GENERAL WRITE UP OF POWER PLANT Steam power plant working principle: Steam or thermal power plant is using steam

as working fluid. Steam is produced in a boiler using coal as fuel and used to drive the prime mover(Steam turbine). The heat energy is converted into mechanical energy by the steam turbine and that mechanical energy is used for generating power with the help of generator. Generally the layout of the steam power plant consists of four main circuits. They are 1. 2. 3. 4. Coal and ash circuit. Air and flue gas circuit. Water and steam circuit. Cooling water circuit.

1. Coal and ash circuit: This circuit consists of coal storage, ash storage, coal handling and ash handling systems. The handling system consists of belt conveyors, screw conveyors etc. Coal from the storage yard is transferred to the boiler furnace by means of coal handling equipment. Ash resulting from the combustion for coal in the boiler furnace is removed to ash storage through ash handling. The Indian coal contains 30 to 40% of ash. 2. Air and flue gas circuit: This circuit consists of air filter, air preheater, dust collector and chimney. Air is taken from the atmosphere to the air preheater, the dust from the air is removed by means of using air filter. After combustion in the furnace, the flue gas which has sufficient quantity of heat is passed around the boiler tubes, dust collector, economizer and preheater before being exhausted of the atmosphere through the chimney. By passing the flue gas around the economizer and air preheater, the water and air are preheated before going to the boiler. 3. Feed water and steam circuit: This circuit consists of boiler feed pump, boiler, turbine, and feed heaters. The steam generated in the boiler passes through super heater and is supplied to the steam turbine. The steam is expanded in the steam turbine then passed to the condenser where it is condensed. The condensate is heated in the HP and LP heaters using the steam tapped from different points of the turbine. The feed water is passing through the economizer, where it is further heated by means of flue gases. Using the economizer, the feed water is heated by the feed water heaters and then it is fed into the boiler. Part of the steam and water are lost while passing through different components of the system. So, feed water is supplied from the external source to compensate losses. 4. Cooling water circuit: This circuit consists of circulating water pump, condenser, cooling water pumps and cooling tower. Abundant quantity of water is required for condensing the steam in the condenser. Adequate water supply is available from various sources like river or lake.

General Layout of Thermal Power Plant

GENERAL DESCRIPTION OF CFBC BOILER

The CFB boiler consists of a steam drum, a suspended whole-membrane waterwall furnace, two water-cooled cyclone separators, two water-cooled loop seals and a steam cooled back pass. The main features of the design are super high-pressure reheating and single drum natural circulation. The boiler is arranged as an island and in complete steel structure. The boiler is entirely hanged. The elevation of the operation floor is 9000 mm above the ground. The boiler is designed to operate with either Design coal or Best, worst coal as the fuel. The boiler is arranged symmetrically with four steel columns at the boiler island. The furnace is in the second column. The furnace water wall is hanged from the roof. The maximum downward expansion is around 190mm. In the third column the water cooled cyclones and the loop seals are laid. The back pass is in the fourth column. There are 14 radiant super heater panels and 2 radiant water wall panels inside the furnace. At the bottom of the furnace, there are a water-cooled air distributor and an insulated primary air wind box. The boiler is started up by heating up the bed with 4 ignition oil burners arranged on the rear water wall. The start-up burners can also be used to maintain combustion temperatures at low load. There are 4 coal feed ports arranged evenly on the front water wall of the furnace. Bunkers are provided for storing the solid fuels. There are 2 rotating and 2 fluid-bed ash coolers. Between the furnace and the back pass there are two water-cooled cyclone with vortex finders. There is a water cooled loop seal under each cyclone. Fluidization air is fed to the loop seals at the bottoms to fluidize circulating solids back to the furnace. In the back pass, a wall enclosure superheater including a cross over duct, a cavity forms a part of the back pass. Reheater-2, Reheater-1, the primary superheater, the economizer and the air preheater are successively arranged in the back pass in the direction of flue gas flow. Two stages of spray desuperheaters are arranged in the superheater piping line. One emergency water spray is at the inlet of Reheater-1. Staged air supplication is applied to the furnace. The boiler is provided with Primary Air (PA) fan, Secondary Air (SA) fan for supplying the required air for fluidization and combustion. The primary air is blown into the furnace through the air distribution plate and the air nozzles at the bottom of the furnace. The secondary air is blown into the furnace through the ports on the furnace walls at two height levels. Seal pot (Loop seal) blower is provided for fluidizing the solids in the seal pot and returning the coarser particles back to the combustor. The flue gas then passes through Electro Static Precipitator (ESP) before exiting through the Chimney. ID fan is provided after ESP for maintaining the balanced draft in the boiler. Boiler Pressure Parts Steam Drum : The steam drum is made up of carbon steel plate, welded construction, with a cylindrical shell and dished ends. Manholes with hinged covers are provided at each end of the drum. Nozzles are

provided in the steam drum. The steam-water mixture entering the drum from combustor and water cooled cyclone top headers is collected in the separating chamber of the drum. A portion of the water is drained off through the perforated continuous blow down pipes at this point of high solids concentration. The blow down line is provided with a motorized regulating globe valve with isolation valves. Two numbers of spring loaded safety valves are mounted on the drum. The drum safety valves are set to open when the drum gets pressurized above the set point. Drum level is measured to control the feed water flow. Drum level is indicated by direct water level gauges and electronic level indicators. The motorized Intermittent blow down valve with isolation valves is to be used for emergency drain when the drum level shoots up abnormally. Drum Internals : The boiler drum is provided with efficient internals for separation of steam from steam-water mixture. The drum internals contains turbo separators and screen boxes provide simple and efficient system to produce high quality steam. The feed water manifold located inside the drum helps to distribute the water evenly through out the drum length. The turbo separators and screen boxes are used to separate the steam from steam-water mixture before it leaves from the drum. The turbo separators equipped with a corrugated plate assembly at its outlet provides with primary and secondary separation of water from steam. These separators are vertically mounted in the steam drum so that the steam rises out at the top and the water falls back into the water space. Screen boxes are mounted above the turbo separator which helps to remove the remaining water particles from the steam using the method of changing the direction of steam flow several times before leaving the steam drum. Down Comers and Risers : The boiler water from steam drum flows through down comers to the combustor bottom headers, Water Cooled Cyclone bottom headers, Loop seal bottom headers, Water Cooled Cyclone inlet duct headers, Evaporator inlet header & Water cooled Bed Ash Cooler bottom headers. Risers carry steam-water mixture from respective outlet headers to steam drum. Combustor (Furnace) : The entire combustor is a gas tight enclosure with completely water cooled tubes. The main components of the combustor are: water-cooled distributor bottom grid water-cooled lower combustor (with refractory lining) water-cooled upper combustor

Bottom Grid : The bottom of the combustor is provided with widely spaced water cooled tubes as distributor grid. Stainless steel air nozzles are mounted on the membrane fins. The primary air from the air box flows through these nozzles for fluidizing bed material as well as fuel and supporting combustion. The design feature of these nozzles and the gas pressure across the system with admission of minimum air

flow avoids any back shifting of bed material to the air box when the unit is operating at low loads. Lower combustor : The lower combustion chamber is made of water cooled membrane wall enclosure and refractory lined for protection against erosion and chemical attack. A special care is taken at the combustor refractory zone with a kick - out (back bump) design to minimize the erosion at the refractory interface with the tube panels. It is in this area that the main combustion takes place. The bed is denser here and very turbulent. All combustion air and fuel are brought into the combustor in this area. In addition to the primary air through grid, secondary air is fed . Secondary air completes the staged combustion with minimum Nox formation. Start-up burners are located above the grid. All the penetrations for bed temperature and pressure measurements are located in this area. Upper combustor : The upper part of the combustor is also made of water-cooled membrane walls. This is the area in which the heat is transferred from the flue gases and bed material to the boiler water. As the walls are water-cooled, the temperature of the tubes is constant throughout the combustor and corresponds to the saturation temperature at the boiler drum pressure. Gas inlet channel from the combustor to water cooled cyclone is lined with a thin layer of refractory. The combustor tubes are of seamless construction and welded to the headers. The combustor is designed for positive pressure operation and accordingly suitable buck stays and tie bars are provided. The entire combustor assembly, water cooled cyclone and back pass are supported from the top. Hence, there is no differential thermal expansion between the combustor and water cooled cyclone. The complete combustor assembly is designed for natural circulation. Saturated water from the drum is circulated through the down comers to the combustor bottom headers. Wing wall / Radiant Superheaters & Evaporators are located in the upper part of the combustor. These are fin welded tubes, positioned parallel to the gas flow path. Water cooled Cyclone,Loop Seal & Water Cooled Cyclone Inlet duct wall : The water cooled cyclone is a gas tight circular enclosure manufactured from membrane panels (similar to combustor tube construction). The water cooled cyclone is lined inside with a thin layer of abrasion resistant refractory. The primary purpose of the water cooled cyclone is to separate the hot coarser solids carried along with the flue gas so that they can be returned back to the lower combustor through the loop seal system. Water cooled cyclone inlet duct wall is made up of seamless membrane tube construction,which is connect the combustor and water cooled cyclone and form a gas tight seal enclosure. The flue gas is passes to water cooled cyclone through the inlet duct wall from combustor. Ash particles in the flue gas is separated in the water cooled cyclone and flows down to the loop seal. Loop seal is a box type membrane tube panel construction,which is acts as a seal preventing the back flow of flue gas from the combustor through the water cooled cyclone. The ash in the loop seal is fluidized by high pressure air coming from the high pressure loop seal blower through the nozzles located on the bottom.

Like the combustor, the water cooled cyclone and loop seal system is also designed for natural circulation system. Saturated water from the steam drum is taken to the inlet headers of water cooled cyclone and loop seal by separate down comers. The steam-water mixture from the loop seal and water cooled cyclone wall tubes is collected in the upper water cooled cyclone headers and returned to the steam drum via riser pipes for further steam water separation in the drum. The entire water cooled cyclone and loop seal assembly is top supported and would expand downward with the combustor and the back pass. Vortex Finder : Hot combustion gases, with the entrained solids, fuel and ash, leave the top of the combustor and enter into the water cooled cyclone. The flue gas and ash are drawn through a fixed center pipe attached to the top of the water cooled cyclone , a device called a vortex finder that causes the gasash mixture to change direction. Coarser material is separated from the flue gases by centrifugal force. This cylinder hangs down into the area and causes the horizontal-traveling flue gas and bed material to make a 90- degree turn to flow up and out of the water cooled cyclone. This change in direction helps separate and size the coarser bed material from the fine bed material and fly ash. The smaller fly ash particles entrained with the flue gas leave the top of the water cooled cyclone and enters the boiler's convection section (back pass). Radiant Wing Evaporator : The Radiant wing Evaporator is made up of multiple panels located in the upper centre part of the combustor. Saturated Water from the Steam drum is supplied to the Radiant wing Evaporator inlet header through the down comer and passes through the panels to the outlet headers and returned to the steam drum via the riser. The lower portion of the walls is protected from possible erosion by abrasion resistant refractory. Weld overlay is carried out immediately following the refractory on the tube to protect from high ash erosion. The Radiant wing Evaporator assembly with inlet and outlet headers are suspended from top through spring hanger supports. Panels are placed vertically at the direct radiant zone. Water cooled Bed Ash Cooler : The CFB boiler is provided with two fluidized bed ash coolers designed to handle 100% of the bed ash flow. The furnace and the bed ash coolers are integrated,which are arranged one on either side of the main furnace. The Bed Ash Coolers are provided to cool the furnace bed ash to approximately 250 - 300C so that the ash can be handled by suitable downstream ash disposal equipment.The ash is cooled by a part of the fluidizing air taken from the primary air system with the hot air from the cooler is fed back to the furnace for sensible heat recovery from the ash. Cooling coils are also provided in the bed ash cooler compartments to further cool the ash. The bed ash cooler is constructed out of fin welded membrane type panels and separated by refractory inside for individual compartments. The cooling coils are bare tubes arranged in in-line arrangement. The cooling water can be taken from the steam drum through down comer, Which is connected to the Bed Ash Cooler side wall bottom header and passes through the panels to the Bed Ash Cooler top headers and returned to the steam drum via the riser.

Steam cooled wall (back pass) : The steam cooled wall is a gas tight enclosure with completely steam cooled membrane walls tubes. This is the area in which the heat is transferred from the flue gas to the steam inside the tubes. The steam cooled wall tubes are of seamless construction and welded to the headers. The steam cooled wall is designed for negative pressure operation and accordingly suitable buck stays and tie bars are provided. The steam cooled wall assembly is supported from top by means of hanger rods. The complete steam cooled wall assembly is designed for natural circulation. Saturated steam from the Steam drum is passes through the Saturated links to steam cooled wall side panel top headers and circulated via the panels. The steam is collected in front wall and goes to the cyclone outlet chamber. Finally the steam enters the roof header and passes through the rear wall panels and gets slightly superheated and led to primary super heater. Primary super heater is located in the steam cooled wall enclosure. Cyclone Outlet Chamber : After leaving the water cooled cyclone, the flue gas fly ash mixture is drawn into and through the steam-cooled refractory-lined cyclone outlet chamber. Saturated steam from steam cooled wall front middle header passes through this cross over section. This tube panel ductwork construction reduces the weight and the amount of refractory necessary to protect the area. The cyclone outlet chamber connect the water cooled cyclone to the convection section (back pass) of the boiler. Primary Superheater : Saturated steam from steam drum flows through steam cooled walls and then the cyclone outlet chamber gets slightly superheated and led to primary super heater, which serves to completely dry and superheat the saturated steam. Primary Superheater is a convective type super heater section located in the back pass enclosure (steam cooled walls). Steam through this section flows cross to the gas flow through multiple banks arrangement. The super heater inlet and outlet headers are located horizontally on the rear side of the steam cooled wall enclosure. The convection super heater consists of specified no. off parallel paths and the complete super heater assembly is supported by the hanger tubes with the help of slider ,support lug & arrester rod. Also the first row of the super heater assembly (each bank) is provided with an erosion shield of stainless steel material to protect the tubes against erosion. Baffle plates are welded with front and rear panels of steam cooled wall which is to protect the super heater bends against erosion. De- superheater- I : De-superheater-I is located in the interconnecting piping between the primary and secondary superheaters. De-superheating is carried out to control the rated steam temperature over the control load range. This is done by means of variable nozzle desuperheater using the boiler feed water. The spray water is regulated through the spray nozzles provided in the variable de-superheater with the feed water tapped off from a point upstream of the feed water control valve by monitoring steam temperature after the desuperheater. Radiant Wing Secondary Superheater : The Radiant wing secondary superheater is made up of multiple tube panels located in the upper

left part of the combustor. Steam from the primary superheater is enter in to the Radiant wing secondary superheater inlet header and passes through the panels to the outlet headers. The differential expansion of the superheater panel walls relative to the combustor wall is accommodated with an expansion arrangement provided at the combustor roof penetration. The lower portion of the walls is protected from possible erosion by abrasion resistant refractory. Weld overlay is carried out immediately following the refractory on the tube to protect from high ash erosion. The Radiant wing secondary superheater assembly with inlet and outlet headers are suspended from top through the spring hanger supports. Panels are placed vertically at the direct radiant zone. De- superheater- II : De-superheater-II is located in the interconnecting piping between the Radiant wing secondary superheater and Radiant wing final superheaters. De-superheating is carried out to control the rated steam temperature over the control load range. This is done by means of Fixed nozzle de-superheater using the boiler feed water. The spray water is regulated through a spray control valve, with the feed water tapped off from a point upstream of the feed water control valve, by monitoring steam temperature after the desuperheater. Radiant Wing Final Superheater : The superheated steam from Radiant wing secondary superheater outlet passes to the Radiant wing final superheater inlet header and passes through the panels to the outlet headers for further superheating. The Radiant wing final superheater is located in the furnace as radiant heat transfer section. The Radiant wing final superheater is made up of multiple tube panels located in the upper Right part of the combustor which is typical arrangement of radiant wing secondary superheater. The differential expansion of the superheater panel walls relative to the combustor wall is accommodated with an expansion arrangement provided at the combustor roof penetration. The lower portion of the walls is protected from possible erosion by abrasion resistant refractory. Weld overlay is carried out immediately following the refractory on the tube to protect from high ash erosion. The Radiant wing final superheater assembly with inlet and outlet headers are suspended from top through spring hanger supports. Panels are placed vertically at the direct radiant zone. Economiser : The Economiser is located at the bottom of back pass which is in between the primary superheater and the tubular air pre-heater. The purpose of the Economiser is to pick up the heat from the hot flue gases to boiler feed water before entering the steam drum. Feed water flows through the tubes arranged by horizontally for cross flow to the gas flow path. The Economiser is of bare tube, in line, horizontal, serpentine type arrangement in multiple banks. The Economiser tubes are supported by straps. The Economiser bank tubes are finally welded to the intermediate headers. Hanger tubes are connected from the intermediate header to the economiser outlet header, Which is located above the boiler roof. De- superheater- III : De-superheater-III is located in the Cold Reheat line which is connected to the Reheater-I inlet header. De-superheating is carried out to control the rated Reheat steam temperature over the control

load range. This is done by means of Fixed nozzle desuperheater using feed water. The spray water is regulated through a spray control valve, with the feed water tapped off from a point upstream of the feed water control valve, by monitoring steam temperature after the de-superheater. Reheaters : Reheater system consists of two stages Reheater 1 & 2 (RH1 & RH 2). Both are arranged in multiple banks and located in convective back pass. Reheater 2 is located on the top of the convective back pass and Reheater 1 is located below the Reheater 2 on flue gas path. Reheated steam is distributed from the High Pressure (HP) turbine to the 1 st stage Reheater inlet header, passes through the tubes to the outlet header and then to the 2nd stage reheater inlet header, passes through the tubes to the outlet header and then the reheated steam enters the intermediate pressure (IP) turbine. The Reheater 1 & 2 are of spaced type, continuous loop, plain tubular, drainable, horizontal inline, arranged for cross flow heat transfer, with steam flows upwards and the flue gas flows downwards. The complete Reheater assemblies are supported by the hanger tubes from the economiser intermediate headers with the help of slider ,support lug & arrester rod. One number of by-pass spray control valve is provided and connected to the 1st stage reheater (RH1) outlet. Feed water is sprayed into the reheated steam to control the reheat steam temperature on emergency situation. System Description Primary Air System : The primary air fan constitutes the combustion air system. The primary air fan is employed primarily for supplying air for fluidization of the fuel / bed material. General write up for Primary Air System : Primary air is drawn from atmosphere by centrifugal fan. Primary air (PA) is being used to fluidize the fuel / bed material in the combustor by passing the air flow up through the air box on the floor of the combustor. Primary air further helps in combustion of fuel. The primary air is heated (heat exchanged from flue gas) in the primary air heater in convection / back pass section before entering in to the combustor. Hot primary air passes through the air box and the grid nozzles creating high velocity air flow that causes the fuel / bed material fluidized. Note that there is a minimum primary air flow required to fluidize the bed and prevent back flow of the material through the nozzles. Hence, at low load operation of the boiler, the minimum primary airflow has to be maintained constant. Primary air fan control is via inlet damper (IGV) with RPC control according to the required airflow demand. The air flow is measured by the provided aerofoil meter with flow transmitter in the PA air at Air heater outlet duct. During start-up of the boiler, the PA fan is started after the ID fan, Seal pot (loop seal) blower and SA fans are started. Before starting the fan, the inlet damper of PA fan is to be kept closed to avoid overloading of the fan motor. The PA fan along with SA and ID fans is used for purging the boiler before start-up burner light-up.

Primary Air Distribution system : The cold primary air from PA fan outlet is connected to Primary air heater. Part of cold primary air is drawn before the air pre-heater and supplied to the bed ash cooler through the air box and air nozzles for fluidizing the ash. The hot primary air (HPA) is distributed to the combustor grid though the air box and the air nozzles located at the combustor bottom. Secondary Air System : The secondary air fan constitutes the combustion air system. The secondary air fan is used for supplying air for combustion in the combustor and assisting the fuel feeding. General write up for Secondary Air System : Secondary air is drawn from atmosphere by centrifugal fan and preheated in the air heater in convection section (back pass) before entering in to the combustion chamber. Hot secondary air is brought into combustor at 2 elevations (20 nos. entry at lower elevation and 20 nos. entry at higher elevation) for staged combustion, and to reduce NOx emission. Hot secondary air is also supplied to air bustle to assist the fuel flow into the combustor. The secondary air flow shall be controlled to optimise the excess air in flue gas and there by the boiler efficiency through O2 trimming at economiser outlet. O2 is kept ~3.5 % to ensure proper combustion. Loop seal Air System General write up for Loop seal air system : The loop seal air is drawn from atmosphere by 1x100% MCR capacity PD blower. The loop seal air passes through the loop seal air box and nozzles creating high velocity that causes the un burnt fuel from cyclone is getting fluidized. Also this air can be used for assisting / re-injecting the fuels return to the combustor. Part of loop seal air from blower O/L is drawn and utilized for bed ash cooler directional air nozzles to assist the bed ash transfers to adjacent compartments. FLUE GAS SYSTEM General write up for flue gas system : The combustor forms the chamber within which the combustion of fuel takes place and products of combustion (flue gases) are generated. The taller combustion chamber and re-circulation of bed material result in a longer residence time for the particles facilitating complete combustion of the fuel particles. As the hot flue gases move up the combustor, heat is transferred to the water walls and final wing wall (radiant) superheater sections before exiting the combustor. Flue gases leaving the top of the combustion chamber enter the water cooled cyclone (WCC) separator through the combustor outlet duct. Once the gas solids enter the WCC separator, the gas travels upwards through the vortex finder and enters the cyclone outlet chamber (COC) and further flue gases pass through the convection section (back pass) of the boiler vertically downwards across various heat transfer sections viz. Reheater- I, Re-heater-II, Primary super heater, economizer and air preheaters. Heat transfer from the flue gases to above sections is purely by convection. The flue gases then pass through the pre dust collector, ESP, ID fan and chimney to the atmosphere.

The flue gas from the boiler is drawn through ID fan, and evacuated / discharged to the atmosphere through the chimney. The ID fan inlet damper opening / position is controlled according to the pressure at the top the combustor which is the balance point (slightly negative pressure, -10 mmWC). Flue gas is analyzed for O2 at the Economiser outlet to monitor the efficiency of combustion process and SOx / NOx / CO analyzer at the common chimney for monitoring the SOx / NOx / CO level in the flue gas leaving the chimney. The SOx level can be controlled by adding lime stone, the NOx level can be controlled by flue gas temperature and CO level can be controlled by trimming the excess air. Solid Fuel Feeding System : Coal bunker is provided for storing the solid fuels. The outlet of the hoppers are connected to drag chain feeders through the rod gate and chain morris wheel operated slide gate connected in series for isolating the bunker. The fuel flows due to gravity into drag chain feeder which is driven by a geared motor and controlled by the VFD for delivering the required quantum of fuel to the combustor through four fuel feed inlets. Air bustles are provided at each of the fuel discharge line to the combustor from drag chain feeder. The air bustles assist free flow of fuel into the combustor and to arrest the reverse flow of hot gases into the fuel feeders, thus preventing any fire hazard. The secondary air flow for the air bustle is set through the manual damper and rotameter provided at the upstream of the air bustle. Additional air sealing is accomplished by providing regulated supply of cold secondary air through the Rotameter to drag chain feeder for providing effective sealing of hot gases entering the feeders. The drag chain feeders are designed to withstand 2 PSI pressure. Start-up Burner System : The start up oil firing system is designed for burning light diesel oil (LDO). Start up Burners are provided to heat up the bed material up to a temperature at which the solid fuel ignites so that solid fuel feeding can start. Four (4) numbers of start up burners are mounted on rear side walls of the lower combustor. Each burner is designed for 30 Mkcal of heat input. The start up oil system comprises of pressurizing pumping unit with screw oil pump and suction strainer.

DOSING SYSTEM
L.P Dosing : In LP dosing system, Hydrazine (N2H4) is dosed to feed water at the inlet of feed pumps (or) inlet of feed water tank to scavenge the last traces of dissolved oxygen in feed water. To ensure proper dosing, a residual concentration of Hydrazine (0.01 to 0.02 ppm) is usually maintained in the feed water. The correct treatment level may vary depending on operating conditions like water characteristics and boiler pressure. Description : DM water or condensate is mixed with concentrated Hydrazine using motorised agitator in mixing cum storage tank and further stored in that tank. Prepared chemical is dosed to feed water using

2 x 100% capacity reciprocating pumps (1W + 1S). The dosing rate from reciprocating pump can be varied by adjusting the stroke of the plunger through a scaled knob. At pump discharge a pressure gauge is provided in the common delivery line to read the chemical discharge pressure. One pressure relieving valve is provided to safeguard the pump against high pressure. Necessary isolation valves are provided to isolate the pump. One NRV is provided in the pump outlet to prevent the back flow of water to the pump. Procedure : When the boiler is under normal operation, chemical is dosed at a particular rate and feed water sample is analysed for residual hydrazine of 0.01 to 0.02 ppm. Based on analysis, the dosing rate is to be increased or decreased to get the required residual hydrazine in the feed water. Once the required residual hydrazine is obtained, the stroke and chemical concentration, ratio of water & concentrated N2H4, shall be recorded and should not be varied unless there is any change in the feed water quality. Handling and Storage : 1. Avoid contact with skin and eyes. 2. Chemical solution if prepared should be made in a covered tank. Since the chemical solution can absorb oxygen from the atmosphere, not more than one day requirement should be prepared at a time. LP Dosing : LP dosing is done at the inlet of economized, preferably at the suction head of feed pump. A mixture of Hydrazine (0.5 % solution of hydrazine in DM water and Ammonia (calculated quantity to maintain 0.5 ppm in feed water) is used for this purpose. Morpholine or cyclo hexylamine can also be used instead of ammonia. While ammonia increases the feed water pH to the required level (90.2) hydrazine will scavenge residual oxygen from deaerator the required level of 0.007 ppm. Alternatively, ammonia and hydrazine can be dosed independently to achieve precise control of these chemicals. H.P Dosing System : In HP dosing system, trisodium phosphate solution is dosed to steam drum to precipitate the dissolved salts forming hardness. These precipitated sludge is removed through blow down. To ensure proper dosing of phosphate, recommended amount of residual phosphate is maintained in the boiler water. The amount of required residual phosphate can be obtained from pH phosphate co-ordination curve which depends on the pH value of boiler water. Description : Trisodium phosphate diluted solution is prepared using DM water in a mixing tank and stored at storage tank. Water is thoroughly mixed with chemicals using motorised agitator. Prepared chemical is dosed to drum using 2x100% capacity common reciprocating pumps (1W+1S) - one pump per boiler. The dosing rate from reciprocating pump can be varied by adjusting the stroke of the plunger through a scaled knob.

Pressure relieving valve is provided to safeguard the pump against high pressure. Necessary isolation valves are provided to isolate the pump. NRV is provided in the pump outlet to prevent the back flow of water to the pump. Procedure : When the boiler is under normal operation chemical is dosed at a particular rate and boiler water sample is analysed for phosphate. Based on analysis, the dosing rate is to be increased or decreased to get the required phosphate (PO4). Once the required phosphate level is obtained, the stroke and chemical concentration (Ratio of water/PO4) shall be recorded and should not be varied unless there is any change in the feed water quality. This should not be varied unless there is any change in the boiler water quality. Handling and Storage : 1. Avoid contact with skin and eyes. 2. Avoid extremes of temperature. 3. Replace caps securely after use. 4. Maximum storage limit is 2 years. HP Dosing : Tri-sodium Phosphate solution (1% TSP in DM water) is dosed directly into the drum to further increase the boiler water pH to the specified level (100.2). The phosphate residual to be maintained in the boiler water is given in the Table -1 under Boiler Water quality. However achieving the desired pH is of paramount important than maintaining phosphate levels. A coordinated phosphate curve is given in FIG-8 to help maintain pH-PO4 levels avoiding free hydroxide in boiler water. Another means of controlling free hydroxide is by measuring P and M alkalinity with a thumb rule that 2P = M. Normally the P & M alkalinity levels to be maintained in Boiler Water are 10% and 20% of Boiler water solids, respectively. Silica Control : Silica carryover in high pressure boiler is more controlled by distribution law than mechanical carryover in high pressure boilers. Hence the silica level in steam is a function of boiler water silica and the drum operating pressure. pH also plays an important role in keeping silica in solution. Boiler water silica to be maintained for the required steam silica of 0.02 ppm versus drum operating pressure is given. Two different curves are given for 2 ranges of pH to be maintained in Boiler Water. Any excess silica build up of silica in Boiler Water is removed by blow down. However the best way to minimize blow down is to control silica and solids ingression through boiler input, viz make up water.

ELECTROSTATIC PRECIPITATOR
Introduction : The suspended particulate matter from the industrial exhaust is the major pollutant of the atmosphere. The exhaust flue gas consists of solid as well as fluid suspended particles. In most of the industrial processes these suspended particles are the residues of those processes and they have to be removed before they are let into the atmosphere. In some industrial processes, these suspended particles may be useful or reusable products to be collected to make the process more profitable. An earlier stage ESP had been used for this purpose only. Later on it has been found as a way of most efficient dust collecting equipment for many of the industrial applications. Principle : Electrostatic precipitator is basically an electrical equipment in which the dust is removed from the flue gas by means of electrical discharge and the removed dust is collected by means of mechanical rapping system. The operation of electrostatic precipitator will be of the following four phases Ionization of flue gas by high voltage discharge Charging of dust particles Igration and collecting of dust particles Removal of collected dust.

Working : In the electrostatic precipitator, the dust laden flue gas is passed through the passages between the collecting and emitting electrodes. The emitting electrode is a self-tensioned spring mounted in a framework and collecting electrode is of curtain like plate hung from top. A Transformer rectifier set will feed a very high DC voltage to the emitting electrodes (negative polarity) whereas the collecting plates are earthed (positive polarity). This high voltage emitting system ionizes the flue gas stream and form positive, negative ion cloud inside the electrostatic precipitator. Once this cloud of charge is produced it will start charging the dust particle to its saturation level. The (negatively charged) dust particles will be attracted towards the (positively charged) earthed collecting electrode plates and get deposited. The movement of dust particles towards collecting electrodes will be opposed by viscous drag, collision of dust particles etc., and the resultant velocity with which the particle moves towards the electrode is known as migration velocity or drift velocity. As soon as the dust particles get precipitated over the collecting electrode panels, they get discharged as the panels are earthed. The collected dust will be removed by the rapping mechanism at suitable preset timings. In order to obtain gas ionization it is necessary to exceed, at least locally, the electrical breakdown strength of the gas. It is called corona discharge. Sparking is essentially an advanced stage of corona in which complete break down of the gas occurs. Precipitators are usually operated at the highest voltage practicable with 5 to 7 sparking, since this increases both the particle charge and the electrical precipitating field.

Corona discharge is accompanied by a relatively small flow of electric current. Sparking usually involves a considerably larger flow of current, which cannot be tolerated except for occasional periods of a fraction of a second duration, and then only when suitable electrical controls are provided to limit the current. However, when suitable controls are provided, precipitators have been operated continuously with a small amount of sparking to ensure that the voltage is in the correct range to ensure corona. Besides disruptive effects on the electrical equipments and electrodes, sparking will result in low collection efficiency because of reduction in applied voltage, re-dispersion of collected dust, and current channeling. Advantages of ESP : Electrostatic precipitators have gained its popularity over other dust collecting equipments because of the following advantages. Low pressure drop Higher collection efficiency Less sensitive for temperature variations Suitable for any type of dust Lower maintenance and runtime cost

Parameters Affecting ESP Performance : Electrostatic Precipitators are usually designed for a set of inlet flue gas conditions. Variations in one or many of these parameters may lead to alteration in collection efficiency in Electrostatic Precipitator. Parameters influencing the performance of Electrostatic Precipitator are Resistivity of dust particles Flue gas temperature at ESP inlet Flue gas volume flow rate through ESP Flue gas composition Flue gas velocity with in ESP Inlet dust concentration Dust particle size distribution Gas distribution inside ESP Rapping frequency

Component Description Introduction : The success of any system depends on proper design, selection of material and method for construction and also the design of associated systems. This section has been developed to provide a general idea about the constructional features of ESPs. The knowledge about the various components involved in a system will help the end user to know the system in detail and operate it in a more

efficient way. This helps in sorting out the possible failure of system during operation and also easy for maintenance. As mentioned earlier the precipitator is made out of several bought out and shop made items. The major bought out items involved are the electrodes both collecting and emitting, insulators and transformer rectifier sets. Collecting Electrodes : The collecting electrodes are 750 mm wide selected as per design requirement. It is of 1.25 mm thick mild steel sheet made by cold rolling process. The profile of collecting electrodes is aerodynamically designed for higher stiffness and to minimize re-entrainment of dust particles along with the moving flue gas. The collecting electrodes are also designed to reduce sparks to sharp edges. The collecting electrode curtains are hung from support angles connected to ESP roof beam. The bottom of collecting electrodes are connected together and made as a panel by means of shock bars at the end of which the shock bar pads are bolted. Emitting Electrodes : The emitting electrode is a spiral wire made of high-alloyed stainless steel material. The electrodes are supplied to site as closely wound coils. During erection the electrodes have to be stretched using stretching device adequately/uniformly and connected between suspension frames. These spiral electrodes are self-tensioned and remain in its position perfectly aligned. Further these electrodes are easy to handle, install and to maintain. Moreover they produce a uniform current distribution over the entire height of the collecting electrode panels. Slide Bearings : The ESP casing is supported over high efficient sliding bearings, which are taking care of casing thermal expansions. Three types of bearings are normally used called fixed, mono-axial and biaxial bearings. The bearings have been designed for various loads such as wind and seismic in addition to dead loads. The bearing top plates to be bolted with casing column base plate and the bearing bottom plate to be welded or placed in races provided in supporting structure bearing plate. TR set with Controller : As the dust laden flue gas passes through the collecting and emitting electrodes, the ESP can be considered as a capacitance load having variable dielectric strength. The dielectric strength varies due to changing parameters of the flue gases. The high voltage DC applied to the ESP has been continuously adjusted to minimize sparking across the discharge and collecting electrodes. The voltage controller in the transformer rectifier control cabinet senses the current feedback from the ESP and does the following functions. It maintains the voltage across the ESP at the spark threshold level in al the conditions to achieve optimum efficiency. During no sparking conditions, maximum power is made available across the ESP.

 In case of spark, it brings down the voltage by preset value. The voltage is raised to spark threshold level if no further sparking is considered. In case of arc, it brings down the voltage to zero and blocks it for preset time. The voltage is restored to the preset value by fast ramp and then to the spark threshold level by slow ramp. High Voltage Support Insulators : The entire emitting system is rested over high voltage porcelain cylindrical insulator that isolates the entire system from the casing, which is earthed. The support insulators have been designed for heavy compression loads. The insulators are located over ESP hot roof inside separate heated compartments. Each insulator is provided with a coil type of heater to maintain the temperature of insulator slightly higher than ash condensation temperature. One number thermostat is provided per field to control the insulator heaters at required temperature level. Mechanical Safety Interlock System : This system provides the safety of person attending ESP. This system ensures that no person can enter into ESP unless all the Transformer Rectifier sets are de-energized and grounding switches of TR sets are in ground position. Hopper Heaters : Continuous removal of collected ash from ESP ash hopper is essential for better as well as safe working of ESP. In order to maintain the free flow of ash through hopper discharge flange, the bottom portion of ash hoppers are heated using coil type of heaters. This prevents ash build up in the hoppers. The heaters are thermostatically controlled to maintain the temperature upto a maximum of 230C. High level Switches in Hopper : RF type capacitance level switches are provided in each hopper. The level switch operates when ash level inside the hopper rises and touches the level switch probe. The level switch gives signal to the audio visual alarm annunciator provided in the Auxiliary control panel to indicate high ash level in the hopper and trips the TR set. Even after tripping the TR set, the dust will continue to buildup in the hopper. Auxiliary contact of high hopper level relay will be provided in the Auxiliary control panel. If the high level alarm is persisting, it is recommended to stop the boiler after one-hour time delay. This prevents ash building up in the hoppers, which ultimately shorts the emitting electrodes. ESP Casing, Hoppers, Inlet and Outlet Funnels : Casing plays the important role in the construction of precipitator. It is made out of rigid welded construction consisting of prefabricated columns, side and roof panels. The casing construction itself requires much higher time during erection. The casing has been designed for various loads and proper selection of column and stiffener members have been done to provide a rigid construction. The casing panels are fabricated either at shop floor or at site to closer tolerances. The casing is being erected with higher care, which minimizes electrode alignment problems and leakages. Pyramidal type of ash hopper is provided for each field with sufficient storage capacity and valley angles as per CVL standard design or to conform the customer requirement. The inlet and outlet

funnels are designed for proper distribution of flue gas over the entire area of collecting electrodes across the cross section of the precipitator. Collecting Electrode Suspension : The collecting electrodes are hung from hooks welded to support angles, which in turn supported to ESP roof beam. The bottom of collecting electrodes is bolted to shock bars, which makes the collecting electrodes into a single curtain. The top and bottom suspension of collecting electrode curtains are suitably locked by support angles and shock bar guides to avoid swinging or misalignment. This firm fixing at top and bottom provides sufficient rigidity and also uniform distribution of rapping force to the entire surface of the collecting electrode curtain. Collecting Electrode Rapping : High efficient tumbling hammer type of rapping has been provided for both collecting as well as discharge electrodes. Individual rapping hammer for each row of collecting electrode panel is provided. The rapping force is transferred to electrode through the shock bar pads. The rapping creates acceleration such that the dust cake dislodges from the collecting electrode panels without getting broken. This avoids the re-entrainment of collected dust into the flue gas stream. The rapping frequency should be kept as low as possible, which provides sufficient cleaning as well as to reduce the reentrainment of collected dust. Micro controller based rapping programmer is provided to control each rapping drive individually. The rapping programmer should be programmed in such a way that minimum percentage of collecting electrode area should be rapped at any one time. Emitting Electrode Suspension : The spiral electrodes are stretched between the top, intermediate and bottom frames thus forming a complete framework. The spirals are kept self tensioned which reduces the swinging of electrodes. The taut wires are also susceptible to rapping forces and hence stay clean always. Emitting Electrode Rapping : Tumbling hammers, which are mounted, on horizontal shafts supported in the frame itself, does rapping of discharge electrodes. The hammers hit the special shock beams, to which the intermediate frames are connected. Due to rigid framework the rapping energy generated by the hammers is distributed efficiently to all parts of the framework, including all the discharge electrodes. The rapping shaft is directly coupled to drive unit via shaft insulator housed in an insulated box. Coil type heater is provided to heat shaft insulator in order to avoid clogging of dust. Gas Distribution Screen Arrangement : The gas velocity inside ESP will be much less than the velocity of flue gas inside ducting before the precipitator. In order to achieve even distribution of flue gas throughout the entire cross section of ESP, specially designed gas distribution screens are located at the inlet of the precipitator. In addition to this, deflector plates are also used to achieve better flow pattern. Clogging of dust on screen plates may disturb the flow pattern and hence GD screens are provided with rapping mechanism with tumbling hammers.

STEAM TURBINE
Introduction : The steam turbine generator is the primary power conversion component of the power plant. The function of the steam turbine generator is to convert the thermal energy of the steam from the steam generator to electrical energy. Two separate components are provided: the steam turbine to convert the thermal energy to rotating mechanical energy, and the generator to convert the mechanical energy to electrical energy. The turbine is directly coupled to the generator. Steam Turbine: Type of the turbine will be super-high, reheat, single-casing, single-exhaust, impulsive and condensing steam turbine. This unit will have only one rotor, which is an integral HP-IP-LP solid rotor without shrunk-on discs to improve the reliability of the rotor. The coupling will be in integrity with rotor and in rigid connection with generator rotor to provide good reliability. MSV( Main Steam Valves) : The steam from the steam generator flows to the main steam stop valves. The primary function of the stop valves is to provide backup protection for the steam turbine during turbine generator trips in the event the main steam control valves do not close. The energy in the main steam and steam generator can quickly cause the turbine to reach destructive over speed on loss of the generator load. The stop valves are also closed on unit normal shutdown after the control valves are closed. Main Steam Control (Governor Valves) : The steam flows from the stop valves to the main steam control or governor valves. The function of the control valves is to regulate the steam flow to the turbine and thus control the power output of the steam turbine generator. The control valves also serve as the primary shutoff of the steam to the turbine on unit normal shutdowns and trips. HP MSV & IP MSV : HP combined stop and control valves, and IP combined stop and control valves will be arranged at both ends of HIP casing of steam turbine. Each HP combined stop and control valve will consist of 1 stop valve and 2 control valves, with inlet at the bottom and outlet at the bottom. Each IP combined stop and control valve will consist of 1 stop valve and 1 control valve, with inlet at the bottom and outlet at the bottom. After working in IP and LP flow path, the steam will be exhausted to condenser from LP casing. Heat recovery system : Six stages heat recovery system is composed of single reheat and two HP heaters (with internal steam condenser), one deaerator and three LP heaters. The draining water of each heater will flow stage by stage. The draining pump is provided at the draining outlet of LP heater # 2

The 3rd stage steam extraction is used to heat the dearator and shall meet the requirements of auxiliary steam consumption of the power plant. Bypass System : The unit is designed with two stages bypass system in series with a total capacity of 60% BMCR. The HP bypass steam will mix with exhaust steam from HP turbine after desuperheater. The LP bypass steam will enter the condenser after the desuperheater. VWO (Valve Wide Open working condition) : The inlet steam flow of turbine shall not be less than 1.05 of the nameplate inlet steam flow when the valve is wide open. such working condition is called valve wide open (VWO) working condition. Under this condition, the steam turbine could operate in stability and safety within the guaranteed life span. This working condition is for evaluating the steam admission capability of turbine. The output under VWO working condition with out make up shall be 142.463 MW. Bearings : Steam turbines have journal bearings and thrust bearings. Journal bearings are at each end of each rotor to support the weight of the rotor. Thrust bearing typically is provided along with the journal bearing for the turbine front bearing to maintain the axial position of the rotor. Journal Bearings : This unit shall be applied with elliptical radial bearing. The front journal bearing shall be consisted of bush pad, bearing shoe sleeve and bearing shoe body. Babbit metal alloy shall be casted on the bush pad. The rear journal bearing shall not have bush pad. The baring shall be divided into the upper half and lower half, and fixed and located by srew and cylindrical pin, and the bearing shoe body and bearing shoe sleeve shall be spherical fit and have the action of self-aligning,(rear journal bearing shall not have spherical faces). Thrust Bearings : The thrust collar shall be incorporated with the main shaft of turbine at the front side and rear side. The positive thrust pad and reverse thrust pad shall be installed respectively. Total of ten pads shall be arranged on the whole circumference and the platinum heat resistance temperature measuring device shall be mounted on each pad to measure the pad temperature. Turning Gear : A turning gear rotates the turbine rotor at slow speeds before startup and just after shutdown. This minimizes uneven temperature distribution in the covers and bases of the turbine. The turning gear consists of an electric motor drives the turbine rotor. Turbine Lube Oil System : The oil system equipped with reliable main oil supply devices and auxiliary oil supply devices to supply the oil flow required by all bearings and control and protection(including oil for test) system

of turbine-generator unit during start, stop, and normal operation and emergency conditions. Lube oil system consist of main oil tank, main oil pump, HP Oil pump, AC lube oil pump, DC oil pump, oil jacking pump, oil coolers, common storage oil system, oil mist separators, centrifuges, piping and instrument to supply required oil flow for the bearings and accessories of each set of turbine-generator unit, thermometer well and movable strainer on oil feeding piping etc. Jacking Oil System : The jacking oil pump to supply oil to all bearings of steam turbine and generator. The Jack oil pumps are arranged in proper position to ensure reliable operation and avoid oil leakage. The unit is equipped with two High Pressure Jacking oil pumps, one shall be put into operation, and the other set shall be kept as stand by. The pumps are equipped to supply jacking oil for bearing, with highest oil pressure; the shaft jacking oil pump shall be started up before the unit putting into barring Gland Steam Supply System : The gland system is automatic type and has the function of pressure automatic control of gland sealing. The gland steam system is equipped with Temperature Control device (desuperheater for selfsteam) overflow relief device pressure auto-regulator and gland steam exhauster. The source for gland steam is from auxiliary PRDS station. External source for sealing the glands to be supplied approximately up to 40 % of the total load. LP gland desuperheater shall reduce the temperature for LP gland sealing steam in the pipes of supply steam before the supply steam pipes entering into condenser, to make LP gland steam temperature maintained at the range of 121Deg. C to 150 Deg. C

GENERATOR
The rotational mechanical energy is converted to electrical energy in the generator by the rotation of the rotor's magnetic field. The rotation of the turbine turns the rotor of the generator, producing electrical energy in the stator of the generator. The generator rotor consists of a steel forging with slots for conductors that are called the field windings. An electrical direct current is passed through the windings, causing a magnetic field to be formed in the rotor, This magnetic field is rotated by the turbine. The rotor is surrounded by the generator stator that includes copper conductors. The magnetic field of the rotor passes through the stator, setting electrons in the stator conductor in motion. The flow of electrons is called current. As the rotor's north pole passes through the same conductor, the current flows in the opposite direction. This type of electrical current is called alternating current (ac). As the coils are displaced in space by 120 mechanical degrees, and there is only one rotating magnetic field, the voltage and current produced in each of the three phases are displaced in time by 120 electrical degrees. Thus, the power produced is called balanced three-phase power. The real power generated is represented by kilowatts (kW). The kilovolt amps reactive (kVAR) component is the reactive component, that is a result of the current that is out of phase with the

generated voltage from the rotor field. The total generator output is represented by kilovolt amperes (kVA). The generated power from 135MW unit at 13.8KV will be stepped up to 400KV through 180MVA generator transformer(GT).The connection from generator to GT will be through isolated phase bus duct(IPBD). The power plant auxiliaries will be powered through unit auxiliary transformer(UAT). The startup power will be obtained from 400KV grid through station transformer (ST) (40MVA). The secondary of ST 6.6KV will be connected to station service switch board. From this station service switch board, unit service switch board will be powered during startup. After synchronizing of generator unit with grid supply at 400KV level, the UAT will take care of its unit auxiliaries power supply and interconnection between unit service switch board and station service switch board will disconnected. UAT primary is tapped of before GT in IPBD.

CONDENSER
Water Cooled condenser are preferred when reasonable soft filtered water is available. The water cooled system operate at lower condensing temperatures, giving better COP as water cooled system consume less power and have a longer life. The condenser receive and condense the whole of the exhaust steam from the turbine, including HP -LP steam bypass system and drains & vents under all modes of operation. The condenser is designed according to the TMCR working condition of turbine. The cooling water temperature is 33C and the back pressure is 9.8 kPa. The condenser is double flow type with partition in the water chamber. The circulating water could go through the inlet and outlet at one side. When single side is in operation, the turbine could operate at 75% of the rated load when the inlet cooling water temperature is 33C. The condenser continuously operate to ensure the oxygen removing requirements under the TVWO working condition and cooling water temperature at 33C. The condenser receive Steam from turbine bypass system upto 60% flow, Condensate from turbine, draining water from heater, draining water from turbine, feedwater, water for condensate pump, LP turbine sparying water, returned water of feed water pump sealing and other returned water entering the condenser and removes the oxygen.The condensate, draining water and returned water effectively heated and sprayed to achieve the best oxygen removing effect. The sprayed water shall not contact with tubes directly. The over-cooling of condensate at condenser outlet under the TMCR working condition shall not exceed 0.5C. The air extraction area of condenser designed according to the cooling requirements of air/steam mixture. Under the rated working condition, the temperature at air outlet shall be 40.5C lower than the saturated steam temperature at the pressure of condenser outlet. The partition is equipped in the water chamber. The circulating water could operate with one side in operation. When the circulating water temperature is 33C, the output of turbine could be 75% of nameplate power with single side of condener being in operation. The following facilities are provided for the condenser: 1. The hot well could exhaust the water at normal operation level in one hour. 2. Receive, distribute and discharge the steam from bypasss system of turbine

3. Receive, distribute and discharge the draining water from extraction piping. 4. Receive,distribute and discharge the draining water of condensate pump, feedwater heater, draining water of turbine proper, draining water of gland cooler, makeup water, draining water of steam piping and other flow. 5.The recirculation of condensate is connected with the devices for eliminateing the pressure, vibration and anti-impact in the condenser. Working Principle : Steam entered into shell of steam side, flowed along with baffles, condensated into drain after cooling, spilled from drain outlet at the bottom of shell and flowed into next stage Low Pressure Heater; feedwater enter into water box through inlet pipe and then heat exchange with steam outside of heat exchange tube, feedwater outlet and enter into next stage Low Pressure Heater through feedwater outlet and enter into next stage Low Pressure Heater , at last enter into deaerator from Low Pressure Heater. Hotwell : The anti-vertex device is equipped at the outlet of hotwell with strainer. The vacuum valve is provided on the draining piping of hotwell. This pipe could exhaust all condensate below the normal water level in one hour. The baffle is equipped in the hot well. The connections are provided to measure the conductiveity of the tube bundle in water chamber. Vacuum of condenser : Two vacuum pumps are provided for each condenser. Two sets used during the startup. One set of vacuum pump ensure the normal vacuum of condenser during operation. The motor-driven vaccum breaker valve is provided on the condenser shell. The strainer and water sealing device are provided at the inlet of valve. The vacuum extraction time shall not excced 40 minutes during unit startup.

DM PLANT TREATMENT SYSTEM:

Raw Water shall be drawn from Korai Annicut on Kholar Nalah (where the water from Ahiran River and Kolhar Nalah is stored) and fed to the plant raw water reservoir. Raw water will be taken through a Flow Control Station to a Stilling Chamber where turbulence of raw water will be broken. An online magnetic flow meter shall be provided at the inlet of Stilling Chamber to measure the flow. In Stilling Chamber, pre chlorination of raw water shall be carried out by use of gaseous chlorine. Chlorination shall be carried out in continuous mode @ of 5 ppm on 100% basis. The System shall be complete with Chlorine Ton Containers, Chlorinators along with chlorine feed rate adjuster, Chlorinator Water Booster Pumps , Strainers, Pressure Regulating Valves, Piping and Diffuser Systems up to the stilling chamber along with all other necessary accessories and auxiliaries like weighing scale, monorail hoist, safety and supervisory equipment etc. The emergency leak absorption system is designed to neutralize one ton of leaked chlorine gas in one Hour as per standard industrial practice. Water will then flow to one (1) no. x 100% High Rate Solid Contact Clarifier. Water loss for disposal of sludge from high rate solid contact clarifier shall be around approx. 5% of treated water.

Chemicals such as Ferric Chloride (Coagulant), Lime& Polymer (Polyelectrolyte) will be added to raw water at the high rate solid contact clarifier on continuous basis.The dosage ppm will be adjusted during commissioning stage by conducting the jar test. The clarified water from the Raw water treatment plant shall flow under gravity to the Clarifier Water storage tank having sufficient storage capacity to meet the requirement of clarified water for general service and for fire water service (5000 m3 Capacity i.e. 3000 M3 for plant water make up and 2000 M3 capacity dead volume for fire fighting). Clarified Water from Clarifier Water Storage tank will be pumped directly to Multi Grade Filters (MGF) by Filter Feed Pumps, located at Clarified Water Pump House for reduction of Suspended Solids. The Multi Grade Filter will operate in backwash mode whenever the difference in pressure across the Multi Grade Filter exceeds 0.8 Kg/Cm2 or once in 24 Hrs whichever is earlier. For backwashing of the Multi Grade Filter a separate 1 x 100% Filter Backwash Pump utilizing clarified water from Clarifier Water Storage Tank shall be provided. Filtered Water from MGFs, shall flow to , Ultra Filtration (UF) system through Pre-Filters. The UF system shall be backwashed automatically as per the requirement. Permeate from UF system shall be stored in Ultrafilter Product Water Storage Tank for further treatment by Reverse Osmosis. Reject from UF system shall be routed to the neutralization pit through trenches. Ultra filtered water from Ultrafilter Product water storage tank shall be pumped to micron Cartridge Filters for further filtration, prior to Reverse Osmosis (RO) Modules. The UF permeate water shall be pumped to the RO module by (3 x 50%) RO Feed pumps. A part of Ultra filtered water shall be used for potable purpose. The Ultra filtered water shall be pumped by (2X100%) Potable Water Transfer Pumps from Ultrafilter Product Water Storage Tank to Potable Water Treatment System for on line disinfection, by a Sodium Hydrochloride Dosing System. Chlroine (Sodium hypochloride) will be added to UF permeate water on continuous basis. After disinfection, the treated water shall be stored in Potable Tank for further distribution. Required quantity of antiscalant shall be dosed before micron Cartridge Filters in order to reduce scale formation tendency of feed water on the surface of the RO Membranes. Sodium Bi Sulphite (SMBS) shall be dosed to de-chlorinate the water and HCl (Hydrochloric Acid) shall be dosed to maintain the pH. After Dosing, filtered Water from Micron Cartridge Filters shall be passed through, RO High Pressure Pumps to deliver water at desired pressure to the inlet of Reverse Osmosis Modules. Each Reverse Osmosis Modules will have a rated continuous treated water output capacity . Permeate shall be passed through , Degasser Tower to reduce the dissolved CO2 content in the water. Water from Degasser Tower shall be collected to the Degassed Water Storage Tank. Degassified RO Permeate water, will finally be pumped by Degasser water transfer pumps to Mixed Bed Units for further reduction of TDS, to get desired following quality of Water. Total SiO2 pH value at 25 0C Conductivity, micro mho/cm 0.01 ppm SiO2, max. 6.8 - 7.2 < 0.1 at 25 Deg C (Before pH correction dosing )

Waste water Treatment System : The basic functions of this Waste Water Treatment Systems are to meet the requirements of pollution control authorities for the power plant effluent. The parameters for power plant effluent discharge if any shall be within the limits as formulated by Central Pollution Control Board (CPCB) and SEIAA CG/EC/TC/TPP/KOR/32/08 dated 22.12.08. Effluents will consist of the following : 1. 2. 3. 4. Sludge from Pretreatment Plant. Waste water from water treatment plant Oily effluents from different areas. Sewage from Plant building and non plant building

1. Sludge from Pretreatment Plant : The sludge from High rate solid contact clarifier will be taken by gravity to a Sludge Sump for storage purpose and subsequently will be pumped by Sludge Transfer Pumps to Thickener. Under flow from the Thickener will be pumped by centrifuge feed pumps to Centrifuges. Clear water from the Thickener and centrifuge will be routed back to stilling chamber by means of clear water transfer pump. 2. Waste water from water treatment plant : The effluent generated in water treatment Plant due to regeneration of MB Units, RO rejects, UF Rejects , MGF & UF Back wash and UF fast flush will be routed to neutralization pit through trenches. Neutralized Effluent from neutralization pit will be transferred to the Central Monitoring Basin for further utilization. A part of Cooling Tower blow down water will be led to the Central Monitoring Basin after quenching, balance Cooling Tower blow down shall be sent to Ash Water Sump near Silo. Boiler blow down from all units shall be collected in a sump called as `Boiler Blow Down Sump after being quenched will be transferred to central monitoring basin by boiler blow down transfer pumps. 3. Oily effluents from different areas : Oily effluents will be generated from Transformer Area,Power house area and Fuel Oil Pump House. Oily effluent from above mentioned areas will be collected in a common oil collection pit .The oil effluent from Oil collection pit (Common) shall be pumped by means of Oil effluent transfer Pumps to Oil Separator (Corrugated Plate Interceptor-CPI type) for removal of oil and suspended solids. Separated oil shall be collected in a Slop Oil Storage Tank . The treated water from oil separator will be discharged in a Treated Water pit from where treated water shall be pumped finally by treated water transfer pumps will routed back to CMB which is an intermittent operation. 4. Sewage from Plant building and non plant building : Sewage from plant building like raw water pump house, TG building , WTP building, PT chemical house and switch yard control room and non plant buildings like Admin. building, plant service building, canteen , security room, time office, security personal room etc. will flow through Bar Screen Chamber (consists of Fixed Bar Screen) for removal of debris and air born larger suspended

solid particles. Sewage from downstream of the bar Screen Chamber will be collected to Sewage Collection Sump. The Sump shall be equipped with air diffusers in order to have the effect of equalization and prevent settlement of the solids. Effective capacity of Sewage Collection Sump shall be sufficient to store the sewage produced in twenty four (24) hrs at full load operation of 2X135 MW Units. From Sewage Collection Sump, sewage will be transferred to Fluidized Aerobic Bio Reactor by Sewage Transfer Pump. Air blower is provided to supply necessary air for Fluidized Aerobic Bio Reactor and sewage collection sump. From Fluidized Aerobic Bio Reactor, the aerated sewage will be transferred to settling tank by gravity for removal of suspended solids. Overflow clear water from settling tank will be collected in clear water tank. Clear water will be pumped by 2 x 100% clear water transfer pump to Pressure sand filter after disinfection. Disinfection of clear Water will be carried out by dosing of Sodium Hypo chloride solution. Chlorine will be added to Clear water on continuous basis. After disinfection, the clear water will pass through to the pressure sand filter and activated carbon filter for effective removal of suspended solids, organics and colour. The filtered water will be then stored in 1 x 100% filtered water tank and further utilized for toilet flushing , gardening and horticulture. Under Sludge from settling tank will be pumped by sludge transfer pump to sludge Drying Beds for separation of the sludge and water. The under-bed filtrate shall be transferred to Sewage Collection Sump and the solid sludge may be used as manure.

FUEL OIL SYSTEM

LDO(Light Diesel Oil) Unloading System : The LDO road tankers unloading station arranged so that two (2) nos. of road tankers can be unloaded simultaneously through individual hose coupling tankers to one (1) no of LDO storage tank. The discharge head adequate to meet the pumping from road tankers into a nearly full storage tank operation with the worst case oil viscosity. LDO Storage Tanks : Fuel oil storage tanks and day tanks surrounded by a containment dyke of sufficient capacity to hold the entire contents of the largest fuel storage tank plus sufficient free board. Effective capacity means the capacity between High level and Low level. High level 100 mm below High High level and Low level will be 100 mm above top of the outlet nozzle. Fire Fighting Arrangement Fixed Foam System : The tank provided with a foam system as per NFPA. The tank provided with adequate nos. of mechanical type foam pourers and foam makers.

Medium Velocity Water Spray System (Fixed Water Spray System) : The tank provided with a medium velocity water spray system. The tank sahll be provided with adequate nos. of spray nozzles, frangible bulb detectors and the associated piping around tank shell.

COOLING TOWER
In cooling towers, the warm water is discharged from the condenser and fed the cooled water back to the condenser. The rate o evaporation of water in cooling tower and subsequent reduction in water temperature depend upon the following parameters. 1. 2. 3. 4. 5. The exposive time Amount of water surface exposed Relative humidity of air. Velocity of air Accessibility of air to various parts of cooling tower

Induced draft cooling towers: In induced draft cooling tower, the draft fan is installed at the top of tower and air is drawn through it. The hot water is sprayed through the nozzle to pass it over the air and the water is cooled. The air is moving in the upward direction to cool the water. The cooling effect of water is done by (1) Evaporation and (2) Heat transfer to the air. The cooling effect is done by about 75% by evaporation.

ASH HANDLING SYSTEM

Ash Collection System Bed Ash Collection : The CFBC boiler is provided with two Fluidized Bed Ash Coolers (FBAC) and two Rotary Bed Ash Coolers (RBAC), designed to handle 100% of the bed ash flow with any one cooler (in either FBAC or RBAC) out of Operation. The cooled ash from both FBAC and RBAC will be directly conveyed to dense phase ash handling system. Fluidized Bed Ash Coolers : The hot bed ash from the CFB furnace at around 900 C is led into the ash cooler where air will be supplied to fluidize the bed ash. Upon fluidization, the ash loses its heat and the air temperature rises. Typically, FBAC has more than one section to increase the residence time of the ash so that it gets completely cooled to a temperature at which it can be easily handled. Apart from air, cooling coils are also inserted into these sections to recover heat from the ash.

Rotary Bed Ash Coolers (Drum Coolers) : The Rotary Bed Ash Coolers (RBAC) (also called as Drum Coolers) are located directly beneath the CFB Furnace. Hot bed ash from the CFB furnace at around 900C is led into the drum coolers through the drain pipes provided in the main furnace grid. Displacement of hot ash from the furnace to the coolers takes place mainly by the difference in pressure levels and by gravity. The drum cooler will be rotating at low speeds and by that way circulates the incoming hot ash within the drum and moves it to the other end with the help of fin like scooping segments attached to the drum. The drum is water jacketed type with cooling water flowing inside. Hot air transfers the heat to the cooling water and in turn gets cooled to a level at which it can be handled by the chain conveyors provided at the bottom of the coolers. Bed Ash Screw Cooler : The integral bed ash cooler provided in the right side and left side of the boiler is having three compartments and each compartment is provided with one ash drain point. During normal working of integral bed ash cooler, heavier ash particles will accumulate in the compartment-I, and needs to be drained. As the drained ash will be at a temperature of 900C, screw type water jacketed ash cooler is provided at the ash drain point. This will cool the ash to around 250C to enable handling of ash and disposal. Ash cooler is provided with screw flights on a hollow shaft cooled by water. The screw flights act like fins and transfer the heat from ash to the water in the shaft. The shaft is supported at both ends on Plummer blocks. The body of the cooler is also jacketed and water cooled. The shaft is provided with a rotating union which is connected to the cooling water inlet. Cooling water after passing through the shaft, enters the casing jacket and comes out. The cooling water circuit is protected by a relief valve to guard against any over pressure. The ash cooler shaft is driven by a geared motor which runs at very low speed. The motor and screw shaft is connected by chain and sprocket. The screw is driven by a low speed geared motor through VFD control. The ash quantity that can be drained can be varied between 100 to 300 kg/hr using VFD control. Cooling Water System : The cooling coils provided in the FBAC and the drum of RBAC both need cooling water to cool the ash which comes from the furnace. It is preferred to have DM water as cooling medium for the rotary bed ash cooler. However, the quantity of cooling water is very high considering the amount of bottom ash generated from the boiler. In view of this, it is proposed to have a closed loop cooling water system wherein the DM water will be made to circulate within the system resulting in very less requirement. The primary cooling of ash is by DM water and the hot DM water is cooled by auxiliary cooling water of the plant in a water to water heat exchanger. The whole cooling water system is made to operate at or near atmospheric pressure by providing a reservoir in the circuit wherein the minimum DM water level is maintained by making up a small percentage of water loss in the system. The schematic arrangement of the system is shown above. The cooling water system is designed in such a way that the FBAC and RBAC can be operated individually, with each of the cooler in each stream can be bypassed. There is flexibility in the system to operate both FBAC and RBAC simultaneously also.

The cooling water flow to each stream is monitored and regulated based on the water outlet temperature that goes to the heat exchanger. Heat exchanger is of a shell and tube type. The cooling media is a plant auxiliary cooling water. Necessary instrumentation such as pressure gauges, temperature elements and relief valves etc. have been provided to monitor and safeguard the cooling water system. Bed Material Feeding System : Please refer the bed material feeding system applicable for this project. The bed material bunker used for storing the required bed material. The bunker outlet is provided with a slide gate for isolation of bed material flow to the rotary feeder provided for feeding the bed material to the combustor. The rotary feeder is provided with slide gate type isolator at the outlet. Fly Ash Collection System : The fine ash that is carried by the flue gas from the hot cyclone separator outlet is collected at various sections of the boiler such as air heater hoppers, pre-dust collector (cyclone) hoppers and ESP hoppers. Ash collected from these hoppers are handled by a separate system (supplied by others) to the ash silo. Each hopper, adequately sized ash vessel with pneumatic operated ash inlet valve, discharge valve, air inlet valve and air vent valves provided. The ash vessels may be either top discharge or bottom discharge. The hopper fluidizing pads, fluidizing air blowers, heaters, pipeline etc required for hopper fluidization also be provided. Knife Gate Valves - Manual/Pneumatic operated : Knife gate valves are manual and pneumatic air cylinder operated for hoppers isolation, fly ash silos, silo changeovers, branch isolation in fly ash streams furnished. Valve provided with a mechanical indicator and limit switches to indicate open or close position of the valve locally and remotely. Pneumatic operated valve provided with limit switches and indicator to indicate open and closed position of valve locally and remotely. Construction of the valve such that worn out components (slide plate and seat etc.) can be replaced easily. Fluidizing Pads : Electrostatic Precipitator hopper adequately sized ceramic fluidizing pads or polyester cloth with SS wire mesh type furnished complete with encased sheet steel frame work, mounting bolts, gaskets etc. as required as well as air connections with isolating valves for the completeness of the system. Ash Vessels : Ash vessels installed beneath Surge hoppers, Economiser, APH and ESP hoppers adequately sized and designed to effectively collect the ash at specified rate. The design of the equipment such as to ensure a perfect seal against any leakage through vessels. Ash vessels can be either top discharge type or bottom discharge type depending upon bidder's design. In case the vessel is top discharge type, suitable fluidizing panel provided on the bottom portion of the vessel for fluidization of ash before transportation. The connecting pipes from Surge hoppers,

Economizes APH or ESP hoppers outlet to ash vessel inlet adequately sized to avoid ash choking in this region. Ash intake/ Ash Discharge/ Air Vent Valves : Ash intake valve at the inlet and Ash discharge valve for each ash vessel provided. Valves shall be totally enclosed type and designed for no air leakages. The valves air electric, pneumatic operated type consisting of a double acting air cylinder. Valves provided with suitably located poking port/access plug/panel. Ash Silos : Fly ash silo an effective capacity of 1150 M3. Bed ash silo an capacity of 1430m. The silos of RCC construction and supports also be of RCC construction. Ash silo complete with RCC covered roof, manhole with ladder for the access inside the silo, pressure relief doors, silo vent filters, handrails, access staircase with intermediate platforms, silo fluidizing equipment complete with air slides, complete piping and valves for the entire air supply system, adequately sized openings for maintaining the air slides, operating platform at the ash conditioner floor and all other needed equipment. Bag Filters : Bag filters of adequate capacity provided on ash silos for separating ash from air. Vent fans provided complete with drive motor and flow accessories. Suitable automatic on line pulse jet type bag cleaning arrangement provided with all accessories such that the dislodged ash from the filter discharged back into the silos as applicable. Fluidizing Blowers : There are three adequately sized (capacity and head) heavy rugged construction, positive displacement and rotary in air cooled ESP fluidizing blowers. There are three adequately sized (capacity and head) heavy rugged construction, positive displacement and rotary in air cooled Silo fluidizing blowers for fly ash silos. The Silo fluidizing blowers located on the operating platforms of fly ash silos. Rotary Feeder : Rotary feeders for bed ash silo & for fly ash silos with suitable drive unit provided below the silos. The rotary feeder designed so that the feed of the material controlled automatically to prevent sudden surges and capable of delivering the specified rate of ash to the ash conditioner/telescopic chute. The rotary feeder compact design capable of handling ash at a wide range of unloading rate. Rotary feeder unit provided with removable type blades with hard facing and suitably heat treated for its design capacity at site. Ash Conditioner : Ash Conditioners provided for conditioning the ash prior to unloading into closed trucks/mixing tanks. The equipment so designed that the feed of material controlled automatically to prevent sudden surges and capable of delivering the specified rate of dust free suppressed ash. The equipment compact

design capable of handling ash at a wide range of unloading rate. Water required for dust suppression is fed from Ash conditioner water pumps. Fluidizing Elements : Adequately sized ceramic fluidizing elements provided in ash silo to convey dry ash to unloading system. The air inlet connection is provided at the bottom. Conveying Air Compressors : Conveying air compressors for conveying both bed ash and fly ash from collection points to ash silos furnished suitably interconnected for flexibility in operation, designed for continuous operation with high efficiency to satisfy the system requirements. The compressors of indoor duty complete with air coolers necessary valves with vent pipe work ducted to a safe discharge outlet. Compressors identical screw type. Compressors have an inlet filter and silencer unit having inlet area large enough to ensure that frequent filter changes are not required. Air Receivers : The air receiver of vertical cylindrical design with dished ends. Thickness, volume and structural calculations furnished for approval. The air receiver have inlet/outlet connections, safety relief valve, fusible plugs, pressure gauge and pressure switch, flanged pipe connections, and inspection manholes with automatic drain traps. The air receiver have structural platforms for maintenance of safety relief valves and instruments. Water Pipe work : Pipe work designed for the maximum pressure (pump shut off) and corrosion margin. All piping internally cleaned and flushed by the bidder before and after erection in a manner suited to the service and to the complete satisfaction of the Engineer. All the piping systems thermostatically tested at a pressure equal to the design pressure of the system All flanged valves match the flanged pipe work, wherever applicable in regard to the drilling details, bolt holes and faces. All pipe flanges and contact surfaces concentric with axis of piping. All flanges accurately machined and drilled true to template. Air Pipe work : All air headers sloped and drained through trap stations. Crosses used where tees and elbows are required and the unused ends of the crosses plugged for blowing out the header or branch pipe connections. All branch connections originate from the main header only. All screwed pipe joints tightened with Teflon tape only. Adequately sized air filter sets with stand by provision (capacity to suit the requirement) at the Purchaser's terminal point on compressed air line furnished. The bidder furnish all instrument impulse tubing from the Purchaser's terminal connection up to various instruments and control panel within the bidder's scope.

COMPRESSED AIR SYSTEM

Introduction : Air Compressors are used to supply the compressed air at required pressure for instrument and utility requirement. The type of compressor used here is oil free multi-stage. Instrument air compressors supplies the air required for power plant instrument like pneumatic actuation of valves,open-close of dampers,I/P converters,Bag filters,Rotary screw compressor,etc.,Three (3x100%) nos. of (one for Instrument air application, one for Service air application and one number for common standby) two stage oil free rotary & screw type, air cooled, air compressors complete with all ancillary equipment such as electrical drives, couplings and coupling covers, aftercoolers and intercoolers, lubricating system, anti-vibration equipment, base plates, intake filter, inlet silencer, moisture separators, drain traps, necessary instrumentation and control system and all other accessories as required for both instrument air and service air application. Air dryers : Air dryers are used to remove the moisture as air for equipment needs to be relatively free of any moisture. The type of dryer is used in Heat of compression type. HOC(Heat of compressor) type dryer consists of Distributor,2Nos: adsorber-Heater. The compressed air coming out from the compressor passes through prefilter to a distributor. The distributor passes part of air to adsorber through a heater for regenerating deciccant. The wet compressed air entering is dried by desiccant in one of the adsorber and part of air leaves the drier get collected in air receiver. Desiccant absorbs water vapour during prefixed time to regenerate the desiccant part of air passes through heater and this hot air generates another adsorber by liberating the absorbed water vapour. Desiccant losses the adsorbed water vapour which expelled into atmosphere by passing the hot air after passing through heater. This hot air get cooled by passing through after cooler. The one adsorber switch over to another automatically. Two (2x100%) (one working and one standby) Refrigerant type air dryers with all control, monitoring and maintenance equipment. The air drying plant an integral unit consisting of reciprocating refrigerant compressor, refrigerant condenser, refrigerant chiller, air-to-air heat exchanger, thermostatic expansion valve, inlet air filter, moisture separator with automatic drain trap and all insulated interconnecting piping, valves, specialties, instrumentation and control cabinet all assembled on a floor mounted common supporting frame. The compressor mounted at the lowest elevation so that it is easily accessible for maintenance. Air receivers : Two (2x100%) air receivers one for the instrument air and one for the service air requirement and one (1x100%) no dedicated air receivers for SG area. The air receivers shop fabricated, vertical, cylindrical vessels with dished heads. System Requirement : Instrument air system provided for the operation of all Pneumatic dampers/valves for boiler & accessories, TG & accessories and for all other BOP systems such as DM Plant Instrument & Control System, Instrument, Electrical, Chemical laboratory, EP converter, Coal handling plant and other areas

as required. Service air required for Soot blower, for atomizing air, for air motor drive and for miscellaneous cleaning purposes in BTG and BOP areas. Compressors, drives and transmissions : The compressors of the air-cooled oil screw type and will be direct electric motor driven. The compressors, drives and auxiliaries skid mounted unit. The whole assembly of the skid-mounted units rigid and balanced to be suitable for operation on a concrete slab. Air intake filter-silencers and inlet air passages of corrosion-resistant materials to inhibit induction of corrosive and/or erosive particles into the compressors. Coolers : Each compressor provide with inter cooler and after cooler. These are horizontal, air cooled cooler of shell and tube design and capable of cooling the rated compressed air capacity of the compressor.

AIR CONDITIONER
System Function : Air Conditioning can be defined as the process of treating air so as to control simultaneously temperature, humidity, cleanliness and distribution to meet the requirements of the conditioning space. Air Conditioning system is to provide a controlled environment in respect of temperature, relative humidity, cleanliness and noise for effective functioning of the sophisticated control panels and other equipment as well as maintaining comfortable and healthy working conditions for the occupants. The air conditioning of provided to the following areas: Common Control room, Control Equipment rooms, UPS rooms, SWAS dry panel rooms Offices, office room and Lab area DM Plant Control Room, Office and Lab Ash Handling system cum ESP Control room Switch Yard Control Room Chimney analyzer room

System Description Air Conditioning System of Power House Areas : A central chilled water type Air Conditioning Plant provided to cater to the air conditioning requirement of the Power House Building including office space.

Normally the VAMs work and the electric Screw chillers / reciprocating chillers operate only during failure of VAM or during initial stage (before boiler lightup) when steam is not available. Condenser water pumps, chilled water pumps and cooling towers common to both Vapour Absorption Machines and the Packaged Screw / reciprocating Chilling Units. The condenser cooling water circulated through these units by means of centrifugal pump sets. The chilled water produced by the chilling units circulated to the air handling units (AHU) located adjacent / inside the AC spaces by centrifugal pump sets. . The flow of chilled water through the cooling coil controlled by means of a motorized 3- way mixing valve provided with the cooling coil outlet. Such control valve operate with the sense of the Temperature Sensors placed in the RA path.. The conditioned air from AHUs is distributed to the areas being air conditioned, through a network of galvanized sheet steel ducting, duct mounted HEPA filters ,duct mounted electric strip heater, and supply air diffusers/grilles. The return air is collected in the RA duct system through RA grilles & diffusers and led back to the AHU rooms. Outside fresh air inducted into the AHU room through a Fresh Air system consisting of an inlet louver, dry panel type filter, a fan, a set of high efficiency filters and volume control damper with a short duct, SA register and mixed with the return air. Such Fresh air system applicable for critical areas like control room, computer room, control equipment room etc. For other non-critical areas fresh air inducted in the AHU room through the wall opening protected with a rain protection cowl & bird screen and a volume control damper. Pan type humidifier provided in the AHU rooms serving the critical areas. AHUs of double skin type. Air Handling units provided in each AHU room for critical areas. For non-critical areas such as service buildings Air Handling units provided in each AHU room for critical areas. For non-critical areas such as service buildings AHU provided. Motorized Fire dampers incorporated with the Supply and Return air ducts. Motorized fire damper sactuated with the sense of both the duct & room mounted smoke detectors. Air Conditioning System of Auxiliary Buildings : The Air Conditioning System of various Auxiliary Buildings in different locations are given below: Esp Control Room And AHP Control Room : Water Cooled Precision Air Conditioners of provided for ESP Control Room and Control room of Ash Handling Plant. Condenser cooling water for the Precision Air Conditioners supplied directly from the ACW system. The Air Conditioning System complete with controls and instrumentation, CW piping, air

distribution system (for each floor) like ducting, grilles/diffusers, volume control dampers, fire dampers, flexible connection, etc. For the above system necessary electrical like Power Distribution Board, Power & Control cabling, Grounding etc provided. Such Precision Air Conditioners operated from their built-in microprocessor based control panel. Each Precision Air Conditioner (water cooled) comprise scroll compressors and water cooled shell and tube condensers with water in the tubes and refrigerant in the shell side, interconnecting refrigerant piping (duly insulated) between condensers and PAC units, evaporator fans with drive motor and drive accessories, insulated refrigerant piping inside the PAC unit, high efficiency filters, electrode type humidifiers with controls, electric strip heaters and built-in microprocessor based control panel, thermally and acoustically lined powder coated MS casing with Supply air outlets and RA grille, SS condensate drip tray with insulated drain piping. The conditioned air from PAC Units is distributed to the areas being air conditioned, through a network of galvanized sheet steel ducting and supply air diffusers/grilles. The return air is collected in the RA plenum through RA grilles & diffusers and led back to the PAC Unit Room where outside fresh air inducted through a Fresh Air system consisting of an inlet louver, dry panel type filter, high efficiency filter, a fan and volume control damper with a short duct, SA register and mixed with the return air. DM Plant Control Room, Office And Lab And Switch Yard Control Room : The Air Conditioning System complete with controls and instrumentation, air distribution system for each floor like ducting, grilles/diffusers, volume control dampers, flexible connection, etc. For the above system necessary electrical like Power Distribution Board, Power & Control cabling, Grounding etc provided. Such Precision Air Conditioners operated from their built-in microprocessor based control panel. Each Precision Air Conditioner (Air cooled) comprise scroll compressors suitable for refrigerant and Remote air cooled Condensers with fans and drive motors, D-X type cooling coil with insulated condensate tray, evaporator fans with drive motor and drive accessories, insulated refrigerant piping inside the PAC unit, high efficiency filters, electrode type humidifiers with controls, electric strip heaters and built-in microprocessor based control panel, thermally and acoustically lined powder coated MS casing with Supply air outlets and RA grille. The conditioned air from PAC Units is distributed to the areas being air conditioned, through a network of galvanized sheet steel ducting and supply air diffusers/grilles. The return air is collected in the RA plenum through RA grilles & diffusers and led back to the PAC Unit Room where outside fresh air inducted through a Fresh Air system consisting of an inlet louver, dry panel type filter, high efficiency filter, a fan and volume control damper with a short duct, SA register and mixed with the return air. Chimney Analyzer (SOX / NOX / CO) Room : Air Cooled non duct able Split units provided in required quantities to maintain the desired inside conditions. For these areas no idle stand-by unit provided.

PRESSURIZATION & VENTILATION SYSTEM

System Function : The purpose of the Pressurization & Ventilation system is to provide ventilation for following buildings in order to: 1) Achieve reasonably dust free environment 2) Limit the temperature rise inside the building 3) Achieve control of pollution for some contaminated areas Name of the buildings to be ventilated: Power House Building ESP /AHS Building Air Compressor Room AC Plant Room DM Plant MCC Room Raw Water Pump House Clarified Water Pump House CW Pump House Chlorination Plant Building DG Set Building.

System Description : Evaporative Cooling System for Power House Building : Evaporative cooling system with Air Washer Units provided for Power House Building. Cooled and filtered air from Air Washer Units (AWU) distributed near various heat sources like turbogenerator, condenser, boiler feed pump, HP & LP heaters, oil coolers etc. The hot air from the TG hall exhausted by means of roof extractors. The quantity of air exhausted from the Turbine Hall kept lower than the quantity of air supplied to maintain an overpressure with respect to the outside atmosphere. Fresh filtered air supplied to the Electrical areas like MCC Room, Switchgear Room of TG

Building by means of wall mounted fan-filter units to maintain an air change rate of 30 per hr. Fresh filtered air supplied to the Elevator Machine Room of TG Building by means of wall mounted fan-filter units to maintain an air change rate of 20 per hr. Unitary Air Filter unit (UAF) for ESP /AHS Building In the switchgear room of ESP / AHS Control Building washed and filtered air will be supplied from Unitary Air Filter unit (UAF) due to the reasons that the ESP / AHS building is located in a very dusty zone & heat load of above Control Building is exorbitantly high. Hot air will be exhausted through Back draft dampers. The UAF Unit using water repellent type nylon filters shall be provided for ESP / AHS building as applicable. Unitary air filtration units shall be located on the roof of ESP / AHS building. Mechanical type Ventilation System (Dry Ventilation) : All mechanically ventilated areas ventilated by means of supply/exhaust fans and wall mounted air inlet/ outlet louvers / back draft dampers. All MCC/switch gear rooms pressurized by filtered air supply through pre-filters and fine filters, with provision of exhaust through gravity operated back draft dampers. Exhaust ventilation system provided for hazardous areas and fumes/odors generating areas such as battery rooms, toilets, chlorination plant etc. by installing wall mounted exhaust fans. A negative pressure maintained inside such areas. Outside air enter such areas through wall mounted louvers. Elevator machine rooms for Power House Building shall be provided with supply fan filter units and Back Draft Dampers.

FIRE PROTECTION SYSTEM

General Information : The fire protection system including alarm and detection systems provided to control any out break of fire in the Power Plants, and its auxiliary plants. Water for the Fire water requirement tapped from Clarified Water pump house which is drawing water from Clarified Water Storage tank of capacity sufficient to meet fire water requirements envisaged within the plant area. All fire fighting pump set and associated equipments erected in clarified water pump house. Fire Pump House : Firewater pump house consist of main equipments such as hydrant and water spray pumps, jockey pumps and diesel engines. All controls and interlocking for firewater pumps are PLC based for the Firewater pump house located in Clarified Water Pump house. Electrical interlocking provided such that at any instance either the Jockey pump or Main pumps would operate.

Hydrant System : Hydrant system consist of a fire water ring main network of piping along with Isolation valves installed underground and above ground around areas to be protected, hydrant valves (external / internal), hoses (15M long hoses), hose cabinets, couplings, branch pipe, nozzles and water monitors along with all accessories All accessories such as MS painted hose boxes etc. provided as per TAC. Water Spray System High Velocity Water Spray System : The high velocity water spray system consist of under ground, above ground piping, along with relevant fittings, Deluge valves, Strainers, isolation gate valves, spray nozzles, quartzoid bulb detector and pressure switches. HVWS system automatically detect, control and extinguish any out-break of fire and simultaneously give audible alarm. This hydraulically open the deluge valve thus allowing water to be sprayed on to the equipment/area through projector nozzles in the form of a solid conical emulsifying spray. Medium Velocity Water Spray System : The medium velocity spray system consist of a network of open spray nozzles fitted with a special deflector to give required angle of discharge for the water around the area to be provided. Automatic Wet Pipe Sprinkler System Automatic wet pipe sprinkler system consist of quartzoid-bulb sprinkler heads, water flow alarm devices, isolation valve, one alarm check valve with trim, piping, and pipe supports. The wet pipe sprinkler system piping normally be filled with water under pressure and shall immediately discharge when any sprinkler operates. Water discharge only from those sprinklers, which have fused open by heat from the fire Co2 flooding system. Generator enclosure for each unit covered under Co2 flooding System Fixed Foam System Fixed foam system is provided for fuel oil storage tanks. The water for the foam system tapped from the Hydrant system. The system consist of AFFF foam concentrate tank complete with first fill of foam, level indicators, foam ejector, foam makers, all piping (GI & SS), along with deluge valves, strainers and isolating valves fixed piping valves and other accessories, etc. Automatic Inert Gas Fire Suppression System The system manufactured, designed, installed & commissioned in conformance with the stipulations of NFPA-2001.Frame work support for cylinders for each area, Discharge manifolds, hoses, nozzles, and pneumatic horn for each area. Seamless pipe work, discharge nozzles, along with evacuation & gas release alarms and Warning sign boards provided. Fire Protection And Alarm System The fire alarm system consist of automatic fire alarm system devices like Multisensor smoke

detectors, photoelectric smoke detectors, rate of rise heat detectors, Notification devices like electronic hooters, hooter cum strobe etc. The Individually Addressable Modules used for wiring the non addressable device in the fire alarm system.

THERMAL INSULATION
Introduction : Thermal Insulation are materials or combination of materials that properly applied retard the flow of heat energy by conductive, convective and / or radiative transfer modes. These materials can be fibrous, particulate, film or sheet block or monolithic, open or closed cell or composites of these materials that can be chemically or mechanically bound or supported. Thermal insulation provided for piping, valves, fittings and equipments for the purpose of heat conservation, temperature maintenance, process stabilization, personnel protection. Thermal insulation required for all hot piping and equipment with fluid temperature grater than 60oC.and for piping and equipment for the following cases: Conservation Energy and thereby increase system thermal efficiency. Maintaining the process temperature. Personnel protection Prevention of condensation. Control surface temperatures of equipment and structures for personnel protection and comfort. Reduce temperature fluctuations within an enclosure when heating is not needed or available. Reduce temperature varations within a conditioned space for increased personal comfort. Provide fire protection.

Piping and equipment insulated with Mineral (Rock) wool material conforming as per the relevant code & provided as below: Mineral (Rock) Wool material provided for piping and Fittings. Mineral (Rock) wool material provided for Valve Boxes and Equipments. Insulation material finally covered with cladding material. Cladding material & Other Accessories materials : Cladding of Marine grade aluminum required for piping and equipment for the following purpose: Cladding over hot thermal insulation to protect insulation surface against moisture in air or rain,

to prevent physical damages etc. Insulation material has backup stainless steel hexagonal wire netting for interface temperature greater than 400C & galvanised steel for interface temperatures less than & equal to 400C. The insulation backed with hexagonal wire mesh on one side. Insulation material wrapped and held in place using binding and lacing wires. The binding and lacing wires of stainless steel material for interface temperature greater than 400C & galvanised steel for interface temperatures less than & equal to 400C. Insulation supporting arrangements for vertical piping and equipments provided. The straps for securing Aluminium cladding sheet shall be of Aluminium material.

CRANES & HOISTS

Introduction : Electric overhead travelling cranes provided for ease of dismantling and maintenance of major plant equipments. The crane comprise a main hoist and an auxiliary hoist each to be capable of lifting and accurately positioning all heavy loads within their specified rating. Each cranes and hoists complete with its accessories, supporting structure, power supply, safety devices and controls and shall conform to local statutory rules and regulation and a recognised standard suitable for their intended application. EOT Crane : All the crane cranes and hoist consider suitable derating factor for the temperature of beyond 40 C. The crane and hoist designed considering for hazardous area or non hazardous classification as required. EOT crane provided in the areas where the handling of the equipments / components required in both transverse and longitudinal direction. The span of the EOT cranes derived based on the building layout with considerations to clearances and hook approach. All the movements of the EOT crane (Hoisting, lowering, LT, CT) are electrically operated. The lift for the EOT crane based on lifting the tallest piece from the operating floor, with consideration of sufficient clearances for lifting over other equipment on operating equipment. Walkway provided at rail level on both sides. Grating provided for the walkway. Clear access walkways of minimum 500 mm wide with safety hand railing provided along the full span length on either side of the double girder crane bridge girders. All the double girder EOT type crane an illumination system below the bridge, in the platform and in cabin (if applicable). Cabin air conditioned and provided with Master controllers for all motions, emergency stop push button, fire extinguisher etc. Fire extinguisher provided in bridge platform for all double girder cranes. Hoist : All the movements of electrical hoist (Hoisting, LT) of electrical operated by pendent switch. All the movement of manual hoist (Hoisting, LT) manual operated through suitable chain. Manual hoist trolley travelling type. Wheels of single flanged type. Hook swivel in type with safety latch. Both load

chain and hand chain electrically welded, calibrated, pitched and polished. The brakes provided for manual hoist hold the load at any position by self brake system. Necessary start/stop and emergency controls provided. Automatic reset type limit switches provided to prevent over-travel for a. Over hoisting and lowering motions of the main hook and the auxiliary hook. b. Long travel motion c. Cross travel motion