INDEX

S.NO. PARTICULARS
1 DESIGN DATA
2 OPERATIONAL DATA
3 CHEMICAL HOUSE
4 CW CHLORINATION PLANT
5 HYDROGEN PLANT
6 PRIMARY WATER
7 COAL
8 INVIRONMENT LIMITS
9 BOILER AND FEED WATER LIMITS
10 TURBINE OIL
11 LDO AND HFO
12 TRANSFORMER OIL
13 FLY ASH
 SALIENT FEATURES OF 1 x 500 MW, HTPS, KORBA WEST

CAPACITY AND
AUXILLARIES
EFFICIANCY
1. BOILER STEAM GENERATOR 1590 MT/Hr.
PRESSURE 178 Kg/cm2
TEMPARATURE 540°C
2. TURBINE INLET PRESS. 178 Kg/cm2
TEMPARATURE 540°C
3. GENERATOR OUT PUT 500 MW
4. MILL 10 No. MILL IN TWO ROWS
4 PASSES, NUMBER OF
5. ESP FIELDS 36 PER PASS
EFFCIANCY 99.99%
6. CHIMNEY HEIGHT 275 METER
EMMISION 50Mg/Nm3
ONLINE ANALYSER FOR SOx, NOx, CO, CO2, DUST
7. SILO CAPACITY 1800 MT EACH
HCSD PUMP( GEHO) 2 NO.
TMCR
8. COAL CONSUMPTION 8000 MT/DAY 347 MT/Hr

ASH 41%, Moist. 14 % , V.M. 1kg coal requires 1.7 kg

9. COAL QUALITY 21.0% F.C 21% HHV 3300 Primary air & 3.1 kg Sec.
KCal /Kg air Total Air 4.8 kg .

10. CHP INTERNAL CONVEYOR CAPACITY 1000 MT/Hr

11. NDCT COOLING RANGE 10°C ,
HEIGHT 170 METER
12. CW PUMP 3 No. ,30,000MT/Hr EACH
INFULENT FROM CPU, DM
REGERATE WASTE, BOILER
13. ETP BLOW
DOWN and Effluent to ash water
sump
DOMESTIC EFFLUENT FROM
14. STP POWER PLANT, CAP. 50 MT/Hr
15. ASH DISCHARGE PIPE 5 No, 2 for HCSD, 2 for wet
LINE disposal 1 for recovery line
16. ASH DYKE AREA 105.92 Ha.
NO OF COMPARTMENT 3
17. ASH DISTRIBUTION
DATA BOTTOM ASH 20%
ECONOMISER 5%
 PAPH 5%
SAPH 5%
ESP 85%

18. FLY ASH SIZE > 40 MICRON 20%

30-40 MICRON 10%
20-30 MICRON 14%
10-20 MICRON 24%
< 10 MICRON 32%
1x500 MW BOILER PARAMETERS
PARAMETERS UNIT COND. FEED BOILE STEAM
R
pH at 25 °C value 9.0 to 9.2 9.0 to 9.1 to 9.0 to 9.2
9.2 9.4
SP.COND. µS/cm --- --- < 30 ---
CATION COND. µS/cm < 0.2 < 0.2 --- ---
HYDRAZINE AS N₂H₄ ppb --- 20 --- ---
AMMONIA AS NH₃ ppm 1 --- --- 1
PHOSPHATE AS ppm --- --- < 2.0 ---
PO₄⁻⁻⁻
SILICA AS SiO₂ ppb < 10 < 10 < 100 < 10
TOTAL IRON AS Fe ppb < 10 < 10 --- < 10
TOTAL COPPER AS ppb <3 <3 --- <3
Cu⁺⁺
CHLORIDE AS Cl⁻ ppb <3 <3 0.500 <3
D.O. AS O₂ ppb < 40 <5 --- ---
SODIUM AS Na⁺ ppb <5 <5 --- <5
TDS ppm --- --- < 20 ---
PRIMARY WATER
pH at 25 °C value 6.5 to 8.5
SP.COND. µS/cm < 2.0
D.O. AS O₂ ppb < 100
GENERATOR SYSTEM
HYDROGEN PURITY % > 96.0
DEW POINT AT
FRAME PRESSURE °C -10°C to + 10°C
(3.5 kg/cm2)
ECW pH at 25 °C value 8.5 to 9.0
 B. NATIONAL AMBIENT AIR QUALITY STANDARDS

Pollutants Time- Concentration in ambient air Method of

weighted Industrial Residential, Sensitive Areas measurement
average Areas Rural &
other Areas
Sulphur Dioxide Annual 80 µg/m3 60 µg/m3 15 µg/m3 -Improved West
(SO2) Average* and

Geake Method
3 3
24 120 80 µg/m 30 µg/m - Ultraviolet
hours** µg/m3 Fluorescence
Oxides of Annual 80 µg/m3 60 µg/m3 15 µg/m3 -Jacob &
Nitrogen as (NO2) Average* Hochheiser

Modified (Na-
Arsenite) Method

24 120 80 µg/m3 30 µg/m3 -Gas Phase

hours** µg/m3 Chemiluminescence
Suspended Annual 360 140 µg/m3 70 µg/m3 - High Volume
Particulate Matter Average* µg/m3 Sampling,
(SPM) (Average flow rate
not less
24 500 200 µg/m3 100 µg/m3 than
hours** µg/m3 1.1 m3/minute).
Respirable Annual 120 60 µg/m3 50 µg/m3 -Respirable
Particulate Matter Average* µg/m3 particulate
(RPM) (size less
than 10 microns)
24 150 100 µg/m3 75 µg/m3 matter sampler
hours** µg/m3
Lead (Pb) Annual 1.0 0.75 µg/m3 0.50 µg/m3 -ASS Method after
Average* µg/m3
Sampling using
EPM 2000
 or
equivalent Filter
paper
24 1.5 1.00 µg/m3 0.75 µg/m3 .
hours** µg/m3
Ammonia1 Annual 0.1 mg/ 0.1 mg/ m3 0.1 mg/m3 .
Average* m3
24 0.4 mg/ 0.4 mg/m3 0.4 mg/m3 .
hours** m3
CarbonMonoxide 8 hours** 5.0 2.0 mg/m3 1.0 mg/ m3 - Non Dispersive
(CO) mg/m3 Infra
1 hour 10.0 4.0 mg/m3 2.0 mg/m3 Red (NDIR)
mg/m3 Spectroscopy
Note:
* Annual Arithmetic mean of minimum 104 measurements in a year taken twice a week 24 hourly at uniform
interval.** 24 hourly/8 hourly values should be met 98% of the time in a year. However,2% of the time, it may
exceed but not on two consecutive days.

C. GENERAL STANDARDS* FOR DISCHARGE OF ENVIRONMENTAL

POLLUTANTS

S. No. Parameter Inland Public Land for Marine/coastalareas

surface sewers irrigation
water
. 2 3 . .
. . (a) (b) (c) (d)
1 Colour and odour See 6 of See 6 of See 6 of Annexure-1I
Annexure- Annexure-
1I 1I
2 Suspended solids 100 600 200 (a) For process waste
mg/l, max. water
(b) For cooling water
effluent 10 per cent
above total suspended
matter of influent.
3 Particle size of shall pass - - (a) Floatable solids,
suspended solids 850 micron solidsmax. 3 mm
IS Sieve
 (b) Settleable solids, max
856 microns
4 pH value 5.5 to 9.0 5.5 to 9.0 5.5 to 9.0 5.5 to 9.0
5 Temperature shall not shall not exceed
exceed 5oC 5oCabove the receiving
above the water temperature
receiving
water
temperature

6 Oil and grease, mg/l 10 20 10 20

max,
7 Total residual 1 - - 1
chlorine, mg/l max
8 Ammonical nitrogen 50 50 - 50
(as N),mg/l, max.
9 Total kjeldahl 100 - - 100
nitrogen (as
N);mg/l, max. mg/l,
max.
10 Free ammonia (as 5 - - 5
NH3), mg/l,max.
11 Biochemical oxygen 30 350 100 100
demand (3 days at
27oC), mg/l, max.
12 Chemical oxygen 250 - - 250
demand, mg/l, max.
13 Arsenic(as As). 0.2 0.2 0.2 0.2
14 Mercury (As Hg), 0.01 0.01 - 0.01
mg/l, max.
15 Lead (as Pb) mg/l, 0.1 1 - 2
max
16 Cadmium (as Cd) 2 1 - 2
mg/l, max
17 Hexavalent chro- 0.1 2 - 1
mium (as Cr +
6),mg/l, max.
18 Total chromium (as 2 2 - 2
Cr) mg/l, max.
19 Copper (as Cu)mg/l, 3 3 - 3
max.
20 Zinc (as Zn) mg/l, 5 15 - 15
max.
21 Selenium (as Se) 0.05 0.05 - 0.05
 22 Nickel (as Ni) mg/l, 3 3 - 5
max.
23 Cyanide (as CN) 0.2 2 0.2 0.2
mg/l, max.
24 Fluoride (as F) mg/l, 2 15 - 15
max.
25 Dissolved phos- 5 - - -
phates (as P),mg/l,
max.
26 Sulphide (as S) mg/l, 2 - - 5
max.

INDIAN STANDARDS FOR DRINKING WATER SPECIFICATION( BIS 10500 : 1991 )

Permissible Limit
Substance or Requirement (Desirable in the absence of
Sl.No Characteristic Limit) Alternate source
Essential characteristics
1 Colour, ( Hazen 5 25
units, Max )
2 Odour Unobjectonable Unobjectionable

3 Taste Agreeable Agreeable

4 Turbidity ( NTU, 5 10
Max)
5 pH Value 6.5 to 8.5 No Relaxsation

6 Total Hardness (as 300 600

CaCo3)
mg/lit.,Max
7 Iron (as Fe) 0.3 1
mg/lit,Max
8 Chlorides (as Cl) 250 1000
mg/lit,Max.
9 Residual,free 0.2 --
chlorine,mg/lit,Min
Desirable Characteristics
10 Dissolved 500 2000
solids mg/lit,Max
11 Calcium (as Ca) 75 200
mg/lit,Max
12 Copper (as Cu) 0.05 1.5
mg/lit,Max
13 Manganese (as 0.1 0.3
Mn)mg/lit,Max
14 Sulfate (as SO4) 200 400
mg/lit,Max
15 Nitrate (as NO3) 45 100
mg/lit,Max
16 Fluoride (as F) 1.9 1.5
mg/lit,Max
17 Phenolic 0.001 0.002
Compounds (as C 6
H5OH)
mg/lit, Max.
18 Mercury (as 0.001 No relaxation
Hg)mg/lit,Max
19 Cadmiun (as 0.01 No relaxation
Cd)mg/lit,Max
20 Selenium (as 0.01 No relaxation
Se)mg/lit,Max
21 Arsenic (as As) 0.05 No relaxation
mg/lit,Max
22 Cyanide (as CN) 0.05 No relaxation
mg/lit,Max
23 Lead (as Pb) 0.05 No relaxation
mg/lit,Max
24 Zinc (as Zn) 5 15
mg/lit,Max
25 Anionic detergents 0.2 1
(as MBAS)
mg/lit,Max
26 Chromium (as 0.05 No relaxation
Cr6+) mg/lit,Max
27 Polynuclear -- --
aromatic hydro
carbons
(as PAH) g/lit,Max
28 Mineral 0.01 0.03
Oil mg/lit,Max
29 Pesticides mg/l, Absent 0.001
Max
30 Radioactive
Materials
 i. Alpha emitters -- 0.1
Bq/l,Max
ii. Beta -- 1
emitters pci/l,Max
31 Alkalinity 200 600
mg/lit.Max
32 Aluminium (as 0.03 0.2
Al) mg/l,Max
33 Boron mg/lit,Max 1 5

II. NOISE LEVEL STANDARDS:

(a)
Standards
Time 6.00 A.M.- 10.00 P.M. -
duration: 10.00 P.M. 6.00 A.M
Noise
Level: Leq 75 dB(A) Leq 70 dB(A)
Note :
decibel (dB)

TURBINE OIL
TURBINE OIL 46 has outstanding thermal and oxidation stability that prevents sludge formation, controls
 deposits and minimises oil degradation leading to reliable operation. Superior anti-wear property and load
carrying capability provide excellent protection for geared turbines. Excellent water separation capability
resists formation of emulsion and leads to easy removal of excess water from the lubrication system.
Effective rust and corrosion inhibitors provide long term protection to critical system components and good
air release properties and foam control avoid erratic operation and pump cavitation leading to trouble free
operation.

Property: Typical Values:

ISO Viscosity 46
Density @ 15°C 868 kg/m3
Kinematic Viscosity @
40°C 41.4 - 50.6 mm2/s
Viscosity Index 104
Flash Point > 185°C
Pour Point < -21°C
Total Acid Number
(TAN) 0.10 mgKOH/g
Rust Test Pass

TURBINE OIL SPECIFICATION

A special refined mineral oil shall be used for lubricating the

bearing and shapt seal of a tubine generator. The should be show little
tendency to aging and should meet following requirment’s.
TYPICAL CHARACTERSTICES:-

Specific gravity at 200C –not more then 0.93g/ml

Viscocity at 500C - 30-38CST
Flash point – not less then 1800C
Solidification NO.
(a) pure mineral oil – not more then 0.05mgKOH/g of oil
(b) inhibited turbine oil – may higher then for (a)
 saponification NO.
(a) pure mineral oil – not more then 0.15mgKOH/gm of oil
(b) inhibited turbine oil – may be higher then (a)

moisture content:-not more then 0.1%by wt.

ash content- not more then 0.01% by wt.

foaming – not more then 200ml at 250C(10ml at 95

ACIDITY TEST (NEUTRALISATION NO.)

10ml of oil sample + 25ml of neutralized alcohol.warm

up to 400C. titrate against N/20KOH using phenopthelene or
bromophenol as indicator in microburette.
Acidity = titer value X normality of KOH X 56/wt. oil taken for
test.(mg of KOH/gm of oil)
Neutralization of alcohol:- alcohol + phenopthelene and add KOH
slowly till pink color is obtened.

Fuel oil specification

Heavy fuel oil (HFO):
ISO 8217, ISO-F-RM K700
Fuel-system related characteristics values
Viscosity (at 50 °C) mm2/s (cSt) max. 700
Viscosity (at 100 °C) mm2/s (cSt) max. 55
Density (at 15 °C) kg/m3 max. 1,010
Flash point °C min. 60
Pour point °C max. 30
Hydrogen sulfide mg/kg max. 2
Acid number mg KOH/g max. 2.5
Total sediment aged mass % max. 0.10
Engine-related characteristic values
Carbon residues (Conradson) m% max. 20
Sulphur m% max. 5
Ash m% max. 0.15
Vanadium mg/kg (=ppm) max. 450
Water Vol.% max. 0.5
Additional parameters
Aluminium and silicon mg/kg max. 60
Asphalts m% max. 2/3 of carbon residues (Conradson)
Sodium mg/kg Sodium < 1/3 vanadium, sodium < 100
Used lubricating oil (ULO) mg/kg Ca >30 and Zn >15 or CA >30 and P >15

SPECIFICATION FOR LIGHT DIESEL OIL (LDO)

S.NO. PARAMETER SPECIFICATION

1 Relative Density @ 15 °C, Kg / m3 855
2 Flash Point (PMC), °C 66 Min. 74
3 Viscosity, Kinematic @ 40°C 5
4 Ramsbottom Carbon Residue (RCR) 1.3
, percent by mass
5 Copper Strip Corrosion, 3 hrs at NO. 1
100°C
6 Water content % by Vol. <0.05
7 Sediment % by Mass 0.04
8 Ash % by Mass. 0.01
9 Acidity, Inorganic, mg KOH /gm, NIL
10 10 Sulphur, Total % by Mass 1.2
11 Pour Point, °C -3
 CHARACTERISTICS OF NEW TRANSFORMER OIL

S.NO CHARACTERISTICS SPECIFICATION

1 Appearance Clear and transparent
free from suspended
matter or sediments
2 Density at 29.5oC (Max) gm/cc 0.89
3 Viscosity, Kinematic at 27oC (Max) 27
4 Interfacial Tension at 27oC (Min) 0.04
Newton / M
5 Flash point, Pensky Marten 140
(closed) in oC (min).
6 Pour point in oC (Max) -6
7 Pour point in oC (Max)
A. Total acidity, mg KOH/gm (Max) 0.03
B. Inorganic acidity / alkalinity NIL
8 Corrosive sulphur (Copper strip) NON-CORROSSIVE
19 hours at 140 oC
9 Electric strength (Breakdown Voltage ) KV 60
(rms).
10 Dielectric dissipation factor 0.002
(Tan Delta) at 90oC (Max).
11 Specific resistance (resistivity)
A. at 90oC , ohm-cms (Min ) 35X1012
B. at 27oC , ohm-cms (Min) 1500X1012
12 Oxidation stability
A. Neutralisation value, after 0.40
Oxidation for 164 hours at 100 o C
mg KOH/gm (Max). 0.10
B. Total sludge, after 164 hours
At 100 o C wt. % (max).
13 Water content, ppm (max) 20
 DGA parameters limit

Gas name symbol Limit ppm

Hydrogen H2 10
Methane CH4 5
Ethane C2H6 2
Ethylene C2H4 2
Acetylene C2H2 NOT DETECTABLE
Carbon mono-oxide CO 30
Carbon -dioxide CO2 300

PARAMETER STD. ACTUAL

DENSITY 0.89 MAX.
BREAKDOWN 50 MIN. 70-80
VOLTAGE
MOISTURE BY 20 MAX. 8 – 10
KARL…
ACID NO. 0.3 MAX. 0.08
FLASH POINT °C 125 MIN. 162
 Primary water/ Generator

Resistivity Tripping at 280 mhos

Alarm at 659 mhos.
Generator Volume and Filling Quantities Volume Units
Generator volume (gas volume) 80 m3
CO2 filling quantity*** 160 m3 (s.t.p.)*
H2 filling quantity (to 3.5 bar)** 480 m3 (s.t.p.)*
s.t.p. = Standard temperature and pressure, 0oC and 1.013 bar
Ion exchanger
Volume 83 litres
Resin Lewatit
Resin volume 56 litres
Design Data for the Primary Water
Cooler, (2 x 100% )
Materials
Shell SS
Tubes SS
Tubesheets SS
Water channels Carbon Steel
Primary Water Side Pressures
Design pressure 10 kg/cm2
Test pressure 15 kg/cm2
Cooling Water Side Pressures
Design pressure 10 kg/cm2
Test pressure 15 kg/cm2
Even with the use of oxygen-poor water, copper
corrosion in the primary water circuit of water-cooled
windings cannot be completely avoided;
It is assumed that generator is at rest during gas filling and removal. Filling during turning gear operation will result
in a higher gas consumption. Due to the whirling motion between the medium to be displaced and medium admitted,

the purity deteriorates so that more gas is required for scavenging.

Bottle Volume
H2 bottle 40 Liters at 150 bar = 6 m3 (s.t.p.)
H2 bottle 50 Liters at 200 bar = 10 m3 (s.t.p.)
CO2 bottle : 40 Liters = 15 m3 (s.t.p.)
45 = 17
66.7 = 25.2
Primary water (design parameters)
Flow 65 m³/hr
Pw inlet temp. 72°c outlet temp. 49°c
Pw press. drop 1.16 kg/cm2
Cooling water flow 250 m³/hr
Cw inlet temp. 38 °c & outlet temp. 44°c
Press.drop 2 kg/cm2
Primary water (Specification)
Cond. < 2 µmhos/cm
pH 6 to 8
D.O. < 100 ppb
Copper(dissolved & undissolved) < 20 ppb
Iron < 20 ppb
Alkalizer Sod. Hydroxide soln. 1 % ( 1kg/100 litre)

*** H2 gas may enter into P.W. through teflon-hoses.

 COOLING WATER

COOLING WATER

Evaporation Loss (m3/hr) = 0.00085 x 1.8 x circulation rate (m3/hr) x (T1-T2)

T1-T2 = Temp. difference between inlet and outlet water.

Blow down losses depend upon cycles of concentration and the evaporation losses and is given
by relation:

Blow Down = Evaporation Loss / (C.O.C. – 1)

Drift Loss in the Cooling Towers

It is very difficult to ignore drift problem in cooling towers. Now-a-days most of the end user
specification calls for 0.02% drift loss.

“Range” is the difference between the cooling tower water inlet and outlet temperature.
“Approach” is the difference between the cooling tower outlet cold water temperature and
ambient wet bulb temperature. Although, both range and approach should be monitored, the
`Approach’ is a better indicator of cooling tower performance.

Cooling tower effectiveness (in percentage) is the ratio of range, to the ideal range, i.e.,
difference between cooling water inlet temperature and ambient wet bulb temperature, or in
other words it is = Range / (Range + Approach).

Range This is the difference between the cooling tower water inlet
and

outlet temperature. A high CT Range means that the cooling tower has been able to

reduce the water temperature effectively, and is thus performing well. The formula is:

CT Range (°C) = [CW inlet temp (°C) – CW outlet temp (°C)]

Approach . This is the difference between the cooling tower outlet coldwater

temperature and ambient wet bulb temperature. The lower the approach the better

the cooling tower performance. Although, both range and approach should be monitored,

the `Approach’ is a better indicator of cooling tower performance.

CT Approach (°C) = [CW outlet temp (°C) – Wet bulb temp (°C)]

Effectiveness. This is the ratio between the range and the ideal range (in percentage), i.e.
difference between cooling water inlet temperature and ambient wet bulb temperature, or

in other words it is = Range / (Range + Approach). The higher this ratio, the higher the

cooling tower effectiveness.

CT Effectiveness (%) = 100 x (CW temp – CW out temp) / (CW in temp – WB temp)

or

CT Effectiveness (%) = 100 x RANGE / (RANGE + APPROACH)

Cooling capacity. This is the heat rejected in kCal/hr or TR, given as product of mass

flow rate of water, specific heat and temperature difference.

Evaporation loss. This is the water quantity evaporated for cooling duty. Theoretically

the evaporation quantity works out to 1.8 m3 for every 1,000,000 kCal heat rejected. The

following formula can be used (Perry):

Evaporation loss (m3/hr) = 0.00085 x 1.8 x circulation rate (m3/hr) x (T1-T2)

T1 - T2 = temperature difference between inlet and outlet water

Cycles of concentration (C.O.C). This is the ratio of dissolved solids in circulating

water

to the dissolved solids in make up water.

Blow down losses depend upon cycles of concentration and the evaporation losses and is

given by formula:
Blow down = Evaporation loss / (C.O.C. – 1)

CW PUMP CAPACITY 32000 m3/hr

NDCT WATER HOLDING CAPACITY(INCLUDING FOREBAY) 40000 m3

30 Hrs.

TOTAL WATER FILLING

TIME BY CT MAKEUP

BACKUP ACW PUMP CAPACITY 3750 m3/hr

Hardgrove grindability index

Calculate the Hardgrove grindability index using the formula:

HGI = 13 + 6.93 M
Where M = mass of the test sample passing through 75-micron sieve fter grinding. In practice M
is obtained by deducting from 50 g the mass of the ground sample retained on 75-micron sieve.
The smaller the HGI, the harder and less grindable is the coal.

50 g of air dried coal featuring a grain size in the range between 0.6 and 1.2 mm are filled into
the sample mill and a weight is put on the mill's grinding stone. After 60 rounds the grinded coal
is put on a sampling sieve. Factor D equals the fraction of the coal passing through the sieve.
HGI is calculated from D as follows:
This procedure only results in relative values because the sampling mill is calibrated using a
reference coal. The HGI of the reference coal is defined as 100

===================================================
***Anthracite Filter Media are filtration materials for turbidity and SS
removal. Since the specific gravity is lighter than that of Filter Sand, it is
much used in combination with Filter Sand in dual-media filtration, to
consist reverse grain layers after backwashing.
It has the highest carbon content, the fewest impurities, and the highest
energy density of all types of coal except for graphite. Anthracite is the
most metamorphosed type of coal (but still represents low-grade
metamorphism), in which the carbon content is between 92% and 98%.
What is dual media :-
…water-treatment plants now use rapid dual-media filters
following coagulation and sedimentation. A dual-media filter consists of
a layer of anthracite coal above a layer of fine sand.

Effective Particle Size

The effective size (ES) is defined by the size of screen opening where 90
percent of a sample of
granular media is retained on the screen and 10 percent passes through
the screen, and is referred to
as D10.
Uniformity Coefficient
The uniformity coefficient (Uc) is a numeric estimate of how sand is
graded, and is a dimensionless number or in other words it has no units.
The term ìgradedî relates to where the concentrations of sand particles
are located by size. Sand with all the particles in two size ranges would
be defined as narrowly graded sand and would have a low Uc. Sand with
near equal proportions in all the fractions would be defined as widely
graded sand and would have a high Uc value. The Uc is calculated by
dividing D60 (the size of screen opening where 60% of a sample passes
and 40% is retained) by D10 (the effective particle size- that size of
screen opening where 10% of a sample passes and 90% is retained). The
larger the Uc the less uniform the sand.
AVGF
Anthracite Filter Media are filtration materials for turbidity and SS removal. Since
the specific gravity is lighter than that of Filter Sand, it is much used in
combination with Filter Sand in dual-media filtration, to consist reverse grain
layers after backwashing.

It has the highest carbon content, the fewest impurities, and the highest energy
density of all types of coal except for graphite. Anthracite is the most
metamorphosed type of coal (but still represents low-grade metamorphism), in
which the carbon content is between 92% and 98%.

What is dual media :-

…water-treatment plants now use rapid dual-media filters following coagulation

and sedimentation. A dual-media filter consists of a layer of anthracite coal above
a layer of fine sand.

Effective Particle Size

The effective size (ES) is defined by the size of screen opening where 90 percent
of a sample of

granular media is retained on the screen and 10 percent passes through the screen,
and is referred to

as D10.

Uniformity Coefficient
The uniformity coefficient (Uc) is a numeric estimate of how sand is graded, and is
a dimensionless number or in other words it has no units. The term ìgradedî relates
to where the concentrations of sand particles are located by size. Sand with all the
particles in two size ranges would be defined as narrowly graded sand and would
have a low Uc. Sand with near equal proportions in all the fractions would be
defined as widely graded sand and would have a high Uc value. The Uc is
calculated by

dividing D60 (the size of screen opening where 60% of a sample passes and 40% is
retained) by D10 (the effective particle size- that size of screen opening where
10% of a sample passes and 90% is retained). The larger the Uc the less uniform
the sand.

Specification of Anthracite:

1. Bulk density 0.9 g/ml

2. Ash < 30 %
3. Effective size 0.5 mm
4. Uniformity Coefficient 1.7
5. Qty. required in one filter 10 MT
6. Diameter of Filter 6.310 m
7. Bed layers Gravels 150 mm
Quartz 300 mm
Anthracite 400 mm

CATION COLUMN

"In high pressure steam systems, cation conductivity is a useful tool for
monitoring return condensate for low levels of contamination by anions
such as Cl-, SO4-, HCO3-, etc. In practice, a cooled sample of
condensate or high purity water flows through a cation exchanger in the
hydrogen form. The cation resin replaces contaminating cations such as
Ca++, Mg++, Na+, NH4+, and amines in the sample with hydrogen ions.
The hydrogen ions exchanged for the other cations in the sample
increase the conductivity contributed by the contaminant salts of mineral
 acid anions listed above by 3 or 4 times. Thus the cation exchange
column can be thought of as a "conductivity amplifier" for mineral and
organic acid contaminants; increasing the sensitivity of the conductivity
analyzer to low levels of contamination. "

D M PLANT
EQUIPMENTS PARTICULARS DATA UNIT
FLOW 110 M³/ Hr
TURBDITY-INLET 20 NTU
OUTLET 1 NTU
DIA. 4 M
AREA 12.56 M²
a-MEDIA DEPTH-
ANTHRACITE 0.35 M
QUANTITY 4.4 M³
1-DUAL MEDIA BULK DENSITY
FILTER OFANTHRACITE 0.9 Gm/ML
QTY. 3960 Kg
b-SAND DEPTH 0.75 M
QTY. 9.42 M³
DENSITY 1600 KG/M³
QTY. 15.072 MT
c- FREE BOARD 0.88 M
HEIGHT OF FILTER 2 M
DESIGN PRESSURE 8 Kg/Cm²
2- DMF CAPACITY 510 NM³/Hr
BLOWER PRESS. 0.4 Kg/Cm²
RECTANGULAR
3- OVER HEAD TYPE RCC
BACK WASH
TANK CAPACITY 160 M³
DIMENSION(LXWXH) 8X8X2.5 M

FLOW 110 M³/ Hr

DIA. 3.2 M
AREA 8 M²
DEPTH 1.2 M
4- ACTIVATED QUANTITY 9.65 M³
CARBON QUANTITY 3860 KG
FILTER BULK DENSITY 400 KG/M³
FREE BOARD 80 %
SUPPORTING MEDIA
DEPTH 0.45 M
QUANTITY OF GRAVEL 3.62 M³
 QUANTITY OF GRAVEL 5789 KG
BULK DENSITY 1600 KG/M³
HEIGHT OF FILTER 2.7 M
ACTIVATED CARBON
BULK DENSITY NOT< 400 KG/M³
UNIFORMITY
COEFFICIENT 1.5 TO 1.6
IODINE NO. 850 MIN.
SIZE 0.8 TO 0.9 MM
ASH CONTENT 8 %
DESIGN PRESSURE 8 Kg/Cm²

FLOW 110 M³/ Hr

DIA. 2.4 M
HEIGHT 3.7 M
DEPTH 1.9 M
5-SCA OBR VALUE 1980 M³
FREE BOARD 80 %
VOUME OF RESIN 8568 LTR
QTY. OF HCl 1055 KG(30%)
DESIGN PRESSURE 8 Kg/Cm²

CO₂ -INLET 56.05 ppm

CO₂ -OUTLET 5.7 ppm
6- DEGASSER PACKING DEPTH 2.1 M
TOWER TOWER HT. 3.3 M
DIA. 1.6 M
BLOWER CAP. 2200 NM³/Hr

7-DEGASSED HEIGHT 8.5 M

WATER VOLUME 250 M³
STORAGE D.W. PUMP 135 M³/ Hr
TANK
HEAD 50 M

FLOW 110 M³/ Hr

DIA. 2 M
HEIGHT 2.5 M
DEPTH 1.2 M
OBR VALUE 1980 M³
8-WBA
VOUME OF RESIN 3750 LTR
REGN.-COCURRENT
THRUGHFARE WITH SBA
NaOH 2-2.5 %
 FLOW 110 M³/ Hr
DIA. 2 M
HEIGHT 2.5 M
DEPTH 1.16 M
9-SBA OBR VALUE 1980 M³
VOUME OF RESIN 3600 LTR
REGN.-COUNTER KG(40%
CURRENT 700 BASIS)
KG(48%
NaOH 5 % 560 BASIS)

FLOW 110 M³/ Hr

DIA. 1.6 M
HEIGHT 2 M
OBR VALUE 13860 M³
VOUME OF RESIN
10-M.B.
RESIN-CATION 994 LTR
ANION 994 LTR
FREE BOARD 100 %
QTY. OF HCl 272 KG(30%)
NaOH 198 KG(40%)

11- N.PIT CAP. 225 NM³/Hr

BLOWER(ALSO PRESS. 0.4 Kg/Cm²
FOR M.B.)

12- ACID DIA. 1.2 M

MEASURING HEIGHT 1.5 M
TANK-SAC VOUME 1.1 M³

13- ACID DIA. 1 M

MEASURING HEIGHT 1 M
TANK-MB VOUME 0.3 M³

14- ACID DIA. 1 M

MEASURING HEIGHT 1 M
TANK-N.PIT VOUME 0.3 M³

15- BULK ACID DIA. 2.4 M

STORAGE LENGTH 4 M
TANK VOUME 26 M³

16-ACID CAP. 15 M³/ Hr

UNLOADING
PUMP PRESS. 2 Kg/Cm²
17- ALKALI DIA. 1 M
MEASURING HEIGHT 1.5 M
TANK-SBA VOUME 0.9 M³

18- ALKALI DIA. 1.0 M

MEASURING HEIGHT 1.0 M
TANK-MB VOUME 0.410 M³

19- ALKALI DIA. 1.0 M

MEASURING HEIGHT 1.0 M
TANK-N.PIT VOUME 0.200 M³

20- BULK DIA. 1.8 M

ALKALI LENGTH 4 M
STORAGE
TANK VOUME 10 M³

21-ALKALI CAP. 15 M³/ Hr

UNLOADING
PUMP PRESS. 2 Kg/Cm²

22-ALKALI DIA. 1.2 M

FILTER HEIGHT 2.5 M

23-DILUTION DIA. 2 M
WATER HEIGHT 2 M
HEATING
TANK VOUME 6.8 M³

RCC-PPG LINING
24-N.PIT
SIZE -L.W.H 15X16X2.5+0.5 M

25-N.PIT CAP. 100 M³/ Hr

TRANSFER PRESS. 2.5 Kg/Cm²
PUMP MATERIAL SS316

26-DM REGN. CAP. 20 M³/ Hr

PUMP PRESS. 4 Kg/Cm²

CPU DESIGN DATA

EQUIPMENTS PARTICULARS DATA UNIT
DIA
FLOW
VESSEL
TOTAL RESIN
RESIN RATIO
ROHM & HASS AMBERLITE
252FRH
CATION RESIN
IN Na+ FORM 4100 LTR
IN H+ FORM 4350 LTR

ROHM & HASS AMBERLITE

SEP900SO4
ANION RESIN IN Cl- FORM 2650 LTR
IN SO4-- FORM 2850 LTR
IN OH - FORM 3312 LTR

CATION 102 KG/M³

REGN. LEVEL ANION 106 KG/M³
RESIN MACROPOROUS

DESIGN PRESS. 41 Kg/Cm²

DIA 2.0 M
HT. 5.6 M
ACTUAL RESIN 2.54 M³
CATION REGN. RESIN DEPTH 2.7 M
VESSEL CATION RESIN 4.35 M³
ANION RESIN 2.85 M³
INTERFACE 0.7 M³
TOTAL RESIN 7.9 M³

ANION REGN. DIA 1.6 M

VESSEL HT. 3.0 M
DESIGN PRESS. 7.0 Kg/Cm²
 DIA 2.3 M
RESIN MIXING /
HT. 3.5 M
STORAGE
VESSEL RESIN DEPTH 1.75 M

DIA 1.2 M
INTERFACE
RESIN VESSEL HT. 1.5 M

DIA 1.0 M
RESIN MAKEUP
HOPPER HT. 1.5 M

ACID DIA 1.4 M

MEASURING HT. 1.5 M
TANK

ALKALI DIA 1.0 M

MEASURING HT. 1.6 M
TANK

ACID DIA 1.0 M

MEASURING HT. 1.0 M
TANK-N.PIT

ALKALI DIA 1.0 M

MEASURING HT. 1.0 M
TANK-N,PIT

DIA 1.8 M
BULK ACID
LENGTH 3.0 M
STORAGE TANK

CAP. 10.0 M³/Hr

HEAD 10.0 M
 ACID
UNLOADING
PUMP

DIA 1.4 M
BULK ALKALI LENGTH 3.0 M
STORAGE TANK

ALKALI CAP. 10.0 NM³/Hr

UNLOADING HEAD 10.0 M
PUMP

DIA 1.0 M
ALKALI FILTER HT. 2.5 M
ACTIVATED CARBON 1.0 M³
GRAVEL 440.0 KG

CAP. 800.0 NM³/Hr

CPP BLOWER HEAD 50.0 M

CAP. 500.0 NM³/Hr

REGN.BLOWER HEAD 50.0 M

CAP. 60.0 M³/Hr

CPU REGN.PUMP HEAD 45.0 M

RINSE WATER CAP. 250.0 M³/Hr

RECIRCULATION HEAD 35.0 M
PUMP

DIA 2.0 M
POWER WATER HT. 2.2 M
HEATING TANK
 SIZE 15X8X3+0.5 FB M
N.PIT M³-
VOLUME 360.0 EACH

CAP. 50.0 M³/Hr

EFFLUENT
WATER PUMP HEAD 35.0 M

Viscosity Conversion Factors

Centipois
Centistokes = ÷ Specific Gravity
e
Centistok
SSU* = x 4.55
es
Degree
x 7.45 = Centistokes
Engler*
Seconds
÷ 4.05 = Centistokes
Redwood*

*Where centistokes are greater than 50

Centistokes Redwood Saybolt SUS Engler

2 30.8 32.6 1.12

2.3 31.5 33.7 1.15

2.6 32.3 34.8 1.18

2.9 33.0 35.7 1.21

3.2 33.8 36.7 1.24

Centistokes Redwood Saybolt SUS Engler

3.5 34.5 37.7 1.26

3.8 35.3 38.6 1.29

4.5 37.0 40.8 1.35

6 40.9 45.6 1.48

7.5 44.9 50.4 1.61

9 49.0 55.5 1.75

11 54.9 62.4 1.93

14 64.5 73.5 2.22

17 74.8 85.2 2.54

20 85.7 97.6 2.87

23 97.0 110 3.22

26 109 123 3.58

29 120 137 3.95

32 132 150 4.32

35 144 163 4.70

Centistokes Redwood Saybolt SUS Engler

38 156 177 5.08

41 168 191 5.47

44 180 204 5.85

47 192 218 6.24

50 204 232 6.62

65 265 301 8.55

80 326 370 10.5

95 387 440 12.5

100 407 463 13.2

 Values valid for temperature 50 oC (122 oF) - can be used for

approximate calculations between 20 oC (68 oF) and 100 oC
(212 oF).
===============================================

500 MW BOILER LIMITING PARAMETERS

PARAMETERS UNIT COND. FEED BOILER STEAM
pH at 25 °C value 9.0 to 9.2 9.0 to 9.1 to 9.4 9.0 to 9.2
9.2
SP.COND. µS/cm --- --- < 30 ---
CATION COND. µS/cm < 0.2 < 0.2 --- ---
HYDRAZINE AS N₂H₄ ppb --- 20 --- ---
AMMONIA AS NH₃ ppm 1 --- --- 1
PHOSPHATE AS ppm --- --- < 2.0 ---
PO₄⁻⁻⁻
SILICA AS SiO₂ ppb < 10 < 10 < 100 < 10
TOTAL IRON AS Fe ppb < 10 < 10 --- < 10
TOTAL COPPER AS ppb <3 <3 --- <3
Cu⁺⁺
CHLORIDE AS Cl⁻ ppb < 3 ppb < 3 ppb < 500 ppb < 3 ppb
D.O. AS O₂ ppb < 40 <5 --- ---
SODIUM AS Na⁺ ppb <5 <5 --- <5
TDS ppm --- --- < 20 ---
PRIMARY WATER
pH at 25 °C value 6.5 to 8.5
SP.COND. µS/cm < 2.0
D.O. AS O₂ ppb < 100
GENERATOR SYSTEM
HYDROGEN PURITY % > 96.0
DEW POINT AT
FRAME PRESSURE °C -10°C to + 10°C
(3.5 kg/cm2)
ECW pH at 25 °C value 8.5 to 9.0