AMARDEEP .M.

JADEJA

B.E. MECHANICAL (THIRD YEAR)

INDUS INSTITUTE OF ENGINEERING

& TECCHNOLOGY,AHMEDABAD.

CONTENTS
1) INTRODUCTION OF BOILER 2) AIR PREHEATER 3) ASH HANDLING PLANT 4) FUEL OIL SYSTEM 5) COAL MILL 6) ID, FD & PA FAN 7) COOLING TOWER 8) FIRE FIGHTING SYSTEM 9) COAL HANDLING PLANT 10) TURBINE 11) SEA WATER SYSTEM 12) DM PLANT 13) TDBFP & MDBFP SYSTEM

CLASSIFICATION OF POWER PLANTS:

Thermal Power Plant Diesel Power Plant Nuclear Power Plant Hydro Power Plant Gas turbine Power Plant Geothermal Power Plant
Installed capacity 2% 3%

10%

26%

59%

Coal

Hydro

Gas

Nuclear

Others

THERMAL POWER PLANT:

A thermal power station is a power plant in which the prime mover is steam driven. Water is heated, turns into steam and spins a steam turbine which either drives an electrical generator or does some other work, like ship propulsion. After it passes through the turbine, the steam is condensed in a condenser and recycled to where it was heated; this is known as a Rankine cycle Thermal power stations produce electricity by burning fuel in a boiler to heat water to produce steam. The steam, at tremendous pressure, flows into a turbine, which spins a generator to produce electricity. The steam is cooled, condensed back into water, and returned to the boiler to start the process over. Power generated by this power plant covers nearly 60% of all power. They work with the help of coal, oil, natural gases, waste heat etc.

INTRODUCTION OF BOILER

INTRODUCTION OF BOILER What is Boiler?

A boiler is defined as "a closed vessel in which water or other liquid is heated, steam or vapor is generated, steam is superheated, or any combination thereof, under pressure or vacuum, for use external to itself, by the direct application of energy from the combustion of fuels, from electricity or nuclear energy."

Boiler

Boiler According to Indian Boiler Regulations.

IBR Steam Boilers means any closed vessel exceeding 22.75 liters in capacity and which is used expressively for generating steam under pressure and includes any mounting or other fitting attached to such vessel, which is wholly, or partly under pressure when the steam is shut off.

Introduction to Adani Power 660 MW Boiler

Description Type Unit Value Supercritical, Once Through Type, Sliding Pressure, Single Furnace, New Tangential Type, Single Reheat, Balanced Draft, Dryed Slag Discharge, Complete Steel Structure, Complete Hanging Construction, Double Gas Passes. HARBIN BOILER COMPANY, CHINA

Manufacturer

Design Code For Pressure Parts

ASME, GB9222-88, IBR

Overall View Of Adani Boiler

2. Spirally wounded evaporators for safe and reliable evaporator

1.

Large Single Funace

4. High Strength material application 5. Economic and safe low load and startup system by circulating pump

3. Proven and economic heating surface arrangement 6. Burner tilting for reheater steam temperature control 7. Low Nox Tangential Burner

8. Long life and high Performance mills

CRITICAL CONDITION Definition CRITICAL is a thermodynamic expression describing the state of a substance beyond which there is no clear distinction between the liquid and gaseous phase. The critical pressure & temperature for water are Pressure = 225.56 Kg / cm2 Temperature = 374.15 C

TEMP

600 500 400 300 200 100

540C

568C

SUPER CRITICAL BOILER CYCLE WITH SH, RH & Regeneration of ADANI 5 x 660 MW
Steam flow Steam temp Steam Pres RH pre RH Temp Feed water Temp :2225 T/Hr : 540 c : 256 kg/cm2 : 51.6 Kg/cm2 : 568c : 291c

0
ENTROPY

WHY SUPERCRITICAL PRESSURE

The purpose of having high inlet steam pressure for turbine can be inferred from Previous deliberations. A Boiler operating at a pressure above critical point is called SUPERCRITICAL BOILER A point where boiling water and dry saturated lines meet so that associated latent heat is zero, this point is called Critical Point and occurs at 225 kg/cm2 (abs) 374.15 C temperature.

SH

DRUM BFP HTR ECO

DOWN COMER

RISERS

Natural Circulation Boiler

SH
SEPERATOR

W/WALL

W/WALL

BFP

HTR

ECO

ONCE THROUGH SYSTEM

FLOW DIAGRAM OF SIPAT SUPER-CRITICAL BOILER

ECONOMIZE R FURNACE WALL FUR. ROOF WALL SEPARAT OR. BP & EXT,d WALL S/H S/H S/H

STORAGE TK

- Horizontal - SIDE (SPIRAL & VERT.) - Pendant - FRONT & REAR (SPIRAL & VERT.)

- FUR. ROOF

- B/P. ROOF - B/P. FRONT & REAR DIVISION - B/P SDIDE (R.L) - EXT. FLOOR & SIDE(R.L)

- PLATEN

- FINAL

LT R/H

HT R/H (Coil)
B Y O T H ER

BLR WTR fill in from F/W HTR No.8

- PLATEN

- FINAL
B Y O T H ER D S B Y O T H ER D S

HP TB
DS

IP TB
B Y O T H ER

LP TB

GENERATO R

BWR P

B Y O T H ER

CONDENSO R

CW in CW

Evaporator Wall Construction (1/3)

Upper Part Vertical Wall

Lower Part Spiral Wall

Supercritical Boiler Technology

Spiral Wall Evaporator

Configuration of Evaporator panel Spiral wall : Vertical wall = 3 : 1

Spiral wall outlet temp at BMCR (front wall)

WALL OF BOILER

spiral wall

spiral wall and windbox

660 MW PLANT BOILER

LTSH COILS

ECONOMISER COILS

ECONOMISER O/L HEADER

ECONOMISER I/L HEADER

AIR PREHEATER

The Air Preheater absorbs waste heat from flue gas, and then transfers this heat to incoming cold air by means of continuously rotating heat transfer elements of specially formed metal plates.

Air Preheater is in general divided into two types: 1.Regenerative

2. Recuperative

 1) Regenerative APH are also known as storage type heat exchangers, have an energy storage medium, called the matrix, which is alternately exposed to the hot and cold fluids. When the hot flue gases flow through the matrix in the first half of the cycle, the matrix is heated and the gas is cooled. In the next half of the cycle when air flows through the matrix, air gets heated and the matrix is cooled. The cycle repeats itself.

 2) Recuperative APH, heat is directly transferred from the hot gases to the air across the heat exchanging surface. They are commonly tubular, although some plate types are still in use. Tubular units are essentially counter-flow shell-and-tube heat exchangers in which the hot gases flow inside the vertical straight tubes and air flows outside. Baffles are provided to maximize air contact with the hot tubes.

Regenerative Type Air Pre Heater

Nos. 2 Speed of Rotation 0.9rpm Cooling water Consumption 18t/h Air temperature at Regenerative APH outlet -

General Arrangement of Airpreheater

TG House

PA

SA

SA
PA

FG

FG

Chimney

Air Preheater, main technical specifications and list of master drawings

List of master drawing

1 General arrangement of Air Preheater. 2. Rotor assembly 3. Rotor radial seal assembly 4. Rotor module assembly. 5. Rotor post and trunnion assembly. 6. Hot end and hot intermediate layer elements and element baskets. 7. Cold end element and element basket. 8. Rotor housing assembly. 9. Hot end primary center section assembly. 10. Cold end primary center section assembly. 11. Hot end connecting plate assembly. 12. Cold end connecting plate assembly. 13. Guide bearing assembly. 14. Support bearing assembly. 15. Static seal assembly (hot end and cold end). 16. Axial and by-pass seal assembly. 17. Rotor drive assembly. 18. Sector plate assembly (hot end and cold end). 19. Air seal pipe, observation port and vapor or dust proof light assembly. 20. Stationary water washing device (hot end and cold end) and fire fighting device 21. Special tools and spare parts.

Isometric view of Air Preheater

AIR PRE-HEATER OPERATION

PRE START CHECKS

Support bearing/ guide bearing lubricating oil pumps RUNNING and lubricating oil coolers are CHARGED. Bearing temperature NOT HIGH (less than 60oC) Electrical supply to APH motor is AVAILABLE. Local operation - Isolating valves of air motors are 'OPEN' and bypass valves of air motor solenoids are 'CLOSED'. 'Air motors' lubricating oil level ADEQUATE Service air pressure is ADEQUATE (> 5 Kg/cm2)

AIR PRE-HEATER OPERATION

APH STARTING PROCEDURE WHEN BOTH APHS ARE OFF START air motor of APH. Air motors ON indications come on Isolating dampers of APHs start opening. INSTRUCT local operator to check, locally for any abnormal sounds from bearings/seals. START air heater electrical motor. Breaker CLOSED & its indication comes on UCB Associated air motor stops. Starting current shoots up and comes down to normal load current.

AIR PRE-HEATER OPERATION

Isolating dampers of the air heater remain open. Isolating dampers of the other air heater, not in service, start closing if its air motor is not ON. INSTRUCT local operator to check, locally for any abnormal sounds from bearings/seals. There should be no abnormal hunting in air heater amperes meter readings. There should be no abnormal sounds from air pre-heater seals or bearings. Bearing temperatures must be within the normal range (65 0C -75 0C)

Parameters related to APH

Make : Ljungstorm Type : Trisector Oil used : TC 680 cyndol (Bearing) EP 320 Parthan (Gear Box) Motor Drive : Main Motor (Electric driven, AC) Stand by motor (Electric driven, AC) Motor: N=970rpm , Speed Reducer Assembly O/P: N=0.89 rpm

ASH HANDLING PLANT

INTRODUCTION
Ash is a waste product of coal and solid fuel combustion. It contains many harmful elements which can contaminate sub-soil water of water is allowed to seep through ash into soil. Further, percentage of ash present in Indian coals is large. As a result, disposal of ash also uses up considerable area of land, which could otherwise be put to better use. Therefore, it is desirable to put ash to use so that the problem of providing land area for its disposal is solved. All out efforts are being made for finding uses of ash. Presently, only negligible amount of total ash produced in the country is put to use. However, ash being a good landfill material can be used in bulk in projects like highway construction. This is being done to as large an extent as possible. Pollution Control Regulations have made it mandatory to dispose ash in dry form only so that harmful elements do not find ingress in the subsoil water

ASH HANDLING SYSTEM

In modern boilers ash is collected in two locations namely (i) Bottom of the furnace and (ii) in Electrostatic Precipitators (or Dust Collection Systems). Out of these two fractions generally the quantity of ash collected in Electrostatic Precipitators (or Dust Collection Systems) is larger. Ash collected in the Bottom of Furnace is generally small in quantity and is handled wet, whereas that collected in Electrostatic Precipitators (or Dust Collection Systems) is now collected by means of dry handling systems.

Silos for collection of FLY-ASH

FLY ASH HANDLING SYSTEM The fly ash handling plant will remove fly ash from Electro static precipitator (ESP) hoppers and transport it to the storage silos. This will be carried out by pressure pneumatic conveying system on a continuous, cyclic basis. One boiler unit will be provided with one pneumatic conveying system for handling fly ash collected in the ESP hopper. The system layout and the conveying pipeline configuration will be designed and constructed to enable evacuation of fly ash at maximum design rate. The output of the system will be not less than 200% of actual ash amount. The capacity of each set of system will be 30t/h.

ELECTROSTATIC PRECIPATATOR
It is a device which captures the dust particles from the flue gas thereby reducing the chimney emission.
Precipitators function by electrostatically charging the dust particles in the gas stream. The charged particles are then attracted to and deposited on plates or other collection devices. When enough dust has accumulated, the collectors are shaken to dislodge the dust, causing it to fall with the force of gravity to hoppers below. The dust is then removed by a conveyor system for disposal or recycling

LOCATION OF ESP

ECO

APH

ESP

CHIMNEY

Electro Static Precipitator

Basic Principle

ESP PROCESS STEPS

1.Electron emission

Dust layer
1

2.Dust particle charging

2 3

Collecting electrode, grounded

3.Migration
5.Rapping 4 4.dust collection 5

Discharge electrode with Negative high tension (20-60kV)

Rapping mechanism

ESP
Collector plate Emitter coil

Flue gas

Gas distribution plate

ESP TECHNICAL SPECIFICATIONS

Description Nos. of Gas Stream / ESP Nos. of Parallel Path per Stream Nos. of electrical fields in series Nos. Nos. Unit Value Double 38 5 3.5

Total active treatment length per stream m

Treatment Time

Seconds 15

Description Total Number of Electrode Total numbers of Rappers per Unit Total Nos. of Transformer Rectifier Unit Capacity of Transformer Rectifier Unit Each Total No. of Dust Hoppers

Unit Nos. Nos. Nos. KVA Nos.

Value 3192 x 2 7 20 1.6A/72 KV 40

FUEL OIL SYSTEM

 There are two types of fuels are used for ignition in combustion chamber. 1) Heavy fuel oil(HFO). 2) Light diesel oil (LDO).

HEAVY FUEL OIL

The density of HFO is higher. Cost is low compare to the LDO. The viscosity is high. The auxilary steam is mixed for easely flowing through pipe. The storage tank of HFO is 2000 m3

BOILER LIGHT-UP
"HFO" inlet and re-circulation flow start increasing "HFO header pressure very low" alarms clear off. HFO temperature in the HFO header increases up to 110 oC. OPEN Ignitor oil trip valve Ignitor oil trip valve opens up. Ignitor air fans A & B, start automatically. Ignitor oil and ignitor air pressure increase up to 23 Kg/cm2 and 400 mm wcl, respectively. "Ignitor air to furnace DP low & "Ignitor oil/Atomising air pressure low" & "Ignitor oil/HFO trip valve closed" alarms clear off. CHECK these parameters are within their operation limits. Drum level normal (-60 mm. to 0, preferably on lower side).

BOILER LIGHT-UP
HFO temp. 110 oC . (Min. temp. required is 95 oC). HFO atomising steam pressure 8.75 Kg/cm2 Light oil pressure more than 15 Kg/cm2. Ignitor atomising air pressure 5 to 7 Kg/cm2 Wind box pressure between 35 to 40 mm wcl ADJUST HFO header pressure set point to 50%(13 Kg/cm2) and TRANSFER its control to auto. HFO pressure controller transfers to auto and modulates to maintain the set HFO header pressure. CLOSE heavy fuel oil re-circulation valve. HFO re-circulation flow valve closes. HFO re-circulation flow comes to minimum position

LIGHT DIESEL OIL

The density of LDO is low. Cost is high compare to the HFO. The viscosity is low. The fuel is easely flowing through pipe. The storage tank of LDO is 300 m3

COAL MILL

INTODUCTION
As coal powder is the most important fuel in the power plant, the plant owners need coal mill or coal pulverizer to grind the coal to micro powders. Raw coal (crushed) is fed through hopper at the top of the coal pulverizer and falls down to grinder ring to be pressed, crushed and milled into pieces by rollers. After the first crush, coal powder fall into the second and third layer. The pumping of the high-pressure centrifugal blower put the outside air into the coal mill. The coarse coal powder will be brought into the classifier.

TYPES OF MILLS
1) Ball mill 2) Ball and Race mill 3) Impact or Hammer mill 4) Bowl mill

COAL MILL

MILL LOCATION
PA-A FD-A
MILL

A
134C

351C

B
1165C
ESP I/L X OVER DUCT WIND BOX SA X-OVER DUCT

ESP PASS A

129C

ECO I/L 493C

CHIMNEY

SA FG

136C

C D E
320C

ESP PASS B

ID-A ID-B

SCAPH

FURNACE

SCAPH

324C

ESP PASS C

WIND BOX

SA FG PA APH

ESP PASS D

F
27C

COLD SA HOT SA
COLD PA HOT PA

PA-B

FD-B

FLUE GAS

126C

APH PA

ESP O/L X OVER DUCT

Milling System
PRE START CHECKS (Typical: Raymond Bowl Mill) Local Ensure R.C. Bunker level satisfactory. R.C. feeder and mill properly boxed up and no maintenance staff working. Gear box oil level normal. lubricating oil coolers charged. Pulveriser START PERMIT is AVAILABLE. (Boiler total airflow is < 40% and all burners are HORIZONTAL). Alternatively, if anyone coal feeder is proven then start permit will come from the proven feeder. Tramp iron gate open. Cold air gate 100 % open. Hot air gate closed. Mill outlet valve open. Seal air valve 100 % open. "No unsuccessful start" permissive for pulveriser is ON. Mill fire fighting system ready.

Milling System
PRE START CHECKS (Typical: Raymond Bowl Mill) UCB Ensure no PTW pending. Ensure at least one P.A. fan and a seal air fan is in service. Check the header pressure for both primary and seal air is normal. Check that mill ignition energy is O.K. (Minimum 3 out of 4 gun nozzle valves in adjacent elevation are open and elevation oil flow is more than 30% OR adjacent feeder speed is more than 50% and boiler load is more than 30%. Check that mill start permissive as per FSSS are satisfied Ensure E.P. zones have been charged (for first mill). Get the electrical supply for the mill. Inform the local operator to be near mill for start up. Start the mill

Milling System
POST START CHECKS Local -Check there is no abnormal sound from mill. Check return oil flow from upper bearing is satisfactory. Check all the rollers are rotating and the rate of reject is normal (after the mill is loaded). U.C.B.-Check mill starting time and current. Ensure that they are normal. Open hot air gate. Warm up the mill. Start the RC feeder and load the mill gradually. Keep the air flow through mill - 54 T/hr. Keep watch on mill differential to avoid mill choking. Maintain mill outlet temperature between 75C to 80C. As the pressure, temperature of main steam shoots up with coal firing proper check should be kept on these parameters. (Especially for first mill).

Milling System
MILL SHUTDOWN PROCEDURE TRANSFER mill feeder and fuel master controller to manual. Fuel master and feeder control transfer to manual. REDUCE feeder speed to minimum, gradually. Coal flow to mill starts coming down. Other running feeders start loading up, to maintain boiler loading, if on auto. STOP the mill feeder. Hot air gate closes with a time delay of 30 sec approx. Mill current and differential pressure start reducing as the mill becomes empty, gradually. EVACUATE the mill reject chamber locally and STOP the mill. Mill temperature comes down to less than 500C. Mill CAD goes to <5% open Airflow to furnace drops slightly.

Coal Pulverisers
Description Type of Design & Construction Unit Value Medium Speed Mill

Number (Each Unit) Capacity of each pulveriser for the design coal Min. load of Pulverisers
Mill Speed Driver Speed Rated Power Avg. life of Rollers/Grind Roll & Bottom Race Liners before Replacement

Nos. TPH
% Rpm Rpm Kw Hrs.

6 70
25 33 982 900 12000

ID, FD & PA FAN

FURNACE

CHIMNEY

SECONDRY AIR HEATER

MILLS

PRIMERY AIR HEATER FD FAN A FD FAN B

ID FAN A

Atmospheric air ESP PA FAN A Atmospheric air PA FAN B

ID FAN B

I.D.FANS (Induced Draught Fan)

The induced draft fans are generally of axial impulse type. The fan consists of the following sub assemblies, (a) Suction Chamber, (b) Inlet valve Control, (c) Impeller, (d) Outlet Guide Vane Assembly.

Induced Draught Fan

 The outlet guides are fixed in between the case of the diffuser and the casing. These guide vanes serve to direct flow axially and to stabilize the draft-flow caused in the impeller. These outlet blades are removable type from outside. During operation of the fan itself These blades can be replaced one by one. Periodically the outlet blades can be removed one at a time to find out the extent of wear on the blade.

F.D Fan: (Forced Draught Fan)

The fan normally of the same type as ID fan consists of the following components: 1) Silencer, 2) Inlet bend, 3) Fan housing, 4) Impeller with blades and setting mechanism, 5) Guide wheel casing with guide vanes and diffuser.

Forced Draught Fan

 The centrifugal and setting forces of the blades are taken up by blade bearing. The blade shaft is placed in combined radial and axial antifriction bearing which are sealed off to the outside The rotor is accommodated in cylindrical roller bearing and an inclined ball bearing at the drive side absorbs the axial thrust. Lubrication and cooling of these bearing is assured by a combined oil level and circulating lubrication system.

PA Fan (primary air fan)

P.A fan if flange mounted design, single stage suction, NDFV type backward curved bladed radial fan operating on the principle of energy transformation due to centrifugal forces. Some amount of the velocity energy is converted to pressure energy in the spiral casing. The fan is driven at a constant speed and the flow is controlled by varying the angle of the inlet vane control.

primary air fan

 The special feature of the fan is that it is provided with inlet guide vane control with a positive and precise link mechanism. Fan can develop high pressures at low and medium volumes and can handle hot air laden with dust particles.

Fans
Description
Fan Model Rated Power of Motor Rotational Speed of Fan Volume flow of fan inlet Temperature of fan inlet Fan total pressure Total efficiency External Diameter of Blade Diameter of Impeller Blade No. of Each Grade kW r/min m^3/s C Pa % mm mm Nos.

Unit

FD
Axial Fan 2000 990 230.1 47.8 3871 87 2880 1600 26

PA
Axial Fan 3150 1490 112.9 47.8 12671 88 2100 1400 22

ID
Axial Fan 4500 990 538.4 137 3989 85.5 3349 1884 18

COOLING TOWER

INTRODUCTION
Cooling towers cool the warm water discharged from the condenser and feed the cooled water back to the condenser. They, thus, reduce the cooling water demand in the power plant.

Cooling tower may classify as:

1) Induced draft cooling tower 2) Forced draft cooling tower 3) Balanced draft cooling tower

Cooling towers can be either mechanical draught or natural draught.

In mechanical draught cooling towers, air is moved through the fill by one or more fans driven by motors. The fans could be of the forced draught (FD) type or induced draught (ID) type.

COOLING TOWER

Cooling tower Detail

There are 20 sets cooling tower for one unit. The design meteorological parameter; Relative humidity: 60 percentage Main air pressure: 1013.25 hpa Inlet water temperature: 42C outlet water temperature: 33C Type: counter flow mechanical draft cooling tower Type of fill: PVC fill Cooling tower stack material: fiber glass reinforced plastics Depth of fill: 1.5m Water basin depth: 2m Tower overall height : about 16.4m Cooling water capacity: 5256 m3/hr Fan specification: Fan dia: 9750 mm Blade of each fan: 6 pieces Motor power: 220Kw Voltage:6600 v

A B C

E
F
A=Mechanical equipment B=Drift eliminator C=Water distribution D=Fill packing E=Air in late louvers F=Cold water basin

Principle of cooling Tower operation

In COOLING TOWER - Water is split up into small droplets & brought into intimate contact with air. - In doing so a small quantity of water is evaporated.

- The EVAPORATION brings about the 75 % of the cooling effect. - Balance 25 % of the cooling is due to sensible heat transfer.

Blowdown

Evaporation
Cooling Tower Heat Load

Recirculating Pump

 Wet cooling towers have a hot water distribution system that showers or sprays water evenly over a lattice of horizontal slats or bars called fill or packing. The fill thoroughly mixes the falling water with air moving through the fill as the water splashes down from one fill level to another by gravity. Outside air enter the tower through louvers on the side of the tower. Intimate mixing of water and air enhances heat and mass transfer (evaporation), which cools the water. More the water evaporates; more will be the cooling since the latent heat of evaporation is taken from the water itself (evaporation cooling). Cold water is collected in a concrete basin at the bottom of the tower, from where it is pumped back to the condenser. Hot and moist air leaves the tower from the top.

FIRE FIGHTING SYSTEM

Water spray fire fighting system HVWS System & Automatic alarming ,Automatic/Manual startup
Generator transformers, category-A Unit auxiliary transformers, category-A Station transformers, category-A outdoor oil storage tanks, category-B Diesel generator room, category-B Boiler burner, category-B Air pre-heater, category-B Mill lube oil system, category-B Medium layer oil device, category-B Turbine lube oil tank, category-B
2000 m3 fresh water reservoir 2000 m3 fresh water reservoir

1
2 2

Hydrogen seal oil device, category-B

Steam driven pump lube oil system, category-B' Steam driven pump lube oil system, category-B' MVW -Bunker bay -10.4 m cable mezzanine -switch yard control building 10.40m cable spreader room - Crusher room - 1#juction house - 2#juction house - 3#juction house - Coal conveyor

To spray fire fighting system(300 nb)

hydro pneumatic tank(80nb)

No

Description
Automatic sprinkler driven F.F Q410,H=115,N=220,1nos Automatic sprinkler F.F jockey pump,Q-18,H-115,N-13.5-2nos Air compressor-2nosX100%Typeww-0.7/25V=170LN=11kw Automatic sprinkler motor drive F.F pump,Q-410,H-115,N-220

2
3 4

Hydrant fire fighting system

Main turbine house-5 unit Main turbine house-6 unit Dearetor & bunker bay Boiler house-5 unit Boiler house-6 unit Central control building ESP& stack area D.M water treatment plant area Waste water treatment building area fuel oil storage area Water clarifiers area Cooling tower area of Unit-5& 6 Coal yard area Junction house-1nos Junction house-2nos Junction house-3nos Crusher room
No

2000 m3 fresh water reservoir

2000 m3 fresh water reservoir

10

To fire hydrant fire fighting system

hydro pneumatic tank(80nb)

Description
Hydrants Diesel- drive F.F pump,Q-273,H-125,N-160

5,6

9,10
7
8

Hydrants Motor- drive F.F pump,Q-273,H-125,N-160

Hydrants F..F jockey pump Air compressor2nosX100%Type-ww0.7/25V=170LN=11kw

COAL HANDLING PLANT

INTRODUCTIO
Coal Handling System and plant shall comprise of following: (a) Track Hopper and paddle Feeders (b) Roller Screens with Single Drive (c) Crushers (d) Stacker & Reclaimer (e) Conveying System (f) Transfer Tower

LAYOUT OF COAL HANDLING PLANT

TT-3

CRUSHER HOUSE

TT-4

TT-1

TT-2
BUNKER

General:
The track hopper together with coal handling facility (to supply coal for units), capable of continuous, efficient, and reliable operation with minimum maintenance under the environmental and operating conditions pertaining to area adjacent to power plant site. Track hopper complex together with Coal Handling System shall be designed for continuous duty of 24 hour/day.

 The entire coal handling plant (CHP) facility shall comply with currently applicable statutes, regulation & safety codes related to design, construction & operation of the CHP. The CHP will supply coal from the track hopper up to and including the bunker fill system. The conveying and handling of coal from the above ground coal stockyard to the main plant boiler bunkers;

The plant will be designed to handle with the whole range and condition of coal that may be delivered to the site in a safe, reliable, economic and environmentally acceptable manner

Conveyor System:
(a) Each conveyor will be fitted with a centrifugal speed switch for use in the sequential starting and tripping interlock scheme and for ensuring that the driving motor will be shut down automatically in the event of the belt slipping or breaking. Start-up and shutdown of each conveyor will be by remote control with provision for local control.

(b) Plant will be designed for ease and flexibility of operation including. All conveyors and transfer towers will be totally enclosed with a central access walkway, maintenance walkways at each side of conveyors. Adequate access will be provided for cleaning all conveyors. Transfer points will be designed to give good material flow and central loading of conveyors without spillage. Access will be provided for chute cleaning. High quality belt scrapers will be provided. They will be positioned and chutes designed such that all scrapings fall into the main chute, to merge with the main flow of material. All operational areas will be well-lit with special lighting provided where the interiors of chutes, hoppers and bunkers must be inspected frequently.

Coal conveyor

Coal Receiving System:

Coal will be discharged from wagons to coal gap for train and be fed to 1AB belt conveyor by paddle feeder, then pass through 2# belt conveyor, ultimately be stacked in coal yard by the bucket wheel stacker & reclaimer.

Coal Reclaim System:

Coal reclaim system will involve the operating flow from the stacker & reclaimer to the coal bunker in main block. Coal will be reclaimed by the stacker & reclaimer, and pass through 2#,3AB belt conveyor, then be injected into the crusher, which could crush coal into smaller pieces. The crushed coal will be conveyed through 5AB belt conveyor, ultimately be discharged into the coal bunker by the plough trippers.

Stacker & Reclaimer

TURBINE

TURBINE MAKE:- Dong Fang Steam Turbine Works

Nominal Capacity- 660 MW

Type- N660-24.2/566/566

 IMPULSE TURBINES

REACTION TURBINES

IMPULSE TURBINE

REACTION TURBINE

TURBINE SPECIFICATION TYPE

Impulse Type Tandem Compounded 3 Cylinders (HP & IP Combined, two LP Cylinders)

Four Flow Exhausts

Reheat Condensing Turbine

From Reheater Boiler

Economiser
8 6 2x7 2x7

FCS

HPT
3
1

IPT
8
7

LPT A
5 6 7

LPT B
8 8
7 5 6 7

HPH - 1

LPH -7A LPH -8A

LPH -7B LPH -8B

HPH - 2

Deaerator

Condensor (HP)

Condenser (LP)

EXT From CRH

(MD BFBP 1x35%)

HPH -3

BFBP
2x50%
LPH-5 Extr from 16th stage LPH-6 From 17th stage LPH-7 From 18th stage

TDBFP 2x50%
(MD BFP 1x35%) 1994 TPH

LPH-8 From 19th stage

CEP
3x50%

HPH-1 Extr from 6th stage HPH-2 From CRH HPH-3 From 11th stage stage Deaerator From 14th

GSC
CPP

1482 TPH
LPH -5
LPH -6

TURBINE SPECIFICATION

Steam Admission Parameters at Turbine Inlet HPT Pressure (bar) Temp (Deg C) Steam Flow (tph) 242 566 1994.25 IPT 44.9 566 LPT 11.6 383.5

No of Stop valves
No of Control valves

2
4

2
2

TURBINE CONSTRUCTION

TB HPT IPT LPT A LPT B

No. of Journal bearings Type

6 HIP Tilting Pad LP Elliptical Type

Thrust Bearing Type Max shaft vibration & bearing housing Type of Coupling

Tapered-land type

125 microns Rigid Coupled with bolts

TURBINE CONSTRUCTION
FEATURES OF 660 MW TURBINE
Combined HP & IP Section Shorter Turbine Length Reduced No.of Bearings thereby Mech losses Reduced No. of Packing segments thereby reduced leakage loss & Smooth Distribution of Temp Gradient Thrust force balanced Easier. maintenance

Impulse type Turbine

Little Steam Leak around the blades Greater axial clearance, thus capable of withstanding transient conditions

Requirement: To lift Turbine Rotor During Turning Gear Operation

System Envisaged to Fulfill The Above Requirement:

1X100 % AC Driven Jacking Oil Pump 1X100 % DC Driven Jacking Oil Pump

SEA WATER SYSTEM

Water balance diagram

Sea water
Sea water reservoir

D.M plant waste water(43m3/hr )

8366m3/hr
124 cum/hr from fresh water sys. Drift losses

Evaporative losses

Over view of water system of phase-III

Intake Water Reservoir (sea water)
8806 m3/hr

Desalination plant (PMC scope)

381 m3/hr

Make water system

service water system

D.M water system

Recirculation water system

Water spray fire fighting system

Hydrant fire fighting system

Potable water supply system

Make up water system

Sea water intake reservoir
Vertical turbine pump, Q=5285m3/hr,H=18m,P=400Kw,3-nos

8806m3/hr

Mechanical accelerated clarifier (Q=1800m3/hr-6nos) According to the sea water quality ,chemical dose such as aluminum sulfate & polyacry lamide (PAM) will be added to the clarifier in order to effectually remove the suspended solids. The chlorinator equipment will be used for disinfection.

8366m3/hr 440m3/hr Mechanical draft cooling tower Blow down water 6121m3/hr

Effluent pit

service water system

2000 m3 fresh water reservoir 2000 m3 fresh water reservoir

Service water pump,Q150m3/hr,H-60Mtr,N-40Kw

To service Water(198m3/hr,250nb)

Consume & stand by water(30m3/hr)

Industrial waste water treatment system(1m3hr loss)

Make up water to cooling tower basin128m3/hr)

Wash water for car & floor(2m3/hr) Ash handling air compressor cooling water(60m3/hr) Mechanical air compressor cooling water(100m3/hr)

Bottom ASH hopper seal water(3 m3/hr)

SSC Seal water( 3m3/h r)

For HAVAC system(8m3/hr )

Wash water for coal handling system(2 m3/hr)

Moisten ing water for dry ash(9m 3/hr)

Wash water for clinker floor(2m3/ hr loss)

Coal water treatment system(6 m3/hr)

Coal storage area spray water(6m3/hr) Spray water for bunker wheel machine(3m3/hr)

TOTAL WATER REQUIREMENT FOR Ph-III & Ph-IV

Sea water make up : 8608+13804 = 22412 cum/hr Back to sea through ETP: 6611+10104= 16715 cum/hr Fresh water reqmt.(from De-sal. Plant) : 371 +548= 919 cum/hr

Waste water treatment System

1. Sanitary sewage treatment system This system function is to send the sewage to the sewage treatment equipment, in which the sewage is treated to remove the suspended solid, colloidal substance, soluble organic matter and to eliminate the pathogenic bacteria 2. Coal wastewater treatment system Storm water runoff from the coal handling area and Coal Handling Plant is collected in a set of coal settling pond. Coal fines, which accumulate in the basin over time, must be periodically removed. These are stacked-out adjacent to the pond for dewatering, and returned to the coal pile. The rain water will be pumped into the coal wastewater treatment system and will be reused in the plant. 3. Industrial wastewater treatment system Industrial wastewater system collects variety of wastewater, which is produced in the course of daily life and production activities. The water will be treated by the Industrial wastewater treatment system and then be reused.

Sea water
Sea water in take reservoir
6611m3/hr
Vertical turbine pump, Q=5285m3/hr,H=18m,P= 400Kw,3-nos

Sea water

Sea water in take reservoir

8806m3/hr Mechanical accelerated clarifier (Q=1800m3/hr-6nos) 8366m3/hr Blow down water 6121m3/hr 43380m3/hr C.W pump,Q-43380m3/hr, H-29.82mP-4800kw,3nos Auxiliary equipment cooling water Condenser cooling water 440m3/hr
C.W pump,Q43380m3/hr,H29.82mP4800kw,3nos

Effluent pit

Mechanical draft cooling tower

Auxiliary equipment cooling water

Condenser cooling water

DM PLANT

What is DM Water?

Demineralization of water is removal of cautions & anions known as TDS( Total dissolved solids ) of all minerals.

Inlet water quality

PH- 5-6 T.D.S - <500ppm T.S.S=Nil Sodium+ potassium=<150ppm Sulphate=<20ppm Chloride<250ppm Silica=<1ppm Reducing agent dosing

Outlet water quality

D.M plant flow diagram

PH= 8 to 7.2 Turbidity<1NTU Free chlorine Nil Conductivity <0.1Micromhos/cm Sodium as Na= <1ppm Free CO2<5ppm Total silica <0.02ppm

D.M water tank

Mixed ion exchanger 2200,Hcation-500mm, Hanion-500mm

precision filter Q=110m3/hr

Condenser storage tank ,V=300m3

High pressure pump Q=110m3/hr,H=1.35Mpa

DM water pump Q=120m3/hr,H=0.4Mpa-2nos Q=300m3/hr,H=0.5Mpa-1nos caustic dosing Anion exchanger

Cleaning agent dosing

Reverse osmosis Q=80m3/hr

Decarbonator

Intermediate water pump Q=90m3/hr,H=0.4Mpa

Fresh water tank V=300m3 Fresh water pump Q=90m3/hr,H=0.3Mpa

Acid dosing

Cation exchanger

Chemical Reactions in SAC

Operation CaCO3 + 2 R-H+ R2-Ca+2 + H2CO3 Na2CO3 + 2 R-H+ 2R-Na+ + H2CO3 Regeneration 2HCl + R-Ca+2 2 R-H+ + CaCl2 R-Na+ + HCl 2 R-H+ + NaCl

Chemical Reactions in SBA

Operation Cl- + R-OH- H2O + R-Cl2(HSiO3) + 2R-OH- 2(HSiO3)R +2H2O Regeneration 2Cl--R + 2NaOH 2 R-OH- +2NaCl 2(HCO3-)R + 2NaOH 2R-OH- + 2NaHCO3

Process Flow Diagram for Conventional DM Plant for Adani Power Ltd. , Mundra SEZ
Bulk Acid Storage Tank

Water Storage Tank

Filter water B/W Tank

DM Water Supply Pumps (3W+1S)

60m3 /hr

Sodium Hypochlorite Dosing Pump-I (1W+1S)

Pressure Sand Filter (2W+1S)

60m3 /hr

Activated Carbon Filter (2W+1S)

60 m3/hr

Strong Acid Cation Exchanger

Acid Unloading & Transfer Pump (1W+1S)

30% HCl for regeneration

Degasser Blower (1W+1S)

Acid Measuring Tank for SAC

Air Scouring Blower (1W+1S)

Degasser Storage tank

Sodium Hypochlorite Dosing Pump-II (1W+1S) Degassed Water Transfer Pump (3W+1S) [

Degasser Tower

Acid Measuring Tank for MB Neutralization Pit (2) Caustic Measuring Tank for MB
Effluent Transfer Pumps (1W+1S)

Sodium Hypochlorite Dosing Tank

Service Water Overhead Tank

Mixed Bed Blower (1W+1S)

Weak Base Anion Exchanger

60m3 /hr

Strong Base Anion Exchanger

60m3 /hr

Mixed bed Exchanger

ETP
45% NaOH for regeneration

Caustic Measuring Tank for SBA

Caustic Unloading Pump (1W+1S)

DM Regeneration Pumps (1W+1S)

DM Water Storage Tank

Condensate Storage Tank

Bulk Caustic Storage Tank

Condensate Water Transfer Pumps (1W+1S)

DM PLANT

TDBFP & MDBFP SYSTEM

Requirement To pump feed water from deaerator to Boiler Type of BFP Horizontal Barrel type outer casing Multistage Configuration of BFP For 500MW 2x50% TDBFP & 1x50% MDBFP For 200MW 3x50% MDBFP

Requirement: To pump feed water from Deaerator to boiler through HP Feed water heaters.

Options Available

1X100% TDBFP & 1X100% MDBFP

2X50% TDBFP & 1X50% MDBFP

3X33% TDBFP & 1X33% MDBFP

 Meets IBR requirements of two independent source

Incase one running TDBFP is out, full unit load can be maintained with 50% MDBFP.
Can facilitate cold as well as hot unit start ups Unit Start up is faster. Better availability and Operational flexibility.

THE BOILER FEED WATER PUMP

Efficiency of generator = 98% (Say) Efficiency of UAT= 97% (Say)

Efficiency of Elect. system = 98% (Say)

Efficiency of BFP Motor = 97% (Say) Efficiency of Hyd. coupling = 87% (Say) Total percentage utilisation when MDBFP used= 78.6% (0.98 X 0.97 X 0.98 X0.97 X 0.87 = 0.786) Power consumed by two TDBFP = 15 MW (approx.) ?? Saving in MW when TDBFP used = 3.21 MW (15 X (1-0.786) = 3.21 MW)

TD BFP
TD BFP Turbine Parameters

TDBFP STEAM PRESSURE STEAM TEMP. STEAM FLOW

NOS Mpa Deg C TPH

2X50% 1.018 353.9 108.4

TD BFP

Numbers Rated Capacity Suction Pressure

Nos Cum/Hr Kg/Cm2

2x50% 1150 12(a)

Discharge Pressure
NPSH Required Pump Efficeincy

Kg/Cm2
mlc %

250(a)
36 82

TD BFPs BOOSTER PUMP

Numbers Rated Capacity Suction Pressure Discharge Pressure NPSH Required Pump Efficeincy

Nos Cum/Hr Kg/Cm2(a) Kg/Cm2 (a) mlc %

2x50% 1150 0.8 12 3.8 80

Motor Rating

kw

540

Gain in Heat Rate When TDBFP Used

When TDBFP used Heat rate (as per EPDC) for 660 MW TG 1900 Kcal/kwhr When MDBFP used

Additional power required to be generated = 3.21MW

Net Generator output =(660 + 3.21) MW = 663.21 MW Total Heat addition in the system 663.21 X 1900 M cal Saving in HR with TDBFP = {(663.21 X 1900)/660} - 1900 = 9.24 kcal / kwhr ~ 9 - 10 kcal / kwhr

TDBFP

MD BFP

MDBFP

NOS

1X35%

Motor Capacity

Kw

12000

MDBFP