Amardeep jadeja copy.ppt [autosaved]

AMARDEEP .M. JADEJA
B.E. MECHANICAL (THIRD YEAR)
INDUS INSTITUTE OF ENGINEERING & TECCHNOLOGY,AHMEDABAD.

CONTENTS
INTRODUCTION OF BOILER
AIR PREHEATER
ASH HANDLING PLANT
FUEL OIL SYSTEM
COAL MILL
ID, FD & PA FAN
COOLING TOWER
FIRE FIGHTING SYSTEM
COAL HANDLING PLANT
TURBINE
SEA WATER SYSTEM
DM PLANT
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

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

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 INTRODUCTION OF 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 Unit Value Type 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. Manufacturer HARBIN BOILER COMPANY, CHINA Design Code For Pressure Parts ASME, GB9222-88, IBR

Large Single Funace
7. Low Nox Tangential Burner 6. Burner tilting for reheater steam temperature control 3. Proven and economic heating surface arrangement 2. Spirally wounded evaporators for safe and reliable evaporator 5. Economic and safe low load and startup system by circulating pump 8. Long life and high Performance mills 4. High Strength material application Overall View Of Adani Boiler

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

SUPER CRITICAL BOILER CYCLE WITH SH, RH & Regeneration of ADANI 5 x 660 MW 256 Kg/cm2 0 100 200 300 400 500 600 540’C 568’C Steam flow :2225 T/Hr Steam temp : 540 ‘c Steam Pres : 256 kg/cm2 RH pre : 51.6 Kg/cm2 RH Temp : 568’c Feed water Temp : 291’c ENTROPY TEMP

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) 374.15º C temperature.

SH DRUM ECO HTR BFP W/WALL DOWN COMER RISERS Natural Circulation Boiler W/WALL BFP HTR ECO SH SEPERATOR ONCE THROUGH SYSTEM

FLOW DIAGRAM OF SIPAT SUPER-CRITICAL BOILER

Evaporator Wall Construction (1/3)
Upper Part
Vertical Wall
Lower Part
Spiral Wall

Spiral wall outlet temp at BMCR (front wall) Spiral Wall Evaporator Configuration of Evaporator panel Spiral wall : Vertical wall = 3 : 1 Supercritical Boiler Technology

spiral wall spiral wall and windbox WALL OF BOILER

660 MW PLANT BOILER

LTSH COILS ECONOMISER COILS ECONOMISER I/L HEADER ECONOMISER O/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:
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
SA
SA PA FG FG PA TG House 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)

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.

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 0 C -75 0 C)

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 sub-soil 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 ESP CHIMNEY APH ECO

Electro Static Precipitator
Basic Principle

ESP PROCESS STEPS Collecting electrode, grounded Rapping mechanism Discharge electrode with Negative high tension (20-60kV) 4.dust collection 4 Dust layer 1 1.Electron emission 2 2.Dust particle charging 3 3.Migration 5 5.Rapping

ESP Flue gas Emitter coil Gas distribution plate Collector plate

ESP TECHNICAL SPECIFICATIONS Description Unit Value Nos. of Gas Stream / ESP Double Nos. of Parallel Path per Stream Nos. 38 Nos. of electrical fields in series Nos. 5 Total active treatment length per stream m 3.5 Treatment Time Seconds 15

Description Unit Value Total Number of Electrode Nos. 3192 x 2 Total numbers of Rappers per Unit Nos. 7 Total Nos. of Transformer Rectifier Unit Nos. 20 Capacity of Transformer Rectifier Unit Each KVA 1.6A/72 KV Total No. of Dust Hoppers Nos. 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 o C.
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 o C . (Min. temp. required is 95 o C).
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

A B C D E F ESP PASS A ID-A ID-B PA-B FD-B PA-A FD-A FURNACE WIND BOX SCAPH SA PA FG SA PA FG SCAPH ESP PASS B ESP PASS C ESP PASS D WIND BOX ESP I/L X – OVER DUCT ESP O/L X – OVER DUCT SA –X-OVER DUCT COLD PA HOT PA FLUE GAS COLD SA HOT SA CHIMNEY MILL LOCATION APH APH MILL 27ºC 324ºC 320ºC 1165ºC ECO I/L 493ºC 351ºC 136ºC 134ºC 129ºC 126ºC

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 75°C to 80°C.
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 50 0 C.
Mill CAD goes to <5% open
Airflow to furnace drops slightly.

Coal Pulverisers Description Unit Value Type of Design & Construction Medium Speed Mill Number (Each Unit) Nos. 6 Capacity of each pulveriser for the design coal TPH 70 Min. load of Pulverisers % 25 Mill Speed Rpm 33 Driver Speed Rpm 982 Rated Power Kw 900 Avg. life of Rollers/Grind Roll & Bottom Race Liners before Replacement Hrs. 12000

ID, FD & PA FAN

FURNACE PRIMERY AIR HEATER SECONDRY AIR HEATER MILLS FD FAN A PA FAN B PA FAN A FD FAN B ESP ID FAN A ID FAN B CHIMNEY Atmospheric air Atmospheric air

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 Unit FD PA ID Fan Model Axial Fan Axial Fan Axial Fan Rated Power of Motor kW 2000 3150 4500 Rotational Speed of Fan r/min 990 1490 990 Volume flow of fan inlet m^3/s 230.1 112.9 538.4 Temperature of fan inlet ˚C 47.8 47.8 137 Fan total pressure Pa 3871 12671 3989 Total efficiency % 87 88 85.5 External Diameter of Blade mm 2880 2100 3349 Diameter of Impeller mm 1600 1400 1884 Blade No. of Each Grade Nos. 26 22 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: 42°C
outlet water temperature: 33°C
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 D C B 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.

Evaporation Heat Load Blowdown Recirculating Pump Cooling Tower

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 To spray fire fighting system(300 nb) hydro pneumatic tank(80nb) 1 4 2 2 2000 m3 fresh water reservoir 2000 m3 fresh water reservoir 3 3 1 Automatic sprinkler driven F.F Q-410,H=115,N=220,1nos 2 Automatic sprinkler F.F jockey pump,Q-18,H-115,N-13.5-2nos 3 Air compressor-2nosX100%Type-ww-0.7/25V=170LN=11kw No Description 4 Automatic sprinkler motor drive F.F pump,Q-410,H-115,N-220 - Coal conveyor - 3#juction house - 2#juction house - 1#juction house - Crusher room - switch yard control building 10.40m cable spreader room -10.4 m cable mezzanine MVW -Bunker bay Steam driven pump lube oil system, category-B' Steam driven pump lube oil system, category-B' Hydrogen seal oil device, category-B Turbine lube oil tank, category-B Medium layer oil device, category-B Mill lube oil system, category-B Air pre-heater, category-B Boiler burner, category-B Diesel generator room, category-B outdoor oil storage tanks, category-B Station transformers, category-A Unit auxiliary transformers, category-A Generator transformers, category-A

Hydrant fire fighting system hydro pneumatic tank(80nb) To fire hydrant fire fighting system 5 10 6 9 7 7 5,6 Hydrants Diesel- drive F.F pump,Q-273,H-125,N-160 9,10 Hydrants Motor- drive F.F pump,Q-273,H-125,N-160 7 Hydrants F..F jockey pump 8 Air compressor-2nosX100%Type-ww-0.7/25V=170LN=11kw No Description 2000 m3 fresh water reservoir Crusher room Junction house-3nos Junction house-2nos Junction house-1nos Coal yard area Cooling tower area of Unit-5& 6 Water clarifiers area fuel oil storage area Waste water treatment building area D.M water treatment plant area ESP& stack area Central control building Boiler house-6 unit Boiler house-5 unit Dearetor & bunker bay Main turbine house-6 unit Main turbine house-5 unit 2000 m3 fresh water reservoir 8 8

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-1 TT-3 TT-2 TT-4 CRUSHER HOUSE 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
TYPES OF TURBINE A TURBINE STAGE IS CALLED AN IMPULSE STAGE WHEN THE TOTAL PRESSURE DROP OF THE STAGE TAKES PLACE IN THE STATIONARY BLADES ONLY. A TURBINE STAGE IS CALLED A REACTION STAGE WHEN THE TOTAL PRESSURE DROP OF THE STAGE TAKES PLACE BOTH IN THE STATIONARY BLADES AS WELL AS IN THE MOVING BLADES.
REACTION TURBINES

REACTION TURBINE IMPULSE TURBINE PRESSURE AND VELOCITY PROFILE THROUGH THE BLADES

Impulse Type
Tandem Compounded
3 Cylinders (HP & IP Combined, two LP Cylinders)
Four Flow Exhausts
Reheat
Condensing Turbine
TURBINE SPECIFICATION – TYPE

HPT IPT LPT A LPT B CPP Condensor (HP) Condenser (LP) 1 HPH - 1 HPH - 2 HPH -3 EXT From CRH LPH -5 LPH -6 LPH -7A LPH -7B LPH -8A LPH -8B 3 Deaerator BFBP TDBFP Boiler CEP 3x50% 2x50% FCS 5 5 6 6 2x50% From Reheater Economiser 1482 TPH 1994 TPH (MD BFP 1x35%) (MD BFBP 1x35%) 7 8 7 8 8 7 7 8 8 6 2x7 2x7 HPH-1 – Extr from 6 th stage HPH-2 – From CRH HPH-3 – From 11 th stage Deaerator – From 14 th stage LPH-5 – Extr from 16 th stage LPH-6 – From 17 th stage LPH-7 – From 18 th stage LPH-8 – From 19 th stage GSC

TURBINE SPECIFICATION HPT IPT LPT Pressure (bar) 242 44.9 11.6 Temp (Deg C) 566 566 383.5 Steam Flow (tph) 1994.25 No of Stop valves 2 2 No of Control valves 4 2 Steam Admission Parameters at Turbine Inlet

TURBINE CONSTRUCTION HPT IPT LPT A LPT B TB
No. of Journal bearings - 6
Type - HIP – Tilting Pad
LP – Elliptical Type
Thrust Bearing Type - Tapered-land type
Max shaft vibration &
bearing housing - 125 microns
Type of Coupling - 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 & maintenance
Smooth Distribution of Temp Gradient
Thrust force balanced Easier.
Impulse type Turbine
Little Steam Leak around the blades
Greater axial clearance, thus capable of withstanding transient conditions

Turbine Jacking Oil System To lift Turbine Rotor During Turning Gear Operation Requirement: System Envisaged to Fulfill The Above Requirement:
1X100 % AC Driven Jacking Oil Pump
1X100 % DC Driven Jacking Oil Pump

SEA WATER SYSTEM

Mechanical accelerated clarifier Sea water in take pump house Sea water reservoir Cooling tower Evaporative losses Drift losses D.M plant waste water(43m3/hr) Effluent plant 440m3/hr 156m3/hr 2200m3/hr 43m3/hr 8806m3/hr 8806m3/hr 8366m3/hr 6121m3/hr 6611m3/hr Water balance diagram Sea water 124 cum/hr from fresh water sys.

Over view of water system of phase-III Desalination plant (PMC scope) Intake Water Reservoir (sea water) Make water system service water system Water spray fire fighting system Hydrant fire fighting system Potable water supply system D.M water system Recirculation water system 381 m3/hr 8806 m3/hr

Make up water system
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.
Mechanical draft cooling tower Effluent pit Vertical turbine pump, Q=5285m3/hr,H=18m,P=400Kw,3-nos Sea water intake reservoir 8806m3/hr 440m3/hr 8366m3/hr Blow down water 6121m3/hr

service water system Consume & stand by water(30m3/hr) Wash water for car & floor(2m3/hr) Ash handling air compressor cooling water(60m3/hr) Mechanical air compressor cooling water(100m3/hr) Industrial waste water treatment system(1m3hr loss) For HAVAC system- (8m3/hr) Wash water for coal handling system(2m3/hr) Moistening water for dry ash(9m3/hr) Wash water for clinker floor(2m3/hr loss) SSC Seal water(3m3/hr ) Coal water treatment system(6m3/hr) Bottom ASH hopper seal water(3 m3/hr) Coal storage area spray water(6m3/hr) Spray water for bunker wheel machine(3m3/hr) 2000 m3 fresh water reservoir 2000 m3 fresh water reservoir Make up water to cooling tower basin128m3/hr) Service water pump,Q-150m3/hr,H-60Mtr,N-40Kw To service Water(198m3/hr,250nb)

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.

Mechanical accelerated clarifier (Q=1800m3/hr- 6nos)
Effluent pit Vertical turbine pump, Q=5285m3/hr,H=18m,P=400Kw,3-nos Sea water in take reservoir 8806m3/hr 440m3/hr 8366m3/hr Blow down water 6121m3/hr Mechanical draft cooling tower C.W pump,Q-43380m3/hr, H-29.82mP-4800kw,3nos Auxiliary equipment cooling water Condenser cooling water 6611m3/hr Sea water in take reservoir C.W pump,Q-43380m3/hr,H-29.82mP-4800kw,3nos Auxiliary equipment cooling water Condenser cooling water 43380m3/hr 43380m3/hr Sea water Sea water

DM PLANT

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

Cation exchanger precision filter Q=110m3/hr High pressure pump Q=110m3/hr,H=1.35Mpa Reverse osmosis Q=80m3/hr Fresh water tank V=300m3 Fresh water pump Q=90m3/hr,H=0.3Mpa Decarbonator Intermediate water pump Q=90m3/hr,H=0.4Mpa Mixed ion exchanger Ø2200,H cation- 500mm, H anion -500mm Anion exchanger D.M water tank Condenser storage tank ,V=300m3 DM water pump Q=120m3/hr,H=0.4Mpa-2nos Q=300m3/hr,H=0.5Mpa-1nos Reducing agent dosing Cleaning agent dosing Acid dosing caustic dosing Caustic & acid dosing D.M plant flow diagram Inlet water quality PH- 5-6 T.D.S - <500ppm T.S.S=Nil Sodium+ potassium=<150ppm Sulphate=<20ppm Chloride<250ppm Silica=<1ppm Outlet water quality 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

Chemical Reactions in SAC
Operation
CaCO 3 + 2 R-H +  R 2 -Ca +2 + H 2 CO 3
Na 2 CO 3 + 2 R-H +  2R-Na + + H 2 CO 3
Regeneration
2HCl + R-Ca +2  2 R-H + + CaCl 2
R-Na + + HCl  2 R-H + + NaCl

Operation
Cl - + R-OH -  H 2 O + R-Cl -
2(HSiO 3 ) + 2R-OH -  2(HSiO 3 )R +2H 2 O
Regeneration
2Cl - -R + 2NaOH  2 R-OH - +2NaCl
2(HCO 3 - )R + 2NaOH  2R-OH - + 2NaHCO 3
Chemical Reactions in SBA

Sodium Hypochlorite Dosing Tank Sodium Hypochlorite Dosing Pump-I (1W+1S) Sodium Hypochlorite Dosing Pump-II (1W+1S) Pressure Sand Filter ( 2W+1S) Activated Carbon Filter ( 2W+1S) Strong Acid Cation Exchanger Degasser Tower Degassed Water Transfer Pump (3W+1S) [ Degasser Storage tank Weak Base Anion Exchanger Strong Base Anion Exchanger Mixed bed Exchanger DM Water Storage Tank Condensate Water Transfer Pumps (1W+1S) DM Regeneration Pumps (1W+1S) Condensate Storage Tank Acid Measuring Tank for MB Service Water Overhead Tank Bulk Acid Storage Tank Acid Unloading & Transfer Pump (1W+1S) Caustic Measuring Tank for SBA Bulk Caustic Storage Tank Caustic Unloading Pump (1W+1S) Acid Measuring Tank for SAC Caustic Measuring Tank for MB Process Flow Diagram for Conventional DM Plant for Adani Power Ltd. , Mundra SEZ 60m 3 /hr 60m 3 /hr 60 m 3 /hr 60m 3 /hr 60m 3 /hr Water Storage Tank DM Water Supply Pumps (3W+1S) Filter water B/W Tank 30% HCl for regeneration Degasser Blower (1W+1S) 45% NaOH for regeneration Mixed Bed Blower (1W+1S) Neutralization Pit (2) ETP Effluent Transfer Pumps (1W+1S) Air Scouring Blower (1W+1S)

DM PLANT

TDBFP & MDBFP SYSTEM

Boiler Feed Pumps
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

Boiler Feed Pump Options Available 1X100% TDBFP & 1X100% MDBFP 2X50% TDBFP & 1X50% MDBFP 3X33% TDBFP & 1X33% MDBFP To pump feed water from Deaerator to boiler through HP Feed water heaters. Requirement:

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.
Reason for MDBFP as Start up & Stand by

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) Reasons for Selection of TDBFP Over MDBFP for Normal Operation

TD BFP
TDBFP NOS 2X50%
STEAM PRESSURE Mpa 1.018
STEAM TEMP. Deg C 353.9
STEAM FLOW TPH 108.4
TD BFP – Turbine Parameters

TD BFP
Numbers Nos 2x50%
Rated Capacity Cum/Hr 1150
Suction Pressure Kg/Cm2 12(a)
Discharge Pressure Kg/Cm2 250(a)
NPSH Required mlc 36
Pump Efficeincy % 82

TD BFP’s BOOSTER PUMP
Numbers Nos 2x50%
Rated Capacity Cum/Hr 1150
Suction Pressure Kg/Cm2(a) 0.8
Discharge Pressure Kg/Cm2 (a) 12
NPSH Required mlc 3.8
Pump Efficeincy % 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

MD BFP
MDBFP NOS 1X35%
Motor Capacity Kw 12000

THANK YOU

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