected)

133

118

127

119

110

110

130

122

110

110

110

110

113

N/A

Exit of secondary air heater (corrected)

134

135

129

119

110

111

130

122

110

110

111

112

115

N/A

xvii) Exit of primary air heater (Uncorrected)

141

126

136

128

120

120

139

131

120

121

116

117

119

N/A

xviii) Exit of secondary air heater (Uncorrected)

140

141

135

126

118

118

137

129

118

117

116

118

119

N/A

Exit of air preheater (average considered)

134

129

128

119

110

111

130

122

110

110

110

111

114

N/A

Entrance of electrostatic precipitator

134

129

128

119

110

111

130

122

110

110

110

111

114

N/A

Stage III viii)

ix)

x)

xiii)

xv)

xvi)

xix)

xx)

Entrance to reheater

Exit of reheater

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 48 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Exit of electrostatic precipitator

132

127

126

117

108

109

128

120

108

108

108

109

112

N/A

xxii) Entrance of ID fans

132

127

126

117

108

109

128

120

108

108

108

109

112

N/A

xxiii) Entrance to Chimney

136

131

130

120

111

112

132

123

111

111

111

112

115

N/A

Identify Mills/elevations in service

B~J

C~J

C~J

D~J

F~J

G~J

C~J

D~J

F~J

G~J

B~J

C~J

C~J

N/A

Burner Tilts (if applicable ) (deg)

-30

-30

-19

11

-5

-25

-25

-25

-25

-30

-25

-25

-1

N/A

Theoretical combustion temperature in the combustion zone (deg C)

1567

1558

1541

1479

1395

1341

1543

1483

1406

1354

1531

1539

1412

N/A

At furnace arch level (Furnace arch level is defined as the level at the entrance to radiant super heater)

1351

1352

1350

1352

1305

1244

1346

1323

1276

1242

1351

1350

1326

N/A

At furnace arch exit (as defined in the specification for FEGT)

1007

1012

991

962

902

867

988

942

891

861

1011

1007

932

N/A

Stage I

1351

1352

1350

1352

1305

1244

1346

1323

1276

1242

1351

1350

1326

N/A

Stage II

1101

1109

1087

1070

1014

980

1084

1043

1000

976

1108

1105

1044

N/A

Stage III

871

871

852

817

761

730

851

806

753

724

871

867

786

N/A

xxi)

C) Top Burner Elevations in Service i)

ii)

iii)

iv)

v)

vi)

vii)

Entrance to superheater

Exit of Superheater

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 49 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Stage I

1101

1109

1087

1070

1014

980

1084

1043

1000

976

1108

1105

1044

N/A

Stage II

1007

1012

991

962

902

867

988

942

891

861

1011

1007

932

N/A

Stage III

737

735

721

688

644

622

721

682

639

617

734

732

663

N/A

Stage I

731

728

714

681

637

614

713

675

632

609

727

724

656

N/A

Stage II

1007

1012

991

962

902

867

988

942

891

861

1011

1007

932

N/A

Stage I

489

488

482

452

429

417

484

461

436

424

490

490

438

N/A

Stage II

889

891

872

837

782

751

871

826

774

745

891

887

807

N/A

Entrance of economizer

489

488

482

452

429

417

484

461

436

424

490

490

438

N/A

xi)

Exit of economizer

324

323

318

298

278

267

319

301

281

269

253

288

286

N/A

xii)

Entrance to primary air heater

324

323

318

298

278

267

319

301

281

269

253

288

286

N/A

Entrance to secondary air heater

324

323

318

298

278

267

319

301

281

269

253

288

286

N/A

Exit of primary air heater (corrected)

132

118

127

123

110

110

129

122

110

110

111

110

113

N/A

Exit of secondary air heater (corrected)

134

135

129

119

109

110

131

126

110

110

111

112

115

N/A

xvii) Exit of primary air heater (Uncorrected)

140

126

136

128

120

120

137

131

120

121

117

117

119

N/A

xviii) Exit of secondary air heater (Uncorrected)

140

141

135

126

117

118

137

133

118

118

116

117

119

N/A

viii)

ix)

x)

xiii)

xv)

xvi)

xix)

Entrance to reheater

Exit of reheater

Exit of air preheater

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 50 OF 117

Modified Sliding Pressure Operation 100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

(average considered)

133

129

128

120

110

110

130

125

110

110

111

111

114

N/A

Entrance of electrostatic precipitator

133

129

128

120

110

110

130

125

110

110

111

111

114

N/A

Exit of electrostatic precipitator

131

127

126

118

108

108

128

123

108

108

109

109

112

N/A

xxii) Entrance of ID fans

131

127

126

118

108

108

128

123

108

108

109

109

112

N/A

xxiii) Entrance to Chimney

135

131

130

121

111

111

132

126

111

111

112

112

115

N/A

A~I

A~H

A~H

B~H

B~F

C~F

A~H

B~H

B~F

C~F

A~I

A~H

B~F

C~E

-8

16

25

25

25

25

20

25

25

0

15

25

25

0

Water entering economizer

290

290

286

270

254

244

287

273

257

247

196

244

261

219

Water leaving economizer

342

342

339

329

315

309

340

327

316

310

299

320

319

282

a) Superheater

290

290

286

270

254

244

287

273

257

247

196

244

261

219

b) Reheater

191

191

191

181

169

161

191

181

169

161

196

195

169

144

A~I

B~I

B~I

C~I

D~H

D~G

B~I

C~I

D~H

D~G

A~I

B~I

B~I

N/A

xx)

xxi)

4.02.04

Pure Sliding Pressure Operation

Feed Water A) Bottom Burner Elevations in Service i)

ii)

iii)

iv)

v)

Identify Mills/elevations in service

Burner Tilts (if applicable ) (deg)

Desuperheating spray water temperature

B) Middle Burner Elevations in Service i)

Identify Mills/elevations in service

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 51 OF 117

Modified Sliding Pressure Operation

ii)

iii)

iv)

v)

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Burner Tilts (if applicable ) (deg)

-30

-23

4

25

25

-16

-13

-5

3

-25

-21

-7

25

N/A

Water entering economizer

290

290

286

270

254

244

287

273

257

247

196

244

244

N/A

Water leaving economizer

342

342

339

326

312

308

340

327

314

308

299

320

317

N/A

a) Superheater

290

290

286

270

254

244

287

273

257

247

196

244

244

N/A

b) Reheater

191

191

191

181

169

161

191

181

169

161

196

195

169

N/A

Identify Mills/elevations in service

B~J

C~J

C~J

D~J

F~J

G~J

C~J

D~J

F~J

G~J

B~J

C~J

C~J

N/A

Burner Tilts (if applicable ) (deg)

-30

-25

-19

11

-5

-25

-25

-25

-25

-25

-25

-25

-1

N/A

Water entering economizer

290

290

286

270

254

244

287

273

257

247

196

244

244

N/A

Water leaving economizer

343

342

339

324

312

306

340

327

315

306

299

320

316

N/A

a) Superheater

290

290

286

270

254

244

287

273

257

247

196

244

244

N/A

b) Reheater

191

191

191

181

169

161

191

181

169

161

196

195

169

N/A

Desuperheating spray water temperature

C) Top Burner Elevations in Service i)

ii)

iii)

iv)

v)

4.02.05

Desuperheating spray water temperature

Steam

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 52 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

A~I

A~H

A~H

B~H

B~F

C~F

A~H

B~H

B~F

C~F

A~I

A~H

B~F

C~E

-8

16

25

25

25

25

20

25

25

0

15

25

25

0

1st Stage

419

414

410

398

371

362

407

381

360

347

402

405

382

334

2nd Stage

452

448

445

436

423

413

443

425

417

411

434

438

431

423

3rd Stage

485

483

482

478

472

470

481

476

471

470

473

476

475

492

1st Stage

462

458

454

446

431

440

453

437

437

424

444

448

431

432

2nd Stage

492

490

489

485

490

491

488

482

492

492

481

484

491

519

3rd Stage

540

540

540

540

540

540

540

540

540

540

540

540

540

540

1st Stage

299

300

296

281

286

289

303

306

310

313

309

306

284

294

2nd Stage

459

456

450

450

449

448

456

455

454

456

460

457

448

431

1st Stage

459

456

451

450

449

448

456

455

454

456

460

458

448

431

2nd Stage

568

568

568

568

568

568

568

568

568

568

540

568

568

540

Outlet of seperator

413

408

405

393

362

349

401

374

347

331

397

400

375

311

A) Bottom Burner Elevations in Service i)

ii)

iii)

iv)

v)

vi)

vii)

Identify Mills/elevations in service Burner Tilts (if applicable ) (deg) Inlet of superheater

Outlet of superheater

Inlet to reheater

Outlet to reheater

B) Middle Burner Elevations in Service SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 53 OF 117

Modified Sliding Pressure Operation

i)

ii)

iii)

iv)

v)

vi)

vii)

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Identify Mills/elevations in service

A~I

B~I

B~I

C~I

D~H

D~G

B~I

C~I

D~H

D~G

A~I

B~I

B~I

N/A

Burner Tilts (if applicable ) (deg)

-30

-23

4

25

25

-16

-13

-5

3

-25

-21

-7

25

N/A

1st Stage

416

414

408

394

372

362

407

381

360

347

402

405

383

N/A

2nd Stage

451

448

443

432

419

412

443

425

415

408

434

438

427

N/A

3rd Stage

485

483

481

477

472

470

481

476

472

470

473

476

474

N/A

1st Stage

461

458

452

442

443

437

453

437

439

429

444

448

441

N/A

2nd Stage

492

490

488

485

490

491

488

482

492

492

480

484

491

N/A

3rd Stage

540

540

540

540

540

540

540

540

540

540

540

540

540

N/A

1st Stage

297

300

296

281

286

289

303

306

310

313

309

306

284

N/A

2nd Stage

457

456

452

444

442

446

456

455

451

453

459

457

442

N/A

1st Stage

457

456

453

444

442

446

457

455

451

453

460

458

442

N/A

2nd Stage

568

568

568

568

568

568

568

568

568

568

568

568

568

N/A

Outlet of seperator

410

409

403

390

362

349

401

374

347

331

397

400

375

N/A

Inlet of superheater

Outlet of superheater

Inlet to reheater

Outlet to reheater

C) Top Burner Elevations in Service SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 54 OF 117

Modified Sliding Pressure Operation

i)

ii)

iii)

iv)

v)

vi)

vii)

4.03.00

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Identify Mills/elevations in service

B~J

C~J

C~J

D~J

F~J

G~J

C~J

D~J

F~J

G~J

B~J

C~J

C~J

N/A

Burner Tilts (if applicable ) (deg)

-30

-25

-19

11

-5

-25

-25

-25

-25

-25

-25

-25

-1

N/A

1st Stage

410

409

406

393

372

360

403

379

360

348

398

402

383

N/A

2nd Stage

444

443

443

432

418

409

441

424

412

403

428

435

426

N/A

3rd Stage

480

480

481

477

472

470

479

473

470

470

468

474

474

N/A

1st Stage

454

452

452

441

441

440

451

435

443

439

438

444

440

N/A

2nd Stage

487

486

488

485

490

491

487

482

490

492

476

480

491

N/A

3rd Stage

540

540

540

540

540

540

540

540

540

540

540

540

540

N/A

1st Stage

285

291

296

281

286

289

300

300

307

313

297

301

284

N/A

2nd Stage

450

450

452

442

442

442

454

452

450

449

452

454

441

N/A

1st Stage

450

451

453

442

442

442

454

452

450

449

452

454

441

N/A

2nd Stage

568

568

568

568

568

568

568

568

568

568

568

568

568

N/A

Outlet of seperator

405

404

402

389

362

348

398

372

347

331

394

398

375

N/A

Inlet of superheater

Outlet of superheater

Inlet to reheater

Outlet to reheater

Pressure

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 55 OF 117

Modified Sliding Pressure Operation

4.03.01

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Air (mmwc) i)

ii) iii)

iv)

v)

vi)

4.03.02

Pure Sliding Pressure Operation

Forced draft fan inlet (with air duct, air foil and silencer) Forced draft fan discharge

-28

-30

-26

-16

-10

-10

-26

-16

-10

-8

-28

-30

-12

-4

201

205

192

156

162

158

192

157

161

146

262

202

201

123

Air heater inlet (Secondary air )

179

182

172

144

154

150

172

145

153

140

240

179

181

120

Air heater outlet (Secondary air)

143

145

139

123

141

137

139

124

140

130

207

144

122

115

In burner windbox (Secondary air)

102

102

102

102

102

102

102

102

102

102

102

102

102

102

-37

-31

-31

-20

-13

-9

-31

-22

-13

-9

-37

-31

-13

-5

vii)

Primary air fan inlet (with air duct, air foil and silencer) Primary air fan discharge

907

925

903

860

887

882

901

858

875

869

1063

949

1045

809

viii)

Air heater inlet (Primary air)

892

912

891

852

882

878

889

849

870

865

1048

936

1040

807

ix)

Air heater outlet (Primary air)

808

830

816

793

841

845

815

792

830

835

931

836

877

790

x)

Hot primary air in the common duct before pulverisers

760

782

773

760

782

798

773

760

783

800

741

773

811

765

xi)

Cold primary air header

739

760

752

740

761

776

752

740

762

778

721

751

788

745

xii)

Hot primary air at the inlet to pulverisers

618

707

638

571

635

665

679

606

678

710

606

705

702

591

Fuel Side (mmwc) i)

In the pulveriser

618

707

638

571

635

665

679

606

678

710

606

705

702

591

ii)

At the pulveriser outlet

278

345

288

239

287

302

330

274

329

347

270

344

321

266

iii)

At the burners inlet

25

25

25

25

25

25

25

25

25

25

25

25

25

25

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 56 OF 117

Modified Sliding Pressure Operation

4.03.03

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Inlet to economizer (at the specified terminal point)

304.2

300.5

292.9

261.0

195.9

165.4

283.1

220.4

165.1

139.1

282.7

289.2

224.4

101.0

ii)

At economizer inlet

301.3

297.7

290.3

259.0

194.3

164.0

280.4

218.4

163.5

137.6

280.3

286.8

222.6

99.7

iii)

Outlet of economizer

295.1

291.7

284.7

254.3

190.1

160.0

274.7

213.6

159.3

133.7

274.9

281.2

218.2

95.9

iv)

Attemperation water for superheater

304.2

300.5

292.9

261.0

195.9

165.4

283.1

220.4

165.1

139.1

282.7

289.2

224.4

101.0

Attemperation water for reheater

91.5

91.9

89.9

80.4

71.3

66.8

90.2

80.7

71.7

67.2

93.7

93.3

75.4

57.8

278.0

274.9

271.1

248.1

187.7

158.3

260.9

207.1

156.5

131.6

266.3

270.2

213.4

99.3

2

Feed Water (kg/cm ) abs i)

v)

4.03.04

4.03.05

Pure Sliding Pressure Operation

Separator Pressure ( Kg/cm2) abs Steam (kg/cm2)(abs) i)

Inlet of superheater

271.9

270.3

267.3

245.8

185.7

156.5

256.7

203.8

153.9

129.3

263.3

266.8

211.3

97.9

ii)

Outlet of superheater

256.0

255.5

254.5

238.0

179.4

151.2

242.9

193.3

145.6

122.3

252.9

255.0

204.4

93.9

iii)

Inlet to reheater

48.3

48.7

46.7

37.2

28.1

23.6

47.0

37.6

28.5

24.0

50.5

50.1

32.2

14.6

iv)

Outlet of reheater

46.6

47.0

45.1

35.9

27.1

22.7

45.4

36.2

27.4

23.1

48.8

48.4

31.1

14.0

v)

Inlet of seperator

278.0

275.9

271.9

248.6

188.0

158.6

261.7

207.5

156.9

132.0

266.8

270.9

213.9

99.4

vi)

Outlet of seperator

277.0

274.9

271.1

248.1

187.7

158.3

260.9

207.1

156.5

131.6

266.3

270.2

213.4

99.3

4.04.00

Pressure Drop

4.04.01

Air Path: (mmwc) SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 57 OF 117

Modified Sliding Pressure Operation

i)

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

In air ducts including bends dampers, vanes etc

167

100

155

201

184

158

113

165

130

103

303

108

151

179

Across aerofoil (flow measuring device)

38

36

35

29

27

26

35

30

27

26

37

36

29

22

c)

Across RAPH

84

82

75

59

41

33

74

57

40

30

117

100

163

17

d)

Total loss through the system

289

218

265

289

252

217

222

252

197

159

457

244

343

218

Primary air circuit a)

b)

4.04.02

4.04.03

Pure Sliding Pressure Operation

Fuel Path (mmwc) i)

Across the pulverisers

340

362

350

332

348

363

350

332

349

363

336

361

381

325

ii)

In the fuel piping from pulveriser outlet to burners

278

345

288

239

287

302

330

274

329

347

270

344

321

266

Furnace pressure (back draught)

3

3

3

3

3

3

3

3

3

3

3

3

3

3

Across SH/RH convection path

67

66

61

52

46

42

61

53

46

41

64

63

39

15

iii)

Across economizers

26

24

22

14

8

6

22

14

8

6

23

24

24

24

iv)

Across air heaters

140

113

122

97

63

48

122

95

63

48

154

138

215

29

v)

In gas ducts

44

42

39

25

17

14

38

26

16

12

44

43

18

6

Flue Gas Path (mmwc) i)

ii)

a)

Between air heater outlet and electrostatic precipitator funnel inlet

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 58 OF 117

Modified Sliding Pressure Operation 100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Between outlet of electrostatic precipitator funnels & inlet of ID fan

24

23

21

13

9

7

21

14

9

7

24

23

10

3

Between ID fan outlet and chimney inlet

13

13

12

8

5

4

12

8

5

4

13

13

6

2

349

316

309

231

163

134

308

232

160

128

357

339

328

86

Saturated steam connections including horizontal and vertical hangers

5.1

4.6

3.8

2.3

2.0

1.8

4.2

3.3

2.6

2.3

3.0

3.4

2.1

1.4

Superheater Stage I

3.3

3.1

2.6

1.4

1.3

1.1

2.8

2.0

1.7

1.4

2.1

2.4

2.4

2.4

Superheater Stage II

4.3

4.0

3.5

2.1

1.7

1.4

3.8

2.8

2.2

1.9

2.8

3.2

1.9

1.1

Superheater Stage III

3.2

3.0

2.7

1.6

1.3

1.1

2.9

2.2

1.7

1.5

2.2

2.5

1.5

0.8

Superheater desuperheater

2.3

2.2

1.9

1.2

0.9

0.8

2.0

1.6

1.2

1.0

1.5

1.7

1.7

1.7

Reheater Stage I

0.5

0.5

0.4

0.4

0.3

0.2

0.4

0.4

0.3

0.3

0.5

0.5

0.3

0.2

Reheater Stage II

0.8

0.8

0.8

0.6

0.5

0.4

0.8

0.6

0.5

0.4

0.8

0.8

0.5

0.3

Reheater desuperheater

0.06

0.06

0.05

0.03

0.02

0.01

0.05

0.03

0.02

0.01

0.04

0.06

0.02

0.00

-0.3

-0.5

-1.0

-2.4

-3.2

-3.6

-0.9

-2.2

-3.1

-3.5

-2.2

-1.6

-2.9

-4.2

b)

c)

vi) 4.04.04

Total loss through the system

Steam Path (kg/cm2) i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

4.04.05

Pure Sliding Pressure Operation

Feed Water Path (kg/cm2) i)

Valves and connected piping

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 59 OF 117

Modified Sliding Pressure Operation

ii) 4.05.00

economizer

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

6.2

6.0

5.6

4.7

4.2

4.0

5.7

4.8

4.2

3.9

5.4

5.6

4.4

3.8

Velocities (m/sec) i)

Furnace throat gas velocity

8.2

8.1

7.8

6.2

4.6

3.9

3.9

7.7

6

4.5

3.8

8.2

5.1

2.3

ii)

Maximum gas velocity through tube banks of TSH

9.1

8.9

8.5

6.7

4.9

4.1

4.2

8.4

6.6

4.8

4

9

5.5

2.4

Maximum gas velocity through tube banks of economizer

9.2

9

8.5

6.6

5

4.2

4.4

8.5

6.7

4.9

4.1

9.1

5.7

2.6

Stage I

-

-

-

-

-

-

-

-

-

-

-

-

-

-

Stage II

7.9

7.8

7.5

6

4.4

3.7

3.7

7.4

5.8

4.3

3.6

7.9

4.9

2.2

Stage III

8.8

8.6

8.2

6.4

4.8

4

4

8.2

6.4

4.7

3.9

8.7

5.4

2.4

Stage I

9.2

9

8.5

6.6

4.9

4.2

4.3

8.4

6.6

4.9

4

9

5.6

2.6

Stage II

8.8

8.6

8.2

6.5

4.8

4

4

8.1

6.3

4.7

3.9

8.6

5.3

2.3

Stage I

8.2

8

7.5

5.9

4.4

3.8

3.9

7.6

6

4.4

3.7

7.6

5.1

2.3

Stage II

-

-

-

-

-

-

-

-

-

-

-

-

-

-

iii)

Note : In case gas biasing in the convective pass is being used for RH temperature control the details of gas flow and velocity through both the passes shall be indicated a)

b)

c)

iii)

Superheater

Reheater

economizer

Gas/air velocities through

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PAGE 60 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

- Secondary RAPH

7.5

7.6

6.9

5.2

3.9

3.3

6.9

5.2

3.8

3.2

6.1

6.6

9

2

- Primary RAPH

11.8

10.4

10.8

9.3

7.1

6.0

10.9

9.3

7.1

6.0

12.1

11.4

15.0

4.3

- Secondary RAPH

5.0

5.1

4.7

3.6

2.9

2.5

4.7

3.6

2.8

2.4

4.6

4.8

6.5

1.5

- Primary RAPH

7.7

7.6

7.2

6.3

5.1

4.5

7.1

6.2

5

4.3

9.2

8.3

10.8

3.1

the air heater heating elements a)

b)

iv)

v)

vi)

4.06.00

Gas

Air

Air velocities a)

Cold air ducts

12.4

12.6

11.7

9.2

7.6

7.3

11.7

9.3

7.4

6.5

12.3

12.6

8.3

4.4

b)

Hot air ducts

13.8

13.6

12.6

9.6

7.6

7.2

12.6

9.9

7.8

6.9

11.7

13.6

8.9

4.6

Gas velocities in gas ducting sections a)

Eco to AH

10.4

10.4

10.3

7.9

6.2

5.6

10.3

8.2

6.2

5.3

9.8

10.3

6.7

3.5

b)

Eco gas bypass ducts

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

c)

AH to ESP

11.9

11.5

10.9

8.6

6.8

6.2

11

8.8

6.7

5.8

11.2

11

7.3

4.2

d)

ESP to ID fan

12.6

12.2

11.6

9.1

7.2

6.5

11.6

9.3

7.1

6.1

11.9

11.7

7.8

4.4

e)

ID fan to stack

12.2

11.8

11.2

8.8

6.9

6.3

11.2

9

6.9

5.9

11.5

11.3

7.5

4.3

27.2

27.9

27.6

26.9

27.6

28.0

27.6

26.9

27.6

28.0

26.6

27.9

28.6

26.2

Air-fuel mixture velocity in the fuel pipe line

Percentage of Oxygen in flue gas

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 61 OF 117

Modified Sliding Pressure Operation 100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

i)

At furnace exit

3.43

3.43

3.43

3.43

3.82

4.14

3.43

3.43

3.43

3.43

3.43

3.43

3.43

4.61

ii)

At economizer outlet

3.43

3.43

3.43

3.43

3.82

4.14

3.43

3.43

3.43

3.43

3.43

3.43

3.43

4.61

iii)

At air heater outlet (primary)

5.09

5.29

5.21

4.51

6.34

7.00

5.20

5.47

5.99

6.39

5.19

5.22

4.86

8.27

iv)

At air heater outlet (secondary)

4.63

4.61

4.70

5.01

5.77

6.32

4.69

4.98

5.42

5.72

5.02

4.84

4.46

7.87

In the common duct before ESP

4.80

4.84

4.89

4.82

6.00

6.59

4.87

5.17

5.64

5.99

5.09

4.98

4.61

8.04

vi)

At ESP outlet

4.80

4.84

4.89

4.82

6.00

6.59

4.87

5.17

5.64

5.99

5.09

4.98

4.61

8.04

vii)

At ID fan inlet

4.80

4.84

4.89

4.82

6.00

6.59

4.87

5.17

5.64

5.99

5.09

4.98

4.61

8.04

v)

4.07.00

Pure Sliding Pressure Operation

Flow rate of air (kg/hr) i)

FD fan outlet

1,546,294

1,567,150

1,461,238

1,148,854

949,824

856,040

1,459,340

1,152,762

920,562

810,160

1,532,090

1,569,818

1,035,707

549,928

ii)

PA fan outlet

1,162,704

1,075,828

1,057,812

868,698

699,992

592,086

1,057,828

918,387

700,594

591,667

1,175,938

1,084,040

682,793

450,948

iii)

Air heater inlet 919,540

914,744

871,162

729,348

655,052

588,658

859,292

764,953

646,568

573,057

1,148,384

1,042,622

671,186

443,652

1,546,294

1,567,150

1,461,238

1,148,854

949,824

856,040

1,459,340

1,152,762

920,562

810,160

1,532,090

1,569,818

1,035,707

549,928

823,340

817,544

774,962

680,348

554,252

486,058

763,892

667,753

546,768

472,257

1,032,184

935,422

615,786

340,052

1,422,894

1,443,750

1,339,638

1,029,854

830,824

737,040

1,344,635

1,038,968

807,548

694,759

1,381,490

1,432,818

969,007

430,928

Tempering air for each pulveriser

27,018

20,136

23,331

19,907

8,988

857

24,817

21,919

10,805

4,653

3,062

5,177

2,321

2,432

vi)

Total air to each pulveriser

118,500

122,329

120,202

117,100

119,838

122,372

120,303

117,312

120,159

122,717

117,749

122,105

125,479

115,783

vii)

Total combustion air (included furnace leakage)

2,565,421

2,498,401

2,377,273

1,925,575

1,506,039

1,302,549

2,383,086

1,936,177

1,484,365

1,261,649

2,517,251

2,485,681

1,672,423

854,299

iv)

v)

a)

Primary air

b)

Secondary air

Air heater outlet a)

Primary air

b)

Secondary air

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 62 OF 117

Modified Sliding Pressure Operation

4.08.00

4.09.00

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Flow rate of flue gases (kg/hr) i)

Primary Airheater inlet

1,010,878

900,096

934,594

822,546

646,816

556,860

935,086

813,139

647,041

550,987

1,143,522

1,038,572

683,249

405,524

ii)

Secondary Airheater inlet

1,840,372

1,876,662

1,707,528

1,317,504

1,023,248

884,888

1,713,497

1,338,698

1,002,599

848,895

1,656,188

1,724,048

1,175,381

537,424

iii)

Primary airheater outlet

1,107,078

997,296

1,030,794

871,546

747,616

659,460

1,030,486

910,339

746,841

651,787

1,259,722

1,145,772

738,649

509,124

iv)

Secondary airheater outlet

1,963,772

2,000,062

1,829,128

1,436,504

1,142,248

1,003,888

1,827,850

1,447,292

1,118,160

964,296

1,806,788

1,861,048

1,242,081

656,424

v)

ESP inlet

3,070,850

2,997,358

2,859,922

2,308,050

1,889,864

1,663,348

2,858,336

2,357,631

1,865,001

1,616,083

3,066,510

3,006,820

1,980,730

1,165,548

vi)

ESP outlet

3,070,850

2,997,358

2,859,922

2,308,050

1,889,864

1,663,348

2,858,336

2,357,631

1,865,001

1,616,083

3,066,510

3,006,820

1,980,730

1,165,548

vii)

ID fan inlet

3,070,850

2,997,358

2,859,922

2,308,050

1,889,864

1,663,348

2,858,336

2,357,631

1,865,001

1,616,083

3,066,510

3,006,820

1,980,730

1,165,548

viii)

Recirculation gas flow (Applicable for the cases where gas recirculation is being used to control RH steam temperature)

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Excess Air (%) i)

At burner

20.0

20.0

20.0

20.0

22.7

25.0

20.0

20.0

20.0

20.0

20.0

20.0

20.0

28.6

ii)

At furnace exit

20.0

20.0

20.0

20.0

22.7

25.0

20.0

20.0

20.0

20.0

20.0

20.0

20.0

28.6

iii)

At economizer outlet

20.0

20.0

20.0

20.0

22.7

25.0

20.0

20.0

20.0

20.0

20.0

20.0

20.0

28.6

iv)

At the air heater exit (primary)

32.35

34.02

33.36

27.71

43.36

49.84

33.24

35.52

40.04

43.77

33.20

33.40

30.51

63.96

At the airheater exit (secondary)

28.69

28.52

29.23

31.72

38.10

43.11

29.14

31.43

35.05

37.65

31.80

30.30

27.34

59.23

vi)

At ESP inlet

29.98

30.30

30.69

30.17

40.13

45.70

30.58

32.97

37.00

40.05

32.37

31.46

28.50

61.25

vii)

At ID fan inlet

29.98

30.30

30.69

30.17

40.13

45.70

30.58

32.97

37.00

40.05

32.37

31.46

28.50

61.25

v)

4.10.00

Pure Sliding Pressure Operation

Leakages (Tonnes per hour)

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 63 OF 117

Modified Sliding Pressure Operation

i)

Primary air a) Regenerative air preheater b)

ii)

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

96.2

97.2

96.2

49.0

100.8

102.6

95.4

97.2

99.8

100.8

116.2

107.2

55.4

103.6

0

0

0

0

0

0

0

0

0

0

0

0

0

0

123.4

123.4

121.6

119.0

119.0

119.0

120.8

118.0

116.2

115.4

150.6

137.0

66.7

119.0

Secondary air a)

4.11.00

Ducts/Dampers

Pure Sliding Pressure Operation

Regenerative air heater

b)

Wind box

0

0

0

0

0

0

0

0

0

0

0

0

0

0

c)

Ducts/Dampers

0

0

0

0

0

0

0

0

0

0

0

0

0

0

Heat Balance (based on GCV of design coal fired) i)

Total coal fired (tonnes/hr)

525.5

511.8

487.0

394.5

301.7

256.2

488.2

396.6

304.1

258.2

515.7

509.2

342.9

163.3

ii)

Gross Calorific value of coal (Kcal/kg)

3000

3000

3000

3000

3000

3000

3000

3000

3000

3000

3000

3000

3000

3000

- Primary

91.1

90.2

90.8

91.9

87.0

81.8

90.5

91.6

88.6

83.8

65.5

72.4

72.4

72.4

- Secondary

166.6

173.8

166.4

148.7

138.9

141.1

167.6

150.9

139.2

130.8

142.2

189.8

189.8

189.8

b)

economizer (kcal)

276.5

274.2

271.4

255.2

251.3

268.8

268.9

261.9

253.8

250.3

389.0

332.8

237.0

255.3

c)

Superheater (kcal) Stage I

271.5

292.2

315.0

352.5

328.0

291.5

303.6

312.6

310.6

301.4

289.2

302.8

342.4

272.5

Stage II

187.6

197.4

208.9

229.9

235.8

227.8

203.6

211.3

225.9

236.9

197.1

203.6

246.1

210.8

Stage III

203.7

210.2

215.8

209.7

190.9

179.1

210.9

194.7

180.0

172.2

212.5

216.6

197.8

104.0

iii)

Heat absorbed per kg of coal in a)

Air preheaters (kcal)

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 64 OF 117

Modified Sliding Pressure Operation 100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Roof tubes

5.8

6.0

6.1

5.8

5.3

5.1

5.9

5.4

5.0

4.9

5.9

6.0

5.5

3.4

Convective pass

47.7

49.6

51.4

52.9

55.4

57.8

51.0

52.5

55.8

59.0

50.7

51.4

54.7

64.4

Enclosure

d)

e)

4.12.00

(Included in steam cooled)

Steam cooled

26.1

27.0

27.9

28.0

26.5

25.2

27.1

25.7

24.8

25.3

27.0

27.6

27.5

18.5

Hanger tubes

10.9

11.4

11.7

11.8

12.0

12.5

11.6

11.7

12.1

12.6

11.6

11.7

11.9

13.6

Stage I

324.7

328.7

330.5

320.5

287.3

277.9

322.0

290.1

258.1

241.6

319.0

325.8

294.7

224.7

Stage II

199.6

209.3

218.4

228.5

221.6

209.0

212.4

207.1

208.0

209.7

206.9

214.1

232.3

179.0

Wall tubing

990.2

978.8

890.7

968.8

956.4

1021.7

927.6

974.6

1016.7

1056.0

882.8

881.2

919.0

1244.4

Screen tubes

32.0

33.2

34.4

35.7

36.6

36.7

33.9

33.7

35.7

36.2

33.6

34.3

37.1

36.3

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

2834.0

2882.0

2839.4

2939.9

2833.0

2836.0

2836.6

2823.8

2814.3

2820.7

2833.0

2870.1

2868.4

2889.1

Reheater (kcal)

Water walls

Any other iv)

Pure Sliding Pressure Operation

Total heat absorbed effectively by the unit (per kg of coal (kcal) be)

Heat losses in the Steam Generator Heat losses in the Steam Generator shall be quoted for guarantee conditions also: i)

Heat loss due to flue gasses (%) -

Dry gas loss

4.73

4.52

4.49

4.12

3.94

4.29

4.58

4.30

3.86

3.95

3.74

3.76

3.81

4.54

-

Hydrogen in the fuel

4.35

4.33

4.33

4.31

4.27

4.28

4.34

4.31

4.27

4.27

4.27

4.28

4.29

4.28

-

Moisture in the fuel

3.15

3.14

3.14

3.12

3.10

3.10

3.14

3.12

3.10

3.10

3.10

3.10

3.11

3.10

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 65 OF 117

Modified Sliding Pressure Operation

ii)

iii)

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

-

Moisture in the air

0.11

0.11

0.11

0.10

0.09

0.10

0.11

0.10

0.09

0.09

0.09

0.09

0.09

0.11

-

Total heat loss due to flue gases

12.34

12.10

12.07

11.65

11.40

11.77

12.17

11.83

11.32

11.41

11.20

11.23

11.30

12.03

Heat loss due to unburnt carbon (%) in: -

Furnace bottom ash

0.65

0.65

0.65

0.65

0.65

0.65

0.65

0.65

0.65

0.65

0.65

0.65

0.65

0.65

-

Fly ash

1.05

1.05

1.05

1.05

1.05

1.05

1.05

1.05

1.05

1.05

1.05

1.05

1.05

1.05

-

Total heat loss due to unburnt carbon

1.70

1.70

1.70

1.70

1.70

1.70

1.70

1.70

1.70

1.70

1.70

1.70

1.70

1.70

Sensible heat loss (%) in: -

Furnace bottom ash

0.49

0.49

0.49

0.49

0.49

0.49

0.49

0.49

0.49

0.49

0.49

0.49

0.49

0.49

-

economizer hopper ash

0.04

0.04

0.03

0.03

0.03

0.03

0.04

0.03

0.03

0.03

0.03

0.03

0.03

0.03

Air heater hopper ash

0.01

0.01

0.01

0.01

0.01

0.01

0.01

0.01

0.01

0.01

0.01

0.01

0.01

0.01

Any other hopper ash

0.18

0.17

0.17

0.16

0.14

0.14

0.17

0.16

0.14

0.14

0.14

0.14

0.15

0.14

Total sensible heat loss

0.72

0.71

0.70

0.69

0.67

0.67

0.71

0.69

0.67

0.67

0.67

0.67

0.68

0.67

iv) Heat loss due to Mill Rejects (%)

0.07

0.07

0.07

0.07

0.07

0.07

0.07

0.07

0.07

0.07

0.07

0.07

0.07

0.07

v)

Heat loss due to radiation (%)

0.18

0.19

0.19

0.23

0.30

0.34

0.19

0.23

0.30

0.34

0.18

0.18

0.26

0.52

vi)

Unaccounted heat loss (%) (give details)

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

Total heat losses {sum of the (i) to (v)}

15.01

14.77

14.73

14.34

14.14

14.55

14.84

14.52

14.06

14.19

13.82

13.85

14.01

14.99

-

-

-

vii)

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 66 OF 117

Modified Sliding Pressure Operation 100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Heat credits (give details of equipment and breakup)

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

ix)

Manufacturer’s margin(%)

0.10

0.10

0.10

0.10

0.10

0.10

0.10

0.10

0.10

0.10

0.10

0.10

0.10

0.10

x)

Steam generator efficiency (%)

84.89

85.13

85.17

85.56

85.76

85.35

85.06

85.38

85.84

85.71

86.08

86.05

85.89

84.91

Furnace bottom hopper (kg/hr)

47299

46063

43829

35501

27155

23054

43937

35696

27365

23235

46410

45828

30857

14696

economizer hopper (kg/hr)

11825

11516

10957

8875

6789

5763

10984

8924

6841

5809

11603

11457

7714

3674

iii)

Air he

7095

6909

6574

5325

4073

3458

6590

5354

4105

3485

6962

6874

4629

2204

iv)

Any other hoppers (kg/hr)

170275

165826

157786

127802

97759

82994

158172

128506

98515

83647

167077

164982

111085

52905

1604.4

1555.8

1457.0

1172.8

895.5

759.7

1468.6

1188.7

904.2

763.8

1541.8

1525.9

1017.6

N/A

Identify mills/elevations in services

B~J

C~J

C~J

D~J

F~J

G~J

C~J

D~J

F~J

G~J

B~J

C~J

C~J

N/A

Burner tilt (deg)

-30

-25

-19

11

-5

-25

-25

-25

-25

-25

-25

-25

-1

N/A

With Middle mills /elevations in operation

1578.0

1535.0

1457.0

1143.9

895.3

763.4

1461.4

1180.4

901.3

768.4

1517.4

1515.1

1018.7

N/A

Identify mills/elevations in services

A~I

B~I

B~I

C~I

D~H

D~G

B~I

C~I

D~H

D~G

A~I

B~I

B~I

N/A

Burner tilt (deg)

-30

-23

4

25

25

-16

-13

-5

3

-25

-21

-7

25

N/A

viii)

4.13.00

Pure Sliding Pressure Operation

Weight and Distribution of Ash collected i)

ii)

4.14.00

Furnace Design Data

4.14.01

Net Heat Input (x106kal/hr) a)

With top mills /elevations in operation i)

ii) b)

i)

ii)

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 67 OF 117

Modified Sliding Pressure Operation

c)

ii)

4.14.02

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

1572.9

1534.9

1453.0

1149.8

903.0

764.5

1461.3

1180.6

904.6

771.6

1518.3

1515.0

1026.8

479.9

A~I

A~H

A~H

B~H

B~F

C~F

A~H

B~H

B~F

C~F

A~I

A~H

B~F

C~E

-8

16

25

25

25

25

20

25

25

0

15

25

25

0

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

146.3

151.8

129.2

87.5

58.3

55.2

134.7

111.4

68.5

58.4

135.1

132.0

44.6

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

156.6

154.3

108.6

58.6

45.7

67.3

147.9

114.5

69.3

74.5

141.7

124.4

61.0

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

147.3

132.3

95.9

59.5

57.5

50.3

103.3

83.8

62.1

75.2

94.1

101.2

64.7

49.7

204.5

202.1

176.3

120.4

96.2

90.7

182.8

150.4

114.6

96.1

180.0

182.1

76.9

N/A

With bottom mills /elevations in operation i)

Pure Sliding Pressure Operation

Identify mills/elevations in services Burner tilt (deg)

Cumulative Heat Absorption in Furnace i)

Passive Heat Absorption (Heat Absorption in furnace from bottom upto mean firing Zone level) a)

b)

c)

ii)

Upto exit of Burner Basket a)

b)

With top mills/elevations in operation and conditions as identified in Clause 3.14.01 With middle mills/elevations in operation and conditions as identified

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 68 OF 117

Modified Sliding Pressure Operation

c)

iii)

b)

c)

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

in Clause 3.14.01

237.9

226.7

166.0

93.9

77.5

107.1

190.8

151.4

108.2

116.9

205.7

186.0

99.2

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

230.4

222.0

145.8

107.3

95.4

81.8

146.9

120.9

103.0

107.7

165.3

146.7

102.5

74.2

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

349.6

349.5

319.0

273.5

210.0

193.9

324.3

282.8

230.7

205.4

311.0

320.2

204.7

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

397.3

391.6

321.9

238.0

202.7

202.3

343.8

291.2

231.4

212.2

351.3

337.9

208.1

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

409.1

409.0

328.9

255.5

217.6

191.3

331.3

288.7

233.8

216.3

340.3

329.0

225.1

160.5

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

392.7

391.9

362.5

323.5

246.2

224.3

366.9

323.3

264.6

237.0

350.4

361.2

246.8

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

443.3

437.7

368.9

284.6

242.1

229.3

388.9

332.9

267.6

238.1

393.3

382.7

241.5

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

459.8

460.5

383.8

301.6

253.7

224.4

386.4

340.5

271.2

246.1

391.9

383.5

260.9

183.1

Upto Furnace Arch Exit a)

b)

c)

v)

100% BMCR

Upto Furnace Arch level a)

iv)

Pure Sliding Pressure Operation

Upto platen superheater Exit

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 69 OF 117

Modified Sliding Pressure Operation

a)

b)

c)

vi)

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

752

739

700

616

462

401

701

596

473

412

698

704

478

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

772

757

695

571

459

398

704

597

474

403

714

713

475

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

767

782

700

565

546

395

702

601

470

408

712

712

466

283

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

1024

1008

946

817

608

521

946

789

615

528

970

969

632

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

1022

1007

941

771

605

516

944

783

613

517

966

968

633

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

1014

1033

941

759

598

513

943

787

608

521

964

967

614

340

1234

1210

1129

962

709

603

1128

926

710

603

1170

1164

737

N/A

Upto final super heater Exit a)

b)

c)

vii)

Pure Sliding Pressure Operation

Upto primary reheater exit a)

b)

With top mills/elevations in operation and conditions as identified in Clause 3.14.01 With middle mills/elevations in operation and

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 70 OF 117

Modified Sliding Pressure Operation

c)

viii)

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

conditions as identified in Clause 3.14.01

1218

1198

1124

918

706

600

1123

916

706

594

1154

1157

740

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

1207

1224

1122

910

703

598

1122

921

701

599

1152

1156

725

386

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

1379

1339

1256

1022

786

669

1265

1033

795

675

1374

1336

889

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

1357

1321

1256

1022

786

669

1259

1026

792

675

1352

1326

889

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

1352

1321

1253

1022

786

669

1259

1026

792

675

1352

1326

889

428

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

1519

1489

1387

1158

853

723

1386

1127

856

722

1473

1493

883

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

1499

1473

1381

1119

851

726

1379

1116

852

720

1454

1447

886

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

1487

1500

1378

1125

859

726

1380

1124

850

730

1452

1447

892

459

Upto economizer exit a)

b)

c)

ix)

Pure Sliding Pressure Operation

Upto air preheater exit a)

b)

c)

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PAGE 71 OF 117

Modified Sliding Pressure Operation

x)

b)

c)

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

48

48

49

51

52

53

49

51

53

55

46

45

52

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

50

50

48

49

52

53

49

52

54

54

48

48

51

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

50

50

49

49

51

53

49

52

54

54

47

48

51

61

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

89.0

86.4

81.0

62.9

84.6

75.2

81.4

63.7

90.7

77.6

73.6

78.4

56.0

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

89.0

86.4

81.0

62.9

85.7

65.5

81.4

63.7

78.9

57.0

73.6

78.4

57.0

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

89.0

86.4

81.0

62.9

51.0

70.4

81.4

63.7

71.9

45.2

73.6

78.4

26.5

37.3

Superheater Spray Quantity in T/hr a)

b)

c)

4.14.04

100% BMCR

Furnace heat absorption as percentage of total heat absorption (upto Arch exit) a)

4.14.03

Pure Sliding Pressure Operation

Reheater Spray Quantity in T/hr a)

With top mills/elevations in operation and conditions as identified

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PAGE 72 OF 117

Modified Sliding Pressure Operation

b)

c)

4.15.00

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

in Clause 3.14.01

48.8

31.6

0.0

0.0

0.0

0.0

10.1

12.1

5.1

0.0

32.1

16.1

0.0

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

8.7

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

Furnace Performance Data Description (As per Clause 5.00.00 Section-VIA, PartBSub-section-MI) i)

Total heat duty (106 Kcal/hr)

1352.0

1321.2

1255.8

1021.5

786.2

669.2

1258.4

1026.2

791.8

674.8

1352.2

1326.4

889.3

430.4

ii)

Efficiency (%)

85.76

86.05

85.96

86.32

86.85

87.08

85.92

86.25

86.80

87.12

87.41

86.83

86.46

87.86

iii)

Total heat generated 6 (10 Kcal/hr)

1576.6

1535.4

1461.0

1183.4

905.2

768.5

1464.6

1189.9

912.2

774.5

1547.0

1527.6

1028.6

489.9

Net heat input (106 Kcal/hr) (Unburnt)

1572.9

1535.0

1457.0

1172.8

895.3

759.7

1461.4

1180.4

901.3

763.8

1518.3

1515.0

1017.6

479.9

v)

Furnace Plan area (m2)

341.4

341.4

341.4

341.4

341.4

341.4

341.4

341.4

341.4

341.4

341.4

341.4

341.4

341.4

vi)

Furnace EPRS (m2)

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

vii)

Furnace Volume (m3)

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

viii)

Net heat input/plan area (106 Kcal/m2/hr)

4.61

4.50

4.27

3.44

2.62

2.23

4.28

3.46

2.64

2.24

4.45

4.44

2.98

1.41

Net heat input /EPRS (106 Kcal/m2/hr)

0.174

0.170

0.161

0.130

0.099

0.084

0.162

0.131

0.100

0.084

0.168

0.168

0.113

0.053

Volumetric Heat Release rate (106 Kcal/m2/hr)

0.073

0.072

0.068

0.055

0.042

0.036

0.068

0.055

0.043

0.036

0.072

0.071

0.048

0.023

iv)

ix)

x)

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 73 OF 117

Modified Sliding Pressure Operation

xi) 4.16.00

4.17.00

4.18.00

Furnace exit gas temp (DegC)

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

976

986

992

962

901

867

981

931

883

861

985

994

932

743

Mass velocity in evaporator tubes (Kg/m2 sec) i)

Maximum

3150

3058

2865

2226

1640

1365

2881

2255

1672

1391

2605

2775

2775

2775

ii)

Minimum

2495

2422

2270

1764

1299

1081

2282

1787

1325

1102

2064

2198

2198

2198

Tube Mass Velocity (Kg/m2sec) (Vertical Wall) i)

Front water walls

1183

1147

1075

835

615

512

1081

846

627

522

977

1041

1041

1041

ii)

Rear water walls

1085

1052

987

769

566

472

993

778

577

481

898

957

957

957

iii)

Side Walls

1173

1140

1067

829

611

508

1073

840

623

517

970

1033

1033

1033

Auxiliary Steam Consumption i)

Steam conditions a)

b)

Pressure range (kg/cm2) (abs) Temperature range (degC)

16

210~310

ii)

Fuel oil heating (kg/hr) Max

N/A

iii)

Fuel oil line tracing (kg/hr) Max

N/A

iv)

Steam coil air pre-heater (kg/hr)Max a)

Primary

9058

b)

Secondary

14084

v) Total auxiliary steam consumSIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 74 OF 117

Modified Sliding Pressure Operation 100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Pure Sliding Pressure Operation 100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

ed from startup to full load a)

b)

c)

d)

e)

After eight hours shutdown (kg/hr)

Later

After four hours shutdown (kg/hr)

Later

Hot restart after trip out (Less than 1 hr shut down) (kg/hr)

Later

After thirty six hours shutdown (Kg/hour)

Later

Cold start, After seventy two hours(kg/hr

Later

4.19.00

Start ups

4.19.01

Recommended Startup time periods to bring steam Generator to full load from ignition (with HP-LP bypass system) i)

ii)

iii)

iv)

v)

vi)

Cold start, (hours), after (72) hours

9.34

After thirty six (36) hours shut down (hours)

4.6

After twenty four (24) hours shut down (hours)

4.3

After twelve (12) hours shutdown (hours) After eight (8) hours shutdown (hours)

4

3.5

After four (4) hours

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 75 OF 117

Modified Sliding Pressure Operation 100% BMCR

vii)

4.19.02

4.20.00

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Pure Sliding Pressure Operation 100% TMCR

80% TMCR

shutdown (hours)

3.3

Hot restart after trip out with less than one hour shut down

2.5

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Number of start ups/life (Nos) of following type for which the unit has been designed a)

Cold startup (after 72 hours)

455

b)

Warm startup (after 36 hours)

910

c)

Hot startups (after 8 hours)

4550

d)

Daily load cycling between 40% to 100%

No limit provided recommended heat-up rates are adhered to.

Quantity of expected steam to be vented out in raising full pressure when starting without HP-LP bypass (Kg) No limit provided recommended heat-up ratesAre adhered to. i) From cold start up after (72) hours ii)

iii)

iv)

v)

vi)

vii)

Later

After thirty six (36) hours shut down

Later

After twenty four (24) hours shut down

Later

After twelve (12) hours shutdown

Later

After eight (8) hours shutdown

Later

After four (4) hours shutdown

Later

Hot restart after trip out

Later

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 76 OF 117

Modified Sliding Pressure Operation 100% BMCR

4.21.00

b)

c)

4.23.00

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

SH drains during starting a)

4.22.00

VWO

Pure Sliding Pressure Operation

Flow rate of drain water from primary superheater header (kg/hr)

N/A

Flow rate of drain water from SH final header (kg/hr)

N/A

Flow rate of drain water from SH final header (kg/hr)

N/A

Wind box performance i)

Free air area (m2)

4.48

3.98

3.98

3.49

2.49

1.99

3.98

3.49

2.49

1.99

4.48

3.98

2.49

1.49

ii)

Secondary air flow into the 3 wind box (m /sec)

674

683

628

469

366

319

634

477

358

304

579

634

425

177

0.587

0.587

0.592

0.610

0.630

0.642

0.589

0.605

0.626

0.635

0.662

0.628

0.633

0.678

iii)

Secondary air density (kg/m3)

iv)

Secondary air temperature in the wind box (degC)

301

300

295

279

261

252

298

283

265

257

235

263

258

224

v)

Secondary air velocity (m/sec)

37.6

42.9

39.4

33.7

36.8

40.0

39.8

34.2

36.0

38.1

32.3

39.8

42.7

29.6

vi)

Differential pressure with respect to the furnace (mmwc)

102

Combustion Data i)

ii)

iii)

Stoichiometric dry air required kg/kg fuel

4.117

Stoichiometric wet air required kg/kg fuel

4.174

Volume of flue gas at Eco outlet per Kg of Coal (NM3)

3.971

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 77 OF 117

Modified Sliding Pressure Operation 100% BMCR

iv)

v)

vi)

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Pure Sliding Pressure Operation 100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Emissivity at mean firing zone (Correct upto fifth place of decimal) a) Flame Emissivity (Luminous emissivity) b) Gas Emissivity (Non-luminous emissivity) c) Total Emissivity (Luminous+Non-luminous emissivity) Specific heat of flue gases at mean firing zone (correct upto fifth place of decimal) Weight of flue gas produced by burning 1 kg of fuel (kg) at Eco outlet

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

0.148 0.3587 0.5067

0.34884 kcal/kg-k

5.4254

PAGE 78 OF 117

5.00.00

ANTICIPATED PERFORMANCE DATA OF STEAM GENERATOR FOR DESIGN/WORST/BEST COALS BASED ON DESIGN AMBIENT AIR CONDITION OF 27℃ & 60%RH C) BEST COAL Modified Sliding Pressure Operation

5.01.00

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Steam flow at superheater outlet (Tonnes/hr)

2225

2160

2023.75

1572.47

1158.41

963.76

2035.24

1592.96

1178.13

982.34

1839.5

1960.0

1335.0

596.1

Steam pressure at superheater outlet (kg/cm2) abs

256

255

254.45

238.01

179.42

151.25

242.89

193.27

145.52

122.33

252.92

254.98

204.40

93.9

Steam temperature at superheater outlet (degC)

540

540

540

540

540

540

540

540

540

540

540

540

540

540

1741.82

1753.03

1678.37

1328.96

996.95

836.41

1686.33

1343.65

1012.39

851.48

1784.2

1784.34

1138

517.2

Steam pressure at reheater inlet (kg/cm2)(abs)

48.3

48.7

46.7

37.2

28.1

23.6

47.0

37.6

28.5

24.0

50.5

50.1

32.2

14.6

Steam temperature at reheater outlet (degC)

568

568

568

568

568

568

568

568

568

568

568

568

568

540

Steam temperature at reheater inlet (degC)

299

300

296

281

286

289

303

306

310

313

309

306

284

294

Pressure drop across reheater (kg/cm2)

1.69

1.70

1.62

1.30

1.02

0.88

1.63

1.34

1.05

0.90

1.70

1.70

1.13

0.57

General i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

Reheater steam flow (Tonnes/hr)

ix)

Control point (% TMCR)

50

50

50

50

50

50

50

50

50

50

50

50

50

50

x)

Feed water temperature (degC)

289.64

290

286.23

270.35

254.09

244.34

287.28

273.24

256.75

246.95

196.15

243.54

261

219

Steam generator efficiency based on the HHV of design coal

87.02

87.01

87.29

87.64

87.57

87.51

87.20

87.54

87.75

87.65

87.98

88.06

87.84

87.72

xi)

xii)

Heat liberated by fuel per

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 79 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

unit furnace volume (x106kal/m3/hr)

0.072

0.070

0.067

0.054

0.042

0.035

0.067

0.054

0.042

0.036

0.071

0.070

0.047

0.022

Furnace cooling factor (x106kcal/m2/hr)

0.173

0.169

0.160

0.129

0.099

0.084

0.161

0.130

0.099

0.084

0.167

0.167

0.112

0.053

Burner zone heat release rate (x106kcal/m2/hr)

1.184

1.157

1.098

0.889

0.683

0.579

1.100

0.894

0.687

0.584

1.162

1.150

0.773

0.368

Plan area heat release rate (x106kcal/m2/hr)

4.58

4.47

4.24

3.42

2.62

2.21

4.25

3.44

2.63

2.23

4.42

4.41

2.96

1.40

Total number of coal pulverisers

10

10

10

10

10

10

10

10

10

10

10

10

10

10

xvii) Number of coal pulverisers working with design coal

7

7

6

5

4

3

6

5

4

3

6

6

4

2

412.4

403.0

382.1

309.5

237.7

201.5

383.0

311.2

239.3

203.3

404.5

400.2

269.1

128.2

Furnace exit gas temperature (degC)

999

1014

1022

991

912

891

1006

956

903

884

1010

1018

954

764

Dryness fraction of steam at drum outlet (%)

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

xiii)

xiv)

xv)

xvi)

xviii) Weight of coal fired (tonnes/hr) xix)

xx)

xxi)

Steam Purity at SH outlet (ppm) a)

Total dissolved solids

b)

Silica

c)

Sodium

d)

Chlorides

e)

Copper

f)

Iron

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

Max 0.002 Max 0.002 Max 0.002 0.002 Max 0.001 Max 0.005

PAGE 80 OF 117

Modified Sliding Pressure Operation 100% BMCR

VWO

100% TMCR

80% TMCR

xxii) Furnish calculations for plan area heat release rate, burner zone heat release rate, volumetric heat release rate furnace cooling factor & heat input per burner alongwith details of EPRS calculation, basis for the fouling factor/surface adjustment factor considered

5.02.00

Temperature ( degC)

5.02.01

Air

60% TMCR

50% TMCR

Pure Sliding Pressure Operation 100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Refer to Furnace Performance and Sizing Calculation (T04019-SY-C0003)

A) Bottom Burner Elevations in Service i)

Identify Mills/Elevations in service

B~H

B~G

B~G

B~F

C~F

C~E

B~G

B~F

C~F

C~E

B~G

B~G

C~F

C~D

Burner Tilts (if appli cable( deg)

16

25

25

25

25

25

25

25

25

0

25

25

25

0

iii)

Design Ambient

27

27

27

27

27

27

27

27

27

27

27

27

27

27

iv)

Inlet to the RAPH (Primary air)

34.7

34.7

34.4

34.0

36.0

49.0

34.4

34.0

38.0

46.0

54.0

34.7

33.9

67.0

Outlet of RAPH (Primary air)

297

298

294

273

266

250

296

279

264

256

225

258

254

221

Inlet to the RAPH (Secondary air)

30.9

30.9

30.6

30.3

38.0

50.0

30.6

30.3

35.0

46.0

53.0

30.9

30.1

65.0

Outlet of the RAPH (Secondary air)

294

295

289

272

257

248

291

277

262

254

226

257

254

221

Secondary air at Inlet to burners

294

295

289

272

257

248

291

277

262

254

226

257

254

221

ii)

v)

vi)

vii)

viii)

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 81 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Hot Primary air in the common duct before pulverisers

297

298

294

273

266

250

296

279

264

256

225

258

254

221

Hot primary air at the inlet to pulverisers

191

189

197

194

191

201

197

195

192

201

202

201

202

198

Identify Mills/Elevations in service

C~I

C~H

C~H

D~H

D~G

E~G

C~H

D~H

D~G

E~G

C~H

C~H

D~G

N/A

Burner Tilts (if appli cable (deg)

-17

10

25

25

25

-17

11

0

-9

-25

10

21

25

N/A

iii)

Design Ambient

27

27

27

27

27

27

27

27

27

27

27

27

27

N/A

iv)

Inlet to the RAPH (Primary air)

37.4

37.4

34.4

34.0

39.5

49.0

34.4

34.0

38.0

46.0

54.0

34.7

33.9

N/A

Outlet of RAPH (Primary air)

297

296

292

274

259

250

294

279

263

255

223

257

253

N/A

Inlet to the RAPH (Secondary air)

30.9

30.9

30.6

30.3

38.0

49.0

30.6

30.3

35.0

46.0

54.0

30.9

30.1

N/A

Outlet of the RAPH (Secondary air)

294

294

288

272

258

248

291

277

262

254

225

257

254

N/A

Secondary air at Inlet to burners

294

294

288

272

258

248

291

277

262

254

225

257

254

N/A

Hot Primary air in the common duct before pulverisers

297

296

292

274

259

250

294

279

263

255

223

257

253

N/A

Hot primary air at the inlet to pulverisers

191

189

197

195

192

201

197

195

192

201

201

200

201

N/A

ix)

x)

B) Middle Burner Elevations in Service i)

ii)

v)

vi)

vii)

viii)

ix)

x)

C) Top Burner Elevations SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 82 OF 117

Modified Sliding Pressure Operation 100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

D~J

E~J

E~J

F~J

G~J

H~J

E~J

F~J

G~J

H~J

E~J

E~J

G~J

N/A

Burner Tilts (if appli cable( deg)

-25

-20

0

20

-18

-25

-25

-25

-25

-25

-25

-7

19

N/A

iii)

Design Ambient

27

27

27

27

27

27

27

27

27

27

27

27

27

N/A

iv)

Inlet to the RAPH (Primary air)

34.7

34.7

34.4

34.0

39.0

48.0

34.4

34.0

37.0

46.0

54.0

34.7

33.9

N/A

Outlet of RAPH (Primary air)

296

296

292

274

260

249

294

279

263

254

223

257

252

N/A

Inlet to the RAPH (Secondary air)

30.9

30.9

30.6

30.3

39.0

50.0

30.6

30.3

35.0

45.0

54.0

30.9

30.1

N/A

Outlet of the RAPH (Secondary air)

294

294

288

273

257

247

291

277

262

254

225

257

254

N/A

Secondary air at Inlet to burners

294

294

288

273

257

247

291

277

262

254

225

257

254

N/A

Hot Primary air in the common duct before pulverisers

296

296

292

274

260

249

294

279

263

254

223

257

252

N/A

Hot primary air at the inlet to pulverisers

192

189

197

195

192

201

197

195

192

201

201

200

201

N/A

Fuel and air mixture leaving the p!ulveriser

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

Fuel & air mixture entering the burner

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

76.7

in Service i) Identify Mills/Elevations in service ii)

v)

vi)

vii)

viii)

ix)

x)

5.02.02

Fuel & air mixture i)

ii)

5.02.03

Pure Sliding Pressure Operation

Flue Gases (Actual Temperatures) SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 83 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

B~H

B~G

B~G

B~F

C~F

C~E

B~G

B~F

C~F

C~E

B~G

B~G

C~F

C~D

16

25

25

25

25

25

25

25

25

0

25

25

25

0

Theoretical combustion temperature in the combustion zone

1591

1570

1553

1492

1389

1350

1548

1499

1410

1356

1544

1547

1390

1236

At furnace arch level (Furnace arch level is defined as the level at the entrance to radiant super heater)

1338

1342

1332

1312

1255

1225

1336

1316

1259

1181

1342

1339

1275

1120

At Furnace arch exit (as defined in the specification for FEGT)

997

1002

993

945

896

874

992

948

890

861

999

998

923

764

Stage I

1338

1342

1332

1312

1255

1225

1336

1316

1259

1181

1342

1339

1275

1120

Stage II

1092

1096

1087

1048

997

987

1088

1052

995

969

1095

1092

1023

879

Stage III

860

864

857

802

763

737

854

809

756

729

862

861

788

633

Stage I

1092

1096

1087

1048

997

987

1088

1052

995

969

1095

1092

1023

879

Stage II

997

1002

993

945

896

874

992

948

890

861

999

998

923

764

Stage III

728

731

726

680

649

626

723

683

642

622

728

728

668

564

A) Bottom Burner Elevations in Service i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

Identify Mills/elevations in service Burner Tilts (if applicable) (deg)

Entrance to superheater

Exit of Superheater

Entrance to reheater

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 84 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Stage I

721

724

719

673

642

619

716

676

635

614

721

721

662

556

Stage II

997

1002

993

945

896

874

992

948

890

861

999

998

923

764

Stage I

487

489

485

446

434

419

484

461

439

429

491

489

445

379

Stage II

879

883

876

822

783

757

874

829

776

749

881

880

808

655

Entrance of economizer

487

489

485

446

434

419

484

461

439

429

491

489

445

379

xi)

Exit of economizer

321

322

318

295

278

266

318

299

280

268

249

286

287

233

xii)

Entrance to primary air heater

321

322

318

295

278

266

318

299

280

268

249

286

287

233

Entrance to secondary air heater

321

322

318

295

278

266

318

299

280

268

249

286

287

233

Exit of primary air heater (corrected)

132

133

126

115

111

111

128

118

111

111

111

110

113

111

Exit of secondary air heater (corrected)

130

130

124

115

110

111

126

117

110

110

110

110

115

109

xvii) Exit of primary air heater (Uncorrected)

145

146

140

129

128

127

141

132

126

128

119

121

121

126

xviii) Exit of secondary air heater (Uncorrected)

136

136

130

121

116

117

131

123

117

117

114

115

118

117

Exit of air preheater (average considered)

131

131

125

115

110

111

126

117

110

110

111

110

114

110

Entrance of electrostatic precipitator

131

131

125

115

110

111

126

117

110

110

111

110

114

110

Exit of electrostatic precipitator

129

129

123

113

108

109

124

115

108

108

109

108

112

108

ix) Exit of reheater

x)

xiii)

xv)

xvi)

xix)

xx)

xxi)

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 85 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

xxii) Entrance of ID fans

129

129

123

113

108

109

124

115

108

108

109

108

112

108

xxiii) Entrance to Chimney

133

133

127

116

111

112

128

118

111

111

112

111

115

111

Identify Mills/elevations in service

C~I

C~H

C~H

D~H

D~G

E~G

C~H

D~H

D~G

E~G

C~H

C~H

D~G

N/A

Burner Tilts (if applicable ) (deg)

-17

10

25

25

25

-17

11

0

-9

-25

10

21

25

N/A

Theoretical combustion temperature in the combustion zone (deg C)

1591

1586

1569

1495

1407

1353

1570

1509

1417

1366

1557

1568

1414

N/A

At furnace arch level (Furnace arch level is defined as the level at the entrance to radiant super heater)

1341

1362

1374

1348

1320

1222

1358

1324

1265

1209

1361

1373

1333

N/A

At furnace arch exit (as defined in the specification for FEGT)

999

1012

1018

975

915

879

1006

956

894

871

1010

1018

943

N/A

Stage I

1341

1362

1374

1348

1320

1222

1358

1324

1265

1209

1361

1373

1333

N/A

Stage II

1094

1113

1126

1087

1029

996

1110

1063

1002

987

1111

1122

1057

N/A

Stage III

861

868

867

824

769

738

859

811

756

731

866

871

794

N/A

Stage I

1094

1113

1126

1087

1029

996

1110

1063

1002

987

1111

1122

1057

N/A

Stage II

999

1012

1018

975

915

879

1006

956

894

871

1010

1018

943

N/A

B) Middle Burner Elevations in Service i)

ii)

iii)

iv)

v)

vi)

vii)

Entrance to superheater

Exit of Superheater

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 86 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

729

731

727

691

649

626

722

683

642

621

728

731

668

N/A

Stage I

722

724

719

684

642

619

716

676

634

613

721

724

661

N/A

Stage II

999

1012

1018

975

915

879

1006

956

894

871

1010

1018

943

N/A

Stage I

487

486

478

451

429

418

481

458

438

425

488

487

438

N/A

Stage II

881

888

888

844

791

759

880

831

777

752

887

892

816

N/A

Entrance of economizer

487

486

478

451

429

418

481

458

438

425

488

487

438

N/A

xi)

Exit of economizer

321

320

315

296

277

265

316

298

279

267

248

284

284

N/A

xii)

Entrance to primary air heater

321

320

315

296

277

265

316

298

279

267

248

284

284

N/A

Entrance to secondary air heater

321

320

315

296

277

265

316

298

279

267

248

284

284

N/A

Exit of primary air heater (corrected)

133

132

128

116

110

110

128

119

111

111

111

111

107

N/A

Exit of secondary air heater (corrected)

130

130

124

115

110

110

126

118

110

110

111

110

115

N/A

xvii) Exit of primary air heater (Uncorrected)

145

145

141

130

125

126

141

133

127

127

119

121

123

N/A

xviii) Exit of secondary air heater (Uncorrected)

136

136

130

121

116

116

132

124

117

117

115

115

119

N/A

Exit of air preheater (average considered)

131

131

125

115

110

110

127

118

110

110

111

110

113

N/A

Entrance of electrostatic precipitator

131

131

125

115

110

110

127

118

110

110

111

110

113

N/A

Stage III viii)

ix)

x)

xiii)

xv)

xvi)

xix)

xx)

Entrance to reheater

Exit of reheater

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 87 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Exit of electrostatic precipitator

129

129

123

113

108

108

125

116

108

108

109

108

111

N/A

xxii) Entrance of ID fans

129

129

123

113

108

108

125

116

108

108

109

108

111

N/A

xxiii) Entrance to Chimney

133

133

127

116

111

111

129

119

111

111

112

111

114

N/A

Identify Mills/elevations in service

D~J

E~J

E~J

F~J

G~J

H~J

E~J

F~J

G~J

H~J

E~J

E~J

G~J

N/A

Burner Tilts (if applicable ) (deg)

-25

-30

0

20

-18

-25

-25

-25

-25

-30

-25

-7

19

N/A

Theoretical combustion temperature in the combustion zone (deg C)

1594

1585

1569

1506

1407

1367

1570

1510

1425

1381

1557

1568

1431

N/A

At furnace arch level (Furnace arch level is defined as the level at the entrance to radiant super heater)

1363

1364

1375

1371

1306

1263

1354

1332

1294

1261

1358

1373

1354

N/A

At furnace arch exit (as defined in the specification for FEGT)

1019

1014

1022

991

912

891

1006

964

903

884

1009

1019

954

N/A

Stage I

1363

1364

1375

1371

1306

1263

1354

1332

1294

1261

1358

1373

1354

N/A

Stage II

1119

1115

1129

1110

1026

1017

1109

1075

1017

1012

1109

1123

1077

N/A

Stage III

875

869

869

831

768

741

859

817

759

734

866

872

797

N/A

xxi)

C) Top Burner Elevations in Service i)

ii)

iii)

iv)

v)

vi)

vii)

Entrance to superheater

Exit of Superheater

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 88 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Stage I

1119

1115

1129

1110

1026

1017

1109

1075

1017

1012

1109

1123

1077

N/A

Stage II

1019

1014

1022

991

912

891

1006

964

903

884

1009

1019

954

N/A

Stage III

737

732

728

693

648

624

722

686

641

619

728

731

666

N/A

Stage I

730

724

721

686

641

617

715

678

634

612

721

724

659

N/A

Stage II

1019

1014

1022

991

912

891

1006

964

903

884

1009

1019

954

N/A

Stage I

486

486

479

449

429

414

481

458

435

421

488

487

434

N/A

Stage II

896

889

890

853

789

762

879

838

781

757

886

892

819

N/A

Entrance of economizer

486

486

479

449

429

414

481

458

435

421

488

487

434

N/A

xi)

Exit of economizer

321

320

315

295

276

264

316

298

279

266

248

284

283

N/A

xii)

Entrance to primary air heater

321

320

315

295

276

264

316

298

279

266

248

284

283

N/A

Entrance to secondary air heater

321

320

315

295

276

264

316

298

279

266

248

284

283

N/A

Exit of primary air heater (corrected)

132

132

128

116

111

111

128

118

110

111

111

110

115

N/A

Exit of secondary air heater (corrected)

130

131

124

116

110

110

126

118

110

110

111

110

115

N/A

xvii) Exit of primary air heater (Uncorrected)

145

145

141

130

126

127

141

133

126

128

119

121

123

N/A

xviii) Exit of secondary air heater (Uncorrected)

135

136

130

122

117

117

132

124

117

117

115

115

119

N/A

viii)

ix)

x)

xiii)

xv)

xvi)

xix)

Entrance to reheater

Exit of reheater

Exit of air preheater

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 89 OF 117

Modified Sliding Pressure Operation 100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

(average considered)

130

131

125

116

110

110

127

118

110

110

111

110

115

N/A

Entrance of electrostatic precipitator

130

131

125

116

110

110

127

118

110

110

111

110

115

N/A

Exit of electrostatic precipitator

128

129

123

114

108

108

125

116

108

108

109

108

113

N/A

xxii) Entrance of ID fans

128

129

123

114

108

108

125

116

108

108

109

108

113

N/A

xxiii) Entrance to Chimney

132

133

127

117

111

111

129

119

111

111

112

111

116

N/A

B~H

B~G

B~G

B~F

C~F

C~E

B~G

B~F

C~F

C~E

B~G

B~G

C~F

C~D

Burner Tilts (if applicable ) (deg)

16

25

25

25

25

25

25

25

25

0

25

25

25

0

Water entering economizer

290

290

286

270

254

244

287

273

257

247

196

244

261

219

Water leaving economizer

339

342

340

321

313

305

339

326

315

307

297

319

319

277

a) Superheater

290

290

286

270

254

244

287

273

257

247

196

244

261

219

b) Reheater

191

191

191

181

169

161

191

181

169

161

196

195

169

144

C~I

C~H

C~H

D~H

D~G

E~G

C~H

D~H

D~G

E~G

C~H

C~H

D~G

N/A

xx)

xxi)

5.02.04

Pure Sliding Pressure Operation

Feed Water A) Bottom Burner Elevations in Service i)

ii)

iii)

iv)

v)

Identify Mills/elevations in service

Desuperheating spray water temperature

B) Middle Burner Elevations in Service i)

Identify Mills/elevations in service

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 90 OF 117

Modified Sliding Pressure Operation

ii)

iii)

iv)

v)

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Burner Tilts (if applicable ) (deg)

-17

10

25

25

25

-17

11

0

-9

-25

10

21

25

N/A

Water entering economizer

290

290

286

270

254

244

287

273

257

247

196

244

261

N/A

Water leaving economizer

339

340

336

323

312

304

337

324

314

305

294

316

316

N/A

a) Superheater

290

290

286

270

254

244

287

273

257

247

196

244

261

N/A

b) Reheater

191

191

191

181

169

161

191

181

169

161

196

195

169

N/A

Identify Mills/elevations in service

D~J

E~J

E~J

F~J

G~J

H~J

E~J

F~J

G~J

H~J

E~J

E~J

G~J

N/A

Burner Tilts (if applicable ) (deg)

-25

-20

0

20

-18

-25

-25

-25

-25

-25

-25

-7

19

N/A

Water entering economizer

290

290

286

270

254

244

287

273

257

247

196

244

261

N/A

Water leaving economizer

340

340

336

321

311

302

337

324

313

303

294

317

314

N/A

a) Superheater

290

290

286

270

254

244

287

273

257

247

196

244

261

N/A

b) Reheater

191

191

191

181

169

161

191

181

169

161

196

195

169

N/A

Desuperheating spray water temperature

C) Top Burner Elevations in Service i)

ii)

iii)

iv)

v)

5.02.05

Desuperheating spray water temperature

Steam

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 91 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

B~H

B~G

B~G

B~F

C~F

C~E

B~G

B~F

C~F

C~E

B~G

B~G

C~F

C~D

16

25

25

25

25

25

25

25

25

0

25

25

25

0

1st Stage

416

413

410

403

371

362

407

384

363

350

401

406

382

333

2nd Stage

450

448

444

440

422

411

443

426

416

408

433

440

429

417

3rd Stage

485

483

481

483

472

470

480

475

471

469

473

477

472

492

1st Stage

460

458

454

451

429

431

453

438

442

422

444

450

429

429

2nd Stage

492

491

488

491

490

490

488

484

491

491

480

484

489

519

3rd Stage

540

540

540

540

540

540

540

540

540

540

540

540

540

540

1st Stage

299

300

296

281

286

289

303

306

310

313

309

306

284

294

2nd Stage

455

456

455

433

447

443

456

454

453

453

458

455

448

424

1st Stage

455

456

455

433

447

443

457

454

453

453

458

456

448

424

2nd Stage

568

568

568

568

568

568

568

568

568

568

568

568

568

568

Outlet of seperator

411

408

405

397

362

349

401

377

349

334

397

401

375

311

A) Bottom Burner Elevations in Service i)

ii)

iii)

iv)

v)

vi)

vii)

Identify Mills/elevations in service Burner Tilts (if applicable ) (deg) Inlet of superheater

Outlet of superheater

Inlet to reheater

Outlet to reheater

B) Middle Burner Elevations in Service SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 92 OF 117

Modified Sliding Pressure Operation

i)

ii)

iii)

iv)

v)

vi)

vii)

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Identify Mills/elevations in service

C~I

C~H

C~H

D~H

D~G

E~G

C~H

D~H

D~G

E~G

C~H

C~H

D~G

N/A

Burner Tilts (if applicable ) (deg)

-17

10

25

25

25

-17

11

0

-9

-25

10

21

25

N/A

1st Stage

416

411

406

396

371

362

405

383

363

351

399

402

383

N/A

2nd Stage

450

446

441

433

417

409

441

425

416

405

432

436

426

N/A

3rd Stage

485

483

480

478

471

469

480

475

471

469

472

476

474

N/A

1st Stage

460

456

450

442

441

426

451

437

441

425

442

446

438

N/A

2nd Stage

492

490

487

485

489

490

487

483

491

491

480

483

490

N/A

3rd Stage

540

540

540

540

540

540

540

540

540

540

540

540

540

N/A

1st Stage

299

300

296

281

286

289

303

306

310

313

309

306

284

N/A

2nd Stage

455

453

448

439

442

442

452

452

451

449

456

453

441

N/A

1st Stage

455

453

449

439

442

443

453

452

452

449

456

454

442

N/A

2nd Stage

568

568

568

568

568

568

568

568

568

568

568

568

568

N/A

Outlet of seperator

410

406

401

391

362

349

400

376

349

334

395

398

375

N/A

Inlet of superheater

Outlet of superheater

Inlet to reheater

Outlet to reheater

C) Top Burner Elevations in Service SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 93 OF 117

Modified Sliding Pressure Operation

i)

ii)

iii)

iv)

v)

vi)

vii)

5.03.00

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Identify Mills/elevations in service

D~J

E~J

E~J

F~J

G~J

H~J

E~J

F~J

G~J

H~J

E~J

E~J

G~J

N/A

Burner Tilts (if applicable ) (deg)

-25

-20

0

20

-18

-25

-25

-25

-25

-25

-25

-7

19

N/A

1st Stage

411

410

406

394

371

362

405

381

363

351

400

402

383

N/A

2nd Stage

446

446

441

430

419

407

441

423

413

400

432

436

425

N/A

3rd Stage

482

482

480

477

472

469

480

473

471

468

473

476

474

N/A

1st Stage

456

455

450

439

434

431

451

435

445

434

442

446

443

N/A

2nd Stage

489

489

487

484

490

490

487

482

491

491

480

483

491

N/A

3rd Stage

540

540

540

540

540

540

540

540

540

540

540

540

540

N/A

1st Stage

291

300

296

281

286

289

303

302

310

312

309

306

284

N/A

2nd Stage

450

453

449

438

442

438

452

450

449

445

455

453

437

N/A

1st Stage

450

453

449

438

442

438

453

450

449

445

456

454

437

N/A

2nd Stage

568

568

568

568

568

568

568

568

568

568

568

568

568

N/A

Outlet of seperator

407

406

401

389

362

349

400

375

349

334

396

398

375

N/A

Inlet of superheater

Outlet of superheater

Inlet to reheater

Outlet to reheater

Pressure

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 94 OF 117

Modified Sliding Pressure Operation

5.03.01

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Air (mmwc) i)

ii) iii)

iv)

v)

vi)

5.03.02

Pure Sliding Pressure Operation

Forced draft fan inlet (with air duct, air foil and silencer) Forced draft fan discharge

-38

-34

-34

-22

-16

-12

-34

-22

-14

-10

-40

-38

-16

-4

232

223

218

177

189

166

218

179

179

159

329

323

246

129

Air heater inlet (Secondary air )

203

196

192

160

177

157

192

162

169

151

298

293

234

125

Air heater outlet (Secondary air)

157

153

151

133

158

143

151

134

152

138

253

248

162

119

In burner windbox (Secondary air)

102

102

102

102

102

102

102

102

102

102

102

102

102

102

-22

-22

-18

-13

-9

-6

-18

-13

-9

-6

-19

-18

-8

-3

vii)

Primary air fan inlet (with air duct, air foil and silencer) Primary air fan discharge

837

832

849

832

828

848

849

831

830

847

939

865

904

823

viii)

Air heater inlet (Primary air)

828

823

842

827

824

846

842

826

826

845

931

857

901

822

ix)

Air heater outlet (Primary air)

795

790

813

804

808

834

813

804

810

833

882

818

835

815

x)

Hot primary air in the common duct before pulverisers

778

774

799

793

785

816

799

793

786

817

805

807

815

805

xi)

Cold primary air header

759

755

779

773

765

795

779

773

766

796

784

786

794

784

xii)

Hot primary air at the inlet to pulverisers

583

610

617

604

586

643

657

645

626

686

645

682

644

625

Fuel Side (mmwc) i)

In the pulveriser

583

610

617

604

586

643

657

645

626

686

645

682

644

625

ii)

At the pulveriser outlet

261

293

279

272

263

292

319

312

302

335

293

332

293

285

iii)

At the burners inlet

25

25

25

25

25

25

25

25

25

25

25

25

25

25

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 95 OF 117

Modified Sliding Pressure Operation

5.03.03

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Inlet to economizer (at the specified terminal point)

304.1

300.4

292.9

261.1

195.9

165.5

283.1

220.7

165.4

139.3

282.6

289.2

224.5

101.1

ii)

At economizer inlet

301.2

297.6

290.3

259.1

194.3

164.0

280.5

218.7

163.8

137.8

280.3

286.7

222.8

99.8

iii)

Outlet of economizer

295.0

291.5

284.6

254.3

190.2

160.0

274.8

213.9

159.6

133.8

274.8

281.1

218.3

95.9

iv)

Attemperation water for superheater

304.1

300.4

292.9

261.1

195.9

165.5

283.1

220.7

165.4

139.3

282.6

289.2

224.5

101.1

Attemperation water for reheater

91.5

91.9

89.9

80.4

71.3

66.8

90.2

80.7

71.7

67.2

93.7

93.3

75.4

57.8

278.0

274.8

271.1

248.2

187.7

158.4

261.0

207.3

156.8

131.8

266.2

270.2

213.6

99.4

2

Feed Water (kg/cm ) abs i)

v)

5.03.04

5.03.05

Pure Sliding Pressure Operation

Separator Pressure ( Kg/cm2) abs Steam (kg/cm2)(abs) i)

Inlet of superheater

271.9

270.3

267.3

245.8

185.7

156.5

256.7

203.9

154.0

129.3

263.3

266.8

211.4

97.9

ii)

Outlet of superheater

256.0

255.5

254.5

238.0

179.4

151.2

242.9

193.3

145.6

122.3

252.9

255.0

204.4

93.9

iii)

Inlet to reheater

48.3

48.7

46.7

37.2

28.1

23.6

47.0

37.6

28.5

24.0

50.5

50.1

32.2

14.6

iv)

Outlet of reheater

46.6

47.0

45.1

35.9

27.1

22.7

45.4

36.2

27.4

23.1

48.8

48.4

31.1

14.0

v)

Inlet of seperator

278.0

275.8

271.9

248.7

188.1

158.7

261.8

207.8

157.2

132.2

266.8

270.8

214.0

99.5

vi)

Outlet of seperator

277.0

274.8

271.1

248.2

187.7

158.4

261.0

207.3

156.8

131.8

266.2

270.2

213.6

99.4

5.04.00

Pressure Drop

5.04.01

Air Path: (mmwc) SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 96 OF 117

Modified Sliding Pressure Operation

i)

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

In air ducts including bends dampers, vanes etc

192

160

175

179

202

169

135

138

164

125

215

115

169

169

Across aerofoil (flow measuring device)

29

29

28

26

24

24

28

26

24

24

30

29

25

22

c)

Across RAPH

33

33

29

23

16

12

29

22

16

12

49

39

66

7

d)

Total loss through the system

254

222

232

228

242

205

192

186

204

161

294

183

260

198

Primary air circuit a)

b)

5.04.02

5.04.03

Pure Sliding Pressure Operation

Fuel Path (mmwc) i)

Across the pulverisers

322

317

338

332

323

351

338

333

324

351

352

349

351

340

ii)

In the fuel piping from pulveriser outlet to burners

261

293

279

272

263

292

319

312

302

335

293

332

293

285

Furnace pressure (back draught)

3

3

3

3

3

3

3

3

3

3

3

3

3

3

Across SH/RH convection path

64

59

59

51

46

41

59

51

46

41

61

61

37

14

iii)

Across economizers

26

24

22

14

8

6

22

14

8

6

23

24

24

24

iv)

Across air heaters

88

84

77

52

35

25

77

52

33

24

70

76

123

11

v)

In gas ducts

42

40

37

25

17

12

37

25

16

12

42

41

18

6

Flue Gas Path (mmwc) i)

ii)

a)

Between air heater outlet and electrostatic precipitator funnel inlet

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 97 OF 117

Modified Sliding Pressure Operation 100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Between outlet of electrostatic precipitator funnels & inlet of ID fan

23

22

20

13

9

7

20

13

9

6

23

22

9

3

Between ID fan outlet and chimney inlet

13

12

11

8

5

4

11

8

5

4

13

12

5

2

291

273

256

185

135

108

256

185

130

103

265

268

231

66

Saturated steam connections including horizontal and vertical hangers

5.1

4.5

3.8

2.4

2.0

1.9

4.3

3.4

2.8

2.5

2.9

3.4

3.4

2.2

Superheater Stage I

3.3

3.0

2.6

1.4

1.3

1.1

2.8

2.0

1.7

1.4

2.1

2.4

2.4

2.4

Superheater Stage II

4.3

4.0

3.5

2.1

1.7

1.4

3.8

2.9

2.2

1.9

2.8

3.2

3.2

1.9

Superheater Stage III

3.2

3.0

2.7

1.6

1.3

1.1

2.9

2.2

1.8

1.5

2.2

2.5

2.5

1.5

Superheater desuperheater

2.3

2.2

1.9

1.2

0.9

0.8

2.0

1.6

1.2

1.0

1.5

1.7

1.7

1.7

Reheater Stage I

0.5

0.5

0.4

0.4

0.3

0.2

0.4

0.4

0.3

0.3

0.5

0.5

0.5

0.3

Reheater Stage II

0.8

0.8

0.8

0.6

0.5

0.4

0.8

0.6

0.5

0.4

0.8

0.8

0.8

0.5

Reheater desuperheater

0.06

0.06

0.05

0.03

0.02

0.01

0.05

0.03

0.02

0.01

0.04

0.06

0.02

0.00

-0.3

-0.5

-1.0

-2.4

-3.3

-3.6

-0.9

-2.2

-3.1

-3.5

-2.3

-1.6

-1.6

-3.0

b)

c)

vi) 5.04.04

Total loss through the system

Steam Path (kg/cm2) i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

5.04.05

Pure Sliding Pressure Operation

Feed Water Path (kg/cm2) i)

Valves and connected piping

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 98 OF 117

Modified Sliding Pressure Operation

ii) 5.05.00

economizer

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

6.2

6.1

5.7

4.8

4.1

4.0

5.7

4.8

4.2

4.0

5.5

5.6

5.6

4.5

Velocities (m/sec) i)

Furnace throat gas velocity

8.1

8.2

8.1

7.8

6.2

4.7

3.9

7.7

6

4.5

3.8

8.1

4.8

2.2

ii)

Maximum gas velocity through tube banks of TSH

8.9

9

8.8

8.4

6.6

5

4.1

8.3

6.5

4.8

3.9

8.9

5.1

2.3

Maximum gas velocity through tube banks of economizer

8.9

8.9

8.7

8.2

6.4

5

4.1

8.2

6.5

4.9

4

8.8

5

2.5

Stage I

-

-

-

-

-

-

-

-

-

-

-

-

-

-

Stage II

7.8

7.9

7.8

7.5

5.9

4.5

3.7

7.4

5.8

4.3

3.6

7.8

4.6

2.1

Stage III

8.6

8.7

8.5

8.1

6.3

4.9

3.9

8

6.3

4.7

3.8

8.6

4.9

2.3

Stage I

8.9

9

8.7

8.2

6.4

5

4

8.2

6.4

4.8

3.9

8.8

5

2.4

Stage II

8.6

8.7

8.5

8.1

6.4

4.9

4

8.1

6.3

4.7

3.8

8.6

4.9

2.3

Stage I

7.7

8

7.8

7.3

5.7

4.5

3.6

7.3

5.8

4.4

3.6

7.4

4.5

2.2

Stage II

-

-

-

-

-

-

-

-

-

-

-

-

-

-

iii)

Note : In case gas biasing in the convective pass is being used for RH temperature control the details of gas flow and velocity through both the passes shall be indicated a)

b)

c)

iii)

Superheater

Reheater

economizer

Gas/air velocities through

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 99 OF 117

Modified Sliding Pressure Operation

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

- Secondary RAPH

8.6

8.4

7.9

6.1

4.8

3.9

7.9

6.2

4.6

3.8

7.2

7.7

10.3

2.3

- Primary RAPH

7.7

7.6

7.0

5.9

4.8

4.0

7.0

5.9

4.7

4.0

8.0

7.4

10.2

2.8

- Secondary RAPH

5.7

5.5

5.4

4.2

3.4

2.9

5.4

4.2

3.2

2.7

5.5

5.5

7.2

1.7

- Primary RAPH

4.6

4.5

4.3

3.7

3

2.5

4.2

3.6

2.9

2.5

5.6

4.9

6.6

1.8

the air heater heating elements a)

b)

iv)

v)

vi)

5.06.00

Gas

Air

Air velocities a)

Cold air ducts

14.1

13.7

13.4

10.8

9

7.7

13.4

10.9

8.5

7.3

14.7

14.3

9.2

5

b)

Hot air ducts

15.5

14.8

14.3

11.2

9

7.5

14.4

11.6

9.1

7.7

15.8

15.5

9.9

5.2

Gas velocities in gas ducting sections a)

Eco to AH

10.8

10.5

9.9

7.8

6.3

5.2

10

7.9

6.1

5.1

9.4

9.9

6

2.9

b)

Eco gas bypass ducts

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

c)

AH to ESP

11.5

11.2

10.5

8.4

6.8

5.8

10.5

8.5

6.6

5.6

10.9

10.7

7.1

4

d)

ESP to ID fan

12.2

11.9

11.2

8.9

7.3

6.2

11.2

9

7

6

11.5

11.3

7.5

4.2

e)

ID fan to stack

11.8

11.5

10.8

8.6

7

6

10.8

8.7

6.8

5.8

11.2

11

7.3

4.1

25.8

25.6

26.5

26.3

25.9

27.1

26.5

26.3

25.9

27.1

27.1

27.0

27.1

27.0

Air-fuel mixture velocity in the fuel pipe line

Percentage of Oxygen in flue gas

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 100 OF 117

Modified Sliding Pressure Operation 100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

i)

At furnace exit

3.46

3.46

3.46

3.46

4.46

4.11

3.46

3.46

3.69

3.46

3.46

3.46

3.46

4.08

ii)

At economizer outlet

3.46

3.46

3.46

3.46

4.46

4.11

3.46

3.46

3.69

3.46

3.46

3.46

3.46

4.08

iii)

At air heater outlet (primary)

5.79

5.83

6.02

6.44

7.81

8.09

6.02

6.40

7.19

7.56

5.93

5.98

5.39

9.29

iv)

At air heater outlet (secondary)

4.52

4.54

4.59

4.83

6.05

6.03

4.57

4.81

5.37

5.45

4.87

4.70

4.37

7.06

In the common duct before ESP

4.84

4.86

4.94

5.26

6.54

6.63

4.93

5.23

5.88

6.07

5.18

5.04

4.64

7.80

vi)

At ESP outlet

4.84

4.86

4.94

5.26

6.54

6.63

4.93

5.23

5.88

6.07

5.18

5.04

4.64

7.80

vii)

At ID fan inlet

4.84

4.86

4.94

5.26

6.54

6.63

4.93

5.23

5.88

6.07

5.18

5.04

4.64

7.80

v)

5.07.00

Pure Sliding Pressure Operation

Flow rate of air (kg/hr) i)

FD fan outlet

1,759,622

1,706,506

1,670,734

1,348,440

1,121,026

960,162

1,668,104

1,353,018

1,060,230

911,198

1,827,040

1,787,020

1,152,065

618,090

ii)

PA fan outlet

898,490

892,640

802,956

681,728

560,266

462,964

801,770

680,540

560,102

461,172

835,944

823,250

534,244

342,382

iii)

Air heater inlet 572,990

565,416

541,416

487,918

417,888

377,006

535,830

479,494

414,704

369,130

741,908

640,204

420,803

306,122

1,759,622

1,706,506

1,670,734

1,348,440

1,121,026

960,162

1,668,104

1,353,018

1,060,230

911,198

1,827,040

1,787,020

1,152,065

618,090

481,190

473,616

447,816

391,718

319,888

275,206

443,230

385,094

317,504

269,330

629,308

537,604

368,603

200,722

1,633,422

1,582,106

1,546,334

1,226,840

999,426

839,362

1,544,704

1,232,218

942,230

793,998

1,669,040

1,645,420

1,083,965

498,290

Tempering air for each pulveriser

46,500

46,746

43,590

38,762

35,595

28,653

44,323

40,209

36,350

30,681

15,673

30,508

28,360

18,130

vi)

Total air to each pulveriser

115,241

114,406

118,226

117,106

115,567

120,388

118,195

117,228

115,726

120,457

120,557

120,108

120,511

118,491

vii)

Total combustion air (included furnace leakage)

2,516,135

2,458,969

2,331,713

1,888,391

1,537,715

1,276,549

2,329,897

1,894,381

1,481,155

1,231,393

2,468,407

2,442,093

1,642,032

811,295

iv)

v)

a)

Primary air

b)

Secondary air

Air heater outlet a)

Primary air

b)

Secondary air

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 101 OF 117

Modified Sliding Pressure Operation

5.08.00

5.09.00

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

656,308

644,612

603,208

518,810

431,636

369,614

594,900

515,970

426,686

361,492

755,936

673,210

460,663

268,816

2,120,678

2,069,276

1,970,216

1,565,292

1,256,194

1,034,256

1,976,520

1,574,740

1,205,396

997,432

1,968,370

2,022,052

1,351,280

623,344

748,108

736,412

696,808

615,010

529,636

471,414

687,500

610,370

523,886

461,292

868,536

775,810

512,863

374,216

Flow rate of flue gases (kg/hr) i)

Primary Airheater inlet

ii)

Secondary Airheater inlet

iii)

Primary airheater outlet

iv)

Secondary airheater outlet

2,246,878

2,193,676

2,094,616

1,686,892

1,377,794

1,155,056

2,099,920

1,695,540

1,323,396

1,114,632

2,126,370

2,163,652

1,419,380

743,144

v)

ESP inlet

2,994,986

2,930,088

2,791,424

2,301,902

1,907,430

1,626,470

2,787,420

2,305,910

1,847,282

1,575,924

2,994,906

2,939,462

1,932,243

1,117,360

vi)

ESP outlet

2,994,986

2,930,088

2,791,424

2,301,902

1,907,430

1,626,470

2,787,420

2,305,910

1,847,282

1,575,924

2,994,906

2,939,462

1,932,243

1,117,360

vii)

ID fan inlet

2,994,986

2,930,088

2,791,424

2,301,902

1,907,430

1,626,470

2,787,420

2,305,910

1,847,282

1,575,924

2,994,906

2,939,462

1,932,243

1,117,360

viii)

Recirculation gas flow (Applicable for the cases where gas recirculation is being used to control RH steam temperature)

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

N/A

Excess Air (%) i)

At burner

20.0

20.0

20.0

20.0

27.2

24.6

20.0

20.0

21.6

20.0

20.0

20.0

20.0

24.4

ii)

At furnace exit

20.0

20.0

20.0

20.0

27.2

24.6

20.0

20.0

21.6

20.0

20.0

20.0

20.0

24.4

iii)

At economizer outlet

20.0

20.0

20.0

20.0

27.2

24.6

20.0

20.0

21.6

20.0

20.0

20.0

20.0

24.4

iv)

At the air heater exit (primary)

38.04

38.36

40.01

43.93

58.09

61.40

40.02

43.55

51.38

55.39

39.21

39.66

34.60

76.74

At the airheater exit (secondary)

27.65

27.72

28.12

30.00

40.33

40.17

28.00

29.85

34.37

35.03

30.33

29.01

26.47

50.02

vi)

At ESP inlet

30.10

30.25

30.91

33.47

44.88

45.76

30.78

33.23

38.82

40.46

32.80

31.67

28.54

58.08

vii)

At ID fan inlet

30.10

30.25

30.91

33.47

44.88

45.76

30.78

33.23

38.82

40.46

32.80

31.67

28.54

58.08

v)

5.10.00

Pure Sliding Pressure Operation

Leakages (Tonnes per hour)

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 102 OF 117

Modified Sliding Pressure Operation

i)

Primary air a) Regenerative air preheater b)

ii)

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

91.8

91.8

93.6

96.2

98.0

101.8

92.6

94.4

97.2

99.8

112.6

102.6

52.2

105.4

0

0

0

0

0

0

0

0

0

0

0

0

0

0

126.2

124.4

124.4

121.6

121.6

120.8

123.4

120.8

118.0

117.2

158.0

141.6

68.1

119.8

Secondary air a)

5.11.00

Ducts/Dampers

Pure Sliding Pressure Operation

Regenerative air heater

b)

Wind box

0

0

0

0

0

0

0

0

0

0

0

0

0

0

c)

Ducts/Dampers

0

0

0

0

0

0

0

0

0

0

0

0

0

0

Heat Balance (based on GCV of design coal fired) i)

Total coal fired (tonnes/hr)

412.4

403.0

382.1

309.5

237.7

201.5

383.0

311.2

239.3

203.3

404.5

400.2

269.1

128.2

ii)

Gross Calorific value of coal (Kcal/kg)

3750

3750

3750

3750

3750

3750

3750

3750

3750

3750

3750

3750

3750

3750

- Primary

72.3

74.7

71.2

71.6

70.6

64.4

71.2

71.6

70.9

65.4

61.9

70.3

74.1

73.0

- Secondary

246.6

244.7

247.2

226.8

217.6

193.3

249.8

230.8

211.4

193.5

165.7

218.9

219.5

181.0

b)

economizer (kcal)

332.3

330.4

326.2

306.3

317.0

305.2

325.0

315.2

310.8

297.7

471.4

401.2

295.0

294.4

c)

Superheater (kcal) Stage I

375.4

404.8

413.7

427.6

396.3

351.6

395.8

378.6

383.9

346.5

400.4

417.0

431.7

336.7

Stage II

249.0

263.4

277.8

301.9

295.3

312.1

269.7

276.8

290.4

308.8

262.4

269.5

311.4

287.7

Stage III

261.6

272.1

279.9

271.2

243.9

231.7

273.0

252.2

230.7

220.3

272.9

277.4

248.4

133.3

iii)

Heat absorbed per kg of coal in a)

Air preheaters (kcal)

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 103 OF 117

Modified Sliding Pressure Operation 100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Roof tubes

7.5

7.7

7.9

7.7

7.1

7.0

7.7

7.2

6.7

6.6

7.6

7.7

7.1

4.9

Convective pass

60.1

62.6

64.6

65.7

68.6

70.4

64.0

65.0

68.3

71.4

62.8

64.0

67.3

78.0

Enclosure

d)

e)

33.6

35.0

36.1

36.4

33.7

33.2

35.2

33.3

31.7

31.6

34.7

35.4

34.5

24.4

Hanger tubes

14.0

14.5

14.8

14.8

15.2

15.3

14.7

14.6

15.0

15.4

14.6

14.8

14.8

16.5

Stage I

404.6

410.0

412.9

399.7

364.4

336.2

401.4

361.9

323.5

297.9

396.9

404.6

133.8

272.8

Stage II

262.7

276.4

289.3

301.0

280.8

283.8

280.6

272.8

268.7

274.2

272.8

280.6

293.6

240.8

1240.0

1163.5

1124.6

1126.7

1241.4

1331.4

1179.0

1283.4

1308.5

1406.6

1113.2

1101.0

1195.9

1670.4

41.1

42.8

44.5

45.9

46.2

47.3

43.8

43.5

45.7

46.1

43.1

43.9

46.6

46.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

3600.6

3602.6

3610.8

3603.3

3598.1

3582.9

3610.7

3607.0

3566.1

3582.0

3580.4

3606.2

3373.9

3659.7

Reheater (kcal)

Water walls

Screen tubes Any other

5.12.00

(Included in steam cooled)

Steam cooled

Wall tubing

iv)

Pure Sliding Pressure Operation

Total heat absorbed effectively by the unit (per kg of coal (kcal) be)

Heat losses in the Steam Generator Heat losses in the Steam Generator shall be quoted for guarantee conditions also: i)

Heat loss due to flue gasses (%) -

Dry gas loss

4.68

4.68

4.43

4.10

4.14

4.16

4.52

4.19

3.97

4.02

3.85

3.78

3.90

3.77

-

Hydrogen in the fuel

4.05

4.05

4.03

4.00

3.98

3.98

4.03

4.01

3.98

3.98

3.99

3.98

4.00

3.98

-

Moisture in the fuel

1.85

1.85

1.84

1.83

1.82

1.82

1.84

1.83

1.82

1.82

1.82

1.82

1.82

1.82

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 104 OF 117

Modified Sliding Pressure Operation

ii)

iii)

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

-

Moisture in the air

0.11

0.11

0.11

0.10

0.10

0.10

0.11

0.10

0.09

0.10

0.09

0.09

0.09

0.09

-

Total heat loss due to flue gases

10.69

10.69

10.41

10.03

10.04

10.06

10.50

10.13

9.86

9.92

9.75

9.67

9.81

9.66

Heat loss due to unburnt carbon (%) in: -

Furnace bottom ash

0.58

0.58

0.58

0.58

0.58

0.58

0.58

0.58

0.58

0.58

0.58

0.58

0.58

0.58

-

Fly ash

0.92

0.92

0.92

0.92

0.92

0.92

0.92

0.92

0.92

0.92

0.92

0.92

0.92

0.92

-

Total heat loss due to unburnt carbon

1.50

1.50

1.50

1.50

1.50

1.50

1.50

1.50

1.50

1.50

1.50

1.50

1.50

1.50

Sensible heat loss (%) in: -

Furnace bottom ash

0.31

0.31

0.31

0.31

0.31

0.31

0.31

0.31

0.31

0.31

0.31

0.31

0.31

0.31

-

economizer hopper ash

0.02

0.02

0.02

0.02

0.02

0.02

0.02

0.02

0.02

0.02

0.02

0.02

0.02

0.02

Air heater hopper ash

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

Any other hopper ash

0.11

0.11

0.11

0.10

0.09

0.09

0.11

0.10

0.09

0.09

0.09

0.09

0.09

0.09

Total sensible heat loss

0.44

0.44

0.44

0.43

0.42

0.42

0.44

0.43

0.42

0.42

0.42

0.42

0.42

0.42

iv) Heat loss due to Mill Rejects (%)

0.07

0.07

0.07

0.07

0.07

0.07

0.07

0.07

0.07

0.07

0.07

0.07

0.07

0.07

v)

Heat loss due to radiation (%)

0.18

0.19

0.19

0.23

0.30

0.34

0.19

0.23

0.30

0.34

0.18

0.18

0.26

0.53

vi)

Unaccounted heat loss (%) (give details)

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

Total heat losses {sum of the (i) to (v)}

12.88

12.89

12.61

12.26

12.33

12.39

12.70

12.36

12.15

12.25

11.92

11.84

12.06

12.18

-

-

-

vii)

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 105 OF 117

Modified Sliding Pressure Operation 100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Heat credits (give details of equipment and breakup)

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

0.00

ix)

Manufacturer’s margin(%)

0.10

0.10

0.10

0.10

0.10

0.10

0.10

0.10

0.10

0.10

0.10

0.10

0.10

0.10

x)

Steam generator efficiency (%)

87.02

87.01

87.29

87.64

87.57

87.51

87.20

87.54

87.75

87.65

87.98

88.06

87.84

87.72

Furnace bottom hopper (kg/hr)

35462

34657

32863

26614

20443

17325

32936

26766

20580

17483

34790

34419

23139

11027

economizer hopper (kg/hr)

8866

8664

8216

6654

5111

4331

8234

6692

5145

4371

8697

8605

5785

2757

iii)

Air heater hopper (kg/hr)

5319

5198

4929

3992

3066

2599

4940

4015

3087

2622

5218

5163

3471

1654

iv)

Any other hoppers (kg/hr)

127665

124764

118306

95811

73596

62370

118568

96359

74089

62939

125243

123908

83299

39698

1580.5

1527.1

1448.1

1166.4

895.1

755.3

1451.9

1179.1

898.6

760.6

1509.8

1506.5

1010.8

N/A

Identify mills/elevations in services

D~J

E~J

E~J

F~J

G~J

H~J

E~J

F~J

G~J

H~J

E~J

E~J

G~J

N/A

Burner tilt (deg)

-25

-20

0

20

-18

-25

-25

-25

-25

-25

-25

-7

19

N/A

With Middle mills /elevations in operation

1563.1

1527.2

1448.1

1167.3

895.1

759.2

1451.9

1174.1

901.3

764.0

1509.8

1506.5

1015.6

N/A

Identify mills/elevations in services

C~I

C~H

C~H

D~H

D~G

E~G

C~H

D~H

D~G

E~G

C~H

C~H

D~G

N/A

Burner tilt (deg)

-17

10

25

25

25

-17

11

0

-9

-25

10

21

25

N/A

viii)

5.13.00

Pure Sliding Pressure Operation

Weight and Distribution of Ash collected i)

ii)

5.14.00

Furnace Design Data

5.14.01

Net Heat Input (x106kal/hr) a)

With top mills /elevations in operation i)

ii) b)

i)

ii)

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 106 OF 117

Modified Sliding Pressure Operation

c)

ii)

5.14.02

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

1563.1

1534.8

1462.0

1155.1

900.9

760.2

1461.4

1177.7

903.0

767.0

1514.6

1511.2

1024.7

476.6

B~H

B~G

B~G

B~F

C~F

C~E

B~G

B~F

C~F

C~E

B~G

B~G

C~F

C~D

16

25

25

25

25

25

25

25

25

0

25

25

25

0

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

159.6

116.2

92.2

62.7

64.6

57.1

119.4

97.3

71.5

60.9

108.1

100.8

39.4

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

158.1

109.8

74.0

63.1

44.8

67.6

98.8

98.5

77.7

78.3

94.2

87.5

51.9

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

113.6

101.6

76.6

84.0

59.1

52.8

97.8

84.9

63.9

86.6

85.8

101.2

66.2

55.8

206.6

188.5

153.9

105.5

102.8

91.1

187.2

155.8

114.2

97.4

173.4

165.4

66.4

N/A

With bottom mills /elevations in operation i)

Pure Sliding Pressure Operation

Identify mills/elevations in services Burner tilt (deg)

Cumulative Heat Absorption in Furnace i)

Passive Heat Absorption (Heat Absorption in furnace from bottom upto mean firing Zone level) a)

b)

c)

ii)

Upto exit of Burner Basket a)

b)

With top mills/elevations in operation and conditions as identified in Clause 3.14.01 With middle mills/elevations in operation and conditions as identified

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 107 OF 117

Modified Sliding Pressure Operation

c)

iii)

b)

c)

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

in Clause 3.14.01

223.9

172.1

121.1

101.4

80.1

106.9

156.7

148.6

124.1

118.5

151.6

141.7

80.8

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

189.2

140.0

142.3

134.2

93.4

88.3

145.7

136.6

100.9

124.9

123.5

152.1

108.7

81.0

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

367.4

351.3

313.5

281.9

218.2

203.2

340.6

300.8

236.7

217.8

329.4

322.2

202.0

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

396.0

348.5

291.0

256.7

206.0

211.5

331.1

302.5

241.3

219.9

328.9

316.8

213.2

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

390.4

335.9

324.4

296.9

220.3

201.8

331.8

301.7

236.9

231.3

325.1

337.6

229.7

166.3

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

415.1

400.3

363.1

341.8

254.2

236.6

386.2

343.6

273.1

252.8

374.4

370.0

248.0

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

446.0

402.2

344.3

305.8

246.5

241.0

383.9

348.3

275.5

247.2

382.0

370.4

255.5

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

449.7

397.8

380.4

344.9

258.4

234.6

388.4

350.4

277.0

259.8

387.9

393.2

265.0

186.5

Upto Furnace Arch Exit a)

b)

c)

v)

100% BMCR

Upto Furnace Arch level a)

iv)

Pure Sliding Pressure Operation

Upto platen superheater Exit

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 108 OF 117

Modified Sliding Pressure Operation

a)

b)

c)

vi)

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

766

744

700

629

463

405

710

603

476

419

713

720

479

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

774

744

681

579

462

402

711

605

474

404

724

721

474

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

775

726

691

593

458

400

699

602

476

412

716

718

468

288

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

1032

1001

953

835

610

527

956

797

617

537

969

980

635

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

1025

1000

932

780

610

523

957

795

613

520

981

981

627

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

1025

979

935

778

601

520

939

790

614

526

969

969

617

347

1230

1189

1133

977

711

607

1131

929

708

609

1152

1165

739

N/A

Upto final super heater Exit a)

b)

c)

vii)

Pure Sliding Pressure Operation

Upto primary reheater exit a)

b)

With top mills/elevations in operation and conditions as identified in Clause 3.14.01 With middle mills/elevations in operation and

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 109 OF 117

Modified Sliding Pressure Operation

c)

viii)

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

conditions as identified in Clause 3.14.01

1214

1187

1111

922

711

605

1132

925

705

659

1164

1165

733

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

1213

1169

1120

915

705

602

1117

922

707

669

1154

1156

727

390

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

1367

1321

1256

1022

786

669

1259

1031

792

675

1352

1326

889

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

1352

1321

1256

1019

786

669

1259

1026

792

675

1352

1326

889

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

1352

1321

1256

1009

786

669

1259

1026

792

675

1352

1324

889

428

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

1501

1451

1380

1164

855

720

1378

1121

849

721

1435

1439

881

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

1482

1448

1357

1114

855

725

1379

1117

852

715

1447

1442

884

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

1481

1442

1388

1103

859

723

1378

1121

856

726

1446

1445

891

453

Upto economizer exit a)

b)

c)

ix)

Pure Sliding Pressure Operation

Upto air preheater exit a)

b)

c)

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 110 OF 117

Modified Sliding Pressure Operation

x)

b)

c)

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

49

49

49

52

52

53

50

52

54

55

48

48

52

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

51

50

48

50

52

53

50

52

54

54

48

48

51

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

51

49

48

52

51

53

49

52

54

54

48

48

51

62

With top mills/elevations in operation and conditions as identified in Clause 3.14.01

89.0

86.4

81.0

62.9

67.2

68.4

81.4

63.7

93.1

76.6

73.6

78.4

92.1

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

89.0

86.4

81.0

62.9

84.6

54.0

81.4

63.7

80.1

56.0

73.6

78.4

69.4

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

89.0

86.4

81.0

62.9

46.3

59.8

81.4

63.7

81.3

48.1

73.6

78.4

36.0

24.4

Superheater Spray Quantity in T/hr a)

b)

c)

5.14.04

100% BMCR

Furnace heat absorption as percentage of total heat absorption (upto Arch exit) a)

5.14.03

Pure Sliding Pressure Operation

Reheater Spray Quantity in T/hr a)

With top mills/elevations in operation and conditions as identified

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 111 OF 117

Modified Sliding Pressure Operation

b)

c)

5.15.00

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

in Clause 3.14.01

26.1

0.0

0.0

0.0

0.0

0.0

0.0

8.1

0.0

0.9

0.0

0.0

0.0

N/A

With middle mills/elevations in operation and conditions as identified in Clause 3.14.01

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

N/A

With bottom mills/elevations in operation and conditions as identified in Clause 3.14.01

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

0.0

Furnace Performance Data Description (As per Clause 5.00.00 Section-VIA, PartBSub-section-MI) i)

Total heat duty (106 Kcal/hr)

1352.0

1321.2

1255.8

1021.5

786.2

669.2

1258.4

1026.2

791.8

674.8

1352.2

1326.4

811.4

427.9

ii)

Efficiency (%)

87.44

87.43

87.64

88.02

88.19

88.58

87.62

87.93

88.23

88.51

89.14

88.38

80.42

88.99

iii)

Total heat generated 6 (10 Kcal/hr)

1546.3

1511.2

1433.0

1160.5

891.4

755.5

1436.1

1167.1

897.4

762.3

1517.0

1500.8

1009.0

480.8

Net heat input (106 Kcal/hr) (Unburnt)

1563.1

1527.1

1448.1

1166.4

895.1

755.3

1451.9

1174.1

898.6

760.6

1509.8

1506.5

1010.8

476.6

v)

Furnace Plan area (m2)

341.4

341.4

341.4

341.4

341.4

341.4

341.4

341.4

341.4

341.4

341.4

341.4

341.4

341.4

vi)

Furnace EPRS (m2)

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

9043.9

vii)

Furnace Volume (m3)

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

21461.8

viii)

Net heat input/plan area (106 Kcal/m2/hr)

4.58

4.47

4.24

3.42

2.62

2.21

4.25

3.44

2.63

2.23

4.42

4.41

2.96

1.40

Net heat input /EPRS (106 Kcal/m2/hr)

0.173

0.169

0.160

0.129

0.099

0.084

0.161

0.130

0.099

0.084

0.167

0.167

0.112

0.053

Volumetric Heat Release rate (106 Kcal/m2/hr)

0.072

0.070

0.067

0.054

0.042

0.035

0.067

0.054

0.042

0.036

0.071

0.070

0.047

0.022

iv)

ix)

x)

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 112 OF 117

Modified Sliding Pressure Operation

xi) 5.16.00

5.17.00

5.18.00

Furnace exit gas temp (DegC)

Pure Sliding Pressure Operation

100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

999

1014

1022

991

912

891

1006

956

903

884

1010

1018

954

764

Mass velocity in evaporator tubes (Kg/m2 sec) i)

Maximum

3150

3058

2751

2137

1575

1310

2766

2165

1605

1335

2501

2664

1314

669

ii)

Minimum

2495

2422

2179

1693

1247

1038

2191

1715

1272

1058

1981

2110

1659

844

Tube Mass Velocity (Kg/m2sec) (Vertical Wall) i)

Front water walls

1183

1147

1032

801

590

491

1038

812

602

501

938

999

623

317

ii)

Rear water walls

1085

1052

948

738

544

453

953

748

555

462

863

920

618

314

iii)

Side Walls

1173

1140

1024

795

586

487

1030

806

598

497

931

991

572

291

Auxiliary Steam Consumption i)

Steam conditions a)

b)

Pressure range (kg/cm2) (abs) Temperature range (degC)

16

210 ~ 310

ii)

Fuel oil heating (kg/hr) Max

N/A

iii)

Fuel oil line tracing (kg/hr) Max

N/A

iv)

Steam coil air pre-heater (kg/hr)Max a)

Primary

7512

b)

Secondary

21570

v) Total auxiliary steam consumSIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 113 OF 117

Modified Sliding Pressure Operation 100% BMCR

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Pure Sliding Pressure Operation 100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

ed from startup to full load a)

b)

c)

d)

e)

After eight hours shutdown (kg/hr)

Later

After four hours shutdown (kg/hr)

Later

Hot restart after trip out (Less than 1 hr shut down) (kg/hr)

Later

After thirty six hours shutdown (Kg/hour)

Later

Cold start, After seventy two hours(kg/hr

Later

5.19.00

Start ups

5.19.01

Recommended Startup time periods to bring steam Generator to full load from ignition (with HP-LP bypass system) i)

ii)

iii)

iv)

v)

vi)

Cold start, (hours), after (72) hours

9.34

After thirty six (36) hours shut down (hours)

4.6

After twenty four (24) hours shut down (hours)

4.3

After twelve (12) hours shutdown (hours) After eight (8) hours shutdown (hours)

4

3.5

After four (4) hours

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 114 OF 117

Modified Sliding Pressure Operation 100% BMCR

vii)

5.19.02

5.20.00

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Pure Sliding Pressure Operation 100% TMCR

80% TMCR

shutdown (hours)

3.3

Hot restart after trip out with less than one hour shut down

2.5

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Number of start ups/life (Nos) of following type for which the unit has been designed a)

Cold startup (after 72 hours)

455

b)

Warm startup (after 36 hours)

910

c)

Hot startups (after 8 hours)

4550

d)

Daily load cycling between 40% to 100%

No limit provided recommended heat-up rates are adhered to.

Quantity of expected steam to be vented out in raising full pressure when starting without HP-LP bypass (Kg) i)

ii)

iii)

iv)

v)

vi)

vii)

From cold start up after (72) hours

Later

After thirty six (36) hours shut down

Later

After twenty four (24) hours shut down

Later

After twelve (12) hours shutdown

Later

After eight (8) hours shutdown

Later

After four (4) hours shutdown

Later

Hot restart after trip out

Later

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 115 OF 117

Modified Sliding Pressure Operation 100% BMCR

5.21.00

b)

c)

5.23.00

100% TMCR

80% TMCR

60% TMCR

50% TMCR

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

SH drains during starting a)

5.22.00

VWO

Pure Sliding Pressure Operation

Flow rate of drain water from primary superheater header (kg/hr)

N/A

Flow rate of drain water from SH final header (kg/hr)

N/A

Flow rate of drain water from SH final header (kg/hr)

N/A

Wind box performance i)

Free air area (m2)

3.49

3.49

2.99

2.49

1.99

1.49

2.99

2.49

1.99

1.49

2.99

2.99

1.99

1.00

ii)

Secondary air flow into the 3 wind box (m /sec)

764

741

716

553

438

361

719

559

416

345

686

720

471

203

0.594

0.593

0.600

0.617

0.635

0.647

0.597

0.612

0.629

0.638

0.676

0.635

0.639

0.681

iii)

Secondary air density (kg/m3)

iv)

Secondary air temperature in the wind box (degC)

294

294

288

273

257

247

291

277

262

254

225

257

254

221

v)

Secondary air velocity (m/sec)

54.8

53.1

59.9

55.5

54.9

60.3

60.2

56.1

52.2

57.8

57.4

60.2

59.2

51.0

vi)

Differential pressure with respect to the furnace (mmwc)

102

Combustion Data i)

ii)

iii)

Stoichiometric dry air required kg/kg fuel

5.148

Stoichiometric wet air required kg/kg fuel

5.22

Volume of flue gas at Eco outlet per Kg of Coal (NM3)

4.916

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

PAGE 116 OF 117

Modified Sliding Pressure Operation 100% BMCR

iv)

v)

vi)

VWO

100% TMCR

80% TMCR

60% TMCR

50% TMCR

Pure Sliding Pressure Operation 100% TMCR

80% TMCR

60% TMCR

50% TMCR

Both HP Heaters out of operation

One String HP Heaters out of operation

60% BMCR (One Stream)

30% BMCR

Emissivity at mean firing zone (Correct upto fifth place of decimal) a) Flame Emissivity (Luminous emissivity) b) Gas Emissivity (Non-luminous emissivity) c) Total Emissivity (Luminous+Non-luminous emissivity) Specific heat of flue gases at mean firing zone (correct upto fifth place of decimal) Weight of flue gas produced by burning 1 kg of fuel (kg) at Eco outlet

SIPAT SUPER THERMAL POWER PROJECT STAGE-I (3x 660MW) MAIN PLANT PACKAGE PART-A(STEAM GENERATOR AUXILIARIES)

0.1539 0.3332 0.4871

0.33920 kcal/kg-k

6.734

PAGE 117 OF 117

VI. PREDICTED PERFORMANCE CURVES

LIST OF PERFORMANCE CURVES

TITLE

CURVE NO.

Load Vs Water/Steam Temperature

T04019-CV-01

Load Vs Reheat Steam Temperature

T04019-CV-02

Load Vs Burner Tilt

T04019-CV-03

Load Vs Excess Air

T04019-CV-04

Load Vs Spray Water Flow

T04019-CV-05

Moisture in Coal Vs Pulveriser Capacity

T04019-CV-09

Moisture in Coal Vs Inlet Air Temperature

T04019-CV-10

Pulveriser Capacity Vs Hardgroove Grindability

T04019-CV-11

Pulveriser Power Consumption Vs Pulveriser Coal Capacity

T04019-CV-12

Pulveriser Power Consumption Vs Pulverised Coal Fineness

T04019-CV-13

V. Predicted Performance Curves.doc

VI. PREDICTED PERFORMANCE CURVES

Load Vs Water/Steam Temperature 600

550 Final SH Outlet

Platen SH Outlet 500

Water/Steam Temperature,℃

Final SH Inlet

450 Primary SH Outlet

Platen SH Inlet 400

350 Primary SH Inlet

300

Economizer Outlet 250 Economizer Inlet

200 0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

110%

Load T04019-CV-01

V. Predicted Performance Curves.doc

VI. PREDICTED PERFORMANCE CURVES

Load Vs RH Steam Temperature 650

600

Final RH Outlet

RH Steam Temperature,℃

550

500

Primary RH Outlet & Final RH Inlet 450

400

350

Pimary RH Inlet 300

250 0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

110%

Load T04019-CV-02

V. Predicted Performance Curves.doc

VI. PREDICTED PERFORMANCE CURVES

Load Vs BurnerTilt

30

Burner Tilt in deg

20 10 0 -10 -20 -30 0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100% 110% 120%

Load

T04019-CV-03

V. Predicted Performance Curves.doc

VI. PREDICTED PERFORMANCE CURVES

Load Vs Excess Air

Excess Air at Economiser Outlet

30%

25%

20%

15% 0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100% 110% 120%

Load

T04019-CV-04

V. Predicted Performance Curves.doc

VI. PREDICTED PERFORMANCE CURVES

Load Vs Spray Water Flow 7%

6%

Spray Water Flow

5%

4% SH Total Spray

3%

2%

1%

RH Spray = 0 0% 0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

110%

Load T04019-CV-05

V. Predicted Performance Curves.doc

VI. PREDICTED PERFORMANCE CURVES Pulverizer Capacity vs. Moisture in Coal Design Coal : HGI = 50. Total Moisture in Coal = 12 wt% Worst Coal : HGI = 47, Total Moisture in Coal = 15 wt% Best Coal : HGI = 52. Total Moisture in Coal = 11 wt% (Fineness 70% through 200 mesh)

90,000

Pulverizer Capacity (kg/hr)

87,500

85,000 Best Coal

82,500

Design Coal

80,000 Worst Coal

77,500

75,000

72,500

70,000

67,500

65,000 8

9

10

11

12

13

14

15

16

17

18

19

20

Moisture Content of Coal (%) T04019-CV-09

V. Predicted Performance Curves.doc

VI. PREDICTED PERFORMANCE CURVES Inlet Air Temperature vs. Moisture in Coal

Worst Coal basis (HGI = 47, Fineness 70% through 200mesh)

400

350

Max. Capacity

Inlet Air Temperature (℃)

300

250 Min. Capacity

200

150

100

50

0 6

8

10

12

14

16

18

20

22

24

26

Moisture Content of Raw Coal (%)

T04019-CV-10

V. Predicted Performance Curves.doc

VI. PREDICTED PERFORMANCE CURVES Pulverizer Capacity vs. Hardgrove Grindability (for Raw Coal) Worst Coal basis ( Total Moisture = 15 wt% ) (Fineness 70% through 200mesh)

95,000

90,000

Pulverizer Capacity (kg/hr)

85,000

80,000

75,000

70,000

65,000 40

45

50

55

60

Hardgrove Grindability

T04019-CV-11

V. Predicted Performance Curves.doc

VI. PREDICTED PERFORMANCE CURVES Pulverizer Power Consumption vs. Pulverized Coal Capacity (for Raw Coal)

Worst Coal basis ( HGI = 47, Total Moisture = 15 wt% ) (Fineness 70% through 200mesh)

Power Consumption (kW/ton)

20

15

10

5 25

50

75

100

Pulverized Coal Capacity (%)

T04019-CV-12

V. Predicted Performance Curves.doc

VI. PREDICTED PERFORMANCE CURVES Pulverizer Power Consumption vs. Pulverized Coal Fineness Worst Coal basis ( HGI = 47, Total Moisture = 15 wt%)

20

15

Power Consumption (kW/ton)

Min. Capacity

10 Max. Capacity

5

0 63

64

65

66

67

68

69

70

71

72

73

74

75

76

77

Pulverized Coal Fineness (% Thru 200 Mesh)

T04019-CV-13

V. Predicted Performance Curves.doc

VI. START-UP CURVES

LIST OF CURVES

CURVE NO.

TITLE

Cold start-up………………………………………………………………………………... T04019-CV-06 Warm start-up……………………………………………………………….. ……………. T04019-CV-07 Hot start-up……………………………………………………. …………………………… T04019-CV-08

i

VI. Start-up curves-cover.doc

VI. PREDICTED STARTUP CURVES PREDICTED PERFORMANCE CURVE (COLD START-UP) S I P A T P H A S E 1 ( 3 X 6 6 0 M W ) C o ld S t a r t -U p C u r v e ( > 7 2 h r ) ( M o d if ie d S li d in g O p e r a t io n )

S H O u t l e t T e m p .( T o ) R H O u tle t T e m p .(T rh )

S H O u t le t P r e s s .( P o )

R H O u t l e t P r e s s .( P r h )

S H D r a in & V e n t C lo s e R H D r a in C lo s e

RH Vent C lo s e

rp m (n )

F ir in g R a t e

S t e a m F lo w

M in . W a t e r W a ll F lo w

S t e a m F lo w to T B N (G o )

E le c t r ic a l L o a d o f T G ( N e )

O il F ir in g R a t e

S w e ll in g F lo w

F e e d w a t e r F lo w

1 0 M in . P u rg e

L ig h t O ff

S te a m A d m is s io n

F u ll L o a d

Synch. B ypass C lo s e

T04019-CV-06 VI. Startup Curves.doc

VI. PREDICTED STARTUP CURVES PREDICTED PERFORMANCE CURVE (WARM START-UP)

S I P A T P H A S E 1 ( 3 X 6 6 0 M W ) W a r m S t a r t -U p C u r v e ( < 3 6 h r ) ( M o d i f ie d S lid in g O p e r a t io n )

S H O u tle t T e m p .(T o ) R H O u t le t T e m p .(T r h )

S H O u tle t P re s s .(P o )

R H O u t l e t P r e s s .( P r h )

S H D r a in & V e n t C lo s e R H D r a in C lo s e

F ir in g R a t e RH Vent C lo s e

r p m (n )

S te a m F lo w to T B N (G o )

S w e ll i n g F l o w M in . W a t e r W a l l F lo w

E le c t r ic a l L o a d o f T G (N e )

O il F ir in g R a t e

F e e d w a t e r F lo w

S t e a m F lo w

1 0 M in . P u rg e

L ig h t O ff

S te a m A d m is s io n

Synch. B ypass C lo s e

F u ll L o a d

T04019-CV-07 VI. Startup Curves.doc

VI. PREDICTED STARTUP CURVES PREDICTED PERFORMANCE CURVE (HOT START-UP)

S I P A T P H A S E 1 ( 3 X 6 6 0 M W ) H o t S t a r t -U p C u r v e ( < 8 h r ) ( M o d if ie d S lid in g O p e r a t io n )

S H O u t le t T e m p .( T o ) R H O u t le t T e m p .( T r h )

S H O u t le t P r e s s .( P o )

R H O u t le t P r e s s .( P r h )

S H D r a in & V e n t C lo s e R H D r a in C lo s e

RH Vent C lo s e F ir in g R a t e rp m (n ) E le c t r ic a l L o a d o f T G ( N e ) = S t e a m F lo w t o T B N ( G o )

S w e llin g F lo w M in . W a t e r W a ll F lo w O il F ir in g R a t e S t e a m F lo w F e e d w a t e r F lo w

1 0 M in . P u rg e

L ig h t O ff

S te a m A d m is s io n

S ynch.

F u ll L o a d

Bypass C lo s e

T04019-CV-08 VI. Startup Curves.doc

VII. GENERAL ARRANGEMENT OF BOILER-DRAWINGS

TABLE OF CONTENTS

DRAWING NO.

TITLE GA of Boiler

Key Plan & General Notes……………………. ............ T04019-GA-A0001

GA of Boiler

Sect. Boiler Side Elev. View “01-01”………… ............ T04019-GA-A0002

GA of Boiler

Mill Side Elev. View “02-02/02a-02a”………............... T04019-GA-A0003

GA of Boiler

Boiler Front Elev. View “03-03”………………. ............ T04019-GA-A0004

GA of Boiler

El. 00 Plan View “04-04”……………………… ............. T04019-GA-A0005

GA of Boiler

El. 22600 Plan Sect. View “05-05”………….. ............ T04019-GA-A0006

GA of Boiler

El. 38000 Plan Sect. View “06-06”………….. ............ T04019-GA-A0007

GA of Boiler

El. 58800 Plan Sect. View “07-07”………….. ............ T04019-GA-A0008

GA of Boiler

El. 92132 Plan Sect. View “08-08”………….. ............ T04019-GA-A0009

GA of Boiler

Boiler Rear Elev. View “09-09”……………….. ............ T04019-GA-A0010

GA of Boiler

Gas A/H Center Elev. View “10-10”………….............. T04019-GA-A0011

GA of Boiler

Gas A/H Rear Elev. View “11-11”…………................. T04019-GA-A0012

i VII. General Arrangement of boiler-Drawings.doc

VIII. PROCESS AND INSTRUMENTATION DRAWINGS

TABLE OF CONTENTS

DRAWING NO.

TITLE

BOILER & DUCT INSTRUMENT INSERT LOCATION CONNECTION LIST ....................................................................................... T04019-GA-A0018 CONNECTION DETAIL .................................................................................. T04019-GA-A0019 P&I P&I P&I P&I P&I P&I P&I P&I P&I P&I P&I P&I P&I P&I P&I P&I P&I P&I P&I P&I P&I P&I P&I P&I P&I P&I P&I P&I P&I P&I P&I P&I

Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram Diagram

– SYMBOLS AND LEGENDS ..................................................... T04019-PI-D0001 – SYMBOLS AND LEGENDS .................................................... T04019-PI-D0002 – SYMBOLS AND LEGENDS .................................................... T04019-PI-D0003 – SYMBOLS AND LEGENDS .................................................... T04019-PI-D0004 – ECONOMIZER SYSTEM ........................................................ T04019-PI-D0005 – EVAPORATOR SYSTEM........................................................ T04019-PI-D0006 – WATER SEPARATOR SYSTEM ............................................. T04019-PI-D0007 – SUPERHEATER SYSTEM(1/3)............................................... T04019-PI-D0008 – SUPERHEATER SYSTEM(2/3)............................................... T04019-PI-D0009 – SUPERHEATER SYSTEM(3/3)............................................... T04019-PI-D0010 – REHEATER SYSTEM ............................................................. T04019-PI-D0011 – CIRCULATION & START-UP SYSTEM................................... T04019-PI-D0012 – BOILER DRAIN & VENT SYSTEM.......................................... T04019-PI-D0013 – COMB. AIR&FLUE GAS SYSTEM(1/3) ................................... T04019-PI-D0014 – COMB. AIR&FLUE GAS SYSTEM(2/3) ................................... T04019-PI-D0015 – COMB. AIR&FLUE GAS SYSTEM(3/3) ................................... T04019-PI-D0016 – FUEL SYSTEN(1/3) ................................................................ T04019-PI-D0017 – FUEL SYSTEN(2/3) ................................................................ T04019-PI-D0018 – FUEL SYSTEN(3/3) ................................................................ T04019-PI-D0019 – OIL BURNER DETAIL............................................................. T04019-PI-D0020 – PRIMARY AIR, SEALING&COOLING AIR SYSTEM ............... T04019-PI-D0021 – COAL FEEDER & PULVERIZER SYSTEM ............................. T04019-PI-D0022 – SCANNER COOLING & DAMPER SEAL SYSTEM ................. T04019-PI-D0023 – STEAM COIL AIR HEATER SYSTEM ..................................... T04019-PI-D0024 – BOILER WATER CIRCULATION PUMP SYSTEM .................. T04019-PI-D0025 – SOOT BLOWING SYSTEM..................................................... T04019-PI-D0026 – CLOSED COOLING WATER SYSTEM ................................... T04019-PI-D0027 – SERVICE AIR SYSTEM.......................................................... T04019-PI-D0028 – BOILER START-UP FLASH TANK SYSTEM .......................... T04019-PI-D0029 – SAMPLING SYSTEM .............................................................. T04019-PI-D0030 – INSTRUMENT AIR SYSTEM (1/4 – 4/4) ................................. T04019-PI-D0031 – SERVICE WATER SYSTEM ................................................... T04019-PI-D0032

P&I P&I P&I P&I P&I P&I

Diagram Diagram Diagram Diagram Diagram Diagram

– MAIN & REHEAT STEAM SYSTEM(1/2 – 2/2) ........................ – FUEL OIL SYSTEM(1/5 - 5/5) ……………………………………. – EQUIPMENT COOLING WATER SYSTEM(1/2 – 2/2)............. – LP DOSING & OXYGENATED TREATMENT SYS.(1/2 – 2/2). – AUXILIARY STEAM SYSTEM................................................. – NITROGEN GAS SUPPLY SYSTEM ......................................

T04019-PI-D0501 T04019-PI-D0502 T04019-PI-D0503 T04019-PI-D0504 T04019-PI-D0505 T04019-PI-D0506

i VIII. Process and Instrumentation Drawings.doc

IX. IMPORTANT DO’S AND DON’TS

IMPORTANT DO’S & DON’TS

I. PREPARATION FOR LIGHTING UP-DO’S 1. 2. 3. 4. 5. 6. 7.

Check and remove any foreign material from Boiler. Ensure that the feed water quality is as per recommendation. Ensure furnace bottom hopper water sealing. Keep all vents and drains as per recommended unit operating procedure. Check and keep ready oil Pumping, Heating and Firing equipment. Ensure correct functioning of all Auxiliaries, Dampers and Valves. Check and ensure correct functioning of Temperature Probes and Metal Temperature Monitoring Thermocouples. 8. Fill up water up to separator NWL. 9. Check that “NO BOILER TRIP” condition exists. 10. Ensure 30% BMCR air flow through Boiler to maintain an air rich furnace. 11. Ensure Boiler Circulating Pump ready for service. 12. Ensure minimum 30%TMCR water flow through evaporator. 13. Check and control firing rate as per recommendation. 14. Ensure that enough oil & air pressure is obtained. 15. Keep burner tilt at horizontal position. 16. Ensure that tilt/damper positions are identical in all the four corners. 17. Maintain firing rate such that the furnace exit gas temperature is below 538 ˚C till such time flow through Reheater is established. 18. Keep Steam Coil Air Preheaters in service during oil firing. 19. Keep Gas Air Preheaters’ soot blowers in service. II. NORMAL LOAD INCREASE 1. Increase boiler load as per recommended rates. 2. Introduce coal firing after ensuring sufficient ignition energy is available. 3. Check and record SH/RH metal temperatures. III. NORMAL REDUCTION OF LOAD 1. Reduce boiler load as per recommended rates. 2. Remove mills from service, empty mills before stopping as per recommended procedures.

1

IX. IMPORTANT DOs and DON'Ts.doc

IX. IMPORTANT DO’S AND DON’TS

IV. NORMAL SHUTDOWN TO COLD 1. 2. 3. 4.

Reduce boiler load as gradually as possible. Ensure furnace purge after tripping of fuel. Check and maintain separator water level periodically. Run the GAPH, FD & ID Fans till the gas temperature drops to below 205 ˚C.

V. BOILER OPERATION-DON’TS 1. Never fill the boiler with water such that differential temperature between the feed water and the boiler metal temperature exceeds 111˚C. 2. Do not exceed firing rate and load increase/decrease rates beyond the recommended values. 3. Never light up and continue firing without GAPHs in service. 4. Never introduce a mill in service without ensuring sufficient ignition energy. 5. Do not keep furnace temperature probes inside the furnace if the flue gas temperature exceeds 538˚C. 6. Never jump or bypass any safety/protection interlocks. 7. Do not keep the boiler in service after identifying a tube leak, if any. VI. SAFETY 1. Above all, safety of personnel is of utmost importance. Never ignore any safety instruction/procedure/measures at any point of time during boiler operation and maintenance.

2

IX. IMPORTANT DOs and DON'Ts.doc