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500MW Boiler at C.S.T.P.S. is supplied by B.H.E.L. The boiler is described as: Controlled Circulation with rifled tubing, single drum, balanced draft, radiant reheat, dry bottom, coal fired boiler, top supported. It is a tangentially fired boiler with tilting burners. The salient features of this boiler (compared with 210 MW BHEL Boilers) are1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) Maximum Continuous Rating: 550 MW Sub critical operating pressure: The operating drum pressure at 90% MCR is 188.8 Kg/ cm Controlled Circulation of Feed Water in Water Walls with the help of 3 Nos. of Boiler Circulating Water Pumps installed on Downcomers. Rifled bore water wall tubes as against smooth bore tubes in 210 MW boilers. Provision of Orifices for equal distribution of water in water wall tubes from Bottom ring headers. All downcomers are connected to front header of the bottom ring header. Design coal: Volatile Matter: 24%, Moisture 8%, Ash 40%, Sulphur 0.4%, Ash fusion temperature 1200 C, High Heating Value of 3750 Kcal/ Kg. 4 Nos. of Bisector air heaters, two for Primary air and two for secondary air. 8nos. XRP 1043 Bowl Mills, 4 I.D. fans, 2 F.D. fans and 2 P.A. Fans 4 E. S. P. Passes H.P. / L. P. Bypass system having capacity of 60% of Full Load Steam flow.

Controlled circulation system is the most features of this boilers (compared with existing 210 MW boilers operated by M.S.E.B.) Due to the sub critical operating pressure of 500 MW Boilers, difference in density of Water and Steam is very low and hence natural circulation is not possible. Hence three pumps are provided in the downcomers of 500 MW Boilers for circulation of water through Water walls. Tubes are rifled bore as against smooth bore tubes used in Boilers operating on Natural Circulation Due to swirling and highly turbulent flow in rifled bore tubes, boundary layer thickness of the fluid flowing through tubes is very small, thus enhancing the convective heat transfer rate. The disadvantage is high frictional resistance offered to fluid. Important Auxiliaries of the Boiler are: Auxiliary Important Data

Motor Rating 1750 KW, 3.3 KV, Squirrel cage induction motor, 990 RPM

F. D. fan

P. A. Fan

Type: Radial, Capacity 249 M/ sec: Head Developed: 430 mmWc Fan Regulation: Inlet Guide vanes Type: Radial Capacity: 169 M/ sec Head developed: 1270 mmWc Regulation: Inlet guide vane

Nos. per boiler 2

2800 KW, 11 KV, 990 RPM, Squirrel Cage induction motor

Auxiliary I. D. Fan

Important Data Type: NDZV-33 S Capacity: 255 M/ sec: Head Developed: 480 mmWc Regulation: Inlet guide vane Type: Pressurized Bowl Mill with classifier Size: XRP 1043 Base Capacity: 72.1 T/Hr for pulverized fuel fineness of 70% through 200 mesh, with raw coal of grindability index of 50HG, total moisture not more than 8% Mill shaft RPM: 35.47 Volumetric feeder, Belt type. Inlet Diameter: 914 mm Capacity: Min; 15 TPH Max: 85 TPH


1800 KW, 1 Squirrel Cag

Coal Mills

600 KW, 3.3

Coal Feeder

B.C.W. Pump

Type: Single suction, double discharge Design Pressure: 208.5 Kg/ cm Design temperature: 366 C Suction Pressure: 195.6 Kgf/cm Suction temp: 349.4 C Sp. Gravity of Water at suction: 0.5993

D.C. shunt w enclosed, fa speed motor Maximum R Min RPM: 1 Motor rating Gear reduct Voltage 240 Wet stator, induction mo Insulation: X Motor Case : 343 C Motor case d 206.5 Kgf/cm

Other important parameters of the Boiler are as follows:

Parameter Value at 500 MW Generation Main steam flow 1524.27 Reheat Steam Flow 1372.64 Pressure at Superheater outlet 177.2 Temperature at Superheater outlet 540 Pressure at Reheater Outlet 41.0 Temperature at Reheater outlet 540 Pressure at Reheater Inlet 43.0 Temperature at Reheater Inlet 342 Feed water inlet temperature 253 Secondary air temperature 326 Coal Flow rate 300 Total Combustion Air 1853 Furnace Draft -4 Temp. of Flue gas at Boiler outlet 136 Efficiency based on HCV 88.10 O2 I flue gas at Economiser Inlet 3.59 Excess Air 20 Boiler performance Data Dry Gas Loss 4.64 H20 and H2 in fuel 5.60 H20 in Air 0.18 Unburnt Carbon 0.60 Radiation 0.19 Unaccounted + Manufacturers 0.90 margin Total Losses 12.11 Heat Credit 0.21 Efficiency 88.10

Unit Tons / Hour Tons / Hour Kg / cm,gage C Kg / cm,gage C Kg / cm, gage C C C Tons / Hr Tons / Hour mm WC C % % % % % % % % % % % %

Boiler External Piping System: Main steam system: It consists of two steam lines from superheater outlet. These two lines join at a Tee connection out side boiler front and runs as a single line to turbine Hall. Similarly one single line is used for CRH steam and HRH steam from boiler to turbine. The sizes of these pipes are: Live Steam Pipe HRH Pipes CRH Pipes : Two lines of 330.2 mm I.D. x 79.0 mm thickness One line of 442 mm I. D. x 109.15 mm thickness : Two lines of 596 mm I. D. x 33.22 mm thickness One line of 812.8 mm I. D. x 44.94 mm thickness : Two lines of 762.00 mm I.D. x 18.71 mm thickness One line of 864 mm I. D. x 21.08 mm thickness

Safety Valves:

Location Drum SH Outlet RH Outlet RH inlet

Numbers 6 2 2 4 2 4 Safety valves ERV Safety valves ERV

Relieving Capacity, T/ Hr 208, 210, 212, 212, 255, 255 187, 187 130,130 165,165, 173, 173 125, 125 208, 208, 215,215

Set Pressure Kg/ cm gage 204, 206, 208, 208, 210, 210 188.5, 188.5 186.6, 186.6 49.96, 52.61 49.46 53.0, 54.6

Waterwall Sootblowers : 104 Nos., LRSB : 128 Nos. Fuel Firing Equipment:

Type and disposition Coal Burners HFO Burners L.D.O. Burners Tilting Tangential, on Corner Tilting Tangential, on Corner Tilting Tangential, on Corner

Nos. 8 elevations * 4 burners per elevation, Nomenclature: A, B, C, D, E, F, G, H 4 elevations * 4 burners per elevation Nomenclature: AB, CD, EF, GH One elevation * 4 burners per elevation Nomenclature: AB

Economiser: Plain tube Economiser, Total H. S. 14948 M, No. of blocks - 3 Each block consists of 130 parallel tube elements arranged in Horizontal manner in Second pass of Boiler. Superheaters: It is in three stages, composed of 1) finishing pendant platen 2) Divisional Panel and 3) Low temperature super heater. The finishing platan is located on horizontal gas path, above furnace real arch tubes and consists of 47.63 / 54 mm I.D. assemblies spaced on 762 centers. Total Heat Transfer surface area is 1458 M. The divisional panel is having H.S. Area of 1362 M. It is located in the furnace between front wall and Pendant Platan section. It is composed of 6 front and 6 rear panel assemblies made from 44.5 mm O.D. tubes. Low temperature super heater is located in the second pass above economiser, consist of 116 assemblies of 51 O.D. tubes spaced on 152. 4 mm centers across the width of furnace. Total H. S. Area is 9620 M.


Reheater: Total heating surface is 5075 M and is composed of three sections. Finishing section is located above furnace arch and consists of 46 Nos. of 54mm O.D. tubes. The front and side radiant wall sections are composed of 60.3 mm O.D. tubes spaced on 63.5 mm centers across furnace width. Furnace wall: It is composed of 51-mm O.D tubes spaced on 63.5 mm centers. The space between the tubes is fusion welded to form gas tight seals. Circulating Water Pumps: Hayward Taylor Circulating Water Pumps are glandless pumps and consists of a single stage centrifugal pump, 3.3 KV wet stator induction motor, which are mounted within common pressure vessel. Motor is suspended beneath the pump casing and is filled with boiler drum water to the drum pressure. No seal exist between pump and motor. Motor is thermally isolated from pump by: a) Thermal Conduction: The pump temperature is very high (340 C) and motor temperature should not exceed 54 C. To prevent heat conduction from pump to motor, a restriction in the form of Neck is provided. b) Hot Water Diffusion: To minimize diffusion of boiler water, a narrow annulus surrounds the rotor shaft, between hot and cold regions. A baffle ring restricts entry of solids from boiler water in to the motor casing. c) Motor Cooling: Motor cavity is maintained at low temperature by a cooler through which cavity water circulates. Separate pumps, installed at Boiler zero elevation, supply the ACW water to the cooler. The pump delivery pressure is 10 - 12 Kg/ cm. An overhead ACW tank is installed at 72- meter elevation, which supplies cooling water to these coolers in case of nonavailability of the cooling water pumps for 45 minutes. d) Cold Water Purging: In emergency, if temperature of motor cavity water increases, cold water can be admitted in to the motor casing from bottom of motor. The water for purging is obtained from B. F. P. Discharge or Boiler Fill Pump discharge. A separate cooler is provided to cool the purge water. The figures 1 and 2 show the arrangement of cooling water and schematic of B.C.W. pump.


Electrostatic Precipitators:

Design gas flow rate Design temp of gas at ESP inlet Inlet Dust concentration: No. of gas paths per boiler N0. Of fields in each gas peth Guaranteed Collection efficiency Velocity of gas in electrode zone Treatment time Total No. of Ash Hoppers for ESP Storage capacity of hopper Gas distribution at inlet Gas distribution at outlet No. of rows of collecting electrodes / field Nominal height of collecting electrodes Specific collecting area with one field out of service No. of collecting electrode plates per field Emitting electrode type Emitting electrode wire diameter No. of Emitting electrode per field No. of Emitting electrode per row frame No. of Rappers for collecting electrodes Rapper size Frequency of rap for collecting electrodes No. of Rappers for emitting electrodes Size of Rappers for emitting electrodes Frequency of rap for emitting electrodes No. of rectifiers Rectifier rating No. of motors for Emitting electrode No. of motors for Collecting electrode ESP Control ESP Manufacturer

750 m / s 123C 54.61 gms/ Nm, 4 6 99.87%, with one field out of service 0.895 m/s 25.2 s 72 8 Hrs of ash collection By perforated plates. U shaped thin sheets, located with 600mm pitch 57 12.5 m 167.96 m/ m/ s 342 Spiral, with hooks 2.7 mm 3024 324 One drop hammer per row of collecting electrodes having collecting area of 112.5 m 4.9 Kg 15 raps to 2 raps per hour, One drop hammer for two rows 3.0 Kg 10 raps / hour 48 70 KV, 1000 mAmps 48 nos 24 nos. With microprocessor controlled EPMS and ICE C control equipment M/s BHEL


Auxiliary P.R.D.S: Steam for Auxiliary P.R.D.S. is obtained from Boiler outlet before boiler outlet valves. For control of Steam Temperature and Pressure, pneumatic valves are provided. Spray water is obtained from BFP discharge header. Steam pressure in maintained at 16 Kg/ cm and temperature at 220C. P.R.D.S. steam is used for : 1) 2) 3) 4) 5) 6) 7) 8) 9) Turbine Gland Sealing, T.D. B.F.P. turbine warm up Deaerater Heating Wet steam washing of turbine Coal Mill inerting system, ( used for extinguishing coal mill fire) F.O. atomization and burner scavenging, SCAPH in Primary air as well as Secondary air, F.O. line tracing Oil handling plant