Plant Handbook for SIPAT STPP Stage 1

PLANT HAND BOOK
SIPAT STPP STAGE-I (3 x 660 MW)

UNITS 1, 2 & 3
CONTRACT NO. T04019
SUPPLIED BY :
DOOSAN HEAVY INDUSTRIES

& CONSTRUCTION CO., LTD
Proprietary Notice:
This hand book contains proprietary data of Doosan Heavy Industries &
Construction Co., LTD. No disclosure, reproduction, or use of any part may
be made without written permission of Doosan Heavy Industries &
Construction Co., LTD.
Date of Issue: June, 2006

PLANT HAND BOOK-SIPAT STAGE 1 (3x660MW) STPP
VOLUME- I
TABLE OF CONTENTS
TITLE PAGE NO.
I. COAL ANALYSIS
II. ASH ANALYSIS
III. BOILER PARAMETERS
IV. DESIGN AND PERFORMANCE DATA
1. STEAM GENERATOR DESCRIPTION

DESIGN ASPECTS …………………………………………………………………………. 1
General …………………………………………………………………………………………1
Mechanical Design Aspects ………………………………. …………………………………1
FURNACE DIMENSIONS…………………………………………………………………… .2
BOILER ARRANGEMENT………………………………………………………………….. .2
General…………………………………………………………………………………………. 2
Arrangement of Tube Banks…………………………………………………………………. 3
Fuels and Fuel Firing Requirements………………………………………………………...3
Boiler Start-up and Bypass System………………………………………………………… 3
The Water Separation System………………………………………………………………. 4
Control of Superheat and Reheat Temperatures…………………………………………… 4
Turbine Operation…………………………………………………………………………….. 4
BOILER LOAD CONDITIONS………………………………………………………………. 5
Boiler Maximum Continuous Rating (BMCR).. ……………………………………………5
Turbine Maximum Continuous Rating (TMCR) …………………………………………… 5
Normal Operation………………………………………………………………………………5
Minimum Once-Through Load……………………………………………………………….. 5
Allowable Steam Temperature Variations…………………………………………………… 5
CONDITIONS OF SERVICE…………………………………………………………………. 6
Description of Service………………………………………………………………………… 6
Operational Mode…………………………………………………………………………… 6
Operation Capability…………………………………………………………………………6
Operation Features…………………………………………………………………………….6
SAFETY VALVES …………………………………………………………………………… 6

SH Safety Valves …………………………………………………………………………….. 6
RH Safety Valves………………………………………………………………………………7
i 01 PLANT HAND BOOK-contents.doc

2. STEAM AND WATER FLOW SYSTEM

SUPERHEATER ………………………………………………………………………...1
DESCRIPTION………………………………………………………………………………… 1
Superheater……………………………………………………………………………………. 1
Steam Flow…………………………………………………………………………………….. 1
Protection and Control…………………………………………………………………………2
OPERATION…………………………………………………………………………………... 3
General………………………………………………………………………………………….3
Superheater …………………………………………………………………………………….4
SUPERHEATER DESUPERHEATERS ……………………………………………….5

DESCRIPTION………………………………………………………………………………... 5
CONTROL STATIONS………………………………………………………………………. 5
BLOWOUT PROCEDURE FOR DESUPERHEATER SPRAY WATER LINES ………6
MAINTENANCE………………………………………………………………………………. 6
REHEATER …………………………………………………………………………... 8
DESCRIPTION………………………………………………………………………………. 8
REHEATER……………………………………….. …………………………………………8
Steam Flow…………………………………………………………………………………. 8
Protection and Contro……………………………………………………………………….. 9
OPERATION………………………………………………………………………………….. 9
General ………………………………………………………………………………………9
Reheater…………………………………………………………………………………….. 10
REHEATER DESUPERHEATERS ………………………………………………….11

DESCRIPTION ……………………………………………………………………….11
CONTROL STATIONS ……………………………………………………………………11
MAINTENANCE ………………………………………………………………………12
BLOWOUT PROCEDURE FOR DESUPERHEATER SPRAY WATER LINES ……12
WATER WALL SYSTEM ………………………………………………………………14

FURNACE WALL WATER CIRCUIT………. …………………….……………………14
ECONOMIZER SYSTEM…………………………………………………………….. 15
ii 01 PLANT HAND BOOK-contents.doc

3. AIR AND FLUE GAS FLOW SYSTEM
AIR AND FLUE GAS SYSTEMS ……………………………………………………….. 1
AIR/GAS FLOW ……………………………………………………………………………...1

Secondary Air and Overfire Air - Combustion…………. …………………………………1
Flame Scanner Cooling Air………………….. ………………………………………………1
Primary Air - Conveying and Drying of Pulverized Coal…….. …………………………2
Seal Air - Pulverizers and Coal Pipes…….. ………………………………………………2
Seal Air - Feeders…………………………. …………………………………………………2
FLUE GAS FLOW………………………. …………………………………………………3

OPERATIONAL PROCEDURES… ……..…………………………………………………3
SCANNER AIR SYSTEM……… …………………………………………………………3
DESCRIPTION…………………………………. ……………………………………………3
SCANNER AIR…………………………………. ……………………………………………3
PULVERIZER SEAL AIR SYSTEM ….……………………………………………………4
INTRODUCTION ……………………………………………………………………………..4
SEAL AIR TO PULVERIZERS………. ……………………………………………………5
SEAL AIR FOR FEEDERS………………. …………………………………………………6
SOOT BLOWING PHILOSOPHY ………………………………………………………. 7
INTRODUCTION………………………….. …………………………………………………7
OPERATIONS ……………………………………………………………………………7
TYPES OF ASH DEPOSITS……………….. ………………………………………………7
BLOWER LOCATIONS…………………… …………………………………………………8
Furnace Walls……………………………… …………………………………………………8
Superheater and Reheater Areas……….. …………………………………………………8
Economizer and Air Preheaters…………….. ………………………………………………8
LIST OF REFERENCE ENGINEERING DRAWINGS………………………………………… 9
P&ID Diagram - Windbox & Burner Unit T04019-PI-D0019

P&ID Diagram - Windbox Detail T04019-PI-D0020
P&ID Diagram – Primary Air, Sealing & Cooling Air System T04019-PI-D0021
Scanner Air System Piping Arrangement T04019-SP-A001
Scanner Air System Piping Arrangement T04019-SP-A002
Suggested Pipe Supports T04019-SP-A003
iii 01 PLANT HAND BOOK-contents.doc

4. TILTING TANGENTIAL FIRING SYSTEM
DESIGN FEATURES………………………………………………………………..……… 1
SYSTEM DESCRIPTION…………………………………………………………………... 2
MAIN WINDBOX COMPONENTS…………………………………………………………. 2
AIRFLOW CONTROL AND DISTRIBUTION……………………………………………… 4
CONTROL SYSTEM PHILOSOPHY……………………………………………………….. 7
WINDBOX MAINTENANCE……………………………………………………………….. 7
LIST OF FIGURES
FIGURE 1. WINDBOX AND CCOFA ELEVATION DESIGNATIONS…………………..11

FIGURE 2. COAL COMPARTMENT-FUEL AIR DAMPER RAMP F(X) ……………….12
FIGURE 3. AUXILIARY AIR DAMPERS CHARACTERISTICS………………………… 13
FIGURE 4. CCOFA DAMPERS CHARACTERISTICS………………………………… 14
FIGURE 5. COAL COMPARTMENT ASSEMBLY…….. …………………………………15
FIGURE 6. EXPLODED VIEW EXTERNAL TILT DRIVE SHEAR PIN FAILURE
MECHANISM…………………………………………………………… 16
LIST OF REFERENCE ENGINEERING DRAWINGS
WINDBOX ARRANGEMENT SHEET 1 (T04019-WB-A001) ……………………………17

WINDBOX ARRANGEMENT SHEET 2 (T04019-WB-A002) …………………………18
WINDBOX ARRANGEMENT SHEET 3 (T04019-WB-A003)…………………………… 19
COAL NOZZLE TIP…………………………………………………………………………. 20
OIL NOZZLE TIP……………………………………………………………………………. 21
STRAIGHT AIR NOZZLE TIP(TOP, END) ………………………………………………. 22
STRAIGHT AIR NOZZLE TIP(AUX. AIR) ………………………………………………… 24
STRAIGHT AIR NOZZLE TIP(CCOFA) ………………………………………………….. 25
5. DESIGN DATA AND CONTRACT DATA SHEET……………………… …………………1

Predicted Performance Data (BMCR, TMCR, 80% TMCR & 60% TMCR) ................ 2
Predicted Performance Data (50%TMCR, 30% TMCR & Both HP Heaters Out) ...... 3
6. PRESSURE PARTS SKETCH
7. PRESSURE PARTS SCHEDULE-UNIT MATERIAL DIAGRAM
Back pass Economiser Tubes Page 1 of 12

Economiser Hanger Tubes Page 2 of 12
iv 01 PLANT HAND BOOK-contents.doc

Lower Furnace Page 3 of 12
Furnace Vertical Wall Page 4 of 12
Furnace Rear Wall Page 5 of 12
Extended Wall Page 6 of 12
Back Pass Wall Page 7 of 12
SH Division Panel Page 8 of 12
SH Platen Page 9 of 12
SH Final Page 10 of 12
Low Temperature Reheater Page 11 of 12
Reheater Final Page 12 of 12
8. SAFETY VALVES DATA
Design Basis for Safety Valves …………………………………………………………..1

Separator Outlet and Superheater Safety Valve …………………………………………2
Cold RH and Hot RH Safety Valve…………………………………………………………3
Soot Blowing Pipe Safety Valve ……………………………………………………………4
Safety Valve Setting Diagram at Superheate r……………………………………………5
Safety Valve Setting Diagram at Reheater System ……………………………………6
Safety Valve Setting Diagram at Soot Blowing System …………………………………7
Design Basis for Power Operated Impulse Safety Valves……………………………… 8
SH Power Operated Impulse type SV Setting Diagram…………………………………9
Hot RH Pipe Power Operated Impulse type SV Setting Diagram ……………………10
SV Setting for High Capacity PRDS Downstream. ………………………………… 11
Safety Valve Setting Table for HT Unit Aux. Steam Header…………………………..12
9. SOOTBLOWER SELECTION DATA AND PHILOSOPHY
Soot Blower Selection Data and Philosophy ……………………………………………1

Wall Blowers…………………………………………………………………………………..1
Retract Blowers, Furnace Probe & Half Retracts ………………………………………..2
Air Pre-Heaters ……………………………………………………………………………….2
Soot Blower Selection Data…………………………………………………………………3
Retractable Soot Blower Locations….. ……………………………………………………3
Wall Blower Locations……. …………………………………………………………………4
10. DUCT DESIGN DATA AND SCHEMATIC
11. PREDICTED PERFORMANCE DATA
Design coal……………………………………………………………………………………1
Worst coal……………………………………………………………………………………40
Best coal……………………………………………………………………………………..79
V. PERFORMANCE CURVES
Load Vs Water/Steam Temperature T04019-CV-01

Load Vs Reheat Steam Temperature T04019-CV-02
Load Vs Burner Tilt T04019-CV-03
Load Vs Excess Air T04019-CV-04
Load Vs Spray Water Flow T04019-CV-05
v 01 PLANT HAND BOOK-contents.doc

Moisture in Coal Vs Pulveriser Capacity T04019-CV-09
Moisture in Coal Vs Inlet Air Temperature T04019-CV-10
Pulveriser Capacity Vs Hardgroove Grindability T04019-CV-11
Pulveriser Power Consumption Vs Coal Capacity T04019-CV-12
Pulveriser Power Consumption Vs Coal Fineness T04019-CV-13
VI. START-UP CURVES
Cold start-up…………………………………………………………………. T04019-CV-06

Warm start-up……………………………………………………………….. T04019-CV-07
Hot start-up……………………………………………………. ……………. T04019-CV-08
VII. GENERAL ARRANGEMENT OF BOILER-DRAWINGS

GA of Boiler Key Plan & General Notes………………. T04019-GA-A0001-Rev.F1
GA of Boiler Sect. Boiler Side Elev. View “01-01”…… T04019-GA-A0002-Rev.F1
GA of Boiler Mill Side Elev. View “02-02/02a-02a”…… T04019-GA-A0003-Rev.F1
GA of Boiler Boiler Front Elev. View “03-03”…………. T04019-GA-A0004-Rev.F1
GA of Boiler El. 00 Plan View “04-04”………………… T04019-GA-A0005-Rev.F1
GA of Boiler El. 22600 Plan Sect. View “05-05”……… T04019-GA-A0006-Rev.F1
GA of Boiler Boiler Rear Elev. View “09-09”………….. T04019-GA-A0010-Rev.F1
GA of Boiler Gas A/H Center Elev. View “10-10”……. T04019-GA-A0011-Rev.F1
GA of Boiler Gas A/H Rear Elev. View “11-11”……… T04019-GA-A0012-Rev.F1
VIII. PROCESS & INSTRUMENTATION DRAWINGS
BOILER & DUCT INSTRUMENT INSERT LOCATION

CONNECTION LIST T04019-GA-A0018-Rev.A
CONNECTION DETAIL T04019-GA-A0019-Rev.A
P&ID – SYMBOLS AND LEGENDS T04019-PI-D0001-Rev.0

P&ID – ECONOMIZER SYSTEM T04019-PI-D0005-Rev.0
P&ID – EVAPORATOR SYSTEM T04019-PI-D0006-Rev.0
P&ID – WATER SEPARATOR SYSTEM T04019-PI-D0007-Rev.0
P&ID – SUPERHEATER SYSTEM(1/3) T04019-PI-D0008-Rev.0
P&ID – REHEATER SYSTEM T04019-PI-D0011-Rev.0
P&ID – CIRCULATION & START-UP SYSTEM T04019-PI-D0012-Rev.0
P&ID – BOILER DRAIN & VENT SYSTEM T04019-PI-D0013-Rev.0
P&ID – COMB. AIR&FLUE GAS SYSTEM(1/3) T04019-PI-D0014-Rev.0
P&ID – FUEL SYSTEN(1/3) T04019-PI-D0017-Rev.0
vi 01 PLANT HAND BOOK-contents.doc

P&ID – OIL BURNER DETAIL T04019-PI-D0020-Rev.0
P&ID – PRIMARY AIR, SEALING&COOLING AIR SYSTEM T04019-PI-D0021-Rev.0
P&ID – COAL FEEDER & PULVERIZER SYSTEM T04019-PI-D0022-Rev.0
P&ID – SCANNER COOLING & DAMPER SEAL SYSTEM T04019-PI-D0023-Rev.0
P&ID – STEAM COIL AIR HEATER SYSTEM T04019-PI-D0024-Rev.0
P&ID – BOILER WATER CIRCULATION PUMP SYSTEM T04019-PI-D0025-Rev.0
P&ID – SOOT BLOWING SYSTEM T04019-PI-D0026-Rev.0
P&ID – CLOSED COOLING WATER SYSTEM T04019-PI-D0027-Rev.0
P&ID – SERVICE AIR SYSTEM T04019-PI-D0028-Rev.F
P&ID – BOILER START-UP FLASH TANK SYSTEM T04019-PI-D0029-Rev.0
P&ID – SAMPLING SYSTEM T04019-PI-D0030-Rev.0
P&ID – INSTRUMENT AIR SYSTEM T04019-PI-D0031-Rev.F
P&ID – SERVICE WATER SYSTEM T04019-PI-D0032-Rev.0
P&ID – MAIN & REHEAT STEAM SYSTEM(1/2) ................ T04019-PI-D0501-Rev.G

P&ID – MAIN & REHEAT STEAM SYSTEM(2/2) ................. T04019-PI-D0501-Rev.0
P&ID – FUEL OIL SYSTEM(1/5) .......................................... T04019-PI-D0502-Rev.0
P&ID – EQUIPMENT COOLING WATER SYSTEM(1/2)…… T04019-PI-D0503-Rev.0

P&ID – EQUIPMENT COOLING WATER SYSTEM(2/2)…… T04019-PI-D0503-Rev.0
P&ID – LP DOSING & OXYGENATED TREATMENT
SYSTEM(1/2)………........................................... …..T04019-PI-D0504-Rev.0
P&ID – LP DOSING & OXYGENATED TREATMENT
SYSTEM(2/2)……….................................................T04019-PI-D0504-Rev.0
P&ID – AUXILIARY STEAM SYSTEM………………………… T04019-PI-D0505-Rev.0
P&ID – NITROGEN GAS SUPPLY SYSTEM………………… T04019-PI-D0506-Rev.0
IX. IMPORTANT DO’s & DON’Ts
VOLUME-II
X. SEQUENCE AND PROTECTION INTERLOCK SCHEMES
XI. ALARM AND TRIP VALUES
vii 01 PLANT HAND BOOK-contents.doc

I. COAL ANALYSIS
TABLE OF CONTENTS
TITLE PAGE NO.
COAL ANALYSIS………………………………………………………………………………………………... 1
i I. Coal Analysis.doc
I. COAL ANALYSIS
COAL ANALYSIS
Design Worst Best

Parameter Unit
Coal Coal Coal
High Heating Value kcal/kg 3,300 3,000 3,750
Total Moisture % 12.0 15.0 11.0
Proximate Volatile Matter % 21.0 20.0 24.0

Analysis Fixed Carbon % 24.0 20.0 29.0
Ash % 43.0 45.0 36.0
Fuel Ratio (FC/VM) - 1.14 1.00 1.21
Combustibility Index - 2,067 2,353 2,476
Carbon % 34.46 30.72 39.7
Hydrogen % 2.43 2.30 2.68
Nitrogen % 0.69 0.60 0.83
Ultimate
Oxygen % 6.64 5.35 8.65
Analysis
Sulfur % 0.45 0.40 0.60
Ash % 43.00 45.00 36.00
Moisture % 12.00 15.00 11.00
Grindability HGI 50 47 52
Note) Proximate Analysis and Ultimate analysis are based on as received coal basis.
1 I. Coal Analysis.doc
II. ASH ANALYSIS
TABLE OF CONTENTS
TITLE PAGE NO.
ASH ANALYSIS………………………………………………………………………………………………... 1
i II. Ash analysis.doc

II. ASH ANALYSIS
ASH ANALYSIS
Parame Design Worst Best

Unit
ter Coal Coal Coal
Silica SiO2 % 61.85 62.40 61.20

Alumina Al2O3 % 27.36 27.31 27.32
Iron Oxide Fe2O3 % 5.18 4.96 5.40
Lime CaO % 1.47 1.42 1.52
Magnesia MgO % 1.00 1.03 0.97
Sodium
Na2O % 0.08 0.08 0.08
Ash Oxide
Analysis Potasium
K2O % 0.63 0.32 1.22
Oxide
Titania TiO2 % 1.84 1.88 1.80
Phosphoric
P2O5 % 0.54 0.55 0.44
Anhydride
Sulphuric
SO3 % 0.05 0.05 0.05
Anhydride
Others % - - -
Initial o
Ash Fusion C 1150 1100 1250
Deformation
Temp. (oC) Softening o
C - - -
(Reducing o
Hemispheric C 1400 1280 1400
Atmos.)
o
Flow C 1400 1280 1400
Ash Content Kg /Gcal 130.3 150.0 96.0
Basic / Acid B/A 0.09 0.09 0.10
1 II. Ash analysis.doc

TABLE OF CONTENTS
TITLE PAGE NO.
Boiler parameters……………………………………………………………………………………1
i III. Boiler Parameters.doc

BOILER PARAMETERS
(Modified Sliding Pressure Operation)
100% 100% 80% 50% Both HP 60%

BMCR TMCR TMCR TMCR Htrs out BMCR
of oprn. (One stream)
SH SYSTEM
Steam Flow at SHO T/Hr 2225 2023.75 1572.47 963.76 1839.5 1335
Steam Pressure at SHO Kg/cm2(a) 256 254.45 238.01 151.25 252.92 204.4
Steam temp. at SHO deg. C 540 540 540 540 540 540
RH SYSTEM
Steam Flow T/Hr 1741.82 1678.37 1328.96 836.41 1784.2 1138

Steam Pressure at RHI Kg/cm2(a) 48.3 46.7 37.2 23.6 50.5 32.2
Steam temp. at RHO deg. C 568 568 568 568 568 568
Steam temp. at RHI deg. C 299 296 281 289 309 284
Pr. Drop across RH Kg/cm2 1.69 1.62 1.30 0.88 1.70 1.16
FEED WATER TEMP. deg. C 289.64 286.23 270.35 244.34 196.15 261
STEAM TEMPERATURE ---------------100% BMCR to 50% TMCR-----------

CONTROL RANGE %
1 III. Boiler Parameters.doc

IV. 1. STEAM GENERATOR DESCRIPTION
TABLE OF CONTENTS
TITLE PAGE NO.
DESIGN ASPECTS......................................................................................................................... １
General.............................................................................................................................................１
Mechanical Design Aspects .............................................................................................................１
FURNACE DIMENSIONS………………………………………………………………………………….２
BOILER ARRANGEMENT ............................................................................................................... 2

General.............................................................................................................................................. 2
Arrangement of Tube Banks… .......................................................................................……… ３
Fuels and Fuel Firing Requirements................................................................................................. 3
Boiler Start-up and Bypass System .................................................................................................. 3
The Water Separation System .......................................................................................................... 4
Control of Superheat and Reheat Temperatures ................................................................................ 4
Turbine Operation ............................................................................................................................. 4
BOILER LOAD CONDITIONS .......................................................................................................... 5

Boiler Maximum Continuous Rating (BMCR).................................................................................... 5
Turbine Maximum Continuous Rating (TMCR)................................................................................. 5
Normal Operation .............................................................................................................................. 5
Minimum Once-Through Load........................................................................................................... 5
Allowable Steam Temperature Variations..........................................................................................５
CONDITIONS OF SERVICE.............................................................................................................. 6
Description of Service ....................................................................................................................... 6
Operational Mode.............................................................................................................................. 6
Operation Capability.......................................................................................................................... 6
Operation Features ........................................................................................................................... 6
SAFETY VALVES ........................................................................................................................... 6

SH Safety Valves ............................................................................................................................. 6
RH Safety Valves ......................................................................................................... …………… 7
i IV.1 Steam Generator description.doc

DESIGN ASPECTS
General
The steam generator is a Doosan Heavy Industries & Construction Co., Ltd., balanced-draft,
once-through, supercritical, single reheat, dry bottom, indoor type. It is designed for sliding
pressure operation, with a balanced draft furnace capable of firing pulverized coal. The steam
generator will produce steam flow to a turbine generator with boiler outlet conditions of main
steam flow of 2023.75 t/h,(660 MW) SH Steam Temperature 540°C @ 255 kg/cm2(g) and RH
outlet steam flow of 1678.37 t/h, RH Steam Temperature 568°C @ 44.08 kg/cm2(g).
The once-through system is characterized by the unique arrangement of the evaporator

sections with the water separator placed at the end of the sections. In a once-through system,
the water and steam flows only once through the evaporator circuit with no re-circulation. The
steam is slightly superheated as it exits the evaporator section, or waterwalls, between
minimum once-through load and maximum load. In this load range, the water separator
operates in a dry mode.
The fluid pressure in the evaporator changes from supercritical to subcritical over the boiler load
range due to the sliding pressure mode of operation. However the once-through circuitry is
always the same above the minimum once-through load. Below about 75% load the water walls
are in subcritical region of flow, and part of the waterwalls will have two phase flow.
Below the minimum once-through load the flow through the evaporator must be maintained at a
constant value to ensure adequate cooling of the evaporator tubes. This flow is ensured by the
Boiler Circulation Pump, which is in service only below the minimum once-through load.
Therefore at low loads a mixture of water and steam leaves the waterwalls, and the water
separator operates in a wet mode with a controlled water level.
A major advantage of the once-through system is that there is no fixed point at which the
waterwall system ends and the superheater system starts. This means that the system can
operate with a very wide range of fuels and different states of furnace cleanliness.
The water separators have been located in the system to ensure a smooth transition from the
constant waterwall flow mode to the once-through flow mode. This also ensures that no
significant steam temperature excursions occur at the superheater outlet.
During startup and at low load, the steam-water mixture generated in the water walls flows to
the separators. In the separator, the steam is separated from the steam water mixture. The
steam passes to the superheaters and the water is recirculated through the Economizer and
Evaporator by the Boiler Recirculation Pump.
The furnace is made up of two sections-the lower spiral wall section and the upper vertical wall
section. The lower furnace spiral wound parallel tube construction results in uniform heat
absorption in all tube circuits, thus avoiding potentially damaging temperature differentials in the
tube panels.
Mechanical Design Aspects

The mechanical design of this boiler meets the demands of the specified pressure, temperature
and transients during load changes. A transient design pressure of ± 889 mmWC the furnace
chamber covers extreme conditions of puffs and implosion.
１ IV.1 Steam Generator description.doc

The furnace chamber is formed of spiral wound parallel tubing welded to form water wall panels
The furnace weight is supported by tension strips and distributed into the upper vertical
waterwalls.
A wrap-around buckstay system is installed over the whole height of the boiler. The upper
vertical walls are reinforced by an internal buckstay system attached perpendicular to the tubes.
This arrangement is capable of sustaining the ± 889 mm WC furnace transient design pressure.
Again, careful attention has been taken by designing the boiler suspension with an even load
distribution over a multitude of links to the steel structure.
High strength materials are used for the waterwall, the superheater and the reheater outlet
headers. These materials make it possible to use smaller wall thickness tubes and reduce
thermal stresses.
FURNACE DIMENSIONS
The complex properties of coal and its ash have a major impact upon the unit. The
combustibility of the coal, the ash content and the ash chemistry determine the slagging and
fouling properties. Furnace dimensions and the burner arrangement must reflect the resulting
fuel ash slagging characteristics. While the ignition of coal particles and the complete
combustion must be allowed, sufficient radiant surfaces must be provided within the furnace to
lower the gas temperature at the inlet to the convection heating surfaces to eliminate sticky
deposits from forming on these surfaces.
BOILER ARRANGEMENT
General
The boiler is a two-pass boiler of gas tight welded wall construction. The furnace is of dry bottom
type with continuous spiral wound tubes that run from the furnace hopper up to the bottom of
the furnace arch. The tubes connect to intermediate headers and from these headers, vertical
tubes are attached to form the upper vertical evaporator walls. From the outlet headers of the
vertical walls, the steam/steam & water mixture is fed to the water separators. The subsequent
steam path is through the steam-cooled roof, the back pass wall, into the superheater extended
sidewall panels, into the superheater division panels, to the superheater platens and finally to
the finishing superheater located above the furnace arch. Two stages of Superheater
desuperheaters are located in the steam circuitry. The first stage is between the SH Division
panels and the superheater platens, and the second stage is between the superheater platens
and the finishing superheater. There are two parallel desuperheater stations in each stage of
the superheater desuperheater.
The Reheater section consists of two stages-the Low Temperature Reheater arranged
horizontally in the rear pass of the boiler and the High Temperature Finishing Reheater
arranged pendant above the furnace arch in the high gas temperature zone. A single stage
Reheater desuperheater is located at the cold reheat line, that is the upstream of horizontal
reheater section.
Feedwater enters the economizer through the lower inlet header and flows through the
horizontal bare tube, in-line tubing comprising the heating surface. Return bends at the ends of
the tube banks provide continuous tube elements, whose upper ends connect to junction
headers. The economizer terminal tubes act as hanger tubes for the horizontal primary reheater
２ IV.1 Steam Generator description.doc

and terminate at the economizer outlet header. The outlet header is linked with the lower
waterwall headers through connecting links.
The economizer is designed for counterflow of gas and water, which results in a maximum log
mean temperature difference for heat transfer. Upward flow of water helps avoid water hammer.
Arrangement of Tube Banks

The location and sequence of superheat and reheat heating surfaces in the flue gas path is dictated
by:
The temperature difference between the gas and the internal fluid.
The method of reheat temperature control.
The metal temperature limits.
The reheat temperature is controlled by burner tilt, which assures reliable and maintenance free
operation. Because of this, the final reheater is located before the final superheater. In this way
the burner tilt has a maximum effect on the finishing reheat platen surface. The first stage of
reheater, the Low Temperature Reheater, is placed in the second pass to take advantage of the
convection heat transfer.
All heating surfaces are bare tubes and are arranged in line. The convection bundle suspension
and tube penetrations are designed for easy access and effective cleaning.
Fuels and Fuel Firing Requirements

1. Ignition and Warm-up Fuel
Light Diesel Oil.
2. Start-up. Low Load and Flame Stabilization Fuel
HFO/HPS/LSHS
3. Fuel for Rating and Performance
The steam generating unit and fuel preparation system is designed for continuous operation at
maximum continuous output with the Design/Worst/Best Coal and the range of Coal as
specified. The Performance Guarantees are based on the Design coal.
Boiler Start-up and Bypass System
The start-up and re-circulation system is designed to provide the necessary mass flow for
adequate cooling of the evaporator during start-up and low load operation. A minimum of
30% of TMCR flow is maintained up to a boiler load of 30% TMCR.
In this re-circulation system the feedwater flows through the boiler feedwater line to the
economizer, to the evaporator, and then to the water separator. From the separator the re-
circulated water returns through the Boiler Recirculation Pump to the boiler feedwater line,
where it is mixed with feedwater. The UG valve, located downstream of the BCP, controls the
amount of flow.
３ IV.1 Steam Generator description.doc

During a cold start-up, as the water swells, the excess re-circulated water is drained from the
water separator (at or near ambient pressure) through the WR and ZR control valves into the
boiler flash tank and thereafter the condenser. As the pressure in the water separator increases
and the water swell reduces, the amount of excess water decreases.
The WR and ZR control valves automatically maintain the water level in the separator. As the
water level increases the WR valve opens, followed by the ZR valve. When water level drops,
the ZR valve closes first followed by the WR valve.
Both the WR and ZR control valves are closed when water level is normal or below normal level.
During shutdown, the return water may become more or less contaminated, depending on the
amount of time the unit is shutdown. The contamination must be removed from the circuit. If this
happens, the return water can be routed through the atmospheric flash tank and then to the
condenser. From the condenser the water will pass through the condensate polishing plant
before returning to the feedwater tank. This will provide the required feedwater quality relatively
quickly.
The Water Separation System
The water separator system consists of 2 vertical separators with tangentially attached inlet
branches. Steam outlet branches are located on the top and the drain discharges are located on
the bottom. The drain discharge lines of the separators are connected to another vertical water
storage tank. The storage tank is provided with water level indicators for indicating water level
during start-up, low load and shut down operation.
Control of Superheat and Reheat Steam Temperatures

The superheater outlet steam temperature is controlled by two stages of spray water
attemperation. The reheater outlet temperature is controlled by modulation of burner tilt. A single
stage spray water attemperation system acts as an emergency control measure for reheater
outlet steam temperature.
There are many methods of steam temperature control such as gas circulation, spray water,
selective sootblowing and burner tilt. Experience has shown that for coal firing, gas recirculation
is less reliable, more expensive to maintain, and is also very vulnerable to erosion problems.
The burner tilt method has been chosen for primary control of the reheat temperature. The
burner tilt characteristics give a wide range within which the reheat temperature can be kept
constant. A spray water attemperation system is also provided to keep the temperature
excursions within allowable limits during fast load changes and upset conditions.
Turbine Operation
Today's power station practice requires increasing operational flexibility. This in turn requires a
mode of operation which is not only economical but also suitable to avoid undue thermal
stresses in thick walled components. For the turbine the best solution is sliding pressure and
temperature during start up and sliding pressure during normal operation. The advantages of
sliding pressure operation are:
Minimal temperature variation for first stage turbine shell under varying load conditions.
Lower thermal stress levels during start-up.
Reduced pressure levels at lower loads enhances component life span.
４ IV.1 Steam Generator description.doc

Improved overall power plant heat rates.
Extended control range of main and reheat steam temperatures.
Natural sliding pressure operation has an inherent disadvantage. Compared to the turbine, the
boiler has a large energy storage capacity, which seriously retards fast load changes. As a
result, modified sliding pressure is recommended, where the turbine admission valves are
modulated briefly with load variation.
BOILER LOAD CONDITIONS
Boiler Maximum Continuous Rating (BMCR)

Boiler Maximum Continuous Rating (BMCR) is the maximum rating specified for the boiler. This
corresponds to 109.94% of Turbine maximum continuous rating.
Turbine Maximum Continuous Rating (TMCR)

Turbine Maximum Continuous Rating (TMCR) is the basis of steam generator output and is
equal to the turbine generator maximum guaranteed rating.
Normal Operation
The steam generator is designed to be operated as follows:
Constant Pressure Operation.

Above 90% TMCR, the main steam pressure remains constant at the rated value, condition,
while the load is controlled by throttling main steam flow with the designated partial arc control
valve. Below 30% TMCR, the main steam pressure remains constant at the minimum. The
minimum constant pressure is 93.84 kg/cm2 (g).
Sliding Pressure Operation.

Between 30% and 90% TMCR, the steam pressure and steam flow rate is controlled by the load
directly.
Governor Regulating Operation.

Load is regulated in response to the network frequency fluctuation.
Minimum Once-Through Load

The minimum once-through load is designed for 30% TMCR and is where the transition is made
from wet to dry operation. Below 30% TMCR, waterwall flow must be kept constant to ensure
adequate waterwall tube cooling. Accordingly, the start-up and re-circulation system is designed
for 30% TMCR.
Allowable Steam Temperature Variations

The control system is designed to meet the performance objectives tabulated below.
Description SH Steam Temp. RH Steam Temp.

Steady state condition ±5°C ±5°C
Load changing rate of ±8°C ±8°C
5% TMCR/min. above
50% TMCR
５ IV.1 Steam Generator description.doc

CONDITIONS OF SERVICE
Description of Service
The steam generator supplies steam to the reheat, condensing type turbine generator for the
generation of electric power.
Each unit may be operated in parallel with other station generating units within the power system.
The steam generator may be subjected to sudden load rejection or rapid load pickup, and also to
adverse conditions of maladjusted unit controls.
Operational Mode
The steam generator is suitable for base load operation and load cycling operation.
Operation Capability
The steam generator will be capable of:
Achieving the maximum continuous load of BMCR at rated steam temperatures of 540°C/568°C.
Supplying steam within the allowable variation for the following load variations:
At a rate of 5% minimum of nominal rating per minute between 50% and 100% TMCR.
At a rate of 3% minimum of nominal rating per minute between 30% and 50% TMCR.
Sustaining the minimum stable load by full automation not more than 30% TMCR without
supporting oil and bypass operation.
Operation Features
This unit is associated supplied with a High Pressure Bypass system with safety function, and a
low pressure bypass system (by others). These systems are used to assist matching steam and
turbine metal temperatures during start-up by bypassing main steam directly to the reheater and
into the condenser.
SAFETY VALVES
This unit is supplied with spring loaded safety valves, power operated impulse type safety valves
and power operated impulse type relief valves located on Separator, Separator outlet links, Main
Steam line, Cold Reheat and Hot reheat lines for protection of the boiler components against
over pressurization.
SH Safety Valves
SH safety valves are located on Separator, Separator outlet links and Main Steam line. Ten nos.
of spring loaded safety valves-one each on separator, two each on separator outlet links, two
each on main steam line are provided having a total relieving capacity of 107.2% of BMCR flow.
Two nos. of power operated impulse type safety valves-one each on main steam line, two nos.
of power operated impulse type relief valves-one each on main steam line are provided having a
total relieving capacity of 41.5%. The combined total relieving capacity of the spring loaded
safety valves and power operated safety and relief valves is 148.7% of BMCR flow.
６ IV.1 Steam Generator description.doc

RH Safety Valves
RH safety valves are located on the cold reheat lines and the hot reheat lines near the boiler.
These valves discharge to atmosphere. There are two hot RH spring loaded safety valves-one
each on hot reheat line, two hot RH power operated impulse type safety valves-one each on hot
reheat line, two hot RH power operated impulse type relief valves-one each on hot reheat line
that operate simultaneously, and eight cold RH spring loaded safety valves-four each on cold
reheat line, that operate simultaneously.
The maximum capacity of the RH spring loaded safety valves is based on the maximum reheat
steam flow at BMCR load. The spring loaded safety valves are sized with a relieving capacity of
107.3% of BMCR reheat flow. The relieving capacity of power operated impulse type valves is
61.4%. The combined capacity of spring loaded safety valves and power operated safety valves
is 168.7.
７ IV.1 Steam Generator description.doc

IV. 2. STEAM AND WATER FLOW SYSTEMS
TABLE OF CONTENTS
TITLE PAGE
1. SUPERHEATER...................................................................................................................1
DESCRIPTION.............................................................................................................................1
Superheater .............................................................................................................................1
Steam Flow ..............................................................................................................................1
Protection and Control .............................................................................................................2
OPERATION................................................................................................................................3
General ....................................................................................................................................3
Superheater .............................................................................................................................4
2. SUPERHEATER DESUPERHEATERS ................................................................................5

DESCRIPTION.............................................................................................................................5
CONTROL STATIONS.................................................................................................................5
BLOWOUT PROCEDURE FOR DESUPERHEATER SPRAY WATER LINES ...........................6
MAINTENANCE ...........................................................................................................................6
3. REHEATER ..........................................................................................................................8
DESCRIPTION ............................................................................................................................. 8
Reheater ..................................................................................................................................8
Steam Flow ..............................................................................................................................8
Protection and Control ............................................................................................................ 9
OPERATION................................................................................................................................. 9
General ................................................................................................................................... 9
Reheater ............................................................................................................................... 10
4. REHEATER DESUPERHEATERS ....................................................................................... 11

DESCRIPTION............................................................................................................................ 11
CONTROL STATIONS................................................................................................................ 11
MAINTENANCE .......................................................................................................................... 11
BLOWOUT PROCEDURE FOR DESUPERHEATER SPRAY WATER LINES.......................... 12
5. WATER WALL SYSTEM......................................................................................................14

FURNACE WALL WATER CIRCUIT .....................................................................................14
ECONOMIZER SYSTEM......................................................................................................15
i
IV.2,3,4 Boiler operation description.doc
1. SUPERHEATER
DESCRIPTION
The flow path and arrangement of the superheat circuits is shown on P&ID drawings
T04019-PI-D0008, D0009, and D0010 and the Pressure Part Arrangement drawings
T04019-PA-A0100, A0101 and A0102.
Superheater
The superheater (SH) is composed of four basic stages or sections; namely the vertical
SH finishing section, the SH vertical platen section, the SH division panel section, and
the back pass wall and roof and extended back pass floor and wall sections.
The SH vertical finishing section (S-35) is located in the back pass extended side. It is
composed of 55 (42.2 mm O.D. tube) assemblies spaced on 336 mm centers across the
width of the furnace, with 336 mm end spaces.
The SH vertical platen section (S-29A) is located directly above the furnace in front of
the furnace arch. It is composed of 20 (50.8 mm O.D. tube) assemblies spaced on 896,
924mm centers across the width of the furnace, with 896 mm end spaces.
The SH division panel section (S-22) is located directly above the furnace between the
front wall and the SH vertical platen section. It consists of six front and six rear division
panel (44.5 mm O.D. tube) assemblies spaced on 2688, 2632 mm centers across the
furnace width, with 2716 mm end spaces.
The back pass wall and roof section forms the back pass roof tubes (S-3), back pass
rear wall tubes (S-4), back pass front wall screen tubes (S-12), back pass front wall
tubes (S-13), and back pass side wall tubes (S-10) of the vertical gas pass. The
extended back pass wall and floor area forms the floor (S-17) and side wall tubes (S-18)
of the extended back pass. The back pass at furnace front roof (S-3) and rear (S-4)
tubes form the roof above the furnace, arch, and extended back pass.
Steam Flow
The steam flow from the water separators to the superheater finishing outlet header can
be followed on the Process (Refer to the attached Superheater System Schematic
diagram). The elements which make up the flow path are essentially listed consecutively.
Where parallel paths exist, first one and then the other circuit is listed.
From the water separators (F-31), the main steam flow is through the back pass
connecting pipes (S-1) to the back pass at roof inlet header (S-2). From the back pass
roof inlet header, the steam flows through the back pass at furnace front roof tubes (S-3)
and back pass at furnace rear roof tubes (S-4) to the back pass at roof outlet header
(S-5).
Steam from the back pass at roof outlet header (S-5) takes two paths. One path flows
through the back pass roof tubes (S-6), down the back pass rear wall tubes (S-7), into
the back pass lower rear header (S-8), and into the rear of the two back pass lower side
headers (S-9). The other path from the back pass at roof outlet header (S-5) flows down
１
the back pass front wall screen tubes (S-12), through the back pass front wall tubes
(S-13), into the back pass lower front header (S-14), and into the front of the two back
pass lower side headers (S-9).
From the back pass lower side headers (S-9), steam flows upward through the back
pass side walls (S-10) and into the two back pass upper side headers (S-11).
Steam from the back pass lower front header (S-14) also flows through the back pass
lower extended side inlet pipe (S-15), to the back pass extended side inlet header (S-16),
through the back pass extended side floor tubes (S-17) and side wall tubes (S-18), and
into the two back pass upper side headers (S-11).
Steam from the two back pass upper side headers (S-11) continues to the two division
panel inlet headers (S-20) via four links (S-19).
The SH division inlet headers (S-20) supply steam through the SH division panels (S-22)
to the two SH division outlet headers (S-24). From the SH division outlet headers, the
steam is carried to the No. 1 SH desuperheaters (S-26) by the SH links to the No. 1 SH
desuperheaters (S-25). The SH links from the No. 1 SH desuperheaters (S-27) carry
steam from the No. 1 SH desuperheaters to the SH vertical platen inlet header (S-28).
This header supplies steam through the SH vertical platen assemblies (S-29) to the SH
vertical platen outlet header (S-30).
Steam continues from the SH vertical platen outlet header (S-30) through the two outlet
links (S-31) to the No. 2 SH desuperheaters (S-32). The SH links from the No. 2 SH
desuperheaters (S-33) cross and carry steam from the No. 2 SH desuperheaters to the
SH vertical finishing inlet header (S-34). This header supplies steam through the SH
vertical finishing assemblies (S-35) to the two SH vertical finishing outlet headers (S-36)
and the four SH outlet leads (S-37) to the main steam lines.
NOTE: Fluid (steam) cooled spacer supply tubes, originating at the SH

division inlet headers (S-20) and discharging into the SH vertical platen outlet
header (S-30), maintain the alignment of the division panels (S-22) and SH
vertical platen assemblies (S-29) and prevent them from swaying excessively.
NOTE: Additional fluid (steam) cooled spacer tubes, originating from the
extended side inlet header (S-16) and discharging into the SH vertical platen
outlet header (S-30), maintain alignment of the SH vertical platen assemblies
(S-29) and the reheater finishing assemblies (R-11).
Superheated steam from the SH finishing outlet headers goes to the high pressure
stages of the turbine via the main steam lines.
After passing through the high pressure stages of the turbine, steam is returned to the
reheater via the cold reheat lines.
Protection and Control

As long as there is a fire in the furnace, adequate protection must be provided for the
superheater elements. This is especially important during periods when there is no
demand for steam, such as when starting up or shutting down the unit. During these
periods of no steam flow through the turbine, adequate flow through the superheater is
assured by means of the HP by-pass drain system.
２
Superheater safety valves, spring loaded safety valves, are located on the separator
outlet connection pipes (S-1) and main steam pipes and power operated impulse safety
valves located on the main steam pipes. These safety valves serve to protect the
superheater from being over-pressurized by sudden interruption.
During all start-ups, care must be taken not to overheat the superheater elements. The
firing rate must be controlled to prevent the furnace exit gas temperature from exceeding
1000°F (538°C). The temperature probe located in the upper furnace side wall should be
used to measure the furnace exit gas temperatures (Refer to the General Arrangement
Drawings for temperature probe location).
NOTE: Gas temperature measurements will be accurate only if a shielded,

aspirated probe is used. If the probe consists of a simple bare thermocouple,
there will be an error due to radiation resulting in a low temperature indication.
At 1000°F (538°C) actual gas temperature, the thermocouple reading will be
approximately 50°F (28°C) low. Unless very careful traverses are made to
locate the point of maximum temperature, it is advisable to allow another 50°F
(28°C) tolerance, regardless of what type of thermocouple is used.
NOTE: The 1000°F (538°C) gas temperature limitation is based on normal

start-up conditions where steam is admitted to the turbine at the minimum
allowable pressure prescribed by the turbine manufacturer. Should turbine
rolling be delayed and the steam pressure be permitted to build up, the gas
temperature limitation should be reduced to 950°F (510°C) when the steam
pressure exceeds two-thirds of the design pressure before steam flow through
the turbine is established.
Thermocouples installed on various superheater terminal tubes above the furnace roof
serve to provide a continuous indication of element metal temperatures during start-up
and when the unit is carrying load. Refer to the Thermocouple Arrangement Drawings
for location. ( P&ID drawing, T04019-PI-D0009, D0010, D0011)
Steam temperature control is provided by means of windbox nozzle tilts and

desuperheaters. Refer to appropriate sections elsewhere in the manual for details.
OPERATION
Operation of the superheater is not independent of the rest of the steam generator.
Therefore, operating procedures for this component are discussed in detail under start-
up procedure for Sipat Project. However, the basic rules in the following paragraphs
must always be followed.
General
It is essential that suitable arrangements are made to assure cleanliness of the external
and internal surfaces of the superheater at all times. Fly ash and/or slag accumulations
result in unequal gas distribution, inefficient heat transfer, and possible localized
overheating. Suitably located soot blowers, operated in the proper cycle, normally
provide adequate means of keeping surfaces clean.
３
The external surfaces of the superheater should be inspected regularly for cleanliness.
Slagging must be kept to a minimum by proper use of soot blowers. Extreme buildups
must be removed immediately. Lancing with compressed air is often effective in slag
removal. Local slagging may become a cause of overheating of element tubes, possibly
resulting in tube failures. Furthermore, it may restrict the gas flow causing uneven heat
transfer and creating further operating difficulties.
Proper feedwater treatment, and control of steam quality and carry-over are essential to
assure cleanliness of interior surfaces of superheaters. Overloads, fluctuating load, high
water level, foaming, high concentrations, etc., all contribute to deposits on interior
surfaces. Accumulation of these deposits inside the tubes will lead to unit failure. Care
must be taken to assure that condensate quality spray water is used for the
desuperheaters to avoid carry-over of solids into the superheater and the turbine blades.
Periodic checks of steam pressure drops across the superheater under identical load
conditions usually indicate whether or not solid deposits are present within the elements.
In the event of failure of one or more superheater elements, check carefully to determine
the cause. Doosan Heavy Industries & Construction Co., LTD. may be consulted for
repair procedures and proper means to prevent recurrence.
Superheater
Make sure the superheater back pass walls and main steam lines are completely
drained (especially after a hydrostatic test) by opening the inlet and outlet header drains
before lighting off. Close the back pass header drains immediately after rolling the
turbine.
The main steam line vents and drains, which serve as starting vents, are kept open until
the turbine is under light load. The drain valves near the turbine should be operated in
conjunction with the start-up vents to provide additional steam flow and to drain and
warm the main steam line prior to turbine rolling.
４
2. SUPERHEATER DESUPERHEATERS
DESCRIPTION
Two spray-type superheater (SH) desuperheaters (No. 1) are installed in the connecting
links between the superheater division panel outlet headers and the SH vertical platen
inlet header, and two additional spray-type superheater (SH) desuperheaters (No. 2) are
installed in the connecting links between the SH vertical platen outlet header and the SH
finishing inlet header to permit reduction of steam temperature, when necessary, and to
maintain the temperatures at design values, within the limits of the nozzle capacity.
Temperature reduction is accomplished by spraying water into the path of the steam
through a nozzle at the inlet end of the desuperheater. It is essential that the spray water
be chemically pure and free of suspended and dissolved solids, containing only
approved volatile organic treatment material, in order to prevent chemical deposition in
the superheater and carry-over of solids to the turbine.
CAUTION: During start-up of the unit, if desuperheating is used to match

the outlet steam temperature to the turbine metal temperatures, care must
be exercised so as not to spray down below a minimum of 20°F (11°C)
above the saturation temperature at the existing operating pressure.
Desuperheating spray is not particularly effective at the low steam flows of
start-up. Spray water may not be completely evaporated but be carried
through the heat absorbing sections to the turbine where it can be the
source of considerable damage. During start-up, alternate methods of
steam temperature control should be considered.
The locations of the desuperheaters, between the SH division panel section and the SH
vertical platen section and between the SH vertical platen section and the SH finishing
section, help to ensure that water carry-over to the turbine does not occur. It also
eliminates the necessity for high temperature resisting materials in the desuperheater
construction.
CONTROL STATIONS
NOTE: For desuperheater piping and valves, refer to the Process and
Instrumentation Diagrams T04019-PI-D0009 and D0010.
One pneumatically operated control valves linked to an automatic control drive regulates
the flow of spray water on the main line supplied to each desuperheater. A manually
operated isolation valve is located downstream of each control valve and pneumatic
diaphragm type isolation valve is upstream of each control valve to permit isolation when
required. There is spray water bypass line which is consisting of the same system as in
the main line. These one manual and one pneumatic isolating valves around the
automatic control valve should be used only in an emergency, or when the automatic
control valve may require maintenance.
A motor operated block valve is installed in the main supply line to the superheater
desuperheater control stations as an additional shutoff valve. These block valves must
be interlocked to close when the superheater desuperheater control valves are closed.
５
The spray water control valves must be interlocked to close upon a turbine trip. Closing
the block valve will prevent water from entering the superheater elements if a
superheater spray water control valve should leak.
Spray water for the superheater desuperheaters is normally taken from the boiler feed
pump discharge line.
BLOWOUT PROCEDURE FOR DESUPERHEATER SPRAY WATER LINES
Each desuperheater is fitted with a renewable liner to take the wear of erosion from the
spray water stream, thus protecting the main desuperheater shell. Excessive noise from
within a desuperheater usually indicates a worn liner and the Service Department of this
Company should be contacted when this or any such abnormal conditions may arise.
Sufficient clearances should be provided around the desuperheaters for replacing liners.
MAINTENANCE
The spray water lines should be blown out before using the desuperheaters on a new
unit and after repairs on the spray water lines have been made. They may also be blown
when there appears to be any indication of plugging. Always have full pressure on the
boiler when blowing out the desuperheaters.
Each desuperheater should be blown out in the following sequence:
1. With the isolating valves closed, open the valves in the blowoff connection and then
open the bypass valve for 1 minute.
2. With the bypass valve closed and the blowoff valves open, open the isolating valves
and then open the control valve for 1 minute (from the control station). Close the
isolating valves and the control valve but leave the blowoff valves open for another
minute to clear the waste line before restoring the system to its operating status.
NOTE: The blowoff valves should be installed close to the spray water piping
and with no bends intervening, if possible.
６
SUPERHEATER SYSTEM SCHEMATIC DIAGRAM
S-19
S-27 S-37
S-25 S-26
S-31
S-1 S-32
S-28 S-30 S-33
S-24
S-11
S-36 S-34
S-29A S-29B
S-35B S-35A
S-20
S-21 S-6
S-23
S-2 S-3 S-4
S-18 S-5
S-22 S-29
S-35
S-12
S-17
S-22A
S-17A
S-7
S-16
S-13
S-10A
S-15
S-10
S-14 S-9 S-8
S-17,18
S-2 S-5 S-9 S-11 S-20 S-24 S-28 S-30 S-31 S-34 S-36
S-8
S-1 S-6,7 S-25
S-32
S-3,4 S-10
S-14 S-26
S-15
S-12,13 S-16 S-19 S-27 S-33 S-37

S-9 S-21,22,23 S-29,29A,29B S-35,35A,35B
７
3. REHEATER
DESCRIPTION
The flow path and arrangement of the reheat circuits is shown on the P&ID drawing
T04019-PI-D0011 and on the Pressure Parts Arrangement Drawings T04019-PA-A0100,
A0101 and A0102.
Reheater
The reheater (RH) is composed of two stages, or sections; namely, the reheater low
temperature (RHLT) section, and the RH finishing section.
The vertical RH (finishing) assemblies (R-11) are located above the furnace arch
between the furnace rear hanger tubes and the SH vertical platen section. This portion
of the RH consists of 41 (50.8, 57.0, 63.5, 70.0 and 76.2 mm O.D. tube) assemblies on
448 mm centers across the furnace width, with 448 mm end spaces.
The RHLT horizontal rear assemblies (R-4) (R-5) (R-6) and RHLT vertical rear pendant
assemblies (R-7) are located in the upper back pass above the economizer. There are
111 (63.5 mm O.D. tube) RHLT horizontal rear assemblies on 168 mm centers across
the furnace width, with 168 mm end spaces. There are 56/55 (63.5 mm O.D. tube) RHLT
vertical rear pendant (front) assemblies on 336 mm centers across the furnace width,
with 168/336 mm end spaces.
Steam Flow
The steam flow course from the cold RH inlet to the hot RH outlet leads can be followed
on the Process which is attached diagram as a Reheater System Schematic diagram.
Section 8. The elements which make up the flow path are essentially listed consecutively.
Where parallel paths exist, first one, and then the other circuit is listed. The reheat
steam flow is as follows:
After passing through the high pressure stages of the turbine, steam is returned to the
reheater via the two cold reheat steam lines (R-1A). From the cold reheat steam lines,
the steam is carried to the RH desuperheaters (R-1).
Steam from the cold reheat steam lines (R-2) enters the reheater through the RHLT rear
horizontal inlet header (R-3), located in the back pass. From the RH inlet header, the
steam flows upward through the back pass RHLT rear horizontal lower (R-4),
intermediate (R-5), and upper (R-6) tube assemblies to the rear RHLT pendant
assemblies (R-7) before discharging into the RHLT outlet header (R-8).
Reheat steam continues from the RHLT outlet header (R-8) through the two outlet links
(R-9) that cross and carry reheat steam to the RH finishing assemblies inlet header
(R-10). This header supplies reheat steam through the vertical RH finishing assemblies
(R-11, 11A and 11B) to the two RH finishing outlet headers (R-12) and the two RH outlet
leads (R-13) to the hot reheat steam lines.
The reheated steam from the reheat finishing section, now at design temperature, is
returned to the intermediate pressure section of the turbine via the two hot reheat steam
lines.
８
Protection and Control

As long as there is a fire in the furnace, adequate protection must be provided for the
reheater elements. This is especially important during periods when there is no demand
for steam, such as when starting up or shutting down the unit. Reheater drains and vents
provide the means to boil off residual water in the reheater elements during initial firing
of the boiler.
Reheater safety valves, located on the cold and hot reheat piping, serve to protect the
reheater should steam flow through the reheater be suddenly interrupted.
During all start-ups, care must be taken not to overheat the reheater elements. The firing
rate must be controlled to keep the furnace exit gas temperature from exceeding 1000°F
(538°C). The temperature probe, located in the upper furnace side wall, should be used
to measure the furnace exit gas temperatures (Refer to the General Arrangement
Drawings for the temperature probe location).
NOTE: Gas temperature measurements will be accurate only if a shielded,

aspirated probe is used. If the probe consists of a simple bare thermocouple,
there will be an error due to radiation resulting in a low temperature indication.
At 1000°F (538°C) actual gas temperature, the thermocouple reading will be
approximately 50°F (28°C) low. Unless very careful traverses are made to
locate the point of maximum temperature, it is advisable to allow another 50°F
(28°C) tolerance, regardless what type of thermocouple is used.
NOTE: The 1000°F (538°C) gas temperature limitation is based on normal

start-up conditions, where steam is admitted to the turbine at the minimum
allowable pressure prescribed by the turbine manufacturer. Should turbine
rolling be delayed and the steam pressure be permitted to build up, the gas
temperature limitation should be reduced to 950°F (510°C) when the steam
pressure exceeds two-thirds of the design pressure before steam flow through
the turbine is established.
Thermocouples installed on various reheater terminal tubes above the furnace roof
serve to provide a continuous indication of element metal temperatures during start-up,
and when the unit is carrying load. Refer to the Thermocouple Arrangement Drawings
for location of permanent thermocouples.
Steam temperature control is provided by means of windbox nozzle tilts and

desuperheaters. Refer to appropriate sections elsewhere in the manual for details.
OPERATION
General
Operation of the reheater is not independent of the rest of the boiler. Therefore, for detail
ed operating procedures for this component, see Start-up procedure for Sipat project.
However, the basic rules in the following paragraphs must always be followed.
９
Reheater
It is essential that suitable arrangements are made to assure cleanliness of the external
and internal surfaces of the reheater at all times. Fly ash and/or slag accumulations
result in unequal gas distribution, inefficient heat transfer, and possible localized
overheating. Suitably located soot blowers, operated in the proper cycle, normally
provide adequate means of keeping surfaces clean.
The external surfaces of the reheater should be inspected regularly for cleanliness.
Slagging must be kept to a minimum by proper use of soot blowers. Extreme buildups
must be removed immediately. Lancing with compressed air is often effective in slag
removal. Local slagging may become a cause of overheating of element tubes possibly
resulting in tube failures. Furthermore, it may restrict the gas flow causing uneven heat
transfer and creating further operating difficulties.
Proper feedwater treatment, and control of steam quality and carry-over are essential to
assure cleanliness of interior surfaces of reheaters. Overloads, fluctuating load, high
water level, foaming, high concentrations, etc., all contribute to deposits on interior
surfaces. Accumulation of these deposits inside the tubes will lead to unit failure. Care
must be taken to assure that condensate quality spray water is used for the
desuperheaters to avoid carry-over of solids into the reheater and the turbine blades.
Periodic checks of steam pressure drops across the reheater under identical load
conditions usually indicate whether or not solid deposits are present within the elements.
In the event of failure of one or more reheater elements, check carefully to determine the
cause. Doosan Heavy Industries & Construction Co., LTD. may be consulted for repair
procedures and proper means to prevent recurrence.
All reheater drains and vents should be opened before lighting off. The vents and drains
to the atmosphere must be closed prior to raising a vacuum in the condenser. Drains
connecting with the condenser may be left open until the turbine is under light load.
１０
4. REHEATER DESUPERHEATERS
DESCRIPTION
Two spray-type reheater (RH) desuperheaters are installed in the connecting links
R1 & R2 to permit reduction of steam temperature, when necessary, and to maintain the
temperatures at design values, within the limits of the nozzle capacity.
Temperature reduction is accomplished by spraying water into the path of the steam
through a nozzle at the inlet end of the desuperheater. It is essential that the spray water
be chemically pure and free of suspended and dissolved solids, containing only
approved volatile organic treatment material, in order to prevent chemical deposition in
the reheater and carry-over of solids to the turbine.
CAUTION: During start-up of the unit, if desuperheating is used to match the

outlet steam temperature to the turbine metal temperatures, care must be
exercised so as not to spray down below a minimum of 20°F (11 °C) above the
saturation temperature at the existing operating pressure. Desuperheating spray
is not particularly effective at the low steam flows of start-up. Spray water may
not be completely evaporated but be carried through the heat absorbing sections to
the turbine where it can be the source of considerable damage. During start-up,
alternate methods of steam temperature control should be considered.
The location of the desuperheaters, at inlet of RH low temperature inlet header, help to ensure that
water carry-over to the turbine does not occur. It also eliminates the necessity for high
temperature resisting materials in the desuperheater construction.
CONTROL STATIONS
NOTE: For desuperheater piping and valves, refer to the Process and Instrumentat
ion Diagram T04019-PI-D0011.
A pneumatically operated control valve linked to an automatic control drive regulates the
flow of spray water on the main line supplied to each desuperheater. A manually
operated isolation valve is located downstream of each control valve and pneumatic
diaphragm type isolation valve is upstream of each control valve to permit isolation when
required. There is spray water bypass line which is consisting of the same system as in
the main line. These one manual and one pneumatic isolating valves around the
automatic control valve should be used only in an emergency, or when the automatic
control valve may require maintenance.
A motor operated block valve is installed in the main supply line to the reheater
desuperheater control stations as an additional shutoff valve. These block valves must
be interlocked to close when the reheater desuperheater control valves are closed. The
spray water control valves must be interlocked to close upon a turbine trip. Closing the
block valve will prevent water from entering the reheater elements if a reheater spray
water control valve should leak.
Spray water for the reheater desuperheaters is normally taken from the boiler feed pump
interstage manifold.
１１
MAINTENANCE
Each desuperheater is fitted with a renewable liner to take the wear of erosion from the
spray water stream, thus protecting the main desuperheater shell. Excessive noise from
within a desuperheater usually indicates a worn liner and the Service Department of this
Company should be contacted when this or any such abnormal conditions may arise.
Sufficient clearances should be provided around the desuperheaters for replacing liners.
BLOWOUT PROCEDURE FOR DESUPERHEATER SPRAY WATER LINES
The spray water lines should be blown out before using the desuperheaters on a new
unit and after repairs on the spray water lines have been made. They may also be
blown when there appears to be any indication of plugging. Always have full pressure
on the boiler when blowing out the desuperheaters.
Each desuperheater should be blown out in the following sequence:
1. With the isolating valves closed, open the valves in the blowoff connection and then
open the bypass valve for 1 minute.
2. With the bypass valve closed and the blowoff valves open, open the isolating valves and
then open the control valve for 1 minute (from the control station). Close the isolating valves a
nd the control valve but leave the blowoff valves open for another minute to clear the waste line
before restoring the system to its operating status.
NOTE: The blowoff valves should be installed close to the spray water piping and
with no bends intervening, if possible.
１２
REHEATER SCHEMATIC DIAGRAM
R-13
R-9
R-10 R-12
R-8
R-11A R-11B R-7A
R-7
R-11 R-4,5,6
R-3
R-1
R-1A R-2
R-1A
R-1
R-10
R-13
R-2
R-4, 5, R-11,11A,
6, 7, 7A 11B
R-9 R-12
R-3
R-8
１３
5. WATER WALL SYSTEM
FURNACE WALL WATER CIRCUIT
In Once Through Supercritical Units, the boiler feed pumps ensure proper circulation of
supercritical fluid through the furnace wall system.
The flow path can be followed on P&ID Drawings T04019-PI-D0005, D0006 and D0007 for the
economizer, evaporator, and water separator systems. The elements which make up the flow
path are essentially numbered consecutively. Where parallel flow paths exist, first one and then
the other circuits are numbered.
Per Drawing T04019-PI-D0005, the supercritical fluid from the boiler feed water line (E-1) and inlet
links (E-2) enters the unit through the economizer inlet header (E-3), flows through the
economizer elements (E-4), to the four economizer junction headers (E-5) that are connected
with the economizer outlet header (E-7) by four rows of 56 economizer hanger tubes (E-6). Two
economizer outlet links (E-8) feed the economizer mixing link (E-9) and two economizer
waterwall inlet links (E-10) to the furnace lower side wall headers (F-21).
The furnace lower side wall headers (F-21) feed the furnace lower front wall (F-1) and rear wall
(F-10) headers. From the furnace lower front, rear and side wall headers, the fluid rises through
furnace spiral waterwall tubes where it absorbs heat and exits into the front, rear, and side wall
intermediate headers (F-5, F-14, F-25). From the intermediate wall headers, the fluid
enters the vertical wall circuitry where additional heat is absorbed.
The front wall spiral tubes (F-3), rear wall spiral tubes (F-12), and side wall spiral tubes
(F-23) form parallel flow paths between the furnace lower wall headers (F-1, F-10, F-21) and the
furnace intermediate front, rear, and side headers (F-5, F-14, F-25) as does the front vertical wall
tubes (F-7), rear wall vertical tubes (F-16) and side wall vertical tubes (F-27) between the
intermediate wall headers and the upper outlet headers (F-8, F-19, F-28).
The fluid collects in the upper outlet headers and is discharged through the front, rear, and side wall
riser pipes (F-9, F-20, F-29) to the water separators (F-31). At loads above minimum once through
load, the fluid then goes to the superheater system.
１４
ECONOMIZER SYSTEM
The function of the economizer is to preheat the boiler feedwater before it is introduced into the
furnace waterwalls by recovering some of the heat of the flue gases leaving the boiler. The
economizer is comprised of one section. The flow path and arrangement of the economizer
circuits is shown on P&ID drawing T0419-PI-D0005 and the Pressure Part Arrangement drawings
T04019-PA-A0100, A0101 and A0102.
The economizer is located below the rear horizontal reheater assemblies in the lower section of
the boiler back pass. It is composed of three banks of 163 parallel bare tube (50.8 mm O.D.)
elements on 114.3 mm centers, arranged in horizontal rows in such a manner that each row is
in line in relation to the row above and below. All tube circuits originate from the
economizer inlet header, and discharge into four economizer junction headers that are
connected with the economizer outlet header by economizer hanger tubes(70.0 mm O.D.).
Per Drawing T04019-PI-D0005, the supercritical fluid from the boiler feed water line (E-1) and inlet
links (E-2) enters the unit through the economizer inlet headers (E-3), flows through the
economizer elements (E-4), to the four economizer junction headers (E-5) that are connected
with the economizer outlet header (E-7) by four rows of 56 economizer hanger tubes (E-6). Two
economizer outlet links (E-8) feed the economizer mixing link (E-9) and two economizer
waterwall inlet links (E-10) to the furnace lower side wall headers (F-21).
Feedwater is supplied to the economizer system via feed stop and check valves. The
feedwater flow is upward through the economizer sections, that is, in counterflow to the
hot flue gases. Most efficient heat transfer is thereby accomplished, while the possibility of
steam generation within the economizer is minimized by the upward water flow.
OPERATION
Operation of the economizer is not independent of the rest of the boiler.

Therefore, operating procedures for the economizer are discussed in general under the
Start-up procedure for Sipat project.
The frequency with which soot blowers are used depends entirely on local conditions.
When the economizer is first placed in operation, the economizer soot blowers should be
blown about once every shift. Observation of the increase in draft loss between blowings
will determine how long an interval may be set as a standard. In many cases, it has been
found that blowing the economizer soot blowers once a day or less is sufficient. For further
details, refer to the Soot Blowing Philosophy section located in the Steam and water flow
system.
１５
IV. 3. AIR AND FLUE GAS FLOW SYSTEMS
TABLE OF CONTENTS
TITLE SECTION
1. AIR AND FLUE GAS SYSTEMS ......................................................................................................................1
AIR/GAS FLOW............................................................................................................................. 1
Secondary Air and Overfire Air - Combustion .......................................................................... 1
Flame Scanner Cooling Air ...................................................................................................... 1
Primary Air - Conveying and Drying of Pulverized Coal ......................................................... 2
Seal Air - Pulverizers and Coal Pipes...................................................................................... 2
Seal Air - Feeders..................................................................................................................... 2
FLUE GAS FLOW.......................................................................................................................... 3
OPERATIONAL PROCEDURES................................................................................................... 3
2. SCANNER AIR SYSTEM ...................................................................................................................................3
DESCRIPTION .............................................................................................................................. 3
SCANNER AIR .............................................................................................................................. 3
3. PULVERIZER SEAL AIR SYSTEM ..................................................................................................................4
INTRODUCTION ........................................................................................................................... 4
SEAL AIR TO PULVERIZERS....................................................................................................... 5
SEAL AIR FOR FEEDERS ............................................................................................................ 6
4. SOOT BLOWING PHILOSOPHY ....................................................................................................................7
INTRODUCTION ........................................................................................................................... 7
OPERATIONS ............................................................................................................................... 7
TYPES OF ASH DEPOSITS ......................................................................................................... 7
BLOWER LOCATIONS ................................................................................................................. 8
Furnace Walls .......................................................................................................................... 8
Superheater and Reheater Areas ............................................................................................ 8
Economizer and Air Preheaters ............................................................................................... 8
i
5. LIST OF REFERENCE ENGINEERING DRAWINGS
P&ID Diagram - Windbox & Burner Unit .............................................................................. T04019-PI-D0019

P&ID Diagram - Windbox Detail............................................................................................ T04019-PI-D0020
P&ID Diagram – Primary Air, Sealing & Cooling Air System ............................................... T04019-PI-D0021
Scanner Air System Piping Arrangement....................................................................T04019-SP-A001, A002
Suggested Pipe Supports .......................................................................................................T04019-SP-A003
ii
1. AIR AND FLUE GAS SYSTEMS
AIR/GAS FLOW
Air and gas flow through the unit is handled by the two forced draft (FD) fans, two induced
draft (ID) fans, and two primary air (PA) fans. Two scanner cooling air booster fans and two
pulverizer seal air booster fans assure that air pressures are adequate to overcome
resistance in their respective systems. The air is utilized for:
1. Combustion - Secondary Air and Overfire Air.
2. Cooling - Flame Scanners (Two Fans).
3. Conveying and Drying of Pulverized Coal - Primary Air.
4. Sealing - Pulverizers and Coal Pipes (Two Booster Fans).
5. Sealing - Feeders.
Secondary Air and Overfire Air - Combustion

The secondary air for combustion is preheated by means of two Ljungstrom bi-sector gas air
preheaters, one for each set of FD and ID fans. The gas air preheater air inlet and outlet
ducts are interconnected to provide an airflow to the furnace and to make it possible to
operate the unit at reduced rating with only one set of fans and one gas air preheater in
service.
To assist in reducing the amount of NOx formed in the furnace, overfire air can be admitted
to the furnace through the two upper levels of furnace main windbox Close Coupled Overfire
Air (CCOFA) nozzles.
Control of unit air flow is obtained by positioning the FD fan blade pitch and the ID fan blade
pitch, while the distribution of secondary air to the windbox compartments is controlled by
secondary air dampers. These are positioned by a sub-loop control system associated with
the burner management system. Refer to the BMS supplier's instructions for details.
The steam coil air heaters at the gas air preheater air inlets are used to control the gas air
heater cold end temperature for corrosion control. Refer to the manufacturer's instructions.
Flame Scanner Cooling Air

Flame scanner cooling air is supplied from atmosphere. Two numbers of scanner
cooling air fan are supplied, one with AC motor and the other with DC motor. Either of
two 100% fans serving the flame scanner air manifold can be used to supply the
cooling air pressure required. A filter upstream of each of the fans helps to assure
clean air for cooling. An alarm system should indicate when a filter requires service.
Refer to Scanner Air System, at Air and Flue Gas System for details.
A scanner fan should be in service whenever a fire is in the furnace and should be kept in
service until the unit is shut down and the flame scanners are cooled to their acceptable
high temperature limit.
1
Primary Air - Conveying and Drying of Pulverized Coal

The air used to convey and dry the pulverized coal is referred to as primary air. Two
primary air (PA) fans supply the air to the pulverizer primary air system. To assure
proper drying in the pulverizers, both hot and cold air must be available; therefore, a
portion of the air from the primary air fans passes through the bi-sector gas air heaters.
Control of unit air flow is obtained by positioning the PA fan blade pitch, which is controlled to
maintain a predetermined pressure in the pulverizer primary air ducts.
The flow of air from the hot and cold air ducts is controlled by the hot and cold air
control dampers at each pulverizer to deliver the necessary total primary air flow
requirement for the pulverizer and also to maintain a predetermined outlet temperature.
Refer to Pulverized Coal System, at Tilting Tangential Firing System and the BMS
supplier's instructions for additional details.
If a PA fan is not available for service and the other fan is operating, it must be isolated
from the system by closing its outlet shutoff dampers. The number of pulverizers in
service is then limited. Refer to Operating Procedures, Start-up procedure, and the BMS
supplier's instructions.
Seal Air - Pulverizers and Coal Pipes

Seal air for the pulverizer bowl hub, journal assemblies, journal springs, and pulverizer
discharge dampers is taken from the cold primary air duct to the pulverizers.
Either of two 100% booster fans in the supply duct can be used to ensure a flow of air
into the pulverizer openings under all normal operating conditions. A shutoff valve in the
seal air duct at each pulverizer inlet can be closed when the pulverizer is out of service for
maintenance.
A mechanical filter upstream of the booster fans is used to remove dust, etc. from the air supply,
thus assuring a clean air supply for the pulverizer bowl hub and journals. Refer to
Pulverizer Seal Air System, Air and Flue Gas System for details.
A power operated valve in each purge air duct to the coal pipes operates in conjunction
with the pulverizer discharge valves to provide a positive seal air pressure in the coal pipes
when the discharge valves are closed.
Seal Air - Feeders

Seal air for the feeders is taken direct from the cold air duct to the pulverizers. Feeder seal
air prevents hot gases from the pulverizer from entering the feeder. A pneumatic operation
shutoff valve in each feeder seal air duct makes it possible to isolate the feeders for maintenance.
2
FLUE GAS FLOW
Flue gases travel upward in the furnace and downward through the rear gas pass and
separated with four gas ducts, two gas ducts lead to bi-sector primary gas air preheaters and
the other two gas ducts lead to bi-sector secondary gas air preheaters. In the gas air
preheaters, the residual heat of the flue gases is utilized to preheat the combustion and
pulverizer primary air. From the bi-sector gas air preheaters, the gases pass through the
precipitators, the ID fans, and to the stack.(Reference P&ID drawings : T-04019-PI-D0015,
D0016)
OPERATIONAL PROCEDURES
Shutoff dampers at each FD, PA fan outlet and ID fan inlet and outlet may be used to isolate
the fans for maintenance. An gas air preheater may be isolated by closing the associated duct
dampers.
For operational procedures refer to Start-up procedure of this manual.
2. SCANNER AIR SYSTEM
DESCRIPTION
The scanner air system is designed to provide adequate cooling air to the flame scanners
under all normal operating conditions and to initiate corrective action or alarms under adverse
operating conditions.
The scanner air system consists of a series of ducts which supply air taken from cold
secondary air crossover duct, boosted to the required pressure by either of two 100% scanner
air fans, to the scanner cooling air manifolds at the tangential windboxes.
SCANNER AIR
Either of the two 100% booster fans in the scanner cooling air system ensures an adequate
supply of cooling air to the scanners during normal unit operating conditions. Two kinds of
scanner air fan drives are installed, one is AC motor type and the other DC motor type.
A supply of clean, cool air must be available to the flame scanners whenever the furnace
temperature is above 140°F (60°C).
CAUTION: With the furnace hot, all flame scanners must be removed from the
furnace with loss of the scanner cooling air fans. An example could be a plant
electrical power failure, with the boiler on line.
A filter located upstream common duct for the scanner booster fans removes dust and dirt
which may be introduced into the system from cold secondary air cross over duct. Differential
pressure switches across the filters may be used to initiate "plugged" or "no filter" alarms. A
differential pressure gauge may provide the operator with a local indication of the filter
condition. It is recommended that pressure readings be taken and recorded immediately after
a new filter is installed, and that periodic readings (at least once per shift) be taken
3
thereafter to assist in establishing a filter cleaning schedule.

The scanner fans must be powered from a reliable power source. As soon as the BMS is
engaged, an alarm will appear and the primary scanner air fan will automatically receive a start
command. This start command is initiated whenever the scanner air duct-to-furnace differential
pressure is below the setting of the scanner fan control pressure switch [approximately 6 in.
w.g. (152 mm H2O) pressure drop across the most remote scanners]. Once the minimum
pressure is satisfied, the alarm will automatically reset and not activate unless the differential
pressure drops below the set point.
The initial low differential pressure will activate an additional alarm after a time delay of
approximately 10 seconds, if the minimum differential pressure is not reached. After a
start command, the primary fan must satisfy the minimum differential pressure within
five seconds or the secondary fan is given a start command. If the secondary scanner
fan satisfies the pressure requirement before the 10 seconds expires, the delayed
alarm will not be activated.
CAUTION: Scanner cooling air is very important. Should the secondary

scanner air fan automatically start, it is important to quickly find the reason
and resolve the problem.
Either scanner fan can be started manually at the operator's discretion. The operator
can also change which fan is the primary and which is secondary. The shutoff valve at
each scanner fan inlet in conjunction with the closed flapper transfer damper isolates an idle
fan.
Scanner fan interlocks are described in the BMS instructions. Control panel indicators
should provide scanner fan status.
3. PULVERIZER SEAL AIR SYSTEM
INTRODUCTION
Seal air for the pulverizer bowl hub, journal assemblies, journal springs and pulverizer discharge
dampers is taken from the cold primary air duct to the pulverizers. Either of two booster fans in
the supply duct can ensure a flow of air into the pulverizer openings under all normal
operating conditions. A power operated shutoff valve in the seal air duct at each pulverizer
can be closed when the pulverizer is out of service for maintenance.
A power operated shutoff damper in the seal air line to the coal pipes is utilized to admit seal air to the
coal pipes for cooling when the pulverizer is isolated. The seal air damper is open whenever the
pulverizer discharge valves are closed and is closed whenever the pulverizer discharge valves
are open.
A mechanical filter upstream of the booster fans removes dirt and dust from the air, ensuring a clean
air supply for the pulverizer.
The pulverizer seal air shutoff valves are always kept wide open. They are closed only when a
pulverizer is isolated for maintenance.
4
SEAL AIR TO PULVERIZERS
An adequate supply of clean seal air for the pulverizer is provided by the two booster fans and
the filter in the seal air system. One fan normally runs continuously, with the self-positioning,
transfer damper directing flow from the operating fan. The non-operating fan may be
isolated for maintenance by closing the associated manual inlet shutoff damper.
The filter in this system is an inertial, separator-type which discharges approximately 90%
of its input as clean air. A bleed-off system, with a control damper, returns the accumulated
dirt and dust to the windbox hot secondary air connecting duct. The control damper regulates
the amount of air being bled from the filter, so that the differential pressure between the filter
air outlet and the filter bleed outlet is zero. Refer to Figure 1.
The control damper should be installed so that the damper fails open with a loss of instrument air.
Figure 1: Suggested Hook Up for Bleed Off Control Valve for Mechanical Filter
5
SEAL AIR FOR FEEDERS
Seal air for the feeders is also taken from the cold primary air duct to the pulverizers.
A manually operated shutoff damper in each feeder purge air duct makes it possible to
isolate a feeder for maintenance.
6
4. SOOT BLOWING PHILOSOPHY
INTRODUCTION
The soot blowing system for this unit has been designed on the basis of specific parameters.
That is, in determining the number and type of blowers, blower location and operating
sequences, the characteristics of the coal to be burned, the configuration of the heat-absorbing
surfaces of the boiler and past experience with slagging tendencies in this type of unit, were
taken into account.
However, it is impossible to predict the performance of the soot blowing equipment for all
operating conditions and for each individual unit. Factors such as variation in coal
characteristics, load changes, fluctuations in furnace temperatures and air flow conditions can
greatly affect the soot blowing requirements. Therefore, operation of the soot blowers must
be continuously evaluated and reviewed on the basis of changing operating conditions.
OPERATIONS
Soot blowers are provided to fulfill a need. Operating practices should be modified as the needs
change. For this reason, ample flexibility is provided in the system to enable manual selective
operation in addition to fully automatic control.
Intelligent use of the soot blower system offers the following advantages:
1. It can prevent troublesome accumulations of slag and ash deposits that, in turn, may cause
additional unit operating problems.
2. It provides for maximum cleaning of the heat absorbing surfaces.
In addition, minimizing the number of blowing cycles will save valuable blowing medium. More
efficient, selective use of the equipment will result in reduced maintenance.
There are several indicators of ineffective use of the soot blowing equipment, such as response
of steam temperature control, changes in draft loss, etc. The best way to monitor the
effectiveness of soot blowing is by frequent furnace observation. If operation of a blower or a
series of blowers does not produce the expected results, the furnace area involved should be
observed and the blower(s) in question checked.
Blowing pressures should be checked periodically (approximately every six months) to

determine whether they have changed from their initial effective settings.
TYPES OF ASH DEPOSITS
To determine if proper cleaning is taking place, the operator should have a basic
knowledge of the types of ash deposits that can build up in the various parts of the unit.
Sintered or dust-like ash deposits or buildups are prevalent on convection surfaces,

such as superheater and reheater elements, and in the back pass. Ash deposits can
also form on the furnace walls if the furnace temperature is low, such as during low
load operation. When an ash deposit fuses it is called "slag". Slag deposits usually
7 IV.2,3,4 Boiler operation description.doc

occur on the furnace walls and other surfaces exposed predominantly to radiant heat and
high furnace gas temperatures.
Slag can appear in a variety of formations, depending on the composition of the ash and
the temperature in the furnace. A change in the type of slag is usually an indication that
either the coal has changed or that furnace conditions have changed. A reduction in
excess air, for instance, or increased unit loads, will result in higher furnace
temperatures; this will produce a more troublesome wet slag, or slag more difficult to
control.
Usually, dry slag can easily be removed by soot blowing. Molten slag is much more
difficult to remove. Thin layers of molten slag are the most difficult to remove and often
cannot be removed by conventional soot blowing. In order to remove thin layers of
molten slag, it may be necessary to increase the excess air or lower the unit load in
order to make the soot blowers effective. "Wet" or molten slag can be dangerous; it will drip
down to the furnace bottom and accumulate. The accumulations can bridge and plug
the furnace bottom.
BLOWER LOCATIONS
Furnace Walls
Blowing wall blowers in the furnace should remove accumulated slag from the walls.
This will improve the furnace heat absorption and lower the gas temperature to the
superheater and reheater. If the steam temperature controls are on automatic, the
cleaning of the walls should cause the tilts to rise and/or spray water flow to
decrease. Consequently, if blowing wall blowers has no effect, either the furnace is
already clean or the soot blowers are only keeping pace with the slag formation.
Superheater and Reheater Areas

Using the long retractable blowers in the convection superheater and reheater areas
should remove accumulated surface deposits. This will improve heat absorption in these
sections. If the steam temperature controls are on automatic, this should cause the tilts to
lower and/or spray water flow to increase. Selective blowing of long, retractable
blowers in the superheater and reheater zones can also be utilized to balance superheater
and reheater outlet temperatures. In any case, draft loss across convection surfaces should
be closely observed. Increased draft loss indicates an advanced plugging condition. If a
plugging condition is allowed to progress too far, it may be impossible to clean the convection
surfaces except by removing the unit from service for water washing.
Economizer and Gas Air Preheaters

The economizer blowers and gas air preheater soot blowers should be blown to provide
maximum unit efficiency consistent with reasonable blowing medium consumption. Constant
blowing of the economizer and the gas air preheaters would assure that these surfaces stay
clean, but the economics of blowing medium consumption, maintenance of equipment, and
metal erosion rates must be considered. An "optimum medium" should be
determined by observing the fouling rate, cost of blowing medium, and blowing effectiveness.
Efficient use of soot blowers can help counter other operational problems with the unit. For
instance, to increase the primary air temperature leaving the bi-sector primary air preheater (to
improve drying of wet coal), it may be desirable to reduce soot blowing of the economizer in
order to cause an increase of the flue gas temperature to the primary air preheater.

Doosan Heavy Industries & Construction Co., LTD. Service Engineers may be consulted in
determining which blowers should be blown, how often, and why. Generally, the best soot
blowing policy is to determine the minimum amount of soot blowing required to keep the unit
clean enough to avoid operational problems.
5. LIST OF REFERENCE ENGINEERING DRAWINGS
Reference Drawing: P&ID Diagram - Windbox & Burner Unit ............................................... T04019-PI-D0019
Reference Drawing: P&ID Diagram - Windbox Detail............................................................. T04019-PI-D0020
Reference Drawing: P&ID Diagram – Primary Air, Sealing & Cooling Air System ................ T04019-PI-D0021
Reference Drawing: Scanner Air System Piping Arrangement.....................................T04019-SP-A001, A002
Reference Drawing: Suggested Pipe Supports ........................................................................T04019-SP-A003

IV. 4. Tilting Tangential Firing System
TABLE OF CONTENTS
TITLE Page No
DESIGN FEATURES ........................................................................................................................ 1

SYSTEM DESCRIPTION .................................................................................................................. 2
MAIN WINDBOX COMPONENTS.................................................................................................... 2
AIRFLOW CONTROL AND DISTRIBUTION ................................................................................... 4
CONTROL SYSTEM PHILOSOPHY ................................................................................................ 7
WINDBOX MAINTENANCE ............................................................................................................. 7
LIST OF FIGURE
TITLE Page No
FIGURE 1. WINDBOX AND CCOFA ELEVATION DESIGNATIONS ............................................ 11

FIGURE 2. COAL COMPARTMENT-FUEL AIR DAMPER RAMP F(X) ........................................ 12
FIGURE 3. AUXILIARY AIR DAMPERS CHARACTERISTICS ..................................................... 13
FIGURE 4. CCOFA DAMPERS CHARACTERISTICS................................................................... 14
FIGURE 5. COAL COMPARTMENT ASSEMBLY ....................................................................... 15
FIGURE 6. EXPLODED VIEW EXTERNAL TILT DRIVE SHEAR PIN FAILURE
MECHANISM ................................................................................................................................. 16
LIST OF REFERENCE ENGINEERING DRAWINGS
TITLE (DRAWING NO.) Page No
WINDBOX ARRANGEMENT SHEET 1 (T04019-WB-A001) ......................................................... 17

COAL NOZZLE TIP ........................................................................................................................ 20
OIL NOZZLE TIP ............................................................................................................................ 21
STRAIGHT AIR NOZZLE TIP(TOP, END) ..................................................................................... 22
STRAIGHT AIR NOZZLE TIP(AUX. AIR)....................................................................................... 24
STRAIGHT AIR NOZZLE TIP(CCOFA).......................................................................................... 25
i
DESIGN FEATURES
The integrated firing system incorporates the following design features to reduce the total
emissions:
1. Secondary air staging

2. Bulk furnace staging
3. Early controlled coal devolatization
4. Active Zone Stoichiometry Controls
Secondary Air Staging is accomplished by aux air nozzles incorporated into the integrated
system. This local air staging technique is accomplished by re-directing a portion of the
main windbox secondary air, horizontally away from the coal stream towards the waterwall,
with offset auxiliary air nozzles, tangent to a larger diameter firing circle. With this
arrangement, near burner stoichiometry is reduced as compared with non-concentric firing,
minimizing the generated prompt NOx, while at the same time maintaining appropriate
oxidizing conditions along the waterwall.
Bulk Furnace Staging takes a portion of the combustion air, and injects this secondaryair
above the main firing zone, diverting air away from the initial devolatization zone, retarding
air and fuel mixing. Staged combustion minimizes NOx emissions with an initial fuel rich
ignition zone, promoting the formation of N2 from volatile nitrogen species. In addition
significantly staged combustion reduces the peak flame temperatures, resulting in lower
thermal NOx.
The firing system specifically incorporates two CCOFA compartments strategically located
at the top of each main windbox. The CCOFA secondary airflow improves carbon burnout
while assisting with the global NOx emission control.
Early Controlled Coal devolatization is another important feature of the firing system which
promotes early ignition of the coal at the nozzle tip. Initiating combustion early, at a point
close to the coal nozzle tip produces a stable volatile matter flame, where the local
stoichiometry and resultant "prompt NOx" can be better controlled. Specifically, the windbox
fuel air dampers behind the coal compartments can be adjusted regulating the surrounding
secondary air flow, matching the volatile matter local requirements while shaping and
positioning the ignition point.
These fuel air dampers will be fine tuned during unit commissioning to maintain the proper
ignition points over the pulverizer load range. An initial curve for coal air damper position
versus pulverizer feeder speed will be programmed into the secondary air damper control
system (SADCS), and will either be confirmed or modified during initial commissioning of
this unit.
NOTE: It is important to be aware that siqnificant changes in the coal can change
the ignition point location. When changing coals the operator must observe these
ignition points and reposition the fuel air dampers accordingly.

SYSTEM DESCRIPTION
In the tangential firing system, the furnace is considered to be the burner. Fuel and air
are introduced into the furnace through windbox assemblies located in the furnace
corners. The fuel and air streams from the windbox nozzles are directed toward
concentric firing circles, swirling clockwise as viewed from above, in the center of the
furnace. The cyclonic action that is characteristic of this type of firing is most effective in
mixing the fuel and air through turbulence and diffusion, thereby completing combustion
of the fuel within the prescribed furnace gas flow path. The windboxes are designed to
distribute all of the supporting combustion air into the furnace through distinct zones:
1. Primary air, which is the portion used to dry and transport pulverized coal from the
pulverizers to the furnace.
2. Fuel air, which is the portion of secondary air admitted to the furnace through air
annulus around the fuel nozzles.
3. Auxiliary air, which is the balance of the secondary air required to complete
combustion. It is injected into the furnace through the air nozzles located between fuel
elevations.
4. Overfire air, which is a portion of secondary air admitted to the furnace through Close-
Coupled Overfire Air (CCOFA) nozzles located in the main windbox above the top
coal elevation. This technique produces staged combustion by introducing a portion of
the secondary air above the primary firing zone, which in turn reduces the amount of
available oxygen in the main combustion zone where NOx is generated.
It is important to understand that the total quantity of combustion air being introduced
to the furnace is not being changed; it is the distribution of the air that is changing.
MAIN WINDBOX COMPONENTS
There are four main windboxes, one in each corner of the furnace. Each main windbox
is 17,743 mm tall by 813 mm wide. Each main windbox assembly contains five oil
elevations situated between six coal elevations. Refer to Figure 1 and Drawings
T04019-WB-A001 thru T04019-WB-A003.
Each main windbox is divided into 23 compartments. Partition plates form the top and
bottom of each main windbox compartment, labeled alphabetically from bottom to top.
Each of the 23 main windbox elevations has independent, secondary airflow damper
controls.
All main windbox nozzles are tied to a common tilt drive. The windbox nozzle tips tilt ±
30° from horizontal.
Bottom End Air Nozzles
The bottom end air nozzle, designated as elevation AA, is located below the coal A
nozzle. The bottom end air nozzle is a straight nozzle design. Refer to Drawing (Later).

Coal Nozzles
Coal nozzles are located at elevations A, B, C, D, E, F, G, H, J and K. The coal nozzles

are designed to promote early ignition at the nozzle tip. Refer to Drawing (Later).
Auxiliary Air Nozzles
The auxiliary air nozzles are located between the coal elevations. Three different
designs of auxiliary air nozzles are incorporated in the main windbox.
Elevations AB, CD, EF, GH and JK contain straight air nozzles that also house the oil
guns. Refer to Drawing (Later).
Elevations BU, DU, FU and HU are also a straight air nozzle design. Refer to Drawing
(Later).
Top End Air Nozzles
The top end air nozzle, designated as elevation KU, is located above the coal K nozzle.
This nozzle is a straight nozzle design. Refer to Drawing (Later).
Close-Coupled Overfire Air (CCOFA)
The CCOFA nozzles, designated as elevations CCOFA-A and CCOFA-B, are straight
nozzle design and are located on top of the main windbox. Refer to Drawing (Later).
Flame Scanners
The flame scanners for coal or oil flame respectively are provided for flame supervision
and supply "Flame" or "No flame" logic signals to the BMS. Flame scanners are located
in the auxiliary air compartments at elevations AA, AB, BU, CD, DU, EF, FU, GH, HU,
JK and KU.
High Energy Arc Ignitors
The High Energy Arc (HEA) igniters provide the ignition source for the oil guns. The
HEA igniters are located at elevations AB, CD, EF, GH and JK.
Oil Guns
Steam atomized heavy oil guns are located at elevations AB, CD, EF, GH and IJ. The

oil guns provide for warm-up and low load stabilization.

The firing system for light oil with air atomized is designed to be used common at
elevations AB only, which provide for cold start-up.
Air and Fuel Nozzle Tilts
The air and fuel streams are vertically adjustable by means of the movable nozzle tips
in each windbox compartment. The coal, oil, auxiliary air and CCOFA compartment
nozzle tips can be positioned upward or downward through a total angle of 60 degrees
(30 degrees up, 30 degrees down) tilt.
The nozzle tip tilt position is the same in all four corners and within each windbox.
The main windbox drive unit normally responds automatically to signals from the steam
temperature control system, but may be positioned manually.
Tilt Stroking Recommendations
The windbox tilt drive mechanism is subjected to harsh operating conditions that can
adversely affect the operation of the system. In particular, dry or slogged ash may
accumulate on or in the tilting nozzle tip, and can impede the tilting motion. Each tilt
indicator is equipped with a shear pin and a locking pin. If tilt linkage movement is
obstructed, the shear pin will break and the spring-loaded locking pin will be released,
keeping the tilt angle at its present position. All tilt linkages should be kept in an
unobstructed condition to prevent failure.
Accumulations usually occur at compartments taken out of service for extended periods
of time. With only minimal leakage airflow through these out-of-service, closed damper
compartments, fly ash can build up around the nozzle. Therefore, it is strongly
recommended the tilt drive mechanism of each windbox be manually stroked at least
once per day. This should be accomplished one corner at a time. After noting the
current tilt position, the operator should stroke the nozzle tips down to at least -20°,
then reverse the stroke and tilt up to at least +20°. The tilts should then be returned to
the starting position and released to automatic control. The same procedure should be
followed for each successive corner.
During the stroking procedure, the tilt action at each corner should be observed to note
any erratic motion, unusual noise, or shear pin breakage. In the event of shear pin
failure, an identical replacement pin should be installed and the tilts stroked again.
AIRFLOW CONTROL AND DISTRIBUTION
Total airflow control to the boiler is accomplished by regulating the forced draft fan
dampers. Combustion air distribution is accomplished by means of the individual
windbox compartment secondary air dampers. This secondary airflow is labeled as fuel
air, auxiliary air, or OFA.
In order to ensure safe light-off conditions, the pre-operational purge airflow (at least

30% of full load airflow) is maintained during the entire warm-up period until the unit is
on the line and the boiler load has reached the point where the airflow must be
increased to accommodate further load increase. To provide proper air distribution for
purging and suitable air velocities for lighting off, all auxiliary air dampers should be
open during the purge, light-off and warm-up periods.
After the unit is on the line, the total required amount of air (total airflow) is a function of
the unit load. Proper airflow at a given load depends on the characteristics of the fuel
fired and the amount of excess air required to satisfactorily burn the fuel. Excess air can
best be determined through flue gas analysis.
NOTE: The excess air values indicated on the predicted performance data sheet
is theoretical, and used as a basis for performance calculations. These figures
should be used as an initial guide. The optimum amount of excess air for a
particular unit, at a given load and with a given fuel must be determined by
experience. This is best accomplished by observing furnace slagging conditions.
Slagging tendency of a particular fuel may dictate an increase of operating
excess air.
Windbox Airflow Distribution
Total airflow control to the boiler is accomplished by regulating the forced draft fan blade
pitch.
Combustion air distribution is accomplished by means of the individual windbox
compartment secondary air dampers. This secondary airflow is labeled as fuel air, auxiliary
air or overfire air.
Fuel air is admitted through operating coal or oil elevations compartment dampers, while
auxiliary air is admitted between, below and above these operating coal elevations.
Auxiliary air flows through eleven(11) elevations, when adjacent or between an operating
fuel elevation.
There are 3 groups distinctly different types of windbox compartment dampers as below :
1. Coal Fuel Air Dampers A, B, C, D, E, F, G, H, J, K

* Oil Fuel Air Dampers AB, CD, EF, GH, JK (Oil firing only)
2. Aux. Air Dampers AA, AB, BU, CD, DU, EF, FU, GH, HU, JK, KU
3. Overfire Air Dampers CCOFA-A, CCOFA-B
Proper secondary air distribution is important for ignition stability when lighting off individual
fuel nozzles, firing at low loads, maintaining the furnace O2 balance, and achieving
optimum low NOx combustion conditions.
Secondary air is admitted to the fuel air, auxiliary air and overfire air compartments through
sets of opposed blade – louvered dampers. These windbox compartment dampers are
used to proportion the amount of secondary air admitted to fuel, auxiliary and OFA
elevations.
By varying the windbox compartment damper position, the air distribution is affected as

follows.
z Opening the fuel air dampers or closing the auxiliary air dampers increases the airflow
around the fuel nozzle
z Closing the fuel air dampers or opening the auxiliary air dampers decreases the airflow
directly around the fuel stream
Coal Elevation Dampers
When firing coal, initially the fuel air damper positions are closed when placing the
feeder in service, and are released to the control system after 50 seconds. Under
normal operation, the SADCS controls these fuel air dampers based on the associated
mill feeder speed. Initially, these field fine tuned set positions are set-up with 30% open
at minimum (25%) feeder speed and linearly ramped to 80% open at 60% feeder speed.
Between 60% feeder speed and 100% feeder speed, the fuel air dampers remain wide,
80% open. Refer to Figure 2.
These fuel air dampers will be fine-tuned during unit commissioning to maintain the
proper ignition points over the pulverizer load range.
NOTE : It is important to be aware that significant changes in the coal can

change the ignition point location. When changing coals the operator must observe
these ignition points and reposition the fuel air dampers accordingly.
Auxiliary Elevation Dampers
During start-up and low load operation (below 30%), all auxiliary air dampers are
released to maintain the windbox-to-furnace differential pressure, at 1.5" wg whether or
not they are adjacent to an in service fuel elevation. Above 30% load, the windbox-to-
furnace differential pressure is linearly ramped to 2.5" wg at 50% load, and then linearly
ramped to 4" wg at 60% load. At unit loadings above 60%, the differential pressure is
normally maintained at 4" wg. Refer to Figure 3.
Oil Elevation Dampers
When an oil elevation is in service for warm-up or stabilizing the adjacent coal
compartment, the center oil compartment fuel air damper is opened to a pre-set, 50%
open fixed position after the third oil gun is placed in service. Like the coal fuel air
dampers, these oil fuel air damper set points are field fine tuned as needed.
NOTE: When lighting off an elevation on manual control, the auxiliary air
dampers should be opened 20% to 40% prior to light off and kept at this position
until the fuel air dampers are open. The fuel air dampers should be closed when
lighting off an elevation. Once ignition of the main fuel is established, the fuel air
dampers should be opened in proportion to the fuel elevation firing rate. When
the fuel air dampers are fully open, further damper adjustments should be made,
if necessary, with the auxiliary air dampers only. When changing damper

positioning, an entire elevation should be treated simultaneously (damper

positioning at the same elevation should be identical in all windboxes).
Overfire Airflow Control
OFA flow control is key to minimizing NOx emissions. The OFA flow control system
consists of two CCOFA elevations located at the top of the main windbox. The
secondary airflow through all OFA elevations are independently controlled with
pneumatically operated opposed blade dampers.
CCOFA flow control is key to minimizing NOx emissions. The secondary airflow through
all CCOFA elevations is independently controlled with pneumatically operated dampers.
The CCOFA flows through the top two main windbox elevations and the CCOFA air
dampers ramp open with total unit airflow. The lower CCOFA-A elevation dampers will
step from 0% to 20% open at 30% unit airflow, linearly ramp to 80% open at 40% unit
airflow, and continue along the same ramp till the actuator reaches 100% open.
Likewise the upper CCOFA-B elevation dampers will step from 0% to 20% open at 43%
unit airflow, ramp to 100% open at 60% unit airflow, and unit air flow at 60% above, the
damper is normally maintained 100% open, as shown below. Refer to Figure 4.
CONTROL SYSTEM PHILOSOPHY
The typical SADCS OFA damper logic is typically indexed on total unit airflow. Under
this scheme, preset, fixed CC-OFA compartment damper ramps were assigned, field
fine tuned as necessary, and implemented. This control philosophy was usually more
than adequate to meet steady state, full load NOx requirements.
Overfire air damper control is key to maintaining consistent NOx emissions. But, with
existing, typical OFA damper control logic, the quantity of in-furnace produced NOx
changes significantly throughout the entire boiler operating envelope. Specifically, at full
load, the unit airflow would be at 100% capacity, and OFA compartments would be in
service. As total unit airflow diminished, these OFA dampers would be sequentially
closed from the top down, until at 40% or 50% unit airflow, OFA dampers would be
typically closed. In other words, as the unit total airflow followed a reduction in boiler
load, the OFA flow diminishes, resulting in an increase in NOx emissions.
Simultaneous with this reduction in total OFA flow, as boiler load is reduced other
operational factors also influence the NOx emissions.
WINDBOX MAINTENANCE
Maintenance on windbox assemblies consists mainly of replacement of adjustable

nozzle tips and adjustment of tilting mechanism.

Auxiliary Air Nozzle Tips
The auxiliary air nozzle tips are replaced from the furnace side as follows:
1. Remove the side windbox access panels.
2. Ensure that the tilt mechanism is in the horizontal position and locked in place with
the maintenance pin.
3. From the furnace side, secure the nozzle do in place utilizing blocks and rope.
4. Disconnect the nozzle adjusting link at the internal bell crank from the side access
panel.
5. Grind away the tack welds on the clamping bolts and remove the two clamping bolts
and the nozzle pivot pin support block retainer caps.
6. The old nozzle can now be removed with the adjusting link attached. The nozzle
adjusting link is removed from the nozzle by grinding away the pin weld.
7. Reinstall the nozzle adjusting link on the new nozzle and weld the pivot pin to the
nozzle body.
8. Install the nozzle in the windbox, positioning the nozzle pins in the support blocks.
Install the pivot pin retainer caps and bolts and nuts. Tack weld the clamping bolt to
the retainer cap and to the nut.
9. Check the nozzle tip clearances. Clearances around the adjustable nozzle tips
should be 38mm between the tips and compartment plates, and 1/2" (13 mm) on the
sides between the tips and channels.
10. Reconnect the nozzle adjusting link and install the windbox access doors.
11. Remove the maintenance pin.
Coal Nozzle and Nozzle Tip
The coal nozzle tips can be replaced from the windbox front as follows:
1. Provide support to the coal piping and remove the coal pipe elbow.
2. Remove the stud nuts from around the rectangular panel at the front of the windbox
and side the access panels. Refer to Figure 5.
3. Ensure that the tilt mechanism is in the horizontal position and locked in place with
the maintenance pin.

4. From outside the windbox, remove the pin "C" clip from between the vertical tilt link
and the horizontal positioning plate. Refer to Figure 6.
5. Temporarily wedge a wooden block between the stationary nozzle and nozzle tip.
6. Loosen the two alien set screws and slide the bell crank and adjusting lever off the
drive shaft. Refer to Figure 6. Wire the bell crank and lever to the stationary coal
pipe.
7. Slide the drive shaft outward until flush with the windbox plate. Refer to Figure 6.
8. Loosen upper or lower jacking bolts on front coal nozzle supports (left and right).
Refer to Figure 5.
9. The complete coal nozzle assembly may now be pulled out through the front of the
windbox.
10. Inspect both the stationary nozzle and nozzle tip.
11. The nozzle tip can be replaced by removing the nozzle tip pivot pins.
12. Upon completion of maintenance, reinstall the nozzle assembly and using the jacking
bolts, center the nozzle assembly. Make sure that a 1/2" (13 mm) minimum clearance
is maintained between the nozzle tip and the compartment partition plate at the top
and bottom and a 1/2" (13 mm) minimum is maintained on each side. Refer to Figure
5.
13. Reinstall the drive shaft and install the "C" clip on the pin between the vertical tilt link
and the horizontal positioning plate. Refer to Figure 6.
14. Reinstall the bell crank with adjusting lever attached. Using two shims, set a 1/16"
(1.58 mm) gap between the bell cranks and frame inside and outside the windbox.
Refer to Figure 6.
15. Tighten the two allen-set screws and remove the shims.
16. Remove any wedge from between the stationary nozzle and nozzle tip.
17. Tighten the jack bolt jam nuts.
18. Reinstall the access plates, stud nuts, and coal pipe elbow.
Adjustment of Tilt Linkage
1. Inspect the tilt linkage to ensure components are in good condition. Run the tilts
through the full range and check that there is no interference with other components,
such as the building steel, platforms, and piping.

2. Check the tilt positions at +30, -30, and return to horizontal position. Using the
maintenance pin, lock the tilts in place.
3. Inspect the tilt indicator and pointer for proper relationship with the tilting nozzles.
4. Inspect the locking pin mechanism.
5. Inspect the shear pin for deformation. Make sure to install the correct shear pin.
6. Inspect the tilt drive lever.
7. Check the adjustable nozzle tip angles from inside the furnace to ensure they are in
the horizontal position (±1-1/2°).
8. Adjustment of the individual nozzle tilt position is achieved by turning both the upper
and lower jacking bolts on the external drive levers. Tighten the jam nuts upon final
adjustment.
9. When all compartments have been adjusted for horizontal position, run tilts through
full range again.
10. Check the tilt position at extreme angles and return to horizontal.

OVERFIRE AIR CCOFA-B
OVERFIRE AIR CCOFA-A
TOP END AIR-KU
COAL NOZZLE TIP-K
AUXILIARY AIR / OIL-JK
COAL NOZZLE TIP-J
AUXILIARY AIR-HU
COAL NOZZLE TIP-H
AUXILIARY AIR / OIL-GH
COAL NOZZLE TIP-G
AUXILIARY AIR-FU
COAL NOZZLE TIP-F
AUXILIARY AIR / OIL-EF
COAL NOZZLE TIP-E
AUXILIARY AIR-DU
COAL NOZZLE TIP-D
AUXILIARY AIR / OIL-CD
COAL NOZZLE TIP-C
AUXILIARY AIR-BU
COAL NOZZLE TIP-B
AUXILIARY AIR / OIL-AB
COAL NOZZLE TIP-A
BOTTOM END AIR-AA
Figure 1. Windbox Elevation Designations

80
DAMPERS
% OPEN
30
25 60 100
COAL FEEDER SPEED RATE(%)
Figure 2. Coal Compartment-Fuel Air Damper Ramp f(x)

100
WINDBOX
TO FURNACE
^P 63
(mm WG)
37
30 50 60 100
UNIT LOAD (%)
Figure 3. Auxiliary Air Dampers Characteristics

100
80
OVERFIRE
AIR
CCOFA-A
DAMPER
OPENING CCOFA-B
(%)
20
30 35 40 43 60 100
UNIT AIR FLOW (%)
Figure 4. CCOFA Dampers Characteristics

Figure 5. Coal Compartment Assembly

Figure 6. Exploded View External Tilt Drive Shear Pin Failure Mechanism










IV. 5. DESIGN DATA AND CONTRACT DATA SHEET
LIST OF DATA SHEETS
TITLE SHEET NO.
Design Data And Contract Data Sheet.............................................................................................. 1

Predicted Performance Data (BMCR, TMCR, 80% TMCR & 60% TMCR) .................................. 2
Predicted Performance Data (50%TMCR, 30% TMCR & Both HP Heaters Out) ........................ 3
i IV.5 Design and Contract Data Sheet.doc

Doosan Heavy Industries &

Construction Co., LTD. CONTRACT DATA SHEET Page 1 of 1
Boiler Basic Design Department
TO: CONTRACT DATA SHEET File alphabetically

Contract No. T04019 Destroy sheet dated:
Contract Date : 2004.04.15
PURCHASER NTPC Limited
USER NTPC Limited
PLANT NAME : Sipat Stage-I Super CONS. ENGR: NTPC Limited
Thermal Power Plant
BOILER Units 1, 2 & 3 P DESIGN: 272.9 kg/cm2 (g)
DESIGNATION: Once-Thru Super-critical, Two-pass, R OPER @ SHO: 255 kg/cm2 (g)
Balanced draft, Outdoor E
440 Spiral Wall Tubes of 38.0 mm OD @ 50 mm spacing S TURB. THROTTLE: 246 kg/cm2 (g)
1,320 Vertical Wall Tubes of 34.0 mm OD @ 56 mm S
spacing
FURNACE VOL.: m³, 21,462 TYPE OF BOTTOM: WIDTH 18,816 mm DEPTH 18,144 mm.
Coutant
SUPERHEATER TYPE: Multi-stage with panel, Platen and REHEATER TYPE: Multi-stage
pendant sections
ECONOMIZER TYPE Bare tube, Inline, Counter flow; 4 banks; 163 Asslys; Tube O.D 50.8 mm
AIR HEATER TYPE: Regener PRI: 2 Nos. 26-VI-1800 M A K E : Doosan Heavy Industries &
ative, Bi-Sector SEC: 2 Nos. 31.5-VI-1900 Construction Co, Ltd
FUEL BURNING Vertical Bowl Mills 10 Nos. XHPS 1103; 10 Nos. 36 inch Gravimetric Feeders;
EQUIPMENT Tilting tangential, Corner Windbox with CCOFA
FUEL Design Coal ASH FUSION GRINDABILITY HHV
TEMP., °C HGI Kcal/Kg
C=34.46%, H2=2.43%, N2=0.69%, 02=6.64%, S=0.45% I.D.T – 1,150 50 3300
Ash=43.00%, Moisture=12.00%, VM 21.00%
OPERATINGCONDITIONS
SH CONTROL
BMCR POINT
50%TMCR
STEAM FLOW SUPERHEATER, kg/hr 2225,000 963,760
REHEAT, kg/hr 1741,820 836,410
STEAM TEMP. SUPERHEATER, °C 540 540
REHEATER, °C 568 568
REHEAT ENTERING TEMP, °C 299 289
2
DATA ENTERING PRESS Kg/cm (g) 46.3 22.6
FEED WATER TEMPERATURE, °C 289.64 244.34
TEMP. AIR TO AIR HEATER Pri / Sec, °C 34.7/30.9 42/41.6
TEMP GAS LVG AIR HEATER (Uncorr.) Pri / Sec, °C 144/137 124/118
BOILER EFFICIENCY, % 86.28 86.85
SUPPLEMENTARY DATA DRAFT SYSTEM: 2 Nos. Two stage, Const. Speed, GENERATOR
Variable pitch, Axial PA Fans; 2 Nos. Const. Speed, Axial FD KW
and 2 Nos Const. Speed, Axial ID Fans with Motor Drives. 660,000
PLANT 282.5 m
BCP: 1 No. Glandless pump with Motor Drive Above MSL.
1 IV.5 Design and Contract Data Sheet.doc

Doosan Heavy Industries & Predicted Performance Sheet

Page 1 of 2
Construction Co., LTD For Instruction Manual
Customer: NTPC Limited Station : Sipat Stage-I, 3x 660 MW STPP Cont. No. : T04019
PREDICTED PERFORMANCE
Load BMCR TMCR 80%TMCR 60%TMCR
Fuel Design Coal Design Coal Design Coal Design Coal
Main Steam Flow kg/hr 2,225,000 2,023,750 1,572,470 1,158,410
Feedwater Temperature °C 289.64 286.23 270.35 254.09
Superheater Outlet Temp. °C 540 540 540 540
Superheater Outlet Press. kg/cm2(g) 255 253.45 237.01 178.42
( 2
Press. Drop Econ Inlet Conn. To SHO Conn. kg/cm 49.2 39.45 24.09 16.48
Reheater Flow kg/hr 1,741,820 1,678,370 1,328,960 996,950
Reheater Inlet Temp. °C 299 296 281 286
Reheater Inlet Press. kg/cm2(g) 47.3 45.7 36.2 27.10
Reheater Outlet Temp. °C 568 568 568 568
Reheater Outlet Press. kg/cm2(g) 45.61 44.08 34.9 26.08
Reheater Press. Drop kg/cm2 1.69 1.62 1.30 1.02
Gas Drop, Furnace to Econ. Outlet mm. w.g. 94 85 69 57
Gas Drop, Econ. Outlet to A.H. Outlet mm. w.g. 84 80 62 45
Gas Temp. Ent. Air Heater °C 322 317 298 279
Gas Temp. Lvg. Air Heater, Uncorr. - Pri/Sec °C 144/137 143/136 134/127 124/118
Gas Temp. Lvg. Air Heater, Corr. - Pri/Sec °C 133/131 132/130 122/120 111/111
Air Temp. Ent Air Heater - Pri/Sec °C 34.7/30.9 34.4/30.6 34/30.3 33.9/33.0
Air Temp. Lvg. Air Heater - Pri/Sec °C 295/296 291/293 275/277 258/261
Air Press. Ent. Air Heater Pri/Sec mm. w.g. 874/200 851/182 828/152 798/131
Ambient Air Temp. °C 27 27 27 27
Excess Air Lvg. Econ. % 20 20 20 23.4
Fuel Fired kg/hr 471,800 438,100 354,900 272,400
Efficiency % 86.28 86.29 86.69 86.88
* NOTES:
• These performance figures are predicted only and are not to be construed as being guaranteed except where the points
coincide with the guarantees.
• Operation of this unit in excess of the above specified Maximum Continuous Rating (MCR) may result in damage to the
equipment and/or increased maintenance.
• Superheat steam temperature control range is from 2,225,000 (BMCR) to 963,760 (50%TMCR) kg/hr.
• Reheat steam temperature control range is from 1,741,820 (BMCR) to 836,410 (50%TMCR) kg/hr.
• The fuel specifications on which the guarantees are based are as follows:
Design Coal: C=34.46%, H2=2.43%, N2=0.69%, 02=6.64%, S=0.45%, Ash=43.00%, Moisture=12.0%, VM= 21.00%

Doosan Heavy Industries & Predicted Performance Sheet

Page 2 of 2
Construction Co., LTD For Instruction Manual
Customer: NTPC Limited Station : Sipat Stage-I, 3 x 660 MW STPP Cont.No. : T04019
PREDICTED PERFORMANCE
BOTH HP HEATE
Load 50% TMCR 30% TMC
R RS OUT
Fuel Design Coal Design Co Design Coal
Main Steam Flow kg/hr 963,760 596,100 1,839,500
Feedwater Temperature °C 244.34 219 196.15
Superheater Outlet Temp. °C 540 540 540
Superheater Outlet Press. kg/cm2(g) 150.25 92.9 251.92
Press. Drop Econ Inlet Conn. To SHO Conn. kg/cm2 15.25 7.2 29.68
Reheater Flow kg/hr 836,410 517,200 1,784,200
Reheater Inlet Temp. °C 289 294 309
Reheater Inlet Press. kg/cm2(g) 22.6 13.6 49.5
Reheater Outlet Temp. °C 568 540 568
Reheater Outlet Press. kg/cm2(g) 21.72 13.03 47.8
Reheater Press. Drop kg/cm2 0.88 0.57 1.70
Gas Drop, Furnace to Econ. Outlet mm. w.g. 50 41 88
Gas Drop, Econ. Outlet to A.H. Outlet mm. w.g. 35 22 103
Gas Temp. Ent. Air Heater °C 265 234 251
Gas Temp. Lvg. Air Heater, Uncorr. – Pri / Sec °C 124/119 125/121 118/115
Gas Temp. Lvg. Air Heater, Corr. – Pri / Sec °C 111/111 110/111 111/110
Air Temp. Ent Air Heater – Pri / Sec °C 42/41.6 57/55.5 51/49.6
Air Temp. Lvg. Air Heater – Pri / Sec °C 249/249 222/222 223/229
Air Press. Ent. Air Heater-- Pri / Sec mm. w.g. 821/146 772/119 972/275
Ambient Air Temp. °C 27 27 27
Excess Air Lvg. Econ. % 24 26.7 20
Fuel Fired kg/hr 231,100 147,300 463,100
Efficiency % 86.85 86.24 87.31
* NOTES:
• These performance figures are predicted only and are not to be construed as being guaranteed except where the points
coincide with the guarantees.
• Operation of this unit in excess of the above specified Maximum Continuous Rating (MCR) may result in damage to the
equipment and/or increased maintenance.
• Superheat steam temperature control range is from 2,225,000 (BMCR) to 963,760 (50%TMCR) kg/hr.
• Reheat steam temperature control range is from 1,741,820 (BMCR) to 836,410 (50%TMCR) kg/hr.
• The fuel specifications on which the guarantees are based are as follows:
Design Coal: C=34.46%, H2=2.43%, N2=0.69%, 02=6.64%, S=0.45%, Ash=43.00%, Moisture=12.0%, VM= 21.00%

IV. 6. PRESSURE PARTS ARRANGEMENT SKETCH
TABLE OF CONTENTS
TITLE PAGE NO.
Pressure Part Schedule and data ……..……………………………………………………………………... 1
Pressure Part flow diagram………………………………………………………………………………2
i IV.6 Pressure parts Arrangement and flow diagram-cover.doc

Pressure Part Sketch and Performance Data
Superheater Platen Tube Reheater Final Tube Superheater Final Tube

Material SA213-T12 Material SA213-T23 Material SA213T-23
SA213-T23 SA213-T91 SA213-T91
SA213-T91 Super304H SA213-T92
Tube Spec. 50.8 x 6.6, 50.8 x 7.3 Tube Spec. 63.5 x 4.4, 63.5 x 4.6 Tube Spec. 42.2 x 5.5, 42.2 x 5.8
50.8 x 8.5, 50.8 x 10.0 70.0 x 4.0 42.2 x 6.4, 42.2 x 6.6
SL/ST, mm 60 / 896 SL/ST, mm 127 / 448 SL/ST, mm 85 / 336
Bank Depth, mm 2,460. Bank Depth, mm 3,683. Bank Depth, mm 2,805 x 2 Bank
Gas Temp.(Inlet/Outlet), ℃ 1,078 / 988 Gas Temp.(Inlet/Outlet), ℃ 988 / 874 Gas Temp.(Inlet/Outlet), ℃ 855 / 727
Max. Avg. Gas Velocity, m/s 8 Max. Avg. Gas Velocity, m/s 8.7 Max. Avg. Gas Velocity, m/s 8.7
6
Heat Absortion, x10 kcal/h 100.3 Heat Absortion, x106 kcal/h 106.4 Heat Absortion, x106 kcal/h 107.1
26,144 18,256
Superheater Division Panel Tube Low Temperature Reheater Tube

SH Fin.
Material SA213-T23 Material SA210-C
SA213-T91 SA213-T12
Tube Spec. 44.5 x 5.4, 44.5 x 5.9 SH Div. SH RH Fin SA213-T23
44.5 x 6.1, 44.5 x 7.0 Panel Platen Tube Spec. 63.5 x 3.4
SL/ST, mm 54 / 2688 SL/ST, mm 127 / 168
Bank Depth, mm 4,266 x 2 Bank Bank Depth, mm 2,222.5 x 3 Bank
Gas Temp.(Inlet/Outlet), ℃ 1,333 / 1,078 Low Temp. RH Gas Temp.(Inlet/Outlet), ℃ 721 / 489
Heat Absortion, x106 kcal/h 149.2 Max. Avg. Gas Velocity, m/s 9.2
Heat Absortion, x106 kcal/h 168.7
73,885
Economizer Economizer Tube
Material SA210-C
Tube Spec. 50.8 x 6.5
SL/ST, mm 102 / 114.3
Bank Depth, mm 1734 x 4 Bank
18,144 Gas Temp.(Inlet/Outlet), ℃ 489 / 322
Max. Avg. Gas Velocity, m/s 7.9
Heat Absortion, x106 kcal/h 140.9
10,356
o
55
SH/RH/ECO Performance & Arrangement Sketch along with Material Data
R-13 Reheater Outlet Leads 2 660.4 21.5 SA335-P91 53.4 573.0
R-12 Reheater Final Outlet Header 2 812.8 42.4 SA335-P91 53.4 573.0 46.0 568.0
76.2 4.0 SUPER304H 53.4 615.6
70.0 4.0 SUPER304H 53.4 606.1
R-11B Reheater Final Outlet Term. Tubes 615 63.5 3.4 SUPER304H 53.4 602.2
63.5 3.6 SA213-T91 53.4 582.2
57.0 3.6 SA213-T91 53.4 562.8
70.0 4.0 SUPER304H 53.4 642.9
63.5 3.4 SUPER304H 53.4 634.0
R-11 Reheater Final Tubes 615
63.5 3.6 SA213-T91 53.4 591.2
63.5 3.4 SA213-T23 53.4 537.9
76.2 4.0 SA213-T23 53.4 456.7
70.0 4.0 SA213-T23 53.4 456.7
R-11A Reheater Final Inlet Term. Tubes 615
63.5 3.4 SA213-T23 53.4 456.7
50.8 3.4 SA213-T23 53.4 456.7
R-10 Reheater Final Inlet Header 1 609.6 29.3 SA335-P12 53.4 462.1 46.8 456.9
R-9 Links to Reheater Final Inlet Header 2 711.2 18.8 SA335-P12 53.4 462.1
R-8 Low Temperature Reheater Outlet Header 1 711.2 31.1 SA335-P12 53.4 462.1 47.2 457.1
R-7A Low Temperature Reheater Outlet Term. Tubes 111 63.5 3.4 SA213-T12 53.4 514.4
63.5 3.4 SA213-T23 53.4 536.2
R-4,5,6,7 Low Temperature Reheater Tubes 111 63.5 3.4 SA213-T12 53.4 504.6
63.5 3.4 SA210-C 53.4 404.6
R-3 Low Temperature Reheater Inlet Header 1 508.0 21.0 SA106-C 53.4 327.3 47.7 299.3
R-2 Reheater Inlet Leads 2 660.4 16.5 SA106-C 53.4 304.3
R-1 Reheater Desuperheater 2 660.4 22.8 SA106-C 53.4 304.3
R-1A Reheater Inlet Leads 2 660.4 16.5 SA106-C 53.4 304.3
S-37 Superheater Final Outlet Leads 2 457.2 57.0 SA335-P91 272.9 545.0
S-36 Superheater Final Outlet Header 2 457.2 64.8 SA335-P91 272.9 545.0 255.0 540.0
42.2 6.6 SA213-T91 276.2 561.7
S-35B Superheater Final Outlet Term. Tubes 935
42.2 6.4 SA213-T23 276.2 557.8
42.2 6.4 SA213-T92 276.2 594.0
42.2 6.6 SA213-T91 276.2 580.1
S-35 Superheater Final Tubes 935 42.2 5.8 SA213-T91 276.2 560.7
42.2 6.4 SA213-T23 276.2 550.1
42.2 5.5 SA213-T23 276.2 531.8
S-35A Superheater Final Inlet Term. Tubes 935 42.2 5.5 SA213-T23 276.2 557.8
S-34 Superheater Final Inlet Header 1 355.6 45.5 SA335-P23 276.2 490.2 258.2 485.2
S-33 Links to Superheater Final Inlet Header 2 457.2 46.8 SA335-P23 277.1 490.2
S-32 Superheater Desuperheater #2 2 457.2 48.6 SA335-P23 277.7 497.3
S-31 Links to Superheater Desuperheater #2 2 457.2 48.6 SA335-P23 278.2 497.3
S-30 Superheater Platen Outlet Header 1 406.4 52.5 SA335-P23 278.2 497.3 260.1 492.3
50.8 6.6 SA213-T23 282.4 520.0
S-29B Superheater Platen Outlet Term. Tubes 420
50.8 8.5 SA213-T12 282.4 513.3
50.8 6.6 SA213-T91 282.4 552.8
50.8 7.3 SA213-T23 282.4 546.7
S-29 Superheater Platen Tubes 420 50.8 6.6 SA213-T23 282.4 528.3
50.8 10.0 SA213-T12 282.4 526.1
50.8 8.5 SA213-T12 282.4 511.1
S-29A Superheater Platen Inlet Term. Tubes 420 50.8 6.4 SA213-T12 282.4 467.2
S-28 Superheater Platen Inlet Header 1 355.6 52.9 SA335-P12 282.4 456.2 264.5 451.2
S-27 Links to Superheater Platen Inlet Header 2 406.4 58.6 SA335-P12 283.1 456.2
S-26 Superheater Desuperheater #1 2 406.4 58.6 SA335-P12 284.7 501.6
S-25 Links to Superheater Desuperheater #1 2 406.4 58.6 SA335-P12 285.5 501.6
S-24 Superheater Division Panel Outlet Headers 2 508.0 72.6 SA335-P23 285.5 501.6 267.5 461.6
S-23 Superheater Division Panel Outlet Term. Tubes 480 44.5 5.4 SA213-T23 289.2 480.0
44.5 5.9 SA213-T91 289.2 546.1
44.5 7.0 SA213-T23 289.2 555.6
S-22 Superheater Division Panel Tubes 480
44.5 6.1 SA213-T23 289.2 533.9
44.5 5.4 SA213-T23 289.2 515.0
S-21 Superheater Division Panel Inlet Term. Tubes 480 44.5 5.9 SA213-T12 289.2 430.6
S-20 Superheater Division Panel Inlet Headers 2 355.6 60.8 SA335-P12 289.2 457.4 270.8 417.4
S-19 Links to Superheater Panel Inlet Header 4 323.9 40.7 SA335-P12 290.3 457.5
S-18 Extended Wall Side Tubes 142 50.8 7.1 SA213-T12 290.9 496.5
S-17 Extended Wall Floor Tubes 142 50.8 7.1 SA213-T12 290.9 496.5
S-16 Extended Wall Inlet Header 1 355.6 60.8 SA335-P12 290.9 483.1 272.8 415.1
S-15 Link to Extended Wall Inlet Header 1 355.6 44.2 SA335-P12 290.9 455.1
S-14 Backpass Lower Front Header 1 406.4 73.9 SA335-P12 290.9 483.1 272.8 415.1
S-13 Backpass Front Wall Tubes 167 57.0 10.5 SA213-T12 291.8 494.1
S-12 Backpass Screen Tubes 167 57.0 10.5 SA213-T12 291.8 494.1
S-11 Backpass Outlet Headers 2 406.4 71.3 SA335-P12 290.3 457.5 272.0 417.5
S-10 Backpass Side Wall Tubes 328 57.0 7.9 SA213-T12 290.9 496.5
S-9 Backpass Lower Side Header 2 406.4 73.9 SA335-P12 290.9 483.1 272.8 415.1
S-8 Backpass Lower Rear Header 1 406.4 68.7 SA335-P12 290.9 483.1 272.8 415.1
S-7 Backpass Rear Wall Tubes 111 70.0 9.6 SA213-T12 291.8 494.1
S-6 Backpass Roof Tubes 111 70.0 9.6 SA213-T12 291.8 494.1
S-5 Furnace Roof Outlet Header 1 219.1 44.6 SA335-P12 291.8 480.3 273.9 412.3
S-4 Furnace Rear Roof Tubes 168 70.0 9.6 SA213-T12 293.2 491.3
S-3 Furnace Front Roof Tubes 168 70.0 9.6 SA213-T12 293.2 491.3
S-2 Furnace Roof Inlet Header 1 273.1 42.9 SA335-P12 293.2 451.2 275.3 411.2
S-1 Links to Roof Inlet Header 4 323.9 40.7 SA335-P12 293.8 451.2
F-33 Storage Tank 1 650.0 80.0 SA302-C 295.3 422.9 382.9

F-32 Link to Storage Tank 2 323.9 41.4 SA335-P12 295.2 422.9 382.9
F-31 Separator 2 650.0 80.0 SA302-C 302.6 452.7 276.9 412.7
F-9, F-20, F-29 Furnace wall Riser Pipe 8 273.1 35.9 SA335-P12 306.1 464.1 277.2 424.1
F-8, F19, F-28 Outlet Front/Rear/Side Header 4 273.1 41.6 SA335-P12 306.1 464.1 277.2 424.1
F-18B - Rear Wall Hanger Tubes 56 48.3 11.5 SA213-T22 307.7 492.1
F-18A - Rear Wall Screen Tubes 280 48.3 8.5 SA213-T22 307.7 484.5
F-17 - Rear Wall Arch Tubes 336 38.0 6.7 SA213-T22 307.7 477.0
F-16 - Rear Wall Tubes 336 38.0 5.4 SA213-T22 307.7 465.9
F-27 - Side Wall Tubes 648 34.0 5.4 SA213-T22 307.7 485.0
F-7 - Front Wall Tubes 336 34.0 5.4 SA213-T22 307.7 485.0
Vertical wall Tube
F-5, F-14, F-25 Intermediate Header 4 273.1 42.4 SA335-P12 307.7 437.6 278.7 397.6
F-3, F12, F-23 Spiral wall Tube 440 38.0 6.6 SA213-T22 327.0 466.0
F-21 Inlet Side Header 2 406.4 49.9 SA106-C 327.0 380.6 297.2 340.6
F-1, F10 Inlet Front/Rear Header 1/1 406.4 60.4 SA106-C 327.0 380.6 297.2 340.6
E-10 Economizer Waterwall Inlet Links 2 355.6 39.8 SA106-C 327.3 340.7
E-9 Economizer Mixing Line 1 457.2 50.8 SA106-C 325.5 340.7
E-8 Economizer Outlet Links 2 355.6 39.8 SA106-C 323.7 340.7
E-7 Economizer Hanger Tube Outlet Header 1 457.2 63.4 SA106-C 323.7 340.7 293.9 340.7
E-6 Economizer Hanger Tubes 224 70.0 13.0 SA210-C 326.2 351.7
E-5 Economizer Junction Headers 4 219.1 34.1 SA106-C 326.2 366.9 296.4 338.9
E-4 Backpass Economizer Tubes 489 50.8 6.5 SA210-C 330.1 349.9
E-3 Backpass Economizer Inlet Header 1 406.4 62.6 SA106-C 330.1 317.7 300.1 289.7
E-2 Economizer Inlet Leads 2 DN 400 46.0 SA106-C 331.4 289.7
E-1 Feedwater Line 1 DN 600 76.1 SA106-C 333.2 289.7
No of Pressure Temp. Pressure Temp.
Outside Minimum
Tubes kg/cm2g o
C kg/cm2g o
C
No. Description of Heating Surface Diameter Thickness Materials
per Operating Data
(mm) (mm) Design Data
Boiler @ BMCR
IV. 7. PRESSURE PARTS SCHEDULE-UNIT MATERIAL DIAGRAM
TABLE OF CONTENTS
TITLE PAGE NO.
Pressure Parts Schedule-Unit Material Diagram
Back pass Economiser Tubes Page 1 of 12

Economiser Hanger Tubes Page 2 of 12
Lower Furnace Page 3 of 12
Furnace Vertical Wall Page 4 of 12
Furnace Rear Wall Page 5 of 12
Extended Wall Page 6 of 12
Back Pass Wall Page 7 of 12
SH Division Panel Page 8 of 12
SH Platen Page 9 of 12
SH Final Page 10 of 12
Low Temperature Reheater Page 11 of 12
Reheater Final Page 12 of 12
i IV.7 Pressure parts schedule-Unit Material Diagram-cover.doc

VI. 8. SAFETY VALVE DATA
TABLE OF CONTENTS
TITLE PAGE NO.
SAFETY VALVES DATA
Design Basis for Safety Valves …………………………………………………………..1

Separator Outlet and Superheater Safety Valve …………………………………………2
Cold RH and Hot RH Safety Valve………………………………………………………………… 3
Soot Blowing Pipe Safety Valve ……………………………………………………………4
Safety Valve Setting Diagram at Superheater……………………………………………………. 5
Safety Valve Setting Diagram at Reheater System………… ……………………………………6
Safety Valve Setting Diagram at Soot Blowing System………. …………………………………7
SH Power Operated Impulse type SV Setting Diagram…………………………………………. 8
Hot RH Pipe Power Operated Impulse type SV Setting Diagram………… ……………………9
Design Basis for Power Operated Impulse Safety Valves…………………………………….. 10
SV Setting for High Capacity PRDS Downstream. …………………………………………….11
Safety Valve Setting Table for HT Unit Aux. Steam Header…………………………………..12
i IV.8 Safety valve-cover.doc

DESIGN BASIS FOR SAFETY VALVES :
Per Technical Specification Section VI-A(Part A), Part B / Sub-section-II-M1
(SG AND AUX.), Clause No. 16.02.01 & Sub-section-II-M4 (PCP), Clause No.8.03.00
1. Minimum Discharge Capacities.
A. Safety valves on Separator and Combined capacity 105%BMCR

Superheater
(excluding power operated impulse
safety valve)
B. Safety valves on Reheater system Combined capacity 105% of Reheat

(excluding power operated impulse flow at BMCR
safety valve)
C. Power operated impulse safety valve 40%BMCR at superheater outlet

60% of Reheat flow at BMCR at
reheater outlet
2. Blow down 4% (max.)
1
SEPARATOR OUTLET AND SUPERHEATER
SAFETY VALVE SETTING DIAGRAM
Main Steam Parameters :

- Boiler Maximum Continuous Rating Steam Flow 2,225,000 kg/hr
- Superheater Header Outlet Steam Pressure 255 kg/cm2(g)
- Separator Outlet Steam Pressure 276 kg/cm2(g)
System Design Pressure :
- Superheater Header Outlet Piping Design Pressure 272.9 kg/cm2(g)
- Separator Design Pressure 294.9 kg/cm2(g)
No. of Relieving Capa.

Set Pressure Steam Blowdown Relieving Percent of
Description Safety Type of each valve
Open Close Temp. Ratio Capacity BMCR flow
Valve type
kg/cm2(g) kg/cm2(g) ℃ (%) (kg/hr) (kg/hr) (%)
Separator Outlet
1st Safety Valve 2 294.9 283.1 412.7 4.0 Spring loaded 337770
2nd Safety Valve 4 302.6 290.5 412.7 4.0 Spring loaded 1654420
1992190 89.5
Superheater Outlet
2nd Safety Valve 2 275.6 264.6 540.0 4.0 Spring loaded 197710 393260 17.7
Power actuated impulse
3rd Safety Valve 2 270.2 262.1 540.0 3.0 type Hydraulic 667500 667500 30.0
4th Safety Valve 2 267.4 262.1 540.0 2.0 type Relief valve 255200 255200 11.5
Spring loaded Safety Valves Total Capacity 2,385,450 107.2

Power actuated impulse type Safety valves Total Capacity 667,500 30.0
Power actuated impulse type Relief valves Total Capacity 255,200 11.5
GRAND TOTAL 148.7
2
COLD REHEAT PIPE AND HOT REHEAT PIPE
Reheater Steam Parameters :

- Boiler Maximum Continuous Rating Reheater Flow 1,741,800 kg/hr
- Cold Reheat Pipe Pressure(at Reheater inlet Header) 45.63 kg/cm2(g)
- Hot Reheat Pipe Pressure(at Reheater outlet Header) 43.94 kg/cm2(g)
- Cold / Hot Reheat Pipe Design Pressure 53.0 kg/cm2(g)
Relieving Capa.
No. of Set Pressure Steam Blowdown Relieving Percent of
Description Type of each valve
S/V Open Close Temp. Ratio Capacity BMCR flow
type
Cold Reheat Pipe
2nd Safety Valve 2 53.5 51.36 299.3 4.0 Spring loaded 343850
3rd Safety Valve 2 54.1 51.94 299.3 4.0 Spring loaded 445800
4th Safety Valve 2 54.6 52.42 299.3 4.0 Spring loaded 449790
1580190 90.7
Hot Reheat Pipe
1st Safety Valve 2 50.3 48.3 568.0 4.0 Spring loaded 288020 288020 16.5
2nd Safety Valve 2 49.8 48.3 568.0 3.0 type Hydraulic 992830 992830 57.0
3rd Safety Valve 2 49.3 48.3 568.0 2.0 type Relief valve 77500 77500 4.4
Spring loaded Safety Valves Total Capacity 1,868,210 107.3

GRAND TOTAL 168.7
3
SOOT BLOWING PIPE SAFETY VALVE SETTING DIAGRAM
Sootblower Steam Parameters :

- Sootblowing steam pressure (at downstream of PRV) 25 kg/cm2(g)
- Maximum sootblowing steam flow 18720 kg/hr
- Sootblowing design steam flow for Safety Valve 30000 kg/hr
- Sootblowing steam Design Pressure 35.0 kg/cm2(g)
Percent of
Relieving Capa.
No. of Set Pressure Steam Blowdown Relieving steam Capa. of
S/V Open Close Temp. Ratio Capacity sootblowing
type
flow
Soot Blowing Pipe
Safety Valve 1 35 33.60 350.0 4.0 Spring loaded 30000 30,000 100.00
4
SAFETY VALVE SETTING DIAGRAM AT SUPERHEATER SYSTEM
Pressure
(Kg/cm2(g))
310 Design Press. : 294.9
at Separator area
Design Press. : 293.8
302.6
at Separator outlet conn. pipe
300
4%
294.9
290
4% ②
280 ①
Design Press. : 272.9
275.6
272.9
Separator Separator
outlet conn. pipe 270.2
Operating
270 Operating
4%
Pressure 267.4
Pressure 4%
: 277.0 kg/cm2g 3%
: 275.9 kg/cm2g 2%
260 ⑥ ⑤ ④
③
PRESSURE DROP
Superheater Outlet Operating
at Superheater System
Pressure : 255 kg/cm2g
250 : 20.9 kg/cm2
SEPARATOR SEPARATOR SYSTEM SUPERHEATER

outlet conn. PRESSURE DROP OUTLET PIPE
Note 1. ①,②,③,④ : Spring Loaded type Safety Valve

2. ⑤ : Power operated impulse type Safety Valve
3. ⑥ : Power operated impulse type relief valve
① ③④⑤⑥
②
②
③④⑤⑥
①
②
SEPARATOR & SH SYSTEM FLOW SCHEME
5
SAFETY VALVE SETTING DIAGRAM AT REHEATER SYSTEM
Pressure
(Kg/cm2(g))
55 54.6
54.1
53.5
53.0 4% Design Pressure : 53.0
53 4%
4%
4% ④
③
②
① 49.8 50.3
50 49.3
3%
2% 4%
48 ⑦ ⑥
Reheater Inlet ⑤
Operating Pressre :
45.63 kg/cm2g
45 PRESSURE DROP
at Reheater Tube : Reheater Outlet
1.69 kg/cm 2 Operating Pressure :
43.94 kg/cm2g
43
COLD REHEAT PIPE SYSTEM HOT REHEAT PIPE

PRESSURE DROP
Note 1. ①,②,③,④,⑤ : Spring Loaded type Safety Valve

2. ⑥ : Power Operated Impulse type Safety Valve
3. ⑦ : Power Operated Impulse type Relief Valve
⑦
①③ ⑥
⑤
②④
⑤
① ③
⑥
②④ ⑦
REHEATER SYSTEM FLOW SCHEME
6
SAFETY VALVE SETTING DIAGRAM AT SOOTBLOWING SYSTEM
Pressure
(Kg/cm2(g))
40
35.0 Design Pressure : 35.0

35
4%
30
25
Sootblowing system Operating Pressre : 25 kg/cm2g
SOOTBLOWING PIPE AT DOWNSTREAM OF PRV
7
VI. 8. SAFETY VALVE DATA
DESIGN BASIS FOR POWER OPERATED IMPULSE SAFETY VALVES :
Per Technical Specification Section VI-A(Part A), Part B / Sub-section-II-M1

(SG AND AUX.), Clause No. 16.02.01 & Sub-section-II-M4 (PCP), Clause No.8.03.00
1. Minimum Discharge Capacities.
A. Power operated impulse safety valve 40%BMCR at superheater outlet
60% of Reheat flow at BMCR at

reheater outlet
2. Blow down 10% to 15%
8 IV.8 Safety valve-cover.doc

SUPERHEATER POWER ACTUATED IMPULSE TYPE
Main Steam Parameters :

- Boiler Maximum Continuous Rating Steam Flow 2,225,000 kg/hr
- Superheater Header Outlet Steam Pressure 255 kg/cm2(g)
- Superheater Header Outlet Piping Design Pressure 272.9 kg/cm2(g)
No. of Relieving Capa.

Set Pressure Steam Blowdown Relieving Percent of
Description Safety Type of each valve
Open Close Temp. Ratio Capacity BMCR flow
Valve type
Superheater Outlet

3rd Safety Valve 2 270.2 262.1 540.0 3.0 type Hydraulic 667500 667500 30.0
4th Safety Valve 2 267.4 262.1 540.0 2.0 type Relief valve 255200 255200 11.5
GRAND TOTAL 41.5
9
HOT REHEAT PIPE POWER ACTUATED IMPULSE TYPE
Reheater Steam Parameters :

- Boiler Maximum Continuous Rating Reheater Flow 1,741,800 kg/hr
- Hot Reheat Pipe Pressure(at Reheater outlet Header) 43.94 kg/cm2(g)
- Cold / Hot Reheat Pipe Design Pressure 53.0 kg/cm2(g)
Relieving Capa.
No. of Set Pressure Steam Blowdown Relieving Percent of
S/V Open Close Temp. Ratio Capacity BMCR flow
type
Hot Reheat Pipe
2nd Safety Valve 2 49.8 48.3 568.0 3.0 type Hydraulic 992830 992830 57.0
3rd Safety Valve 2 49.3 48.3 568.0 2.0 type Relief valve 77500 77500 4.4
GRAND TOTAL 61.4
10
SAFETY VALVES SETTING
FOR HIGH CAPACITY PRDS DOWNSTREAM
Service Safety valves for High Capacity PRDS

Safery Valves Tag. No. 10LBG11-AA191, 10LBG11-AA192, 10LBG11-AA193(Total 3ea/per boiler)
Location Downstream piping of HC PRDS
Relieving Capacity The relieving capacity of safety valves shall not be less than the full capacity of
HC PRDS(including the spray quantity).(As the MOM of 5th TCM)
High Capacity PRDS Parameters :

- Full Capacity of HC PRDS(Refer to Attachment #1) 172,754 kg/hr
System Operating & Design Pressure :
- Operating Pressure of High Capacity PRDS downstream 15 kg/cm 2(g)
- Design Pressure of High Capacity PRDS downstream 20 kg/cm 2(g)
Relieving Percent
Set Pressure Blowdown
Description Tag. No. Type Capacity per of Full
Open Close Ratio
each valve Capacity
kg/cm 2(g) kg/cm 2(g) (%) (kg/hr) (%)
1st Safety Valve 10LBG11-AA191 20 18.0 10.0 Spring loaded 57,585 33.3
2nd Safety Valve 10LBG11-AA192 21 18.9 10.0 Spring loaded 57,585 33.3
3rd Safety Valve 10LBG11-AA193 22 19.8 10.0 Spring loaded 57,585 33.3
Total 100
11
SAFETY VALVE SETTING TABLE
FOR HT UNIT AUX. STEAM HEADER
Service Safety valves for HT AUX. STEAM HEADER

Safery Valves Tag. No. LBG11-AA194, LBG11-AA195(Total 2ea/per boiler)
Location HT Unit Aux. Steam Header
Relieving Capacity The relieving capacity of safety valves shall not be less than the full capacity of LC PRDS.
(As the MOM of 5th TCM)
Low Capacity PRDS Parameters :

- Full Capacity of LC PRDS(Refer to Attachment #2) 40,000 kg/hr
System Operating & Design Pressure :
- Operating Pressure of Low Capacity PRDS downstream 15 kg/cm 2(g)
- Design Pressure of Low Capacity PRDS downstream 20 kg/cm 2(g)
Relieving Percent
Set Pressure Blowdown
Description Tag. No. Type Capacity per of Full
Open Close Ratio
each valve Capacity
kg/cm 2(g) kg/cm 2(g) (%) (kg/hr) (%)
Safety Valve 10LBG11-AA194 20 18.0 10.0 Spring loaded 8,000 20.0

Safety Valve 10LBG11-AA195 21 18.9 10.0 Spring loaded 32,000 80.0
Total 100
12
IV. 9. SOOT BLOWER PHILOSOPHY
TABLE OF CONTENTS
TITLE PAGE NO.
SOOTBLOWER SELECTION DATA AND PHILOSOPHY
Soot Blower Selection Data and Philosophy…….. …………………………………………… 1

Wall Blowers………….. …………………………………………………………………………….. 1
Retract Blowers, Furnace Probe & Half Retracts…… ………………………………………. 2
Air Pre-Heaters……… ………………………………………………………………………………. 2
Soot Blower Selection Data………………………………………………………………………… 3
Retractable Soot Blower Locations………… …………………………………………………… 3
Wall Blower Locations…………… ………………………………………………………………… 4
i IV.9 Soot blower selection data and philosphy.doc

Soot blower selection data and philosophy
1. Soot blower selection philosophy
The sootblower selection is dependent on the expected slagging and fouling potential of the
ash of coals.
Sipat coals range in higher heating value from 3000 ~ 4000 kcal/kg. The ash content varies
from 32% to 48% with silica and alumina forming 88% to 92 % in the ash and the ash fusion
temperature (initial deformation) ranges between 1100℃ and 1450℃. The sulphur content
is less than 0.6%.
As a result of these and characteristic of slagging, fouling potential of ash analysis forwarded
to Doc. No.: T04019-PE-C0001, Sipat coal is generally of the non-slagging, fouling type which
are normal property for indian coal as described below.
Note : Characteristics of Indian Coals

Coal being the major fossil fuel for centuries to come, a brief look at its characteristics is
relevant here. Considering the type of coal formation, the major part of the Indian coals
theses coals presently range in higher heating value from about 3000 to 4000 Kcal/Kg. The
ash content varies from 35 to 50 percent with silica and alumina forming 80 to 90 percent in
the ash, thus making the pulverized coal as well as the ash highly abrasive. The sulphur
content is generally less than 0.5 percent in most of the areas leading to a fairly high resistivity
of the ash. The ash fusion temperature ranges between 1100 and 1500℃ and the coals are
generally of the non-slagging type.
For the non-slagging, fouling type, the sootblower blowers are selected as basic guide below;
WALL BLOWERS
Futures only at elevation below burners -no openings.
Two rows of openings above burners, each row has:
Blowers in the two openings closest to hot comers.
Blower in every other opening, after the two with blowers, going toward cold comers.
Third row above burners -futures only, no openings.
Note: "Futures" means space allowed for future wallblowers but no bent tube openings or
1 IV.9 Soot blower selection data and philosphy.doc

sealboxes are supplied. "Openings only" means bent tube inserts with blanked off seal
boxes packed with refractory
RETRACT BLOWERS, FURNACE PROBE & HALF TRACKS

Retract Blowers are located on the ash deposits area of superheater and reheater area.
For same objects, half tracks are located on economizer area.
Furnace temperature probes are monitoring flue gas temperature at the top of furnace
during the lighting-off period and remains in the furnace until reheater steam flow has been
established. These are usually located below the platen 'midway between the front and
rear of the platen.
AIR PREHEATERS
The sootblower is normally located at the cold end of the air preheater where deposit
formation usually occurs.
Generally, the gas side is the preferred location for this equipment in order to eliminate fly
ash being carried into the burner wind boxes.
In addition to the design concepts mentioned above, the results of investigation about the
existing sootblowing systems were sufficiently taken into consideration for Sipat project after
the site survey of Korba and Talcher Power Plants.
If the actual performance of steam generators requires provision of additional sootblowers/

Retractable soot blowers, the same shall be installed by DOOSAN free of charges.

2. Sootblower selection data
(1) Retractable sootblower locations
1020 oC 877 oC 800 oC 730 oC
◎ 15860 mm
◎ ◎
◎ 3658mm
3658mm ● ●
3658mm (Typ.)
(Typ.) 610 mm
(Typ.) ●
◎ ● LTRH
1075 oC ● ● ● 610 oC
● LTRH
1220 mm ● ◎ ◎ 550 oC
(Typ.) LTRH
914 mm
▲ 18256 mm
914 mm
Future Econ.
◎
o
1538 C ◆ 490 oC
Economizer
FW = 18816 mm ◆ 450 oC
FD = 18144 mm Economizer
◆
Economizer
◆
Economizer
Fuels: Coal ■ Heavy Oil □ Coal Type: High Vol. C , Ash Softening Temp. Min. 1100 (IDT) °C
Blowing Medium: Steam ■ Air □ , Location of Steam Take-off: Division SH Outlet
Single Double Total
Side Side No.
Present ● (B) - 9 18 KEY
Retractable
Opening ◎ (O) - 8 16 F = Future - Allow space for future
Sootblowers
Future ○ (F) - - - blower only no bent tubes
O = Opening Only - Bent tubes
Present ◆ (B) - 4 8
Half Track B = Opening with blower
Opening (O) - 7 14
Sootblowers - Complete installation
Future ◇ (F) - - -
Temp. Probe Present ▲ - 1 2
AH Blowers : Cold End * 1 Location/Conditions 4
* = per AH Hot End * of AH steam take-off
Total = per BLR Fut. H.E. * 1 : 4

(2) Wall blower locations
2438 mm (Typ.) 2438 mm (Typ.) 2438 mm (Typ.) 2438 mm (Typ.)
Row 4 O B O B O O O O O O B O B O O B O B O O O O O O B O B O
3048 mm 3048 mm 3048 mm 3048 mm
Row 3 B B O B O B B B B O B O B B B B O B O B B B B O B O B B
3048 mm 3048 mm 3048 mm 3048 mm
Row 2 B B B B B B B B B B B B B B B B B B B B B B B B B B B B
2438 mm 2438 mm 2438 mm 2438 mm
CL Top Fuel CL Top Fuel CL Top Fuel CL Top Fuel
Nozzle Nozzle Nozzle Nozzle
Width = 18816 mm Width = 18816 mm Width = 18144 mm Width = 18144 mm
CL Bot. Fuel CL Bot. Fuel CL Bot. Fuel CL Bot. Fuel

Nozzle Nozzle Nozzle Nozzle
2438 mm 2438 mm 2438 mm 2438 mm
Row 1 F F F F F F F F F F F F F F F F F F F F F F F F F F F F
H Front Wall C C Rear Wall H H Right Side C C Left Side H
View from outside front wall View from outside right side wall
C H
KEY C
H
F = Future - Allow space for future blower only no
H = Hot
bent tubes
C = Cold
O = Opening Only - Bent tubes
B = Opening with wall blower - Complete installation C H
H C
Front
Wall blowers B O F
Location : Row 1 - - 28
Row 2 28 - -
Row 3 20 8 -
Row 4 8 20 -
Total 56 28 28

IV. 10. DUCT DESIGN DATA AND SCHEMATIC
TABLE OF CONTENTS
TITLE PAGE NO.
Duct Design Data and Schematic……………….…………………………………………………………... 1
i IV.10 Duct Design Data and Schematic-cover.doc

5. Duct schematic and design data
Pluv. Pluv. Pluv. Pluv. Pluv.
K K K K K
D1
H1 J1 H1 J1 H1 J1 H1 J1 H1 J1
(AIR) "B"
PRI. AH
Ci PA FAN C D J
"B"
H2 J2
H
(AIR) "A"
PRI. AH
Ci PA FAN C D J
"A"
H1 J1 H1 J1 H1 J1 H1 J1 H1 J1
D1
K K K K K
Pluv. Pluv. Pluv. Pluv. Pluv.
(GAS) "A" (GAS) "A"

PRI. AH SEC. AH
E
F1 G1
E1 WINDBOX M'
F
G
(AIR) "A"
SEC. AH
Bi FD FAN B F2 G2 ID FAN
"B" O M
"B"
FURNACE EP
L B1 N G' O'
(GAS) "B" (GAS) "B"

PRI. AH SEC. AH
ID FAN
(AIR) "B"
SEC. AH
F1 G1 O M
Bi FD FAN B "B"
"B" G
F
B1 E1 WINDBOX F2 G2
E
Schematic for Draft System
Excess air, % 25% (STOICH) 20% (STOICH) Air &

Coal Firng Worst Worst Gas Side
I 100% BMCR 60%BMCR (Rev.) Duct Size One Total Duct Design
1) 1)
t Mass Opera. Density Volume Max. Mass Opera. Density Volume Max. Duct Duct Duct Design Pressure
Description e Flow Temp. Flow Vel. Flow Temp. Flow Vel. Width Depth Area Q'ty Area Temp. mm wg
3
m kg/hr ℃ kg/m m3/sec m/sec kg/hr ℃ kg/m3 m3/sec m/sec m m m2 m2 ℃ Pos. Neg.
Sec. Air Fan Inlet Bi 885,912 27 1.127 218 14.2 1,005,673 27 1.127 248 16.0 3.21 4.80 15.4 2 30.8 50 +660 -660
Sec. Air to AH B 885,912 31 1.112 221 14.2 1,005,673 31 1.112 251 16.0 3.95 3.95 15.6 2 31.2 50 +660 -660
Bypass Duct to Sec. AH B1 885,912 31 1.112 221 12.7 1,005,673 31 1.112 251 14.5 4.40 3.95 17.4 2 34.8 50 +660 -660
Cold Sec. Air Xover L 885,912 31 1.112 221 14.2 1,005,673 31 1.112 251 16.0 3.95 3.95 15.6 1 15.6 50 +660 -660
Hot Sec. Air to WB E 821,012 300 0.590 386 15.7 469,937 257 0.638 205 8.3 5.95 4.14 24.6 2 49.3 304 +660 -660
WB to WB Conn. Duct E1 821,012 300 0.590 386 15.7 469,937 257 0.638 205 8.3 5.95 4.14 24.6 2 49.3 304 +660 -660
Hot Sec. Air Xover N 410,506 300 0.590 193 13.0 469,937 257 0.638 205 13.7 4.14 3.60 14.9 1 14.9 304 +660 -660
PA Fan Inlet Ci 586,499 27 1.127 145 14.0 674,324 27 1.127 166 16.0 3.21 3.21 10.3 2 20.6 50 +660 -660
Air from PA Fan C 586,499 34 1.101 148 13.9 674,324 34 1.101 170 16.0 3.54 3.00 10.6 2 21.2 50 +1425 -660
Air to Pri. AH D 466,547 34 1.101 118 11.3 660,188 34 1.101 167 16.0 3.46 3.00 10.4 2 20.8 50 +1425 -660
Bypass Duct to Pri. AH D1 466,547 34 1.101 118 11.3 660,188 34 1.101 167 16.0 3.46 3.00 10.4 2 20.8 50 +1425 -660
Cold Air to Mills H 119,952 34 1.101 30 6.7 14,136 34 1.101 4 0.8 2.12 2.12 4.5 2 9.0 50 +1425 -660
Cold Air per Mill H1 26,656 34 1.101 7 5.1 2,827 34 1.101 1 0.5 1.15 1.15 1.3 10 13.2 50 +1425 -660
PA Air Xover H2 586,499 34 1.101 148 13.9 674,324 34 1.101 170 16.0 3.54 3.00 10.6 1 10.6 50 +1425 -660
Hot Air to Mills J 417,947 290 0.601 193 12.0 604,788 243 0.656 256 15.9 6.05 2.665 16.1 2 32.2 304 +1003 -660
Hot Air per Mill J1 92,877 293 0.598 43 13.5 120,958 243 0.659 51 15.9 1.19 2.69 3.2 10 32.0 304 +1003 -660
Hot Pri. Air Xover J2 278,632 293 0.598 129 13.5 362,874 243 0.655 154 16.0 3.60 2.665 9.6 1 9.6 304 +1003 -660
2) 2)
Total Air per Mill K 130,771 258 0.637 57 15.7 130,771 239 0.661 55 15.2 3.048 1.19 3.6 10 36.3 271 +876 -660
Gas Leaving Econ. F 1,543,482 327 0.576 744 11.9 1,813,486 285 0.619 814 13.0 6.25 10.00 62.5 2 125.0 332 +660 -660
Gas to Sec. AH F1 1,032,188 327 0.576 498 12.8 1,129,774 285 0.619 507 13.0 4.09 9.50 38.9 2 77.7 332 +660 -660
Gas to Pri. AH F2 511,294 327 0.576 247 10.4 683,712 285 0.619 307 13.0 5.75 4.12 23.7 2 47.4 332 +660 -660
Gas from Sec. AH G1 1,097,088 132 0.854 357 12.6 1,195,574 113 0.893 372 13.0 4.66 6.08 28.3 2 56.7 138 +660 -660
Gas from Pri. AH G2 559,894 132 0.854 182 10.2 739,112 114 0.886 232 13.0 6.80 2.62 17.8 2 35.6 138 +660 -660
Gas from Sec.& Pri. AH G 1,656,982 132 0.854 539 11.5 1,934,686 113 0.890 604 12.9 6.42 7.30 46.9 2 93.7 138 +660 -660
Gas Xover before EP G' 828,491 132 0.854 269 6.5 967,343 113 0.890 302 7.3 6.42 6.42 41.2 1 41.2 138 +660 -660
Gas Xover from EP O' 828,491 130 0.858 268 6.5 967,343 111 0.895 300 7.3 6.42 6.42 41.2 1 41.2 138 +660 -660
Gas to ID Fan O 1,656,982 130 0.858 536 11.2 1,934,686 111 0.895 600 12.5 6.42 7.47 48.0 2 95.9 138 +660 -660
ID Fan Outlet M 1,656,982 130 0.858 536 11.7 1,934,686 111 0.895 600 13.0 6.11 7.50 45.8 2 91.7 138 +660 -660
Gas to Common Stack M' 3,313,964 130 0.858 1073 12.7 1,934,686 111 0.895 600 7.1 7.70 11.00 84.7 1 84.7 138 +660 -660
Note : 1) Refer to attachment for air & gas weight calculation
2) Maximum Mill Air Flow
IV. 11. PREDICTED PERFORMANCE DATA
TABLE OF CONTENTS
TITLE PAGE NO.
Predicted Performance Data
Design coal……………………………………………………………………………………………. 1
Worst coal…………………………………………………………………………………………..…40
Best coal………………………………………………………………………………………………79
i IV.11 Predicted performance data-cover.doc

3.00.00 ANTICIPATED PERFORMANCE DATA OF STEAM GENERATOR FOR DESIGN/WORST/BEST COALS BASED ON DESIGN
AMBIENT AIR CONDITION OF 27℃ & 60%RH
A) DESIGN COAL
Modified Sliding Pressure Operation Pure Sliding Pressure Operation
100% VWO 100% 80% 60% 50% 100% 80% 60% 50% Both HP One String 60% 30%
BMCR TMCR TMCR TMCR TMCR TMCR TMCR TMCR TMCR Heaters HP Heaters BMCR BMCR
out of out of (One
operation operation Stream)
3.01.00 General
i) Steam flow at superheater

outlet (Tonnes/hr) 2225 2160 2023.75 1572.47 1158.41 963.76 2035.24 1592.96 1178.13 982.34 1839.5 1960.0 1335.0 596.1
ii) Steam pressure at super-

heater outlet (kg/cm2) abs 256 255 254.45 238.01 179.42 151.25 242.89 193.27 145.52 122.33 252.92 254.98 204.40 93.9
iii) Steam temperature at

superheater outlet (degC) 540 540 540 540 540 540 540 540 540 540 540 540 540 540
iv) Reheater steam flow

(Tonnes/hr) 1741.82 1753.03 1678.37 1328.96 996.95 836.41 1686.33 1343.65 1012.39 851.48 1784.2 1784.34 1138 517.2
v) Steam pressure at reheater

inlet (kg/cm2)(abs) 48.3 48.7 46.7 37.2 28.1 23.6 47.0 37.6 28.5 24.0 50.5 50.1 32.2 14.6
vi) Steam temperature at

reheater outlet (degC) 568 568 568 568 568 568 568 568 568 568 568 568 568 540
vii) Steam temperature at

reheater inlet (degC) 299 300 296 281 286 289 303 306 310 313 309 306 284 294
viii) Pressure drop across

reheater (kg/cm2) 1.69 1.70 1.62 1.30 1.02 0.88 1.64 1.34 1.05 0.91 1.70 1.70 1.16 0.57
ix) Control point (% TMCR) 50 50 50 50 50 50 50 50 50 50 50 50 50 50
x) Feed water temperature

(degC) 289.64 290 286.23 270.35 254.09 244.34 287.28 273.24 256.75 246.95 196.15 243.54 261 219
xi) Steam generator efficiency

based on the HHV of design
coal 86.28 86.26 86.29 86.69 86.88 86.85 86.29 86.61 86.85 86.91 87.31 87.17 86.86 86.24
xii) Heat liberated by fuel per
SIPAT SUPER THERMAL POWER PROJECT

STAGE-I (3x 660MW)
MAIN PLANT PACKAGE PAGE
PART-A(STEAM GENERATOR AUXILIARIES) 1 OF 117
out of out of (One
unit furnace volume

(x106kal/m3/hr) 0.073 0.071 0.067 0.055 0.042 0.036 0.068 0.055 0.042 0.036 0.071 0.071 0.047 0.023
xiii) Furnace cooling factor

(x106kcal/m2/hr) 0.174 0.169 0.161 0.129 0.099 0.084 0.161 0.130 0.099 0.085 0.168 0.167 0.112 0.053
xiv) Burner zone heat release

rate (x106kcal/m2/hr) 1.192 1.165 1.107 0.897 0.688 0.584 1.110 0.902 0.694 0.589 1.170 1.159 0.780 0.372
xv) Plan area heat release

rate (x106kcal/m2/hr) 4.60 4.49 4.26 3.43 2.62 2.22 4.27 3.45 2.64 2.24 4.44 4.43 2.97 1.40
xvi) Total number of coal

pulverisers 10 10 10 10 10 10 10 10 10 10 10 10 10 10
xvii) Number of coal pulverisers

working with design coal 7 7 7 6 5 4 7 6 5 4 7 7 5 3
xviii) Weight of coal fired

(tonnes/hr) 471.8 461.1 438.1 354.9 272.4 231.1 439.3 356.8 274.4 233.2 463.1 458.6 308.5 147.3
xix) Furnace exit gas tempe-

rature (degC) 988 1003 1004 977 910 880 994 943 894 864 1000 1007 943 754
xx) Dryness fraction of steam

at drum outlet (%) N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
xxi) Steam Purity at SH

outlet (ppm)
a) Total dissolved Max

solids 0.002
Max
b) Silica 0.002
Max
c) Sodium 0.002
d) Chlorides 0.002
Max
e) Copper 0.001
Max
f) Iron 0.005

STAGE-I (3x 660MW)
out of out of (One
xxii) Furnish calculations for

plan area heat release
rate, burner zone heat
release rate, volumetric
heat release rate furnace
cooling factor & heat input
per burner alongwith details
of EPRS calculation, basis
for the fouling factor/surface
adjustment factor considered Refer to Furnace Performance and Sizing Calculation (T04019-SY-C0003)
3.02.00 Temperature ( degC)
3.02.01 Air
A) Bottom Burner Elevations

in Service
i) Identify Mills/Elevations
in service B~H B~H B~H B~G B~F C~F B~H B~G B~F C~F B~H B~H B~F C~E
ii) Burner Tilts (if appli

cable( deg) 8 25 25 25 25 25 25 25 25 25 25 25 25 0
iii) Design Ambient 27 27 27 27 27 27 27 27 27 27 27 27 27 27
iv) Inlet to the RAPH

(Primary air) 34.7 34.7 34.4 34.0 33.9 42.0 34.4 34.0 33.9 39.0 51.0 34.8 33.9 57.0
v) Outlet of RAPH
(Primary air) 295 295 293 276 258 250 295 279 262 255 223 258 254 222
vi) Inlet to the RAPH

(Secondary air) 30.9 30.9 30.6 30.3 33.0 41.6 30.6 30.3 30.1 35.6 49.6 30.9 30.1 55.5
vii) Outlet of the RAPH

(Secondary air) 296 296 294 277 261 251 296 282 265 256 229 262 259 222
viii) Secondary air at

Inlet to burners 296 296 294 277 261 251 296 282 265 256 229 262 259 222

STAGE-I (3x 660MW)
out of out of (One
ix) Hot Primary air in

the common duct
before pulverisers 295 295 293 276 258 250 295 279 262 255 223 258 254 222
x) Hot primary air at the

inlet to pulverisers 208 206 202 198 191 196 202 198 191 196 206 206 201 184
B) Middle Burner Elevations

in Service
in service C~I C~I C~I C~H D~H D~G C~I C~H D~H D~G C~I C~I D~H N/A

cable (deg) -30 0 20 25 25 13 7 -5 0 -25 -1 10 25 N/A
iii) Design Ambient 27 27 27 27 27 27 27 27 27 27 27 27 27 N/A

(Primary air) 34.7 34.7 34.4 34.0 33.9 42.0 34.4 34.0 33.9 39.0 51.0 34.7 33.9 N/A
v) Outlet of RAPH
(Primary air) 295 295 291 275 258 249 292 277 261 251 223 256 254 N/A

(Secondary air) 30.9 30.9 30.6 30.3 30.1 40.6 30.6 30.3 30.1 35.6 50.6 30.9 30.1 N/A

(Secondary air) 296 296 293 277 260 249 294 281 263 252 229 262 259 N/A

Inlet to burners 296 296 293 277 260 249 294 281 263 252 229 262 259 N/A

the common duct
before pulverisers 295 295 291 275 258 249 292 277 261 251 223 256 254 N/A

inlet to pulverisers 208 206 202 197 191 196 202 198 192 196 206 205 202 N/A
C) Top Burner Elevations

STAGE-I (3x 660MW)
out of out of (One
in Service
in service D~J D~J D~J E~J F~J G~J D~J E~J F~J G~J D~J D~J F~J N/A

cable( deg) -30 -30 -8 12 0 -15 -25 -25 -25 -25 -25 -25 10 N/A

(Primary air) 34.7 34.7 34.4 34.0 33.9 42.0 34.4 34.0 33.9 41.0 51.0 34.7 33.9 N/A
v) Outlet of RAPH
(Primary air) 295 295 291 274 257 248 293 277 260 250 222 257 252 N/A

(Secondary air) 30.9 30.9 30.6 30.3 30.1 40.6 30.6 30.3 30.1 35.6 50.6 30.9 30.1 N/A

(Secondary air) 296 296 293 278 259 249 295 280 262 251 229 262 259 N/A


the common duct

3.02.02 Fuel & air mixture
i) Fuel and air mixture

leaving the p!ulveriser 76.7 76.7 76.7 76.7 76.7 76.7 76.7 76.7 76.7 76.7 76.7 76.7 76.7 76.7
ii) Fuel & air mixture

entering the burner 76.7 76.7 76.7 76.7 76.7 76.7 76.7 76.7 76.7 76.7 76.7 76.7 76.7 76.7
3.02.03 Flue Gases (Actual Temperatures)

STAGE-I (3x 660MW)
out of out of (One

in Service
i) Identify Mills/elev-
ations in service B~H B~H B~H B~G B~F C~F B~H B~G B~F C~F B~H B~H B~F C~E
ii) Burner Tilts (if appli-

cable) (deg) 8 25 25 25 25 25 25 25 25 25 25 25 25 0
iii) Theoretical combustion

temperature in the
combustion zone 1579 1565 1531 1457 1382 1345 1543 1491 1404 1359 1539 1538 1386 1224
iv) At furnace arch level

(Furnace arch level is
defined as the level at
the entrance to radiant
super heater) 1324 1339 1328 1293 1243 1213 1332 1305 1248 1215 1338 1334 1266 1080
v) At Furnace arch exit (as

defined in the specifi-
cation for FEGT) 988 999 986 946 888 868 986 939 882 862 996 996 916 754
vi) Entrance to superheater
Stage I 1324 1339 1328 1293 1243 1213 1332 1305 1248 1215 1338 1334 1266 1080
Stage II 1078 1093 1078 1041 987 978 1080 1040 984 975 1091 1089 1013 858
Stage III 855 862 854 815 759 734 852 804 751 727 860 862 784 631
vii) Exit of Superheater
Stage I 1078 1093 1078 1041 987 978 1080 1040 984 975 1091 1089 1013 858
Stage II 988 999 986 946 888 868 986 939 882 862 996 996 916 754
Stage III 727 731 725 693 648 625 722 682 640 619 727 730 667 565
viii) Entrance to reheater

STAGE-I (3x 660MW)
out of out of (One
Stage I 721 723 718 686 642 618 715 674 633 612 720 723 660 557
Stage II 988 999 986 946 888 868 986 939 882 862 996 996 916 754
ix) Exit of reheater
Stage I 489 490 487 461 436 420 487 462 439 427 491 493 446 383
Stage II 874 882 873 834 779 754 871 824 771 748 879 881 804 652
x) Entrance of econo-
mizer 489 490 487 461 436 420 487 462 439 427 491 493 446 383
xi) Exit of economizer 322 322 319 300 279 267 319 301 281 268 251 288 288 234
xii) Entrance to primary

air heater 322 322 319 300 279 267 319 301 281 268 251 288 288 234
xiii) Entrance to secondary

air heater 322 322 319 300 279 267 319 301 281 268 251 288 288 234
xv) Exit of primary air

heater (corrected) 133 133 130 120 111 110 132 123 113 111 111 113 119 110
xvi) Exit of secondary air

xvii) Exit of primary air

heater (Uncorrected) 144 144 142 132 124 124 144 136 126 125 118 123 127 125
xviii) Exit of secondary air

xix) Exit of air preheater

(average considered) 132 132 130 120 111 110 131 123 114 110 110 114 119 110
xx) Entrance of electrostatic

precipitator 132 132 130 120 111 110 131 123 114 110 110 114 119 110
xxi) Exit of electrostatic

precipitator 130 130 128 118 109 108 129 121 112 108 108 112 117 108

STAGE-I (3x 660MW)
out of out of (One
xxii) Entrance of ID fans 130 130 128 118 109 108 129 121 112 108 108 112 117 108
xxiii) Entrance to Chimney 134 134 132 121 112 111 133 124 115 111 111 115 120 111

in Service
ations in service C~I C~I C~I C~H D~H D~G C~I C~H D~H D~G C~I C~I D~H N/A

cable ) (deg) -30 0 20 25 25 13 7 -5 0 -25 -1 10 25 N/A

temperature in the
combustion zone (deg C) 1579 1573 1558 1485 1404 1359 1559 1499 1412 1362 1545 1557 1410 N/A

super heater) 1324 1347 1361 1342 1313 1254 1348 1313 1266 1197 1345 1355 1327 N/A
v) At furnace arch exit (as

cation for FEGT) 988 1003 1004 968 907 880 994 943 889 864 1000 1007 936 N/A
Stage I 1324 1347 1361 1342 1313 1254 1348 1313 1266 1197 1345 1355 1327 N/A
Stage II 1078 1099 1106 1076 1018 1000 1093 1046 996 977 1097 1106 1046 N/A
Stage III 855 863 861 823 764 736 854 805 753 728 862 866 791 N/A
Stage I 1078 1099 1106 1076 1018 1000 1093 1046 996 977 1097 1106 1046 N/A
Stage II 988 1003 1004 968 907 880 994 943 889 864 1000 1007 936 N/A

STAGE-I (3x 660MW)
out of out of (One
Stage III 727 730 724 692 647 623 721 681 641 619 727 729 666 N/A
Stage I 721 723 718 686 639 616 714 674 633 612 720 722 659 N/A
Stage II 988 1003 1004 968 907 880 994 943 889 864 1000 1007 936 N/A
Stage I 489 488 481 454 429 416 483 461 438 427 491 489 439 N/A
Stage II 874 883 881 843 786 757 874 825 774 749 881 886 812 N/A
mizer 489 488 481 454 429 416 483 461 438 427 491 489 439 N/A
xi) Exit of economizer 322 322 317 298 277 265 318 300 281 268 251 286 286 N/A

air heater 322 322 317 298 277 265 318 300 281 268 251 286 286 N/A

air heater 322 322 317 298 277 265 318 300 281 268 251 286 286 N/A

heater (corrected) 133 133 132 122 112 111 133 123 113 108 110 114 120 N/A


heater (Uncorrected) 144 144 143 134 125 124 144 135 126 122 117 123 127 N/A


(average considered) 132 132 131 121 112 110 131 123 114 108 110 114 120 N/A

precipitator 132 132 131 121 112 110 131 123 114 108 110 114 120 N/A

STAGE-I (3x 660MW)
out of out of (One

precipitator 130 130 129 119 110 108 129 121 112 106 108 112 118 N/A
xxii) Entrance of ID fans 130 130 129 119 110 108 129 121 112 106 108 112 118 N/A
xxiii) Entrance to Chimney 134 134 133 122 113 111 133 124 115 109 111 115 121 N/A

in Service
ations in service D~J D~J D~J E~J F~J G~J D~J E~J F~J G~J D~J D~J F~J N/A

cable ) (deg) -30 -30 -8 12 0 -15 -25 -25 -25 -25 -25 -25 10 N/A

temperature in the

super heater) 1353 1349 1362 1356 1318 1267 1348 1326 1282 1241 1353 1352 1339 N/A

Stage I 1353 1349 1362 1356 1318 1267 1348 1326 1282 1241 1353 1352 1339 N/A
Stage II 1112 1102 1108 1090 1024 1012 1094 1063 1005 999 1107 1104 1058 N/A
Stage III 874 865 862 825 765 736 854 814 755 732 867 865 792 N/A

STAGE-I (3x 660MW)
out of out of (One
Stage I 1112 1102 1108 1090 1024 1012 1094 1063 1005 999 1107 1104 1058 N/A
Stage II 1015 1005 1006 977 910 886 996 957 894 877 1008 1006 943 N/A
Stage III 738 731 725 692 646 622 722 686 640 619 731 729 665 N/A
Stage I 731 724 718 684 639 614 714 678 633 612 723 722 658 N/A
Stage II 1015 1005 1006 977 910 886 996 957 894 877 1008 1006 943 N/A
Stage I 488 488 481 452 428 413 483 459 437 422 489 489 437 N/A
Stage II 893 884 882 846 786 758 874 834 776 753 887 885 813 N/A
mizer 488 488 481 452 428 413 483 459 437 422 489 489 437 N/A

air heater 322 322 317 297 277 264 318 300 280 267 251 286 285 N/A

air heater 322 322 317 297 277 264 318 300 280 267 251 286 285 N/A





STAGE-I (3x 660MW)
out of out of (One

precipitator 131 132 131 121 112 111 131 122 114 110 111 114 120 N/A

precipitator 129 130 129 119 110 109 129 120 112 108 109 112 118 N/A
3.02.04 Feed Water

in Service

cable ) (deg) 8 25 25 25 25 25 25 25 25 25 25 25 25 0
iii) Water entering

economizer 290 290 286 270 254 244 287 273 257 247 196 244 261 219
iv) Water leaving

economizer 341 342 341 329 315 306 340 326 316 307 297 321 319 280
v) Desuperheating spray
water temperature
a) Superheater 290 290 286 270 254 244 287 273 257 247 196 244 261 219
b) Reheater 191 191 191 181 169 161 191 181 169 161 196 195 169 144

in Service

STAGE-I (3x 660MW)
out of out of (One

cable ) (deg) -30 0 20 25 25 13 7 -5 0 -25 -1 10 25 N/A
iii) Water entering

economizer 290 290 286 270 254 244 287 273 257 247 196 244 244 N/A
iv) Water leaving

economizer 341 341 338 325 312 303 339 326 315 306 296 318 317 N/A
water temperature
a) Superheater 290 290 286 270 254 244 287 273 257 247 196 244 244 N/A
b) Reheater 191 191 191 181 169 161 191 181 169 161 196 195 169 N/A

in Service

cable ) (deg) -30 -30 -8 12 0 -15 -25 -25 -25 -25 -25 -25 10 N/A
iii) Water entering

economizer 290 290 286 270 254 244 287 273 257 247 196 244 244 N/A
iv) Water leaving

economizer 341 341 338 323 311 302 339 326 314 304 297 318 315 N/A
water temperature
a) Superheater 290 290 286 270 254 244 287 273 257 247 196 244 244 N/A
b) Reheater 191 191 191 181 169 161 191 181 169 161 196 195 169 N/A
3.02.05 Steam

STAGE-I (3x 660MW)
out of out of (One

in Service

cable ) (deg) 8 25 25 25 25 25 25 25 25 25 25 25 25 0
iii) Inlet of superheater
1st Stage 418 413 410 399 371 362 406 383 363 351 401 405 382 338
2nd Stage 451 447 444 435 423 411 442 427 417 406 433 439 430 421
3rd Stage 485 483 480 477 472 469 480 475 472 469 473 476 473 491
iv) Outlet of superheater
1st Stage 462 457 454 445 430 431 453 439 443 434 444 449 430 432
2nd Stage 492 489 487 485 490 490 487 484 492 492 480 483 490 518
3rd Stage 540 540 540 540 540 540 540 540 540 540 540 540 540 540
v) Inlet to reheater
1st Stage 299 300 296 281 286 289 303 306 310 313 309 306 284 294
2nd Stage 457 456 456 450 448 445 457 455 453 450 458 459 448 428
vi) Outlet to reheater
1st Stage 457 457 457 450 449 445 458 455 453 450 459 459 448 429
2nd Stage 568 568 568 568 568 568 568 568 568 568 568 568 568 540
vii) Outlet of seperator 412 407 404 394 362 349 401 376 349 334 397 401 375 315

in Service

STAGE-I (3x 660MW)
out of out of (One

cable ) (deg) -30 0 20 25 25 13 7 -5 0 -25 -1 10 25 N/A
1st Stage 417 412 406 395 371 362 405 383 363 351 400 404 383 N/A
2nd Stage 451 447 442 432 419 408 442 426 416 406 433 437 427 N/A
3rd Stage 485 483 480 477 472 470 480 475 471 469 472 476 474 N/A
1st Stage 462 456 451 441 441 436 452 438 445 425 443 447 439 N/A
2nd Stage 492 490 487 484 490 491 488 484 492 491 480 483 491 N/A
3rd Stage 540 540 540 540 540 540 540 540 540 540 540 540 540 N/A
1st Stage 299 300 296 281 286 289 303 306 310 313 309 306 284 N/A
2nd Stage 457 455 450 443 442 440 454 453 452 450 457 455 442 N/A
1st Stage 457 455 451 443 442 440 455 454 452 450 458 456 442 N/A
2nd Stage 568 568 568 568 568 568 568 568 568 568 568 568 568 N/A
vii) Outlet of seperator 412 407 402 391 362 349 400 376 349 334 396 399 375 N/A

in Service

STAGE-I (3x 660MW)
out of out of (One

cable ) (deg) -30 -30 -8 12 0 -15 -25 -25 -25 -25 -25 -25 10 N/A
1st Stage 411 411 406 394 371 362 405 380 363 351 399 406 383 N/A
2nd Stage 445 446 442 431 418 407 441 423 414 401 432 441 426 N/A
3rd Stage 481 482 480 477 472 470 480 473 471 468 471 476 474 N/A
1st Stage 455 456 451 440 441 436 451 435 447 435 442 452 441 N/A
2nd Stage 488 489 487 484 490 491 487 482 491 490 480 489 491 N/A
3rd Stage 540 540 540 540 540 540 540 540 540 540 540 540 540 N/A
1st Stage 289 299 296 281 286 289 303 300 310 309 305 306 284 N/A
2nd Stage 450 454 450 440 441 437 454 450 450 445 455 455 439 N/A
1st Stage 450 455 451 440 441 437 455 451 450 445 455 456 440 N/A
2nd Stage 568 568 568 568 568 568 568 568 568 568 568 568 568 N/A
3.03.00 Pressure

STAGE-I (3x 660MW)
out of out of (One
3.03.01 Air (mmwc)
i) Forced draft fan inlet

(with air duct, air foil -36 -34 -30 -18 -12 -8 -30 -20 -10 -10 -36 -34 -14 -4
and silencer)
ii) Forced draft fan discharge 228 220 205 167 140 153 206 168 140 154 303 217 194 122
iii) Air heater inlet

(Secondary air ) 200 194 182 152 131 146 183 153 131 147 275 191 184 119
iv) Air heater outlet

(Secondary air) 155 152 145 128 117 135 146 129 117 135 235 151 122 114
v) In burner windbox
(Secondary air) 102 102 102 102 102 102 102 102 102 102 102 102 102 102
vi) Primary air fan inlet

and silencer)
vii) Primary air fan discharge 884 877 861 835 803 825 861 835 804 826 982 890 904 774
viii) Air heater inlet (Primary air) 874 867 851 828 798 821 851 828 799 822 972 880 899 772
ix) Air heater outlet (Primary air) 831 825 811 797 775 803 811 797 776 804 902 827 805 761
x) Hot primary air in the

common duct before
pulverisers 808 802 790 781 764 778 790 781 765 779 793 797 790 746
xi) Cold primary air header 786 781 769 761 745 758 769 766 755 773 772 776 770 728
xii) Hot primary air at the

3.03.02 Fuel Side (mmwc)
i) In the pulveriser 658 688 620 596 561 584 620 596 563 586 648 643 613 496
ii) At the pulveriser outlet 299 335 279 267 249 261 279 267 250 262 294 291 276 203
iii) At the burners inlet 25 25 25 25 25 25 25 25 25 25 25 25 25 25

STAGE-I (3x 660MW)
out of out of (One
2
3.03.03 Feed Water (kg/cm ) abs
i) Inlet to economizer (at the

specified terminal point) 304.2 300.4 292.9 261.1 195.9 165.5 283.0 220.6 165.3 139.2 282.6 289.2 224.4 101.1
ii) At economizer inlet 301.2 297.6 290.3 259.1 194.3 164.0 280.4 218.6 163.7 137.7 280.3 286.7 222.7 99.8
iii) Outlet of economizer 295.0 291.6 284.6 254.4 190.1 160.0 274.7 213.8 159.5 133.8 274.8 281.1 218.3 96.0
iv) Attemperation water

for superheater 304.2 300.4 292.9 261.1 195.9 165.5 283.0 220.6 165.3 139.2 282.6 289.2 224.4 101.1
v) Attemperation water
for reheater 91.5 91.9 89.9 80.4 71.3 66.8 90.2 80.7 71.7 67.2 93.7 93.3 75.4 57.8
3.03.04 Separator
Pressure ( Kg/cm2) abs 278.0 274.8 271.0 248.2 187.7 158.3 260.8 207.2 156.7 131.7 266.2 270.2 213.5 99.4
3.03.05 Steam (kg/cm2)(abs)
i) Inlet of superheater 271.9 270.3 267.3 245.9 185.7 156.5 256.7 203.8 154.0 129.3 263.3 266.8 211.4 97.9
ii) Outlet of superheater 256.0 255.5 254.5 238.0 179.4 151.2 242.9 193.3 145.6 122.3 252.9 255.0 204.4 93.9
iii) Inlet to reheater 48.3 48.7 46.7 37.2 28.1 23.6 47.0 37.6 28.5 24.0 50.5 50.1 32.2 14.6
iv) Outlet of reheater 46.6 47.0 45.1 35.9 27.1 22.7 45.3 36.2 27.4 23.1 48.8 48.4 31.1 14.0
v) Inlet of seperator 278.0 275.8 271.8 248.7 188.0 158.7 261.7 207.7 157.1 132.1 266.8 270.9 213.9 99.5
vi) Outlet of seperator 277.0 274.8 271.0 248.2 187.7 158.3 260.8 207.2 156.7 131.7 266.2 270.2 213.5 99.4
3.04.00 Pressure Drop
3.04.01 Air Path: (mmwc)

STAGE-I (3x 660MW)
out of out of (One
i) Primary air circuit
a) In air ducts including

bends dampers,
vanes etc 150 115 169 180 195 199 169 185 203 212 232 162 172 247
b) Across aerofoil (flow

measuring device) 33 32 32 28 24 24 32 23 15 10 32 32 25 20
c) Across RAPH 43 42 40 31 23 18 40 31 23 18 70 53 94 11
d) Total loss through

the system 226 189 241 239 242 241 241 239 241 240 334 247 291 278
3.04.02 Fuel Path (mmwc)
i) Across the pulverisers 359 353 341 329 312 323 341 329 313 324 354 352 337 293
ii) In the fuel piping from

pulveriser outlet to burners 299 335 279 267 249 261 279 267 250 262 294 291 276 203
3.04.03 Flue Gas Path (mmwc)
i) Furnace pressure
(back draught) 3 3 3 3 3 3 3 3 3 3 3 3 3 3
ii) Across SH/RH

convection path 65 65 60 52 46 41 60 52 46 41 62 62 31 14
iii) Across economizers 26 24 22 14 8 6 22 14 8 6 23 24 24 24
iv) Across air heaters 84 82 80 62 45 35 80 62 45 35 103 89 157 22
v) In gas ducts
a) Between air heater

outlet and electrostatic
precipitator funnel
inlet 43 41 37 25 17 13 38 26 16 13 43 41 18 6

STAGE-I (3x 660MW)
out of out of (One
b) Between outlet of
electrostatic precipitator
funnels & inlet of ID fan 23 22 20 14 9 7 20 14 9 7 23 22 10 3
c) Between ID fan outlet

and chimney inlet 13 12 11 8 5 4 11 8 5 4 13 13 5 2
vi) Total loss through the system 289 286 262 197 145 119 263 198 142 119 302 283 260 77
3.04.04 Steam Path (kg/cm2)
i) Saturated steam conn-

ections including horizontal
and vertical hangers 5.1 4.5 3.7 2.3 2.0 1.8 4.1 3.4 2.7 2.4 2.9 3.4 2.1 1.5
ii) Superheater
Stage I 3.3 3.0 2.6 1.4 1.3 1.1 2.8 2.0 1.7 1.4 2.1 2.4 2.4 2.4
iii) Superheater
Stage II 4.3 4.0 3.5 2.1 1.7 1.4 3.8 2.8 2.2 1.9 2.8 3.2 1.9 1.1
iv) Superheater
Stage III 3.2 3.0 2.7 1.6 1.3 1.1 2.9 2.2 1.7 1.5 2.2 2.5 1.5 0.8
v) Superheater
desuperheater 2.3 2.2 1.9 1.2 0.9 0.8 2.0 1.6 1.2 1.0 1.5 1.7 1.7 1.7
vi) Reheater
Stage I 0.5 0.5 0.4 0.4 0.3 0.2 0.4 0.4 0.3 0.3 0.5 0.5 0.3 0.2
vii) Reheater
Stage II 0.8 0.8 0.8 0.6 0.5 0.4 0.8 0.6 0.5 0.4 0.8 0.8 0.6 0.3
viii) Reheater
desuperheater 0.06 0.06 0.05 0.03 0.02 0.01 0.05 0.03 0.02 0.01 0.04 0.06 0.02 0.00
3.04.05 Feed Water Path (kg/cm2)
i) Valves and connected

piping -0.3 -0.5 -1.0 -2.4 -3.3 -3.6 -0.9 -2.2 -3.1 -3.5 -2.3 -1.6 -3.0 -4.2

STAGE-I (3x 660MW)
out of out of (One
ii) economizer 6.2 6.0 5.7 4.7 4.2 4.0 5.7 4.8 4.2 3.9 5.5 5.6 4.4 3.8
3.05.00 Velocities (m/sec)
i) Furnace throat gas velocity 8.2 8.1 7.7 6.2 4.6 3.9 7.7 6 4.6 3.8 8.1 8.1 5.3 2.2
ii) Maximum gas velocity through

tube banks of TSH 9 8.9 8.4 6.6 4.9 4.1 8.4 6.5 4.9 4 8.9 8.8 5.6 2.4
iii) Maximum gas velocity through

tube banks of economizer 9 8.8 8.3 6.5 4.9 4.1 8.3 6.6 5 4.2 8.9 8.8 5.5 2.6
Note : In case gas biasing in the

convective pass is being
used for RH temperature
control the details of gas flow
and velocity through both the
passes shall be indicated
a) Superheater
Stage I - - - - - - - - - - - - - -
Stage II 7.9 7.8 7.5 5.9 4.4 3.7 7.4 5.8 4.4 3.6 7.8 7.8 5 2.1
Stage III 8.7 8.6 8.1 6.4 4.8 3.9 8.1 6.3 4.7 3.9 8.6 8.5 5.4 2.3
b) Reheater
Stage I 9 8.8 8.3 6.5 4.9 4.1 8.3 6.5 4.9 4.1 8.9 8.8 5.5 2.5
Stage II 8.7 8.6 8.1 6.4 4.8 4 8.1 6.3 4.7 3.9 8.6 8.5 5.4 2.3
c) economizer
Stage I 8 7.9 7.4 5.8 4.4 3.7 7.4 5.9 4.5 3.7 7.5 7.6 4.9 2.3
Stage II - - - - - - - - - - - - - -
iii) Gas/air velocities through

STAGE-I (3x 660MW)
out of out of (One
the air heater heating

elements
a) Gas
- Secondary RAPH 8.3 8.1 7.6 5.8 4.3 3.6 7.6 5.9 4.3 3.7 6.8 7.4 9.8 2.1
- Primary RAPH 8.7 8.6 8.4 7.1 5.7 4.9 8.4 7.1 5.8 4.9 9.4 8.8 12.4 3.7
b) Air
- Secondary RAPH 5.6 5.4 5.0 3.9 2.9 2.5 5.1 3.9 2.9 2.6 5.2 5.2 6.6 1.5
- Primary RAPH 5.4 5.3 5.1 4.4 3.7 3.2 5.1 4.4 3.6 3.2 6.8 5.9 8.1 2.3
iv) Air velocities
a) Cold air ducts 13.9 13.5 12.6 10.1 7.9 6.9 12.6 10.1 7.7 7 13.8 13.5 8.5 4.4
b) Hot air ducts 15.3 14.6 13.5 10.4 7.8 6.7 13.6 10.6 7.7 6.9 13.1 13.7 8.5 3.9
v) Gas velocities in gas

ducting sections
a) Eco to AH 10.4 10.2 9.6 7.5 5.7 4.7 9.6 7.5 5.6 4.8 9.1 9.5 6.1 2.9
b) Eco gas bypass

ducts N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
c) AH to ESP 11.6 11.4 10.8 8.6 6.8 5.9 10.8 8.7 6.7 5.9 11 10.9 7.3 4.1
d) ESP to ID fan 12.3 12 11.4 9.1 7.2 6.2 11.5 9.2 7.1 6.2 11.7 11.5 7.7 4.3
e) ID fan to stack 11.9 11.7 11 8.8 6.9 6 11.1 8.9 6.9 6 11.3 11.2 7.4 4.2
vi) Air-fuel mixture velocity

in the fuel pipe line 27.6 27.2 26.7 26.2 25.5 26.0 26.7 25.5 25.5 26.0 27.3 27.2 26.6 24.6
3.06.00 Percentage of Oxygen in flue gas

STAGE-I (3x 660MW)
out of out of (One
i) At furnace exit 3.45 3.45 3.45 3.45 3.94 4.02 3.45 3.45 3.55 4.02 3.45 3.45 3.45 4.38
ii) At economizer outlet 3.45 3.45 3.45 3.45 3.94 4.02 3.45 3.45 3.55 4.02 3.45 3.45 3.45 4.38
iii) At air heater outlet (primary) 5.60 5.62 5.66 6.00 6.87 7.35 5.64 5.99 6.53 7.38 5.62 5.60 5.09 8.58
iv) At air heater outlet

(secondary) 4.55 4.57 4.62 4.88 5.69 6.06 4.62 4.86 5.35 6.01 4.91 4.73 4.40 7.51
v) In the common duct

before ESP 4.84 4.86 4.92 5.23 6.08 6.50 4.91 5.20 5.74 6.47 5.15 4.99 4.62 7.93
vi) At ESP outlet 4.84 4.86 4.92 5.23 6.08 6.50 4.91 5.20 5.74 6.47 5.15 4.99 4.62 7.93
vii) At ID fan inlet 4.84 4.86 4.92 5.23 6.08 6.50 4.91 5.20 5.74 6.47 5.15 4.99 4.62 7.93
3.07.00 Flow rate of air (kg/hr)
i) FD fan outlet 1,732,318 1,681,102 1,570,672 1,252,816 980,482 863,822 1,575,972 1,260,852 955,412 873,054 1,720,416 1,682,782 1,058,293 548,946
ii) PA fan outlet 946,376 939,530 924,792 794,714 665,082 561,960 924,712 795,138 665,594 563,298 960,794 945,314 642,986 434,342
a) Primary air 661,390 650,496 635,816 572,586 497,226 443,646 633,822 565,624 491,666 443,622 879,964 752,148 502,852 358,342
b) Secondary air 1,732,318 1,681,102 1,570,672 1,252,816 980,482 863,822 1,575,972 1,260,852 955,412 873,054 1,720,416 1,682,782 1,058,293 548,946
a) Primary air 566,990 556,096 541,416 476,386 399,226 343,846 540,222 470,224 394,466 343,822 765,564 650,348 450,152 253,942
b) Secondary air 1,606,118 1,555,902 1,447,272 1,132,016 861,482 744,822 1,452,572 1,141,052 838,212 755,054 1,565,216 1,543,982 991,093 429,946
v) Tempering air for each

pulveriser 40,712 41,291 41,282 37,021 33,571 29,579 41,556 38,252 34,786 29,919 11,547 27,595 28,027 25,333
vi) Total air to each pulveriser 121,711 120,733 118,627 116,419 113,416 115,540 118,730 116,623 113,679 115,875 120,913 120,502 118,057 109,981
vii) Total combustion air 2,534,117 2,477,055 2,353,687 1,906,553 1,504,587 1,283,005 2,359,707 1,916,813 1,482,629 1,294,575 2,487,633 2,463,519 1,657,402 835,911
(included furnace leakage)

STAGE-I (3x 660MW)
out of out of (One
3.08.00 Flow rate of flue gases (kg/hr)
i) Primary Airheater inlet 741,312 731,628 716,986 622,238 521,538 454,480 718,156 620,380 521,840 449,248 889,340 798,468 560,000 346,860
ii) Secondary Airheater inlet 2,058,744 2,005,122 1,883,450 1,484,138 1,136,344 958,576 1,888,932 1,497,334 1,115,400 976,552 1,859,100 1,923,326 1,271,079 571,880
iii) Primary airheater outlet 835,712 826,028 811,386 718,438 619,538 554,280 811,756 715,780 619,040 549,048 1,003,740 900,268 612,700 451,260
iv) Secondary airheater outlet 2,184,944 2,130,322 2,006,850 1,604,938 1,255,344 1,077,576 2,012,332 1,617,134 1,232,600 1,094,552 2,014,300 2,062,126 1,338,279 690,880
v) ESP inlet 3,020,656 2,956,350 2,818,236 2,323,376 1,874,882 1,631,856 2,824,088 2,332,914 1,851,640 1,643,600 3,018,040 2,962,394 1,950,979 1,142,140
vi) ESP outlet 3,020,656 2,956,350 2,818,236 2,323,376 1,874,882 1,631,856 2,824,088 2,332,914 1,851,640 1,643,600 3,018,040 2,962,394 1,950,979 1,142,140
vii) ID fan inlet 3,020,656 2,956,350 2,818,236 2,323,376 1,874,882 1,631,856 2,824,088 2,332,914 1,851,640 1,643,600 3,018,040 2,962,394 1,950,979 1,142,140
viii) Recirculation gas flow

(Applicable for the cases
where gas recirculation
is being used to control
RH steam temperature) N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
3.09.00 Excess Air (%)
i) At burner 20.0 20.0 20.0 20.0 23.4 24.0 20.0 20.0 20.7 24.0 20.0 20.0 20.0 26.7
ii) At furnace exit 20.0 20.0 20.0 20.0 23.4 24.0 20.0 20.0 20.7 24.0 20.0 20.0 20.0 26.7
iii) At economizer outlet 20.0 20.0 20.0 20.0 23.4 24.0 20.0 20.0 20.7 24.0 20.0 20.0 20.0 26.7
iv) At the air heater exit

(primary) 36.40 36.62 36.96 39.93 48.24 53.17 36.79 39.82 44.84 53.51 36.57 36.42 32.11 67.50
v) At the airheater exit

(secondary) 27.87 28.02 28.42 30.47 37.22 40.46 28.39 30.29 34.30 40.02 30.74 29.28 26.78 54.88
vi) At ESP inlet 30.13 30.32 30.77 33.26 40.69 44.55 30.71 33.08 37.66 44.28 32.63 31.37 28.41 59.65
3.10.00 Leakages (Tonnes per hour)

STAGE-I (3x 660MW)
out of out of (One
i) Primary air
a) Regenerative air
preheater 94.4 94.4 94.4 96.2 98.0 99.8 93.6 95.4 97.2 99.8 114.4 101.8 52.7 104.4
b) Ducts/Dampers 0 0 0 0 0 0 0 0 0 0 0 0 0 0
ii) Secondary air
a) Regenerative air
heater 126.2 125.2 123.4 120.8 119.0 119.0 123.4 119.8 117.2 118.0 155.2 138.8 67.2 119.0
b) Wind box 0 0 0 0 0 0 0 0 0 0 0 0 0 0
c) Ducts/Dampers 0 0 0 0 0 0 0 0 0 0 0 0 0 0
3.11.00 Heat Balance (based on GCV of

design coal fired)
i) Total coal fired (tonnes/hr) 471.8 461.1 438.1 354.9 272.4 231.1 439.3 356.8 274.4 233.2 463.1 458.6 308.5 147.3
ii) Gross Calorific value of

coal (Kcal/kg) 3300 3300 3300 3300 3300 3300 3300 3300 3300 3300 3300 3300 3300 3300
iii) Heat absorbed per kg

of coal in
a) Air preheaters (kcal)
- Primary 77.3 77.6 78.3 79.5 80.8 79.1 78.4 79.1 80.5 79.2 77.7 78.0 78.9 80.5
- Secondary 219.9 218.2 211.1 192.0 176.5 171.9 212.0 194.8 172.6 174.9 163.7 189.6 179.2 136.4
b) economizer (kcal) 298.8 297.1 293.2 276.1 274.2 272.5 292.5 284.2 277.2 279.5 422.0 360.2 263.1 360.2
c) Superheater (kcal)
Stage I 316.2 342.0 364.7 370.9 362.8 319.6 352.1 332.4 339.5 289.4 338.4 350.6 381.9 350.6
Stage II 212.6 225.7 236.4 257.1 261.8 268.1 230.8 237.6 251.2 253.9 224.8 230.2 270.2 230.2
Stage III 227.0 236.8 240.6 234.6 211.6 200.0 235.7 219.5 200.6 191.5 238.2 241.1 216.7 241.1

STAGE-I (3x 660MW)
out of out of (One
Roof tubes 6.5 6.7 6.7 6.6 6.0 5.9 6.6 6.2 5.6 5.8 6.7 6.8 6.1 6.8
Convective pass 52.7 55.0 56.5 57.8 60.3 62.3 55.6 57.6 60.4 63.9 55.7 56.4 59.7 56.4
Enclosure (Included in steam cooled)
Steam cooled 29.1 30.4 31.1 31.4 29.3 28.6 30.4 28.9 27.5 27.0 30.2 30.8 30.0 30.8
Hanger tubes 12.2 12.7 12.9 12.9 13.2 13.4 12.3 12.8 13.2 13.7 12.6 13.0 13.0 13.0
d) Reheater (kcal)
Stage I 357.6 362.0 363.6 352.6 316.1 295.8 353.8 320.3 284.6 269.2 350.8 357.3 320.2 357.3
Stage II 225.6 237.6 246.1 257.1 246.7 243.7 240.1 234.2 232.0 229.1 234.8 241.1 254.9 241.1
e) Water walls
Wall tubing 1095.7 1042.5 978.8 1102.5 1065.4 1146.8 1020.2 1115.3 1138.2 1137.6 970.7 986.1 1039.6 986.1
Screen tubes 35.5 37.2 38.3 39.8 40.3 41.0 37.8 37.7 39.8 39.9 37.6 38.1 40.7 38.1
Any other 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
iv) Total heat absorbed

effectively by the unit
(per kg of coal (kcal) be) 3166.8 3181.5 3158.3 3270.8 3145.0 3148.7 3158.2 3160.6 3123.0 3054.5 3163.9 3179.3 3154.2 3128.6
3.12.00 Heat losses in the Steam

Generator
Heat losses in the Steam Generator
shall be quoted for guarantee
conditions also:
i) Heat loss due to flue gasses

(%)
- Dry gas loss 4.69 4.70 4.67 4.30 4.10 4.11 4.67 4.38 4.11 4.05 3.82 3.92 4.10 4.52
- Hydrogen in the fuel 4.17 4.17 4.17 4.14 4.11 4.11 4.17 4.14 4.12 4.10 4.11 4.12 4.14 4.11
- Moisture in the fuel 2.29 2.29 2.29 2.27 2.26 2.25 2.29 2.27 2.26 2.25 2.25 2.26 2.27 2.25

STAGE-I (3x 660MW)
out of out of (One
- Moisture in the air 0.11 0.11 0.11 0.10 0.10 0.10 0.11 0.10 0.10 0.10 0.09 0.09 0.10 0.11
- Total heat loss due

to flue gases 11.26 11.27 11.24 10.81 10.57 10.57 11.24 10.89 10.59 10.50 10.27 10.39 10.61 10.99
ii) Heat loss due to unburnt

carbon (%) in:
- Furnace bottom ash 0.58 0.58 0.58 0.58 0.58 0.58 0.58 0.58 0.58 0.58 0.58 0.58 0.58 0.58
- Fly ash 0.92 0.92 0.92 0.92 0.92 0.92 0.92 0.92 0.92 0.92 0.92 0.92 0.92 0.92
- Total heat loss due to

unburnt carbon 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50
iii) Sensible heat loss (%) in:
- economizer hopper
ash 0.03 0.03 0.03 0.03 0.03 0.02 0.03 0.03 0.03 0.03 0.02 0.03 0.03 0.02
- Air heater hopper

ash 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01
- Any other hopper

ash 0.15 0.15 0.15 0.14 0.12 0.12 0.15 0.14 0.13 0.12 0.12 0.13 0.14 0.12
- Total sensible heat

loss 0.61 0.61 0.61 0.60 0.58 0.57 0.61 0.60 0.59 0.58 0.57 0.59 0.60 0.57
iv) Heat loss due to Mill

Rejects (%) 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07
v) Heat loss due to radiation (%) 0.18 0.19 0.19 0.23 0.30 0.34 0.19 0.23 0.30 0.34 0.18 0.18 0.26 0.53
vi) Unaccounted heat loss (%)

(give details) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
vii) Total heat losses {sum of the

(i) to (v)} 13.62 13.64 13.61 13.21 13.02 13.05 13.61 13.29 13.05 12.99 12.59 12.73 13.04 13.66

STAGE-I (3x 660MW)
out of out of (One
viii) Heat credits (give details of

equipment and breakup) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
ix) Manufacturer’s margin(%) 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10 0.10
x) Steam generator efficiency

(%) 86.28 86.26 86.29 86.69 86.88 86.85 86.29 86.61 86.85 86.91 87.31 87.17 86.86 86.24
3.13.00 Weight and Distribution of Ash

collected
i) Furnace bottom hopper

(kg/hr) 40572 39655 37680 30521 23422 19876 37776 30685 23598 20055 39824 39438 26532 12672
ii) economizer hopper

(kg/hr) 10143 9914 9420 7630 5856 4969 9444 7671 5899 5014 9956 9859 6633 3168
iii) Air heater hopper (kg/hr) 6086 5948 5652 4578 3513 2981 5666 4603 3540 3008 5974 5916 3980 1901
iv) Any other hoppers (kg/hr) 146059 142757 135646 109875 84320 71554 135993 110466 84953 72199 143367 141977 95514 45619
3.14.00 Furnace Design Data
3.14.01 Net Heat Input (x106kal/hr)
a) With top mills /elevations

in operation 1592.6 1534.3 1453.8 1170.8 894.2 765.4 1458.0 1185.9 899.7 764.4 1523.4 1512.1 1013.2 N/A
i) Identify mills/elevations
in services D~J D~J D~J E~J F~J G~J D~J E~J F~J G~J D~J D~J F~J N/A
ii) Burner tilt (deg) -30 -30 -8 12 0 -15 -25 -25 -25 -25 -25 -25 10 N/A
b) With Middle mills /elevations

in operation 1569.2 1532.9 1453.8 1175.2 895.6 757.1 1457.9 1178.0 901.8 764.6 1515.0 1512.1 1016.4 N/A
in services C~I C~I C~I C~H D~H D~G C~I C~H D~H D~G C~I C~I D~H N/A
ii) Burner tilt (deg) -30 0 20 25 25 13 7 -5 0 -25 -1 10 25 N/A

STAGE-I (3x 660MW)
out of out of (One
c) With bottom mills /elevations

in operation 1569.2 1536.4 1466.4 1186.2 903.2 761.7 1464.6 1180.8 904.8 765.4 1516.9 1519.5 1024.7 476.8
in services B~H B~H B~H B~G B~F C~F B~H B~G B~F C~F B~H B~H B~F C~E
ii) Burner tilt (deg) 8 25 25 25 25 25 25 25 25 25 25 25 25 0
3.14.02 Cumulative Heat Absorption in

Furnace
i) Passive Heat Absorption

(Heat Absorption in furnace
from bottom upto mean firing
Zone level)
a) With top mills/eleva-

tions in operation and
conditions as identified
in Clause 3.14.01 161.0 157.5 125.1 69.2 53.1 54.8 136.3 94.6 69.8 65.2 141.6 107.3 39.3 N/A
b) With middle mills/eleva-

in Clause 3.14.01 166.2 129.6 88.6 59.6 45.9 50.4 108.8 100.5 74.1 50.4 124.1 91.7 45.0 N/A
c) With bottom mills/eleva-

in Clause 3.14.01 128.5 86.1 80.1 74.2 57.6 51.5 82.6 83.6 61.8 51.5 92.6 33.4 63.5 41.3
ii) Upto exit of Burner Basket

in Clause 3.14.01 207.5 203.2 165.3 120.1 90.4 90.0 177.5 157.0 116.7 106.1 183.6 158.7 66.2 N/A


STAGE-I (3x 660MW)
out of out of (One
in Clause 3.14.01 233.9 187.7 135.5 101.3 76.6 86.5 161.0 155.8 113.6 86.5 179.4 143.4 71.1 N/A

in Clause 3.14.01 207.7 150.8 142.5 114.3 95.5 83.1 157.1 129.0 102.5 83.1 144.8 60.7 105.6 76.2
iii) Upto Furnace Arch level

in Clause 3.14.01 365.0 358.1 315.7 283.0 208.8 200.3 330.5 295.3 235.2 218.6 328.1 325.9 201.0 N/A

in Clause 3.14.01 405.4 364.2 308.8 248.5 204.6 198.9 330.0 301.2 234.8 198.9 336.8 328.2 206.9 N/A

in Clause 3.14.01 400.0 344.1 321.0 262.6 218.5 199.7 333.4 295.7 233.4 199.7 331.0 132.5 226.3 164.9
iv) Upto Furnace Arch Exit

in Clause 3.14.01 410.5 403.4 360.4 335.2 247.7 233.5 374.8 336.3 270.3 251.2 370.7 376.7 245.7 N/A

in Clause 3.14.01 453.8 414.3 361.6 295.3 246.4 232.6 381.3 344.5 271.0 232.6 383.3 384.4 252.9 N/A

in Clause 3.14.01 455.0 402.3 375.3 308.3 255.7 233.8 387.5 345.4 271.9 233.8 386.8 152.5 261.9 188.0
v) Upto platen superheater Exit

STAGE-I (3x 660MW)
out of out of (One

in Clause 3.14.01 758 739 697 619 464 406 700 602 475 417 712 714 478 N/A

in Clause 3.14.01 772 748 698 572 462 404 707 603 474 392 716 724 473 N/A

in Clause 3.14.01 772 730 688 564 457 399 700 600 471 398 714 477 466 285
vi) Upto final super heater Exit

in Clause 3.14.01 1026 995 946 822 611 528 942 796 615 534 973 971 633 N/A

in Clause 3.14.01 1020 1002 946 774 608 525 949 792 613 508 971 981 625 N/A

in Clause 3.14.01 1020 984 932 760 599 518 941 787 608 514 914 731 614 343
vii) Upto primary reheater exit

in Clause 3.14.01 1230 1185 1127 965 711 608 1119 931 707 608 1163 1158 737 N/A


STAGE-I (3x 660MW)
out of out of (One
in Clause 3.14.01 1211 1191 1127 920 709 606 1126 924 706 583 1156 1168 732 N/A

in Clause 3.14.01 1211 1175 1118 911 704 601 1121 920 702 589 1100 921 725 388
viii) Upto economizer exit

in Clause 3.14.01 1372 1322 1256 1022 786 669 1259 1033 792 677 1360 1326 889 N/A

in Clause 3.14.01 1352 1321 1256 1022 786 669 1259 1026 792 675 1352 1326 889 N/A

in Clause 3.14.01 1352 1321 1256 1022 786 669 1259 1026 792 675 1352 1326 889 428
ix) Upto air preheater exit

in Clause 3.14.01 1508 1452 1377 1155 852 720 1368 1120 849 723 1454 1438 881 N/A

in Clause 3.14.01 1485 1458 1375 1117 853 721 1375 1118 852 702 1446 1449 886 N/A

in Clause 3.14.01 1485 1447 1387 1125 860 723 1382 1118 851 709 1394 1215 892 454

STAGE-I (3x 660MW)
out of out of (One
x) Furnace heat absorption as

percentage of total heat
absorption (upto Arch exit)

in Clause 3.14.01 48 49 49 51 52 53 50 53 54 55 47 48 52 N/A

in Clause 3.14.01 50 50 49 49 52 53 50 52 54 54 48 48 51 N/A

in Clause 3.14.01 50 49 48 48 51 53 49 52 54 54 49 37 50 61
3.14.03 Superheater Spray Quantity in T/hr

in Clause 3.14.01 89.0 86.4 81.0 62.9 83.4 75.2 81.4 63.7 94.3 76.6 73.6 78.4 82.8 N/A

in Clause 3.14.01 89.0 86.4 81.0 62.9 82.2 72.3 81.4 63.7 88.4 56.0 73.6 78.4 72.1 N/A

in Clause 3.14.01 89.0 86.4 81.0 62.9 47.5 59.8 81.4 63.7 80.1 67.8 73.6 78.4 36.0 24.4
3.14.04 Reheater Spray Quantity in T/hr


STAGE-I (3x 660MW)
out of out of (One
in Clause 3.14.01 36.6 1.8 0.0 0.0 0.0 0.0 0.0 12.1 0.0 4.3 10.7 0.0 0.0 N/A

in Clause 3.14.01 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 N/A

in Clause 3.14.01 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
3.15.00 Furnace Performance Data

Description (As per Clause 5.00.00
Section-VIA, PartBSub-section-MI)
i) Total heat duty (106 Kcal/hr) 1352.0 1321.2 1255.8 1021.5 786.2 669.2 1258.4 1026.2 791.8 674.8 1352.2 1326.4 889.3 427.9
ii) Efficiency (%) 86.85 86.83 86.86 87.22 87.47 87.74 86.81 87.16 87.44 87.68 88.49 87.65 87.35 88.00
iii) Total heat generated

6
(10 Kcal/hr) 1556.8 1521.6 1445.8 1171.1 898.8 762.7 1449.5 1177.4 905.5 769.6 1528.1 1513.3 1018.1 486.2
iv) Net heat input (106 Kcal/hr)

(Unburnt) 1569.2 1532.9 1453.8 1170.8 894.2 757.1 1457.9 1178.0 899.7 764.6 1515.0 1512.1 1013.2 476.8
v) Furnace Plan area (m2) 341.4 341.4 341.4 341.4 341.4 341.4 341.4 341.4 341.4 341.4 341.4 341.4 341.4 341.4
vi) Furnace EPRS (m2) 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9
vii) Furnace Volume (m3) 21461.8 21461.8 21461.8 21461.8 21461.8 21461.8 21461.8 21461.8 21461.8 21461.8 21461.8 21461.8 21461.8 21461.8
viii) Net heat input/plan area

(106 Kcal/m2/hr) 4.60 4.49 4.26 3.43 2.62 2.22 4.27 3.45 2.64 2.24 4.44 4.43 2.97 1.40
ix) Net heat input /EPRS

(106 Kcal/m2/hr) 0.174 0.169 0.161 0.129 0.099 0.084 0.161 0.130 0.099 0.085 0.168 0.167 0.112 0.053
x) Volumetric Heat Release rate

(106 Kcal/m3/hr) 0.073 0.071 0.067 0.055 0.042 0.036 0.068 0.055 0.042 0.036 0.071 0.071 0.047 0.023

STAGE-I (3x 660MW)
out of out of (One
xi) Furnace exit gas temp (DegC) 988 1003 1004 977 910 880 994 943 894 864 1000 1007 943 754
3.16.00 Mass velocity in evaporator

tubes (Kg/m2 sec)
i) Maximum 3150 3058 2865 2226 1640 1365 2881 2255 1672 1391 2605 2775 1314 669
ii) Minimum 2495 2422 2270 1764 1299 1081 2282 1787 1325 1102 2064 2198 1659 844
3.17.00 Tube Mass Velocity (Kg/m2sec)

(Vertical Wall)
i) Front water walls 1183 1148 1075 838 615 512 1081 849 627 522 977 1041 623 317
ii) Rear water walls 1085 1054 987 771 567 472 992 781 577 481 899 957 618 314
iii) Side Walls 1173 1138 1067 826 611 508 1073 836 623 517 970 1033 572 291
3.18.00 Auxiliary Steam Consumption
i) Steam conditions
a) Pressure range (kg/cm2)

(abs) 16
b) Temperature range
(degC) 210 ~ 310
ii) Fuel oil heating (kg/hr) Max N/A
iii) Fuel oil line tracing (kg/hr)

Max N/A
iv) Steam coil air pre-heater

(kg/hr)Max
a) Primary 7406
b) Secondary 17490
v) Total auxiliary steam consum-

STAGE-I (3x 660MW)
out of out of (One
ed from startup to full load
a) After eight hours

shutdown (kg/hr) Later
b) After four hours

c) Hot restart after trip out

(Less than 1 hr shut
down) (kg/hr) Later
d) After thirty six hours

shutdown (Kg/hour) Later
e) Cold start, After

seventy two hours(kg/hr Later
3.19.00 Start ups
3.19.01 Recommended Startup time periods

to bring steam Generator to full load
from ignition (with HP-LP bypass system)
i) Cold start, (hours),

after (72) hours 9.34
ii) After thirty six (36) hours

shut down (hours) 4.6
iii) After twenty four (24) hours

iv) After twelve (12) hours

shutdown (hours) 4
v) After eight (8) hours

shutdown (hours) 3.5
vi) After four (4) hours

STAGE-I (3x 660MW)
out of out of (One
vii) Hot restart after trip out with

less than one hour shut down 2.5
3.19.02 Number of start ups/life (Nos) of following

type for which the unit has been designed
a) Cold startup (after 72 hours) 455
b) Warm startup (after 36 hours) 910
c) Hot startups (after 8 hours) 4550
d) Daily load cycling between

40% to 100% No limit provided recommended heat-up ratesAre adhered to.
3.20.00 Quantity of expected steam to be vented

out in raising full pressure when starting
without HP-LP bypass (Kg)
i) From cold start up

after (72) hours Later

shut down Later

shut down Later

shutdown Later

shutdown Later

shutdown Later
vii) Hot restart after trip out Later

STAGE-I (3x 660MW)
out of out of (One
3.21.00 SH drains during starting
a) Flow rate of drain water from

primary superheater header
(kg/hr) N/A
b) Flow rate of drain water from

SH final header (kg/hr) N/A
c) Flow rate of drain water from

3.22.00 Wind box performance
i) Free air area (m2) 3.49 3.49 3.49 2.99 2.49 1.99 3.49 2.99 2.49 1.99 3.49 3.49 2.49 1.49
ii) Secondary air flow into the

3
wind box (m /sec) 754 731 676 514 379 321 680 521 370 327 648 681 435 176
iii) Secondary air density (kg/m3) 0.591 0.591 0.594 0.611 0.632 0.645 0.594 0.608 0.629 0.641 0.671 0.630 0.632 0.680
iv) Secondary air temperature

in the wind box (degC) 296 296 293 278 259 249 294 281 262 252 229 262 259 222
v) Secondary air velocity (m/sec) 54.1 52.4 48.5 43.0 38.0 40.3 48.7 43.6 37.2 41.1 46.5 48.9 43.7 29.4
vi) Differential pressure with

respect to the furnace (mmwc) 102
3.23.00 Combustion Data
i) Stoichiometric dry air

required kg/kg fuel 4.539
ii) Stoichiometric wet air

iii) Volume of flue gas at Eco

outlet per Kg of Coal (NM3) 4.338

STAGE-I (3x 660MW)
out of out of (One
iv) Emissivity at mean firing zone

(Correct upto fifth place of
decimal)
a) Flame Emissivity 0.1516

(Luminous emissivity)
b) Gas Emissivity 0.3431
(Non-luminous emissivity)
c) Total Emissivity 0.4947
(Luminous+Non-luminous emissivity)
v) Specific heat of flue gases
at mean firing zone
(correct upto fifth place of
decimal) 0.33062 kcal/kg-k
vi) Weight of flue gas produced

by burning 1 kg of fuel (kg) at
Eco outlet 5.935

STAGE-I (3x 660MW)
B) WORST COAL
out of out of (One
4.01.00 General

outlet (Tonnes/hr) 2225 2160 2023.75 1572.47 1158.41 963.76 2035.24 1592.96 1178.13 982.34 1839.5 1960.0 1335.0 596.1



(Tonnes/hr) 1741.82 1753.03 1678.37 1328.96 996.95 836.41 1686.33 1343.65 1012.39 851.48 1784.2 1784.34 1138 517.2

inlet (kg/cm2)(abs) 48.3 48.7 46.7 37.2 28.1 23.6 47.0 37.6 28.5 24.0 50.5 50.1 32.2 14.6



reheater (kg/cm2) 1.69 1.69 1.62 1.30 1.02 0.88 1.63 1.34 1.05 0.90 1.70 1.70 1.13 0.57

(degC) 289.64 290 286.23 270.35 254.09 244.34 287.28 273.24 256.75 246.95 196.15 243.54 261 219

coal 84.89 85.13 85.17 85.56 85.76 85.35 85.06 85.38 85.84 85.71 86.08 86.05 85.89 84.91

STAGE-I (3x 660MW)
out of out of (One
unit furnace volume

(x106kal/m3/hr) 0.073 0.072 0.068 0.055 0.042 0.036 0.068 0.055 0.043 0.036 0.072 0.071 0.048 0.023

(x106kcal/m2/hr) 0.174 0.170 0.161 0.130 0.099 0.084 0.162 0.131 0.100 0.084 0.168 0.168 0.113 0.053

rate (x106kcal/m2/hr) 1.208 1.176 1.119 0.906 0.693 0.589 1.122 0.911 0.699 0.593 1.185 1.170 0.788 0.375

rate (x106kcal/m2/hr) 4.61 4.50 4.27 3.44 2.62 2.23 4.28 3.46 2.64 2.24 4.45 4.44 2.98 1.41

pulverisers 10 10 10 10 10 10 10 10 10 10 10 10 10 10


(tonnes/hr) 525.5 511.8 487.0 394.5 301.7 256.2 488.2 396.6 304.1 258.2 515.7 509.2 342.9 163.3

rature (degC) 976 986 992 962 901 867 981 931 883 861 985 994 932 743


outlet (ppm)

solids 0.002
Max
b) Silica 0.002
Max
c) Sodium 0.002
d) Chlorides 0.002
Max
e) Copper 0.001
Max
f) Iron 0.005

STAGE-I (3x 660MW)
out of out of (One

4.02.01 Air

in Service
in service A~I A~H A~H B~H B~F C~F A~H B~H B~F C~F A~I A~H B~F C~E

cable( deg) -8 16 25 25 25 25 20 25 25 0 15 25 25 0

(Primary air) 34.7 34.7 34.4 34.0 41.0 51.0 34.4 34.0 38.4 47.4 48.5 34.8 33.9 67.0
v) Outlet of RAPH
(Primary air) 289 280 283 269 252 243 287 272 255 249 219 248 243 220

(Secondary air) 30.9 30.9 30.6 30.3 39.0 51.0 30.6 30.3 36.0 45.6 48.0 30.9 30.1 63.0

(Secondary air) 301 300 295 279 262 252 298 284 266 258 235 263 257 224

Inlet to burners 301 300 295 279 262 252 298 284 266 258 235 263 257 224

STAGE-I (3x 660MW)
out of out of (One

the common duct


in Service
in service A~I B~I B~I C~I D~H D~G B~I C~I D~H D~G A~I B~I B~I N/A

cable (deg) -30 -23 4 25 25 -16 -13 -5 3 -25 -21 -7 25 N/A

(Primary air) 34.7 34.7 34.4 34.0 42.0 52.0 34.4 34.0 38.4 47.4 48.5 34.7 33.9 N/A
v) Outlet of RAPH
(Primary air) 289 280 283 268 250 242 287 272 254 249 219 248 243 N/A

(Secondary air) 30.9 30.9 30.6 30.3 38.0 51.0 30.6 30.3 35.0 45.6 48.0 30.9 30.1 N/A

(Secondary air) 301 300 295 279 261 252 298 283 265 258 233 263 258 N/A


the common duct


STAGE-I (3x 660MW)
out of out of (One
in Service
in service B~J C~J C~J D~J F~J G~J C~J D~J F~J G~J B~J C~J C~J N/A

cable( deg) -30 -25 -19 11 -5 -25 -25 -25 -25 -25 -25 -25 -1 N/A

(Primary air) 34.7 34.7 34.4 34.0 42.0 52.0 34.4 34.0 39.0 47.4 49.5 35.7 33.9 N/A
v) Outlet of RAPH
(Primary air) 288 280 283 267 250 241 286 272 254 248 220 248 243 N/A

(Secondary air) 30.9 30.9 30.6 30.3 37.0 50.0 30.6 30.3 35.0 43.6 48.0 30.9 30.1 N/A

(Secondary air) 300 300 295 279 261 252 298 283 265 257 233 263 258 N/A


the common duct




STAGE-I (3x 660MW)
out of out of (One

in Service
ations in service A~I A~H A~H B~H B~F C~F A~H B~H B~F C~F A~I A~H B~F C~E

cable) (deg) -8 16 25 25 25 25 20 25 25 0 15 25 25 0

temperature in the
combustion zone 1562 1555 1540 1447 1372 1325 1542 1480 1396 1332 1527 1537 1371 1208

super heater) 1297 1326 1331 1289 1237 1204 1325 1301 1242 1161 1324 1336 1262 1074

cation for FEGT) 976 988 983 936 883 854 979 929 877 839 985 994 910 743
Stage I 1297 1326 1331 1289 1237 1204 1325 1301 1242 1161 1324 1336 1262 1074
Stage II 1062 1080 1078 1028 981 956 1073 1027 979 936 1077 1089 1007 840
Stage III 848 854 847 808 756 727 844 797 748 718 853 858 779 627
Stage I 1062 1080 1078 1028 981 956 1073 1027 979 936 1077 1089 1007 840
Stage II 976 988 983 936 883 854 979 929 877 839 985 994 910 743
Stage III 724 726 718 689 646 623 717 678 638 619 723 726 664 564

STAGE-I (3x 660MW)
out of out of (One
Stage I 717 719 711 682 639 617 710 671 632 612 717 719 657 557
Stage II 976 988 983 936 883 854 979 929 877 839 985 994 910 743
Stage I 491 489 481 461 436 423 484 461 440 432 492 491 445 385
Stage II 866 873 866 826 774 747 864 817 768 738 872 878 799 648
mizer 491 489 481 461 436 423 484 461 440 432 492 491 445 385

air heater 324 323 318 301 280 268 319 301 282 271 253 288 288 236

air heater 324 323 318 301 280 268 319 301 282 271 253 288 288 236






precipitator 134 129 128 118 110 110 130 121 110 110 110 111 114 110

precipitator 132 127 126 116 108 108 128 119 108 108 108 109 112 108

STAGE-I (3x 660MW)
out of out of (One

in Service
ations in service A~I B~I B~I C~I D~H D~G B~I C~I D~H D~G A~I B~I B~I N/A

cable ) (deg) -30 -23 4 25 25 -16 -13 -5 3 -25 -21 -7 25 N/A

temperature in the

super heater) 1321 1324 1342 1339 1306 1203 1328 1307 1263 1191 1325 1336 1324 N/A

Stage I 1321 1324 1342 1339 1306 1203 1328 1307 1263 1191 1325 1336 1324 N/A
Stage II 1067 1078 1089 1059 1011 961 1074 1029 990 953 1078 1089 1040 N/A
Stage III 851 853 853 815 760 727 846 798 748 721 853 858 786 N/A
Stage I 1067 1078 1089 1059 1011 961 1074 1029 990 953 1078 1089 1040 N/A
Stage II 979 986 992 956 901 856 981 931 883 848 986 994 930 N/A

STAGE-I (3x 660MW)
out of out of (One
Stage III 726 725 722 689 644 623 717 678 637 618 723 726 663 N/A
Stage I 719 718 714 682 637 616 711 672 630 611 717 719 656 N/A
Stage II 979 986 992 956 901 856 981 931 883 848 986 994 930 N/A
Stage I 490 489 482 455 429 422 484 462 437 429 492 491 439 N/A
Stage II 869 872 872 835 781 747 865 818 769 741 872 878 807 N/A
mizer 490 489 482 455 429 422 484 462 437 429 492 491 439 N/A

air heater 324 323 318 299 278 268 319 301 281 270 253 288 286 N/A

air heater 324 323 318 299 278 268 319 301 281 270 253 288 286 N/A






precipitator 134 129 128 119 110 111 130 122 110 110 110 111 114 N/A

STAGE-I (3x 660MW)
out of out of (One

precipitator 132 127 126 117 108 109 128 120 108 108 108 109 112 N/A

in Service
ations in service B~J C~J C~J D~J F~J G~J C~J D~J F~J G~J B~J C~J C~J N/A

cable ) (deg) -30 -30 -19 11 -5 -25 -25 -25 -25 -30 -25 -25 -1 N/A

temperature in the

super heater) 1351 1352 1350 1352 1305 1244 1346 1323 1276 1242 1351 1350 1326 N/A

Stage I 1351 1352 1350 1352 1305 1244 1346 1323 1276 1242 1351 1350 1326 N/A
Stage II 1101 1109 1087 1070 1014 980 1084 1043 1000 976 1108 1105 1044 N/A
Stage III 871 871 852 817 761 730 851 806 753 724 871 867 786 N/A

STAGE-I (3x 660MW)
out of out of (One
Stage I 1101 1109 1087 1070 1014 980 1084 1043 1000 976 1108 1105 1044 N/A
Stage II 1007 1012 991 962 902 867 988 942 891 861 1011 1007 932 N/A
Stage III 737 735 721 688 644 622 721 682 639 617 734 732 663 N/A
Stage I 731 728 714 681 637 614 713 675 632 609 727 724 656 N/A
Stage II 1007 1012 991 962 902 867 988 942 891 861 1011 1007 932 N/A
Stage I 489 488 482 452 429 417 484 461 436 424 490 490 438 N/A
Stage II 889 891 872 837 782 751 871 826 774 745 891 887 807 N/A
mizer 489 488 482 452 429 417 484 461 436 424 490 490 438 N/A

air heater 324 323 318 298 278 267 319 301 281 269 253 288 286 N/A

air heater 324 323 318 298 278 267 319 301 281 269 253 288 286 N/A





STAGE-I (3x 660MW)
out of out of (One

precipitator 133 129 128 120 110 110 130 125 110 110 111 111 114 N/A

precipitator 131 127 126 118 108 108 128 123 108 108 109 109 112 N/A
4.02.04 Feed Water

in Service

cable ) (deg) -8 16 25 25 25 25 20 25 25 0 15 25 25 0
iii) Water entering

economizer 290 290 286 270 254 244 287 273 257 247 196 244 261 219
iv) Water leaving

economizer 342 342 339 329 315 309 340 327 316 310 299 320 319 282
water temperature
a) Superheater 290 290 286 270 254 244 287 273 257 247 196 244 261 219
b) Reheater 191 191 191 181 169 161 191 181 169 161 196 195 169 144

in Service

STAGE-I (3x 660MW)
out of out of (One

cable ) (deg) -30 -23 4 25 25 -16 -13 -5 3 -25 -21 -7 25 N/A
iii) Water entering

economizer 290 290 286 270 254 244 287 273 257 247 196 244 244 N/A
iv) Water leaving

economizer 342 342 339 326 312 308 340 327 314 308 299 320 317 N/A
water temperature
a) Superheater 290 290 286 270 254 244 287 273 257 247 196 244 244 N/A
b) Reheater 191 191 191 181 169 161 191 181 169 161 196 195 169 N/A

in Service

cable ) (deg) -30 -25 -19 11 -5 -25 -25 -25 -25 -25 -25 -25 -1 N/A
iii) Water entering

economizer 290 290 286 270 254 244 287 273 257 247 196 244 244 N/A
iv) Water leaving

economizer 343 342 339 324 312 306 340 327 315 306 299 320 316 N/A
water temperature
a) Superheater 290 290 286 270 254 244 287 273 257 247 196 244 244 N/A
b) Reheater 191 191 191 181 169 161 191 181 169 161 196 195 169 N/A
4.02.05 Steam

STAGE-I (3x 660MW)
out of out of (One

in Service

cable ) (deg) -8 16 25 25 25 25 20 25 25 0 15 25 25 0
1st Stage 419 414 410 398 371 362 407 381 360 347 402 405 382 334
2nd Stage 452 448 445 436 423 413 443 425 417 411 434 438 431 423
3rd Stage 485 483 482 478 472 470 481 476 471 470 473 476 475 492
1st Stage 462 458 454 446 431 440 453 437 437 424 444 448 431 432
2nd Stage 492 490 489 485 490 491 488 482 492 492 481 484 491 519
3rd Stage 540 540 540 540 540 540 540 540 540 540 540 540 540 540
1st Stage 299 300 296 281 286 289 303 306 310 313 309 306 284 294
2nd Stage 459 456 450 450 449 448 456 455 454 456 460 457 448 431
1st Stage 459 456 451 450 449 448 456 455 454 456 460 458 448 431
2nd Stage 568 568 568 568 568 568 568 568 568 568 540 568 568 540

in Service

STAGE-I (3x 660MW)
out of out of (One

cable ) (deg) -30 -23 4 25 25 -16 -13 -5 3 -25 -21 -7 25 N/A
1st Stage 416 414 408 394 372 362 407 381 360 347 402 405 383 N/A
2nd Stage 451 448 443 432 419 412 443 425 415 408 434 438 427 N/A
3rd Stage 485 483 481 477 472 470 481 476 472 470 473 476 474 N/A
1st Stage 461 458 452 442 443 437 453 437 439 429 444 448 441 N/A
2nd Stage 492 490 488 485 490 491 488 482 492 492 480 484 491 N/A
3rd Stage 540 540 540 540 540 540 540 540 540 540 540 540 540 N/A
1st Stage 297 300 296 281 286 289 303 306 310 313 309 306 284 N/A
2nd Stage 457 456 452 444 442 446 456 455 451 453 459 457 442 N/A
1st Stage 457 456 453 444 442 446 457 455 451 453 460 458 442 N/A
2nd Stage 568 568 568 568 568 568 568 568 568 568 568 568 568 N/A

in Service

STAGE-I (3x 660MW)
out of out of (One

cable ) (deg) -30 -25 -19 11 -5 -25 -25 -25 -25 -25 -25 -25 -1 N/A
1st Stage 410 409 406 393 372 360 403 379 360 348 398 402 383 N/A
2nd Stage 444 443 443 432 418 409 441 424 412 403 428 435 426 N/A
3rd Stage 480 480 481 477 472 470 479 473 470 470 468 474 474 N/A
1st Stage 454 452 452 441 441 440 451 435 443 439 438 444 440 N/A
2nd Stage 487 486 488 485 490 491 487 482 490 492 476 480 491 N/A
3rd Stage 540 540 540 540 540 540 540 540 540 540 540 540 540 N/A
1st Stage 285 291 296 281 286 289 300 300 307 313 297 301 284 N/A
2nd Stage 450 450 452 442 442 442 454 452 450 449 452 454 441 N/A
1st Stage 450 451 453 442 442 442 454 452 450 449 452 454 441 N/A
2nd Stage 568 568 568 568 568 568 568 568 568 568 568 568 568 N/A
4.03.00 Pressure

STAGE-I (3x 660MW)
out of out of (One
4.03.01 Air (mmwc)

and silencer)

(Secondary air ) 179 182 172 144 154 150 172 145 153 140 240 179 181 120

(Secondary air) 143 145 139 123 141 137 139 124 140 130 207 144 122 115
(Secondary air) 102 102 102 102 102 102 102 102 102 102 102 102 102 102

and silencer)

common duct before
pulverisers 760 782 773 760 782 798 773 760 783 800 741 773 811 765


STAGE-I (3x 660MW)
out of out of (One
2


for superheater 304.2 300.5 292.9 261.0 195.9 165.4 283.1 220.4 165.1 139.1 282.7 289.2 224.4 101.0
for reheater 91.5 91.9 89.9 80.4 71.3 66.8 90.2 80.7 71.7 67.2 93.7 93.3 75.4 57.8
4.03.04 Separator

STAGE-I (3x 660MW)
out of out of (One

bends dampers,
vanes etc 167 100 155 201 184 158 113 165 130 103 303 108 151 179

c) Across RAPH 84 82 75 59 41 33 74 57 40 30 117 100 163 17

the system 289 218 265 289 252 217 222 252 197 159 457 244 343 218

i) Furnace pressure
(back draught) 3 3 3 3 3 3 3 3 3 3 3 3 3 3
ii) Across SH/RH

convection path 67 66 61 52 46 42 61 53 46 41 64 63 39 15
v) In gas ducts

precipitator funnel
inlet 44 42 39 25 17 14 38 26 16 12 44 43 18 6

STAGE-I (3x 660MW)
out of out of (One


ii) Superheater
Stage I 3.3 3.1 2.6 1.4 1.3 1.1 2.8 2.0 1.7 1.4 2.1 2.4 2.4 2.4
iii) Superheater
Stage II 4.3 4.0 3.5 2.1 1.7 1.4 3.8 2.8 2.2 1.9 2.8 3.2 1.9 1.1
iv) Superheater
Stage III 3.2 3.0 2.7 1.6 1.3 1.1 2.9 2.2 1.7 1.5 2.2 2.5 1.5 0.8
v) Superheater
desuperheater 2.3 2.2 1.9 1.2 0.9 0.8 2.0 1.6 1.2 1.0 1.5 1.7 1.7 1.7
vi) Reheater
Stage I 0.5 0.5 0.4 0.4 0.3 0.2 0.4 0.4 0.3 0.3 0.5 0.5 0.3 0.2
vii) Reheater
Stage II 0.8 0.8 0.8 0.6 0.5 0.4 0.8 0.6 0.5 0.4 0.8 0.8 0.5 0.3
viii) Reheater
desuperheater 0.06 0.06 0.05 0.03 0.02 0.01 0.05 0.03 0.02 0.01 0.04 0.06 0.02 0.00

piping -0.3 -0.5 -1.0 -2.4 -3.2 -3.6 -0.9 -2.2 -3.1 -3.5 -2.2 -1.6 -2.9 -4.2

STAGE-I (3x 660MW)
out of out of (One
ii) economizer 6.2 6.0 5.6 4.7 4.2 4.0 5.7 4.8 4.2 3.9 5.4 5.6 4.4 3.8
i) Furnace throat gas velocity 8.2 8.1 7.8 6.2 4.6 3.9 3.9 7.7 6 4.5 3.8 8.2 5.1 2.3

tube banks of TSH 9.1 8.9 8.5 6.7 4.9 4.1 4.2 8.4 6.6 4.8 4 9 5.5 2.4

tube banks of economizer 9.2 9 8.5 6.6 5 4.2 4.4 8.5 6.7 4.9 4.1 9.1 5.7 2.6

a) Superheater
Stage I - - - - - - - - - - - - - -
Stage II 7.9 7.8 7.5 6 4.4 3.7 3.7 7.4 5.8 4.3 3.6 7.9 4.9 2.2
Stage III 8.8 8.6 8.2 6.4 4.8 4 4 8.2 6.4 4.7 3.9 8.7 5.4 2.4
b) Reheater
Stage I 9.2 9 8.5 6.6 4.9 4.2 4.3 8.4 6.6 4.9 4 9 5.6 2.6
Stage II 8.8 8.6 8.2 6.5 4.8 4 4 8.1 6.3 4.7 3.9 8.6 5.3 2.3
c) economizer
Stage I 8.2 8 7.5 5.9 4.4 3.8 3.9 7.6 6 4.4 3.7 7.6 5.1 2.3
Stage II - - - - - - - - - - - - - -

STAGE-I (3x 660MW)
out of out of (One

elements
a) Gas
- Secondary RAPH 7.5 7.6 6.9 5.2 3.9 3.3 6.9 5.2 3.8 3.2 6.1 6.6 9 2
- Primary RAPH 11.8 10.4 10.8 9.3 7.1 6.0 10.9 9.3 7.1 6.0 12.1 11.4 15.0 4.3
b) Air
- Secondary RAPH 5.0 5.1 4.7 3.6 2.9 2.5 4.7 3.6 2.8 2.4 4.6 4.8 6.5 1.5
- Primary RAPH 7.7 7.6 7.2 6.3 5.1 4.5 7.1 6.2 5 4.3 9.2 8.3 10.8 3.1
iv) Air velocities
a) Cold air ducts 12.4 12.6 11.7 9.2 7.6 7.3 11.7 9.3 7.4 6.5 12.3 12.6 8.3 4.4
b) Hot air ducts 13.8 13.6 12.6 9.6 7.6 7.2 12.6 9.9 7.8 6.9 11.7 13.6 8.9 4.6

ducting sections
a) Eco to AH 10.4 10.4 10.3 7.9 6.2 5.6 10.3 8.2 6.2 5.3 9.8 10.3 6.7 3.5
b) Eco gas bypass

c) AH to ESP 11.9 11.5 10.9 8.6 6.8 6.2 11 8.8 6.7 5.8 11.2 11 7.3 4.2
d) ESP to ID fan 12.6 12.2 11.6 9.1 7.2 6.5 11.6 9.3 7.1 6.1 11.9 11.7 7.8 4.4
e) ID fan to stack 12.2 11.8 11.2 8.8 6.9 6.3 11.2 9 6.9 5.9 11.5 11.3 7.5 4.3


STAGE-I (3x 660MW)
out of out of (One
i) At furnace exit 3.43 3.43 3.43 3.43 3.82 4.14 3.43 3.43 3.43 3.43 3.43 3.43 3.43 4.61

(secondary) 4.63 4.61 4.70 5.01 5.77 6.32 4.69 4.98 5.42 5.72 5.02 4.84 4.46 7.87

before ESP 4.80 4.84 4.89 4.82 6.00 6.59 4.87 5.17 5.64 5.99 5.09 4.98 4.61 8.04
vi) At ESP outlet 4.80 4.84 4.89 4.82 6.00 6.59 4.87 5.17 5.64 5.99 5.09 4.98 4.61 8.04
i) FD fan outlet 1,546,294 1,567,150 1,461,238 1,148,854 949,824 856,040 1,459,340 1,152,762 920,562 810,160 1,532,090 1,569,818 1,035,707 549,928
ii) PA fan outlet 1,162,704 1,075,828 1,057,812 868,698 699,992 592,086 1,057,828 918,387 700,594 591,667 1,175,938 1,084,040 682,793 450,948
a) Primary air 919,540 914,744 871,162 729,348 655,052 588,658 859,292 764,953 646,568 573,057 1,148,384 1,042,622 671,186 443,652
b) Secondary air 1,546,294 1,567,150 1,461,238 1,148,854 949,824 856,040 1,459,340 1,152,762 920,562 810,160 1,532,090 1,569,818 1,035,707 549,928
a) Primary air 823,340 817,544 774,962 680,348 554,252 486,058 763,892 667,753 546,768 472,257 1,032,184 935,422 615,786 340,052
b) Secondary air 1,422,894 1,443,750 1,339,638 1,029,854 830,824 737,040 1,344,635 1,038,968 807,548 694,759 1,381,490 1,432,818 969,007 430,928

pulveriser 27,018 20,136 23,331 19,907 8,988 857 24,817 21,919 10,805 4,653 3,062 5,177 2,321 2,432

STAGE-I (3x 660MW)
out of out of (One
i) Primary Airheater inlet 1,010,878 900,096 934,594 822,546 646,816 556,860 935,086 813,139 647,041 550,987 1,143,522 1,038,572 683,249 405,524
ii) Secondary Airheater inlet 1,840,372 1,876,662 1,707,528 1,317,504 1,023,248 884,888 1,713,497 1,338,698 1,002,599 848,895 1,656,188 1,724,048 1,175,381 537,424
iii) Primary airheater outlet 1,107,078 997,296 1,030,794 871,546 747,616 659,460 1,030,486 910,339 746,841 651,787 1,259,722 1,145,772 738,649 509,124
iv) Secondary airheater outlet 1,963,772 2,000,062 1,829,128 1,436,504 1,142,248 1,003,888 1,827,850 1,447,292 1,118,160 964,296 1,806,788 1,861,048 1,242,081 656,424
v) ESP inlet 3,070,850 2,997,358 2,859,922 2,308,050 1,889,864 1,663,348 2,858,336 2,357,631 1,865,001 1,616,083 3,066,510 3,006,820 1,980,730 1,165,548
vi) ESP outlet 3,070,850 2,997,358 2,859,922 2,308,050 1,889,864 1,663,348 2,858,336 2,357,631 1,865,001 1,616,083 3,066,510 3,006,820 1,980,730 1,165,548
vii) ID fan inlet 3,070,850 2,997,358 2,859,922 2,308,050 1,889,864 1,663,348 2,858,336 2,357,631 1,865,001 1,616,083 3,066,510 3,006,820 1,980,730 1,165,548

i) At burner 20.0 20.0 20.0 20.0 22.7 25.0 20.0 20.0 20.0 20.0 20.0 20.0 20.0 28.6

(primary) 32.35 34.02 33.36 27.71 43.36 49.84 33.24 35.52 40.04 43.77 33.20 33.40 30.51 63.96

(secondary) 28.69 28.52 29.23 31.72 38.10 43.11 29.14 31.43 35.05 37.65 31.80 30.30 27.34 59.23
vi) At ESP inlet 29.98 30.30 30.69 30.17 40.13 45.70 30.58 32.97 37.00 40.05 32.37 31.46 28.50 61.25

STAGE-I (3x 660MW)
out of out of (One
i) Primary air
a) Regenerative air
preheater 96.2 97.2 96.2 49.0 100.8 102.6 95.4 97.2 99.8 100.8 116.2 107.2 55.4 103.6
b) Ducts/Dampers 0 0 0 0 0 0 0 0 0 0 0 0 0 0
ii) Secondary air
a) Regenerative air
heater 123.4 123.4 121.6 119.0 119.0 119.0 120.8 118.0 116.2 115.4 150.6 137.0 66.7 119.0
b) Wind box 0 0 0 0 0 0 0 0 0 0 0 0 0 0
c) Ducts/Dampers 0 0 0 0 0 0 0 0 0 0 0 0 0 0

design coal fired)

coal (Kcal/kg) 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000 3000

of coal in
- Primary 91.1 90.2 90.8 91.9 87.0 81.8 90.5 91.6 88.6 83.8 65.5 72.4 72.4 72.4
- Secondary 166.6 173.8 166.4 148.7 138.9 141.1 167.6 150.9 139.2 130.8 142.2 189.8 189.8 189.8
Stage I 271.5 292.2 315.0 352.5 328.0 291.5 303.6 312.6 310.6 301.4 289.2 302.8 342.4 272.5
Stage II 187.6 197.4 208.9 229.9 235.8 227.8 203.6 211.3 225.9 236.9 197.1 203.6 246.1 210.8
Stage III 203.7 210.2 215.8 209.7 190.9 179.1 210.9 194.7 180.0 172.2 212.5 216.6 197.8 104.0

STAGE-I (3x 660MW)
out of out of (One
Roof tubes 5.8 6.0 6.1 5.8 5.3 5.1 5.9 5.4 5.0 4.9 5.9 6.0 5.5 3.4
Convective pass 47.7 49.6 51.4 52.9 55.4 57.8 51.0 52.5 55.8 59.0 50.7 51.4 54.7 64.4
Steam cooled 26.1 27.0 27.9 28.0 26.5 25.2 27.1 25.7 24.8 25.3 27.0 27.6 27.5 18.5
Hanger tubes 10.9 11.4 11.7 11.8 12.0 12.5 11.6 11.7 12.1 12.6 11.6 11.7 11.9 13.6
d) Reheater (kcal)
Stage I 324.7 328.7 330.5 320.5 287.3 277.9 322.0 290.1 258.1 241.6 319.0 325.8 294.7 224.7
Stage II 199.6 209.3 218.4 228.5 221.6 209.0 212.4 207.1 208.0 209.7 206.9 214.1 232.3 179.0
e) Water walls
Wall tubing 990.2 978.8 890.7 968.8 956.4 1021.7 927.6 974.6 1016.7 1056.0 882.8 881.2 919.0 1244.4
Screen tubes 32.0 33.2 34.4 35.7 36.6 36.7 33.9 33.7 35.7 36.2 33.6 34.3 37.1 36.3
Any other 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0


Generator
conditions also:

(%)
- Dry gas loss 4.73 4.52 4.49 4.12 3.94 4.29 4.58 4.30 3.86 3.95 3.74 3.76 3.81 4.54

STAGE-I (3x 660MW)
out of out of (One

to flue gases 12.34 12.10 12.07 11.65 11.40 11.77 12.17 11.83 11.32 11.41 11.20 11.23 11.30 12.03

carbon (%) in:
- Fly ash 1.05 1.05 1.05 1.05 1.05 1.05 1.05 1.05 1.05 1.05 1.05 1.05 1.05 1.05

unburnt carbon 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.70 1.70
- economizer hopper
ash 0.04 0.04 0.03 0.03 0.03 0.03 0.04 0.03 0.03 0.03 0.03 0.03 0.03 0.03
- Air heater hopper

ash 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01 0.01
- Any other hopper

ash 0.18 0.17 0.17 0.16 0.14 0.14 0.17 0.16 0.14 0.14 0.14 0.14 0.15 0.14

loss 0.72 0.71 0.70 0.69 0.67 0.67 0.71 0.69 0.67 0.67 0.67 0.67 0.68 0.67

Rejects (%) 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07

(give details) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

(i) to (v)} 15.01 14.77 14.73 14.34 14.14 14.55 14.84 14.52 14.06 14.19 13.82 13.85 14.01 14.99

STAGE-I (3x 660MW)
out of out of (One


(%) 84.89 85.13 85.17 85.56 85.76 85.35 85.06 85.38 85.84 85.71 86.08 86.05 85.89 84.91

collected

(kg/hr) 47299 46063 43829 35501 27155 23054 43937 35696 27365 23235 46410 45828 30857 14696

(kg/hr) 11825 11516 10957 8875 6789 5763 10984 8924 6841 5809 11603 11457 7714 3674
iii) Air he 7095 6909 6574 5325 4073 3458 6590 5354 4105 3485 6962 6874 4629 2204

in operation 1604.4 1555.8 1457.0 1172.8 895.5 759.7 1468.6 1188.7 904.2 763.8 1541.8 1525.9 1017.6 N/A
in services B~J C~J C~J D~J F~J G~J C~J D~J F~J G~J B~J C~J C~J N/A
ii) Burner tilt (deg) -30 -25 -19 11 -5 -25 -25 -25 -25 -25 -25 -25 -1 N/A

in operation 1578.0 1535.0 1457.0 1143.9 895.3 763.4 1461.4 1180.4 901.3 768.4 1517.4 1515.1 1018.7 N/A
in services A~I B~I B~I C~I D~H D~G B~I C~I D~H D~G A~I B~I B~I N/A
ii) Burner tilt (deg) -30 -23 4 25 25 -16 -13 -5 3 -25 -21 -7 25 N/A

STAGE-I (3x 660MW)
out of out of (One

in operation 1572.9 1534.9 1453.0 1149.8 903.0 764.5 1461.3 1180.6 904.6 771.6 1518.3 1515.0 1026.8 479.9
in services A~I A~H A~H B~H B~F C~F A~H B~H B~F C~F A~I A~H B~F C~E
ii) Burner tilt (deg) -8 16 25 25 25 25 20 25 25 0 15 25 25 0

Furnace

Zone level)

in Clause 3.14.01 146.3 151.8 129.2 87.5 58.3 55.2 134.7 111.4 68.5 58.4 135.1 132.0 44.6 N/A

in Clause 3.14.01 156.6 154.3 108.6 58.6 45.7 67.3 147.9 114.5 69.3 74.5 141.7 124.4 61.0 N/A

in Clause 3.14.01 147.3 132.3 95.9 59.5 57.5 50.3 103.3 83.8 62.1 75.2 94.1 101.2 64.7 49.7

in Clause 3.14.01 204.5 202.1 176.3 120.4 96.2 90.7 182.8 150.4 114.6 96.1 180.0 182.1 76.9 N/A


STAGE-I (3x 660MW)
out of out of (One
in Clause 3.14.01 237.9 226.7 166.0 93.9 77.5 107.1 190.8 151.4 108.2 116.9 205.7 186.0 99.2 N/A

in Clause 3.14.01 230.4 222.0 145.8 107.3 95.4 81.8 146.9 120.9 103.0 107.7 165.3 146.7 102.5 74.2

in Clause 3.14.01 349.6 349.5 319.0 273.5 210.0 193.9 324.3 282.8 230.7 205.4 311.0 320.2 204.7 N/A

in Clause 3.14.01 397.3 391.6 321.9 238.0 202.7 202.3 343.8 291.2 231.4 212.2 351.3 337.9 208.1 N/A

in Clause 3.14.01 409.1 409.0 328.9 255.5 217.6 191.3 331.3 288.7 233.8 216.3 340.3 329.0 225.1 160.5

in Clause 3.14.01 392.7 391.9 362.5 323.5 246.2 224.3 366.9 323.3 264.6 237.0 350.4 361.2 246.8 N/A

in Clause 3.14.01 443.3 437.7 368.9 284.6 242.1 229.3 388.9 332.9 267.6 238.1 393.3 382.7 241.5 N/A

in Clause 3.14.01 459.8 460.5 383.8 301.6 253.7 224.4 386.4 340.5 271.2 246.1 391.9 383.5 260.9 183.1

STAGE-I (3x 660MW)
out of out of (One

in Clause 3.14.01 752 739 700 616 462 401 701 596 473 412 698 704 478 N/A

in Clause 3.14.01 772 757 695 571 459 398 704 597 474 403 714 713 475 N/A

in Clause 3.14.01 767 782 700 565 546 395 702 601 470 408 712 712 466 283

in Clause 3.14.01 1024 1008 946 817 608 521 946 789 615 528 970 969 632 N/A

in Clause 3.14.01 1022 1007 941 771 605 516 944 783 613 517 966 968 633 N/A

in Clause 3.14.01 1014 1033 941 759 598 513 943 787 608 521 964 967 614 340

in Clause 3.14.01 1234 1210 1129 962 709 603 1128 926 710 603 1170 1164 737 N/A


STAGE-I (3x 660MW)
out of out of (One
in Clause 3.14.01 1218 1198 1124 918 706 600 1123 916 706 594 1154 1157 740 N/A

in Clause 3.14.01 1207 1224 1122 910 703 598 1122 921 701 599 1152 1156 725 386

in Clause 3.14.01 1379 1339 1256 1022 786 669 1265 1033 795 675 1374 1336 889 N/A

in Clause 3.14.01 1357 1321 1256 1022 786 669 1259 1026 792 675 1352 1326 889 N/A

in Clause 3.14.01 1352 1321 1253 1022 786 669 1259 1026 792 675 1352 1326 889 428

in Clause 3.14.01 1519 1489 1387 1158 853 723 1386 1127 856 722 1473 1493 883 N/A

in Clause 3.14.01 1499 1473 1381 1119 851 726 1379 1116 852 720 1454 1447 886 N/A

in Clause 3.14.01 1487 1500 1378 1125 859 726 1380 1124 850 730 1452 1447 892 459

STAGE-I (3x 660MW)
out of out of (One


in Clause 3.14.01 48 48 49 51 52 53 49 51 53 55 46 45 52 N/A

in Clause 3.14.01 50 50 48 49 52 53 49 52 54 54 48 48 51 N/A

in Clause 3.14.01 50 50 49 49 51 53 49 52 54 54 47 48 51 61

in Clause 3.14.01 89.0 86.4 81.0 62.9 84.6 75.2 81.4 63.7 90.7 77.6 73.6 78.4 56.0 N/A

in Clause 3.14.01 89.0 86.4 81.0 62.9 85.7 65.5 81.4 63.7 78.9 57.0 73.6 78.4 57.0 N/A

in Clause 3.14.01 89.0 86.4 81.0 62.9 51.0 70.4 81.4 63.7 71.9 45.2 73.6 78.4 26.5 37.3


STAGE-I (3x 660MW)
out of out of (One
in Clause 3.14.01 48.8 31.6 0.0 0.0 0.0 0.0 10.1 12.1 5.1 0.0 32.1 16.1 0.0 N/A

in Clause 3.14.01 8.7 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 N/A

in Clause 3.14.01 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0

ii) Efficiency (%) 85.76 86.05 85.96 86.32 86.85 87.08 85.92 86.25 86.80 87.12 87.41 86.83 86.46 87.86

6
(10 Kcal/hr) 1576.6 1535.4 1461.0 1183.4 905.2 768.5 1464.6 1189.9 912.2 774.5 1547.0 1527.6 1028.6 489.9

(Unburnt) 1572.9 1535.0 1457.0 1172.8 895.3 759.7 1461.4 1180.4 901.3 763.8 1518.3 1515.0 1017.6 479.9
vi) Furnace EPRS (m2) 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9

(106 Kcal/m2/hr) 4.61 4.50 4.27 3.44 2.62 2.23 4.28 3.46 2.64 2.24 4.45 4.44 2.98 1.41

(106 Kcal/m2/hr) 0.174 0.170 0.161 0.130 0.099 0.084 0.162 0.131 0.100 0.084 0.168 0.168 0.113 0.053

(106 Kcal/m2/hr) 0.073 0.072 0.068 0.055 0.042 0.036 0.068 0.055 0.043 0.036 0.072 0.071 0.048 0.023

STAGE-I (3x 660MW)
out of out of (One

tubes (Kg/m2 sec)
i) Maximum 3150 3058 2865 2226 1640 1365 2881 2255 1672 1391 2605 2775 2775 2775
ii) Minimum 2495 2422 2270 1764 1299 1081 2282 1787 1325 1102 2064 2198 2198 2198

(Vertical Wall)
iii) Side Walls 1173 1140 1067 829 611 508 1073 840 623 517 970 1033 1033 1033
i) Steam conditions

(abs) 16
(degC) 210~310

Max N/A

(kg/hr)Max
a) Primary 9058
b) Secondary 14084

STAGE-I (3x 660MW)
out of out of (One

b) After four hours


down) (kg/hr) Later


4.19.00 Start ups





shutdown (hours) 4


STAGE-I (3x 660MW)
out of out of (One



40% to 100% No limit provided recommended heat-up rates are adhered to.

No limit provided recommended heat-up ratesAre adhered to.

shut down Later

shut down Later

shutdown Later

shutdown Later

shutdown Later

STAGE-I (3x 660MW)
out of out of (One

(kg/hr) N/A


i) Free air area (m2) 4.48 3.98 3.98 3.49 2.49 1.99 3.98 3.49 2.49 1.99 4.48 3.98 2.49 1.49

3
wind box (m /sec) 674 683 628 469 366 319 634 477 358 304 579 634 425 177






STAGE-I (3x 660MW)
out of out of (One

decimal)

at mean firing zone

Eco outlet 5.4254

STAGE-I (3x 660MW)
C) BEST COAL
out of out of (One
5.01.00 General

outlet (Tonnes/hr) 2225 2160 2023.75 1572.47 1158.41 963.76 2035.24 1592.96 1178.13 982.34 1839.5 1960.0 1335.0 596.1



(Tonnes/hr) 1741.82 1753.03 1678.37 1328.96 996.95 836.41 1686.33 1343.65 1012.39 851.48 1784.2 1784.34 1138 517.2

inlet (kg/cm2)(abs) 48.3 48.7 46.7 37.2 28.1 23.6 47.0 37.6 28.5 24.0 50.5 50.1 32.2 14.6



reheater (kg/cm2) 1.69 1.70 1.62 1.30 1.02 0.88 1.63 1.34 1.05 0.90 1.70 1.70 1.13 0.57

(degC) 289.64 290 286.23 270.35 254.09 244.34 287.28 273.24 256.75 246.95 196.15 243.54 261 219

coal 87.02 87.01 87.29 87.64 87.57 87.51 87.20 87.54 87.75 87.65 87.98 88.06 87.84 87.72

STAGE-I (3x 660MW)
out of out of (One
unit furnace volume

(x106kal/m3/hr) 0.072 0.070 0.067 0.054 0.042 0.035 0.067 0.054 0.042 0.036 0.071 0.070 0.047 0.022

(x106kcal/m2/hr) 0.173 0.169 0.160 0.129 0.099 0.084 0.161 0.130 0.099 0.084 0.167 0.167 0.112 0.053

rate (x106kcal/m2/hr) 1.184 1.157 1.098 0.889 0.683 0.579 1.100 0.894 0.687 0.584 1.162 1.150 0.773 0.368

rate (x106kcal/m2/hr) 4.58 4.47 4.24 3.42 2.62 2.21 4.25 3.44 2.63 2.23 4.42 4.41 2.96 1.40

pulverisers 10 10 10 10 10 10 10 10 10 10 10 10 10 10


(tonnes/hr) 412.4 403.0 382.1 309.5 237.7 201.5 383.0 311.2 239.3 203.3 404.5 400.2 269.1 128.2

rature (degC) 999 1014 1022 991 912 891 1006 956 903 884 1010 1018 954 764


outlet (ppm)

solids 0.002
Max
b) Silica 0.002
Max
c) Sodium 0.002
d) Chlorides 0.002
Max
e) Copper 0.001
Max
f) Iron 0.005

STAGE-I (3x 660MW)
out of out of (One

5.02.01 Air

in Service
in service B~H B~G B~G B~F C~F C~E B~G B~F C~F C~E B~G B~G C~F C~D

cable( deg) 16 25 25 25 25 25 25 25 25 0 25 25 25 0

(Primary air) 34.7 34.7 34.4 34.0 36.0 49.0 34.4 34.0 38.0 46.0 54.0 34.7 33.9 67.0
v) Outlet of RAPH
(Primary air) 297 298 294 273 266 250 296 279 264 256 225 258 254 221

(Secondary air) 30.9 30.9 30.6 30.3 38.0 50.0 30.6 30.3 35.0 46.0 53.0 30.9 30.1 65.0

(Secondary air) 294 295 289 272 257 248 291 277 262 254 226 257 254 221

Inlet to burners 294 295 289 272 257 248 291 277 262 254 226 257 254 221

STAGE-I (3x 660MW)
out of out of (One

the common duct


in Service
in service C~I C~H C~H D~H D~G E~G C~H D~H D~G E~G C~H C~H D~G N/A

cable (deg) -17 10 25 25 25 -17 11 0 -9 -25 10 21 25 N/A

(Primary air) 37.4 37.4 34.4 34.0 39.5 49.0 34.4 34.0 38.0 46.0 54.0 34.7 33.9 N/A
v) Outlet of RAPH
(Primary air) 297 296 292 274 259 250 294 279 263 255 223 257 253 N/A

(Secondary air) 30.9 30.9 30.6 30.3 38.0 49.0 30.6 30.3 35.0 46.0 54.0 30.9 30.1 N/A

(Secondary air) 294 294 288 272 258 248 291 277 262 254 225 257 254 N/A


the common duct


STAGE-I (3x 660MW)
out of out of (One
in Service
in service D~J E~J E~J F~J G~J H~J E~J F~J G~J H~J E~J E~J G~J N/A

cable( deg) -25 -20 0 20 -18 -25 -25 -25 -25 -25 -25 -7 19 N/A

(Primary air) 34.7 34.7 34.4 34.0 39.0 48.0 34.4 34.0 37.0 46.0 54.0 34.7 33.9 N/A
v) Outlet of RAPH
(Primary air) 296 296 292 274 260 249 294 279 263 254 223 257 252 N/A

(Secondary air) 30.9 30.9 30.6 30.3 39.0 50.0 30.6 30.3 35.0 45.0 54.0 30.9 30.1 N/A

(Secondary air) 294 294 288 273 257 247 291 277 262 254 225 257 254 N/A


the common duct




STAGE-I (3x 660MW)
out of out of (One

in Service
ations in service B~H B~G B~G B~F C~F C~E B~G B~F C~F C~E B~G B~G C~F C~D

cable) (deg) 16 25 25 25 25 25 25 25 25 0 25 25 25 0

temperature in the
combustion zone 1591 1570 1553 1492 1389 1350 1548 1499 1410 1356 1544 1547 1390 1236

super heater) 1338 1342 1332 1312 1255 1225 1336 1316 1259 1181 1342 1339 1275 1120

cation for FEGT) 997 1002 993 945 896 874 992 948 890 861 999 998 923 764
Stage I 1338 1342 1332 1312 1255 1225 1336 1316 1259 1181 1342 1339 1275 1120
Stage II 1092 1096 1087 1048 997 987 1088 1052 995 969 1095 1092 1023 879
Stage III 860 864 857 802 763 737 854 809 756 729 862 861 788 633
Stage I 1092 1096 1087 1048 997 987 1088 1052 995 969 1095 1092 1023 879
Stage II 997 1002 993 945 896 874 992 948 890 861 999 998 923 764
Stage III 728 731 726 680 649 626 723 683 642 622 728 728 668 564

STAGE-I (3x 660MW)
out of out of (One
Stage I 721 724 719 673 642 619 716 676 635 614 721 721 662 556
Stage II 997 1002 993 945 896 874 992 948 890 861 999 998 923 764
Stage I 487 489 485 446 434 419 484 461 439 429 491 489 445 379
Stage II 879 883 876 822 783 757 874 829 776 749 881 880 808 655
mizer 487 489 485 446 434 419 484 461 439 429 491 489 445 379

air heater 321 322 318 295 278 266 318 299 280 268 249 286 287 233

air heater 321 322 318 295 278 266 318 299 280 268 249 286 287 233






precipitator 131 131 125 115 110 111 126 117 110 110 111 110 114 110

precipitator 129 129 123 113 108 109 124 115 108 108 109 108 112 108

STAGE-I (3x 660MW)
out of out of (One

in Service
ations in service C~I C~H C~H D~H D~G E~G C~H D~H D~G E~G C~H C~H D~G N/A

cable ) (deg) -17 10 25 25 25 -17 11 0 -9 -25 10 21 25 N/A

temperature in the

super heater) 1341 1362 1374 1348 1320 1222 1358 1324 1265 1209 1361 1373 1333 N/A

Stage I 1341 1362 1374 1348 1320 1222 1358 1324 1265 1209 1361 1373 1333 N/A
Stage II 1094 1113 1126 1087 1029 996 1110 1063 1002 987 1111 1122 1057 N/A
Stage III 861 868 867 824 769 738 859 811 756 731 866 871 794 N/A
Stage I 1094 1113 1126 1087 1029 996 1110 1063 1002 987 1111 1122 1057 N/A
Stage II 999 1012 1018 975 915 879 1006 956 894 871 1010 1018 943 N/A

STAGE-I (3x 660MW)
out of out of (One
Stage III 729 731 727 691 649 626 722 683 642 621 728 731 668 N/A
Stage I 722 724 719 684 642 619 716 676 634 613 721 724 661 N/A
Stage II 999 1012 1018 975 915 879 1006 956 894 871 1010 1018 943 N/A
Stage I 487 486 478 451 429 418 481 458 438 425 488 487 438 N/A
Stage II 881 888 888 844 791 759 880 831 777 752 887 892 816 N/A
mizer 487 486 478 451 429 418 481 458 438 425 488 487 438 N/A

air heater 321 320 315 296 277 265 316 298 279 267 248 284 284 N/A

air heater 321 320 315 296 277 265 316 298 279 267 248 284 284 N/A






precipitator 131 131 125 115 110 110 127 118 110 110 111 110 113 N/A

STAGE-I (3x 660MW)
out of out of (One

precipitator 129 129 123 113 108 108 125 116 108 108 109 108 111 N/A

in Service
ations in service D~J E~J E~J F~J G~J H~J E~J F~J G~J H~J E~J E~J G~J N/A

cable ) (deg) -25 -30 0 20 -18 -25 -25 -25 -25 -30 -25 -7 19 N/A

temperature in the

super heater) 1363 1364 1375 1371 1306 1263 1354 1332 1294 1261 1358 1373 1354 N/A

Stage I 1363 1364 1375 1371 1306 1263 1354 1332 1294 1261 1358 1373 1354 N/A
Stage II 1119 1115 1129 1110 1026 1017 1109 1075 1017 1012 1109 1123 1077 N/A
Stage III 875 869 869 831 768 741 859 817 759 734 866 872 797 N/A

STAGE-I (3x 660MW)
out of out of (One
Stage I 1119 1115 1129 1110 1026 1017 1109 1075 1017 1012 1109 1123 1077 N/A
Stage II 1019 1014 1022 991 912 891 1006 964 903 884 1009 1019 954 N/A
Stage III 737 732 728 693 648 624 722 686 641 619 728 731 666 N/A
Stage I 730 724 721 686 641 617 715 678 634 612 721 724 659 N/A
Stage II 1019 1014 1022 991 912 891 1006 964 903 884 1009 1019 954 N/A
Stage I 486 486 479 449 429 414 481 458 435 421 488 487 434 N/A
Stage II 896 889 890 853 789 762 879 838 781 757 886 892 819 N/A
mizer 486 486 479 449 429 414 481 458 435 421 488 487 434 N/A

air heater 321 320 315 295 276 264 316 298 279 266 248 284 283 N/A

air heater 321 320 315 295 276 264 316 298 279 266 248 284 283 N/A





STAGE-I (3x 660MW)
out of out of (One

precipitator 130 131 125 116 110 110 127 118 110 110 111 110 115 N/A

precipitator 128 129 123 114 108 108 125 116 108 108 109 108 113 N/A
5.02.04 Feed Water

in Service

cable ) (deg) 16 25 25 25 25 25 25 25 25 0 25 25 25 0
iii) Water entering

economizer 290 290 286 270 254 244 287 273 257 247 196 244 261 219
iv) Water leaving

economizer 339 342 340 321 313 305 339 326 315 307 297 319 319 277
water temperature
a) Superheater 290 290 286 270 254 244 287 273 257 247 196 244 261 219
b) Reheater 191 191 191 181 169 161 191 181 169 161 196 195 169 144

in Service

STAGE-I (3x 660MW)
out of out of (One

cable ) (deg) -17 10 25 25 25 -17 11 0 -9 -25 10 21 25 N/A
iii) Water entering

economizer 290 290 286 270 254 244 287 273 257 247 196 244 261 N/A
iv) Water leaving

economizer 339 340 336 323 312 304 337 324 314 305 294 316 316 N/A
water temperature
a) Superheater 290 290 286 270 254 244 287 273 257 247 196 244 261 N/A
b) Reheater 191 191 191 181 169 161 191 181 169 161 196 195 169 N/A

in Service

cable ) (deg) -25 -20 0 20 -18 -25 -25 -25 -25 -25 -25 -7 19 N/A
iii) Water entering

economizer 290 290 286 270 254 244 287 273 257 247 196 244 261 N/A
iv) Water leaving

economizer 340 340 336 321 311 302 337 324 313 303 294 317 314 N/A
water temperature
a) Superheater 290 290 286 270 254 244 287 273 257 247 196 244 261 N/A
b) Reheater 191 191 191 181 169 161 191 181 169 161 196 195 169 N/A
5.02.05 Steam

STAGE-I (3x 660MW)
out of out of (One

in Service

cable ) (deg) 16 25 25 25 25 25 25 25 25 0 25 25 25 0
1st Stage 416 413 410 403 371 362 407 384 363 350 401 406 382 333
2nd Stage 450 448 444 440 422 411 443 426 416 408 433 440 429 417
3rd Stage 485 483 481 483 472 470 480 475 471 469 473 477 472 492
1st Stage 460 458 454 451 429 431 453 438 442 422 444 450 429 429
2nd Stage 492 491 488 491 490 490 488 484 491 491 480 484 489 519
3rd Stage 540 540 540 540 540 540 540 540 540 540 540 540 540 540
1st Stage 299 300 296 281 286 289 303 306 310 313 309 306 284 294
2nd Stage 455 456 455 433 447 443 456 454 453 453 458 455 448 424
1st Stage 455 456 455 433 447 443 457 454 453 453 458 456 448 424
2nd Stage 568 568 568 568 568 568 568 568 568 568 568 568 568 568

in Service

STAGE-I (3x 660MW)
out of out of (One

cable ) (deg) -17 10 25 25 25 -17 11 0 -9 -25 10 21 25 N/A
1st Stage 416 411 406 396 371 362 405 383 363 351 399 402 383 N/A
2nd Stage 450 446 441 433 417 409 441 425 416 405 432 436 426 N/A
3rd Stage 485 483 480 478 471 469 480 475 471 469 472 476 474 N/A
1st Stage 460 456 450 442 441 426 451 437 441 425 442 446 438 N/A
2nd Stage 492 490 487 485 489 490 487 483 491 491 480 483 490 N/A
3rd Stage 540 540 540 540 540 540 540 540 540 540 540 540 540 N/A
1st Stage 299 300 296 281 286 289 303 306 310 313 309 306 284 N/A
2nd Stage 455 453 448 439 442 442 452 452 451 449 456 453 441 N/A
1st Stage 455 453 449 439 442 443 453 452 452 449 456 454 442 N/A
2nd Stage 568 568 568 568 568 568 568 568 568 568 568 568 568 N/A

in Service

STAGE-I (3x 660MW)
out of out of (One

cable ) (deg) -25 -20 0 20 -18 -25 -25 -25 -25 -25 -25 -7 19 N/A
1st Stage 411 410 406 394 371 362 405 381 363 351 400 402 383 N/A
2nd Stage 446 446 441 430 419 407 441 423 413 400 432 436 425 N/A
3rd Stage 482 482 480 477 472 469 480 473 471 468 473 476 474 N/A
1st Stage 456 455 450 439 434 431 451 435 445 434 442 446 443 N/A
2nd Stage 489 489 487 484 490 490 487 482 491 491 480 483 491 N/A
3rd Stage 540 540 540 540 540 540 540 540 540 540 540 540 540 N/A
1st Stage 291 300 296 281 286 289 303 302 310 312 309 306 284 N/A
2nd Stage 450 453 449 438 442 438 452 450 449 445 455 453 437 N/A
1st Stage 450 453 449 438 442 438 453 450 449 445 456 454 437 N/A
2nd Stage 568 568 568 568 568 568 568 568 568 568 568 568 568 N/A
5.03.00 Pressure

STAGE-I (3x 660MW)
out of out of (One
5.03.01 Air (mmwc)

and silencer)

(Secondary air ) 203 196 192 160 177 157 192 162 169 151 298 293 234 125

(Secondary air) 157 153 151 133 158 143 151 134 152 138 253 248 162 119
(Secondary air) 102 102 102 102 102 102 102 102 102 102 102 102 102 102

and silencer)

common duct before
pulverisers 778 774 799 793 785 816 799 793 786 817 805 807 815 805


STAGE-I (3x 660MW)
out of out of (One
2


for superheater 304.1 300.4 292.9 261.1 195.9 165.5 283.1 220.7 165.4 139.3 282.6 289.2 224.5 101.1
for reheater 91.5 91.9 89.9 80.4 71.3 66.8 90.2 80.7 71.7 67.2 93.7 93.3 75.4 57.8
5.03.04 Separator

STAGE-I (3x 660MW)
out of out of (One

bends dampers,
vanes etc 192 160 175 179 202 169 135 138 164 125 215 115 169 169

c) Across RAPH 33 33 29 23 16 12 29 22 16 12 49 39 66 7

the system 254 222 232 228 242 205 192 186 204 161 294 183 260 198

i) Furnace pressure
(back draught) 3 3 3 3 3 3 3 3 3 3 3 3 3 3
ii) Across SH/RH

convection path 64 59 59 51 46 41 59 51 46 41 61 61 37 14
v) In gas ducts

precipitator funnel
inlet 42 40 37 25 17 12 37 25 16 12 42 41 18 6

STAGE-I (3x 660MW)
out of out of (One


ii) Superheater
Stage I 3.3 3.0 2.6 1.4 1.3 1.1 2.8 2.0 1.7 1.4 2.1 2.4 2.4 2.4
iii) Superheater
Stage II 4.3 4.0 3.5 2.1 1.7 1.4 3.8 2.9 2.2 1.9 2.8 3.2 3.2 1.9
iv) Superheater
Stage III 3.2 3.0 2.7 1.6 1.3 1.1 2.9 2.2 1.8 1.5 2.2 2.5 2.5 1.5
v) Superheater
desuperheater 2.3 2.2 1.9 1.2 0.9 0.8 2.0 1.6 1.2 1.0 1.5 1.7 1.7 1.7
vi) Reheater
Stage I 0.5 0.5 0.4 0.4 0.3 0.2 0.4 0.4 0.3 0.3 0.5 0.5 0.5 0.3
vii) Reheater
Stage II 0.8 0.8 0.8 0.6 0.5 0.4 0.8 0.6 0.5 0.4 0.8 0.8 0.8 0.5
viii) Reheater
desuperheater 0.06 0.06 0.05 0.03 0.02 0.01 0.05 0.03 0.02 0.01 0.04 0.06 0.02 0.00

piping -0.3 -0.5 -1.0 -2.4 -3.3 -3.6 -0.9 -2.2 -3.1 -3.5 -2.3 -1.6 -1.6 -3.0

STAGE-I (3x 660MW)
out of out of (One
ii) economizer 6.2 6.1 5.7 4.8 4.1 4.0 5.7 4.8 4.2 4.0 5.5 5.6 5.6 4.5
i) Furnace throat gas velocity 8.1 8.2 8.1 7.8 6.2 4.7 3.9 7.7 6 4.5 3.8 8.1 4.8 2.2

tube banks of TSH 8.9 9 8.8 8.4 6.6 5 4.1 8.3 6.5 4.8 3.9 8.9 5.1 2.3

tube banks of economizer 8.9 8.9 8.7 8.2 6.4 5 4.1 8.2 6.5 4.9 4 8.8 5 2.5

a) Superheater
Stage I - - - - - - - - - - - - - -
Stage II 7.8 7.9 7.8 7.5 5.9 4.5 3.7 7.4 5.8 4.3 3.6 7.8 4.6 2.1
Stage III 8.6 8.7 8.5 8.1 6.3 4.9 3.9 8 6.3 4.7 3.8 8.6 4.9 2.3
b) Reheater
Stage I 8.9 9 8.7 8.2 6.4 5 4 8.2 6.4 4.8 3.9 8.8 5 2.4
Stage II 8.6 8.7 8.5 8.1 6.4 4.9 4 8.1 6.3 4.7 3.8 8.6 4.9 2.3
c) economizer
Stage I 7.7 8 7.8 7.3 5.7 4.5 3.6 7.3 5.8 4.4 3.6 7.4 4.5 2.2
Stage II - - - - - - - - - - - - - -

STAGE-I (3x 660MW)
out of out of (One

elements
a) Gas
- Secondary RAPH 8.6 8.4 7.9 6.1 4.8 3.9 7.9 6.2 4.6 3.8 7.2 7.7 10.3 2.3
- Primary RAPH 7.7 7.6 7.0 5.9 4.8 4.0 7.0 5.9 4.7 4.0 8.0 7.4 10.2 2.8
b) Air
- Secondary RAPH 5.7 5.5 5.4 4.2 3.4 2.9 5.4 4.2 3.2 2.7 5.5 5.5 7.2 1.7
- Primary RAPH 4.6 4.5 4.3 3.7 3 2.5 4.2 3.6 2.9 2.5 5.6 4.9 6.6 1.8
iv) Air velocities
a) Cold air ducts 14.1 13.7 13.4 10.8 9 7.7 13.4 10.9 8.5 7.3 14.7 14.3 9.2 5
b) Hot air ducts 15.5 14.8 14.3 11.2 9 7.5 14.4 11.6 9.1 7.7 15.8 15.5 9.9 5.2

ducting sections
a) Eco to AH 10.8 10.5 9.9 7.8 6.3 5.2 10 7.9 6.1 5.1 9.4 9.9 6 2.9
b) Eco gas bypass

c) AH to ESP 11.5 11.2 10.5 8.4 6.8 5.8 10.5 8.5 6.6 5.6 10.9 10.7 7.1 4
d) ESP to ID fan 12.2 11.9 11.2 8.9 7.3 6.2 11.2 9 7 6 11.5 11.3 7.5 4.2
e) ID fan to stack 11.8 11.5 10.8 8.6 7 6 10.8 8.7 6.8 5.8 11.2 11 7.3 4.1


STAGE-I (3x 660MW)
out of out of (One
i) At furnace exit 3.46 3.46 3.46 3.46 4.46 4.11 3.46 3.46 3.69 3.46 3.46 3.46 3.46 4.08

(secondary) 4.52 4.54 4.59 4.83 6.05 6.03 4.57 4.81 5.37 5.45 4.87 4.70 4.37 7.06

before ESP 4.84 4.86 4.94 5.26 6.54 6.63 4.93 5.23 5.88 6.07 5.18 5.04 4.64 7.80
vi) At ESP outlet 4.84 4.86 4.94 5.26 6.54 6.63 4.93 5.23 5.88 6.07 5.18 5.04 4.64 7.80
i) FD fan outlet 1,759,622 1,706,506 1,670,734 1,348,440 1,121,026 960,162 1,668,104 1,353,018 1,060,230 911,198 1,827,040 1,787,020 1,152,065 618,090
ii) PA fan outlet 898,490 892,640 802,956 681,728 560,266 462,964 801,770 680,540 560,102 461,172 835,944 823,250 534,244 342,382
a) Primary air 572,990 565,416 541,416 487,918 417,888 377,006 535,830 479,494 414,704 369,130 741,908 640,204 420,803 306,122
b) Secondary air 1,759,622 1,706,506 1,670,734 1,348,440 1,121,026 960,162 1,668,104 1,353,018 1,060,230 911,198 1,827,040 1,787,020 1,152,065 618,090
a) Primary air 481,190 473,616 447,816 391,718 319,888 275,206 443,230 385,094 317,504 269,330 629,308 537,604 368,603 200,722
b) Secondary air 1,633,422 1,582,106 1,546,334 1,226,840 999,426 839,362 1,544,704 1,232,218 942,230 793,998 1,669,040 1,645,420 1,083,965 498,290

pulveriser 46,500 46,746 43,590 38,762 35,595 28,653 44,323 40,209 36,350 30,681 15,673 30,508 28,360 18,130

STAGE-I (3x 660MW)
out of out of (One
i) Primary Airheater inlet 656,308 644,612 603,208 518,810 431,636 369,614 594,900 515,970 426,686 361,492 755,936 673,210 460,663 268,816
ii) Secondary Airheater inlet 2,120,678 2,069,276 1,970,216 1,565,292 1,256,194 1,034,256 1,976,520 1,574,740 1,205,396 997,432 1,968,370 2,022,052 1,351,280 623,344
iii) Primary airheater outlet 748,108 736,412 696,808 615,010 529,636 471,414 687,500 610,370 523,886 461,292 868,536 775,810 512,863 374,216
iv) Secondary airheater outlet 2,246,878 2,193,676 2,094,616 1,686,892 1,377,794 1,155,056 2,099,920 1,695,540 1,323,396 1,114,632 2,126,370 2,163,652 1,419,380 743,144
v) ESP inlet 2,994,986 2,930,088 2,791,424 2,301,902 1,907,430 1,626,470 2,787,420 2,305,910 1,847,282 1,575,924 2,994,906 2,939,462 1,932,243 1,117,360
vi) ESP outlet 2,994,986 2,930,088 2,791,424 2,301,902 1,907,430 1,626,470 2,787,420 2,305,910 1,847,282 1,575,924 2,994,906 2,939,462 1,932,243 1,117,360
vii) ID fan inlet 2,994,986 2,930,088 2,791,424 2,301,902 1,907,430 1,626,470 2,787,420 2,305,910 1,847,282 1,575,924 2,994,906 2,939,462 1,932,243 1,117,360

i) At burner 20.0 20.0 20.0 20.0 27.2 24.6 20.0 20.0 21.6 20.0 20.0 20.0 20.0 24.4

(primary) 38.04 38.36 40.01 43.93 58.09 61.40 40.02 43.55 51.38 55.39 39.21 39.66 34.60 76.74

(secondary) 27.65 27.72 28.12 30.00 40.33 40.17 28.00 29.85 34.37 35.03 30.33 29.01 26.47 50.02
vi) At ESP inlet 30.10 30.25 30.91 33.47 44.88 45.76 30.78 33.23 38.82 40.46 32.80 31.67 28.54 58.08

STAGE-I (3x 660MW)
out of out of (One
i) Primary air
a) Regenerative air
preheater 91.8 91.8 93.6 96.2 98.0 101.8 92.6 94.4 97.2 99.8 112.6 102.6 52.2 105.4
b) Ducts/Dampers 0 0 0 0 0 0 0 0 0 0 0 0 0 0
ii) Secondary air
a) Regenerative air
heater 126.2 124.4 124.4 121.6 121.6 120.8 123.4 120.8 118.0 117.2 158.0 141.6 68.1 119.8
b) Wind box 0 0 0 0 0 0 0 0 0 0 0 0 0 0
c) Ducts/Dampers 0 0 0 0 0 0 0 0 0 0 0 0 0 0

design coal fired)

coal (Kcal/kg) 3750 3750 3750 3750 3750 3750 3750 3750 3750 3750 3750 3750 3750 3750

of coal in
- Primary 72.3 74.7 71.2 71.6 70.6 64.4 71.2 71.6 70.9 65.4 61.9 70.3 74.1 73.0
- Secondary 246.6 244.7 247.2 226.8 217.6 193.3 249.8 230.8 211.4 193.5 165.7 218.9 219.5 181.0
Stage I 375.4 404.8 413.7 427.6 396.3 351.6 395.8 378.6 383.9 346.5 400.4 417.0 431.7 336.7
Stage II 249.0 263.4 277.8 301.9 295.3 312.1 269.7 276.8 290.4 308.8 262.4 269.5 311.4 287.7
Stage III 261.6 272.1 279.9 271.2 243.9 231.7 273.0 252.2 230.7 220.3 272.9 277.4 248.4 133.3

STAGE-I (3x 660MW)
out of out of (One
Roof tubes 7.5 7.7 7.9 7.7 7.1 7.0 7.7 7.2 6.7 6.6 7.6 7.7 7.1 4.9
Convective pass 60.1 62.6 64.6 65.7 68.6 70.4 64.0 65.0 68.3 71.4 62.8 64.0 67.3 78.0
Steam cooled 33.6 35.0 36.1 36.4 33.7 33.2 35.2 33.3 31.7 31.6 34.7 35.4 34.5 24.4
Hanger tubes 14.0 14.5 14.8 14.8 15.2 15.3 14.7 14.6 15.0 15.4 14.6 14.8 14.8 16.5
d) Reheater (kcal)
Stage I 404.6 410.0 412.9 399.7 364.4 336.2 401.4 361.9 323.5 297.9 396.9 404.6 133.8 272.8
Stage II 262.7 276.4 289.3 301.0 280.8 283.8 280.6 272.8 268.7 274.2 272.8 280.6 293.6 240.8
e) Water walls
Wall tubing 1240.0 1163.5 1124.6 1126.7 1241.4 1331.4 1179.0 1283.4 1308.5 1406.6 1113.2 1101.0 1195.9 1670.4
Screen tubes 41.1 42.8 44.5 45.9 46.2 47.3 43.8 43.5 45.7 46.1 43.1 43.9 46.6 46.0
Any other 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0


Generator
conditions also:

(%)
- Dry gas loss 4.68 4.68 4.43 4.10 4.14 4.16 4.52 4.19 3.97 4.02 3.85 3.78 3.90 3.77

STAGE-I (3x 660MW)
out of out of (One

to flue gases 10.69 10.69 10.41 10.03 10.04 10.06 10.50 10.13 9.86 9.92 9.75 9.67 9.81 9.66

carbon (%) in:
- Fly ash 0.92 0.92 0.92 0.92 0.92 0.92 0.92 0.92 0.92 0.92 0.92 0.92 0.92 0.92

unburnt carbon 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50
- economizer hopper
ash 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02
- Air heater hopper

ash 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
- Any other hopper

ash 0.11 0.11 0.11 0.10 0.09 0.09 0.11 0.10 0.09 0.09 0.09 0.09 0.09 0.09

loss 0.44 0.44 0.44 0.43 0.42 0.42 0.44 0.43 0.42 0.42 0.42 0.42 0.42 0.42

Rejects (%) 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07 0.07

(give details) 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

(i) to (v)} 12.88 12.89 12.61 12.26 12.33 12.39 12.70 12.36 12.15 12.25 11.92 11.84 12.06 12.18

STAGE-I (3x 660MW)
out of out of (One


(%) 87.02 87.01 87.29 87.64 87.57 87.51 87.20 87.54 87.75 87.65 87.98 88.06 87.84 87.72

collected

(kg/hr) 35462 34657 32863 26614 20443 17325 32936 26766 20580 17483 34790 34419 23139 11027

(kg/hr) 8866 8664 8216 6654 5111 4331 8234 6692 5145 4371 8697 8605 5785 2757
iii) Air heater hopper (kg/hr) 5319 5198 4929 3992 3066 2599 4940 4015 3087 2622 5218 5163 3471 1654

in operation 1580.5 1527.1 1448.1 1166.4 895.1 755.3 1451.9 1179.1 898.6 760.6 1509.8 1506.5 1010.8 N/A
in services D~J E~J E~J F~J G~J H~J E~J F~J G~J H~J E~J E~J G~J N/A
ii) Burner tilt (deg) -25 -20 0 20 -18 -25 -25 -25 -25 -25 -25 -7 19 N/A

in operation 1563.1 1527.2 1448.1 1167.3 895.1 759.2 1451.9 1174.1 901.3 764.0 1509.8 1506.5 1015.6 N/A
in services C~I C~H C~H D~H D~G E~G C~H D~H D~G E~G C~H C~H D~G N/A
ii) Burner tilt (deg) -17 10 25 25 25 -17 11 0 -9 -25 10 21 25 N/A

STAGE-I (3x 660MW)
out of out of (One

in operation 1563.1 1534.8 1462.0 1155.1 900.9 760.2 1461.4 1177.7 903.0 767.0 1514.6 1511.2 1024.7 476.6
in services B~H B~G B~G B~F C~F C~E B~G B~F C~F C~E B~G B~G C~F C~D
ii) Burner tilt (deg) 16 25 25 25 25 25 25 25 25 0 25 25 25 0

Furnace

Zone level)

in Clause 3.14.01 159.6 116.2 92.2 62.7 64.6 57.1 119.4 97.3 71.5 60.9 108.1 100.8 39.4 N/A

in Clause 3.14.01 158.1 109.8 74.0 63.1 44.8 67.6 98.8 98.5 77.7 78.3 94.2 87.5 51.9 N/A

in Clause 3.14.01 113.6 101.6 76.6 84.0 59.1 52.8 97.8 84.9 63.9 86.6 85.8 101.2 66.2 55.8

in Clause 3.14.01 206.6 188.5 153.9 105.5 102.8 91.1 187.2 155.8 114.2 97.4 173.4 165.4 66.4 N/A


STAGE-I (3x 660MW)
out of out of (One
in Clause 3.14.01 223.9 172.1 121.1 101.4 80.1 106.9 156.7 148.6 124.1 118.5 151.6 141.7 80.8 N/A

in Clause 3.14.01 189.2 140.0 142.3 134.2 93.4 88.3 145.7 136.6 100.9 124.9 123.5 152.1 108.7 81.0

in Clause 3.14.01 367.4 351.3 313.5 281.9 218.2 203.2 340.6 300.8 236.7 217.8 329.4 322.2 202.0 N/A

in Clause 3.14.01 396.0 348.5 291.0 256.7 206.0 211.5 331.1 302.5 241.3 219.9 328.9 316.8 213.2 N/A

in Clause 3.14.01 390.4 335.9 324.4 296.9 220.3 201.8 331.8 301.7 236.9 231.3 325.1 337.6 229.7 166.3

in Clause 3.14.01 415.1 400.3 363.1 341.8 254.2 236.6 386.2 343.6 273.1 252.8 374.4 370.0 248.0 N/A

in Clause 3.14.01 446.0 402.2 344.3 305.8 246.5 241.0 383.9 348.3 275.5 247.2 382.0 370.4 255.5 N/A

in Clause 3.14.01 449.7 397.8 380.4 344.9 258.4 234.6 388.4 350.4 277.0 259.8 387.9 393.2 265.0 186.5

STAGE-I (3x 660MW)
out of out of (One

in Clause 3.14.01 766 744 700 629 463 405 710 603 476 419 713 720 479 N/A

in Clause 3.14.01 774 744 681 579 462 402 711 605 474 404 724 721 474 N/A

in Clause 3.14.01 775 726 691 593 458 400 699 602 476 412 716 718 468 288

in Clause 3.14.01 1032 1001 953 835 610 527 956 797 617 537 969 980 635 N/A

in Clause 3.14.01 1025 1000 932 780 610 523 957 795 613 520 981 981 627 N/A

in Clause 3.14.01 1025 979 935 778 601 520 939 790 614 526 969 969 617 347

in Clause 3.14.01 1230 1189 1133 977 711 607 1131 929 708 609 1152 1165 739 N/A


STAGE-I (3x 660MW)
out of out of (One
in Clause 3.14.01 1214 1187 1111 922 711 605 1132 925 705 659 1164 1165 733 N/A

in Clause 3.14.01 1213 1169 1120 915 705 602 1117 922 707 669 1154 1156 727 390

in Clause 3.14.01 1367 1321 1256 1022 786 669 1259 1031 792 675 1352 1326 889 N/A

in Clause 3.14.01 1352 1321 1256 1019 786 669 1259 1026 792 675 1352 1326 889 N/A

in Clause 3.14.01 1352 1321 1256 1009 786 669 1259 1026 792 675 1352 1324 889 428

in Clause 3.14.01 1501 1451 1380 1164 855 720 1378 1121 849 721 1435 1439 881 N/A

in Clause 3.14.01 1482 1448 1357 1114 855 725 1379 1117 852 715 1447 1442 884 N/A

in Clause 3.14.01 1481 1442 1388 1103 859 723 1378 1121 856 726 1446 1445 891 453

STAGE-I (3x 660MW)
out of out of (One


in Clause 3.14.01 49 49 49 52 52 53 50 52 54 55 48 48 52 N/A

in Clause 3.14.01 51 50 48 50 52 53 50 52 54 54 48 48 51 N/A

in Clause 3.14.01 51 49 48 52 51 53 49 52 54 54 48 48 51 62

in Clause 3.14.01 89.0 86.4 81.0 62.9 67.2 68.4 81.4 63.7 93.1 76.6 73.6 78.4 92.1 N/A

in Clause 3.14.01 89.0 86.4 81.0 62.9 84.6 54.0 81.4 63.7 80.1 56.0 73.6 78.4 69.4 N/A

in Clause 3.14.01 89.0 86.4 81.0 62.9 46.3 59.8 81.4 63.7 81.3 48.1 73.6 78.4 36.0 24.4


STAGE-I (3x 660MW)
out of out of (One
in Clause 3.14.01 26.1 0.0 0.0 0.0 0.0 0.0 0.0 8.1 0.0 0.9 0.0 0.0 0.0 N/A

in Clause 3.14.01 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 N/A

in Clause 3.14.01 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0

ii) Efficiency (%) 87.44 87.43 87.64 88.02 88.19 88.58 87.62 87.93 88.23 88.51 89.14 88.38 80.42 88.99

6
(10 Kcal/hr) 1546.3 1511.2 1433.0 1160.5 891.4 755.5 1436.1 1167.1 897.4 762.3 1517.0 1500.8 1009.0 480.8

(Unburnt) 1563.1 1527.1 1448.1 1166.4 895.1 755.3 1451.9 1174.1 898.6 760.6 1509.8 1506.5 1010.8 476.6
vi) Furnace EPRS (m2) 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9 9043.9

(106 Kcal/m2/hr) 4.58 4.47 4.24 3.42 2.62 2.21 4.25 3.44 2.63 2.23 4.42 4.41 2.96 1.40

(106 Kcal/m2/hr) 0.173 0.169 0.160 0.129 0.099 0.084 0.161 0.130 0.099 0.084 0.167 0.167 0.112 0.053

(106 Kcal/m2/hr) 0.072 0.070 0.067 0.054 0.042 0.035 0.067 0.054 0.042 0.036 0.071 0.070 0.047 0.022

STAGE-I (3x 660MW)
out of out of (One

tubes (Kg/m2 sec)
i) Maximum 3150 3058 2751 2137 1575 1310 2766 2165 1605 1335 2501 2664 1314 669
ii) Minimum 2495 2422 2179 1693 1247 1038 2191 1715 1272 1058 1981 2110 1659 844

(Vertical Wall)
iii) Side Walls 1173 1140 1024 795 586 487 1030 806 598 497 931 991 572 291
i) Steam conditions

(abs) 16
(degC) 210 ~ 310

Max N/A

(kg/hr)Max
a) Primary 7512
b) Secondary 21570

STAGE-I (3x 660MW)
out of out of (One

b) After four hours


down) (kg/hr) Later


5.19.00 Start ups





shutdown (hours) 4


STAGE-I (3x 660MW)
out of out of (One



40% to 100% No limit provided recommended heat-up rates are adhered to.



shut down Later

shut down Later

shutdown Later

shutdown Later

shutdown Later

STAGE-I (3x 660MW)
out of out of (One

(kg/hr) N/A


i) Free air area (m2) 3.49 3.49 2.99 2.49 1.99 1.49 2.99 2.49 1.99 1.49 2.99 2.99 1.99 1.00

3
wind box (m /sec) 764 741 716 553 438 361 719 559 416 345 686 720 471 203






STAGE-I (3x 660MW)
out of out of (One

decimal)

at mean firing zone

Eco outlet 6.734

STAGE-I (3x 660MW)
VI. PREDICTED PERFORMANCE CURVES
LIST OF PERFORMANCE CURVES
TITLE CURVE NO.
Load Vs Water/Steam Temperature T04019-CV-01
Load Vs Reheat Steam Temperature T04019-CV-02
Load Vs Burner Tilt T04019-CV-03
Load Vs Excess Air T04019-CV-04
Load Vs Spray Water Flow T04019-CV-05
Moisture in Coal Vs Pulveriser Capacity T04019-CV-09
Moisture in Coal Vs Inlet Air Temperature T04019-CV-10
Pulveriser Capacity Vs Hardgroove Grindability T04019-CV-11
Pulveriser Power Consumption Vs Pulveriser Coal Capacity T04019-CV-12
Pulveriser Power Consumption Vs Pulverised Coal Fineness T04019-CV-13
V. Predicted Performance Curves.doc

Load Vs Water/Steam Temperature

600
550
Final SH Outlet
Platen SH Outlet
500
Final SH Inlet
Water/Steam Temperature,℃
450
Primary SH Outlet
Platen SH Inlet
400
350
Primary SH Inlet
300
Economizer Outlet
250
Economizer Inlet
200
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 110%
Load
T04019-CV-01

Load Vs RH Steam Temperature

650
600
Final RH Outlet
550
500
RH Steam Temperature,℃
Primary RH Outlet & Final RH Inlet

450
400
350
Pimary RH Inlet
300
250
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 110%
Load
T04019-CV-02

Load Vs BurnerTilt
30
20
Burner Tilt in deg
10
-10
-20
-30
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 110% 120%
Load
T04019-CV-03

Load Vs Excess Air
30%
Excess Air at Economiser Outlet
25%
20%
15%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 110% 120%
Load
T04019-CV-04

Load Vs Spray Water Flow

7%
6%
5%
Spray Water Flow
4%
SH Total Spray
3%
2%
1%
RH Spray = 0
0%
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 110%
Load
T04019-CV-05

Pulverizer Capacity vs. Moisture in Coal

Design Coal : HGI = 50. Total Moisture in Coal = 12 wt%
Worst Coal : HGI = 47, Total Moisture in Coal = 15 wt%
Best Coal : HGI = 52. Total Moisture in Coal = 11 wt%
(Fineness 70% through 200 mesh)
90,000
87,500
Pulverizer Capacity (kg/hr)
85,000
Best Coal
82,500
Design Coal
80,000
Worst Coal
77,500
75,000
72,500
70,000
67,500
65,000
8 9 10 11 12 13 14 15 16 17 18 19 20
Moisture Content of Coal (%)
T04019-CV-09

Inlet Air Temperature vs. Moisture in Coal
Worst Coal basis

(HGI = 47, Fineness 70% through 200mesh)
400
350
Max. Capacity
300
Inlet Air Temperature (℃)
250
Min. Capacity
200
150
100
50
0
6 8 10 12 14 16 18 20 22 24 26
Moisture Content of Raw Coal (%)
T04019-CV-10

Pulverizer Capacity vs. Hardgrove Grindability

(for Raw Coal)
Worst Coal basis ( Total Moisture = 15 wt% )

(Fineness 70% through 200mesh)
95,000
90,000
85,000
Pulverizer Capacity (kg/hr)
80,000
75,000
70,000
65,000
40 45 50 55 60
Hardgrove Grindability
T04019-CV-11

Pulverizer Power Consumption vs. Pulverized Coal

Capacity (for Raw Coal)
Worst Coal basis ( HGI = 47, Total Moisture = 15 wt% )

(Fineness 70% through 200mesh)
20
Power Consumption (kW/ton)
15
10
5
25 50 75 100
Pulverized Coal Capacity (%)
T04019-CV-12

Pulverizer Power Consumption vs. Pulverized Coal

Fineness
Worst Coal basis
( HGI = 47, Total Moisture = 15 wt%)
20
15
Min. Capacity
Power Consumption (kW/ton)
10
Max. Capacity
0
63 64 65 66 67 68 69 70 71 72 73 74 75 76 77
Pulverized Coal Fineness (% Thru 200 Mesh)
T04019-CV-13

VI. START-UP CURVES
LIST OF CURVES
TITLE CURVE NO.
Cold start-up………………………………………………………………………………... T04019-CV-06

Warm start-up……………………………………………………………….. ……………. T04019-CV-07
Hot start-up……………………………………………………. …………………………… T04019-CV-08
i VI. Start-up curves-cover.doc

VI. PREDICTED STARTUP CURVES
PREDICTED PERFORMANCE CURVE (COLD START-UP)
S I P A T P H A S E 1 ( 3 X 6 6 0 M W ) C o ld S t a r t -U p C u r v e ( > 7 2 h r )
( M o d if ie d S li d in g O p e r a t io n )
S H O u t l e t T e m p .( T o )
R H O u tle t T e m p .(T rh )
S H O u t le t P r e s s .( P o )
R H O u t l e t P r e s s .( P r h )
S H D r a in RH
& V e n t C lo s e Vent
R H D r a in C lo s e
C lo s e
rp m (n ) F ir in g R a t e
S t e a m F lo w
to T B N (G o )
S t e a m F lo w
M in . W a t e r W a ll F lo w E le c t r ic a l L o a d o f T G ( N e )
S w e ll in g F lo w O il F ir in g R a t e
F e e d w a t e r F lo w
1 0 M in . L ig h t S te a m Synch. F u ll L o a d
P u rg e O ff A d m is s io n
B ypass
C lo s e
T04019-CV-06
VI. Startup Curves.doc

PREDICTED PERFORMANCE CURVE (WARM START-UP)
S I P A T P H A S E 1 ( 3 X 6 6 0 M W ) W a r m S t a r t -U p C u r v e ( < 3 6 h r )
( M o d i f ie d S lid in g O p e r a t io n )
S H O u tle t T e m p .(T o )
R H O u t le t T e m p .(T r h )
S H O u tle t P re s s .(P o )
R H O u t l e t P r e s s .( P r h )
F ir in g R a t e
S H D r a in
& V e n t C lo s e RH
R H D r a in Vent
C lo s e
C lo s e
S te a m F lo w
r p m (n ) to T B N (G o )
S w e ll i n g F l o w
O il F ir in g R a t e E le c t r ic a l L o a d o f T G (N e )
M in . W a t e r W a l l F lo w
S t e a m F lo w
Synch.
1 0 M in . L ig h t S te a m F u ll L o a d
P u rg e O ff A d m is s io n B ypass
C lo s e
T04019-CV-07

PREDICTED PERFORMANCE CURVE (HOT START-UP)
S I P A T P H A S E 1 ( 3 X 6 6 0 M W ) H o t S t a r t -U p C u r v e ( < 8 h r )
( M o d if ie d S lid in g O p e r a t io n )
S H O u t le t T e m p .( T o )
R H O u t le t T e m p .( T r h )
S H O u t le t P r e s s .( P o )
R H O u t le t P r e s s .( P r h )
S H D r a in RH
& V e n t C lo s e Vent
R H D r a in C lo s e
C lo s e
F ir in g R a t e
rp m (n )
E le c t r ic a l L o a d o f T G ( N e )
= S t e a m F lo w t o T B N ( G o )
S w e llin g F lo w
M in . W a t e r W a ll F lo w
O il F ir in g R a t e
S t e a m F lo w
S ynch.
1 0 M in . L ig h t S te a m F u ll L o a d
P u rg e O ff A d m is s io n Bypass
C lo s e
T04019-CV-08

VII. GENERAL ARRANGEMENT OF BOILER-DRAWINGS
TABLE OF CONTENTS
TITLE DRAWING NO.
GA of Boiler Key Plan & General Notes……………………. ............ T04019-GA-A0001

GA of Boiler Sect. Boiler Side Elev. View “01-01”………… ............ T04019-GA-A0002
GA of Boiler Mill Side Elev. View “02-02/02a-02a”………............... T04019-GA-A0003
GA of Boiler Boiler Front Elev. View “03-03”………………. ............ T04019-GA-A0004
GA of Boiler El. 00 Plan View “04-04”……………………… ............. T04019-GA-A0005
GA of Boiler El. 22600 Plan Sect. View “05-05”………….. ............ T04019-GA-A0006
GA of Boiler Boiler Rear Elev. View “09-09”……………….. ............ T04019-GA-A0010
GA of Boiler Gas A/H Center Elev. View “10-10”………….............. T04019-GA-A0011
GA of Boiler Gas A/H Rear Elev. View “11-11”…………................. T04019-GA-A0012
i
VII. General Arrangement of boiler-Drawings.doc
VIII. PROCESS AND INSTRUMENTATION DRAWINGS
TABLE OF CONTENTS
TITLE DRAWING NO.
BOILER & DUCT INSTRUMENT INSERT LOCATION

CONNECTION LIST ....................................................................................... T04019-GA-A0018
CONNECTION DETAIL .................................................................................. T04019-GA-A0019
P&I Diagram – SYMBOLS AND LEGENDS ..................................................... T04019-PI-D0001

P&I Diagram – SYMBOLS AND LEGENDS .................................................... T04019-PI-D0002
P&I Diagram – ECONOMIZER SYSTEM ........................................................ T04019-PI-D0005
P&I Diagram – EVAPORATOR SYSTEM........................................................ T04019-PI-D0006
P&I Diagram – WATER SEPARATOR SYSTEM ............................................. T04019-PI-D0007
P&I Diagram – SUPERHEATER SYSTEM(1/3)............................................... T04019-PI-D0008
P&I Diagram – REHEATER SYSTEM ............................................................. T04019-PI-D0011
P&I Diagram – CIRCULATION & START-UP SYSTEM................................... T04019-PI-D0012
P&I Diagram – BOILER DRAIN & VENT SYSTEM.......................................... T04019-PI-D0013
P&I Diagram – COMB. AIR&FLUE GAS SYSTEM(1/3) ................................... T04019-PI-D0014
P&I Diagram – FUEL SYSTEN(1/3) ................................................................ T04019-PI-D0017
P&I Diagram – OIL BURNER DETAIL............................................................. T04019-PI-D0020
P&I Diagram – PRIMARY AIR, SEALING&COOLING AIR SYSTEM ............... T04019-PI-D0021
P&I Diagram – COAL FEEDER & PULVERIZER SYSTEM ............................. T04019-PI-D0022
P&I Diagram – SCANNER COOLING & DAMPER SEAL SYSTEM ................. T04019-PI-D0023
P&I Diagram – STEAM COIL AIR HEATER SYSTEM ..................................... T04019-PI-D0024
P&I Diagram – BOILER WATER CIRCULATION PUMP SYSTEM .................. T04019-PI-D0025
P&I Diagram – SOOT BLOWING SYSTEM..................................................... T04019-PI-D0026
P&I Diagram – CLOSED COOLING WATER SYSTEM ................................... T04019-PI-D0027
P&I Diagram – SERVICE AIR SYSTEM.......................................................... T04019-PI-D0028
P&I Diagram – BOILER START-UP FLASH TANK SYSTEM .......................... T04019-PI-D0029
P&I Diagram – SAMPLING SYSTEM .............................................................. T04019-PI-D0030
P&I Diagram – INSTRUMENT AIR SYSTEM (1/4 – 4/4) ................................. T04019-PI-D0031
P&I Diagram – SERVICE WATER SYSTEM ................................................... T04019-PI-D0032
P&I Diagram – MAIN & REHEAT STEAM SYSTEM(1/2 – 2/2) ........................ T04019-PI-D0501
P&I Diagram – FUEL OIL SYSTEM(1/5 - 5/5) ……………………………………. T04019-PI-D0502
P&I Diagram – EQUIPMENT COOLING WATER SYSTEM(1/2 – 2/2)............. T04019-PI-D0503
P&I Diagram – LP DOSING & OXYGENATED TREATMENT SYS.(1/2 – 2/2). T04019-PI-D0504
P&I Diagram – AUXILIARY STEAM SYSTEM................................................. T04019-PI-D0505
P&I Diagram – NITROGEN GAS SUPPLY SYSTEM ...................................... T04019-PI-D0506
i
VIII. Process and Instrumentation Drawings.doc
IX. IMPORTANT DO’S AND DON’TS
IMPORTANT DO’S & DON’TS
I. PREPARATION FOR LIGHTING UP-DO’S
1. Check and remove any foreign material from Boiler.

2. Ensure that the feed water quality is as per recommendation.
3. Ensure furnace bottom hopper water sealing.
4. Keep all vents and drains as per recommended unit operating procedure.
5. Check and keep ready oil Pumping, Heating and Firing equipment.
6. Ensure correct functioning of all Auxiliaries, Dampers and Valves.
7. Check and ensure correct functioning of Temperature Probes and Metal Temperature
Monitoring Thermocouples.
8. Fill up water up to separator NWL.
9. Check that “NO BOILER TRIP” condition exists.
10. Ensure 30% BMCR air flow through Boiler to maintain an air rich furnace.
11. Ensure Boiler Circulating Pump ready for service.
12. Ensure minimum 30%TMCR water flow through evaporator.
13. Check and control firing rate as per recommendation.
14. Ensure that enough oil & air pressure is obtained.
15. Keep burner tilt at horizontal position.
16. Ensure that tilt/damper positions are identical in all the four corners.
17. Maintain firing rate such that the furnace exit gas temperature is below 538 ˚C till such
time flow through Reheater is established.
18. Keep Steam Coil Air Preheaters in service during oil firing.
19. Keep Gas Air Preheaters’ soot blowers in service.
II. NORMAL LOAD INCREASE
1. Increase boiler load as per recommended rates.

2. Introduce coal firing after ensuring sufficient ignition energy is available.
3. Check and record SH/RH metal temperatures.
III. NORMAL REDUCTION OF LOAD
1. Reduce boiler load as per recommended rates.

2. Remove mills from service, empty mills before stopping as per recommended procedures.
1 IX. IMPORTANT DOs and DON'Ts.doc

IX. IMPORTANT DO’S AND DON’TS
IV. NORMAL SHUTDOWN TO COLD
1. Reduce boiler load as gradually as possible.

2. Ensure furnace purge after tripping of fuel.
3. Check and maintain separator water level periodically.
4. Run the GAPH, FD & ID Fans till the gas temperature drops to below 205 ˚C.
V. BOILER OPERATION-DON’TS
1. Never fill the boiler with water such that differential temperature between the feed water
and the boiler metal temperature exceeds 111˚C.
2. Do not exceed firing rate and load increase/decrease rates beyond the recommended
values.
3. Never light up and continue firing without GAPHs in service.
4. Never introduce a mill in service without ensuring sufficient ignition energy.
5. Do not keep furnace temperature probes inside the furnace if the flue gas temperature
exceeds 538˚C.
6. Never jump or bypass any safety/protection interlocks.
7. Do not keep the boiler in service after identifying a tube leak, if any.
VI. SAFETY
1. Above all, safety of personnel is of utmost importance. Never ignore any safety
instruction/procedure/measures at any point of time during boiler operation and
maintenance.
2 IX. IMPORTANT DOs and DON'Ts.doc

Plant Handbook for SIPAT STPP Stage 1

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Plant Handbook for SIPAT STPP Stage 1

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PLANT HAND BOOK

SIPAT STPP STAGE-I (3 x 660 MW)

CONTRACT NO. T04019

DOOSAN HEAVY INDUSTRIES

Date of Issue: June, 2006

TITLE PAGE NO.

II. ASH ANALYSIS

III. BOILER PARAMETERS

IV. DESIGN AND PERFORMANCE DATA

1. STEAM GENERATOR DESCRIPTION

SAFETY VALVES …………………………………………………………………………… 6

i 01 PLANT HAND BOOK-contents.doc

2. STEAM AND WATER FLOW SYSTEM

SUPERHEATER DESUPERHEATERS ……………………………………………….5

REHEATER DESUPERHEATERS ………………………………………………….11

WATER WALL SYSTEM ………………………………………………………………14

ii 01 PLANT HAND BOOK-contents.doc

3. AIR AND FLUE GAS FLOW SYSTEM

AIR AND FLUE GAS SYSTEMS ……………………………………………………….. 1

AIR/GAS FLOW ……………………………………………………………………………...1

FLUE GAS FLOW………………………. …………………………………………………3

SCANNER AIR SYSTEM……… …………………………………………………………3

PULVERIZER SEAL AIR SYSTEM ….……………………………………………………4

SOOT BLOWING PHILOSOPHY ………………………………………………………. 7

LIST OF REFERENCE ENGINEERING DRAWINGS………………………………………… 9

P&ID Diagram - Windbox & Burner Unit T04019-PI-D0019

iii 01 PLANT HAND BOOK-contents.doc

4. TILTING TANGENTIAL FIRING SYSTEM

FIGURE 1. WINDBOX AND CCOFA ELEVATION DESIGNATIONS…………………..11

LIST OF REFERENCE ENGINEERING DRAWINGS

WINDBOX ARRANGEMENT SHEET 1 (T04019-WB-A001) ……………………………17

5. DESIGN DATA AND CONTRACT DATA SHEET……………………… …………………1

6. PRESSURE PARTS SKETCH

7. PRESSURE PARTS SCHEDULE-UNIT MATERIAL DIAGRAM

Back pass Economiser Tubes Page 1 of 12

iv 01 PLANT HAND BOOK-contents.doc

8. SAFETY VALVES DATA

Design Basis for Safety Valves …………………………………………………………..1

9. SOOTBLOWER SELECTION DATA AND PHILOSOPHY

Soot Blower Selection Data and Philosophy ……………………………………………1

10. DUCT DESIGN DATA AND SCHEMATIC

11. PREDICTED PERFORMANCE DATA

Load Vs Water/Steam Temperature T04019-CV-01

v 01 PLANT HAND BOOK-contents.doc

VI. START-UP CURVES

Cold start-up…………………………………………………………………. T04019-CV-06

VII. GENERAL ARRANGEMENT OF BOILER-DRAWINGS

VIII. PROCESS & INSTRUMENTATION DRAWINGS

BOILER & DUCT INSTRUMENT INSERT LOCATION

P&ID – SYMBOLS AND LEGENDS T04019-PI-D0001-Rev.0

vi 01 PLANT HAND BOOK-contents.doc

P&ID – MAIN & REHEAT STEAM SYSTEM(1/2) ................ T04019-PI-D0501-Rev.G

P&ID – EQUIPMENT COOLING WATER SYSTEM(1/2)…… T04019-PI-D0503-Rev.0

IX. IMPORTANT DO’s & DON’Ts

X. SEQUENCE AND PROTECTION INTERLOCK SCHEMES

XI. ALARM AND TRIP VALUES

vii 01 PLANT HAND BOOK-contents.doc

TITLE PAGE NO.

Design Worst Best

Proximate Volatile Matter % 21.0 20.0 24.0

TITLE PAGE NO.

i II. Ash analysis.doc

Parame Design Worst Best