DBR 300 MW PDF

JSW Energy (Vijayanagar) Limited
TCE CONSULTING ENGINEERS LTD
BTG PACKAGE FOR 2300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU, BELLARY
DESIGN BASIS REPORT

FOR BTG MECHANICAL PART
DOCUMENT NO. 50-F271C-J01-01 REV.1
SHANGHAI ELECTRIC GROUP CORPORATION,LTD 3669 Jindu Road,Shanghai,China SOUTHWEST ELECTRIC POWER DESIGN INSTITUTE 18 Dongfeng Road,Chengdu,China
.
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Design Basis Report for BTG Mechanical Part
DOCUMENT CONTROL SHEET
PROJECT: BTG PACKAGE FOR 2300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU, BELLARY
CLIENT: JSW ENERGY (Vijayanagar) LIMITED /SHANGHAI ELECTRIC GROUP CORPORATION,LTD
DOCUMENT TITLE: DESIGN BASIS REPORT FOR BTG MECHANICAL PART
DOCUMENT NO.: 50-F271C-J01-01
REV. NO. : 1
ENDORSEMENTS
10.11. Revised as per 2006 MOM of second coordination meeting
08.200 6
REV. DATE DESCRIPTION PREP. BY NO.
REVW.
BY APPD
BY
SIGN.(INITIAL) SIGN.(INITIAL) SIGN.(INITIAL)
SOUTHWEST ELECTRIC POWER DESIGN INSTITUTE 18dongfengRoad,chengdu,China
DOCUMENT NO.: 50-F271S-J01-01 REV.1
Page 1
Design Basis Report for Mechanical Part
CONTENTS 1 GENERAL 1.1 Major design principle 1.2 Boiler 1.2.1 Introduction 1.3.1 General 1.3.2 Turbine HBD 1.4 Generator 1.4.1 General 2 FUEL 2.1 Fuel characteristics 1 1 2 2 3 4 6 6 7 7
3 COMBUSTION SYSTEM AND SELECTION OF AUXILIARY EQUIPMENT 11 3.1 Boiler Fuel Consumption 3.2 Design principle of Flue gas and air system & pulverized coal 11
system 11 3.3 System Description 3.4 Calculation results 3.5 Major Auxiliary Equipments Selection 3.6 Pyrites handling system 11 16 18 23
4 THERMAL SYSTEM AND SELECTION OF AUXILIARY EQUIPMENT 25 4.1 Design principle of Thermal System 4.2 System Description 4.2.1 Main steam, reheat steam and bypass system 4.2.2 Feed-water system 4.2.3 Extraction steam system 4.2.4 Condensate water system 4.2.5 Heater drains and vents system
DOCUMENT NO.: 50-F271C-J01-01 REV.1 Page 2
25 26 26 30 34 35 36
4.2.6 Auxiliary steam system 4.2.8 Vacuum system 4.2.9 Condenser tube cleaning system 4.2.10 Closed cycle DM water system 4.2.10 Boiler blowdown and drain system 4.2.11 Steam turbine lube oil and Lube oil handling system 4.2.12 Lubrication Oil System 4.3 Major Auxiliary Equipment Selection 4.3.1 Feed-water pump 4.3.2 Heaters 4.3.3 Condensate extraction pump 4.3.4 Vacuum pump 4.3.5 Condenser 4.4 Table of economic index 5 INSULATING MATERIAL
37 39 39 39 40 41 41 45 45 51 64 66 67 72 73
DOCUMENT NO.: 50-F271C-J01-01 REV.1
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1 GENERAL
1.1 Major design principle
This project is designed to be the coal-fired power plant located in India, with nominal generator output capacity of 2X300MW.
Main design basis codes and standards will be international codes & standards, IBR or equivalent standards subject to owners approval as below (refer to contract technical specification.)
1) American society of testing & materials;
2) ASME Test codes;
3) Technical code for designing fossil fuel power plant
4) Technical code for design of thermal power plant air & flue gas ducts/raw coal & pulverized coal piping;
5) Code for design of thermal power plant steam/water piping.
6) Guaranteed availability of each unit is higher than 85%.
7) Unit start-up time from ignition to full load <7.5 Hr,<4 Hr, <1.5 Hr for Cold, Warm and Hot start respectively.
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8) Plant makeup water3%.
9) The steam turbine, turbine generator and all equipments and auxiliaries are suitable for continuous operation in the frequency range of 47.5Hz to 51.5Hz. Also, for all equipments, noise level measured at a distance of 1 m from the equipment will not exceed 85dBA except for places as mentioned below: TG unit in which case it will not exceed 88 dBA;
1.2 Boiler
1.2.1 Introduction
The boiler is a natural circulation, subcritical pressure with single steam drum and single reheat. It is semi outdoor arranged and has a single furnace of reverse u-form (-type, Double pass) arrangement and full pendant steel structure, dry bottom type water-cooled, balanced draft furnace and is designed with tangential firing arrangement of burners. There are six pulverizers with 24 coal nozzles in different elevations in the furnace zone of the boiler. Light diesel oil will be used for start-up. The light diesel oil will be designed for 10 % BMCR load and mechanical atomization. The steam generator shall be designed for firing heavy fuel oil up to 30 % BMCR load. The minimum load without oil support is 30 % BMCR with design coal and 40 % BMCR with worst coal with two adjacent mill in service. The HFO will be steam atomization.
1.2.2 Boiler capacity and main parameters
Items
Unit
BMCR
Page 2
Items
Unit
BMCR
Boiler Max. Continuous rating (BMCR) Superheater outlet steam pressure Superheater outlet steam temperature Reheat steam flow Reheater inlet steam pressure Reheater outlet steam pressure Reheater inlet steam temperature Reheater outlet steam temperature Economizer inlet feed water temperature Efficiency(Based on higher heating value of the design fuel)
t/h MPa.(a) C t/h Mpa(a) Mpa(a)
1015 17.57 541 840.7 3.816 3.622 323 541 279 88.77
1.3 Steam turbine 1.3.1 General The steam turbine will be of a tandem compound, single reheat, and axial flow type with steam exhausting from one double flow low-pressure cylinder to condenser.
The unit will be capable of producing rated output of 300mw when operating with rated steam conditions and design ambient conditions. Main specification
Type: Subcritical, Reheat, Tandem compound, Two cylinder, Double flow, Condensing Rated Power (TMCR Condition): 300MW Rated Speed: 3000r/min Direction of Rotation: Clockwise viewing from Governing End Steam Inlet Pressure: 16.67MPa(a) STEAM INLET TEMPERATURE 538 STEAM REHEAT TEMPERATURE538
1.3.2 Turbine HBD Type N30016.67/538/538 (K156) 1) VWO (valve wide open) condition 1
Items Maximum output Steam pressure at the inlet of MSV Steam temperature at the inlet of MSV Reheat steam temperature at combined valves Steam flow for main steam Steam flow for hot reheat steam Back pressure of condenser Final feed water temperature Circulate cooling water
Unit MW MPa.a t/h t/h kPa(a)
VWO 312.970 16.67 538 538 966.623 798.881 10.05 277.8 33
1
2) Heat Rate Guarantee Condition
Items
Unit
Heat Rate Guarantee
Rate output Steam pressure at the inlet of MSV Steam temperature at the inlet of MSV Reheat steam temperature at combined valves Steam flow for main steam Steam flow for hot reheat steam Back pressure of condenser Final feed water temperature Circulate cooling water guaranteed heat rate
MW MPa.(a)
300.078 16.67 538
538
t/h t/h kPa(a) Kcal/Kwh
913.624 761.991 10.05 274.5 33 1909.6
3) All HP Heater out of service Condition

All HP Heater out Items Unit of service Rate output Steam pressure at the inlet of MSV Steam temperature at the inlet of MSV MW MPa.(a) 300.115 16.67 538
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All HP Heater out Items Unit of service Reheat steam temperature at combined valves Steam flow for main steam Steam flow for hot reheat steam Back pressure of condenser Final feed water temperature Circulate cooling water t/h t/h KPa(a) 538 796.851 778.005 10.05 178.6 33
1.4 Generator 1.4.1 General The generator is a two-pole, cylindrical rotor type synchronous machine, directly coupled with steam turbine. Generator type: Rated output Rated voltage Rated current Power factor Speed Frequency No. of phase Cooling method Stator winding Rotor winding Direct Water cooled Direct Hydrogen cooled QFSN-300-2 353MVA/300 MW 20 kV 10189 A 0.85 (Lagging) 3000 r/min 50 Hz 3
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Exciter method Class of insulation
Brushless excitation system Class F with temperature rise limited to class B 5% - 5.0% to + 3.0% 48 deg C 88 dBA at 1.5 m 1
Permissible variation in voltage Permissible variation in frequency Max cooling inlet H2 temperature Noise level
2 FUEL 2.1 Fuel characteristics The fuel and its characteristic data is listed below. 2.1.1 Coal Analysis
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Sl.No Proximate Analysis Design coal 1 2 3 4 5 Fixed Carbon % Volatile Matter % Moisture % Ash % High Heating Value Kcal/Kg 54.82 23.02 11.04 11.12 6300 5977(LHV) Worst Coal 41.59 20.09 15.01 23.31 5000 4679(LHV)
1 2 3 4 5 6 7 8
Carbon % Hydrogen % Sulphur % Nitrogen % Oxygen % Moisture % Ash % Grindability index (HGI)
64.64 4.75 0.30 2.24 5.94 11.04 11.12 53
49.19 4.24 0.46 1.39 6.40 15.00 23.32 45
Initial Deformation TEMP. C
1180
10 11 12 13
Hemispherical TEMP. Fluid Deg. C Crucibie swelling index (FSI) Bulk Density
1240 1290 >1 0.91
<1400 <1400
Ash charactorisics %/Wt
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Design coal 1 2 3 4 5 6 7 8 9 Silico Alumina Ferric Oxide Calclum Oxide Magnesium Oxide Sodium Oxide Potassium Oxide Tilanium Oxide Phosphate pent Oxide 10 11 Sulphur Trioxide Undetemined 0.40 53.3 35.3 4.0 2.2 0.50 0.30 0.50 1.40 1.30
Worst coal 37.0 45.8 10.7 1.69 0.44 0.08 0.29 1.27 0.67
0.94 1.1
Sieve analysis
+60 Mesh +120 Mesh +200 Mesh -200 Mesh Un-burnt % 02-0.4% 2.5-6.5% 8-11% 80-90% 4.0-18.0
2.1.2 Fuel Oil 2.1.2.1 LIGHT DIESEL OIL ANALYSIS LIGHT DIESEL OIL (LDO) ANALYSIS AS PER IS 1460, 1995 Viscosity at 40o C Density at 15o C Flash point, Min Cst kg/m3
o
2.5 to 15.7 920 66
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Pour point, Max. Water content, Max. Sediment, Max. Sulphur, Max. Ash content, Max. Gross calorific value
12o C 21 o C % vol. % wt % wt % wt (Approximate)
for Winter for summer 0.25 0.05 1.8 0.02 9950Kcal/kg
2.1.2..2 HEAVY FUEL OIL ANALYSIS
Furnace Oil Sl.No. Particulars Unit Grade MV2 (IS : 1593)
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 14. 15
Flash point Viscosity @ 150C Maxi. Pour point Ash content by weight Free Water content by volume Sediments by weight Total sulphur by weight Calcium Sodium Lead content Vanadium Carbon residence (Rams bottom) Approximate gross calorific value SP gravity at 150C Max.
Deg. C min. Cst 0C % max. % max. % max. % max. PPM PPM PPM PPM % wt Kcal/kg
66 180 21 01 1.0 0.25 4.0 30.5 10 0.2 40.50 7.74 10,000 0.933
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3 COMBUSTION SYSTEM AND SELECTION OF AUXILIARY EQUIPMENT 3.1 Boiler Fuel Consumption The fuel consumption is about 112.6t/h (design coal) and 146.8t/h (worst coal) per unit at boiler maximum operation condition (BMCR). At TMCR condition it is 103.3 t/h for design coal and 131.9t/h for worst coal per unit.
3.2 Design principle of Flue gas and air system & pulverized coal system Considering the high volatile matter and easy burning character of the raw coal, medium speed mill (MSM) (positive pressure)& direct-firing pulverizing system with cold primary air fan will be adopted based on heat calculation of coal pulverizing system.
3.3 System Description 3.3.1 Pulverized Coal System
Direct firing, pressurized cold primary air, pulverized coal system with MSM will be adopted in this project. Six (6) sets of HP863 (not finalized) type MSMs, electric gravimetric coal feeders (EGCF) and raw coal bunkers will be matched with each boiler. The output of four (4) MSMs will meet the requirement of boiler capacity at BMCR with design coal, and has suitable margin, the output of five MSMs will meet the requirement of boiler capacity at BMCR with worst coal, and has suitable margin. Raw coal from raw coal bunker via EGCF will be pulverized and dried in the MSM, then be separated in the MSM separator. There are four (4) pulverized coal pipes on each separator connected to four corners of boiler burners in the same layer. Six (6) sets of MSMs correspond to six (6) layer burners of each
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boiler. Diameter adjustable device will be placed at pulverized coal pipes, so that the resistance of each pipe is the same. Each MSM will be equipped with one EGCF. Inlet and outlet motor operated coal gates with good seal of the feeder can endure the exploding pressure of 0.35MPa, and have the function of self-clean. At the outlet of the bunker there is a motor operated rack & pinion gate, and the bunker emptying chute will be equipped between the two gates. The EGCFs have alarms of coal flow break and block, coal flow monitor etc, so that operator can handle emergency and ensures safe operation.
Six (6) bunkers will be set for each boiler. The capacity of series of bunkers per each unit will be normal sufficient to provided 16 hours requirement at boiler maximum continuous rate with worst coal firing. The coal bunkers are designed and supplied by JSW.
System design scope will include raw coal pipe and pulverized coal pipe.
3.3.2 Flue Gas and Air System
Direct firing, pressurized cold primary air system with MSM shall be adopted in the project. The boiler manufactured by Shanghai Boiler Works Co. Ltd (SBWL) in China shall be of natural circulation, drum type, double pass, water tube, direct pulverized coal tangential fired, dry bottom, single reheat, balance draft, and each boiler will be equipped with two (2) axial flow forced draft fans (FDF) with adjustable moving-blade, two (2) centrifugal induced draft fans (IDF) with hydraulic coupling, two (2) centrifugal primary air fans (PAF) and two (2) sealing air fans. During operation, pressurized air shall be forced into furnace. Flue gas from the furnace shall be induced to atmosphere.
Online vibration monitoring system and bearing metal temperature measurement system shall be provided for all fans and their drive motors .
3.3.2.1 Primary air system
Main function of the system is to feed pulverized coal and primary hot air heated by air preheater to MSMs. Primary hot air will be acted as dry medium, and cold primary air to MSMs (boosted by sealing air fan) and EGCFs will be acted as seal medium. The inlet vanes of centrifugal primary air fan can adjust air flow and pressure automatically.
Primary air will be heated in air preheater, and be sent to MSMs via common manifold. Primary air damper will be placed at air preheater inlet and outlet. When air preheater failure happen, the damper will be closed.
Pressurized cold air from PAFs will be regarded as regulating temperature for MSMs. The pressurized cold air will be mixed with hot primary air. Mixed air can meet the temperature requirement of coal dried in the MSM and pulverized coal at the MSM outlet.
When one MSM failure happens and shuts down, the corresponding pneumatic damper on primary hot air duct shall be closed immediately. To avoid primary hot air enter into the duct of primary cold air, motorized damper on the cold duct will be also closed immediately. Mixed air flow measurer will be installed on the mixed duct.
The air velocity in air ducts will be 10-12m/s for cold air and 15-25m/s for hot air.
3.3.2.2 Secondary air system
The system shall provide air for furnace combusting. Cold air from FDFs shall be forced into trisector regenerative air preheater, and hot air shall be sent into secondary air box and be distributed to furnace for combusting.
Two (2) FDFs will be equipped for each boiler. Cold air liaison duct, which connect two ducts between FDFs downstream; The hot air liaison duct arranged at air preheater outlet. Secondary hot air box is special design, when one FDF out of operation, hot air flow to the boiler four corners will be almost equal, so that stable combusting and reasonable temperature field in the furnace can be ensured, and will reduce temperature deviation at two sides of boiler.
Damper and air flow measurer shall be placed at hot air duct of air preheater outlet, when air preheater is out of operation, the damper shall be closed automatically.
Two trisector regenerative air preheater will be equipped which primary and secondary air will be heated in it. Also, water washing system and fire protection system and soot blowing system will be equipped for GAH.
Forced lubrication oil system (with 2x100% capacity pumps, filters, and associated piping/ accessories) is provided for air preheater.
The air velocity in air ducts will be 10-12m/s for cold air and 15-25 m/s for hot air.
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3.3.2.3 Sealing air system
2x100% centrifugal sealing air fans will be equipped in the system, one in operation and another standby. Sealing air from cold primary air manifold will be sent into MSMs via seal fan boost. At sealing air fans inlet, air filters and motorized control dampers will be arranged, when one fan is in operation, anothers inlet damper is closed. If pressure difference of the filter inlet & outlet reaches to setting value, the filter will clean itself via pressure difference.
3.3.2.4 Flue gas system
The system consists of two ESPs and two centrifugal induced draft fans (IDF) with hydraulic coupling. Flue gas from economizer will enter into two (2) air preheaters, each one isolating damper will set at the inlet and outlet of each air preheater. When emergency happens to one air preheater, the respective damper will be closed. During air preheater start up or shut down, the damper will be opened or closed.
Flue gas from air preheater enters into ESP with double path, six electric-fileds. Each boiler will be equipped with two ESPs. Isolating Guillotine type gates will be placed at ESP inlet & outlet. Fluel gas via ESP, IDF & chimney will be vented into atmosphere. 1
Isolating dampers will be placed at IDF inlet & outlet. When IDF failure happens, it will be overhauled after the dampers closed. During IDFs starting up or shutting down, the damper will be opened or closed.
Two (2) ID fans are in operating.

DOCUMENT NO.: 50-F271C-J01-01 REV.1 Page 1 15
The GAH outlet flue gas velocity in gas ducts will be 10-20m/s.
3.4 Calculation results The results are based on design coal for one boiler at MCR and it can adapt the characteristic data range of the coal.
3.4.1 Pulverized coal system
Value NO. Item Symbol Unit (For one unit) 1 2 3 Boiler coal consumption (BMCR) Hard grove grindability index Maximum Size of raw coal at inlet of mill Bg HGI dmax mesh 200 mill quantity / set t/h / mm 112.6 53 <32
Fineness of coal powder
70
Medium 5 Medium
speed
4/6(design coal)
operate/install speed mill quantity
operate/install
set
5/6(worst coal)
Medium speed mill operating output
BF1
t/h
38.79(design coal)
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Value NO. Item Symbol Unit (For one unit) 36.72(worst coal) 7 8 9 Medium speed mill max output Medium speed mill rated inlet air flow Primary air temperature at outlet of GAH BSJ Qv tkr t/h t/h C C 43.1 72.12 306
214(design coal) 239(worst coal)
10 Air temperature at inlet of medium speed mill
t1
1
11 Ratio of air and coal mass at inlet of medium speed mill / kg/kg
2.28(design coal) 2.31(worst coal)
Temperature at outlet of medium speed

12
mill Mill reject rate
tm
C % m3
80
13
<0.05
14 Effective volume of each raw coal bunker Duration for boiler burning at BMCR condition with worst coal bunker storage
Refer to TCE related
15
documents
3.4.2 Flue gas and air system (BMCRl)
NO.
Item (one unit)
Symbol
Unit
Value
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Design coal 1 2 Theoretical air volume for combustion (per kg coal) Volume of combustion result at the outlet of furnace 3 Air temperature at inlet of GAH V
Worst coal 5.2988
Nm3/kg
6.8174
Vy t 'kg tky
Nm3/kg
8.7713
6.9371
35
35
Air temperature at outlet of GAH Flue gas temperature at outlet of GAH ( corrected) Flue gas volume at outlet of GAH Flue gas excess air coefficient at outlet of GAH
304
302
tpy
138.3
137.2
Vy
m3/s
455.92
466.18
Apy
1.283
1.283
3.5 Major Auxiliary Equipments Selection

3.5.1 Pulverized coal system
Six (6) medium speed mills and six (6) coal feeders will be furnished for each boiler. These will be of sufficient capacity to attain the MCR of the steam generator when boiler firing any specified coal with any one mill out of service. In other words, when firing the performance coal, four (4) mills will be in operation and two (2) will be standby, and when firing the worst coal, five (5) mills will be in operation and one (1) will be standby, together with its associated feeders. Because of the positive pressure in the mill and coal feeder, two (2) sealing air fan are furnished to supply the sealing air to avoid the powder leaking.
The maximum capacity of mill shall be
43.1 TPH corresponding to 53 HGI,
70% through 200 mesh and moisture content 11.04 %.
Value NO. Item Unit Design coal 1 2 3 4 5 Worst coal
Type of MSM Grindability Index Moisture(AR) Powder fineness Maximum capacity of mill(HGI=53, 70% through 200 mesh)
mesh 200 t/h HGI 53
HP863 45 15 70% 40.8
11.04% 70% 43.1
6 7 8
Minimum capacity of mill Mill loading Max. air flow rate Max. resistance Inlet temperature of mill Outlet temperature of mill Inlet air/ inlet coal Rotary speed Shaft power of mill (BMCR)
t/h % t/h
10.78 65.5 72.12
10.2 71.6
9 10
11 12 13 14
kPa
Kg/Kg r/min KW 250
4.5 214
80 2.28 38.7 274
239
80 2.31
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Value NO. Item Unit Design coal 15 16 17 18 Worst coal
Rated power of motor Voltage Gravimetric coal feeder Coal feed distance (from feeder inlet to feeder outlet)
KW KV t/h mm
400 6.6 40 2200
3.5.2 Flue gas and air system
Each boiler will be furnished with two (2) sets of primary air fantwo (2) sets of forced draft fan and two (2) sets of induced draft fan. These fans will be
designed for outdoor installation. Under normal operation, all of PAF,FDF and IDFwill be in operation. The fans sizing are based on the flow and total pressure at BMCR conditions with a specific margin as below:
Value NO. Item Unit Design coal Worst coal
Primary air fan (2x60%BMCR)

Double suction centrifugal
Type
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QBMCR100BMCR with 35 degree

B
ambient temperaturel PBMCR QTB (test block, 60BMCR with 5
m3/s
46.7
57.3
Pa
10907
11913 73.5
degree above maximum ambient temperature PTB(test block, considering 30%
m3/s
1
Pa / 15934 1500 later 6.6
margindesign coal) Speed
rpm kW kV
F G
Motor ( with 15 % margin) Voltage Primary air fan (2x60%BMCR)
Adjustable movingA
Type
blade axial flow

B
ambient temperaturel PBMCR
m3/s
109.9
99.8
Pa
3179
3043
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QTB (test block, 60BMCR with 5

D
/ m /s
3
degree above maximum ambient temperature PTB(test block, considering 30%
148
1
Pa 4133 /
margin,design coal) Speed Motor ( with 15 % margin) Voltage Sealing air fan (2x100%BMCR)
F G H
rpm kW kV
Later later 6.6
Type
m3/h Pa kW kV
Double suction centrifugal 42221 6382 132 0.415
B C D E
Rated flow Rated head Motor Voltage Induced draft fan (2x60%BMCR)
Type
Double suction centrifugal type
Page 22

B
ambient temperature PBMCR QTB (test block, 60BMCR with 15
m3/s
239
244
Pa
3738
3775
degree above flue gas temperature margin)
m3/s
329
PTB(test block, considering 30% margin) Motor (The motor rating shall be arrived at considering 15% margin over the duty point input or 10% over
Pa
4908
the maximum demand of the driven equipment, considering frequency) whichever highest is higher, system
later
H I J
Speed Motor Voltage
rpm kW kV
later 2240 6.6
Two (2) electrostatic precipitators (double-pass, six electric field) are equipped for each boiler, The ESP remove particulate from the boiler flue gas to achieve a guaranteed outlet emission of less than 75 mg/Nm3 with all fields in service,and 100 mg/Nm3 with one field out of service when fired with specified coal range.
Air in leakage through ESP of the total gas flow is less than 3 %.
Value No Value
Electrostatic precipitator
Unit (design coal) (worst coal)
Double-pass, electric fields Flue gas flow (including 10%

m3/s 522 per unit g/Nm3 mg/Nm3 534
margin and 10 margin,design ) flue gas temperature(including 10
145.9
145.4
margin,design coal)
4 5 6 A B
Inlet dust concentration Outlet dust concentration Efficiency of ESP With (n-1) field in service With n field in service
10.5 75 /
29.2 75
% %
/ /
/ /
3.5.3 Boiler Igniting and Fire Stabilizing Oil System
The oil of the boiler igniting is diesel oil and fire stabilizing is HFO, and the boiler ignition mode is high-energy ignition. The system will be furnished with two 200m3 HFO daily oil tank, one 50m3 LDO daily tank for both units. (These oil tanks are in the scope of JSW, the capacity and quantity of tanks will be finalized by JSW/TCE ). 1
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Two motor-driven HFO oil transfer pumps per unit (one operation and another standby); Three motor-driven LDO oil transfer pumps and other associated equipments are common for two boilers. All these equipments are arranged centralized and located nearly the oil tank area. Light diesel oil pump capacity: Q8 t/h H450m (Total 3 sets for two units) Heavy fuel oil pump capacity: Q25.4 t/h H290m (Total 4 sets for two units) 3.6 Pyrites handling system Pyrites quantity(not finalized): Quantity(t/h)
1X300MW 2X300MW
0.11 0.22
Mechanical system will be used for pyrites handling. For details please see drawing 50-F127C1-J01-36 Pyrites Handling System Diagram. In each shift, pyrites discharged from each mill will be hold in pyrites hopper for unloading to chain conveyor by screw conveyor. Pyrites will be conveyed out of the boiler by chain conveyor then to be lifted to pyrites bunker by bucket elevator to make pyrites discharge into a truck for further transportation to ash yard. volume of each bunker is about 20m3. Chain conveyor is located below ground, each chain conveyors capacity is 10-15t/h. Mechanical system will operate about one(1) hour each eight(8) hours. 1
4 THERMAL SYSTEM AND SELECTION OF AUXILIARY EQUIPMENT
4.1 Design principle of Thermal System
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The thermal system will ensure the security, economy and flexibility of the unit. All of the systems are unit system except auxiliary steam system.
4.2 System Description 4.2.1 Main steam, reheat steam and bypass system
The pipe sizing shall be as per ASME B31.1 and velocities shall be limited to the values mentioned in specification.
In addition to above, when steam turbine at 100% TGMCR guarantee point : pressure drop in main steam line from superheater outlet to steam turbine stop valve is about 5.5 bar; overall pressure drop between HP turbine exhaust and IP turbine interceptor valves for reheater circuit shall be less than 10% of HP turbine exhaust pressure
4.2.1.1 Main steam system
Main steam system will convey superheated steam from the superheater outlet to the HP main steam stop valve. Main steam is unit system. Main steam flow through single pipe from outlet of boiler superheater header, and then divided into two branches and connects to left and right main HP steam stop valve separately.
1) A Motor operated Main steam isolation valve with motor operated integral bypass valve is set on main steam pipe near boiler outlet for boiler hydraulic test as well as for normal operation.
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2) One branch leads to gland steam system as HP steam source when normal gland steam pressure is too low and one branch leads to turbine casing steam heating header as heating steam source before turbine startup, another branch leads to auxiliary steam header when the cold reheat pipe pressure is inadequate or not available.
3) To prevent water from entering turbine, drain system is set to discharge condensate water of main steam pipe during warm-up and shut-down. Drain points are set at the lowest points on main steam pipe. A pneumatic drain valve and a hand-operated valve are set on drain pipe of each drain point. Drain water is led to drain flash tank. All drains including drain pot shall be checked with respect to ASME TDP guideline for turbine water damage protection.
4) Two spring safety valves, Two solenoid PCVs and two motorized venting valves are set on main steam pipe near superheater outlet.
4.2.1.2 Reheat steam system
Reheat steam system will convey cold-reheat steam from HP casing exhaust spout to inlet of boiler reheater and convey hot-reheat steam from outlet of reheater to IP main steam stop valve. Reheat steam is unit system. One cold reheat steam pipe is connected from turbine HP casing exhaust pipe and divided into two pipes in front of boiler, then connect to two inlets of boiler reheater header separately.
Two hot reheat steam pipes are connected at two end of outlet header of boiler reheater and join one pipe at front of boiler, and divided into two pipes again in front of turbine, then connect with left and right IP steam stop valve.
1) To prevent steam from flowing back into turbine, one pneumatic check valves is provided on cold-reheat pipes;
2) Desuperheaters are set on the pipe of reheater inlet, to adjust steam temperature of reheater outlet under emergency condition. Desuperheating water come from intermediate stage extraction of BFP.
3) Hydraulic test valve is set on each cold-reheat steam pipe near reheater inlet to prevent pressurized water entering cold-reheat pipe during hydraulic test of boiler.
4) To prevent water entering turbine, one drain pot is set on the pipe near HP casing exhaust spout. A pneumatic valve is set on drain pipe to automatically control drain water into condenser in time.
5) One spring safety valve are set on each cold-reheat pipe near reheater inlet separately.
6) A hydraulic test valve is set on hot-reheat main pipe to make sure that the pressurized water is stopped during boiler reheater hydraulic test and cant enter into the hot reheat pipes.
7) One pipe connecting the outlet of HP bypass valve and the inlet of LP bypass valve is set to form the heat circuit by pressure difference which is able to warm the outlet of HP bypass valve and pipe, the inlet of LP bypass valve and pipe.
8) Three spring safety valves are set on hot-reheat pipe near reheater outlet, its
set pressure is lower than the spring safety valve on cold-reheat steam pipe near reheater inlet, so the former will open before the later when over pressure happens to ensure enough steam through reheater and avoid over heating of reheater.
9) Drain points are set on hot-reheat steam pipe branches after tee to remove condensate water during startup and shut-down. Drain water enters into condenser. A pneumatic valve and a hand-operated valve are set on each drain pipe.
4.2.1.3 Bypass steam system
The capacity of bypass system is 60% BMCR. HP & LP bypass valves shall be of angle type and combined throttle cum spray valve, bypass valves and spray control valves are hydraulic operated valves. This system can convey main steam bypass HP-casing to cold-reheat piping and convey hot-reheat steam bypass IP&LP-casing to condenser when unit startup, shutdown and other various operating modes. TG set is capable of operating on house load during sudden total export load throw-off and in the event of turbine trip and generator breaker open, HP-LP bypass system will open automatically. The leakage class of valves shall be minimum class V. For Spray valve Trim exit velocity of liquid shall not exceed 30m/s.
1) Desuperheating water of HP bypass is from feed water system, one control valve and one isolation valve are set on desuperheating water pipe.
2) LP-bypass system is connected with HP-bypass system in series to achieve the function of whole bypass system. One upstream and one downstream
isolation valves are provided for LP bypass spray control valve.
3) One drain pot is set at the lowest point downstream of LP-bypass valve. A pneumatic valve is set on each drain pipe.
4) Desuperheating water of LP-bypass is from condensate water system.
Table 4.2.1
Item 1
Name Main steam pipe
Diameter ID368.341.275 ID273.05x30
Material A335P91 A335P91 A335P22 A335P22
Velocity (m/second) 50 45 67 60 33 35
Hot reheated steam pipe
ID679.5X32 ID50824.8
Cold reheated steam pipe 812.822.225 A672B70CL32 558.816

A672B70CL32
4.2.2 Feed-water system
HP feedwater system is unit system. The function of this system is to pump deaerated feed-water from deaerator water tank to inlet header of boiler economizer. Feed water is heated to the given temperature in HP-heaters by turbine extraction steam to improve heat efficiency of the units. There are three 50% capability motorized variable speed feedwater pump in this system, during
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normal operation, two pumps work and one pump is standby. The main boiler feed pump and booster boiler feed pump shall be manufactured of following or superior materials
a) Outer casing b) Inner casing c) Impellers d) Wearing rings
Forged Carbon steel ASTM A743 CA 6 NM ASTM A743 CA 6 NM 13 - 17% Chrome steel (Material shall be non-galling type with differential hardness not less than 100 BHN)
e) Stuffing box bushing & Stuffing box f) Pump shaft g) Shaft sleeves h) Base plate i) Diffuser / Volute j) Strainer k) Hydraulic Coupling 1) Make 2) Coupling wheels & casing 3) Scoop tube l) Balancing drum
13% chrome steel
13% Forged chrome steel Stellite on 13% chrome steel Structural steel 13% chrome steel Stainless steel mesh
Voith Alloy steel Stainless steel ASTM A 182 Grade F6 a
One full flow motorized orifice valve and one full flow motorized gate valve is located in major feedwater pipe. When the orifice valve in operation, the orifice valve can be reduce openning by manual remotely in control room when boiler load is <60%MCR. 30% BMCR bypass control valve is provided for low load operation and startup. Two motorized isolating valve are located in boiler filling bypass pipe.
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There are three HP heaters. HP heaters are horizontal type. Bypass piping will be provided to divert feedwater flow around any of the high-pressure heater for heater isolation of the respective each unit. All bypass and isolation valves will be motor operated.
Feedwater system can be divided into three parts: LP feedwater, IP feedwater, and HP feedwater pipes.
1) LP feedwater pipes
Pipes between the outlets of feedwater tank and the inlets of booster pumps are called LP feedwater pipes. There are motorized valve and strainer on each pipe. When startup, the strainer can separate the welding slag, impurities etc., which were accumulated in feedwater tank, and LP feedwater pipes during erection and maintenance to protect feedwater booster pumps.
2) IP feedwater pipes
Pipes between the outlets of booster pumps and the inlets of feedwater pumps are called IP feedwater pipes. Each pipe has a flow metering nozzle to
measure the feedwater flow at the inlet of feedwater pump in order to control opening and closing of minimum flow unit at the outlet of feedwater pump. There are also filters in these pipes in order to protect feedwater pumps.
3) HP feedwater pipes
Pipes between the outlets of feedwater pumps and inlet header of boiler economizer are called HP feedwater pipes, which pass through HP heaters.
There are one check valve and one motorized gate valve at the outlet of each feedwater pump. In order to prevent cavitation of booster pump, one recirculation pipe is extracted from the feedwater pipe and connected to the deaerator which has one minimum flow unit including a pneumatic control valve, two manual valves and one check valve. Signal of the minimum flow unit comes from the flow metering nozzle at the outlet of booster pipe. Each feedwater pump has a recirculation pipe which is connected to deaerator.
The interstage extractions from each feedwater pump are collected together and flow to the reheater attemperator as emergency desuperheating water to adjust steam temperature of reheater.
One pipe is branched from outlet manifold of feedwater pumps and connected to boiler superheater primary and secondary spray attemperator. Another pipe is branched for HP bypass control valve. The former adjust superheating steam temperature and the latter adjust main steam temperature to cold reheat steam system.
The feedwater control station is located between outlet of HP heaters and inlet header of boiler economizer.
One full flow motorized orifice valve and one full flow motorized gate valve is located in major feedwater pipe. One check valve is located at inlet pipe of economizer.
The capacity of bypass is 30% rated feedwater flow which adjusts feedwater flow when unit startup and low load operation.
Two motorized isolating valve are located in boiler filling bypass pipe.
One pipe is branched from the economizer inlet heater to drum as the economizer recirculating water pipe.
Table 4.2.2
Item 1 Name HP feed water common pipe Diameter 355.630 Material 15NiCuMoNb5-6-4 (EN10216-2) (DIN17175-79) 2 HP feed water branch pipe 244.5x20 15NiCuMoNb5-6-4 (EN10216-2) (DIN17175-79) 4.8 velocity(m/s) 5.3
4.2.3 Extraction steam system The system extracts steam from steam turbine to specified heating device and increases the temperature of condensate water and feed-water so as to raise thermal efficiency of the power plant.
There are 8 stages non-adjustable extraction of the steam turbine. Extraction No.8&7&6 supply steam to three (3) HP heaters, extraction No.5 supplies steam to deaerator. Extraction No.4&3&2&1 supply steam to four (4) LP heaters. LP heaters No.2 and No.1 are combined heaters which are located at neck of condenser.
Pneumatic-driven check valve and motor-driven isolation valve are set in each
extraction pipe except No2&1 extraction pipes. To prevent condensate water entering into steam turbine to harm it during startup, shutdown & low load, drain water pipe is set at the low point of each extraction pipe, near the valves.
Item 1 2 3 4 5 6
Name No. 8 extraction pipe No. 7 extraction pipe No. 6 extraction pipe No. 5 extraction pipe No. 4 extraction pipe No. 3 extraction pipe
Diameter 19410 2197 2739 37710 4269 5309
Material 12Cr1MoV 20 12Cr1MoV 20 20 20
Velocity (m/second) 41 39 36 36 51 45
4.2.4 Condensate water system
The system conveys condensate water from hot well of condenser to deaerator through gland steam condenser and four LP heaters to ensure safe operation and improve circulation heat efficiency. Beside these, the system also provides desuperheating water, make-up cooling water and other miscellaneous water requirements.
The system is unit system. There are two (2) 100% capability vertical Condensate extraction pumps in the system. Main control valve, auxiliary control valve and their bypass valve are set on condensate water pipe before No.1 LP heater to ensure water level control of
deaerator under all kinds of condition. Recirculation pipe at the gland steam condenser outlet pipe is set for the minimum flow when Condensate extraction pump is startup or the unit runs at the low load. One water discharge pipe branches from No.4 LP header outlet pipe is set to discharge unqualified water during startup.
Return water pipe to condenser make-up water tank (surge tank) from the outlet of condensate extraction pump is set for collecting water when the condenser hot well water level is high.
There are branches at
the low pressure desuperheating water pipe such as
desuperheating water pipe to fuel oil sweeping steam desuperheater turbine gland steam desuperheater, LP-bypass desuperheater, third-stage pressure and temperature reducer, LP casing spray, HP emergency drain flash tank; and also the make-up water pipe of closed circuit cooling water expansion tank.
Pipe is set to generator stator cooling water tank and vacuum pump startup make-up water from condensate water.
4.2.5 Heater drains and vents system
The functions of the system is recovering condensed water from heating steam of each HP heater and overflow & drain water of the deaerator, recovering condensed water of LP heater and gland steam condenser, removing noncondensable gas in HP heaters, LP heaters and deaerator. The normal cascade HP heater drain pipes from No.8, No.7 and No.6 HP heater to deaerator, LP heater drain pipes from No.4,No.3,No.2 and No.1 LP heater to condenser. Emergency drain pipe from each HP heater to emergency drain flash tank which
attach to condenser, and LP heaters to condenser. Non-condensable gas pipes from each HP heaters to deaerator and from each LP heaters to condenser and from deaerator vent to atmosphere. Over flow pipe will maintain normal water level of feed-water tank and discharge pipe can empty water in case of maintenance. Control valve is designed in each drain pipe to control water level.
Normal drain water from HP heaters cascade to deaerator. Emergency drain pipes are set for each heater and respectively led to emergency drain flash tank or deaerator in order to ensure smooth drain and keep normal level in case that high water level in HP heaters appears or HP heater is out of service. Normal drain water from LP heaters cascade to condenser; Pipes for emergency drain water of each LP heater can ensure smooth drain to condenser when water level in LP heater is high or at low load or its downstream LP heater(s) is (are) out of service.
Control valve is designed in each drain pipe of HP&LP heaters to control water level.
Multi-stage water sealing device is set in the drain piping of gland steam condenser to ensure smooth drain to main condenser in all operating conditions.
4.2.6 Auxiliary steam system
Auxiliary steam system provide steam to deaerator when start-up, low-load and trip, provide steam to boiler bottom heating, provide steam to turbine gland steam system when start-up and standby, provide steam to soot-blower when air preheater start-up, and provide steam to mill inerting steam and fuel oil system.
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Auxiliary steam is taken from cold reheat pipe at normal operation. During unit startup, shutdown and when cold reheat pipe pressure is inadequate, the steam is taken from main steam pipe. When the unit start up, start-up steam will be provided from the existing 2*130MW thermal power plant. JSW/TCE indicated that the parameters of the steam from the existing unit will be about 9.0 bar (g) and 280 Deg C at the terminal point. The terminal point location shall be 1m from the turbine building Column -1 between B-C row. There is a interconnection of auxiliary steam headers between the two units, so the auxiliary steam can be provided when one unit is startup and another is in service. Steam header has continuous drain pipes, it can drain condensed water of header to condenser. 1
One auxiliary steam header is provided for each unit. The pressure of auxiliary steam header is about 1.20MPa and temperature is about 320 0C in normal operation. Two safety valves are set on the header with different pressure setting.
The source of auxiliary steam come from cold reheat steam pipe at normal condition and main steam pipe when unit startup, shutdown or cold reheat pipe pressure is inadequate. However if steam is required for pre commissioning/ commissioning of first unit, auxiliary steam source shall be arranged by JSW.
4.2.7 Condensate make-up water system
Condensate make-up water system will fill condenser and boiler and deaerator with water before the starting of unit, and complement water to hot well when operating. Beside these, the system will supply sealing water for condensed pump, make-up water for HVAC system, make-up water for vacuum pump and etc.
4.2.8 Vacuum system
The function of this system is extracting the non-condensable gas from condenser and maintain rated vacuum in condenser during normal operating condition. The vacuum will be break to protect turbine during emergency. Two vacuum pumps are set in this system. Before unit startup, two pumps will operate in parallel to establish vacuum as fast as possible (17 minutes reach to 35KPa). Under normal operation, one pump is in operation and another is standby. 1
Mixture of steam and air is extracted from exhaust to atmosphere.
condenser. Uncondensed gas
There is one vacuum breaker pipe at neck of condenser. During the unit load rejection, air admission valve will be opening to break vacuum in condenser and decrease rotating speed of turbine, then shorten time of turning by inertia to protect turbine. This will be used only in emergency case.
4.2.9 Condenser tube cleaning system JSW not adopt.
4.2.10 Closed cycle DM water system
Closed cooling water shall be used to turbine auxiliary equipments and boiler auxiliary equipments such as generator hydrogen cooler, turbine lube oil cooler, generator stator water cooler, BFP motor cooler, the bearing of equipments, etc
The closed cooling water for auxiliary equipments is demineralized water.

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Chemical department will guarantee the water quality. The demineralized water is pumped by the closed cooling water pumps and is sent to the heat exchanger in which the demineralized water is cooled by the Aux. cooling water. 3x50% CCW pumps and 2x50% PHEs shall be provided for CCW system. Demineralized water will be sent to the equipments and return to the inlet of the cooling water pumps. An expansion water tank with volume 10m3 is set to meet the needs of volume change of cooling water caused by water temperature. The water tank will be arranged at a high place to gives the closed cooling water pump sufficient NPSH. Make-up water of the system is from outlet of condensate water pump in normal condition and from condensate make-up water system in emergency condition. The make-up water is led to expansion water tank with control valve for water tank level set in the pipe.
4.2.10 Boiler blowdown and drain system
1) Continuous blowdown system
Drum will continuously blowdown some unqualified boiler water to continuous blowdown tank to separate steam and water, steam flow into deaerator and water is discharged to intermittent blowdown flash tank. When continuous blowdown flash tank is failure during operation, blowdown water will flow through bypass to intermittent blowdown flash tank directly. If quality of boiler water is getting worse, this bypass can also be used to increase continuous blowdown water flow.
2) Boiler intermittent blowdown system
According to quality of boiler water, the water accumulated in bottom headers of

boiler with some deposits will be discharged intermittently. This water will be discharged to intermittent blowdown flash tank directly. After steam water separate in tank, steam is exhausted to atmosphere. The water in intermittent blowdown flash tank then discharge to a concrete pit underground and mixed with cooling water there, then discharged out.
3) Drainage and discharge system
Drainage and discharge pipes of each header would collect together to drainage manifold in boiler house during startup and shutdown, and then water is discharged to boiler intermittent blowdown flash tank.
4.2.11 Steam turbine lube oil and Lube oil handling system
Steam turbine lube oil system will supply lube oil to the bearing of steam turbine and generator, with main oil tank, oil pumps, oil coolers etc.
4.2.12 Lubrication Oil System
The function of the lubrication system is to :
Provide oil to lubricate the turbine and generator journal bearings . Provide oil to lubricate the thrust bearing Provide oil to lubricate the turning gear . Provide oil pressure for the generator hydrogen seal oil system . Provide oil pressure for the governor system
The lubrication oil system is a closed system using oil stored in a reservoir which
is pumped to various points of use. the lubrication system uses both shaft-driven and motor-driven pumps .A shaft-driven pump in the turbine governor pedestal ,together with oil ejector in the reservoir ,pumps the oil when the turbine is operating at or near rated speed .Motor-driven pumps are used when the main oil pump and oil ejector cannot supply sufficient oil pressure. The system uses two oil coolers to regulate the temperature of the lubricating oil system for the turbine generator unit consists of the following major components: Lubrication oil reservoir :
Turbine shaft driven main oil pump oil ejector
Auxiliary motor driven oil pumps
Vapor extractors
oil coolers
Oil piping
Protective devices
Bearing lift oil system
The lubrication oil reservoir is a steel tank in which the lubrication oil is stored. Mounted on the reservoir are the auxiliary motor driven pumps, vapour extraction system, level sensors, pressure transducers, and pressure gages .the oil ejector uses high-pressure oil from the main oil pump discharge to pick up oil from the reservoir when the unit is operating at or near rated speed .Strainers on the oil
ejector intake ,auxiliary oil pump suctions ,and oil return drain help to prevent particle contaminants from circulating through the system. The Reservoir is provided with man way access openings on the top of the shell and a drain connection on the bottom.
The main oil pump is a volute-type centrifugal pump mounted horizontally on the turbine extension shaft in the governor pedestal area. At or near rated turbine speed, the main oil pump supplies all of the oil requirements of the lubrication system. Provide oil pressure for the governor system and provides two source of backup for the generator hydrogen seal oil system.
The oil ejector is mounted inside the oil reservoir. The inlet is supplied with highpressure oil from the discharge of the main oil pump when the turbine generator is at or near rated speed. One outlet, the oil is directed through the oil coolers to the turbine generator bearings. The other outlet supplies the inlet side of the mail oil pump with oil.
The bearing oil pump (BOP) is an AC motor-driven centrifugal pump, vertically mounted on the top of plate of the oil reservoir which is used at startup and shutdown. During startup, the BOP is placed in service before the unit is put on turning gear operation. It stays in service until the main oil pump can satisfy the system oil requirements.
The emergency oil pump (EOP) is a DC motor-driven centrifugal pump which is identical to the BOP except for the motor. The EOP serves as a backup to the BOP in case of AC power failure.
The seal oil backup pump (SOB) is an AC motor-driven gear pump, horizontally
mounted on the top of the oil reservoir which is used during startup and shutdown of the turbine generator when main oil pump discharge pressure is too low to meet the oil pressure for the governor system and the generator seal system high-pressure oil backup requirements.
Two vapor extractors are supplied for the reservoir, one vapor extractor is normally operating and the other vapor extractor is on standby. The main function is to remove oil vapors and maintain a slight vacuum at the turbine pedestal, bearing housings, oil reservoir, and oil guard piping system.
The lubrication oil system includes two full-size oil coolers to maintain an acceptable temperature range of oil to the bearings while the system is in operation. The coolers are identical in construction. One cooler is used during normal operation and the other cooler is kept on standby. Valves between the two coolers direct oil flow from reservoir to the selected cooler.
Design basis of oil system
The Main oil tank capacity shall provide a minimum of 8 minutes retention time. There shall be a minimum of 0.023 m2 of free oil surface for each lpm of normal oil flow.
Turbine unit oil purification system shall be of centrifuge type. The hourly conditioning capacity shall be equivalent to 20 percent of the combined capacity of the main oil tank at operating level plus the oil in the lubricator system that flows back into the main oil tank during a shutdown of the turbine each hour. The equipment shall be designed to meet all lube oil purity requirements established by the turbine generator manufacturer and ASME Standard 118. The oil
conditioning equipment shall be designed to provide for removal of particulate matter greater than 10 microns absolute and all free water in accordance with ASME.
In addition to unit oil purification ( centrifuge type) , a common turbine oil purification system for both unit comprising of Dirty oil tank, Clean oil tank, Purification system, two convey pump, one cleaning oil pump and one dirty oil pump set will be provided.
Lube oil handling system will handle the unqualified lube oil before unit startup or under normal operation. The lube oil volume of steam turbine is 32m3, so a 48m3 dirty oil tank and a 48m3 clean oil tank is set in this system, with water coalescer type oil purifier and lube oil transfer pump.
4.3 Major Auxiliary Equipment Selection 4.3.1 Feed-water pump
Each unit will be furnished with three 50% capacity motor-driven variable speed feed-water pump with hydraulic coupling. Two pumps are working at normal operation and one pump is standby. Three booster pumps are set for each feedwater pump.
The capacity of the pumps is regulated by throttling pump discharge across a feedwater regulator. The pumps are capable of operating satisfactorily at deliveries ranging from minimum recirculation flow to the maximum specified. The pumps furnished for each installation is operate satisfactorily both in two
Page 45
pump parallel operation and single pump operation and when bringing in or taking a pump out of service with one or two other pumps in service.
During startup and low load operation, when the variable speed drive cannot provide the required feedwater flow control, a low load regulating valve is used. The low load regulating valve is bypassed.
Boiler feed pumps design is based on 110% feed water flow at BMCR. Pump is designed for complete frequency range of 47.5 to 51.5 Hz during normal operation. Pump and motor are provided with online vibration monitoring system and bearing metal temperature measurement.
BFP SIZING DATA SHEET

No Name Symbo l Unit Calculation & Remark BMCR TMCR (3%MU) Technical evaluatio n sheet
BFP inlet suction flow HBD from
Maximun steam flow
G1 t/h
Shanghai steam turbine works
1015
920.593
BFP 2
gland
seal G2 t/h 2 2
discharge and injection flow difference Interstage flow for RH spray Total suction flow of BFPs
Data from G3 t/h Shanghai boiler works Co.ltd G4 t/h G4=G1*110%+ G2+G3 1160.5 964.593 42 42
Page 46
BTG PACKAGE FOR 2300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU, BELLARY Technical evaluatio n sheet
No
Name
Symbo l specific G Q
Unit
Calculation & Remark According to
BMCR
TMCR (3%MU)
5 6 7
Feedwater volume
m3/kg kg/m3 t/h m3/h m3/h
HBD =1/ G=G4/2 Q=G**1000
0.001119 893.66 580.25 649.3 650
0.001119 893.66 482.3 539.7 550
Feedwater density Capacity of each BFP
BFP suction flow 8 Interstage flow of BFP
Q1=G3**1000 Q1 m3/h m3/h /2 23.5 30 650 23.5 30 550
9 B 1
BFP
booster
pump
suction flow BFP head
Q2
m3/h
Pipe and equipments pressure drop Pipe pressure drop from PLP PIP+PHP Considering 20 Mpa margin 1.051 0.881
deaerator tank outlet to economizer inlet
PPIPE
Mpa
0.876
0.734
Equipment pressure drop HP heaters PEQUI

P
Mpa
0.1*3
(3 HP
heaters) Considering 20
0.3
0.3
Mpa Total pressure drop from deaerator tank outlet to ecoonmizer inlet P1 Mpa
margin PPIPE+PEQUI
P
0.36
1.411
1.181
Page 47
No
Name
Symbo l
Unit
Calculation & Remark
BMCR
TMCR (3%MU)
Water pressure 2 economizer
differential between inlet and P2 Mpa (29.524.8)*9.81/
0.041
0.041
deaerator tank normal water level Drum relieving Total pressure drop from economizer drum Economizer inlet inlet to safety valve
According to P3 Mpa data sheet from boiler works 20.4
1
0.45
feedwater pressure at MCR condition 4 Rated working pressure of deaerator(neagative) Total head of BFP P4 P Mpa
18.78
From HBD P=P1+P 2+P3+P4
-0.814
-0.778
Mpa
21.487
19.224
BFP sizing result Head Suction flow P Q mH2o m /h

3
2454 650
2200 550
Note: all these data is primary data for the selection of BFP.
NPSH calculation for BFP

No. 1 BFP flow Name Symbol Unit Calculation W kg/s SG BMCR condition Data 294.200
Page 48
2 a)
Water weight from deaerator to BFP booster pump Pipe length of BFP booster pump A LP feedwater pipe Water weight of one meter in pipe
L1 Q1 G1 L3 Q3 G3 L2 Q3 G2 MS
m kg/m 325X8 kg m kg/m 325X8 kg m kg/m 325*8 kg kg Q3L2 Normal operation is two BFP, Ms= G3+G2 L3XQ3 L3XQ3
35.64 67.02 2388.59 37.1 67.02 2486.44 55.62 67.02 3727.65 6214.09
Total weight of water Pipe length of BFP booster pump B b) LP feedwater pipe Water weight of one meter in pipe Total weight of water Pipe length of BFP booster pump C LP feedwater pipe Water weight of one meter in pipe Total weight of water Water weight from deaerator to d) BFP booster pump Water weight in condensate pipe from No. 4 LP heater to 3 deaerator a) Pipe length Water weight of one meter in pipe Total weight of water Total weight of metal Operation weight of No. 4 LP b) heater Total metal weight of No. 4 LP heater Total water weight of No. 4 LP heater Convert coefficient of metal Weight of valve Water weight in condensate pipe c) from No. 4 LP heater to deaerator Water weight in condensate pipe from No. 2 LP heater outlet to No. 4 4 LP heater inlet Pipe length from No. 2 LP heater a) outlet to No. 3 LP heater inlet Pipe length from No. 3 LP heater b) outlet to No. 4 LP heater inlet c) Water weight of one meter in pipe Water weight of L2-3 and L3-4
c)
L Q1 Gs1 Gi Gb Gc Gs2 Gs3 Gcf ML
m kg/m 325*8 kg kg kg kg kg Convert coefficient: C'=0.1185 kg kg Valve handbook Gs1+Gs2+0.1185(Gi+Gc+Gcf) LQ1 325*8 weight: 62.542kg/mL Data of manufactory Data of manufactory
71.3 69.55 4958.92 4459.24 16380 12820 3560 0.1185 1600 10756.11
L2-3 L3-4 Q1 Gs1
m m kg/m 325*8 kg (L2-3+L3-4)Q1
89 56.9 72.06 10513.55
Page 49
d) Metal weight of L2-3 and L3-4 Operation weight of No. 3 LP e) heater Total metal weight of No. 3 LP heater Total water weight of No. 3 LP heater Operation weight of No. 1&2 LP 6) heater Total metal weight of No. 1&2 LP heater Total water weight of No. 1&2 LP heater Convert coefficient of metal Weight of valve Water weight in condensate pipe from No. 2 LP heater outlet to No. 4 LP heater inlet 5 a) Water weight of deaerator Cubage of deaerator water tank Metal weight of deaerator water b) tank Radius of deaerator water tank Center elevation of deaerator water d) tank The lowest water level elevation of e) deaerator water tank Water weight of the lowest water f) level in deaerator water tank Water calculation weight of the lowest water level in deaerator Saturation water enthalpy of deaerator when transient load 6 rejection Condensate water enthalpy of No.4 LP heater outlet when load 7 rejection Condensater water enthalpy of 8 condensor 9 Calculation time after load rejection c)
Gi Gb3 Gc3 Gs2 Gb2 Gc2 Gs3 C' Gcf
kg kg kg kg kg kg kg
3258 weight: 62.542kg/m*(L2-3+L3-4) Data of manufactory Data of manufactory
9124.88 14920 11850 3070
Data of manufactory Data of manufactory
48345 36320 12025
C'=0.1185 kg Valve handbook
0.1185 3200
Mc Q Gj R V V1 Gs M
kg m3 kg m m m kg kg
Gs1+Gs2+Gs3+0.1185*(Gi+Gc6+Gc7+Gcf ) 32777.20 Data of manufactory Data of manufactory 180 73300 1.8 23.55 22.85 63.233m3 Gs+C'*Gj 56511 65197.05
HO
kJ/kg VWO
736.3
HL HC TS N Nr
kJ/kg VWO kJ/kg VWO S m standard 3.6*1.25
589.6 192.2 300 1 4.5
10 Kind of downcomer 11 NPSH25% margin Level difference from calculation water elevation of deaerator to BFP booster pump C 12
Hj
m Page 50
21.955
BTG PACKAGE FOR 2300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU, BELLARY 20 0.001119 0.309 55.62
13 Resistance of strainer Specific volume of BFP booster 14 pump inlet 15 Inner diameter of downcomer 16 Calculatiom length of downcomer Part resistance coefficient of 17 downcomer Outside diameter of pipe Thickness of pipe Inner diameter of pipe Equivalence roughness of pipe Friction coefficient of pipe Length of pipeline Friction coefficient of pipeline Part resistance coefficient of pipeline Elbow90 total 11.5 Motorized gate valves Inlet resistance cofficient of downcomer Total resitance coefficient of pipe 18 Flow of each downcomer Available NPSH of load ejection result condition Originality data for calculation program 294.2,6214.09,10756.11,32777.2,65197 736.3,589.6,192.2,300,1 4.5,21.955,20,0.001119 0.309,55.62 11.36,147.1
PL VV DN L
kPa m3/kg VWO: 173.9C m [325-28)]/1000 m The max
DW S Di L A
mm mm mm DW-2*S E.2.1-1 1/(1.14+2*logDi/) m *L/Di/1000)

2
325 8 309 0.2 0.01769 55.62 3.18482
1 2 3 G ZH kg/s m
E.2.2-1 E.2.2-16 PN2.5;DN300 P180 E.2.2-14
2.875 2.8 2.5 11.36 147.1 0.237
4.3.2 Heaters
The extraction system of each unit will be set with three HP heaters, four LP heaters, one deaerator, and one gland steam condenser.
Page 51
All of the heaters are horizontal type and are designed in accordance with HEI standard. Shell wall thickness shall be determined in accordance with the ASME code utilizing the allowable stress value for the shell material at the design pressure and temperature. They are arranged indoors. Two LP heaters are arranged at the neck of condenser.
The deaerator has enough volume to ensure the boiler working at the maximum operation condition for about 10 minutes. The deaerator storage tank is also sized in conjunction with the deaerator outlet piping and height to provide a storage volume which allow adequate transient NPSH for the boiler feed due to a sudden full load rejection and prevent flashing at the pump suction. Deaerator shall remove dissolved oxygen from the condensate in excess of 0.005 cc per liter at any load from 5 percent to and including rated capacity.
HP heaters:
Closed feedwater heaters are used in a regenerative steam cycle to improve the thermodynamic gain. This is accomplished by extracting system at various points from the turbine and condensing kit using boiler feedwater. The resultant heating of the feed water aids in avoiding thermal shock to the boiler and reduces the fuel consumption required to convert the feedwater to steam. Since the work lost by extracting the steam is derived from sensible heat, i.e. no change of phase, the much greater latent heat recovered in the feedwater heater by changing phase from steam to water result in a net energy gain. Without a feedwater heater, the latent heat is wasted or thrown out in the main condenser or cooling tower. Therefore, feedwater heaters also help to reduce thermal pollution.
The high pressure heater is essentially an all-welded assembly. A special insert

is assembled in the inlet end of every heater-transfer U tube. Each high pressure heater has indicating, regulating and alarming devices of level. When accident has taken place, automatic regulating of drain level can fast bypass high pressure heater. Heater shell is provided with relief valves to protect the shell in case of tube failure. On tube side, relief valve is provided to prevent excessive pressure. Each high pressure heater contains three zones, (i.e. desuperheating zone, condensing zone and subcooling zone).
The welded seams are radiographed to insure the quality of the joint.
Stainless steel impingement plates have been installed in these heaters of steam and other drains inlets to avoid direct impingement of steam and drains upon the tubes to prevent tube erosion.
HP HEATER Nos. 8 DATA SHEET

SL. No 1 DESCRIPTION Tube side Sort Parameter Shell side Unit
Class 3rd pressure Class 2nd pressure vessel vessel JG-1370 1370 27.5 295 27.5 7.58 420/295 7.58 m2 MPa(a)
o
2 3 4 5 6
Type Heating area Design pressure Design temperature Max. pressure operating
MPa(a)
7 8
Operating pressure Operating temperature
21.5 279.5
6.2145 393.4/277.9
MPa(a)
o
Max. pressure drop
<0.1
<0.069
MPa
Page 53
SL. No 10 11 12 13 14
DESCRIPTION Tube side Flow Medium Weld coefficient Test pressure Corrosion allowable 1015 Water 1 41.25
Parameter Shell side 80.785 Steam & Water 1 11.37 1
Unit T/h
MPa(a)
15
Estimated weight Net weight Operating weight Flooded weight Manhole weight 64956 70861 82717 120 Kg Kg Kg Kg m3 m3 m3 m3
16
Estimated Volume Volume of water in sub-cooler zone at normal water level Volume of water in shell at normal water level outside sub-cooler zone Volume of steam in shell operating Volume of tube side 12.1 3.78 0.86 1.40

SL. No 1 DESCRIPTION Tube side Sort Parameter Shell side Unit
Class 3rd pressure Class 2nd pressure vessel vessel JG-1575 1575 27.5 265 4.81 360/265 m
o 2
2 3 4 5
Type Heating area Design pressure Design temperature
MPa(a) C
Page 54
SL. No 6
DESCRIPTION Tube side Max. pressure operating 27. 5
Parameter Shell side 4.81
Unit MPa(a)
7 8
21.5 245
3.6542 324/245
MPa(a)
o
9 10 11 12 13 14
Max. pressure drop Flow Medium Weld coefficient Corrosion allowable Test pressure
<0.1 1015 Water 1 1 41.25
<0.069 68.042 Steam & Water 1
MPa T/h
7.215
MPa(a)
15
Estimated weight Net weight Operating weight Flooded weight Manhole weight 62121 69767 81407 120 Kg Kg Kg Kg m3 m3 m3 m3
16

SL.N o DESCRIPTION Tube side Parameter Shell side
Page 55
Unit
SL.N o 1
DESCRIPTION Tube side Sort
Parameter Shell side
Unit
Class 3rd pressure Class 2nd pressure vessel vessel JG-1230 1230 27. 5 215 27. 5 2.07 470/215 2.07 m2 MPa(a)
o
2 3 4 5 6
MPa(a)
7 8
21.5 207.6
1.915 455/207.6
MPa(a)
o
9 10 11 12 13 14
Max. pressure drop Flow Medium Weld coefficient Corrosion allowable Test pressure
<0.1 1015 Water 1 1 41.25
<0.069 37.799 Steam & Water 1
MPa T/h
3.105
MPa(a)
15
Estimated weight Net weight Operating weight Flooded weight Manhole weight 48739 55961 69272 120 Kg Kg Kg Kg
3
16
Estimated Volume Volume of water in sub-cooler zone at normal water level Volume of water in shell at normal water level outside sub-cooler zone 1.32 m3 2.55 m
Page 56
SL.N o
DESCRIPTION Tube side Volume of steam in shell operating Volume of tube side
Parameter Shell side 13.6 3.50
Unit m3 m3
Note: class III: 10 to 100MPa, class II: 1.6 to 10MPa.
The high-pressure feedwater heaters shall be manufactured of following materials or superior materials:-
a) Channel: Carbon steel ASTM A516 Gr 70.
b) Shell: Carbon steel ASTM SA516Gr70.
c) Shell skirt: Carbon steel ASTM A516 Gr 70.
d) Tubes: Stainless steel ASTM SA688TP304N
e) Tubesheet: forged steel ASTM SA 350 Gr LF 2 with SS Cladding
Feed pump hydraulic coupling shall be rated up to lower operating range of 20% of the maximum output speed.
LP Heaters:
The low pressure heater system adopts single string arrangement, which consists of four low pressure feedwater heaters. The low-pressure feedwater heaters shall increase the temperature of the condensate in stages by the use of extraction steam. The low pressure heaters contain two zones(condensing zone and subcooling zone). Heat transfer tubes are stainless steel U-tubes. Heater
shell is provided with relief valves to protect the shell in case of tube failure. On tube side, relief valve is provided to prevent excessive pressure. Each channel of low pressure heaters consists of a cylindrical shell and an ellipsoidal head. LP heaters 1 & 2 are located in the neck of the condenser.
The maximum tube side flow shall be the condensate flow at turbine valves wide open and a design margin of no less than 10 percent. LP HEATERS Nos. 1 & 2 DATA SHEET
SL. No 1 2 3 4 5 6 Parameter DESCRIPTION Tube side Heater No. Type Heating area Design pressure Design temperature Max. pressure 7 8 Operating pressure Operating temperature 9 Max. pressure drop across heater 10 11 Flow Medium 791. 6 15.345 Steam & Water 0.85 1
Page 58
Shell side #1
Tube side #2
Shell side
Unit
JD-840-2-1 840 3.92 130 3.92 0.206 130 0.206
JD-740-2-2 740 3.92 130 3.92 0.206 130 0.206 m2 MPa(a)

o
operating
MPa(a)
1.724 59.79
0.0235 62.56
1.724 87.33
0.0738 90.11
MPa(a)
o
<0.1
<0.0055
<0.1
<0.0156
MPa
791. 6
33.583 Steam & Water 0.85
T/h
Water 1
Water 1
12 13
Weld coefficient Corrosion allowance
SL. No 14
Parameter DESCRIPTION Tube side Test pressure 5.88 Shell side 0.31 Tube side 5.88 Shell side 0.31 MPa(a) Unit
15
Estimated weight Net weight Operating weight Flooded weight
Heaters #1 & #2 combined 41100 48345 69555 Kg Kg Kg m3 m3
16
Estimated Volume Volume of water in sub-cooler zone at normal water level Volume of water in shell at normal water zone Volume of steam in shell operating Volume of tube side 21.2 6.24 m3 m3 level outside sub-cooler 3.86 1.92
LP HEATER No. 3 DATA SHEET

SL. No 1 DESCRIPTION Tube side Sort 2nd Class pressure vessel 2 3 4 5 6 Type Heating area Design pressure Design temperature Max. pressure 7 Operating pressure 1.724 0.158 MPa(a) operating 3.92 138 3.92 JD-530-1-2 530 0.48 266/138 0.48 m2 MPa(a)
o
Parameter Shell side 1st Class pressure vessel
Unit
MPa(a)
Page 59
SL. No 8
DESCRIPTION Tube side Operating temperature 108.6
Parameter Shell side 155.9/111.4
Unit
o
Max. pressure drop across heater
<0.1
<0.019
MPa
10 11 12 13 15
Flow Medium Weld coefficient Corrosion allowable Test pressure
791. 6 Water 1 1 5.88
T/h
0.72
MPa(a)
16
Estimated weight Net weight Operating weight Flooded weight Manhole weight 14000 17070 23130 275 Kg Kg Kg Kg m3 m3 m3 m
3
17
LP HEATER No. 4 DATA SHEET

SL. No DESCRIPTION Tube side Parameter Shell side Unit
Page 60
SL. No 1
DESCRIPTION Tube side Sort
Parameter Shell side 1st Class pressure vessel JD-580-6-4 580 3.92 164 3.92 0.686 332/164 0.686 2nd Class pressure vessel
Unit
2 3 4 5 6
m2 MPa(a)
o
MPa(a)
7 8
1.724 139.9
0.4104 256/142.7
MPa(a)
o
Max. pressure drop across heater
<0.1
<0.0344
MPa
10 11 12 13 14
Flow Medium Weld coefficient Corrosion allowable Test pressure
791.6 Water 1 1 5.88
T/h
1.029
MPa(a)
15
Estimated weight Net weight Operating weight Flooded weight Manhole weight 15400 18960 25200 275 Kg Kg Kg Kg m3
16
Estimated Volume Volume of water in sub-cooler zone at normal water level 0.65
Page 61
SL. No
DESCRIPTION Tube side
Parameter Shell side 0.84
Unit m3 m3 m3
Volume of water in shell at normal water level outside sub-cooler zone Volume of steam in shell operating Volume of tube side
Note: class II: 1.6 to 10MPa, class I: 0.1 to 1.6MPa.
6.36 2.16
10% Design margin shall be kept.
The low-pressure feedwater heaters shall be manufactured of following materials or superior materials:-
a) Channel: Carbon steel ASTM SA516 Gr. 70. 1 b) Shell: Carbon steel ASTM A516 Gr. 70
c) Shell skirt: Carbon steel ASTM A515 Gr. 70.
d) Tubes: Stainless steel ASTM SA688 TP 304
e) Tubesheet: carbon steel ASTM SA350 Gr LF2.
Deaerator:
The horizontal deaerator is one of the main auxiliary equipment in feedwater regenerative system for steam generating units. The primary use of deaerator is to remove noncondensable gases such as oxygen, carbon dioxide, etc. The boiler water is to reduce oxygen content below 0.005 cc/l. In addition, with
extraction on the intermediate pressure side of the turbine and other residual steam and drain, the deaerator shall heat the boiler feedwater to saturated temperature under operating pressure of deaerator so as to raise the thermal efficiency of the unit. The deaerator can store a definite amount of saturated water at deaerator pressure and conform to the standard of oxygen content to meet the needs of the boiler and guarantee its safe operation.
DEAERATOR AND TANK DATA SHEET

SL.N o 1 2 3 4 5 DESCRIPTION Sort Type Design pressure Design temperature Max. pressure 6 Working temperature 7 8 9 10 11 12 13 Effective Volume Total volume Rated capacity Weld coefficient Corrosion allowable Medium Nozzle drop 14 Max. capacity t/h pressure 180 257 1080 1 3.2 Steam & Water 0.05 MPa mm m3 m3 t/h 356.2
o
Parameter Deaerator Class 1st pressure vessel GC-1080/ GS-180 1.19/full vacuum 365 0.954
Unit
MPa(a)
o
working
MPa(a)
Page 63
Parameter 15 Set pressure of MPa(a)
safety valve 16 Others
The deaerator shall be manufactured of following materials or superior materials:
6.12.1 6.12.2 6.12.3 6.12.4 6.12.5 6.12.6 6.12.7 6.12.8 6.12.9 6.12.10 6.12.11 6.12.12
Deaerating shell & heads Feed water storage tank shell & heads Trays Tray enclosure Spray valves / sprayer assembly Steam distribution pipe (Internal) / Nozzles / Condensate pipes Splash plates & Baffle plates Bolts Nuts Gaskets Internal bolting, if any Vent orifice
Carbon steel to SA 516 Gr. 70 or equivalent Carbon steel to SA 516 Gr. 70 or equivalent Stainless steel to SS 304 / SS 431 Stainless steel to SS 304 Stainless steel to SS 304 Carbon steel to SA 106 Gr. B or equivalent Stainless steel to SS 304 SA - 193 B7 or equivalent SA - 194 2H or equivalent CAF 40 Stainless steel to SS 304 Stainless steel to SS 304
4.3.3 Condensate extraction pump
Two 100% capacity constant speed motor driven Condensate extraction pumps are set for each unit, one operate and one standby. The Condensate extraction pump is can type with single suction impeller and with derivational stage.
Each Condensate extraction pump shall be sized to supply 110 percent of the flow requirements at VWO operation with 3% makeup for each unit.
The Condensate extraction pump & motor shall be provided with online vibration
measurement system and bearing metal temperature measurement system.
CEP SIZING DATA SHEET

No Name Symbo l Unit Calculation & Remark VWO TMCR (3%MU) Technical evaluatio n sheet
A 1
Capacity of CEP Condensate steam flow at VWO Normal drain to condenser Normal makeup water to condenser Other flow to condenser Maximum condensate flow Capacity of each G1 HBD from Shanghai t/h t/h steam turbine works 607.2 125.3 583.3 117.8
G2
" " "
" " "
G3
t/h
29
27.6
G4
t/h
50
50
G'
t/h
G'=G1+G2+G3+G4
811.5
778.7
CEP Condensate water
G Q' Q
t/h m3/K g m3/h m3/h
G=1.1*G' According to HBD Q=G**1000
892.6 0.00101 901.6 910 0.00101 786.5 795
7 8
specific volume CEP flow
CEP head Pipe pressure drop
from condenser hotwell outlet to deaerator inlet
P1
Mpa
Calculation result
0.82
0.617
Mpa
Considering 20 margin 0.984 0.74
Page 65
No
Name
Symbo l
Unit
Calculation & Remark Including GSC, 4
VWO
TMCR (3%MU)
Equipments pressure drop
Mpa
LP heaters & spring nozzle 0.485 0.485
Mpa Water differential pressure between 3 deaerator inlet and condenser hotwell lowest water level 4 Deaerator max. working pressure Condenser highest vacuum CEP discharge head P3 P4 P Mpa P2 Mpa
Considering 20 margin 26.35(inlet of deaerator condensater water)-(0.662)(water level of condenser well) *1.25 margin 735x133.3/100010.05 P=P1+P2+ P3+P4 1.14 0.9120(no margin) 0.088 0.2701 0.2701 0.582
Mpa
0.088
Mpa
3.06
C 1 2
CEP sizing result Discharge pressure Flow H Q Mpa m3/h 3.06 910 795
Note: all these data is primary data for the selection of CEP.
To counter the surging effect on hotwell 100 m3 size surge tank is provided.
4.3.4 Vacuum pump
2X100% capacity vacuum pumps will be furnished in the system. Two pumps will be in operation for establish vacuum in condenser fast to shorten the start-up
Page 66
time before the unit starting. During normal operation, one operates for maintain the vacuum in condenser and another standby.
The vacuum pumps are of liquid ring type, and are sized in accordance with HEI standards. Each vacuum pump designed capacity is of 80Kg/h approximately of dry air plus associated water vapor to saturate at 1 inch (25.4 m/sec.) Hg atm. Besides, the pump capacity is also such that at starting, with both pumps working in parallel, it is possible to create within 20 minutes vacuum (about 35 KPa) in the condenser.
The design capacity of each pump shall be selected to meet the above requirements with a margin of 10%.
The pumps shall not cavitate under all operating conditions including part loads and design point, at CW temperature of 33 Deg.C.
3.10.1
Vacuum pumps a) Casing b) Shaft c) Impeller d) Shaft sleeves Cast iron Carbon steel EN-8 SS SS Carbon steel Stainless Steel Carbon steel with epoxy coating as required SS
3.10.2
Heat Exchangers : a) Shell b) Tubes c) Tube sheet d) Baffle and tie rod cage
4.3.5 Condenser
4.3.5.1 Structural Characteristic
Page 67
The condenser is designed in the form single shell, divided water boxes Two pass and installed in transversal arrangement. The condenser mainly consists of neck, shell, waterbox, exhaust expansion joint and so on. Four fixed base supports are arranged at the four angles at bottom of the condenser. Each fixed base support with three slot holes is connected to the foundation with M36 anchor bolt in order to satisfy the requirements of condenser expansion. Four sliding base supports are arranged at middle at the bottom of the condenser, so that the complete condenser can steadily upon the eight base supports. The condenser is connected to turbine exhaust hood with expansion joint.
4.3.5.2 Neck
Condenser neck is made of welded carbon steel plates and steel plate is applied for inside supporting and ribbed plates for reinforcement. T-type beam steel are applied inside each sideplate of neck to increase transversal rigidity of sideplates so that the complete neck could be rigid enough. Extraction lines go through neck. Stainless steel lagging is adopted to cover the outside of extraction lines in order to avoid erosion. All extraction lines are equipped with stainless steel waveform expansion joints to absorb thermal expansion in the lines. In order to protect abnormal higher temperature caused by turbine bypass inlet steam. Water screen spray protection device is equipped inside neck.
4.3.5.3 Shell
Shell made of full welded structure is the main part of condenser and possesses reliable tightness.
Two tube bundles are set up in shell. Triangular conventional layout is adopted for the arrangement of tube bundle. All tubes are seam welded. Air extracting line in cooling area are evenly distributed at cooling water entrance.
Support plates are distributed between front and back tube sheets to support cooling tubes. So that tubes could contact support plates closely to improve the vibration property of tubes and avoid resonance. Tube sheets are welded to two ends of shell and thinner steel plate is applied for flexible transition to compensate thermal expansion difference between cooling the and shell. Proper access manhole and other connections are provided on the shell.
An access manhole is provided on the tube bundle. Access openings or manhole is provided on the interior of the condenser to provided access to the tube support plates.
In some place where steam of water enters the condenser shell provided suitable approved baffle to prevent impingement on the tube and shell, and proper distribution of condensate and steam.
Hot well is designed below tube bundles with enough space so that subcooling could be minimized in the process for reheating transfer and raise deaerating effect as well. The hotwell has enough space for the requirements of condensate level change.
Two flash box is for absorbing drain. In this way, draining water can be temperature-reduced and pressure breakdown and then drained into condenser so that tube bundle could be protected from erosion of steam and water higher
temperature and pressure.
4.3.5.4 Waterboxes
Waterboxes are designed in the form of semicircle and cone-type. Thus resulting in good rigidity of the hole waterbox body, lightweight and favorable flowing property of cooling water. The water box is provided cathodic protection equipment. Inside of this condenser safety ladder is assembled to the inside wall of waterbox and both vacuum extracted outlet and air vent displaced at the top of waterbox. Manhole is equipped outlet the lower part of waterbox for maintenance personnel easy access. The type of water box connection to condenser is hinged connection. 1
Sufficient tube extract space shall be kept in the front of tubesheets for taking out of tubes if tubes are required to be taken out.
4.3.5.5 Exhaust expansion joint
Stainless steel waveform expansion joint is arranged at the exhaust expansion joint to absorb thermal expansion from turbine low pressure exhaust cylinder and condenser at vertical centerline direction of flow pressure exhaust cylinder.
The surface condenser is a double pass design with divided water boxes which will facilitate operation of one half of the condenser while the other half is under maintenance. The bottom of the condenser serves as a hot well for condensate storage.
Design Basis:
The thermal design of surface condenser is based on HEI standard considering 33C cooling water temperature for a temp rise of 10C corresponding to heat load for VWO, 3% makeup and 10.05KPa(a)back pressure. The condenser hot well minimum storage capacity at the normal water level shall be 4 minutes of condensate storage when operating at the turbine valves wide open. The oxygen content of the condensate leaving the hot well shall not exceed 0.015 cc per liter at all conditions
CONDENSER DATA SHEET

Sl.No Description Parameter Unit
Type
N-17000
Model
Single pressure divided two passes surface
Condenser effective surface area
17000m2
Condenser back pressure
10.05
KPa(a)
Condenser design pressure
Shell side
0.1/Full vacuum
MPa(g)
Waterbox side
0.343
MPa(g)
Page 71
Sl.No
Description
Parameter
Unit
Waterbox side test pressure
0.525
MPa(g)
Condenser design temperature
Shell side
121
Waterbox side
60
7 8
Inlet temperature of cooling water Max. inlet temperature of cooling water
33 36
C C
9 10 11 12 13 14
Design flow of cooling water Cleanliness factor Water velocity in condenser tubes Tube thickness Tube plugging margin Tube sheet material
35000 0.85 2.15 0.7 & 0.5 5% TP304+SA516Gr70
t/h
m/s mm
4.4 Table of economic index

7995 KJ/kW.h Heat consumption rate of turbine (1909.6 Kcal/kw.h)
Page 72
Guarantee efficiency of boiler (high heating value)
88.8%
NoteThe above results are based on TMCR (Heat Rate Guarantee) condition. Turbine cycle heat rate is 1909.6 Kcal/kW.h based on with 0% makeup, 33 Deg CCW inlet temp & 10.05 kPa(a) back pressure of condenser.
5 INSULATING MATERIAL According to different temperature and pressure, different layout of equipments and pipes in the BTG, the insulation material is considering as following (Code for designing insulation and painting of fossil and fuel power plant DL/T 50721997) taking care of the following design data: a) Design ambient temperature: 30 b) Maximum cladding temperature: 60 1) Temperature over 350 degrees equipments and pipes will adopt silicate or aluminium silicate material. Silicate: conductivity factor 0.031+0.00015tm W/m aluminium silicate: conductivity factor =0.035+0.00018tm W/m 2) Temperature under 350 degrees equipments and pipes will adopt rock wool or glass wool material. rock wool: conductivity factor 0.032+0.00018 tm W/m 3) Valves will adopt insulating material and abnormities will adopt slurry of silicate and aluminum for protecting layer.
Page 73
4) Aluminum material will adopt for protecting layer, the thickness will satisfy the IS requirement.
Page 74

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DESIGN BASIS REPORT

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Design Basis Report for BTG Mechanical Part

DOCUMENT CONTROL SHEET

CLIENT: JSW ENERGY (Vijayanagar) LIMITED /SHANGHAI ELECTRIC GROUP CORPORATION,LTD

DOCUMENT TITLE: DESIGN BASIS REPORT FOR BTG MECHANICAL PART

DOCUMENT NO.: 50-F271C-J01-01

10.11. Revised as per 2006 MOM of second coordination meeting

REV. DATE DESCRIPTION PREP. BY NO.

SIGN.(INITIAL) SIGN.(INITIAL) SIGN.(INITIAL)

SOUTHWEST ELECTRIC POWER DESIGN INSTITUTE 18dongfengRoad,chengdu,China

DOCUMENT NO.: 50-F271S-J01-01 REV.1

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Design Basis Report for Mechanical Part

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Design Basis Report for Mechanical Part

DOCUMENT NO.: 50-F271C-J01-01 REV.1

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Design Basis Report for Mechanical Part

1.1 Major design principle

1) American society of testing & materials;

2) ASME Test codes;

3) Technical code for designing fossil fuel power plant

5) Code for design of thermal power plant steam/water piping.

6) Guaranteed availability of each unit is higher than 85%.

DOCUMENT NO.: 50-F271C-J01-01 REV.1

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Design Basis Report for Mechanical Part

8) Plant makeup water3%.

1.2.2 Boiler capacity and main parameters

DOCUMENT NO.: 50-F271C-J01-01 REV.1

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Design Basis Report for Mechanical Part

t/h MPa.(a) C t/h Mpa(a) Mpa(a)

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Design Basis Report for Mechanical Part

Unit MW MPa.a t/h t/h kPa(a)

VWO 312.970 16.67 538 538 966.623 798.881 10.05 277.8 33

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Design Basis Report for Mechanical Part

2) Heat Rate Guarantee Condition

Heat Rate Guarantee

300.078 16.67 538

t/h t/h kPa(a) Kcal/Kwh

913.624 761.991 10.05 274.5 33 1909.6

3) All HP Heater out of service Condition

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Design Basis Report for Mechanical Part

DOCUMENT NO.: 50-F271C-J01-01 REV.1

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Design Basis Report for Mechanical Part

Exciter method Class of insulation

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Design Basis Report for Mechanical Part

64.64 4.75 0.30 2.24 5.94 11.04 11.12 53

49.19 4.24 0.46 1.39 6.40 15.00 23.32 45

Initial Deformation TEMP. C

1240 1290 >1 0.91