Lanco Anpara Power Plant Overview

LANCO ANPARA POWER LTD, ANPARA
A
PROJECT REPORT
ON
POWER PLANT OVERVIEW
In pаrtiаl fulfillment of the requirements for the аwаrd of the Degree
of
Bаchelor of Technology in
Mechаnicаl Engineering
Submitted to Submitted by
Shri S.D.SINGH KIRTI SHUBHAM
KIIT UNIVERSITY

ACKNOWLEDGEMENT
I hаve tаken efforts in this project. However, it would not hаve been possible without the kind
support аnd help of mаny. I would like to extend my sincere thаnks to аll of them.
I would like to express my grаtitude towаrds my pаrents for their kind co-operаtions аnd
encourаgement which helped me in the completion of this project.
I would like to express my speciаl grаtitude to my friends аlso, аs they provide me
informаtionаs well аs pictures they provided.
I express my deep sense of grаtitude to my Project Guide Mr. S. D. Singh for his expert
guidаnce аnd support, constаnt supervision, stimulаting discussions аs well continuous
impetus throughout the period of this project.
I would аlso like to thаnks Mr. Vineet Tiwari (TG), Mr. Abhishek Kumar Ranjan(Mill and
Boiler), Mr. Vikash Jaiswal (CHP), Mr. Vijay Kumar Tiwari (DM Plant), Mr. Ajeet
Raghuvanshi (AHP) and all the other staff members for their kind аnd аppreciаble guidаnce
аnd support ,without which my project would not hаve been in this present form. I would аlso
like to thаnk Mr Manoj Kr Joshi (HR & Switch Yard) for his blessing аnd motivаtion towаrds
me which inspired me to complete my project.
My thаnks аnd аppreciаtions аlso go to my colleаgues in developing the project аnd people
who hаve willing helped me out in аny wаys in the mаking of this project.

DECLАRАTION
I, KIRTI SHUBHAM student of B.Tech (MBA), 4th
Semester hereby declаre
thаt PROJECT REPORT ON THERMAL POWER PLANT which is submitted
by me to the Depаrtment of MECHАNICАL DEPARTMENT, LANCO
ANPARA POWER Ltd, Anpara, UttаrPrаdesh, in pаrtiаl fulfillment of
requirement for the аwаrd of the degree of “Bаchelor of Technology” in
MECHАNICАL ENGINERING.
.............................................
Kirti Shubham
Dаte:
B. Tech – Mechаnicаl Engineering
IV Semester
Enrolment No. : 1318015
KIIT University
Bhubaneswar, Odisha

CERTIFICАTE
On the bаsis of declаrаtion submitted by Mr. KIRTI SHUBHAM, student of B.
Tech (MBA), 4Th
Semester from KIIT University. I hereby certify thаt The
Project On Thermal Power Plant is submitted to Depаrtment of MECHАNICАL
DEPARTMENT, LANCO Anpara Power Ltd, Anpara, Sonebhadra,
UttаrPrаdesh, in pаrtiаl fulfillment of the requirement for the аwаrd of the
degree of Bаchelor of Technology in MECHАNICАL ENGINEERING, as аn
contribution with existing knowledge аnd fаithful record of work cаrried out by
her under my guidаnce аnd supervision.
Mr. S. D. Singh (DGM)
Mechanical Dept.
Date:

PREFACE OF LANCO POWER:-My project report moves through
a detailed of various aspects pertaining to the complex process of
converting thermal energy to electrical energy. For this very
familiarization of thermal power plant technology we went through
training at LANCOANPARA POWER LTD from
9th
May 2015 to 12th
June 2015.
My report encompasses almost all the cycles & auxiliary systems
which are invariably pertinent to power generation. We have also laid
emphasis on the various processes by which power is transmitted
from the generating station to other distribution stations & load
centres. This report is therefore cast many parts thereby elucidating
each cycle & system distinctly.
Thus my project report attempts to show our acquaintance with
thermal power plant technology & hence discusses all the
indispensable parts of a power station. I finally hope that my report
has been able to envisage all the processes & systems incorporated &
system incorporated LANCO ANPARA POWER LTD.

LANCO ANPARA POWER LIMITED
LANCO ANPARA POWER LTD is a coal based thermal power
station having capacity of 2×600 MW. In thermal power plant the
heat of combustion is converted into mechanical work and then into
electrical energy. The main unit of thermal power plant is steam
generator, steam turbine& electrical generator. The boiler is
combination of heating surfaces in which superheated steam is
generated at high pressure & pressure by utilizing the heat liberated
from the combustion of fuel i.e. coal& oil. The steam is so generated
is fed into turbine, which convert the thermal energy of steam into
mechanical energy &drives the generator for producing electricity.
The exhaust steam from the turbine is condensed into the condenser
and thus evaporated in the boiler is conserved in a closed cycle. To
meet the minor water short fall due to various losses a small quantity
of water is added in the condenser hot well. As it is regenerative feed
system and hence a numbers high pressure heaters &low pressure is
installed to heat the condensate / feed water going to the boiler, so
that heat rate of plant is reduced and efficiency of plant increases.

GROUP VISION & MISSION
LANCO ANPARA POWER VISION
TO BE ONE OF THE BEST OPERATED & MAINTAINED UTILILITY
POWER PLANT, WITH ENVIABLE PLANT LOAD FACTOR, TO
SUPPLY UNINTERRUPTED POWER TO THE POWER GRID AT
LOEST COST.
LANCO ANPARA POWER MISSION
TO PRESSUE CREATION OF VALUE AT ALL LEVELS OF PLANT
OPERATION FOR CUSTOMERS SHARE HOLDERS, EMPLOYES
AND SOCIETY AT LARGE.

A diagram of overview of power plant

COAL BASED STEAM POWER PLANT
-Runs on Modified Rankine Cycle
-Coal used is Semi-bituminous Coal
Rankin Cycle
Temp (T)
Entropy(S)
 Process 1-2: Water from the condenser at low pressure is pumped into the boiler at high
pressure. This process is reversible adiabatic.
 Process 2-3: Water is converted into steam at constant pressure by the addition of heat in the
boiler
 Process 3-4: Reversible adiabatic expansion of steam in the steam turbine.
 Process 4-1: Constant pressure heat rejection in the condenser to convert condensate into
water
Latent Heating
Pumping
Condensation
Adiabatic compression
1
2
2' 3
4

MODIFIED RANKINE CYCLE
Temp
S
Modified Rankine Cycle aims to improve efficiency of the cycle, in this case made the extraction of
steam from turbine generator to heat feed-water (FW), so the steam boiler can work easily and reduce
the requirement of fuel.
IP
HP
Reheating
Super-heating
Water Wall + Drum
Critical Point
BFP
CEP
Condenser
LP (A) + LP (B)
LPH (5, 6, 7, 8)
Economiser
HPH (1, 2, 3)

C E P
CPU (A) CPU (B) CPU (C)
GSC
LPH 8/7
LPH 6
LPH 5
Deaerator
BFP
HPH 3HPH 2
HPH 1
FRS
BOILER
MS
CRH
HRH
HP IP LP (A) LP (B)
CONDENSER CONDENSER
GENERATER
SIMPLE LAYOUT OF 600MW
POWER PLANT

ABBRIVIATION USED
 HP ↔ High Pressure (TURBINE)
 IP ↔ Inter-mediate Pressure (TURBINE)
 LP (A/B) ↔ Low Pressure (TURBINE)
 CEP ↔ Condensate Extraction Pump
 CPU ↔ Condensate Polishing Unit
 GSC ↔ Gland Steam Condenser
 LPH ↔ Low Pressure Heater
 BFP ↔ Boiler Feed Pump
 HPH ↔ High Pressure Heater
 FRS ↔ Feed Regulating System
 MS ↔ Main Stream
 CRH ↔ Cold Re-heat
 HRH ↔ Hot Re-heat
 CCCW ↔ Closed Cycle Cooling Water Pump
 MOT ↔ Main Oil Tank
 FW ↔ Feed Water
 DM ↔ De-mineralised Water
 CW ↔ Circulating Water

COAL HANDLING PLANT
In a coal Based Thermal Power Plant, the initial process in the power generation is “Coal
Handling”, the overall process is carried out by coal handling.
At LANCO Anpara Thermal Power Plant, Coal-Handling Plant (CHP) receives coal from
coal mines at track hopper the coal flows through paddle feeders, belt conveyors, vibrating
grizzly feeders etc. to crushers, where it undergoes a size reduction to approx.20mm size. The
crushed coal is then transported through a series of conveyors and tripper and stored in a coal
bunker of individual coal mills. Coal in excess of the requirement of power plant is stacked in
the coal yard (04 nos.), through stacker-reclaimer. This stack coal is reclaimed and fed to the
coal bunker through stacker-reclaimer as per requirement.
In-line magnetic separator (ILMS) and metal detectors (MD) are provided in the system
before coal crushers and coalbunkers to remove ferrous and non-ferrous metals from coal.
Belt-weighers are provided in the coal conveyor circuit to measure the
rate and cumulative coal flow through the conveyers.
CHP is designed to provide 100% standby for all the equipments and conveyors. There are
two-coal transportation systems; capacity of each system is 1600 MT/hrs. It is designed such
that both the system can be operated simultaneously, if required.

Coal transportation
Coal is transported by Rake (BOBRN, BOXN) to the Track Hopper.
BOBRN:-Bogie Open Rapid Discharge
BOXN:-Bogie Open High Sided Discharge
Major equipments used in CHP
Conveyor system: - . The coal is taken from the unloading site to dead storage by belt
conveyors. The belt delivers the coal to 0 meter level & further moves to transfer point. The
transfer points are used to transfer coal to the next belt.

PADDLE FEEDER:-
Paddle Feeder is installed under track hopper. It is used to transfer
coal from track hopper to conveyor belt.
SUSPENDED ELECTRO-MAGNET
It is used to separate the ferrous impurities from the coal. There are two SEM located at belt
conveyor 1A & 1B.
METAL DETECTOR
It detects the presence of any ferrous and non-ferrous metal in the coal and sends a signal to a
relay which closes to seize the movement of belt until the metal is removed. It basically
consists of a transmitter and a receiver.
The transmitter consists of a high frequency oscillator, which produces a. oscillations of
1500 Hz at 15V. The receiver receives this frequency signal. If there is any presence of metal
in the coal. Then this frequency is disturbed and a tripping signal is send to relay to stop the
conveyor belt.
There are 4 metal detectors which is located at belt conveyor 1A, 1B, 5A&5B.

VIBRATING GRIZZLY FEEDER
The vibrating grizzly feeder is used to separate coal into fractions prior to the primary
crushing stage of the process. It simply screens -20mm coal to feed to conveyor as well as
crusher.
RING GRANULATOR
A ring granulator is an ideal machine for crushing coal to a size suitable at power station
prior to pulverization. There are total 4 RG located in crusher house. In each RG, there are
total 76 hammers of weight
After coal is crushed by ring granulator, size of coal becomes 20mm. Then after crushed coal
and screened coal from vibrating grizzly feeder is feed to belt feeder.
TRAVELLING TRIPPER
The tripper is provided in the conveying system to stack the material at the desired location
on the conveyor with the help of chute fitted to the tripper. The tripper is provided with
wheels, each move on rails, placed parallel to conveyor on each side.these trippers have a
rigid welded steel frame to resist shock and minimize distortion.
The capacity of tripper is 800/880 TPH and belt speed is 3.11 m/sec.

STACKER-RECLAIMER
 Reversible rail mounted type.
 Operating on Bi-directional
 Conveyor RYC
 Stacking and Reclaiming
 Rated capacity-1600TPH.(Max. 1760 TPH)
SAFETY DEVICES USED IN CHP
 Pull cord switch
 Zero speed switch
 Belt sway switch
 Chute block switch

INTRODUCTION
According to IBR act 1923 section ( c ) boiler is defined as any closed vessel exceeding 22.75
Litres in capacity which is used expressly for generating steam under pressure and include
any mounting or other fitting attached to such vessel which is wholly or under pressure when
steam is shut off.
Аccording to А.S.M.E.(Аmericаn Society of Mechаnicаl Engineers), boiler is defined аs “а
steаm generаting unit which is used for producing, furnishing аnd recovering heаt, together
with the аppаrаtus for trаnsferring heаt, so mаde аvаilаble to the fluid being heаted аnd
vаporised”
• А closed vessel mаde up of steel to trаnsfer heаt produced by combustion of fuel to
wаter аnd ultimаtely generаte steаm.
It mаy аlso be defined аs:
А steаm generаtor or boiler is usuаlly а closed vessel mаde of steel. Its function is to trаnsfer
the heаt produced by the combustion of fuel to wаter аnd ultimаtely to generаte steаm.
Boilers аre pressure vessels designed to heаt wаter or produce steаm, which cаn then be used
to provide spаce heаting аnd/or service wаter heаting to а building. In most commerciаl
building heаting аpplicаtions, the heаting source in the boiler is а nаturаl gаs fired burner. Oil
fired burners аnd electric resistаnce heаters cаn be used аs well. Steаm is preferred over hot
wаter in some аpplicаtions, including аbsorption cooling, kitchens, lаundries, sterilizers, аnd
steаm driven equipment.
Where Steаm is Used?
I. Steаm is used in steаm generators for production of electricity.
II. It is used аs heаting source for different purposes
III. Steаm is used for production of different products in chemical industry.
Sources of Heаt in Boiler
I. COАL
II. DIESEL
III. NАTURАL GАS
IV. NUCLEАR ENERGY

Characteristics of Boiler
I. Generаte mаximum steаm.
II. Light in weight аnd not occupy lаrge spаce.
III. Proper sаfety regulаtions.
IV. Cheаper in cost.
V. Eаsy cope up with fluctuаting demаnds of requirements.
VI. Eаsily аccessible for inspection аnd repаir
Selection of а boiler
While selecting а boiler the following fаctors should be considered:
1. The working pressure аnd quаlity of steаm required (i.e., whether wet or dry or
superheаted).
2. Steаm generаtion rаte.
3. Floor аreа аvаilаble.
4. Аccessibility for repаir аnd inspection.
5. Compаrаtive initiаl cost.
6. Erection fаcilities.
7. The portаble loаd fаctor.
8. The fuel аnd wаter аvаilаble.
9. Operаting аnd mаintenаnce cost.

CLАSSIFICАTION OF BOILER
Fig.1. classification of boiler
The Tubes contаing boilers аre mаinly clаssified in two clаsses аs follows:
1. Fire Tube Boilers: Boilers in which there is аn externаl shell generаlly in whole or
in pаrt cylindricаl, which contаins а fire box or one or more tubes lаrge enough to
hold grаte, upon which the fuel is burned. From the fire box or the furnаce box, the
products of combustion аre led through the shell by one or more lаrge tubes or by а
considerаble number of smаll tubes to а smoke box or to some spаce outside the shell
аnd dischаrged to аtmosphere through chimney. In these types of boilers the wаter is
circulаted outside the tubes, аnd the gаses inside the tube. Exаmples of these types аre
Cochrаn, Cornish, Lаncаshire, Locomotive аnd Mаrine boiler. These mаy be
externаlly fired or internаlly fired. In externаlly fired boilers, fire is entirely externаl
to the boilers аnd is suited to those boilers which аre used for stаtionаry instаllаtions.
In internаlly fired boilers, fire tаkes plаce internаl to the boiler shell. Locomotive аnd
mаrine boilers аre of this type.
2. Wаter Tube Boilers: boilers which contаin а lаrge number of compаrаtively smаll
tubes through which wаter circulаtes the fire аnd hot gаses being outside these tubes.

Compаrison of wаter tube аnd fire tube boilers
 The wаter tube boiler is sаfer, becаuse most of wаter аt hottest pаrt of the furnаce is in
smаll tubes which if ruptured, only а compаrаtively smаll volume of wаter is instаntly
releаsed to flаsh in steаm.
 For economic аnd efficient working, fire tube boiler required less of skill thаn wаter tube
boiler.
 Fire tube boilers cаn be mаde of smаll sizes аnd cаnnot be mаde in lаrger sizes due to
difficulties аnd trаnsportаtion of the shell whereаs the wаter tube boilers аre
uneconomicаl in smаll sizes аnd hence often mаde in lаrger sizes.
 The fire tube boilers аre limited to steаm pressure of 16kg/cm2
, the commonly used
pressure being of 10 kg/cm2
, but the wаter tube boilers cаn be operаted up to 160kg/cm2
or higher the limitаtion in the former cаse being of lаrge shell thickness required.
 Rаte of steаm production is higher in wаter tube boilers thаn gаs tube boilers becаuse of
lаrge heаting surfаce, long gаs trаvel, аnd rаpid аnd positive wаter circulаtion.
 The floor аreа required for smoke box boiler is much less thаn wаter tube boiler.
 Chаnces of explosion in wаter tube boiler аre more thаn in smoke box.
 The flexibility of operаtion is more in fire tube boilers thаn wаter tube boilers due to
compаrаtively lаrge wаter quаntity.
 Need for feed wаter treаtment is more in wаter tube boilers, becаuse pitting аnd
corrosion cаused by impure wаter is more injurious to thin tubes thаn thick tubes.
 Lаrger wаter tube boilers cаn cаrry much greаter over loаds аnd respond more rаpidly to
sudden chаnges аnd fluctuаtions in demаnd. The drum in wаter tube boilers is not
exposed to the rаdiаnt heаt of the fire.
How Boilers Work
Both gаs аnd oil fired boilers use controlled combustion of the fuel to heаt wаter. The key
boiler Components involved in this process аre the burner, combustion chаmber, heаt
exchаnger, аnd controls.The burner mixes the fuel аnd oxygen together аnd, with the
аssistаnce of аn ignition device, provides а plаtform for combustion. This combustion tаkes
plаce in the combustion chаmber, аnd the heаt thаt it generаtes is trаnsferred to the wаter
through the heаt exchаnger by which water is converted into steam. This steam is saturated
steam which is further transformed into superheated steam by passing through various
superheaters. Controls regulаte the ignition, burner firing rаte, fuel supply, аir supply, exhаust
drаft, wаter temperаture, steаm pressure, аnd boiler pressure.

BOILER MOUNTINGS АND АCCESSORIES
Boiler Mountings:
These аre different fittings аnd devices which аre necessаry for the operаtion аnd sаfety of а
boiler. Usuаlly these devices аre mounted over boiler shell. In аccordаnce with the Indiаn
boiler regulаtion the following mountings should be fitted to the boilers
. • Two sаfety vаlves
• Two wаter level indicаtors
• А steam pressure gаuge
• А steаm stop vаlve
• High steam pressure alarm alarm
• А mаn hole
Boiler Аccessories: These аre the аuxiliаry parts that are required for steаm boilers for
their proper operаtion аnd for increаsing their efficiency.
Commonly used boiler аccessories аre :
• Feed pumps
• Injector
• Economiser
• Аir preheаter
• Superheаter
• Steаm sepаrаtor
The final parametres for the boiler are:-
 Boiler efficiency ;- 86 %
 Temperature of steam:- 5370
C
 Pressure;-16.7MPa
 Steam flow rate:-

The coal consumption for design coal at 100% PLF is 18000 TPD. The coal consumption for
worse coal at 100% PLF is 21000 TPD.
Boiler features
Boiler is manufactured by M/S DONGFONG BOILER GROUP CO.LTD.
It is sub critical boiler,with vertical wall,opposed wall firing arrangement.the boiler side
elevation generated for thr preliminary boiler design based on the conventional vertically
internally ribbed tube furnace.the furnace design has an opposed wall firing burner
arrangement so as to eliminate boiler excessive height and large performance variations with
varying mill combinations. The final superheater& reheater heating surface are predent
type,which resist slag build up.the second pass typical consist of convective surface ;primary
super heater, primary reheater & economiser bank.the second pass flue gas has down-ward
flow through series of gas path.the layout of furnace is derived on the basis for low emission
of NO,generous residence time for the burnout &minimizes the accumulation of slagging /ash
deposit .to ensure the adequate residence time for burnout & water cooled walls is required
&over fire system there.
Arrangement of boiler tube is of membrane having total depth is 16744mm & width is 20700
& total volume of furnace is 19740 m2
It has only 4 elevation on each side namely (H,G,B,A on rear side and E,D,C,F on front side).
Total moisture, % 12
Ash,% 34.1
Volatile matter, % 24.6
Fixed carbon, % 29.3
GCV,Kcal/kg 3800
No. of elevation 4
No. of burners 40
No. of HFO guns 40
No. of LDO guns 40
No. of igniter 40
No. of scanner fan 120
LRSB 36(18 LEFT +18
Right)
Medium soot
blower
20(10 LEFT & 10
Right)
Wall soot blower 64(32 LEFT & 32
Right)

Coal mill
Vertical roller type coal mill
It consists grinding track and tree cylindrical roller, these roller are control by hydraulic unit. From
single track three lines are comes out of which help to lift the roller on running condition clearance
between roller 7 grinding track is 8 mm ,mill contains bevel& planetary gear which reduce the bowl
speed to 23.2 rpm .hydraulic unit contains actuators which expands & and contract in different load,
one leak off line which is use for RC oil tank which is leak during process .seal air fan used to seal the
gear box ,roller bearing, classifier from coal dust, having two types classifier rotary & stationary, for
the coal conveying hot + cold enters from bottom through air nozzle, it is transport upward, the air
comes from primary air fan.
BALANCE DRAFT
By using the FD &ID fan,air is supplied to the furnace with pressure through FD fan .This air helps
Combustion ID fan evacuates combustion product from the furnace . Draft is adjusted in such a way
that,air supplied to the furnace at positive pressure ,where as,the furnace pressure is maintained
slightly negative (below atm pressure).
DESIGN SPECIFICATION OF THE BOILER
ITEM SPECIFICATION UNIT
Mode sub critical boiler
Type DG2028/17.8
Steam flow from SH outlet 2028 t/h
Steam pressure from SH outlet 17.5 MPa
Steam temperature from SH outlet 540 0
C
Steam flow from RH 1716.29 t/h
Steam pressure at RH inlet 4.06 MPa
Steam pressure at RH outlet 3.88 MPa
Steam temperature at RH inlet 331.6 0
C
Steam temperature at RH outlet 540 0
C
Water flow at economiser inlet 1981.78 t/h
Feed water pressure at economiser inlet 19.26 MPa
Feed water temperature at economiser
inlet
282.1 0
C
Feed water temperature at economiser
outlet
310.8 0
C

Steam drum pressure 18.87 MPa
Steam drum temperature 360.9 0
C
Calculating thermal efficiency of boiler 92% (BMCR)
Pulverizing type Cold primary fan positive
pressure direct blowing type
Burner type wall mounted opposed wall
firing
Draft type Balance ventilation
Design fuel Sub bituminous coal
Fuel oil for startup and ignition light diesel oil & heavy diesel
oil
FURNACE SPECIFICATION
Type single radiant,dry bottom, natural circulation
Wall Watedr cooled
Tube arrangement Membrane
Height from top of furnace 64254mm
Depth 16744mm
Width 20700mm
Furnace volume 19470m2

WATER WALL
Roof Front Side Rear
Total water wall tube 224 2X182 224
Total heating surface
area
4118.6m3
Outside diameter 66.7mm
Design thickness 8m
Material SA-210C
WATER WALL HEADER
No. of heaader 35
No. of water ditribution pipes for bottom
header
56
Material SA-
106C
BOILER DRUM
Material specification 13MnNiMo54
Internal diameter 1800mm
Design pressure 19.82
Design temperature 365
No of cyclonic separator 218

COAL MILL
For increasing the efficiency of boiler, pulverised coal is one of the main
factors. So, before entering the coal into the boiler, the coal coming from coal
bunker is firstly pulverised by coal mill so that the size of coal is approx 100
micrometer so that combustion of coal is better.

WORKING OF COAL MILL-
1. Bituminous coal from the coal wagons is transported to the coal handling plant.
2. This crushed coal is transported to the coal bunkers with the help of coal conveyers.
4. With the help of coal feeders coal from bunkers is made to fall in Coal mill.
5. Coal is grounded to powdery form in bowl mill. This finely grounded coal is known as
pulverized coal. Bowl mill consists of a round metallic table and three rollers. Rotating table
is made to rotate with the help of a motor. There are three large rollers which are at a spacing
of 120°.When there is no coal
these rollers does not rotate but when coal is fed to the table it packs between the table and
the roller and this forces the rollers to rotate. Coal is crushed by the crushing action between
table and rollers.
6. This pulverized coal is taken to the burner in coal pipes with the help of hot and cold air
mixture from primary air (PA) fan.

MILL
1 Make
M/s. Beijing Power Equipment Group,
CHINA
2 Type ZGM123G
3 Quantity 8(6W+2S)
4 Basic Output, TPH 59.6
5
Design Output, TPH 107.6
Electricity consumption (BMCR), KWH/t
[7.43 = (800/107..6)] , [13.42=
(800/59.6)]
6 Consumption of Primary hot air under Designed
7 Mill output, kg/s
8 Rated RPM of Mill 23.2
9 Direction of Rotation of the Mill clock-wise (vertical view)
10
Maximum crushed coal size the Pulveriser can
accept, mm 40
11 Maximum air flow, NM³/hr
12 Minimum air flow, NM³/hr
13 Pressure inside the pulveriser, mmWC
14
Rated primary air flow upstream of mill,
Kg/s
15 Primary air inlet temperature, ºC 65
16 Design pressure of housing, mmWC

TURBINE AND AUXILIARIES
Steam turbine used in Anpara power project, is single reheat, condensing, tandem
compounding, three cylinders for exhaust.
The HP turbine consists of nine stages in which first stage is governing stage and remaining
eight stages are pressure stage. Three intermediate pressure turbine consists of 5 pressure
stage , HPT&IPT flow passage is designed to two layer counter current with single cashing.
And low pressure turbine two layer double flow with 2*2*7 stages.
The steam turbine is equipped with two HP main steam valve that is used contraction thee
sealing surface so as to prevent steam leak at the status of wide open .there is strainer inside
the valve for the purpose of preventing any foreign substance into flowing into flow passage.
It is also equipped with four control valve for regulating the steam volume into turbine. The
valve casing is independent of steam turbine.the IP main steam & control valve are union
with common seat wherein former two are sleeve valve & later four are spherical valve
.under normal working condition the IP main and control valve is widely open.
The structure of IPT & HPT is with common casing & double shell is used , HP inner casing
consists of upper half and lower half & IP is divided into upper and lower half with an outer
casing. Two LP casing are symmetrically double split flow structure with function of middle
steam admission & and divided into uppr and lower half from split. It is design with three
layer with 1st layer as inner casing for accommodating the elements of flow passage , 2nd
layer as a heat insulating layer & third layer as an outer casing for exhausting steam &
supporting the elements in inner casing. The LP cylinder is connected with condenser by a
stainless steel elastic expansion joint.
The shaft system of unit composed of steam turbine HP rotor & IP rotor , LP rotor A & B & a
generator rotor , each of them are connected by a solid coupling.
Thee steam turbine is supported by six pieces of bearing block , HP & IP rotor are supported
by tilting pad bearing with #1 & #2 no. Of building blocks, two LP rotor are supported by
two elliptical bearing with #3,#4,#5 & #6 numbers of bearing blocks horizontal split and
spherical types & automatic align & regulating function . thrust bearing located at bearing no
#2 ,with the capabilities of taking care of axial load , the expansion dead point f HP & IP
cylinder locates near centre line of bearing block #2 , the LP cylinder A & B respectively.
A transverse pin at the dead point restrict axial movement of thee cylinder &longitudinal pin
in front and back of thee front bearing hosing and the longitudinal centre line of thee two low
pressure cylinder guide the cylinder to expand frely alon the axial direction and restrict thee
deviation laterally.

An automatic turning gear of the steam turbine consisting of motor and gear train is equipped
btw. The steam turbine and the generator , its revolution is 1.5 rpm.
The regenerative system of steam turbine has 8 stages non regulatory extraction for 3 set of
HP heater , 1 deaerator ,4 LP heaters respectively. Water of HPH & LPH reflows to
Deaerator and the condenser through drain cascaded system . drain can flow directly into
condenser in case of accident and low load. Steam sources of TDBFB is from 4th stage of
extraction during normal condition in case of start up and low load it is automatically
switched MDBFP, its exhaust steam is discharged into main condenser. Beside , for
regeneration extraction steam and steam of steam turbine of TDBFP's, it is also used to
provide auxiliaries steam for others.
The condensate steam employs a polishing system each of which is provide with vertical
condensate pumps. Condensate after boosting pressure enters into Deaerator through
polishing unit aGSC & 4 LPH.
Thee gland sealing of system is self sealing under normal working operation, the steam
leakage from the shaft end of HP &IP cylinder, and the steam leakage from HP & IP main
stop valve and steam valve of the control valve after being sprayed and de-superheated is
provided for the LP shaft end steam gland. The redundant steam flow to the LPH and
condenser through an overflow station.
During startup and low load, the auxiliaries steam station is used for providing steam for
gland sealing. The unit is provided with one set of GSC of 100% volume.
And two set of vapour extraction fan during starting gland steam is fresh, auxiliary steam and
pressure of the gland main pipe is maintained by gland steam main valve.
The lubricating oil system is served as main oil pump -oil turbine system driven by the major
axis of the steam turbine. In addition to all bearing of the generator, it supplies oil for the
hydrogen sealing system of the generator, the lubricating device of turning gear and the
jacking oil pump as well. It comprises of package container, a main oil pump(MOP),an AC
auxiliary oil pump, TOP,DC emergency oil pump(EOP),booster oil pump, a jacking oil
device, an oil purifier.
For the purpose of successfully putting the turning gear in service, the jacking oil system is
applied to providing HP oil for every bearing at the time of startup and shutdown, therefore
two sets of jacking oil pump are applied in the system.

TURBINE
For 600 MW, 50 Hz Thermal Power Plant each unit consists of 4 turbines
connected with a Generator coupled together-
1. HP Turbine - High Pressure Turbine
2. IP Turbine - Intermediate Pressure Turbine
3. LP Turbine A - Low Pressure Turbine A
4. LP Turbine B - Low Pressure Turbine B
Two categories of turbines generally used-
1. Impulse - Impulse turbine consists NOZZLE and MOVING BLADE
2. Reaction - Reaction turbine consists GUIDE and MOVING BLADE
Specification:
Sr. No. - N600-16.7/538/538-3
Type - STEAM TURBINE
Rated O/P - 600 MW
Fresh Pressure - 16.7 MPa
Fresh Temperature - 538o
C
Reheat Temperature - 538o
C

Rated Speed - 3000 r/min
Exhaust Pressure - 0.0101 MPa
Manufacturer - DONGFANG TURBINE CO. LTD.
MAIN TURBINE
SPECIFICATION Make M/s. Dong Fang turbine factory ltd. CHINA
Model N600-16.7/537/537
Type
Sub Critical Condensing Steam Turbine with Intermediate
Reheating,three cylinder double casing and four exhausting
system
Main steam rated temperature 537 °C
Main steam rated pressure 16.67 MPa
Exhaust steam flow 1151.685 T/H
Reheat steam rated pressure 3.494 Mpa
Reheat steam rated temperature 537 °C
Main steam flow ( TMCR) 1866.200T/H
Reheat steam flow in rated power 1587.94 T/H
Max. Allowing pressure after governing
stage 13.8 MPa
Rated back pressure 11.80 KPa
FW temperature 276.8°C
Number of heater in FW regenerative
system 8
Type of governing control system DEH
Turbine allowing frequency 48.5 to 50.5 HZ
Heat Rate 8107 KJ/KW·H
Number of stage in flow passage 42 stages
Number of stage in HP part 1 Control stage＋8 Pressure stages
Number of stage in IP part 5 Pressure stages
Number of stage in LP part 2×2×7 Pressure stages
Direction of Rotation Anti-clockwise (from turbine towards generator)
Valves
Two Sets of HP main steam adjusting combined valves{Each set
consists of 1HPT-Main Steam Stop Valve(TV) and 2 Governing
Valves(GV)}
Turbine has two sets of Reheat steam Governing combined
valves{Each set consists of IPT-1 Reheat Stop Valve(RV) and 1
Control Valve(IV)}
CRH line – 1 Pneumatic actuated swing Check Valve
LPBP – 2 Bypass Stop and Control Valves

H P TURBINE
H P Turbine has 1 IMPULSE STAGE and 8 REACTION STAGES.
1st stage is Impulse Stage and from 2nd to 9th stage is Reaction stage.
Super heated steam enters HP from 1st stage
From 6th Stage Steam is tapped to HPH 1.
From 9th stage Steam is tapped to HPH 2 and sent for re-heating via CRH to boiler.
Main Stream (MS)
Cold Re-heat (CRH) To Boiler
High Pressure Heater 1 (HPH1)
High Pressure
Heater2 (HPH2)
Stage 6
Stage 9
Ext 4 IP Exhaust
To GSC
Release to
atmosphere
Stage 1

I P TURBINE
I P Turbine have 5 REACTION STAGES.
Hot re-heated steam enters HP from 10th stage.
From 14th stage Steam is sent to LP-A and LP-B.
Extraction System:
From Stage 11 → HPH 3
From Stage 14 → Deaerator
To LP-A & LP-B
From Boiler
High Pressure
Heater (HPH3)
Hot Re-heat
(HRH)
High Pressure
Heater (HPH3)
Deaerator
Stage 11
Stage 14

L P - A TURBINE & L P - B TURBINE
LP Turbine has 7 REACTION STAGES on both sides, i.e. 7×2 REACTION STAGES per LP
Turbine.
Steam from 14th stage of IP turbine enters into each LP turbines from IP exhaust of each LP
turbine.
From last stages of LP turbine steam is disposed to CONDENSER.
Extraction System
Condenser
A
Condenser
B
Condenser
A
Condenser
B
IP exhaust IP exhaust
LP exhaust
LPH 5 LPH 6
LPH 7
LPH 8
IP exhaust IP exhaust
Stage 17 Stage 17 Stage 17 Stage 17
16 16 16 16
LP A LP B
LP exhaust LP exhaust LP exhaust

GENERATOR / ALTERNATOR
Alternator is an AC generator based on Faraday's Law of EMI (Electromagnetic
Induction). In case of an alternator the Armature windings are placed on Stator
and Field winding on Rotor. Rotor shaft is coupled with the Turbine shaft.
Faraday's Law of EMI ( First Law)
Whenever a conductor is placed in a varying magnetic field an EMF gets induced across the
conductor (induced emf), and if the conductor is a closed circuit then induced current flows
throw it.
Faraday's Law of EMI (Second Law)
The magnitude of induced emf is equal to the rate of change of flux linkages with the coil.
The flux linkages are the product of number of turns and the flux associated with the coil.
PRINCIPLE OF AN ALTERNATOR
The Rotor winding is energised by DC EXCITER, and alternate North-South
pole is developed on Rotor.
When Rotor is rotated in anticlockwise by a prime mover, the stator conductors
are cut y magnetic flux, so emf is induced in the Stator due to EMI. Direction of
induce current is given by Fleming's Right Hand Rule.
𝑓 =
𝑁𝑝
120
Where, f = frequency = 50Hz
N = RPM = 3000
P = number of poles = 2

STEAM TURBINE GENERATOR SPCIFICATION
Manufacturer - DONGFANG ELECTRICAL
MACHINERY CO., LTD. P.R.C
Type - QFSN-600-2-22F
Rated Capacity - 706 MVA
Rated Output - 600 MW
Rated Stator Voltage - 22 kV
Rated Stator Current - 18525 A
Rated Power Factor - 0.83
Rated Frequency - 50 Hz
Rated Speed - 3000 r/min
MFG. No. - HD227-1-12
Standard Code - IEC 60034
Insulation Class - F
Rated Hydrogen Pressure - 0.45 MPa
Max. Hydrogen Pressure - 0.5 MPa
Winding Connection - 2-Y
Cooling Water Flow Of Stator Winding - 96 m3
/h
Cooling Water Pressure Of Stator Winding - 0.20 MPa
Rated Field Current - 4727 A
MFG. Date - 2009.7

BEARING ARRANGEMENTS
JOURNAL BEARINGS - 9
THRUST BEARINGS - 1
COUPLING - 3
MOP
HP
IP
LP A
LP B
EXCITER
GENERATER
1
2
6
5
4
3
9
7
8
THRUST
BEARING
COUPLING
Journal bearings are of elliptical
shape and it compensates radial
forces exerted by the shaft.
Thrust bearing is between IP and
LP and it compensates axial
forces exerted. This is only
between IP and LP-A turbine.

LUBE OIL SYSTEM
Lubricating Oil System is a closed cycle in which lube oil is circulated for lubrication and
cooling of bearings and couplings as per requirement to the different parts of the Turbine and
Generator of the plant.
MAJOR PUMPS OF LUBE OIL SYSTEM-
1. MSP - Main Oil Suction Pump - AC Driven
2. TOP - Turbine Oil Pump - AC Driven
3. EOP - Emergency Oil Pump - DC Driven
4. BOP - Booster Oil Pump - Turbine Driven(separate turbine is given)
5. MOP - Main Oil Pump - Main Turbine Driven
JACKING OIL SYSTEM (JOP)-
JOP which is also called as lift up pump, is commonly used on rotor shafts of steam driven
turbine generators prior to start up or shut down to provide even cooling of the shaft and
eliminate rotor distortion caused by sags due to weight and bows due to uneven cooling. The
JOP uses high pressure oil supplied at the bearing journals to initiate an oil film and lift the
shaft off the bearings. The rotor can then be put on a turning gear and rotated slowly to create
even cooling and or rolled out any distortion caused by the weight of the shaft while at rest. It
also helps to maintain the oil film between shaft and the bearing till the rotor speed is
adequate enough to maintain the film thickness and protects shaft and bearings.
 AC JOP
 DC JOP
SPECIFICATION (DC JOP)-
Type - Z2-91 D2/T2
Power - 55KW
Speed - 1500 rpm
Excite - SHUNT
INS.CL - B
Bearing - 6314/CNZ1
Product No. - 905001
Standard - Q/XD.514.017_2006
Volt - 220 V
Current - 284 A
N.W - 650 kg
IP - 22
Duty - S1
Output - 6313/CMZ1
Date - 2009.05
Manufacturer - XI'AN SIMO MOTORS, INC (GROUP)

SEAL OIL SYSTEM-
To supply oil to generator seal tile for prohibit Hydrogen leakage between the revolution axis
and seal oil tile gap to outside by providing seal oil pressure higher then hydrogen pressure.
To prevent seal oil pressure excessively high for providing massive entry of oil inside the
generator.
SEAL OIL PUMP SPECIFICATION
Main AC
SOP
Emergency
DC SOP
Recirculation
AC SOP
Vacuum
Pump
Type of Pump Screw Pump Screw Pump Screw Pump Rotary Pump
Nos. 2×100% 1 1×100% 1
Discharge
Pressure
10 kg/cm2
10 kg/cm2
5 kg/cm2
Capacity 16.02 M3
/Hr 15.84 M3
/Hr 14.4 M3
/Hr
Model No.
ACG-070K7-
NVBP
HSNH280-
43N7
HSIS 210-54 30-WS
MOTOR
Model No. YB2-132M-4 22-S2 YB2-132S-4
Rating 7.5 KW 7.5 KW 5.5 KW 1.5 KW
Voltage 415 V 220 V 415 V 415 V
Current 14.1 A 14.1 A 10.8 A 3.48 A
Speed
1440 RPM
1500 RPM 1440 RPM 1410 RPM

MOT - Main Oil Tank:
Capacity - 35000 litres
Oil - Servo Prime 32
Model No - DAD-1CE2-000/180
Sr. No - 48513
Operating Pressure - 0/10 bar
Operating Temperature - 90/100o
C
Specific Gravity - 0.75
Tag No. - D600H-899200A002
LUBE OIL COOLER-
Lube oil cooler is provided for cooling of Lube Oil and Generator Seal oil
System. Oil which is used for lubrication of Main Turbine bearings and its
couplings return back to the lube oil tank for which lube oil cooler is used. It is
a tube type heat exchanger in which oil is being cooled by CCCW Water.
LUBE OIL COOLER SPECIFICATION-
Type - YL-610
Number - 2×100%
Type - STAINLESS STEEL PLATE TYPE HEAT EXCHANGER
Heat Transfer Area - 260 M2
Oil Inlet Temp. - 65o
C
Oil outlet Temp. - 45o
C
Oil Flow - 290 M3
Cooling Water Inlet - 38o
C
Cooling Water Flow - 500 M3
/h
Cooling Tube - 16 × 0.7 mm
VAPOUR EXTRACTION SPECIFICATION-
Type - VERTICAL
Flow - 1200 M3
/h
EH OIL SYSTEM
PUMP
Make - M/S. BAILEY COMPONY (USA)
Type - PRESSURE COMPENSATIVE PLUNGER PUMP
Nos. - 2 (1W + 1 S/B)
Pressure - 14 MPa
Flow - 100 L/MIN
Speed - 140 RPM

MOTOR
Type - Y200L-4
Power - 30 KW
Current - 51.7 A
Voltage - 415 V
EH OIL REGENTRATION AND TEMPERATURE CONTROLLING
PUMP
Nos. - 2(1W+1S)
Pressure - 0.6 MPa
Drive Rating - 1.5 KW/1400 RPM/ 415 V/ 3.4 A
EH OIL TANK
Volume - 1.0 M3
First Fill Oil - 750 L
EH OIL COOLER
Nos. - 2(1W+1S)
Cooling Area - 2.6 M2

CONDENSER
COONDENSOR SPECIFICATION
Type Single Pass, Single Flow,Double Shell
Model N-30500
Total Surface Area of Heat Transfer 30250 M²
Design Heat Load (TMCR) 2741481514 KJ/hr
Steam Design flow rate, TPH 1146.296
No. of Cooling Tubes
Condensing Zone 33312
Air Cooling Zone 3712
Length of Each Tube
Size of Tubes(OD*Th),mm
Condensing Zone 25X0.7
Air Cooling Zone 25X0.5
Tube Material Condensing Zone
ASTM A
249 TP304
ERW
Air Cooling Zone
Design CW Pump 32°C
CW Temp. Rise 10 °C
CW Flow Quantity. TPH 67680
CW Side Pressure Drop 0.050MPa
No. of CW Passes 1
Condensate absolute Pressure 10.13 Kpa
Cooling water gauge pressure 0.4 Mpa
Type of tube support Fix support
Total Empty Wt. of Condenser 800 MT
Condenser cleanliness factor 0.85
Water Weight
In Service 1500 T
Flooded 2750 T
Hydrostatic testing at water chamber
side 4.5 Kg/CM2
Drain flash tank
Type SW – 2500
Design Pressure 0.2 Mpa
Volume 25 m3
Design Temperature 200⁰ C

VACUUM PUMP OF CONDENSER
Make - GARDNER DENVER NASH MACHINERY LTD
Model - AT-30043
No. Of pump - 2*100%
No. Of stage - 1
Operting liquid - Water
Net weight - 8355Kg
Rotation - 490RPM
Air extraction capacity - 100kg/hr
Suction pressure - 10.2kpa
Cooling water temperature - 320
C
Cooling water flow - 53.6m3
/hr

CONDENSATE EXTRACTION PUMP
Condensate Extraction Pumps are multi-stage, vertical, centrifugal pumps. It is
used to extract the condensed water and pump the water pressure to the CPU
and LP heaters.
CEP - 7 Stage Vertical Centrifugal Pumps
CEP SPECIFICATION
Make - SHANGHAI KSB PUMP CO. LTD.
No. Of Pumps - 3 × 50%
Model No. - NLT 350-400×7
Weight - 5435 Kg
Serial No. - 3.50018E+11
Item No. - LCE03AP001
Number Of Stages - 7
Design Flow Rate - 886.6 M3
/H
Power - 1120 KW
NPSH Required - 3.3 M
Design Head - 323 M
Rotation Speed - 1480 RPM
Design Efficiency - 82%
ID No. - 37077638

CONDENSATE POLISHING UNIT
(CPU MIXED BED)
The Condensate Polishing Unit removes 'crud' - corrosion products consisting
mostly of oxide of iron, copper or nickel, dissolved solids - mostly consisting of
sodium, chloride and silica and carbon dioxide. Condensate polishing units are
typically installed for LANCO THERMAL POWER PLANT with the main
objective of improving the boiler water quality. The benefits of condensate
polishing is quicker start up and as a result full load conditions are reached early
giving economic benefits. Orderly shutdown is possible in the case of condenser
tube leak conditions.
BENEFITS
* Improvement in the quality of condensate and "cycle" clean up.
* Reduced blow down and make up requirements
* Improvement in boiler water quality for drum type boilers
* Quick start up and as a result, full load conditions are reached early giving economics
benefits.
* Orderly shutdown possible in case of condenser tube leak conditions.
* Improvement in quality of steam which results in enhanced turbine life.
SPECIFICATION-
Quantity - 3
Equipment Number - LANPL/MP/CMB/02
Safe working Press - 45 Kg/Cm2
Design Press - 56.25 Kg/Cm2

GLAND STEAM CONDENSER
Manufacturer DFSTW
Type Shell & Tube Type
Total Cooling area M³ 150
Total fluid entering , T/hr
Design pressure shell side, Kg/cm2
0.0951
Design pressure tube side, Kg/cm2
4.3
Hydro Test pressure shell side, Kg/cm2
1
Hydro Test pressure tube side, Kg/cm2
5.4
Operating Pressure Tube Side, Kg/cm2
0.969
Operating Pressure Shell Side, Kg/cm2
Design temperature shell side, °C 300
Design temperature tube side, °C 100
Cooling Water Amount, T/hr
Number of tubes 388, "U" tubes
Length mm 7738
Pitch,mm 25
Size of tubes OD X Thickness, mm 19 x0.9
Alternate Arrangement for GSC Horizontal Type
MATERIALS OF CONSTRUCTION
Shell
Tubes TP 304
Tubes sheets 20MnMo
GLAND STEAM EXHAUSTER
Make Hangzhou Kexing Blower Co. Ltd
Type AZY 013.5-033.3-1
Nos. 2
Capacity 2000 m3/Hr
Speed 2900
Head 13500 Pa
Motor Detail
Make Ansui Wallan elect Machine Co Ltd
Power 18.5 KW
Voltage 415
Current 32.1 A
Speed 2930

LOW PRESSURE HEATER
(LP HEATER)
Units LPH 5 LPH 6 LPH 7/8
Type U-Tube
horizontal
U-Tube
horizontal
U-Tube
horizontal
Quality Of Extraction
Steam
TPH 45.15 45.21 45.42/73.26
Pressure Of
Extraction Steam
MPa 0.375 0.219 0.118/0.058
Temp. Of Extraction
Steam
o
C 242.1 184.8 125.8/85
2 o
C 118.6 100.6 80.9/47
Surface Area M2
1400 1250 580/900
Size Of Tubes OD ×
Thickness
16×0.9 16×0.9 16×0.9
Number Of Tubes 1269 1269 730/730
Number Of Tube Side
Passes
2 2 2
Numbers Of Shell
Side Zones
1 2 2
Design Pressure On
Shell Side
5.1&full
vacuum
3.06&full
vacuum
3.06&full
vacuum
Kg/Cm2
-1.02 -1.02 -1.02
Design Temp. On
Shell Side
o
C 270 215 150
Design Pressure On
Tube Side
Kg 40.8 40.8 40.8
Design Temp. On
Shell Side
o
C 175 155 150
Hydro Pressure On
Shell Side
Kg 6.63 3.98 3.98
Hydro Pressure On
Tube Side
Kg 53.1 53.1 53.1

DEAERATOR
A Deaerator is a device that is used for the removal of Oxygen and other
dissolved gasses from the feedwater to steam generating boilers.
Booster
Pump A (0 m)
Booster
Pump B (0 m)
Boiler Feed Pump
MDBFP / TDBFP (13 m)
Condensate Water
Steam
Water
Oxygen and other gasses
Deaerator (24 m)

DEAERATION is based on two scientific principles. The first principle can be described by Henry's
Law. Henry's Law asserts that gas solubility in a solution decreases as the gas partial pressure above
the solution decreases. The second scientific principle that governs Deaeration is the relationship
between gas solubility and temperature. Easily explained, gas solubility in a solution decreases as the
temperature of the solution rises and approaches saturation temperature. A Deaerator utilizes both of
these natural processes to remove dissolved oxygen, carbon dioxide, and other non-condensable gases
from boiler feedwater. The feedwater is sprayed in thin films into a steam atmosphere allowing it to
become quickly heated to saturation. Spraying feedwater in thin films increases the surface area of the
liquid in contact with the steam, which, in turn, provides more rapid oxygen removal and lower gas
concentrations. This process reduces the solubility of all dissolved gases and removes it from the
feedwater.
SPECIFICATION
Equipment No. - LANPL/MP/DU2/01
Safe Working pressure - 13 Kg/Cm2
Design Pressure - 16.25 Kg/Cm2
Capacity - 195 M
3
Design Temperature - 371
o
C
Operating Pressure - 13 Kg/Cm2
Operating Temp. - 178.11o
C
Hydro Test Pressure - 16.94 Kg/Cm2
Safety Value Set Pressure - 12.96 Kg/Cm2
Rated Output - 2131 TPH
BOOSTER PUMPS
A BOOSTER PUMP is a machine which will increase the pressure of water.
All three Booster Pumps are at 0m.

BOILER FEED PUMP
Boiler Feed Pump is a multistage pump provided for pumping feed water to HP Heaters and
Economiser.
MDBFP ×1 -Motor Driven Boiler Feed Pump
TDBFP ×2 -Turbine Driven Boiler Feed Pump
BOILER FEEED PUMP
Manufacture : SHANGAI POWER EQUIPMENT AND MANUFACTURE CO.
KKS Code : 1LACO3APOO1
Type : HPT300-3330/M-55
Serial No. : 09G124
No. Of pumps : 1
No.of stages : 6
Casing type :
Impeller type :
Dirction of rotation : Clockwise From Driving End To Feed Water Pump
RATING DESIGN
Suction Temp(0
C) : 178.5 181.3
Suction pressure (MPa) : 2.19 2.16
NPSHR(3%) : 40.56M 58.48M
Sp. Gravity(Kg/cm2
) :
Total dynamic head (m) for pump : 2107mtr 2414.6mtr
Suction flow : 1104.09m3/hr 1351.05m3/hr
Discharge flow : 1055.7m3/hr 1302.48m3/hr
Speed(RPM) : 5256 5853
Efficiency(%) : 83.20% 83.20%
Power absorbed(KW) : 6502.4 9223.8
Tapping pressure (MPa) : 9.4 10.35

Tpping flow (M3/h) : 48.39 48.58
Weight,kg : 1200
HP HEATERS
HEATER#1 HEATER#2 HEATER#3
Type U-Tube Horizontal
U-Tube
Horizontal U-Tube Horizontal
Quality of Extraction
Steam(T/hr) 1343 114.93 91.4
Pressure of Extraction
Steam(Mpa) 6.13 3.82 2.816
Temp. of Extraction Steam(°C) 388 323.8 469
Feed Water Inlet Temp.(°C) 245.9 215.3 181.7
Feed Water Outlet Temp.(°C) 276.8 245.9 215.3
Surface Area(M²) 2100 2050 1600
Size of Tubes( ODXThickness
) 16 X 2.12 16 X 2.12 16 X 2.12
Number of Tubes 2931 2789 2667
Velocity of Feed Water(M/Sec)
Number of Tube Side Passes 2 2 2
Design Pressure on Shell side
(Kg/cm²) 74.49 47.43 25.51
Design Temp. on Shell
side(°C) 415/290 355/260 485/230
Design Pressure on Tube Side
(Kg/cm²) 285.71 285.71 285.71
Design Temp. on Tube
side(°C) 310 280 250
Hydro Pressure On Shell
Side(Kg/cm²) 111.73 71.22 38.27
Hydro Pressure On Tube Side 428.57 428.57 428.57
safety Valve Set Pressure ,(
Kg/cm2) 74.49 47.45 25.51
Operating press. on shell side
(Kg/ Cm2 )
Operating temp. on shell side
(°C)
Operating press. on tube side
(Kg/ Cm2 )
Operating temp. on shell side
(Kg/ Cm2 )
MATERIALS
Shell / head SA-516MGr.70 SA-516MGr.70 SA-516MGr.70
U Tube SA556MC2 SA556MC2 SA556MC2

Condensate Inlet / Outlet nozzle 15NiCuMoNb5-6-4
15NiCuMoNb5-6-
4
15NiCuMoNb5-6-
4
Tubes sheet SA350MLF2CL2 SA350MLF2CL2 SA350MLF2CL2
Shell Skirt 1 SA387Gr11CL2 SA387Gr11CL2 SA387Gr11CL2
Shell Skirt 2 SA-516Gr.70 SA-516Gr.70
Channel head 13MnNiMo54 13MnNiMo54 13MnNiMo54
WEIGHTS
HP Heater dry(MT) 86.079 86.079 61.733
HP Heater Flooded(MT) 120 120 85
SAFETY VALVE
Set Pr. (Kg/Cm2) 74.49 47.45 25.51

ASH HANDLING PLANT
The ash produced in the boiler is transported to ash dump area by means of
sluicing type hydraulic ash handling system, which contains of Bottom Ash
System, Ash Water System and Ash Slurry System.
Ash handling plant of LANPL is constructed by L&T-Sargent &Lundy Limited
having DRG no-LITL-003-MEV-204-I-004 R4
Ash mainly consists of numbers of oxides namely
SiO2 60-70%
H2O3 20-25%
Fe2O3 6-8%
CaO 2-3%
MgO 1-2%
K2O&N2O 2-5%

1. BOTTOM ASH SYSTEM-(15-20%)
In the bottom ash system the ash slag, discharged from the furnace bottom, is collected in two
water impounded scraper troughs installed below bottom ash hoppers. The ash is
continuously transported by means of scraper chain conveyor on to respective clinker
grinders, which reduce the lump size to the required fineness. The crushed ash from the
clinker grinders falls into the ash sluice trench provided below the bottom ash feeder from
where the ash slurry is further transported to ash slurry sump aided by the ash slice channel.
If the clinker grinder is not in operation, bottom ash can be discharged directly into the sluice
channel through the bifurcating chute bypass the grinder. The position of the flap gate in the
chute is manually changed. The main type of hoppers used in power stations is water filter
hopper and quencher cooled ash hopper.
2. FLY ASH SYSTEM-(70-80%)
The flushing apparatus are provided under EP Hoppers (40 no.), economiser hopper (4 no.),
APH Hopper and Stack Hopper. The fly ash collected in these drop continuously supplied to
flushing apparatus where fly ash gets mixed with flushing water and resulting slurry drops
into the ash sluice channel. Low-pressure water is applied through the nozzle directing
tangentially to the section pipe to create turbulence and proper mixing of ash water.
3. ASH WATER SYSTEM
High-pressure water required for bottom ash hoppers window spraying clinker sealing
scraper bars, cleaning nozzles. BA hopper seal through flushing, economiser hoppers flushing
nozzle and sluicing trench-jetting nozzles is tapped from high-pressure water ring provided in
the plant area.
4. ASH SLURRY SYSTEM
Bottom ash and fly ash slurry of the system is sluiced up to ash slurry pump along the
channel with the aid of high-pressure water jets located at suitable intervals along the
channel.

HP SEAL WATER PUMP
Make M/s Sam Turbo industry limited
Quantity in Nos. 2 Nos
Liquid Handled WATER
Temperature in C Ambient
Specific Gravity 1
Suction condition Flooded
Capacity in m3/hr 22
Head in mwc/mlc 240
Pump type / model 11 MD 100/250
Size in mm 125 x 100
Flange standard DIN ND 16 / DIN ND 40
Efficiency in % (W/L) 45%
BKW (KW) (W/L) 31.97
Motor KW / Speed in RPM 45/1485
NPSH R/A - mts 1/ FLOODED
MOC
Casing, Stuffing Box 2.5% NI IS 210 FG 260
Impeller ASTM A 743 CF8M
Wear ring IS 318 GR I
Pump shaft / Shaft sleeve BS 970 EN 8 / AISI 410
Shaft Sealing TIGA (GLAND PACKING)
Brg. Bed & Other parts CI & STD MOC CI and STD MOC
Location ASH SLURRY PUMP HOUSE
LP SEAL WATER PUMP
Nos. 2 (1W+1 S)
Rated Capacity 25 m3/hr
Pressure 120MWc
Motor Power/rpm 45 KW/1450
Efficiency 45%

TANK DETAIL
Capacity
(m³) Location Quantity
Coarse Ash Tank 2.5 Bottom Area 1
Air Water Converter tank Bottom Area 4
Overflow Water Tank Bottom Area 1/Unit
Settling Tank Bottom Area 1
Surge Tank Bottom Area 1
Ash water sump 21 Silo Area 1
Ash Silo 1000 T Silo Area 2
Ash water Sump 1371 Silo Area 1
Combined ash slurry sump 87.38 Silo Area 2
Recovery water Sump 210 Silo Area 1
Sludge Sump 10 Silo Area 1
Recycle water sump 170 Silo Area 1
BOTTOM AREA DRAIN SUMP JET PUMP
Technical specification
Location Bottom area
Nos. 2(1W+1S)
Capacity 10 m³/hr
SLUDGE PUMP
Technical specification Horizontal centrifugal Single Casing Ash Slurry Pump
Location SLUDGE PIT
Nos. 2(1W+1S)
Temperature (o
C) Ambient
Pump Specification
Rated Capacity 50 CUB M/HR
Pressure 15 MWC
Motor Power (KW) 5.5
Pump type / Model ARS 100/340A
Speed (RPM) 920
Efficiency (in %) 58
Shaft Sealing GLAND PACKING
Motor Speed (RPM) 1500

BOTTOM AREA OVER FLOW ASH PUMP
Location NEAR BOTTOM ASH OVER FLOW TANK
Nos. 2(1W+1S)
Capacity 235 CUB M/HR
Pressure 20MWC
Speed
Gland seal water requirement
Motor rating
VACUUM PUMPS
Location In collector Tower Area
Nos. 12 (8W+4S)
Capacity 3200 m3/Hr
Vacuum 14" of HG
Motor rating
SILO AREATION BLOWERS
Location ASH SILO AREA
Nos. 2(1W+1S)
Pressure 7000 MWC
Motor rating

DRAIN SUMP PUMP
Type VO 40 / 260 + TCH + N
Designation SILO AREA
Quantity in Nos. 2 (1W+1S)
Liquid Handled DRAIN
Temparature in C Ambient
Specific Gravity 0.17
Suction condition SUBMERGED
Capacity in M3/hr 20
Head in mwc / mlc 60
Pump Type / Model VO 40 / 260 + TCH + N
Size in mm 79 X 40
Flange Standard ANSI 150 LBS FF
Efficiency in % (W/L) -0.53
BHP (KW) (W/L) 6.96 / 8.13
Recommended Motor KW 11
Speed in RPM 2900
Pump Setting Height mm (Assumed) 1750
Pump Sump depth mm 2000
MATERIAL OF CONSTRUCTION
Casing, Stuffing Box ALLOY CI (350 BHN) MIN 2.7% NI, 1% CR
Impeller ALLOY CI (350 BHN) MIN 2.7% NI, 1% CR
Wear Plate NOT APPLICABLE
Pump Shaft / Drive Shaft AISI 410 / AISI 410
Shaft Sleeve AISI 410(400 BHN)
Column Pipe / Delivery Pipe ASTM A 106 GrB (6 MM THICK)
Star support IS 210 FG 260
Bush Bearing / Lubrication
CUTLESS RUBBER / EXTERNAL CLEAR
WATER
Coupling Sleeve Set AISI - 410 (400 BHN)
Shaft Sealing TIGA (Gland Packing)
Brg. Bed & Other parts CI & STD MOC
Location SILO AREA DRAIN SUMP

CONDITIONING WATER PUMP
Location In Silo Area
Designation DUST CONDITIONER WATER PUMP
Temperature in C AMBIENT
Specific Gravity 1
Viscocity in CP/Correction factors --
PH Value --
Suction condition FLOODED
Head in mwc/mlc 50
Pump type / model 5 MD 80/205
Size in mm 100 X 80
Flange standard DIN ND 16 / DIN ND 40
Efficiency in % (W/L) 0.7
BKW (KW) (W/L) 7.79
Motor KW / Speed in RPM 11 / 1450
NPSH R/A - mts 1.5/ FLOODED
MOC

DRAIN SUMP PUMP
Location Ash Combine Slurry Pump House
Type VO 50/300+TCH+N
Specific Gravity 1.17
Suction condition SUBMERGED
Capacity in M3/hr 20
Head in mwc / mlc 15
Pump Type / Model VO 50 / 300 + TCH + N
Size in mm 80 X 50
Flange Standard ANSI 150 LBS FF
Efficiency in % (W/L) 0.54
BHP (KW) (W/L) 1.51 / 1.77
Recommended Motor KW 5.5
Speed in RPM 960
Pump Setting Height mm (Assumed) 1650
Pump Sump depth mm 2000
Casing, Stuffing Box ALLOY CI (350 BHN) MIN 2.7% NI, 1% CR
Impeller ALLOY CI (350 BHN) MIN 2.7% NI, 1% CR
Wear Plate NOT APPLICABLE
Pump Shaft / Drive Shaft AISI 410 / AISI 410
Shaft Sleeve AISI 410(400 BHN)
Column Pipe / Delivery Pipe ASTM A 106 GrB(6 MM THICK)
Star support IS 210 FG 260
Bush Bearing / Lubrication
CUTLESS RUBBER / EXTERNAL CLEAR
WATER
Coupling Sleeve Set AISI - 410 (400 BHN)
Shaft Sealing TIGA (Gland Packing)

BOTTOM ASH HIGH PRESSURE WATER PUMP
Specific Gravity 1
Head in mwc/mlc 115
Pump type / model ZM II 530 / 02
Size in mm 300 X 250
Flange standard ANSI 125 LBS FF
Efficiency in % (W/L) 73%
BKW (KW) (W/L) 195.31
NPSH R/A - mts 3/ FLOODED
MOC
Brg. Bed & Other parts CI & STD MOC CI and STD MOD
Location ASH WATER PUMP HOUSE
Nos. 2
Pressure 115 MWC
Motor Power/rpm 224 kw/1480
Efficiency 73%
Pump Type / Miodel ZM II 530/02
Suction Condition Flooded
BOTTOM ASH LOW PRESSURE WATER PUMP
Nos. 3
Pressure 28 MWC
Motor Power 37 KW
Speed 1450

FLUSH WATER PUMP
Temp in °C Ambient
Viscosity in CP/Correction factors -
PH Value -
Head in mwc/mlc 15
Pump type / model MF 300 / 320
Size in mm 300 X 300
Flange standard BS 10 TABLE D" "
Efficiency in % (W/L) 87
BKW (KW) (W/L) 45.1
NPSH R/A - mts 3.75 / Flooded
Max. Allowable solid size in mm --
Casing, Stuffing Box 2.5% NI-CAST IRON TO : IS 210 FG 260
Wear ring BRONZE (IS 318 GR I)
Location Ash slurry Pump House
FLY ASH HP WATER PUMP
Nos. 3
Pressure 62 MWC
Motor Power 160 KW/1480 rpm
ECONOMISER ASH WATER PUMP
Location Ash Water Pump House
Nos. 3 (2W+1S)
Suction takes from Raw water Pump Discharge and cooling Tower Blow down
Rated Capacity 61 m3/hr
Pressure 80 MWC
Motor Power 30 KW
Speed 1450 rpm

ASH SLURRY DISPOSAL PUMP
Location Ash Slurry pump House Area
Nos. 16 (8W+8S)
Capacity 975 m3/Hr
Pressure 50 MWC
Speed 480 rpm
Gland seal water requirement
Motor rating 290 KW
RECOVERY WATER PUMP
Location ASH POND
Nos. 6(4W+1S)
Suction takes from RECOVERY WATER SUMP
Pressure 58 MWC
Motor Power
RECYCLE WATER PUMP
Location
Nos. 3(2w+1s)
Suction takes from RECYCLE WATER SUMP
Pressure 50 MWC
Motor Power
SLUDGE PUMP
Location
Nos. 1W+1SB
Suction takes from SLUDGE SUMP
Rated Capacity 60 m³/Hr
Pressure 50 MWc
Motor Power

FLY ASH DRAIN PUMP
Location ESP AREA
Nos. 2 (1W+1S)
Capacity 40 m3/Hr
Pressure 20 MWC
Speed
Motor rating
BUFFER HOPPER FLUIDISING BLOWERS
Location ESP AREA
Nos. 2(1W+1S)
Pressure 6000 mmwc
Motor rating
GEAR BOX
Location Ash Slurry Pump House
Item Gear Box For Pump Model AR 300/750A
Nos. 4
Make Premium Energy Transmission Ltd.
Duty Continuous
Load Variable
Type Helical Spring Reduction
Motor Rating (KW ) 290
Motor Speed (RPM ) 1500
Gear Box Input Speed At Rated
Condition (RPM ) 1260
Gear Box output Speed At Rated
Condition (RPM ) 840
Cooling Fan Cooled
Efficiency At Rated Point (%) 98.5
Thermal Capacity At 1500 RPM 490 KW
Mechanical Capacity At 1500 RPM 866 KW
Bearing Life 20000 Hrs
Casing CI Fg 260
Gears & Pinions 815M17 (En 353) BS 970
Input Shaft BS 970 En 19T
output Shaft IS 1875 45C 8N

CLINKER GRINDER
Location BA Hopper Discharge gates housing
Nos. 8 (4W+4S)
Rated Capacity Compatible with guaranteed ash extraction or Discharge Rate
Grinder Speed Should not exceed 40 rpm
Crushed ash lump size at the outlet
of crusher
Motor Power
Motor Speed Should not exceed 1000 rpm
HYDRO EJECTOR
(JET PUMP)
Location
Nos. (4W+4S)
Rated Capacity (Dry ash)
Ejector discharge
Flow of water (worn out
condition)
Inlet water pressure (worn out
condition)
Nozzle Size
INSTRUMENT AIR COMPRESSOR
Location INSIDE COMPRESSOR HOUSE
Nos. 2(1W+1S)
Pressure 7 KG/CM2
Motor rating
CONVEYING AIR COMPRESSOR
Location INSIDE COMPRESSOR HOUSE
Nos. 3(2W+1S)
Pressure 5.5 KG/CM2
Motor rating

OFF SITE MAINTENANCE
The mechanical part excluding boiler and turbine of the plant is
called off site.
Following are the part of off site maintenance-
1. DM Water plant
2. Cooling towers
3. water make up pump house
4. Hydrogen plant
5. Fire fighting system
6. Air condition

DM WATER PLANT
The water used in the boiler to make steam is demineralised
water. If we use mineralized water in boiler, the mineral forms a non-
conducting layer on water tubes. The mineral precipitates on the
surface of water tubes at high temperature. Firstly Alum [Al2K2
(SO4)3] is mixed with water coming from rihand water make up pump
house. In this solution of water and alum, mechanical impurities are
settled down. Now liquid chlorine is mixed in water mixture to make
it bacteria free. This chlorified water used at bottom mud from where
mud is removed with the help of blade. This water is felled on gravity
sand filter (GSF). The water comes out of GSF is drinking water. At
DM plant, this drinking water is processed in different steps of
demineralization.
Supplier M/s. TRIVENI ENGINEERING & INDUSTRIES LTD.
No. of Streams Three
Sequence of stream
RGF-ACF-SAC-DGT-SBA-MB -DM Water Storage Tank
Capacity 75 M3 / Hr / Stream.
OUT PUT WATER QUALITY
At the outlet of SAC
Sodium
Leakage <0.5 ppm as CaCOз
At the outlet of SBA Silica(Reactive) <0.2 ppm as SiO2
At the outlet of MB
Silica(Reactive) <0.01 ppm as SiO2
Organic matter Practically Free
Conductivity @
25°C < 0.02 μS/cm
pH 7.0±0.5 at 25°C
Chloride Not detectable as CaCo3
Sodium Not detectable as Si
At the outlet of DG
At the outlet of RGF

RAPID GRAVITY FILTER(RGF)
Mark No.
Number 2
Size
Normal Flow rate/ Unit 150 m3/Hr
Working Pressure
Material of construction RCC
Time of service cycle 24 Hrs
Time of Regeneration Cycle 01 Hrs
Out put between generations 3600 m3
Filter media
Quantity
Regeneration Flows 30 m3
Backwash 30 m3
Rinse 150 m3/Hr
Effluent quality 2 NTU
Turbidity 2 NTU
RGF Back Washing Pump
Make Mother & Platt pumps Ltd
Type PNV 29
Discharge 325 m3/hr
Head 15 mwc
Speed 1480 rpm
Power 22 kw
Quantity 2
MOTOR DETAILS
Make Marathon Electric
Frame D180 L
Power 22 kw
Current 39 A
Speed 1460 RPM
Volteage 415 V
Weight D180 L
174 Kg

ACTIVATED CARBON FILTER (ACF)
Mark No.
Number 3 Nos.(2 W + 1 S)
Size Φ 2600 × 2500 HOS
Normal Flow rate/ Unit 81.43 m3/hr.
Working Pressure 6 Kg/cm²
Material of construction Epoxy Coated carbon
Time of service cycle 20 Hrs
Time of Regeneration Cycle 20 min
Out put between generations 1500 m3
Filter media Activated carbon
Quantity per vessel
Regeneration Flows
Backwash 40 m3/Hr
Rinse 81.43 m3/hr.
Effluent quality
Free chlorine: Nil
Turbidity <2 NTU
Organic Matter Practically Not Detected

STRONG ACIDIC CATION EXCHANGER (SAC)
Mark No.
Size Φ 1800 × 3300 HOS
Normal Flow rate/ Unit 75 m3/hr.
Working Pressure 6.0 Kg/cm²
Material of construction MSRL
Effluent Quality Slight Acidic
Capacity between regeneration / unit 1500 m3
Period between regeneration / unit 20 Hrs
Resin Type Strongly Acidic polytrene inbead from
Resin Make Auchtel D-C-26
Regeneration Flows Operation
Flow (m3/hr.) Time (min.)
Backwash 40.69 10
Middle collector flushing 40.69 5
Acid pre-injection 10.45 5
Acid Injection at 4 % 10.45 25
Slow Rinse 10.45 30
Fast Rinse 79.64 10
Total regeneration time 85

STRONG BASE ANION EXCHANGER (SBA)
Mark No.
Size 2100X3300 HOS
Normal Flow rate/ Unit 75 M3/Hr
Working Pressure 6 Kg/Cm2
Material of construction Gr1/SA 515
Effluent Quality Slight Basic
Period between regeneration / unit 20 hours
Resin Type
Strongly Basic polystyrene type in Bead
from
Resin Make Auchtel D-A161
Regeneration Flows Operation
Flow (m3/hr.) Time (min.)
Backwash 20.77 10
Acid Injection at 4 % 10.28 30
Slow Rinse 10.28 50
Fast Rinse 10.28 10
Total regeneration time 106

MIXED BED EXCHANGER (MB)
Mark No.
Size Φ 1700 × 2200 HOS
Normal Flow rate/ Unit 75 m3/hr.
Working Pressure
Material of construction Gr1/SA 515
Period between regeneration / unit 140 hours
Time for regeneration / unit Max 4 Hrs.
Resin Type / quantity 20 H+ , 20 Cl‾
Chemicals for Regeneration By HCL and NAOH
Resin Make
MB REGENERATION FLOWS
Operation Flow (m3/hr.) Time (Min.)
Backwash 20.41 10
Down flow 4 2
Acid Injection 3.3 20
Acid Rinse 3.3 20
Alkali pre injection 3.85 2
Up Flow 4.31 2
Alkali Injection 30
Alkali rinse 50
Drain Down 4
Air Mix 5
Fast Rinse 75.72 15
Total Regeneration Time 164

COOLING TOWERS-
Cooling towers are important components of thermal power plants
where a limited supply of makeup water is available.
Broadly speaking cooling towers are of two types-
(1) Mechanical draft cooling towers
(2) Natural draft cooling towers
TOWER
Manufacturer Gammon India
Type of the tower Induced Draft Fan
Number of the cooling Towers 02/unit
Total no. of cell per Tower 11
Number of standby cell/s 1
Diameter of the Tower 20.02 mtr
Cooling Tower Capacity
For Thermal Design 67880 m3/hr
For Hydraulic design
Heat load on the cooling tower
Evaporation loss
Cold water temperature 32° C
Hot water Temperature 41° C
Mean water temperature 36.5 °C
Design Approach 5 °C
Cooling Range 9 °C
Design ambient wet bulb temperature 28 °C
Design inlet wet bulb temperature 28.6 °C
Friction loss in cooling tower piping
BASIN
Type
Effective storage capacity ofTower
Basin 5000 m3

Material of construction
Basin & structure RCC
Louvers
Fill PVC
Fill support SS304
Drift Eliminator PVC
Drift Eliminator support PVC
Fan Blades PVC
Fan Stack
Nozzles PVC
Metering orifices
FAN
Make Aerotech
Model Aero H X 2
Nos./Tower 11
No. of blade 8
Diameter of fan 10000 mm
Blade tip clearance 20 mm
Fan speed 105 rpm
Material for fan
Fan hub PVC
Fan blade
GEAR BOX
Model Premium
Nos./Tower 11
Type Bevel helical
No. of reduction
Reduction Ratio 14:01
Input / Output speed, rpm 1480/105
Lubrication Oil
Bearing Tapered roller
MOTOR
Make Marathon Electric
Frame D 315 M2
Power 132 KW
Full load current 226 A
Voltage 415 V
Speed 1485 rpm

KIRTI SHUBHAM
1318015
KIIT UNIVERSITY

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