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Power house specifications & operations
 

Power house specifications & operations

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Working parameters ...

Working parameters
Specifications
Operation Parameters
Alarms and actions
Oil pumps and lines
Regulators and Valves
Ejectors
Air compressors
Pump house
Steam header
Feed water System
Operating Parameters
Fuel Gas path
Ash content vs fuel efficiency
Operating alarms
operating instruments on panel

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    Power house specifications & operations Power house specifications & operations Presentation Transcript

    • BPLBilt Power House
    • POWER HOUSE 46 Kg/ cm2 pressure and 35 TPH Babcock and wilcox spreader stoker BoilerX 1 NO85 Kg/ cm2 pressure and 35 TPH x 03 nos (IJT)TG Turbine 1 x 18 mw 46 Kg/ cm2 pressure and 25 TPH Heat recovery Boiler X 1 NO (JMW) BTH TURBINE 6.25 MW X 1 NO (BRITISH THOMSON HOUSTEN) 46 Kg/ cm2 pressure and 25 TPH Heat recovery Boiler X 1 NO (ABL)Ash handling plantCoal handling plant
    • BOILER SPECIFICATIONS BOILER PARAMETERSBoiler No. Unit 7 1 2 3 Boiler No. Units 7 s 1 2 3Type of Water Water Water Waterboiler Tube Tube Tube tubeMake B&W IJT IJT IJT Steam kg/cm2 46 85 85 85 pressureDesigned t/hr 35 35 35 35Capacity Steam ºC 404 490 490 490Designed % 78 81 81 81 temperatureefficiencyOperating t/hr 10 to 30 to 30 to 30 toCapacity 35 40 40 40 Blow down % 4-5 5-6 5-6 5-6Operating % 75-77 77 to 77to 77 toefficiency 80 80 80 % Pollution (ESP, ESP ESP ESP ESPFuel used coal coal coal Coal control cyclone) device used
    • COAL HANDLING LAY OUT TRF/GB Make : Capacity, tons /hr 80/40 1.FEEDING SCREEN 2.VIBRATOR 3.COAL CRUSHER OR GRANULATOR (HAMMER TYPE) 4.CONVEYER BELTS 5.ROLLERS 6.COAL BUNKER Details of belt conveyor: Belt conveyer 1 [ 800 x 34, 263 long ] Belt conveyer 2 [ 600 x 14, 362 long ] Belt conveyer 3 [ 600 x 126,267 long] Belt conveyer 4 [ 600 x 21, 168 long ] Belt conveyer 5a & 5b [ 800 x 32, 500 long ] Vibrating feeder [ 915 wide x 1500 long ]Coal size ¾ inches ( 15 – 20 mm ) Grade of coal B Calorific value of coal 4500- 5000 kcal/kg
    • 1 Type: V1000 TRF COAL HANDLING LAY OUT m coalCoal charge crusher 2Type: 7 sfm 800x800x450 3 5A 4 me 1- gear ratio : 30:15B 2- : 30:1 ELECON 3- :20 :1 4- :20:1 crusher crusher 5a : :30:1 5b : :30:1 OPP
    • FLUE GAS PATH HP BOILER SECONDARY AIRBOILER 1 ST CYCLON 2 ND CYCLON 3RD CYCLON TO GRATE HOT AIR OUT AIR PRE ESP ECONOMISER HEATER FD AIR SCREW CONVEYERS TO SUBMURGED ASH BELT
    • FLUE GAS PATH MP BOILER econ GRN ESPID 90 KW ID 200 KW
    • WORKING OF ESPThe flue gas laden with fly ash is sent through pipes having negativelycharged plates which give the particles a negative charge. The particlesare then routed past positively charged plates, or grounded plates,which attract the now negatively-charged ash particles. The particlesstick to the positive plates until they are collected. The air that leavesthe plates is then clean from harmful pollutants. Just as the spoonpicked the salt and pepper up from the surface they were on, theelectrostatic precipitator extracts the pollutants out of the air.
    • ASH HANDLING LAY OUT ASH HANDLING PLANT Impact rollers MAIN EQUIPMENTS: plain rollers 1.ASH BELT CONVEYER Scrapper 2.SUBMERGE BELTS Skirting 3.SCREW CONVEYERS (SMALL AND LONG) 4.ASH HOPPERS 5.RIDDLING HOPPERS 6. ROLLERS To main ash Hooper SB1 SB3 SB3 ABC 3 ABC 1Plain return ABC 3 BYPASS Carrying idler Impact Carrying idler Return Trough
    • ASH HANDLING LAY OUT BL 7 ESP HB SB RAH FAH ECO APH ESP ESPAPH
    • ASH HANDLING PRE CAUTIONSIf inclined belt trips, Horizontal and submerged belt will automatically stopsOPP Submerged belt bypass : Trolley is used to transfer ash when it is bypassed.Inclined belt : Bypass ABC 3 with in 3-5 minutesHorizontal belt : ESP Hooper bypassNPP Submerged belt has two bypass.ABC 3 bypass PCSPull cord switch ZSS BSS ( Belt 1,Belt 2, Belt 3 (ABC 3by pass) ,horizontal belt, Inclined belt, submerged belts (3 in NPP and 1 in OPP). Only horizontal belt in OPP is having chain drive.
    • PDM DEAERATOR OT Suction TO HP BOILERS TO ABL BOILERS DARE. ABL Suction ABL EFP1 85 KG ABL FP EFP2 STEAM STEAM FP FPABLdeae. pump LAY OUT FEED WATER (HP) SYSTEM
    • FEED PUMP SPECIFICATIONS ABL 85 KG ELECT ELECT ABL FP STEAM SFP FP 1 FP 2 FPMAKE KSB MATH & MATH & MATH & KSB NEW POWER PLANT PLATT PLATT PLATTTYPE HAD 4/6 BFO 4/6 BFO 4/6 BFO HAD 50/15 50/15 9 CHR 9 CHR 9 CHRFLOW 25.3 145 145 145 25.3HEAD 747MLC 1068 M 1068 M 1068 M 747 MLCRPM 2960 2980 2980 2980 2950KW/HP ------- ------- 700/938 700/938 100/134
    • Cond. From plant Over head Prv outlet tank Prv outlet Prv outlet Deaerator Vent Vent Cond tank ST 3 KG Exh M ST Exh suction MAIN DIRECT 46 KG BL 7 FEED PUMP LINES
    • BL 7 FEED PUMP AREA PRE CAUTIONSCondensate pump running indication by bulbs.ABL feed pumps running indication by bulbs.Inside feed pump attendants room electric feed pump running indication bulbOT Level 10.5 feet indication bulbOCT and NCT Level gauges (OCT-0-50-100 %=0-0.25-0.50 LEVEL), (NCT-0-50-100 % = 0-0.20-0.4 LEVEL) Inform DM plant if OCT level falls below 20 %)OT level graphical indication alsoAlarm will ring when any of the above condition is not satisfied.Electric feed pump Amps above 370 Amps (OL on 380), Immediately steamfeed pump to be taken in service. Or if demand is more, inform NPP to startsupply from their end for ABL boiler in case BL 7 is running.If any pump stops or trips immediately standby pump to be started.
    • BL 7 FEED PUMP AREA PRE CAUTIONSDeaerator bypass system always in lineBalancing pressure should be within operating range to maintain the thrustclearanceThere are 2 supplies for ABL/Condensate / Deaerator pump viz. BTH / TGIncase 2nd extraction pressure is more in BTH , Steam pump extraction line valverequired to be operate if instructed from BTHGland cooling line is to be continuously observed, There are two valves which areof 55 & 150 hp , and if this is not available third one which comes from emergencytank , valve to be openedWhen JMW & BL 7 are in operation, ABL boiler feed water supply to be stoppedand ABL condensate pump to be started. (Valve near ABL boiler stairs entry). If onlyJMW boiler is running feed water supply is from BL 7 feed pump.JMW boiler feed water heater out temperature 130 deg. Cel. Maximum and steamoutlet temperature 405 deg. Cel. Maximum (Runs max 450 deg. Cel. )No steam / water valve should be opened till the written memo is received andphysical check for drain, or isolation is confirmed
    • BL 7 FEED PUMP LINES TI TO STEAM DRUM ECO OUT RTDECO IN MAIN Direct
    • JMW FEED WATER LINES To Boiler DrumEco in 3 kg steam Direct Feed water heater Main Condensate to NCT
    • Sr no Parameter OV Alarm Trip FEED PUMP FEED PUMP OPERATING PARAMETERSMake: M&P 1 Condensate pump load 30-32 A 2 Deaerator water temperature 105Type: V.G PLUROVANE 3 Deaerator pump load 15-17 AHead : 1980 ft. (600 m) 4 Deaerator discharge pressure 2-2.5Size : 6” x 4” 5 Electric feed pump load 350 370 380Discharge : 349 GPM 6 Suction pressure 1.5-2 92 M3/HR 7 Discharge pressure 58-60Motor : 322 HP 430 KW 8 Balancing pressure 3 6RPM : 9 Oil levelSP 1 : 3850 10 Overhead tank level ABOVE 10.5SP 2 : 3740 10.5 FTEFP : 2960 11 OCT LEVEL Above 30 % 30 % Below 20% 12 NCT Level Above 50 % 50 % Below 40 %
    • CONDENSATE TANKS AND PDM TG condensate goes to PDM tank and from PDM tank to HP deaeratorBTH turbine,PM4, SPL machine condensate to NCT, then it is pumped to DMplant for polishing, back to PDM tankRemaining condensate from clo2,PM1,PM2,Pulp mill, S/R plant, chemical housecomes in OCTFrom OCT it is pumped to Overhead feed tank of Boiler no 7 and other pump forABL overhead tankOCT & NCT are inter connected ,OCT being on height than NCT. Level is maintained by DM plant, still if OCT level drops to 25 – 20 % verbally tobe inform to DM plant SE.Hydrazine + Ammonia –LP Dosing & Nalcol 2518 + Caustic – HP DosingPOLISHING: NCT Charcoal filter Iron filter DM tankPDM PUMPTotal head:45 m PDM Tank Secondary mixed bedFlow : 416.7 lps BEFORE START UP OF BL 7, DM PLANT TO BE IMFORMED
    • 85/46 STEAM HEADER Attempt. Line Range v/v BL2 Range v/v BL 3 85 kg st pump Range v/v BL1 TO TG pg 85/46Condensate tank pump ( 1 and 3) and 2 46 KG HEADER 46 kg to TG EjectorRaw water pump 1 and 3 To ABL st pumpType: 4 U P3 (Double extraction)Size : 150 x 100Capacity : 40 lps (144 m3 / hr)Head : 40 mHP : 50RPM : 1450
    • 46/3 STEAM HEADER BTH TURBINE ABL 46 JMW 46 OLD 46 Steam feed pump46 KG/CM2 FROM 46/3 PRV85/46 PRV Location: JMW 46/17/7 BTH When condensate flow to TG condenser is less ,46/3 PRV is required to be charged. Control of opening of this valve is in TG Control room. It is assumed that steam flow from this line is 5 Tons Per Hour.
    • SOOTING JMW 46 HEADER 650/250/100 Blade coating Pulp mill46/17/7 17 7 From 10/7 TG Chem house 7/3 PRV Not in use BTH 7
    • PM1 , PM2 LINESSupplim. For PM1From BTH 7 / 3 PRV PM 1 Supplim PM 2 Supplim 3 kg PM1 PM2
    • OPP office10KG STEAM HEADER rail clo2 SM PULP MILL ABL PRV 10/7 10 KG TG LIME KLIN From 46/17/7 prv Dorr plant JMW APH 7 KG BTH
    • PMC4 3 KG NETWORK 85 KG SFP ABL PULP MILL DEAERATOR PM 4 DORR JMW FW HEATERCH DEAERATOR FP EXH LINE BTH 7 KG SM 10 KG CLO2 SR EVAP CLO2 SPL M/C
    • MP STEAM VALVE LOCATIONSSr. Customer Pr. LocationNo Kg/cm2.1 PM 5 10 Back side of CT2 STARCH MILL 10 Railway gate3 ABL 10 Railway gate4 PULP MILL 10 Behind TG room platform5 CLO2 10 Behind OPP Office6 PULP MILL 7 Wooden bridge Boiler & BTH7 CHEMICAL HOUSE 7 BTH header chain valve8 BLADE COATING 17 Wooden bridge Boiler & BTH9 FEED PUMP 46 ASH plant
    • LP STEAM VALVE LOCATIONSSr. Customer Pr. LocationNo. Kg/cm21 CHEMICAL HOUSE 3 Above MW section TR 18 (Toilet)2 PM 1 3 Platform in front of PM 13 PM2 3 Platform in front of PM 24 PM1 SUPPLM.VALVE 3 BTH house5 PM2 SUPPLM.VALVE 3 In front of BTH between 2 tanks6 S/R EVAPORATOR 3 Near 46/3 PRV STAIRS7 PM 5 / 6 / 7 3 Above BL 7 Control room8 PM4 3 Near BL 1 FD fan area9 DORR PLANT 3 Near JMW ESP Stairs10 HP DEAERATOR 3 Hp deaerator11 ABL DEAERATOR 3 ABL deaerator12 BL 7 DEAERATOR 3 BL 7 feed pump area13 PULP MILL 3 Rail gate + 46/10 PRV14 MC NO 4 3 From BTH also15 CLO2 3 Above BL 7 Control room
    • BOILER NO 7 FRONT AND REAR TUBES GOES TO STEAM DRUM RIGHT & LEFT END TUBES FORM HEADER ,THEN GOES TO STEAM DRUM RIGHT COAL FEEDER SIDE FRONTREAR LEFT
    • BL NO 7 WATER WALLSREAR ENDLEFT END RIGHT ENDFRONT END
    • BOILER NO 7,8 MOUNTINGS AND FITTINGSDrum safety valvesSH stop valveSH safety valveDrum gauge glassRange valveBlow down valve (04 + 02) RGGEconomizer safety valveSteam flow meterWater flow meterHi and LO Whistle DOSING
    • COOLING TOWERSMAKE : PAHARPUR COOLING TOWERS (Induced draft )BTH TGTotal fans :9 nos Fans : 02 nosCurrent : 36 amps Current : Fan 1 VFD 45 ampsCirculation rate: 2900 m3/hr Fan 2 65 ampsEvaporation lass : 16 m3/hr Circulation rate : 3200 m3/hr Evaporation loss: 32 m3/hr.TUBE WELL SUPPLY: 3,4,8,16,20,22. 10,12,14,15,17 18,19 1,21CHEMICALS USED:H2SO4 - PH CONTROL 70022718: 75007000: CHLORINE
    • 150 HP PUMP HOUSE NOT IN USEPump 1 current: 25 A OLD PH PULP MILLVFD 40 HZ PM 4 & OLD PH 5 4 3 2 1 TANK LEVEL 12 FEET SCALE READING -------FEET EMPTY TO HYDRANT TUBE WELL LINES: 3,4,8,16,20,22. 10,12,14,15,17 18,19 1,21
    • 150 HP PUMP HOUSE ELECTRICAL SUPPLY PUMP NO 1 IS HAVING VFD.PUMP NO 2 IS HAVING COS FROM DB2 (BTH AND TG).PUMP NO 3 IS HAVING BTH SUPPLYPUMP NO 4 AND 5 HAS COS FROM DB2.FROM 150 HP PUMP HOUSE COS DB2 AND COS DB1 SUPPLY IS GIVEN.PUMP NO 1 RUNS NORMALLY IN 150 HP PUMP HOUSEPUMP NO 4 – HYDRANT
    • 55 HP PUMP HOUSE NOT IN USEMC 1,4 NOT IN USE COATING PLANT NOT IN USE Pump 5 current: 82-84 A 1 2 4 5 TANK LEVEL 5 FEET SCALE READING -------FEET FULL MC 1,4 / DM/ DORR/ SR/ PH/ CH/ NPPTUBE WELL LINES: 3,4,8,16,20,22. 10,12,14,15,17 18,19 1,21
    • FROM SPL PUMP 55 HP PUMP HOUSE DM PLANT TUBE WELL NO 6 / 9 CONNECTION 55 PMC 1 , 2 EMERGENCYFROM SPLITY PUMP HOUSE GLAND FILLING TANK BTH SUMP BFW PUMPS GLAND DORR / SR/NPP BFW PUMPS GLAND BTH OIL / AIR COOLER SR/NPP BTH DRINKING/WASHING CH
    • 55 HP PUMP HOUSE ELECTRICAL SUPPLY PUMP NO 5 IS HAVING VFD.SUPPLY FROM PANEL NO 2DB1 SUPPLY TO TUBE WELL NO 1 AND 2 ,AND TO SERVICE PUMP NO 4.COS IS FOR ABOVE. (Main supply from 150 HP pump house)SUPPLY FOR PUMP NO 1 FROM PANEL NO 1.COS FOR DB2 IS FOR SERVICE PUMP NO 1 , 2 , AND 5.PUMP NO 5 RUNS NORMALLY.
    • FIRE PUMP DETAILSAt four location Fire pump stations are available Main fire pump house at S/R area (4 Pumps)At ETP (2 Pumps, One electric driven and other Diesel 12 cyl driven )At Yard sump Electric pumpAt 150 HP pump house , pump no 4.From main fire pump house, pump no 4 runs normallyYard fire pump some times used when sump level to be make upAll three supply available
    • FIRE PUMP DETAILSFire hydrant circuit 1 (cooling pond) Pump 2Pump 1 (Pump no 3) Make Mather and greevesMake : Mather and Platt Type: 8/8 MHLType : 7.2 ST MEDI Capacity: 1500 gpmCapacity: 1000 gpm Head : 290 ftHead : 290 ft HP : 200 RPM: 1450HP : 190 RPM : 1450 Pump 2B (ETP) Diesel engine driven pump : Make : Kirloskar 8/8 MHL Mather and platt Type: SVA 8 Capacity : 1500 gpm Size: 8 x 8 Head : 290 ft Capacity : 1400 gpm RPM : 1450 Head : 225 ft Diesel engine make: MWM HP : 200 RPM : 1450 Type: TD – 237 – VIZFire hydrant circuit 3 ( Chipper yard) BHP : 200Pump no 3: RPM : 1500Make : Mather and PlattCapacity : 1500 gpmHead : 290 ftHP : 200 RPM : 1440Reservoir capacity : 2 lacs gallon
    • FIRE PUMP HOUSESometimes pump no 2 is started for CH increased consumption 1 2 4 3 66 A / 2.5 K/c2
    • SPECIALITY PUMP HOUSE DETAILS 250 M3/HR 4 K/C2 TW NO 9 / 6 85 A COATING PLANT NEW POWER HOUSE AIR COMPRESSOR M3/HR 55/ 150 LINE 2-2.5 K/C2 65-70 A PULP MILL SHUT 1 RUNNING 1 RUNNINGTUBE WELL LINES: 3,4,8,16,20,22. 10,12,14,15,17 18,19 1,21
    • AIR COMPRESSORS Air compressors in power house are situated as follows Motor load: 230-250 A1) 2 nos at old power plant2) 2 nos at new power plant3) 4 nos at specialty machine area cooler 2.5 kg/cm2 Air comp no 2,6,4,5 PROCESS cooler Coating plant 5 kg/cm2AD AD cooler 5 kg/cm2 Pulp mill , spl machines , RECIEVER Clo2 plant, power house TANK cooler
    • AIR COMPRESSORSNPP : KG KHOSLA MAKE SPL : KG KHOSLA MAKE Double stage Double stage 3H Y2TCER Air comp no 4,5,6 RPM : 650 RPM : 800 Pr. : 7 kg/cm2 Pr. : 7 kg/cm2 Cap : 5.89 m3/min Cap : 51.41 m3/min Pr 1 st stage : 2 kg/cm2 Pr 1 st stage : 2 kg/cm2 pr 2 nd stage : 5.5 kg/cm2 pr 2 nd stage : 5.5 kg/cm2 oil pr. : 2.5 kg/cm2 oil pr. : 2.5 kg/cm2 SPL : KG KHOSLA MAKE Single stage Air comp no 2 RPM : 560 Pr. : 7 kg/cm2 Cap : 11.01 m3/min oil pr. : 2.5 kg/cm2
    • AIR COMPRESSORS PRE CAUTIONS Air is distributed from new power plant air compressors to POWER HOUSE Air compressors in Old Power House are standby.In case of air pressure drop or compressor trip, SPL pump house air compressorvalve can be opened which is at NPP electrical panel room.Also one line from S/R plant air compressors is available for the same purposebut it is rarely used.Air compressors in Old Power Plant can be started in emergencies, can be put inAuto mode .One will be Auto and other will be stand by.
    • TUBE WELL NETWORKINSIDE 1,2,6,7,9,10,12,14,15,17,21 OUT SIDE 3,4,8,16,20,22 TUBE WELL LOCATION SUPPLY CHANGE OVER NO 1 CHAIR REPAIR WORK SHOP 55 HP PUMP HOUSE 2 COATING PLANT (BEHIND 55 HP PUMP HOUSE) 55 HP PUMP HOUSE 3 TI CLUB NEAR TUBE WELL 8 4 RAMLEELA STAGE NEAR TUBE WELL 8 5 DOES NOT EXSISTS ------- 6 BEHIND DM PLANT SAME LOCATION 7 DISPENSARY NO 5 NEAR TUBE WELL 8 8 TR BUILDING NEAR TEMPLE NEAR TUBE WELL 8 9 GHEE PLANT FROM BOILER HOUSE DB 10 GATE NO 9 NEAR TUBE WELL 10 PUNJAB 18,19 11 DOES NOT EXSISTS ------- 12 ETP MACHINE NO 5 / 7 13 DOES NOT EXSISTS ------- 14 200 QTR NEW GATE SAME LOCATION 15 GATE NO 8 NEAR TUBE WELL 10 16 CHUNA BHATTI NEAR DR BUILDING 17 NANGAL POWER HOUSE 18 PUNJAB MILL NANGAL NO CCHANGE OVER 19 PUNJAB MILL NANGAL NO CHANGE OVER 20 TR BUILDING GROUND NEAR TUBE WELL 8 21 NEAR TRAFFIC DEPT. Location 22 DR BUILDING OLD NEAR DR BUILDING