Boiler Design Dossier PDF

AC 09.06.2017 M.
Charles See compliance sheet Bhavannarayana

AB 31.03.2017 M.Charles See compliance sheet Bhavannarayana
AA 14.11.2016 Premnath See compliance sheet Bhavannarayana
REV. DATE NAME REVISION DESCRIPTION APPD.
Digitally signed by
EMPLOYER DILIP DILIP SINGH
DN: cn=DILIP SINGH,
NTPC Limited SING

c=IN, o=NTPC Ltd.,
ou=DGM-Task Force,
email=dilipsingh@ntpc.
co.in
Reason: Cat-IVR
(A Government of India Enterprise) H Date: 2017.06.30

09:54:39 +05'30'
PROJECT
SOLAPUR SUPER THERMAL POWER
PROJECT (2x660 MW)
PACKAGE STEAM GENERATOR (SG) PACKAGE
SG CONTRACTOR
BGR ENERGY SYSTEMS LIMITED
CHENNAI – HYDERABAD – MUMBAI - NOIDA
DOC. NO.
JV COMPANY
BGR BOILERS PRIVATE LIMITED
CHENNAI – INDIA
DOC. NO. BBX-0001-01-S-H__-IB02-00021

QSGM SUB CONTRACTOR
HITACHI POWER EUROPE (IF APPLICABLE)
GMBH
Duisburg - Germany
DOC. NO. DOC. NO.
TITLE: Boiler Design Dossier
SIZE SCALE NTPC DOCUMENT NO. REV.

A4 NTS 9571-102-PVM-X-0344 03
NAME SIGN DATE
PREPARED BY Premnath signed by Premnath 20.05.2016
CHECKED BY Charles signed by Charles 24.05.2016
REVIEWED BY Bhavannarayana signed by Bhavannarayana 27.05.2016
APPROVED BY Bhavannarayana signed by Bhavannarayana 27.05.2016
REVIEWED BY (QSGM) - - -
APPROVED BY (QSGM) - - -
THIS DOCUMENT SHALL NEITHER BE DUPLICATED; TRANSFERRED NOR REVISED OTHER THAN STIPULATED WITH THE GCC
Index
1.0 Design Parameters

Salient Features
1.1 Boiler Parameters
1.2 Fuel Analysis
2.0 Project Details

2.1 Site Conditions
3.0 Process Details

3.1 Predicted Performance
3.2 Start Up Curves (Cold, Warm & Hot)
3.3 Shut Down Diagram
3.4 HP Diagram
3.5 Sliding Pressure Curves (HP & RH)
4.0 Pressure Parts Details

4.1 Pressure Parts Schedule
4.2 Boiler Upper Part - Longitudinal Section G.A. drawing
4.3 Boiler lower Part - Longitudinal Section G.A. drawing
4.4 Boiler Arrangement - Longitudinal Section G.A. drawing
Auxiliaries
5.0 FANS
5.1 Performance data for Fans
5.2 Characteristic Curves
6.0 APH
6.1 Performance data for PAPH & SAPH
7.0 SCAPH
7.1 Performance data for Primary SCAPH & Secondary SCAPH
8.0 Mill
8.1 Mill Design Data
8.2 Mill & Burner Designation
8.3 Performance data for Mill
9.0 Raw coal (RC) Feeder

9.1 Performance data for Feeder
Fuel Firing
10.0 Burner
10.1 Burner Design Data
10.2 DS-X Burner - Overview
10.3 Furnace Geometry
11.0 Coal Firing
11.1 Coal Firing System Details
12.0 Oil Firing

12.1 LDO Firing System Details
12.2 HFO Firing System Details
12.3 Fuel Oil Forwarding System
13.0 Boiler Circulation Pump

13.1 Performance Data for Boiler Circulation pump
14.0 Boiler Condensate Transfer Pump

14.1 Performance Data for Boiler Condensate Transfer pump
15.0 Safety Valve & EMRV

15.1 Performance data for Boiler Safety Valve and EMRV
15.2 Safety Valve Setting Diagram (HP & RH)
16.0 Soot Blower

16.1 Performance data for Boiler Sootblower
17.0 Furnace Instrumentation

17.1 Performance data for Furnace Temperature Probe
17.2 Performance data for Acostic Pyrometer
17.3 Performance data for Acoustic Steam Leak Detection System
17.4 Performance data for Furnace Flame Monitoring System 17.5
Performance data for Flame scanner
18.0 Control & Instrumentation

18.1 Metal Temperature Measurement Points
19.0 Control Valves

19.1 Performance data for Control Valves
20.0 Equipment Cooling Water System

20.1 Equipment Cooling Water System Details
21.0 Dosing System

21.1 Dosing System Details
22.0 Compressed Air System

22.1 Compressed Air System Details
23.0 PRDS System

23.1 PRDS System Details
24.0 Annexure - 1- Sizing Calculations

1.0 Design Parameters
Salient Features
1.2 Fuel Analysis

Salient Features
 Steam Generator
 Tower Type
 Spiral Walls
 Wall Burners
 Regenerative Bi-Sector Air Preheaters
 Pressure Part Arrangement
 Evaporator - Spiral + Vertical walls

 Superheater - 3 sections
 Reheater - 2 sections
 Economiser - 2 sections
 Separators - 2 no.
 Collecting vessel - 1no.
 Boiler Water Circulating Pump - 1 no.
 Air & Flue Gas System
 FD Fans - 2 no.
 PA Fans - 2 no.
 ID Fans - 2 no.
 PAPH - 2no.
 SAPH - 2no.
 SCAPH - 4 no.
 Fuel Preparation and Firing System
 MPS Mills, 8 no., arranged on both sides of the Boiler

 Burners 32 no. – 16 on front wall & 16 on rear wall – arranged in 4 levels on each wall
 LDO & HFO firing facility for Boiler start up and support.
Sl. No. Description Units 100% BMCR VWO 100% TMCR
Steam flow at
1 T/hr 2120.0 2060.2 1918.6
Superheater Outlet
2 Pressure at Turbine Inlet kg/cm²(a) 247.0 247.0 247.0
Pressure at Superheater
3 kg/cm²(a) 256.0 255.5 254.4
Outlet
Temperature at
4 °C 568.0 568.0 568.0
Superheater Outlet
5 Steam Flow to Reheater T/hr 1717.3 1729.7 1612.6
Steam Pressure at HP
6 kg/cm²(a) 63.6 58.1 56.0
turbine Exhaust
Steam Temperature at HP
7 °C 353.0 347.8 336.7
turbine Exhaust
Steam Temperature at
8 °C 596.0 596.0 596.0
Reheater Outlet
Total Pressure drop of RH
System inclusive of cold
9 kg/cm² 5.7 5.8 5.3
reheat and hot reheat
piping
Feed Water Temperature

10 °C 293.2 293.1 290.0
at Economiser inlet
Reference Documents: Data Sheet Basic Boiler Performance Parameter (9571-102-

PVM-Y-0002, Rev-06)
1.2 Fuel Analysis
Description Design Coal Worst Coal Best Coal

GCV kcal/kg 3300 2800 4200
NCV kJ/kg 12755 10765 16506
Moisture % 14.00 16.00 12.00
Ash % 41.00 45.00 32.00
Fixed carbon % 24.00 20.00 32.00
Carbonates % 0.30 0.38 0.27
Phosphorus % 0.05 0.04 0.06
=> Ash incl. % 41.35 45.42 32.33
Carbon % 31.70 27.70 41.90
Hydrogen % 3.30 2.60 3.60
Nitrogen % 0.83 0.52 1.00
Sulphur % 0.28 0.50 0.25
Oxygen % 8.54 7.26 8.92
Volatiles % 21.00 19.00 24.00
Volatiles (daf) % 46.67 48.72 42.86
Grindability HGI 55 50 60
YGP Index Mg/kg 75 80 70
Silicia % 58.50 59.54 58.20
Alumina % 28.63 29.00 28.00
Iron Oxide % 6.32 6.42 6.10
Titania % 1.72 1.60 1.85
Phosphoric Anh. % 1.57 0.51 1.91
Lime % 1.53 1.50 1.70
Magnesia % 0.57 0.50 0.70
Sulphuric Anh. % 0.28 0.25 0.29
Sodium Oxide % 0.10 0.08 0.30
Balance Alkalies % 0.78 0.60 0.95
IDT °C 1150 1100 1200
HT °C 1350 1300 1400
FT °C 1400 1350 1400
Reference Documents: Fuel Analysis Data Sheet (9571-102-PVM-Y-0003, Rev-04)

2.0 Project Details
2.1 Site Conditions
2.1 Site Conditions
Kennwort / Code Word
Site Conditions Data Sheet Solapur
Dok-Nr. / Doc-No. Proj-Nr.:/ Job No.:
N-100131-S-H__-IB02-00011 N100130
Site Conditions Minimum Design Maximum Unit
Ambient temperature 6 27 50 °C
Level above Mean Sea 479 m

Level
Humidity 22 60 82 %
Rainfall in 24h 191 mm
Rainfall in month 518.8 mm
Basic wind speed at 39 m/s

10m above ground
Risk coefficient K 1.06
Category of Terrain 2
Criteria for earthquake and wind resistant design of structures and equipment:
Please refer to ANNEXURE-V and ANNEXURE-VI
of the Tender “Technical Specification Section-VI
BID DOC.No.:CS-9575/9571/0370/0360/9586-102(R)-2”
and to the document
“Design Criteria for Boiler House Steel Structure” (NTPC Doc. No. 9571-102-PVC-U-0694).
Additional site information Comments

Location: N17°31´50´´ ,
E75°59´30´´
Size of area: 6.68 km² Equals 1650 acres
Distance to raw water 110 km Ujjani Dam Reservoir
source
Raw water supply amount 52.6 Mill.m³
Raw water supply flow 6116.44 m³/h Equals 60 cusecs
Reference Documents: Site Conditions Data Sheet ( 9571-102-PVM-Y-0005,Rev-AB)
Ersteller / Prepared by Geprüft / Checked by: Datum /Date: Rev.:

Haske Adorni 13.02.2013 AB
Seite/Page 2 von/of 2
3.0 Process Details
3.2 Start Up Curves (Cold, Warm & Hot)
3.4 HP Diagram
3.5 Sliding Pressure Curves (HP&RH)

HP System
Design Coal Worst Coal Best Coal

Description
100% BMCR VWO 100% TMCR 100% BMCR VWO 100% TMCR 100% BMCR VWO 100% TMCR
HP-System: Water/Steam mass flow rate* [t/h]
Feed Water 2014.0 1957.2 1812.1 2014.0 1957.2 1822.7 2014.0 1957.2 1765.1
SH2 attemperator 53.0 51.5 48.0 53.0 51.5 48.0 53.0 51.5 48.0
SH3 attemperator 53.0 51.5 58.5 53.0 51.5 48.0 53.0 51.5 105.5
SH3 Outlet 2120.0 2060.2 1918.6 2120.0 2060.2 1918.7 2120.0 2060.2 1918.6
HP-System: Water/Steam-Pressure* [kg/cm²]
Inlet 289.3 287.1 281.9 288.6 286.4 281.4 289.9 287.6 282.1
ECO1
Outlet 288.1 286.0 280.8 287.5 285.3 280.3 288.7 286.5 281.0
Inlet 288.8 286.6 281.6 288.2 286.0 281.1 289.4 287.2 281.8
ECO2
Outlet 288.3 286.2 281.1 287.7 285.5 280.6 288.9 286.7 281.3
Inlet 291.6 289.6 284.9 290.9 288.9 284.3 292.3 290.3 285.2
Spiral1
Outlet 285.5 283.7 279.6 284.9 283.1 279.1 286.1 284.3 280.0
Inlet 285.5 283.7 279.6 284.9 283.1 279.1 286.1 284.3 280.0
Spiral2
Outlet 282.9 281.3 277.4 282.4 280.7 276.9 283.4 281.7 277.7
Inlet 282.9 281.3 277.4 282.4 280.7 276.9 283.4 281.7 277.7
vertical wall tubes
Outlet 280.7 279.1 275.5 280.2 278.6 275 281.2 279.5 275.7
Inlet 277.2 275.7 272.2 276.7 275.2 271.8 277.5 276 272.4
supporting tubes
Outlet 271.3 270.1 267.3 271.1 269.9 267.2 271.5 270.2 267.3
Inlet 271.3 270.1 267.3 271.1 269.9 267.2 271.5 270.2 267.3
SH1
Outlet 268.1 267 264.5 268 266.9 264.5 268.1 267.1 264.6
Inlet 263.8 263.3 261.3 263.8 263.3 261.2 263.9 263.4 261.3
SH2
Outlet 262.6 262.1 260.2 262.6 262.1 260.2 262.6 262.2 260.2
Inlet 260.1 260.8 259.1 260.1 260.8 259 260.2 260.9 259.1
SH3
Outlet 256 255.5 254.4 256 255.5 254.4 256 255.5 254.4
Description
HP-System: Water/Steam-Temperature* [°C]
Inlet 293.2 293.1 290 293.2 293.1 290 293.2 293.1 290
ECO1
Outlet 324.1 323.3 319.5 325.8 324.9 320.7 322.8 321.9 319.3
Inlet 324.1 323.3 319.5 325.8 324.9 320.7 322.8 321.9 319.3
ECO2
Outlet 338.2 336.7 332.6 340.8 339.3 334.7 336 334.7 332.5
Inlet 338.2 336.7 332.6 340.8 339.3 334.7 336 334.7 332.5
Spiral1
Outlet 395.1 395.9 394.6 394.2 393.7 392.4 399 398.4 398
Inlet 395.1 395.9 394.6 394.2 393.7 392.4 399 398.4 398
Spiral2
Outlet 408.6 408.2 407.8 405.3 404.9 403.7 412.2 411.8 415
Inlet 408.6 408.2 407.8 405.3 404.9 403.7 412.2 411.8 415
vertical wall tubes
Outlet 422.1 422 423.1 417.8 417.7 417.4 426.1 426.2 433.4
Inlet 422.1 422 423.1 417.8 417.7 417.4 426.1 426.2 433.4
supporting tubes
Outlet 429.2 429.2 430.5 424.9 424.8 424.5 433.3 433.4 441.6
Inlet 429.2 429.2 430.5 424.9 424.8 424.5 433.3 433.4 441.6
SH1
Outlet 472.9 473.6 478.1 468.2 469 470.8 476.2 477 493.5
Inlet 470.9 471.8 476.4 466.3 467.1 469.1 474.2 475.1 491.9
SH2 Attemperator
Outlet 461.3 462 466.1 457.1 457.8 459.5 464.3 465.1 479.9
Inlet 461.3 462 466.1 457.1 457.8 459.5 464.3 465.1 479.9
SH2
Outlet 514.7 514.9 518.4 512 512.2 512.7 517.1 517.3 534.6
Inlet 514.6 514.8 518.3 511.9 512.1 512.6 517 517.2 534.5
SH3 Attemperator
Outlet 501.7 501.9 502.1 499.2 499.4 499.7 503.9 504.1 503.5
Inlet 501.7 501.9 502.1 499.2 499.4 499.7 503.9 504.1 503.5
SH3
Outlet 568 568 568 568 568 568 568 568 568
Temperature of SH Spray Water* [°C]
SH2 & SH3 Spray 293.2 293.1 290 293.2 293.1 290 293.2 293.1 290
RH System

Description
RH-System: Water/Steam mass flow rate* [t/h]
RH2 Outlet 1754.7 1749.3 1612.5 1769.7 1763.6 1624.2 1746.4 1741.0 1612.8
RH Attemperator 37.5 19.5 0.1 52.5 33.8 11.8 29.2 11.2 0.4
RH-System: Water/Steam-Pressure* [kg/cm²]
Inlet 61.6 56.0 54.0 61.6 56.0 54.0 61.6 56.0 54.0
RH1
Outlet 60.9 55.2 53.4 60.9 55.2 53.3 60.9 55.2 53.4
Inlet 60.6 54.9 53.1 60.6 54.9 53.1 60.6 54.9 53.1
RH2
Outlet 60.1 54.3 52.6 60.1 54.3 52.5 60.1 54.3 52.6
RH-System: Water/Steam-Temperature* [°C]
Inlet 351.2 345.8 334.8 351.2 345.8 334.8 351.2 345.8 334.8
RH1
Outlet 512.2 504.3 493.7 518.4 510.3 498.8 508.5 500.6 494.2
Inlet 512.2 504.3 493.7 518.4 510.3 498.8 508.5 500.6 494.2
RH Attemperator
Outlet 488.3 491.8 493.6 485.1 488.6 490.6 489.9 493.4 494.0
Inlet 488.3 491.8 493.6 485.1 488.6 490.6 489.9 493.4 494.0
RH2
Outlet 596.0 596.0 596.0 596.0 596.0 596.0 596.0 596.0 596.0
Temperature of RH Spray Water* [°C]
RH Spray 186.3 187 184.7 186.3 187 184.7 186.3 187 184.7
Flue Gas System

Description
Flue gas mass flow rate* [t/h]; no ash considered
Inlet 2810.9 2731.0 2552.8 2921.4 2836.5 2646.7 2735.3 2657.2 2508.8
APH (pri. & sec.)
Outlet 3011.8 2926.1 2736.0 3134.9 3044.2 2839.7 2924.6 2841.8 2682.7
Inlet 1030.3 1010.9 981.4 1232.3 1219.7 1093.7 803.2 790.6 771.1
PAPH
Outlet 1123.6 1102.3 1069.9 1343.5 1329.8 1192.7 875.5 861.8 841.0
Inlet 1780.6 1720.1 1571.4 1689.1 1616.8 1553.0 1932.1 1866.6 1737.7
SAPH
Outlet 1888.2 1823.8 1666.1 1791.4 1714.3 1647.0 2049.1 1980.0 1841.8
Flue gas pressure* [g/cm²]
Inlet 978.9 978.9 978.9 978.9 978.9 978.9 978.9 978.9 978.9
SH1
Outlet 978.9 978.9 978.9 978.9 978.9 978.9 978.9 978.9 978.9
Inlet 978.9 978.9 978.9 978.9 978.9 978.9 978.9 978.9 978.9
SH3
Outlet 978.8 978.8 978.8 978.8 978.8 978.8 978.8 978.8 978.9
Inlet 978.8 978.8 978.8 978.8 978.8 978.8 978.8 978.8 978.9
RH2
Outlet 978.7 978.7 978.8 978.7 978.7 978.8 978.7 978.8 978.8
Inlet 978.7 978.7 978.8 978.7 978.7 978.8 978.7 978.8 978.8
SH2
Outlet 978.5 978.6 978.6 978.5 978.5 978.6 978.6 978.6 978.6
Inlet 978.5 978.6 978.6 978.5 978.5 978.6 978.6 978.6 978.6
RH1
Outlet 977.9 977.9 978.1 977.8 977.9 978 977.9 978 978.1
Inlet 977.9 977.9 978.1 977.8 977.9 978 977.9 978 978.1
ECO2
Outlet 977.7 977.8 978 977.6 977.7 977.9 977.8 977.9 978
Inlet 977.7 977.8 978 977.6 977.7 977.9 977.8 977.9 978
ECO1
Outlet 977.2 977.3 977.6 977.1 977.2 977.5 977.3 977.4 977.6
Inlet 968.9 969.1 969.8 968.2 968.7 969.3 969 969.3 969.8
PAPH
Outlet 958.7 959.5 960.6 953.2 955.1 957.7 963 963.6 964.3
Inlet 968.9 969.1 969.6 968.2 968.7 969.3 969 969.3 969.8
SAPH
Outlet 958.7 960 962.1 955.9 960.1 961.9 957.2 958.6 960.3
Inlet 956.3 957.1 958.6 951.6 952.6 955.5 954.6 955.4 957.9
ESP
Outlet 953.7 954.8 956.6 948.7 950 953.2 952.2 953.3 956
Inlet 952.4 953.5 955.5 947.4 982.8 952.1 951 952.2 954.9
ID FAN
Outlet 982.4 982.3 982 982.8 982.7 982.2 982.3 982.2 981.9
Description
Flue Gas Temperature* [°C]
Inlet 1248 1238.6 1216.8 1239 1231 1211.8 1267 1257.1 1236.3
SH1
Outlet 1112.2 1102.2 1079.2 1108.1 1098.4 1075.5 1129.7 1119.3 1099
Inlet 1112.2 1102.2 1079.2 1108.1 1098.4 1075.5 1129.7 1119.3 1099
SH3
Outlet 942.7 933.2 911.4 941.3 931.8 909.9 956.5 946.7 927.9
Inlet 942.7 933.2 911.4 941.3 931.8 909.9 956.5 946.7 927.9
RH2
Outlet 818.3 810.3 792 819.2 811.2 792.5 827.1 818.9 803.1
Inlet 818.3 810.3 792 819.2 811.2 792.5 827.1 818.9 803.1
SH2
Outlet 692.8 686.5 672.9 695 688.5 673.5 697.3 690.9 683.5
Inlet 692.8 686.5 672.9 695 688.5 673.5 697.3 690.9 683.5
RH1
Outlet 497.2 489.5 475.2 502.8 495 479.9 494.6 487 476.1
Inlet 497.2 489.5 475.2 502.8 495 479.9 494.6 487 476.1
ECO2
Outlet 452.1 446.4 434.5 457.8 451.8 439.1 448.8 443 434.2
Inlet 452.1 446.4 434.5 457.8 451.8 439.1 448.8 443 434.2
ECO1
Outlet 360 356.7 348.9 363.9 360.5 352.1 357.3 354.2 348.3
Inlet 361.6 358.5 351.1 365.3 362 353.9 359.1 356.1 350.8
PAPH/SAPH
Outlet 127.5 127 125 131.5 130.1 126.8 130.5 130.1 129.1
Air System

Description
Air mass flow rate* [t/h]
PAPH Outlet 913.0 891.4 863.3 1098.7 1090.1 977.4 662.4 649.4 629.6
Tempering Air 35.1 43.8 49.3 7.0 2.7 2.0 199.5 204.0 208.0
SAPH Outlet 1548.0 1488.2 1350.7 1459.4 1396.4 1345.7 1594.4 1531.8 1413.7
Sealing Air Mills 30.2 30.2 30.2 34.6 34.6 30.2 30.2 30.2 30.2
Total Combustion Air 2526.3 2453.7 2293.6 2599.7 2523.8 2355.3 2486.6 2415.5 2281.6
Air pressure * [g/cm²]
Inlet 975.3 975.4 975.6 973.9 974.1 975.1 976.0 976.1 976.3
PA FAN
Outlet 1093 1090 1084 1107.6 1104.2 1106.8 1068.7 1066.3 1063.3
Inlet 975.1 975.4 976 975.5 975.7 976 974.7 975.1 975.7
FD FAN
Outlet 1009.2 1006.8 1002.1 1011 1008.5 1001.7 1011.5 1008.8 1004.8
Inlet 1090.9 1087.8 1081.9 1104.1 1101.2 1104.3 1067.2 1064.8 1061.9
PAPH
Outlet 1080.7 1078 1072.8 1089.8 1088.2 1092.6 1061.7 1059.5 1056.9
Inlet 1006.8 1004.6 1000.3 1016.8 1006.5 999.8 1008.8 1006.5 1002.8
SAPH
Outlet 996.6 995.3 992.7 1004.8 998.2 992.3 998.1 996.8 994.2
Air Temperature* [°C]
Inlet 40.0 40.0 40.0 40.0 40.0 40.0 40.0 40.0 40.0
Primary SCAPH
Outlet 40 40 40 40 40 40 40 40 40
Inlet 40 40 40 40 40 40 40 40 40
PAPH
Outlet 330.5 328.2 321.9 332.3 329.2 323.1 334.9 332.6 328.2
Inlet 32 32 32 32 32 32 32 32 32
Secondary SCAPH
Outlet 32 32 32 32 32 32 32 32 32
Inlet 32 32 32 32 32 32 32 32 32
SAPH
Outlet 330.5 328.4 323.2 336.2 333.7 326.3 329.7 327.8 324.3
Reference Documents: Best/Design/Worst coal for variable pressure operation at 50, 60, 80, 100, 105% TMCR and 60, 100% BMCR load – HP heaters out of operation (9571-102-PVM-Y-
0012,Rev-09)
3.2 Cold Start Up Diagram
NTPC_DRG_NO. Dok.-Nr. / Doc.-No. Seit e / page

Cold start-up diagram
> 36 h ≤ 72 h of shutdown 9571-102-PVM-N-0008 N-100131-0-051-IB06-00001
Kennwort / code word Dat um / dat e
modified sliding pressure
- for reference only - NTPC Solapur 06.03.2014
HP steam bypass system closed xx % open on control stand by
LP steam bypass system closed xx % open on control stand by
SH and RH drains controlled closing

former editions:
120 330 720
VWO
transfer operation completed
turbine rolling
once through mode

synchronize
firing rate
110 300 660

105%
HP st eam f low
turbine load, HP steam flow , firing rate [% of TMCR]
100 600
270 593 °C
565 °C HPT temp. inlet
90 540
240 247 kg/cm ²
IPT temp. inlet
80 480
temperature, speed [°C] [rpmx10]
210
steam pressure (abs.) [kg/cm²]
422 °C
70 circulation
420
390 °C
180
60 360 HPT steam inlet pressure
150
311 °C 3000 rpm
50 300 IPT inlet steam pressure
120
38,7% TMCR
40 240 102 kg/cm ² 2190 rpm turbine speed
Steinmetz
90 160 °C
30 180
turbine load
Revision AF
20% BMCR
60 54,3
20 120
120 °C
name
temp. at separator
15 % BMCR
10 30 Bensonpoint at
checked: 60
Busekrus/SG1
13,5 kg/cm ² 35% BMCR =
38,7 % TMCR
0 0 0
resp.: 0 0 50
0 50 60 100 100 120 150 150
180 200 200
240 250 300 250 300 360 300
Zimmer/SG1
t el.: start 1 st mill time [min]
Reference Documents: Start-up Diagram Cold Start: 9571-102-PVM-N-0008 Seite/Page 2 von/of 19

Start-up Diagram Cold-Start Solapur
N-100131-0-051-IB06-00001 N100131
The following table shows the sequence of the oil burner level/ coal mill cut-in points with respect to
the firing rate and time. Furthermore the switch over from light diesel oil (LDO) to heavy fuel oil (HFO)
is included.
Table 1: Sequential cut in for mills & oil burner level

Start-up step Firing capacity Firing capacity Time
[-] [% BMCR] [% of TMCR] [min]
1. oil burner level 0 0 0
switch-over LDO to HFO 12 13 79
1. mill 20 22 94
2. mill 20 22 94
3. mill 25 28 178
4. mill 30 33 189
5. mill 45 50 220
6. mill 60 66 251
7. mill 75 83 282
Reference Documents: Start-up Diagram Cold Start: 9571-102-PVM-N-0008

Name: Zimmer Name: Busekrus 23.07.2014 AG
3.2 Warm Start Up Diagram
NTPC_DRG_NO. Dok.-Nr. / Doc.-No.

Warm start-up diagram
> 8 h and ≤ 36 h of shutdown 9571-102-PVM-N-0009 N-100131-0-051-IB06-00002
Kennwort / code word Kennwort / code word Dat um / dat e
- for reference only - NTPC Solapur NTPC Solapur 06.03.2014
HP steam bypass s ys tem closed xx % open on control stand by
LP steam bypass s ys tem closed xx % open on control stand by
SH and RH drains controlled closing
120 330 720

temp. at separat or
VWO
synchronize
start of turbine
once through mode

transfer completed
110 300 660
105 % firing rate
100 600
boiler load (HP steam flow ), firing rate [% of TMCR]
270
593 °C HP steam flow
565 °C
90 540
240 247
HPT temp. inlet
480 °C
80 480
475 °C
210
IP T temp. inlet
422 °C
70 420
180
IP T inlet steam pres sure
60 360
150 311 °C
3000 rpm circulation
50 300
120 280 °C
40 HPT inlet steam
240 pressure
38,7% 102 kg/cm ²

Steinmetz
90
30 180 turbine speed
30% TMCR
60 54,3
20 120 turbine load
name
10 30 8,7 % Bensonpoint
checked: 60
15 kg/cm ² at 35 % BMCR
Busekrus/SG1
= 38,7 % TMCR
0 0 0
0 0 20 0 20 40 30 40 60 60 60 80 90 80100
120 120
100
150 140
120
180 140
210 160 180
240 160 270 180
Zimmer/SG1
start 1 st mill time [min]
Reference Documents: Start-up Diagram Warm Start: 9571-102-PVM-N-0009
Start-up Diagram Warm-Start Solapur
N-100131-0-051-IB06-00002 N100131
the firing rate and time. During warm start-up procedure only HFO burners are in use.
Table 1: Sequential cut in for mills & oil burner level during warm-start
1. oil burner level 0 0,0 0
1. mill 20 22,1 78
2. mill 20 22,1 78
3. mill 25 27,6 84
4. mill 30 33,1 154
5. mill 45 49,7 173
6. mill 60 66,3 192
7. mill 75 82,9 211
Reference Documents: Start-up Diagram Warm Start: 9571-102-PVM-N-0009

3.2 Hot Start Up Diagram
NTPC_DRG_NO. Dok.-Nr. / Doc.-No. Seit e / page

Hot start-up diagram
≤ 8 h of shutdown 9571-102-PVM-N-0010 N-100131-0-051-IB06-00003
Kennwort / code word Datum / date
HP steam bypass system closed xx % open on control stand by
LP steam bypass system closed xx % open on control stand by
SH and RH drains
controlled closing
former editions:
120 330 720 temp. at separator
transfer completed
once through mode

110 300 660
synchronize
firing rate
105 %
100 600 593 °C

270
boiler load (HP steam flow ), firing rate [% of TMCR]
HP steam flow
565 °C
90 535 °C 247
540
240
530 °C HPT temp. inlet
start of turbine
80 480
210
IPT temp. inlet

410 °C
TMCR
422 °C
70 420
180
IPT inlet steam pres sure
60 360
150 318 °C
circulation
50 290 °C 3000 rpm
300
120
38,7 % TMCR 112 kg/cm ² HPT inlet steam pressure
40 240
Steinmetz
90
30 30 % TMCR turbine speed
180
AF
60 54,3
20 120 turbine load
revision
name
Bensonpoint at
in
10 30
checked: 60 8,7 %
14,3
35% BMCR =
Busekrus/SG1 38,7 % TMCR
0 0 0
resp.: 0 0 20 0 20 40 20 40 60 60 80
40 60100
80 120
100
80 140
120100 160
140 120 180 140
160 180
Zimmer/SG1
start of 1st mill
tel.: time [min]
Reference Documents: Start-up Diagram Hot Start: 9571-102-PVM-N-0010
Start-up Diagram Hot-Start Solapur
N-100131-0-051-IB06-00003 N100131
the firing rate and time. During hot start-up procedure only HFO burners are in use.
Table 1: Sequential cut in for mills & oil burner level during hot start
1. mill 20 22,1 45
2. mill 20 22,1 45
3. mill 25 27,6 53
4. mill 30 33,1 67
5. mill 45 49,7 82
6. mill 60 66,3 96
7. mill 75 82,9 111
Reference Documents: Start-up Diagram Hot Start: 9571-102-PVM-N-0010

NTPC_DRG_NO. Doc.-No. page

Shut-Down Diagramm
from 100 % Load 9571-102-PVM-N-0011 N-100131-0-051-IB06-0004 1 of 1
code word dat e
modified/pure sliding pressure
closed
HP s team bypas s s ys tem on control
closed
LP s team bypass s ys tem on control
110 330 660
100,0 %
100 300 600 585 °C 581°C
596 °C
fire off
568 °C 568 °C
90 270 540 568 °C

255,5 kg/cm²
254,4 kg/cm²
500 °C
80 240 480
turbine shut down

circulation mode
70 210 420
422 °C
boiler load (100%=VWO), firing rate [%]

modified sliding
60 180 360
pure sliding 317 °C
50 150 300
40 120 240
35,0 %
99,0 kg/cm²
99,0 kg/cm²
30 90 180
27,0 %
58,4 kg/cm²
20 60 120
20,0 %
12,0 %
10 30 60 21,7kg/cm²
0 0 0
0 0 -10
0,2 0,2 0,4 0 0,4 0,6 10 0,6 0,8 20 0,8 1 30 1 1,2 40 1,2 45
temp. at seperator life steam pressure. firing rate HP steam flow
100%BMCR =2120 t/hr
Live Steam temp. HRH temp. circulation turbine load VWO =2060,2 t/hr
HRH press. live steam pressure (pure sliding) turbine speed 100%TMCR =1918,6 t/hr
time [min] Seite/Page 2 von/of 10

Reference Documents: Shut-Down Diagram: 9571-102-PVM-N-0011
Start-up Diagram Cold-Start Solapur
N-100131-0-051-IB06-00001 N100131
The following table shows the sequence of the oil burner level/ coal mill cut-out points with respect to
the firing rate and time. For detailed information please refer to document no. 9571-102-PVM-X-0069.
Table 1: Sequential cut out for mills & oil burner level
Oil Burner and Mill Shut-down Points (Firing Capacity %

BMCR)
Same sequence for all shut-down modes, but with different burner level selection
Shut-down step Firing capacity Firing capacity Time

(% BMCR) (% TMCR) (min)
1. shut down mill 10 75 82,9 7
2. shut down mill 20 60 66,3 17
3. shut down mill 30 45 49,7 27
4. shut down mill 40 32 35,3 35
5. start up oil burner level 60 30 33,1 30
6. start up oil burner level 70 29 32 30
Switch over from control mode to
28 30,9 31
mill basis load
7. shut down mill 50 28 30,9 31
8. shut down mill 60 20 22 36
9. shut down oil burner level 60 10 11 47
10. shut down mill 70 10 11 47
Reference Documents: Shut-Down Diagram: 9571-102-PVM-N-0011

Name: Hockauf Name: Busekrus 04.12.2015 AD
Hitachi - Power 3.4 HP - Diagram Project: Solapur
Project - Nr.: N-100131
Europe Design Coal
4000
3900 MCR 750 °C
3800 60% MCR VWO 700 °C
3700 35% BMCR TMCR 35% Benson Point

650 °C
3600 50% MCR 60% MCR
RH 2 80% MCR
600 °C
3500 VWO
100%
3400 550 °C
TMCR 100%
3300
500 °C BMCR SH3
RH 1 100%
3200
MCR
450 °C
3100
SH2
3000
50% MCR 400 °C
BMCR
2900
80% MCR 350 °C
300 °C
250 °C SH1 supporting tubes +
200 °C
2800 screen
∆=7K ∆ = 11 K
2700
x = 90 % steamcontent
Evaporator wall
2600
vertical tubes
2500
80 %
2400
enthalpy [ kJ/kg ]
70 %
2300
2200
60 % Evaporator wall spiral
2100
2000 50 %
1900
40 %
1800
1700
30% 350 °C
1600
1500 20 % ∆ = 19 K
∆=9K
1400 Economiser
300 °C 300 °C
10 %
1300
1200
1100 250 °C
1000
900
200 °C
800
700
150 °C
600
500
100 °C
400
300
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
270
280
290
300
310
320
330
340
350
pressure [ bar a ]
Date: 11.11.2013
REV.: AA Reference Issued:
Documents:
Denis HP-Diagram: 9571-102-PVM-Y-0362 Page: 9 / 92
3.5 HP Sliding Pressure Curve
Pure Sliding Pressure Curve HP Proj.: NTPC Solapur
Proj. No.: N-100131
N-100131-S-HA_-IB06-00001
300,0 Design Pressure and Set Pressure Spring Loaded Safety Valve Seperator (297,8kg/cm² abs )
Design Pressure MS (272,5 kg/cm² abs). Set Pressure Spring Loaded Safety Valve MS (270,1kg/cm² abs)
270,1 266,7 kg/cm²a
264,0 kg/cm²a
256,0 kg/cm²a
Set Pressure Electro
250,0 Matic Relief Valve
Set Pressure HP Bypass Station
200,0
Pure Sliding Pressure Boiler Outlet

Main Steam Pressure [kg/cm² abs]
150,0
109,7 kg/cm²a Fixed Pressure Operation
107,0 kg/cm²a
100,0
99,0 kg/cm²a
Fixed Pressure Pure Sliding Pressure

Operation Operation
100% TMCR (532,9 kg/s)
Benson Minimum Load
50,0
50% MCR (257,1 kg/s)
80% MCR (416,8 kg/s)
100% BMCR (588,9
0,0
0 20 40 60 80 100
100% BMCR =110,5% TMCR
Boiler Load [%]
2/14
Reference Documents: Diagram for Sliding Pressure Curve HP: 9571-102-PVM-N-0055

Diagram for Sliding Pressure Curve HP Proj.: NTPC Solapur
Proj. No.: N-100131
Table 1: Data for pure sliding pressure

MCR Load/ Operating P Opening Set P Opening Set P Opening Set P Opening Set P Sep.
Boiler Load
Denomination Boiler Outlet EMRV HP Bypass MS Safety Valve Safety Valve
% of BMCR kg/cm² abs kg/cm² abs kg/cm² abs kg/cm² abs kg/cm² abs
0,00 99,0 109,7 107,0 270,1 297,8
35,00 min. Benson Load 99,0 109,7 107,0 270,1 297,8
43,70 50,0 123,4 134,1 131,4 270,1 297,8
70,80 80,0 199,2 209,9 207,2 270,1 297,8
90,50 100% TMCR 254,4 265,1 262,4 270,1 297,8
100,00 256,0 266,7 264,0 270,1 297,8
opening set pressure HP bypass = operating pressure boiler outlet + 8 kg/cm²
opening set pressure EMRV = opening set pressure HP bypass + 2,7 kg/cm²
Remark:
Constant difference of 8 kg/cm²/ 10,7 kg/cm² between set point of HP Bypass/ EMRV and set point of superheater
outlet pressure corresponding to boiler load as per sliding pressure curves/ run back curves.
3/14
Modified Sliding Pressure Curve HP Proj.: NTPC Solapur
Proj. No.: N-100131
N-100131-S-HA_-IB06-00001
Design Pressure and Set Pressure Spring Loaded Safety Valve Seperator (297,8kg/cm² abs)
300,0
Design Pressure MS (272,5 kg/cm² abs). Set Pressure Spring Loaded Safety Valve MS (270,1kg/cm² abs)
270,1 266,7 kg/cm²a
264,0 kg/cm²a
Set Pressure Electro 256,0 kg/cm²a
Matic Relief Valve
250,0
modified sliding
pressure boiler outlet
200,0
Set pressure at HP Bypass station

Main Steam Pressure [kg/cm² abs]
Pure Sliding Pressure Boiler Outlet
150,0
109,7 kg/cm²a Fixed Pressure Operation
107,0 kg/cm²a
100,0
99 kg/cm²a
Fixed Pressure Modified Sliding

Operation Pressure Operation
100% BMCR (588,9 kg/s)
50,0
Benson Minimum Load
90% BMCR (528,1 kg/s)

95% TMCR (505,0 kg/s)
65% TMCR (341,6 kg/s)
80% TMCR (424,3 kg/s)

50% MCR (257,1 kg/s)
60% TMCR (314,9 kg/s)
0,0
0 20 40 60 80 100
Boiler Load [%]
4/14
Diagram for Sliding Pressure Curve HP Proj.: NTPC Solapur
Proj. No.: N-100131
Table 2: Data for modified sliding pressure

mass flow at MCR Load/ Operating P Opening Set P Opening Set P Opening Set P Opening Set P Sep.
Boiler Load
SHO Denomination Boiler Outlet EMRV HP Bypass MS Safety Valve Safety Valve
% of BMCR kg/s - kg/cm² abs kg/cm² abs kg/cm² abs kg/cm² abs kg/cm² abs
0 0,0 0 99 109,7 107,0 270,1 297,8
35,00 206,1 Bensonpoint 99,0 109,7 107,0 270,1 297,8
53,48 314,9 60% TMCR* 157,1 167,8 165,1 270,1 297,8
58,01 341,6 65% TMCR* 169,7 180,4 177,7 270,1 297,8
72,05 424,3 80% TMCR* 208,7 219,4 216,7 270,1 297,8
85,75 505,0 95% TMCR* 245,5 256,2 253,5 270,1 297,8
89,67 528,1 ** 256,0 266,7 264,0 270,1 297,8
100,00 588,9 BMCR 256,0 266,7 264,0 270,1 297,8
opening set pressure HP bypass = operating pressure boiler outlet + 8 kg/cm²
opening set pressure EMRV = opening set pressure HP bypass + 2,7 kg/cm²
Remark:
Constant difference of 8 kg/cm²/ 10,7 kg/cm² between set point of HP Bypass/ EMRV and set point of superheater outlet
pressure corresponding to boiler load as per sliding pressure curves/ run back curves.
*please refer to HBDs of Alstom (modified sliding pressure operation with 5% reserve in MCV)
**Data interpolated because no HBD for modified sliding pressure between 80% LOAD and BMCR available
5/14
3.5 RH Sliding Pressure Curve Proj.: NTPC Solapur
Sliding Pressure Curve RH Proj. No.: N-100131
N-100131-S-HAJ-IB06-00001
Set Pressure CRH Spring Loaded Safety Valve (71,1 kg/cm² abs)
70,0 Opening Set Pressure HRH Spring Loaded Safety Valve ( 68,0 kg/cm² abs)
67,0 kg/cm²a
64,1 kg/cm²a
Set P EMRV
60,0 60,1 kg/cm²a

Sliding Pressure Curve RH
according to HBDs of Alstom
Set Pressure LP
Bypass Station
50,0
Hot Reheat Pressure [kg/cm² abs]
Pure Sliding Pressure

Curve RH
40,0
31,0 kg/cm² a
30,0
28,1 kg/cm² a
24,1 kg/cm² a
21,7 kg/cm² a
20,0
Fixed Pressure Sliding Pressure

Operation Operation
Benson Minimum Load
10,0
53,5% BMCR
58,0% BMCR
96,4% BMCR
72,0% BMCR
85,8% BMCR
43,8% BMCR
0,0
0 20 40 60 80 100
Boiler Load [% of BMCR]; 100% BMCR = 2120 t/h main steam flow
2/11
Reference Documents: Sliding Pressure Curve RH: 9571-102-PVM-N-0056
Sliding pressure curve RH Proj.: NTPC Solapur
Proj. No.: N-100131
25.07.2014
Operating p boiler outlet Operating P Boiler Outlet according
Opening Set P Opening Set P Opening Set P Opening Set P
Boiler Load Denomination of load case according to simplified to HBDs of Alstom for modified &
LPB EMRV HRH Safety Valve CRH Safety Valve
approach pure sliding pressure
% of BMCR - kg/cm² abs kg/cm² abs kg/cm² abs kg/cm² abs kg/cm² abs kg/cm² abs
0,0 - 21,7 24,1 28,1 31,0 68,0 71,1
35,0 Bensonpoint 21,7 24,1 28,1 31,0 68,0 71,1
43,8 50% TMCR* 26,9 29,1 33,1 36,0 68,0 71,1
53,3 60% TMCR* 32,5 34,4 38,4 41,3 68,0 71,1
53,5 60% TMCR** 32,6 34,5 38,5 41,4 68,0 71,1
58,0 65% TMCR** 35,3 37,3 41,3 44,2 68,0 71,1
71,8 80% TMCR* 43,4 45,4 49,4 52,3 68,0 71,1
72,0 80% TMCR** 43,6 45,6 49,6 52,5 68,0 71,1
85,8 95% TMCR** 51,7 53,8 57,8 60,7 68,0 71,1
96,4 *** 57,9 60,1 64,1 67,0 68,0 71,1
100,0 BMCR 60,1 60,1 64,1 67,0 68,0 71,1
opening set pressure LPB = operating pressure boiler outlet + 4 kg/cm²
opening set pressure EMRV = opening set pressure LPB + 2,9 kg/cm²
*please refer to HBDs of Alstom for pure sliding pressure operation

**please refer to HBDs of Alstom for modified sliding pressure operation
***Data interpolated
Reference Documents: Sliding Pressure Curve RH: 9571-102-PVM-N-0056
3/11
4.0 Pressure Parts Details
4.2 Boiler Upper Part - Longitudinal Section
4.3 Boiler lower Part - Longitudinal Section
4.4 Boiler Arrangement - Longitudinal

2
Size (mm) Pressure (kg/cm (g)) Temperature (°C)
ST SL Material
Description Out
thick (mm) (mm) Specification Operation Design Operation Design
dia.
Economizer system
ECO1 Inlet Header 457 66 - - SA-106M Gr. C 290.6 307.1 296 336
ECO1 Bundle Part 1 44.5 5.50 120 80 SA-210M Gr. C 290.6 307.1 299.5 350.5
ECO1 Outlet Header 457 70 - - SA-106M Gr. C 290.6 307.1 325.8 365.8
ECO2 Inlet Header 457 70 - - SA-106M Gr. C 290.6 307.1 325.8 365.8
ECO2 Bundle Part 2 44.5 6.5 120 80 SA-210M Gr. C 290.6 307.1 342 393
ECO2 Outlet Header 457 74 - - SA-106M Gr. C 290.6 307.1 342 382
Evaporator system
Evap. Inlet Header 323.8 55 - - SA-106M Gr. C 292.7 309.2 342 382
Evap. Spiral Part 1
38 7.1 - - SA-213M T12 292.3 308.8 359 449
(Hopper)
Evap. Spiral Part 2 38 7.1 - - SA-213M T12 292.3 308.8 395.1 485.1
Evap. Spiral Part 3 42.2 8.1 - - SA-213M T12 292.3 308.8 399 489
Intermediate Header 273 52 - - SA-335M P12 284.5 301 415 455
Evap. Vertical Part 1 38 6.8 - 60 SA-213M T12 284.3 300.8 421 511
Evap. Vertical Part 2 42.2 7.1 - 120 SA-213M T12 284.3 300.8 427 506
Evap. Outlet Header
273 40 - - SA-335M P91 282 298.5 427 467
(FW/RW)
Evap. Outlet Header
457 58 - - SA-335M P91 282 298.5 427 467
(LSW/RSW)
Separator 950 95 - - SA-335M P91 280.3 296.8 427 467

Water vessel Part 1 753 84 - - SA-335M P91 282.3 298.8 427 467
Superheater system
SH1 Inlet Header 406.4 55 - - SA-335M P91 278.7 295.2 427 467
SH1 Bundle Part 1 44.5 6.3 960 60 SA-213M T91 271.2 287.7 459.5 549.5
SH1 Bundle Part 2 44.5 7.2 960 60 SA-213M T91 271.2 287.7 480 570
SH1 Outlet Header 273 36 - - SA-335M P91 268.2 284.7 480 520
SH2 Inlet Header 406.4 56 - - SA-335M P91 263.1 279.6 469 474
SH2 Bundle Part 1 38 4.6 120 70 SA-213M T91 262.8 279.3 486.8 525.8
SH2 Bundle Part 2 38 5.1 120 70 SA-213M T91 262.8 279.3 517.1 556.1
SH2 Outlet Header 406.4 63 - - SA-335M P91 262.1 278.6 517.1 532
SH3 Inlet Header 406.4 52 - - SA-335M P91 261 277.5 504 509
SH3 Bundle Part 1 44.5 6.7 960 80 SA-213M T91 259.1 275.6 527.7 577.7
SA-213M UNS
SH3 Bundle Part 2 44.5 5.5 960 80 259.1 275.6 548.8 598.8
S30432
SA-213M UNS
SH3 Bundle Part 3 44.5 5.7 960 80 259.1 275.6 567.1 617.1
S30432 SP
SH3 Outlet Header 457 78 - - SA-335M P91 255 271.5 568 568
Reheater system
2
Size (mm) Pressure (kg/cm (g)) Temperature (°C)
ST SL Material
Description Out
thick (mm) (mm) Specification Operation Design Operation Design
dia.
RH1 Inlet Header 610 30.96 - - SA-106M Gr. C 60.6 70.1 353 358
RH1 Bundle Part 1 44.5 3.6 120 80 SA-213M T12 60.6 70.1 493.3 532.3
RH1 Bundle Part 2 44.5 3.6 120 80 SA-213M T22 60.6 70.1 511 550
RH1 Outlet Header 660 35 - - SA-335M P91 60.6 70.1 518.4 528
RH2 Inlet Header 660 28 - - SA-335M P91 60.6 70.1 495 500
SA-213M UNS
RH2 Bundle Part 2 63.5 3.6 240 105 60.6 70.1 596 646
S30432 SP
RH2 Outlet Header 711 63 - - SA-335M P91 60.6 70.1 596 596
Reference Documents: Pressure Parts Schedule (9571-102-PVM-Y-0031, Rev-06)

500
5.0 Fans

Sl.No Description Units FD Fan ID Fan PA Fan Seal Air Fan
1 Fan Make Howden Solyvent Howden Solyvent Howden Solyvent CB Doctor
2 Fan Type/Model PFSH-224-112-02 PFSG-450-300-78 PFTU-212-125-02 SBH 170 IIM5
3 No. of Fans 2X60 % 2X60 % 2X60 % 2X100%
4 No. of Blades no 15 32 30 08
5 Type of Lubrication Forced Oil Forced Oil Forced Oil Grease
6 Type of Control Hydraulic Blade Pitch Hydraulic Blade Pitch Hydraulic Blade Pitch IGV
7 No. of Stages Single Stage Single Stage Single Stage Single Stage
3
8 Fan Max Flow Handled m /s 400 950 260 14.60
100 % BMCR Best Coal 100 % BMCR Worst Coal 100 % BMCR Worst Coal 100 % BMCR Worst Coal
9 Load Case Firing (8 Mills in operation)
Firing Firing Firing
3
a Flow m /s 331.91 813.18 233.61 10.10
b Head mbar 68.4 55 172.3 105.7
c Temperature Deg C 50 150 50 50
d Speed rpm 1490 590 1490 1490
e Efficiency % 88.7 89.1 87.1 83.5
f Shaft Power KW 2501 4929 4372 234.8
10 First Critical Speed rpm 2116 1248 2226 1975
11 Second Critical Speed rpm 3827 1372 2812 2257
12 Motor Make BHEL BHEL BHEL CGL –INDIA
13 Motor Model/Frame Size 1LA 7905 -4 1TF4551-3 1RN7804-4 NG315L
14 Motor Rating KW 2780 5650 4840 275
15 Motor Speed rpm 1490 590 1490 1490
16 Motor Voltage KV 11 11 11 3.3
Referance documents :
Sl.no Tiltle of the document NTPC MDL no
G.A. Drawing for FD ,ID & PA Fan with Foundation Plan and 9571-102-PVM-B-0220,9571-102-PVM-B-
1 221,
Loading Details
9571-102-PVM-N-0231,9571-102-PVM-N-
2 Performance Curve For FD , ID, PA & Seal air Fan
0232,9571-102-PVM-N-0233,9571-102-PVM-
N-0234
9571-102-PVM-Y-0385,9571-102-PVM-Y-
3 Data sheet of FD , PA & ID Fan
0386,9571-
102-PVM-Y-0387
Installation and O&M Manual for Seal Air Fan for Mill (Refer O&M Manual Solapur)
4 Process Description - Seal air system Mill & Feeder 9571-102-PVM-X-0952
SOLAPUR 2 X 660 MW
FD Fan 50 Hz
PERFORMANCE CHART PF= CODE FOR PROPELLER FAN
PFSH-224-112-02 S=CODE FOR SINGLE STAGE
Single stage V-blade+IGV H=CODE FOR BLADE DESIGN
224=CODE FOR IMPELLER DIAMETER (cm)
Motor rating :2780 Kw,1490 rpm,11KV

112= CODE FOR HUB DIAMETER (cm)
0=CODE FOR TRANSPORTED MEDIUM
2=CODE FOR ROTATING SPEED
Duty Point 1 2 3 4
Load BMCR DC TMCR DC VWO DC DP1 60% BMCR BC
Actual Flow [m3/s] 208,63 180,76 199,3 362,87
Total Pressure Rise [mbar] 33,5 25,7 30,8 58,7
Inlet Temperature [degC] 27 27 27 50
Inlet Density [kg/m3] 1,101 1,102 1,101 0,992
Fan Total Efficiency [%] 78 70,1 75,7 83,6
Shaft Power (incl. bearing loss) [kW] 886 657 803 2499
8050
Bearing loss (estimated) [kW] 3 3 3 3
Compressibility Factor 0,989 0,992 0,990 0,981
Isentropic Head [Nm/kg] 3043 2332 2797 5917
Duty Point 5 6 7 8
Load 60% BMCR BC DP2 100% BMCR BC 80% MCR DC 60% MCR DC 6881
Actual Flow [m3/s] 306,13 331,91 179,92 162,02
Total Pressure Rise [mbar] 47 68,4 28,2 28,3
Inlet Density [kg/m3] 1,096 0,994 1,102 1,077 5950
Fan Total Efficiency [%] 79 88,7 73,8 74,7
Isentropic Head [Nm/kg] 4288 6881 2559 2628 4540
Duty Point 9
Load 50% MCR DC
Actual Flow [m3/s] 157,27
Total Pressure Rise [mbar] 22,5
Inlet Temperature [degC] 27
Inlet Density [kg/m3] 1,077
Fan Total Efficiency [%] 67,1
Shaft Power (incl. bearing loss) [kW] 524
Bearing loss (estimated) [kW] 3
Compressibility Factor 0,993
Isentropic Head [Nm/kg] 2089
Isentropic Head (Nm/kg) = Total Pressure Rise (mbar) / Inlet Density (kg/m3) * 100 (mbar to Pa)
Shaft Power (kW) = Compressibility ( - ) * Actual Flow (m3/s) * Isentropic Head (Nm/kg) * Inlet Density (kg/m3) / Fan Total Efficiency ( - ) / 1000 (W to kW)
The formulae above can be obtained from BS-848, Section 14.8, especially 14.8.1 and 14.8.2.
Example: Duty point 4, 60% BMCR BC

Shaft Power = 0.981*362.87*5917*0.992/0.836/1000=2499kW
Example: Duty Point 6, 100% BMCR BC

Shaft Power = 0.977*331.91*6881*0.994/0.887/1000=2501kW
Compressibility ( - ) = LN(1+x) / x * Zp / LN(1+Zp)

where x = Total Pressure Rise / Absolute Inlet Pressure
and Zp = ( Isentropic Exponent - 1 ) / Isentropic Exponent * Shaft Power / Actual Flow / Absolute Inlet Pressure
Example: Duty Point 6, 100% BMCR BC

Compressibility = LN(1+0.07189)/0.07189*0.02281/LN(1+0.02281) = 0.977
x = 6840/95140 = 0.07189
Zp = (1.4-1)/1.4*2501*1000/331.91/95140 = 0.02281
Max. Shut off Pressure = 50mbar at 1.102kg/m3

SOLAPUR 2 X 660 MW
ID Fan 50 Hz
PFSG-450-300-78 S=CODE FOR SINGLE STAGE
Single stage G=CODE FOR BLADE DESIGN
Motor rating :5650 Kw , 590 rpm, 11KV

Duty Point 1 2 3 4
Load 100% BMCR DC 100% TMCR DC 105% VWO DC 60% DP 1 WC
Actual Flow [m3/s] 514,32 461,93 497,54 893,27
Fan Total Efficiency [%] 80,4 74,6 78,9 86,7
Bearing loss (estimated) [kW] 6 6 6 6 8553
Compressibility Factor 0,99 0,992 0,992 0,984 8440
Duty Point 5 6 7 8
7503
Load 60% BMCR WC Design Point 2 WC 80% MCR DC 60% MCR DC
Actual Flow [m3/s] 751,77 813,2 424,82 357,06
Total Pressure Rise [mbar] 44,9 55 22,8 18,7 6861
Duty Point 9
Load 50% MCR DC
Fan Total Efficiency [%] 51,8
Example: Duty point 4, 60% DP1 WC

Shaft Power = 0.984*893.27*6861*0.7346/0.867/1000=5110kW
Example: Duty Point 6, DP2 WC

Shaft Power = 0.982*813.2*7503*0.733/0.891/1000=4929kW

Example: Duty Point 6, Design Point 2 WC

x = 5500/91180 = 0.06032
Zp = (1.4-1)/1.4*4929*1000/813.2/91180 = 0.01902

SOLAPUR 2 X 660 MW
PA Fan 50 Hz
PFTU-212-125-02 T=CODE FOR TWO STAGE
Two Stage U=CODE FOR BLADE DESIGN
Motor rating : 4840 Kw , 1490 rpm, 11 KV
Duty Point 1 2 3 4
Load BMCR DC TMCR DC VWO DC DP 1 WC
Actual Flow [m3/s] 135,99 131,18 134,34 236,79
19375
Duty Point 5 6 7 8
Load 60% BMCR WC Design Point 2 WC 80% MCR DC 60% MCR DC
Actual Flow [m3/s] 201,96 233,61 110,69 88,8
17299
Total Pressure Rise [mbar] 141 172,3 102,2 92,8
15760
Fan Total Efficiency [%] 86 87,1 82,3 75
Duty Point 9
Load 50% MCR DC
Fan Total Efficiency [%] 68,8 9990
Example: Duty point 4, DP1 WC

Shaft Power = 0.951*236.79*15760*0.993/0.864/1000=4079kW
Example: Duty Point 6, DP2 WC

Shaft Power = 0.946*233.61*17299*0.996/0.871/1000=4372kW

Example: Duty Point 6, Design Point 2 WC

x = 17240/95210 = 0.1811
Zp = (1.4-1)/1.4*4372*1000/233.61/95210 = 0.05623

CLIENT: BGR BOILERS PVT LTD. SEAL AIR FAN (SISW) : SBH 170 II M5
Project :NTPC Solapur - (2 x 660 MW)
DATE: 25.08.13
REV: 00
PERFORMANCE CURVE
Note : Point P3 is not guaranteed from us.

6.0 APH
6.1 Performance data for PAPH & SAPH

6.1 Performance data for Primary Airpreheater
Type : Bi sector
Model : 28 VI R 80 (92’’ casing)
Equipment supplier : Arvos Group,USA
Project : NTPC Solapur 2x660MW
Quantity : 2 Nos Per Boiler.
Description 100% BMCR 100% TMCR 105% VWO

Design coal Design coal Design coal
Flows: kg/sec
Air entering 138.330 131.482 135.732
Air leaving 125.451 119.215 123.096
Gas entering 143.100 136.300 140.400
Gas leaving 155.979 148.567 153.036
Primary Air by-pass 6.149 7.585 6.804
Mixed primary Air temperature 131.600 126.800 129.900
at mills inlet
Temperatures: °C
Air entering 40.0 40.0 40.0
Air leaving 333.3 325.0 331.1
Mixed primary Air temperature 320.6 308.3 316.7
at mills inlet
Gas entering 361.6 351.1 358.5
Gas leaving corrected 125.6 125.0 126.7
Average cold end temp 86.7 85.0 86.1
Pressure differentials: mmwc
Pressure drop on air side 59.69 54.61 58.42

Pressure drop on gas side 90.17 82.55 86.36
Total Leakage : kg/sec
Air to gas side 12.879 12.267 12.636
Reference Documents: APH - Data Sheet (PAPH & SAPH) (9571-102-PVM-U-0966, Rev - 06)
6.1 Performance data for secondary Airpreheater
Type : Bi sector
Model : 31.5 VI R 68 (80’’ casing)
Equipment supplier : Arvos Group.USA
Description 100% BMCR 100% TMCR 105% VWO

Design coal Design coal Design coal
Flows: kg/sec
Air entering 229.868 200.698 221.064
Air leaving 215.000 187.600 206.700
Gas entering 247.300 218.300 238.900
Gas leaving 262.168 231.398 253.264
Temperatures: °C
Air entering 32.0 32.0 32.0
Air leaving 333.3 326.7 331.7
Gas entering 361.6 351.1 358.5
Gas leaving corrected 123.9 123.4 126.1
Average cold end temp 80.6 78.9 80.0
Pressure differentials: mm wc
Pressure drop on air side 57.15 45.72 53.34
Pressure drop on gas side 81.28 66.04 76.20
Total leakage: kg/sec
Air to gas side 14.868 13.098 14.364
Reference Documents: APH - Data Sheet (PAPH & SAPH) (9571-102-PVM-U-0966, Rev - 06)
7.0 SCAPH
7.1 Performance data for Primary SCAPH & Secondary SCAPH

7.1 Performance data for Primary SCAPH
Equipment supplier : Patel Airtemp, Ahmedabad

Description Unit 100% BMCR 60% BMCR 30% BMCR

Worst coal Worst coal Worst coal
(Single line)
Air flow per SCAPH Ton/hr 604.98 762.7 229.68
Ambient Air Temperature Deg.C 6 27 6
Air Entering temperature Deg.C 18 40 15
Air Leaving temperature Deg.C 27 40 100
Pressure Drop on Airside (Max) mmWC 25 35 7
Steam Flow Ton/hr 2.9 - 10.10
Steam Operating Pressure Kg/sq.cm (g) 13.9568 - 13.9568
Steam Operating Temperature Deg.C 210/197 - 210/197

(In/Out)
Reference Documents: Assembly of SCAPH Primary (9571-102-PVM-F-0227, Rev - 13)

7.1 Performance data for Secondary SCAPH
Equipment supplier : Patel Airtemp, Ahmedabad

Description Unit 60% BMCR

100% BMCR 30% BMCR
Best coal
Best coal Oil Firing
(Single line)
Air flow per SCAPH Ton/hr 844.92 1202.8 440.10
Ambient Air Temperature Deg.C 6 27 6
Air Entering temperature Deg.C 9 32 8
Air Leaving temperature Deg.C 27 49.6 100
Pressure Drop on Airside (Max) mmWC 25 46 10
Steam Flow Ton/hr 7.8 10.90 20.75
Steam Operating Pressure Kg/sq.cm (g) 13.9568 13.9568 13.9568
Steam Operating Temperature Deg.C 210/197 210/197 210/197

(In/Out)
Reference Documents: Assembly of SCAPH Secondary (9571-102-PVM-F-0226, Rev - 13)

8.0 Mill
8.1 Mill Design Data
8.2 Mill & Burner Designation

8.1 MILL DESIGN DATA

Description
Total coal flow kg/s 131.400 127.700 119.300 158.500 153.900 143.200 100.300 97.400 91.600
Grinding Data
Mills in operation 7 7 7 8 8 7 7 7 7
Raw coal flow per mill kg/s 18.771 18.243 17.043 19.813 19.238 20.457 14.329 13.914 13.086
Max mill throughput kg/s 27.948 27.948 27.948 25.506 25.506 25.506 30.294 30.294 30.294
Mill load % 67 65 61.0 77.7 75.4 80.2 47.3 45.9 43.2
200 mesh % 70.0 70.0 70.0 70.0 70.0 70.0 70.0 70.0 70.0
R0,2 % 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5 3.5
50 mesh % 99.4 99.4 99.4 99.4 99.4 99.4 99.4 99.4 99.4
R 0,09 % 23.3 23.3 23.3 23.3 23.3 23.3 23.3 23.3 23.3
Moisture p,f, dust % 1.7 1.7 1.7 2.3 2.1 2.5 1.3 1.3 1.3
Mill pressure drop mbar 57.7 56.9 55.0 62.2 61.3 63.3 49.1 48.5 47.3
Power mill kW 527.1 519.2 501.2 571.1 561.7 581.7 443.9 438.2 426.8
Drying Data
Pressure loss p,f, pipe mbar 36 36 34 38 38 35 30 30 30
Raw coal temperature °C 15 15 15 15 15 15 15 15 15
temperature °C 320.0 315.0 307.0 330.0 334.0 326.0 330.0 328.0 324.0
Hot gas mass flow kg/s 35.990 35.759 34.744 38.143 37.666 38.631 25.543 25.108 24.220
volume flow m³/s 57.584 56.775 54.611 61.678 61.367 62.164 42.135 41.303 39.621
temperature °C 40 40 40 40 40 40 40 40 40
Cold gas mass flow kg/s 1.564 1.395 1.501 0.200 0.241 0.200 8.645 8.766 9.027
volume flow m³/s 1.321 1.179 1.273 0.168 0.203 0.168 7.404 7.512 7.744
Sealing air kg/s 0.812 0.812 0.812 0.812 0.812 0.812 0.812 0.812 0.812
Purge air feeder kg/s 0.380 0.380 0.380 0.380 0.380 0.380 0.380 0.380 0.380
temperature °C 309 305 296 329 332 325 258 255 248
Primary gas mass flow 37.554 37.154 36.245 38.343 37.907 38.831 34.188 33.874 33.247
volume flow m³/s 58.933 57.978 55.909 61.850 61.575 62.336 49.668 48.943 47.490
temperature °C 105 105 105 101 105 97 105 105 105
Classifier mass flow kg/s 41.096 40.629 39.570 42.317 41.829 42.861 36.930 36.571 35.854
volume flow m³/s 45.865 45.318 44.165 46.907 46.811 47.170 41.094 40.676 39.838
mass related kg/kg 0.400 0.393 0.377 0.402 0.395 0.411 0.346 0.339 0.326
Coal/air ratio
vol, related kg/m³ 0.358 0.352 0.338 0.363 0.353 0.374 0.311 0.305 0.293
Reference Documents: Design Report MPS Mill (9571-102-PVM-X-0159, Rev-05)

8.2 Mill and Burner Designation
41.24 m
Level 80
35.66 m
Level 60
30.08 m
Level 40
24.5 m
Level 20
21 22 23 24
Rear Wall
Mill 60 80 Mill
Mill 20 40 Mill
Furnace
Mill 30 10 Mill
Mill 70 50 Mill
Front Wall
11 12 13 14
24.5 m
Level 10
30.08 m
Level 30
35.66 m
Level 50
41.24 m
Level 70
Mill
Make HPE
Type Babcock roller bowl Mill
No. of Mills 8
Mill size MPS 255 S
Gear unit Planetary-type bevel gear unit KPV 1500
Grinding force Hydro-pneumatically
Rejects 1 outlet port
Classifier type Static classifier SLK 410
P.F. pipes 4 pulverized fuel coal dust pipes per mill
Number of grinding rollers 3
Shape of grinding track dished
Lifetime of mill grinding elements hr 5500 to 8000
Turn down ratio of mill 4:1
Input coal size up to mm 50
Classifier
Type and size SLK410
Type of vane adjustment manually
Number of p.f. discharge pipes qty 4
Gearbox
Type Bevel Planetary
Size KPV 1500
Input speed rpm 990
Output speed rpm 28
Reduction-gear ratio 35.4
Gearing manufacturer HPE
Mill Motor
Make ABB, Vadodara, India
Motor Type Squirrel Cage Motor
Rated output KW 770
Mains voltage V 3300
Nominal frequency Hz 50
Rated Speed rpm 990
Efficiency at 100% Load % 94.8
Reference Documents
1. Process Description Firing System, NTPC Doc. No - 9571-102-PVM-X-0069
2. Design Report - MPS Mill, NTPC Doc. No - 9571-102-PVM-X-0159
3. Data Sheet for Burner Design Data, NTPC Doc. No - 9571-102-PVM-Y-0065
9.0 Raw coal (RC) Feeder

Type Gravimetric Belt type

Size 36”
Material to be handled Raw coal – up to 50mm size
Coal density considered Kg/m3 800 to 1100
Maximum Capacity (1.2 times of the max
t/h 141
capacity of pulveriser)
Minimum Capacity t/h 14.1
Feeder Turndown 1 :10
Method of output control Microprocessor with VFD
Feeder inlet size 914.4 mm (I.D.) (36")
Feeder center distance 2134 mm
Feeder Belt width 1168 mm
Weighing accuracy at works ±0.5 %
Repeatability ±0.1 %
Calibration with in-built facility
Number of Load cells 2
Method of measurement Strain gauge
Range of measurement 141 TPH
Type of drive AC motor with VFD
Motor rating 7.5 KW- 1500 rpm
Cleanout motor rating 0.37 KW
Number of Bull-eye ports 4
Number of inlet support rollers 6
Number of weigh span rollers 2
Number of weighing rollers 1
Weigh span length 36” (914.4 mm)
Coal chute at Bunker outlet

Size 914.4 mm (36”) internal diameter
Quantity (per steam generator) qty 8
Distance between feeder outlet and mm 2134
Center line of coal bunker
Feeder outlet Gate

Type Knife edge type slide gate
Size 820 x 750 mm
Mode of operation with Pneumatic actuator
Double acting air cylinder with solenoid
Actuator type valves, open & close limit switches, over
ride for manual operation, AFR etc.
Feeder outlet chute

Size 800 mm internal diameter
Quantity (per steam generator) 8 nos.
Reference Documents
3. GA of Gravimetric Feeder and Associated Vendor Drawings,
NTPC Doc. No - 9571-102-PVM-B-0240
10.0 Burner
10.2 DS-X Burner - Overview
10.3 Furnace Geometry

Coal designation Design Worst Best

100% BMCR
Basis Data
Firing capacity (coal) % 100.000 101.790 98.760
Firing capacity (coal) MW 1676 1706 1655
Coal mass flow kg/s 131.400 158.476 100.283
> Lower heating value (LHV) MJ/kg 12.755 10.765 16.506
Combustion air mass flow kg/s 701.700 722.110 690.720
> Total air fuel ratio - 1.20 1.20 1.20
Burner air mass flow kg/s 590.598 620.936 582.780
> Burner air fuel ratio - 1.010 1.032 1.012
Cooling air mass flow (burner out of operation) kg/s 20.000 0.000 20.000
Furnace hopper air mass flow kg/s 0.000 0.000 0.000
> Burner zone air fuel ratio - 1.044 1.032 1.047
Over fire air mass flow kg/s 91.103 101.174 87.940
Number of burners in operation - 28 32 28
Burner capacity (coal) MW 59.9 53.3 59.1
Burner capacity (coal) % 100.00 89.07 98.76
Coal mass flow per burner kg/s 4.693 4.952 3.582
Burner air mass flow per burner kg/s 21.093 19.404 20.814
> Primary air including sealing air kg/s 9.689 9,885 8,847
> Core air + Secondary air + Tertiary air kg/s 11.404 9.519 11.967
Number of mills in operation - 7 8 7
Mill load (primary air) % 85.3 90.0 65.1
Coal mass flow per mill kg/s 18.771 19.810 14.326
Primary air mass flow per mill (without false air) kg/s 37.554 38.341 34.186
Burner Nozzles / Air Distribution
> Core Air
Mass flow kg/s 0.440 0.443 0.438
Volume flow m3/s 0.801 0.809 0.802
Exit velocity m/s 7.1 7.2 7.1
> Primary Air (+ Pulverized Coal)
Mass flow air kg/s 9.689 9,885 8,847
Mass flow steam (coal moisture) kg/s 0.600 0.703 0.398
Volume flow m3/s 12.132 12.212 10.805
PC concentration kg/kg 0.40 0.40 0.34
> Secondary Air
Ratio secondary air / tertiary air - 0.6 0.6 0.6
Mass flow kg/s 4.112 3.403 4.323
Volume flow m3/s 7.487 6.211 7.924
> Tertiary Air
Mass flow kg/s 6.853 5.672 7.206
Volume flow m3/s 12.479 10.352 13.207
> OFA Nozzles
OFA mass flow kg/s 91.103 101.174 87.940
> Exit velocity (mean) m/s 53.5 59.5 52.0
> Conditions
Moisture content of raw coal % 14.00 16.00 12.00
Moisture content of pulverized coal % 1.40 2.10 1.00
Mill exit temperature (classifier) °C 105 95 105
Hot air temperature (secondary side) °C 331.00 332.30 334.90
Number of mills installed - 8 8 8
100 % Coal mass flow per mill (100 % Air) kg/s 22.000 22.000 22.000
100 % Air mass flow per mill (100 % Coal) kg/s 40.000 40.000 40.000
Minimum air portion at 40 % coal portion % 75 75 75
False air mass flow per mill kg/s 1.200 1.200 1.200
Standard air density kg/m3 1.282 1.282 1.282
Ambient pressure mbar 960 960 960
Reference Documents: Data Sheet for Burner Design Data (9571-102-PVM-Y-0065, Rev-05)
10.2
10.3
Reference Documents: Diagram for Furnace Design (Sketch):

9571-102-PVM-B-0023
11.0 Coal Firing

Boiler Type Tower type BENSON boiler

Steam Capacity at 100 % Boiler Load t/h 2120
Hard-coal Firing System with dry ash
disposal and burner
Type of Firing System
elevations on front and rear wall in opposed
arrangement
Firing Capacity at 100 % Boiler Load (fuel heat
MW 1676.1
of design coal ref. NCV)
32 x DS-X-Burners with integrated oil
Burners
igniters
8 x vertical spindle mills,
Mills
MPS type 255 with static classifier
8 x coal bunkers with connected belt
Coal Feeding
conveyor
2 x Forced Draught Fans (FDF)
Fans 2 x Primary Air Fans (PAF)
2 x Induced Draught Fans (IDF)
4 x Steam Air Preheater
(2 x primary and 2 x secondary)
Air Heaters
4 x Flue Gas Air Preheater
(2 x primary and 2 x secondary)
Cleaning De-dusting via electrostatic
Flue Gas
precipitator (ESP)
Usage of Coal Firing system Main Fuel

Firing Capacity of Coal system % BMCR 100
Firing Operating Data for Design Coal

Boiler Load 100% BMCR
Firing Capacity (Fuel Heat ref. NCV) MW 1676.1
Total Coal Flow Kg/s 131.4
Total Combustion Air Flow Kg/s 701.7
Excess Air at Furnace Exit % 20
Number of Mills in Operation qty 7 of 8
Number of Burners in Operation qty 28 of 32
Burner Capacity (Fuel Heat rev. NCV) MW 59.90
Total Burner Primary Air Flow (28 burners) Kg/s 271.30
Total Burner Secondary Air Flow (28 burners) Kg/s 319.30
Total Burner Cooling Air Flow (4 burners) Kg/s 20.00
Total Over Fire Air Flow (8 nozzles) Kg/s 91.10
Coal Burner
Type Ds-x Burner (Swirl stage, Low Nox type)
No per each pulveriser 4
Reference Documents
12.0 Oil Firing

Usage of LDO Firing system Start up Fuel

Firing Capacity of LDO system % BMCR 7.5
Thermal Capacity of LDO Firing system MW 125.71
No.of Burners in which LDO can be Fired qty 8
LDO Burner capacity MW 15.71
LDO flow per Boiler Kg/s 3.0
Atomizing medium for LDO system Air
Atomizing steam, per boiler Kg/s 0.3
LDO parameters at Boiler Inet

Flow rate Kg/s 3.0
Pressure Kg/cm2 a 23.45
Temperature Deg C 40
Viscosity cSt 2.5 - 15.7
Reference Documents
2. Process Description Oil Firing System, NTPC Doc. No - 9571-102-PVM-X-0068
Usage of HFO Firing system Stabilizing Fuel

Firing Capacity of HFO system % BMCR 30
Thermal Capacity of HFO Firing system MW 502.83
No.of Burners in which HFO can be Fired qty 32
HFO Burner capacity MW 15.71
HFO flow per Boiler Kg/s 13.97
Atomizing medium for HFO system Steam
Atomizing steam, per boiler Kg/s 1.4
Recirculation Flow rate % 10
Viscosity is maintained by Steam Tracing
HFO parameters at Boiler Inet

Flow rate Kg/s 13.97
Pressure Kg/cm2 a 25.49
Temperature Deg C 110
Viscosity cSt 12 - 20
Other Stabilizing Fuels used LSHS / HPS
Reference Documents
2. Process Description Oil Firing System, NTPC Doc. No - 9571-102-PVM-X-0068
HFO/HPS/LSHS PUMPS
1) Make : M/s. Tushaco Pumps

2) Type : Rotary, positive displacement, horizontal three screw pump.
3) Model Number : T3ST-110/46
4) Capacity of each pump : 65 m3/hr
5) Capacity at Min.Viscosity : 1084 LPM
6) Capacity at Max.Viscosity : 1103 LPM
7) Viscosity Range : 180-500 cst
8) Speed : 970 RPM
9) Discharge pressure : 30 Kg/Sq.cm
10) Rotating Assembly : CW
11) Relief valve pressure setting : 33 Kg/Sq.cm
12) Steam jacketing arrangement details : Yes – Axial from end cover.
13) Quantity : 3 nos
HFO/HPS/LSHS MOTOR
1) Make : Bharat Bijlee Ltd

2) Type : Squarrel cage induction motor
3) Frame size : 315M
4) Flame proof : Yes
5) Power requirement : 90 KW, 440 Volts, 3 Phase, 50Hz
6) Quantity : 3 nos.
LDO PUMPS

2) Type : Rotary, positive displacement, horizontal three screw pump.
3) Model Number : T3ST-70/40
5) Capacity at Min.Viscosity : 566 LPM
6) Capacity at Max.Viscosity : 616 LPM
7) Viscosity Range : 2.5-15.7 cst
8) Speed : 2900 RPM
11) Relief valve pressure setting : 29.7 Kg/Sq.cm
12) Steam jacketing arrangement details : No
13) Quantity : 2 nos
LDO MOTOR

5) Power requirement : 45 KW, 440 Volts, 3 Phase, 50Hz
DRAIN OIL PUMP

2) Type : Rotary positive displacement, Internal Gear pump.
3) Model Number : R20DG-SJ
4) Capacity of pump : 4 m3/hr
5) Capacity at Min.Viscosity : 75.6 LPM
6) Capacity at Max.Viscosity : 77.0 LPM
7) Viscosity Range : 180-500 cst
8) Speed : 1450 RPM
11) Relief valve pressure setting : 11 Kg/Sq.cm
12) Steam jacketing arrangement details : Yes-End cover
13) Quantity : 1 no
CONDENSATE TANK
1) Make : M/s. Sakthi Hi-Tech Constructions Ltd.

2) Design, Fabrication & Erection : As per ASME Sec-VIII Div.1
3) Medium to be stored : Flash Steam / Condensate Water
4) Quantity : One / Boiler
5) Tank Capacity : 1.0 m³
6) Design Temperature : 215°C
7) Tank Design Pressure : 3.5 Kg/cm²(g)
8) Material of Construction : SA 516 Gr.70
9) Insulation : Provided - LRB-40 mm Thick
DRAIN OIL TANK
1) Make : M/s. Sakthi Hi-Tech Constructions Ltd.

2) Design, Fabrication & Erection : As per IS 800/IS 804
3) Medium to be stored : Heavy Fuel Oil (HPS/LSHS/HFO) & LDO
4) Quantity : One / Boiler
5) Tank Capacity : 6.0 m³ (Effective) / 8.0 m³ (Hydro)
6) Design Temperature : 180 °C
7) Type of construction : Rectangular
8) Material of Construction : E 250B
9) Insulation : LRB – 25 mm Thick (For tank) / 55 mm thick for
Floor coil heater
DRAIN OIL MOTOR

5) Power requirement : 3.7 KW, 440 Volts, 3 Phase, 50Hz
6) Quantity : 1 no.
HFO/HPS/LSHS PUMP SUCTION STRAINERS
1) Type : Duplex basket type (Coarse filter)

2) Quantity : 3 nos
3) Flow Capacity : 65 m3/hr
4) Pressure drop (Clean condition) : 0.05/0.05/0.02 kg/Sq.cm
5) Pressure drop (50% clogged condition) : 0.12/0.2/0.07 Kg/Sq.cm
6) Steam Jacketing details : Yes
7) Degree of filteration (Micron) : 250
HFO/HPS/LSHS HEATER DISCHARGE STRAINERS
1) Type : Duples basket type (Fine filter)

2) Quantity : 3 nos
4) Pressure drop (Clean condition) : 0.04/0.04/0.04 kg/Sq.cm
5) Pressure drop (50% clogged condition): 0.19/0.18/0.18
LDO PUMP SUCTION STRAINERS
1) Type : Duplex basket type (Coarse filter)

2) Quantity : 2 nos
4) Pressure drop (Clean condition) : 0.01 kg/Sq.cm
5) Pressure drop (50% clogged condition) : 0.02 Kg/Sq.cm
6) Steam Jacketing details : No
LDO PUMP DISCHARGE STRAINERS
1) Type : Duples basket type (Fine filter)

2) Quantity : 1 no
5) Pressure drop (50% clogged condition): 0.04 kg/Sq.cm
6) Steam Jacketing details : No
DRAIN OIL PUMP SUCTION STRAINER
1) Type : Duples basket type (Coarse filter)

2) Quantity : 1 no
5) Pressure drop (50% clogged condition): 0.014 kg/Sq.cm
FORWARDING HEATERS – HFO/HPS/LSHS
1) Type : Shell and tube type

2) Quantity : 3 nos
3) Oil flow rate for HFO : 60125 kg/hr
4) Steam flow rate for HFO : 6378 Kg/hr
5) Oil flow rate for HPS & LSHS : 55575 kg/hr
6) Steam flow rate for HPS & LSHS : 10340 kg/hr
7) Inlet Oil Temperature : 30 °C
8) Outlet Oil Temperature : 130/140/140 °C
9) Heater Surface Area : 221.65 m2
10) Safety relief Valve Particulars : M/s. Brightech Valves and controls Pvt Ltd.
11) Safety relief Valve set pressure - Oil : 34 Kg/cm²
12) Safety relief Valve set pressure – Steam : 17 Kg/cm²
RETURN OIL COOLERS – HFO/HPS/LSHS
1) Type : Shell and tube type

2) Quantity : 2 nos
3) Oil flow rate – HFO/HPS & LSHS : 10080 kg/hr
4) Cooling Water Flow rate for HFO : 26311 Kg/hr
5) Cooling Water Flow rate for HPS : 43576 Kg/hr
6) Cooling Water Flow rate for LSHS : 46388 Kg/hr
7) Inlet Oil Temperature : 130/140/140 °C
8) Outlet Oil Temperature : 57/72/66 °C
9) Design Pressure (Shell / Tube side) : 32 / 10 Kg/cm²
10) Design Temp. (Shell / Tube side) : 180 / 65 Kg/cm²
11) Heater Surface Area : 108.79 m2
12) Safety relief Valve Particulars : M/s. Brightech Valves and controls Pvt Ltd.
13) Safety Valve Set pressure (Oil side) : 27 Kg/cm²
SUMP PUMP
1) Make : M/s. Sam Turbo (Tap Engineering Ltd)

2) Type : Vertical centrifugal pump.
3) Model Number : VO 25/230+TCH+N
5) Capacity of each pump : 166.67 LPM
6) Speed : 2935 RPM
7) Discharge pressure : 50 mlc
8) Temperature handled : 50~80OC
9) Suction condition : Submerged
SUMP PUMP MOTOR

4) Power requirement : 7.5 KW, 440 Volts, 3 Phase, 50Hz
6) Frame Size : 315 m
ACCUMULATOR
1) Make : EPE Process filters & Accumulators pvt ltd

2) Type : Bladder type (Poppet design)
3) Capacity : 50 Ltrs
4) Max working pressure : 35 Bar
5) Test pressure : 1.5 x max working pressure
6) Quantity per set (HFO/HPS/LSHS) : 21 Nos.
7) Quantity per set (LDO) : 7 Nos.
STEAM TRAPS
1) Type : Inverted Bucket type

2) Design/Operating pressure(In/Out) : 21/(14/atm) Kg/cm2(g)
3) Design/Operating temp : 240/210 0C
4) Quantity : 55 Nos.
13.0 Boiler Circulation Pump

Descriptions Unit Cold Start Hot Start
Pump type Glandless
Pump model HLAV300-365/1K
Pump tag.no. 1 0HAG20 AP001 / 2 0HAG20 AP001
No.of.Stages 1
Operating Temperature 20 336.7
Density kg/m³ 1000 621
Pump Design Capacity t/h 742 742
m3/hr 743.5 1195
Suction Pressure kg/cm²g 5.1 141.8
Discharge Pressure kg/cm²g 19.8 148.9
Design Pressure kg/cm²g 301.9
Design Temperature °C 347
NPSH Available mlc 33.6 28.13
NPSH Required mlc 17.5 20.9
Pump Efficiency % 63.3 72.0
Pump Shaft Power kW 469.1 322.7
Minimum Flow m³/h 105
Speed of Revolution min-1 2940
Motor type HLV55/2CQ55-335
Rated Output KW 550
Rated Voltage V 3300
Efficiency at full load % 85
Frequency Hz 50
Heat Barrier
Normal Cooling Emergency
Operating Condition
Water Cooling Water
Flow Rate L/min 30 18
Inlet / Outlet Temp. 38 / 40 38 / 41
Inlet Press. kg/cm²g 2~4 2~4
Motor Cooler Shell side Tube side
Type Shell & Tube
Fluid - Cooling Water Boiler Water
Flow Rate L/min 542 183
Inlet Temp. 38 50
Outlet Temp. 40.7 42
Reference Documents:
1. Data Sheet of Boiler circulation pump - "9571-102-PVM-Y-0971"
2. Data sheet & Curves, OGA and Terminal box arrangement for BCW Motor - "9571-102-
PVE-Y-0620"
14.0 Boiler Condensate Transfer Pump
14.1 Performance Data for Boiler Condensate Transfer Pump

14.1 Performance data for Boiler Condensate Transfer pump
Sl.No. Descriptions Unit

1 0LCL 21 AP010 / 2 0LCL 21 AP010
1 Pump Tag no.
1 0LCL 22 AP010 / 2 0LCL 21 AP010
2 Quantity 2 x 50% per unit
3 Pump Model CZ 200-500
4 No. of stages 1
5 Medium Boiler Condensate water
6 Temperature oC 105
7 Specific gravity at P.T 0.955
8 Suction Pressure Kg/cm2 a 1.3
Runout
Condition Design (120% of
design)
9 Rated Capacity m3/hr 482.5 580
tph 460.8 554
10 Differential Head m 64 58.5
11 Discharge Pressure Kg/ cm2(a) 7.4 6.9
12 Efficiency (Cold/ hot)) % 79 / 80.5 81 / 82.4
13 Pump BKW Liquid (With Hot / ρ = 0.955) KW 100 107
14 Pump BKW Liquid (With Cold / ρ = 1) @20°C KW 107 114
15 NPSH Required at impeller eye mwc 2.2 2.7
16 NPSH Available (at Suction Nozzle) m 3
17 Pump Operating Speed RPM 1480
18 Shut Off Head m 74
19 Safe minimum flow m3/ hr. 65
20 Motor KW / no.of poles kW 125 kW / 4 poles
1. GA Data sheet & foundation details of condensate transfer pump - "9571-102-PVM-B-0325"
2. DATA SHEET & CURVES OGA AND TERMINAL BOX ARRANGEMENT FOR CONDENSATE TRANSFER PUMP
MOTOR - "9571-102-PVE-Y-0663"
15.0 Safety Valve & EMRV
15.1 Performance Data for Boiler Safety Valve & EMRV
15.2 Safety Valve Setting Diagram (HP & RH)

15.1 Performance data for Boiler Safety Valve and EMRV
Air heater
Item Separator Safety Main Steam Safety Cold Reheat Safety Hot Reheat Safety Sootblower Safety
Description Unit Sootblower Safety Main Steam EMRV Hot Reheat EMRV
No. Valve Valve Valve Valve Valve
Valve
10/20 HAD61 AA191 10/20 LBA10 AA191 10/20 LBC40 AA191 10/20 LBB10 AA191 10/20 LBA10 AA192 10/20 LBB10 AA192
1 Valve Tag No/Application 10/20 HCB12 AA191 10/20 HCB61 AA191
10/20 HAD62 AA191 10/20 LBA20 AA191 10/20 LBC50 AA191 10/20 LBB20 AA191 10/20 LBA20 AA192 10/20 LBB20 AA192
2 Required Quantity nos. 2 2 2 2 1 1 2 2
Required Capacity per valve
3 kg/hr 834750 278250 692150 236900 170000 36100 159000 176950
4 Operating Pressure Kg/cm2 (a) 281.3 255.1 61.8 59.9 23.5 18.4 254.7 59.9
5 Operating Temperature ◦C 427 568 351.2 596 339.8 – 313 498.5 – 466 568 596
6 Set Pressure Kg/cm2 (a) 297.8 270.1 71.1 68 30.6 30.6 266.7 67
7 Rated Capacity per valve kg/hr 851256 286270 702825 240910 173733 37591 171840 188810
8 Allowable Overpressure % 3 3 3 3 3 3 3 3
9 Blowdown % 5 5 5 5 5 5 3 3
Overpressure
10 Imposed Backpressure outlet kg/cm² 20.69 8.51 7.28 5.51 4.11 3.16 32.37 6.26
abs
11 Inlet Size & Rating in/Lbs 6" 6" 10" 8" 8" 4" 21/2" 6"
12 Inlet Type/Standard in/Lbs Welded Welded Welded Welded Welded Welded Welded Welded
13 Valve Type Type Spring Loaded Safety Spring Loaded Safety Spring Loaded Safety Spring Loaded Safety Spring Loaded Safety Spring Loaded Safety Power Control – Power Control –
Valve Valve Valve Valve Valve Valve Pneumatic actuator Pneumatic actuator
Outlet Size & Rating (ASME

14 in/Lbs NPS 10" class 600 NPS 10" class 300 NPS 16" class 400 NPS 12" class 400 NPS 12" class 300 NPS 6" class 150 NPS 4" class 600 RF NPS 10" class 300 RF
B16.5)
1. Data sheet & GA of Boiler Safety vales (including Soot blower safety valves) & EMRV (including interconnection diagram) - "9571-102-PVI-Y-0836"
15.2 HP Safety Valve Setting Diagram
Safety Valves Sizing & Selection Solapur
N-100131-S-LBA-IB02-00001 N100131
Safety Valve Setting Diagram at Superheater System

Design Pressure at Separator outlet conn. pipe
310,0 Set Pressure Safety Valve
306,7
Lift Pressure Difference SV (3%)

Design Pressure at
300,0 Separator area
297,8 297,8
Design Pressure
290,0 ReseatPressure Difference SV (5%)
Pressure [kg/cm²(a))
2 3
Separator Operating
Pressure 282,9
281,3 278,2
280,0 281,3
1
274,7
Lift Pressure Difference SV
(3%)
272,5
Lift Pr. Difference
270,0 Separator outlet 270,1 EMRV (3%)
conn.pipe
266,7
Operating Pressure ReseatPressure Reseat.Pr.
Difference SV (5%) Difference
260,0 EMRV (3%)
258,7
256,0 256,6
Superheater Outlet Operating Pressure
255,1
254,7
SEPARATOR SEPARATOR Pressure drop up to EMRV
250,0 SYSTEM PRESSURE DROP Pressure drop up to SV
OUTLET CONN. Main Steam Line
Separator Main Steam Safety
Safety Valve Valve Main Steam EMRV
Separator
SH - 3 Outlet Headers
SH - 3 Inlet Headers
Main Steam Safety

Separator
Valve Main Steam EMRV
Safety Valve
Separator
Figure 1: Safety Valve Setting Diagram at Superheater System. 1, 2 Safety Valve; 3 EMRV Reference Documents: Safety Valves Sizing & Selection:
9571-102-PVM-Y-0047
Name: Zimmer Name: Busekrus 18.12.2013 AJ
15.2 RH Safety Valve Setting Diagram
Safety Valves Sizing & Selection Solapur
N-100131-S-LBA-IB02-00001 N100131
80,0
Safety Valve Setting Diagram at Reheater System

75,0 Set Pressure Safety Valve Design Pressure
73,2
2 3
Lift Pressure Difference SV (3%)
71,1 71,1
71,1
70,0 70,0
Lift Pressure Lift Pressure
ReseatPressure Difference SV (5%) 69,0
Difference SV (3%) Difference EMRV
Pressure [kg/cm²(a))
68 (3%)
67,5
67 Reseat Pressure
ReseatPressure
1 Difference EMRV
65,0 Difference SV (5%)
64,6 65,0 (3%)
Operating Pressure RH
61,8 61,6 60,1

59,9 59,9
60,0 59,9
RH Outlet Operating Pressure
Pressure drop up to EMRV
Pressure drop up to SV
55,0
COLD REHEAT SYSTEM PRESSURE DROP HOT REHEAT
50,0
Hot Reheat Hot Reheat
Cold Reheat Safety EMRV
Safety Valve
Valve
RH - 1 Outlet Headers
RH - 2 Outlet Headers
RH - 1 Inlet Headers
RH - 2 Inlet Headers
Hot Reheat Hot Reheat
Cold Reheat Safety
Safety Valve EMRV
Valve
Figure 3: Safety Valve Setting Diagram at RH System. 1, 2 Safety Valve; 3 EMRV

Reference Documents: Safety Valves Sizing & Selection:
Ersteller / Prepared by Geprüft / Checked by: Datum /Date: Rev.: 9571-102-PVM-Y-0047
Name: Zimmer Name: Busekrus 18.12.2013 AJ
16.0 Soot Blower
16.1 Performance Data for Boiler Soot Blower

16.1 Performance data for Boiler Sootblower
Item Long Retractable
Description Unit Wall Blower
No. Soot blower
1 Boiler Zone Furnace SH1/SH3/RH1 SH2/RH1 ECO1,2/RH1
2 No.of Soot Blower Qty. 70 20 20 20
3 Blowing Radius mm 3,500 3,000 3,000 3,000
4 Total Travel mm 255 9910 9910 9910
5 Blowing Travel mm - 9425 9575 9575
6 Blowing Angle Deg 360 360 360 360
7 Operational Blowing Pressure Bar-g 10 11.1 10.2 7.8
8 Steam Consumption Kg 6.10 1,372.9 922.4 503.2
9 Total Steam Consumption tons 0.427 55.97
Motor
Motor type Squirrel Cage
10 Squirrel Cage Induction
Induction
11 Type of duty continuous continuous
Rated speed at rated voltage &
12 RPM 1380 1400
frequency
Standard continuous rating at 40
13 deg.C ambient temp. as per Indian KW 0.4 1.2
Std.
Derated rating for specified normal
14 condition i.e. 50 deg. C ambient KW 0.37 1.1
15 Rated voltage volts 415 415

Efficieny at rated voltage &
16 % 70.1 81.4
frequency 100% load
Reference Documents: GA Drawing & Data sheet of LRSBs and Wall Blowers - "9571-102-PVM-B-1486"
17.0 Furnace Instrumentation
17.1 Performance Data for Furnace Temperature Probe
17.2 Performance data for Acoustic pyrometer
17.3 Performance data for Acoustic Steam Leak Detection

System
17.4 Performance data for Furnace Flame Monitoring System
17.5 Performance data for Flame scanner

17.1 Performance data for Furnace Temperature Probe
Sl. No. DESCRIPTION FTP
1 0HBK01 AE001/002
1 Tag Nos:
2 0HBK01 AE001/002
2 Location Platen SH1 - Spiral
3 Drive - way, mm 9883
4 Flue gas temp. max, end of run.
1450
time °C
5 Flue gas temp. 100% ref.coal °C 1275
6 Quantity (per boiler) 2
7 Model FTP IIE (AC)
8 Power in kw 0.45
9 Rated voltage 415V
10 Phase & Frequency 3PH / 50 HZ
11 Speed in rpm As applicable to 4 pole electric motor
12 Duty S2 – 30 MINUTES
13 Direction of rotation REVERSIBLE
14 No. of ploes 4
15 Full load current ( amps) 1.3
Reference Documents: Furnace temp.probe: GA/Write up/ Scheme/ Data
sheet/Interconnection diagram - "9571-102-PVI-Y-0837"
17.2 Performance data for Acoustic Pyrometer
Sl. No. Description Acoustic Pyrometer
3020 TR- SSL

1 Model
(As per SEI standard)
2 Qunatity Two (2 No's)
10HBK01CT003/10HBK70CT003
3 Tag Nos:
20HBK01CT003/20HBK70CT003
4 Location Furnace and downstream Economiser Coils
5 Number of Paths (physical) up to 24 paths (Maximum)
6 Measurement Range 33°F to 3500°F (1°C to 1927°C)
7 Accuracy Better than ± 1.5%
8 Measurement Acquisition Time 5 seconds per path, typical
9 AC Power Input 100-127 V / 9.0A / 50 Hz or 200-240 V / 4.5A / 50 Hz
10 Air Pressure to Sound Source 80 – 120 psig (5.5 – 8.3 Bar)
11 Air Consumption-Acoustic & Purge 9.04 (m³/min)
Reference Documents: Data Sheet and GA of Acoustic Pyrometer-

9571-102-PVI-Y-0789
17.3 Performance data for Acoustic Steam Leak Detection System
Sl. No. Description Acoustic Steam Leak Detection System
1 Sensor Model No 765 Mod 7
2 Quantity 30 No's
10HBK01CA001 to 10HBK01CA0010, 10HBK10CA001,

10HBK20CA001 to 10HBK20CA004, 10HBK30CA001,
3 Tag Nos:
10HBK40CA001 to 10HBK40CA004,10HBK50CA001 to 10HBK50CA004,
10HBK60CA001 to 10HBK60CA005, 10HBK70CA001
4 Location Upstream & Downstream of Heat Transfer surfaces
5 Configuration type Balanced Floating Compression
6 Waveguide Coupling for sensor attachment
7 Sensor charge Sensitivity 2000 pC/psi
8 Sensor Temperature range -10 to +500 °F
9 Housing 316 stainless Steel mat’l
10 Sensor Mounting Size 1”NPT Male
Dual Signal Processor

11 1 to 500 KHz., flat +/- 2 dB
Module - Bandwidth
Reference Documents: Acoustic Steam Leak Detection System: GA/Write up/ Scheme/ Data sheet/ Interconnection diagram-
9571-102-PVI-Y-0838
17.4 Performance data for Furnace Flame Monitoring System
Sl. No. Description Furnace Flame Monitoring System
M530/VTP/AIN/ CEI/CCV/L42
High temperature camera-
1 The M530 Lynx(R) Camera is an air-purged, visible light camera. This camera is best suited
Model No
for hightemperature viewing applications. Four Cameras are provided for viewing one Boiler.
AC-Q-M353/AL30/RL54
Pneumatic retract system
2 The Pneumatic Retract System ensures that the camera retracts automatically in certain
Model No
conditions
2 Quantity 4 Nos
3 Tag Nos 10HBK01CR001 to 10HBK01CR004
4 Location Furnace zone
Local Control Cabinet is mounted in the field, one for each Camera and placed within 1..3
5 Camera control box
meters of the Camera.
Armored FRLS Coaxial video cable RG11U is laid in the field for connection of Camera to
6 Video cables
VPU installed in Control Panel of CER.
Magnetic lock is a Mechanical device used to hold the camera in the retract position by
7 Magnetic lock
magnetic force during prolonged absence of air supply.
8 Video connector kit For connection of the video cables to the CCTV equipment in field / Control room.
This Panel is provided for mounting Remote Retract Actuator, Digital Video Recorder (DVR),
9 Control panel in CER
Video Distribution Unit & Monitor in the control equipment room (CER).
Remote Retract Actuator is mounted in Control Panel in Control Equipment Room, one for
10 Remote retract actuator
each Camera & it permits operator to control the Camera position from Remote
The Pelco high performance, color Digital Video Recorder utilizes the latest in digital video
11 Digital video recorder processing technology, providing high quality multi camera displays in multiplexed mode up
to 4 cameras
This TIPL Video Distribution Unit is placed inside the Control Panel in CER & utilizes the
12 Video distribution unit latest in digital color video processing technology, providing high quality multi camera
displays in multiplexed mode up to 4 cameras.
Reference Documents: Furnace Flame Monitoring System: GA/Write up/ Scheme/ Data sheet/
Interconnection diagram -9571-102-PVI-Y-0799
17.5 Performance data for Flame scanner
Sl. No. Description Flame scanner
UV Compact flame monitor

1 D- LX 200 UAF - 30/MP
Type (for Oil Flame detection)
2 Quantity 32 No's
3 Tag Nos: 1 0HJA11 CR001 … 1 0HJA84 CR001
4 Location Burner
5 Analogue output 4 - 20mA
6 Safety time 1 sec
IR Compact flame monitor

7 D- LX 200 IG - 30/MP
Type (for Coal Flame detection)
8 Quantity 32 No's
9 Tag Nos: 1 0HHA11 CR001 … 1 0HHA84 CR001
10 Location Burner
11 Analogue output 4 - 20mA
12 Safety time 1 sec
Reference Documents: Data Sheet & GA drg. of Fuel Oil Igniters and Scanners-9571-102-PVM-B-0538
18.0 Control & Instrumentation
The number of the single tube temperature measurements is given in the table below:
Thermocouples (outside flue gas path)
Evaporator spiral 64
Evaporator vertical 36
Sum 100
The number of the single tube temperature measurements is given in the table below:
Chromel Alumel Thermocouples Acromat Thermocouples
(outside flue gas path) (inside flue gas path)
SH-1 Platen 88 20
SH-3 44 20
RH-2 126 20
SH-2 112 20
RH-1 136 0
Sum 506 80
Reference Documents: General Design Drawing for SH and RH Temperature Measurement

Points (9571-102-PVM-B-0054, Rev 08)
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82
● ● ● ● ● ● ● ●
Zimmer
1 2 3 4 5 6 7 8
4.1
left side wall
1 0HAD11 CT001-CT016
83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164
● ● ● ● ● ● ● ●
9 10 11 12 13 14 15 16
Ersteller / Prepared by
165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246
● ● ● ● ● ● ● ●
1 2 3 4 5 6 7 8
front wall
1 0HAD13 CT001-CT016
247 248 249 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298 299 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328
● ● ● ● ● ● ● ●
9 10 11 12 13 14 15 16
329 330 331 332 333 334 335 336 337 338 339 340 341 342 343 344 345 346 347 348 349 350 351 352 353 354 355 356 357 358 359 360 361 362 363 364 365 366 367 368 369 370 371 372 373 374 375 376 377 378 379 380 381 382 383 384 385 386 387 388 389 390 391 392 393 394 395 396 397 398 399 400 401 402 403 404 405 406 407 408 409 410
Busekrus
● ● ● ● ● ● ● ●
1 2 3 4 5 6 7 8
right side wall
1 0HAD12 CT001-CT016
NTPC DRG NO.
VENDOR DRG NO.
411 412 mme414 415 416 417 418 419 420 421 422 423 424 425 426 427 428 429 430 431 432 433 434 435 436 437 438 439 440 441 442 443 444 445 446 447 448 449 450 451 452 453 454 455 456 457 458 459 460 461 462 463 464 465 466 467 468 469 470 471 472 473 474 475 476 477 478 479 480 481 482 483 484 485 486 487 488 489 490 491 492
● ● ● ● ● ● ● ●
Geprüft / Checked by:

9 10 11 12 13 14 15 16
493 494 495 496 497 498 499 500 501 502 503 504 505 506 507 508 509 510 511 512 513 514 515 516 517 518 519 520 521 522 523 524 525 526 527 528 529 530 531 532 533 534 535 536 537 538 539 540 541 542 543 544 545 546 547 548 549 550 551 552 553 554 555 556 557 558 559 560 561 562 563 564 565 566 567 568 569 570 571 572 573 574
● ● ● ● ● ● ● ●
1 2 3 4 5 6 7 8
rear wall
9571-102-PVM-B-0054
1 0HAD14 CT001-CT016
575 576 577 578 579 580 581 582 583 584 585 586 587 588 589 590 591 592 593 594 595 596 597 598 599 600 601 602 603 604 605 606 607 608 609 610 611 612 613 614 615 616 617 618 619 620 621 622 623 624 625 626 627 628 629 630 631 632 633 634 635 636 637 638 639 640 641 642 643 644 645 646 647 648 649 650 651 652 653 654 655 656
● ● ● ● ● ● ● ●
9 10 11 12 13 14 15 16
N-100131-S-HA_-ID16-00013
11.03.2016
Datum /Date:
Evaporator Spiral Thermocouple Arrangement
General Design Drawing for SH and
RH Temperature Measurement Points
AI
N-100131
Rev.:
Proj-Nr.:/ Job No.:
NTPC Solapur
Page: 7 / 36
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82
● . ● ● ●
Zimmer
1 2 3 4
4.2
left side wall
1 0HAD21 CT001-CT09
83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165
● ● ● ● ●
5 6 7 8 9
166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245 246 247
● . ● ● ●
1 2 3 4
front wall
1 0HAD23 CT001-CT09
248 249 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298 299 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330
● ● ● ● ●
5 6 7 8 9
331 332 333 334 335 336 337 338 339 340 341 342 343 344 345 346 347 348 349 350 351 352 353 354 355 356 357 358 359 360 361 362 363 364 365 366 367 368 369 370 371 372 373 374 375 376 377 378 379 380 381 382 383 384 385 386 387 388 389 390 391 392 393 394 395 396 397 398 399 400 401 402 403 404 405 406 407 408 409 410 411 412
Busekrus
● . ● ● ●
1 2 3 4
right side wall
1 0HAH22 CT001-CT009
NTPC DRG NO.
413 414 415 416 417 418 419 420 421 422 423 424 425 426 427 428 429 430 431 432 433 434 435 436 437 438 439 440 441 442 443 444 445 446 447 448 449 450 451 452 453 454 455 456 457 458 459 460 461 462 463 464 465 466 467 468 469 470 471 472 473 474 475 476 477 478 479 480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 495
VENDOR DRG NO.
● ● ● ● ●

5 6 7 8 9
496 497 498 499 500 501 502 503 504 505 506 507 508 509 510 511 512 513 514 515 516 517 518 519 520 521 522 523 524 525 526 527 528 529 530 531 532 533 534 535 536 537 538 539 540 541 542 543 544 545 546 547 548 549 550 551 552 553 554 555 556 557 558 559 560 561 562 563 564 565 566 567 568 569 570 571 572 573 574 575 576 577
● . ● ● ●
1 2 3 4
rear wall
9571-102-PVM-B-0054
1 0HAH24 CT001-CT009
578 579 580 581 582 583 584 585 586 587 588 589 590 591 592 593 594 595 596 597 598 599 600 601 602 603 604 605 606 607 608 609 610 611 612 613 614 615 616 617 618 619 620 621 622 623 624 625 626 627 628 629 630 631 632 633 634 635 636 637 638 639 640 641 642 643 644 645 646 647 648 649 650 651 652 653 654 655 656 657 658 659 660
● ● ● ● ●
5 6 7 8 9
N-100131-S-HA_-ID16-00013
11.03.2016
Datum /Date:
Evaporator Vertical Thermocouple Arrangement

AI
N-100131
Rev.:
Proj-Nr.:/ Job No.:
NTPC Solapur
Page: 8 / 36
RH Temperature Measurement Points NTPC Solapur
VENDOR DRG NO. Proj-Nr.:/ Job No.:
N-100131-S-HA_-ID16-00013
NTPC DRG NO. N-100131
9571-102-PVM-B-0054
4.3 SH-1 Platen Thermocouple Arrangement

front wall
tube no. tube no.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
horizontal vertical
● 16 ● 17 28 ● 12
● 15 ● 16 27 ● 11
● 14 ● 15 26 ● 10
● 13 ● 14 25 ● 9
● 12 ● 13 24 ● 8
● 11 ● 12 23 ● 7
● 10 ● 11 22 ● 6
● 9 ● 10 21 ● 5
● 8 ● 9 20 ● 4
● 7 ● 8 19 ● 3
● 6 ● 7 18 ● 2
● ● ● ● ● ● ● ● ● ● ● 1
1 (45) 2 (46) 3 (47) 4 (48) 5 (49) 1 (45) 2 (46) 3 (47) 4 (48) 6
5 (49)
Outside flue gas path 1 0HAH22 CT001-CT016 1 0HAH21 CT001-CT028
Inside flue gas path 1 0HAH22 CT045-CT049 1 0HAH21 CT045-CT049
rear wall
tube no. tube no.
21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
horizontal vertical
● 33 44 ● 44 ● 12
● 32 43 ● 43 ● 11
● 31 42 ● 42 ● 10
● 30 41 ● 41 ● 9
● 29 40 ● 40 ● 8
● 28 39 ● 39 ● 7
● 27 38 ● 38 ● 6
● 26 37 ● 37 ● 5
● 25 36 ● 36 ● 4
● 24 35 ● 35 ● 3
● 23 34 ● 34 ● 2
● ● ● ● ● ● ● ● ● ● ● 1
17 (50) 18 (51) 19 (52) 20 (53) 22 29 (50) 30 (51) 31 (52) 32 (53) 33 (54)
21(54)
1 0HAH22 CT017-CT044 1 0HAH21 CT029-CT044
1 0HAH22 CT050-CT054 1 0HAH21 CT050-CT054

Zimmer Busekrus 11.03.2016 AI
Page: 9 / 36
N-100131-S-HA_-ID16-00013
9571-102-PVM-B-0054
4.4 SH-3 Thermocouple Arrangement

tube no. tube no.
horizontal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 vertical
● 16 22 ● ● 16 22 ● 1
2
3
4
● 15 21 ● ● 15 21 ● 5
6
7
8
● 14 20 ● ● 14 20 ● 9
10
11
12
● 13 19 ● ● 13 19 ● 13
14
15
16
● 12 18 ● ● 12 18 ● 17
18
19
20
● 11 17 ● ● 11 17 ● 21
22
23
● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● 24
1 (23) 3 (25) 5 (27) 7 (29) 9 (31) 1 (23) 3 (25) 5 (27) 7 (29) 9 (31)
2 (24) 4 (26) 6 (28) 8 (30) 10 (32) 2 (24) 4 (26) 6 (28) 8 (30) 10 (32)
1 0HAH71 CT001-CT022 1 0HAH72 CT001-CT022
1 0HAH71 CT023-CT032 1 0HAH72 CT023-CT032

Page: 10 / 36
Zimmer
4.5
tube no. tube no.
horizontal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 vertical
● 28 35 ● 42 ● 49 ● 56 ● 63 ● 1
● 27 34 ● 41 ● 48 ● 55 ● 62 ● 2
● 26 33 ● 40 ● 47 ● 54 ● 61 ● 3
● 25 32 ● 39 ● 46 ● 53 ● 60 ● 4
● 24 31 ● 38 ● 45 ● 52 ● 59 ● 5
● 23 30 ● 37 ● 44 ● 51 ● 58 ● 6
● 22 29 ● 36 ● 43 ● 50 ● 57 ● 7
● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● 8
1 (64) 2 3 4 (65) 5 6 7 (66) 8 9 (67) 10 11 (68) 12 13 (69) 14 15 (70) 16 17 (71) 18 19 (72) 20 21 (73)
Busekrus
1 0HAJ31 CT001-CT063 1 0HAJ31 CT064-CT073
NTPC DRG NO.
VENDOR DRG NO.
tube no. tube no.

42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82
horizontal vertical
● 28 35 ● 42 ● 49 ● 56 ● 63 ● 1
● 27 34 ● 41 ● 48 ● 55 ● 62 ● 2
● 26 33 ● 40 ● 47 ● 54 ● 61 ● 3
9571-102-PVM-B-0054
● 25 32 ● 39 ● 46 ● 53 ● 60 ● 4
RH-2 Thermocouple Arrangement
● 24 31 ● 38 ● 45 ● 52 ● 59 ● 5
● 23 30 ● 37 ● 44 ● 51 ● 58 ● 6
● 22 29 ● 36 ● 43 ● 50 ● 57 ● 7
N-100131-S-HA_-ID16-00013
● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● 8
1 (64) 2 3 (65) 4 5 (66) 6 7 (67) 8 9 (68) 10 11 (69) 12 13 (70) 14 15 (71) 16 17 18 (72) 19 20 21 (73)
11.03.2016
Datum /Date:
1 0HAJ32 CT001-CT063 1 0HAJ32 CT064-CT073
AI
N-100131
Rev.:
Proj-Nr.:/ Job No.:
NTPC Solapur
Page: 11 / 36
N-100131-S-HA_-ID16-00013
9571-102-PVM-B-0054
4.6 SH-2 Thermocouple Arrangement

Temperature measurements SH2 outlet
tube no. tube no.

● 32 ● 40 9
● 31 ● 39 8
● 30 ● 38 7
● 29 ● 37 6
● 28 ● 36 5
● 27 ● 35 4
● 26 ● 34 3
● 25 ● 33 2
● ● ● ● ● ● ● ● ● ● ● ● 1
1 2 3 (97) 4 5 (98) 6 7 (99) 8 9 (100 10 11 12 (101)
tube no. tube no.

● 48 ● 56 9
● 47 ● 55 8
● 46 ● 54 7
● 45 ● 53 6
● 44 ● 52 5
● 43 ● 51 4
● 42 ● 50 3
● 41 ● 49 2
● ● ● ● ● ● ● ● ● ● ● ● 1
13 14 (102) 15 16 (103) 17 18 (104) 19 20 (105) 21 22 (106) 23 24
1 0HAH52 CT0001-CT056
1 0HAH52 CT097-CT106
tube no. tube no.

32 ● ● 40 9
31 ● ● 39 8
30 ● ● 38 7
29 ● ● 37 6
28 ● ● 36 5
27 ● ● 35 4
26 ● ● 34 3
25 ● ● 33 2
● ● ● ● ● ● ● ● ● ● ● ● 1
1 2 3 (97) 4 5 (98) 6 7 (99) 8 9 (100) 10 11 (101) 12
tube no. tube no.

● 48 56 ● 9
● 47 55 ● 8
● 46 54 ● 7
● 45 53 ● 6
● 44 52 ● 5
● 43 51 ● 4
● 42 50 ● 3
● 41 49 ● 2
● ● ● ● ● ● ● ● ● ● ● ● 1
13 (102) 14 15 16 (103) 17 18 (104) 19 20 (105) 21 22 (106) 23 24
1 0HAH51 CT001-CT056
1 0HAH51 CT097-CT106

Page: 12 / 36
N-100131-S-HA_-ID16-00013
9571-102-PVM-B-0054
4.7 RH-1 Thermocouple Arrangement (Chromel Alumel)

Temperature measurements RH1 outlet
tube no. tube no.

● 35 ● 46 12
● 34 ● 45 11
● 33 ● 44 10
● 32 ● 43 9
● 31 ● 42 8
● 30 ● 41 7
● 29 ● 40 6
● 28 ● 39 5
● 27 ● 38 4
● 26 ● 37 3
● 25 ● 36 2
● ● ● ● ● ● ● ● ● ● ● ● 1
1 2 3 4 5 6 7 8 9 10 11 12
tube no. tube no.

● 57 68 ● 12
● 56 67 ● 11
● 55 66 ● 10
● 54 65 ● 9
● 53 64 ● 8
● 52 63 ● 7
● 51 62 ● 6
● 50 61 ● 5
● 49 60 ● 4
● 48 59 ● 3
● 47 58 ● 2
● ● ● ● ● ● ● ● ● ● ● ● 1
13 14 15 16 17 18 19 20 21 22 23 24
1 0HAJ12 CT001-CT68
tube no. tube no.

35 ● ● 46 12
34 ● ● 45 11
33 ● ● 44 10
32 ● ● 43 9
31 ● ● 42 8
30 ● ● 41 7
29 ● ● 40 6
28 ● ● 39 5
27 ● ● 38 4
26 ● ● 37 3
25 ● ● 36 2
● ● ● ● ● ● ● ● ● ● ● ● 1
1 2 3 4 5 6 7 8 9 10 11 12
tube no. tube no.

● 57 68 ● 12
● 56 67 ● 11
● 55 66 ● 10
● 54 65 ● 9
● 53 64 ● 8
● 52 63 ● 7
● 51 62 ● 6
● 50 61 ● 5
● 49 60 ● 4
● 48 59 ● 3
● 47 58 ● 2
● ● ● ● ● ● ● ● ● ● ● ● 1
13 14 15 16 17 18 19 20 21 22 23 24
1 0HAJ11 CT001-CT68

Page: 13 / 36
19.0 Control Valves

RH Spray attemperator 2 x 50% Discharge control

Sl. No.: Description HP Spray attemperator control valve Boiler Steam Sootblower Control valve Boiler Airheater Sootblower Control valve Boiler Recirculation control valve NPSH Control Valve
Control valve valve
1 0LAE41 AA001/AA002 1 0LAE61 AA001/AA002 1 0LAF21 AA001/AA002 1 0HAG61 AA001
1 Valve KKs No.: 1 0HCB10 AA001 1 0HCB12 AA001 1 0HCB11 AA001 1 0HCB23 AA001 1 0HCB43 AA001 1 0HCB60 AA001 1 0HCB61 AA001 1 0HCB75 AA001 1 0HAG30 AA001 1 0LAE05 AA001
1 0LAE42 AA001/AA002 1 0LAE62 AA001/AA002 1 0LAF22 AA001/AA002 1 0HAG62 AA001
2 No.of valves 4 4 4 1 1 1 1 1 1 1 1 1 2 1
3 Type of valve Angle Angle Angle Straight Way Straight Way Straight Way Straight Way Straight Way Straight Way Straight Way Straight Way Straight Way Angle Straight Way
4 Type of Actuation Pneumatic Diaphragm Pneumatic Diaphragm Pneumatic Diaphragm Pneumatic Diaphragm Motorised Pneumatic Diaphragm Pneumatic Diaphragm Pneumatic Diaphragm Pneumatic Diaphragm Motorised Pneumatic Diaphragm Electro Hydraulic Electro Hydraulic Motorised
5 Design Pressure (Kg/cm2 (a)) 310.9 310.9 249 71.1 71.1 71.1 30.6 30.6 71.1 71.1 30.6 309.2 302.9 359.96
6 Design Temperature (Deg. C) 301 301 203 358 358 358 350 350 500 500 500 347 347 215
Max. Operating Pressure (Kg/cm2
7 292 292 131 61.5 61.5 61.5 19.9 21.6 60.4 60.4 17.2 149 145.5 113.9
(a))
Max. Operating Temperature (Deg.
8 293 293 187 351.1 351.1 351.1 250 250 500 500 320 336.7 337 140
C)
Line Size (mm) OD 219.1 x Thk. 15.09 / OD 219.1 x Thk. 15.09 / OD 141.3 x Thk. 12.7/ OD 168.3 x Thk. 14.27/ OD 168.3 x Thk. 14.27/
9 OD 114.3/ Thk. 17.12 OD 114.3/ Thk. 17.12 OD 141.3/ Thk. 21 OD 141.3 x Thk. 12.7 OD 114.3 x Thk. 8.56 OD 88.9 x Thk. 11.13 OD 406.4 x Thk. 55 OD 323.8 x 43 Thk. OD 114.3 x Thk. 17.12
(Inlet/ Outlet) OD 273.0 x Thk.18.26 OD 273.0 x Thk.18.26 OD 168.3 x Thk. 14.27 OD 219.1 x Thk. 18.26 OD 219.1 x Thk. 18.26
10 Valve Size (Inch) 4 4 4 6 6 4 4 3 4 4 3 16 12 4
11 Pressure Rating 2500# 2500# 1500# 600# 600# 600# 300# 300# 900# 900# 600# 2500# 1803 # SPl Int. Class 2500
12 Valve Material A 217 Gr. WC9 A 217 Gr. WC9 A 216 Gr. WCC A 217 Gr. WC9 A 217 Gr. WC9 A 217 Gr. WC9 A 217 Gr. WC9 A 217 Gr. WC9 A 217 Gr. WC9 A 217 Gr. WC9 A 217 Gr. WC9 A 217 Gr. WC9 A182-F22 A217 WC9
13 Valve Characteristic Mod. % Mod. % Mod. % Mod. % Mod. % Mod. % Equal % Equal % Mod. % Mod. % Equal % Mod. Linear % Mod. Parabolic % Mod. Equal %
14 Leakage Class V V V V V V IV IV IV IV IV V V V
15 Rated Cv 50 40 20 300 300 195 195 110 95 95 110 950 423.6 75
Electrical/ Control Signal - Air/Control Signal - Electrical/ Control Signal - Electric Power/ Hydraulic/ Control Electric Power/ Hydraulic/ Electric Power/ Control Signal -
16 Failure condition Air/Signal - Open Air/Control Signal - Open Air/Control Signal - Open Air/Control Signal - Open Air/Control Signal - Open Air/Control Signal - Close Air/Control Signal - Open Air/Control Signal - Open
Stay Put Close Stay Put signal - Open Control signal - Close Stay Put
Valve Opening and Closing Time
17 <10 <10 <10 <10 <16 <10 <10 <10 <10 <16 <10 <40 <10 <30
(Sec.)
19 Reference Doc. No.: 9571-102-PVM-B-0510 9571-102-PVM-B-1501 9571-102-PVI-Y-0684A

20.0 Equipment Cooling Water System

EQUIPMENT COOLING WATER PUMPS
1) Make : M/s. Kirloskar Brothers Limited

2) Type : Horizontal Split Casing/SCT 200/48
3) Rated Speed : 1475 RPM
4) Capacity : 560 Cu.m/ hr
5) Number : 1W+1S
6) Total discharge head at rated capacity : 55 MWC
7) Pump efficiency at design capacity : 85 %
8) Pump Input power at duty Point : 98.4 KW
9) Power consumption at duty point,
at motor input terminals (guaranteed) : 104.69 KW
10) Guranteed noise level : 85 dBA at 1m distance
11) Operating range : 40 to 120 %
12) Direction of rotation : CW
13) Shut of Head : 64 m
14) Critical speed : 130 % of rated speed
15) Impeller type & design : Closed/Double Suction
16) Number of stage : Single
17) Coupling type : Spacer
18) Suction nozzle size : 250 mm/ANSI B 16.5 # 150 FF
19) Delivery Nozzle size : 200 mm/ANSI B 16.5 # 150 FF
20) NPSHR at design condition : 2.4 m
21) NPSHR at run out condition : 5.9 m
22) Weight of total pump set : 2081 kg
23) Motor weight : 1210 kg
24) Bearing type : SKF/FAG/EQULT
25) Bearing Life : L10
26) Motor make : Marathon Electric Motors (India) Limited
27) Motor type : sp cage
28) Frame size : SE 315 M
29) Duty Type : S1
30) Type of enclosure /Method of cooling/
Degree of protection : TEFC / IC411 / IP55
PLATE HEAT EXCAHANGERS
1) Make : Trannter India pvt limited

2) Type : Plate Type/GLD-145-L-6-PR-417
3) Operating flow ECW/ACW : 560/750 Cu.m/ hr
4) Operating temperature ECW (I/O) : 46/38 °C
5) Operating temperature ACW (I/O) : 36/42 °C
6) Pressure drop (ECW) : 0.30/0.20 kg/cm2
7) Pressure Drop (ACW) : 0.30/0.30 kg/cm2
8) Total Heat Exchanged : 4500000 kcal/hr
9) Total heat transfer Area : 693.05 m2
10) LMTD : 2.88 °C
11) Fouling Factor : 0.00008 h.m2.°C/kcal
12) Plate material/Thickness : 316SS/0.6 mm
13) Pressure ( Design/Test) : 12/18 kg/cm2
14) Temperature (Min/Design) : 0.00/60 °C
15) Area of Each plate : 1.67 m2
21.0 Dosing System

Ammonia Dosing System:

Ammonia measuring tank:
1) Numbers : One (1) No
2) Capacity : 125 Lit
Ammonia mixing/storage tank:

Ammonia handling pumps:

1) Hand (Barrel pump) pump : One (1) No
2) Delivery head : Upto 5 meters W.C
3) Metering Pump : Two (2) No
4) a). Type : Reciprocating Simplex plunger
b). Capacity : 50 L/h
c). Presuure : 45 kg/Sq.cm
d). Motor Rating : 1 HP
Hydrazine Dosing System:

Hydrazine measuring tank:
Hydrazine mixing/storage tank:

Hydrazine handling pumps:

1) Hand (Barrel pump) pump : One (1) No
2) Delivery head : Upto 5 meters W.C
3) Metering Pump : Two (2) No
4) a). Type : Reciprocating Simplex plunger
b). Capacity : 50 L/h
c). Presuure : 45 kg/Sq.cm
d). Motor Rating : 1 HP Please include NaOH dosing system for ECW system also.
22.0 Compressed Air System

Service Air Compressor:
1) Type : Oil Free Screw Air Compressor
2) Make : Elgi
3) Motor rating : 410 KW
4) Discharge pressure : 8.5 kg/SQ.cm
5) FAD Capacity : 62.59 Cu.m/min
6) Speed : 1489 RPM
Instrument Air Compressor:

1) Type : Oil Free Screw Air Compressor
2) Make : Elgi
3) Motor rating : 410 KW
4) Discharge pressure : 8.5 kg/SQ.cm
5) FAD Capacity : 62.59 Cu.m/min
6) Speed : 1489 RPM
Inter Coolers:
1) Type : Water cooled, shell and tube with removable bundle
2) Make : Elgi
3) Tube Inlet air temperature : 190 °C
4) Tube Outlet air temperature : 40 °C
5) Tube cooling media pressure : 3 kg/Sq.cm
After Coolers:
1) Type : Water cooled, shell and tube with removable bundle
2) Make : Elgi
3) Tube Inlet air temperature : 190 °C
4) Tube Outlet air temperature : 44 °C
5) Tube cooling media pressure : 3 kg/Sq.cm
Air Drying Unit:

1) Make : Summits Hygronics Private Limited
2) Type : Heat of Compression
3) Inlet temperature : 140 to 180 °C
4) Inlet pressure : 8.5 kg/Sq.cm
23.0 PRDS System

High Capacity Pressure Reducing Desuperheating Station
1) Make : HORA, Germany

2) Type : Angle Type
3) Inlet Size: : Buttweld End SA182 F91, ø219.1 x 33 mm
4) Outlet Size : Buttweld End SA182 F22, ø610 x 9.52 mm
5) Stress calculation : Inlet 272.5 kg/cm² / 573 °C, Outlet 21 kg/cm² / 350 °C
6) leakage class : FCI 70-2-2006 class V
Low Capacity Pressure Control Valve
1) Make : HORA, Germany

2) Type : Globe type
3) Inlet Size: : Buttweld End (~ A182 F22), ø168.3 x 7.11 mm
4) Outlet Size : Buttweld End (~ A182 F22), ø273.1 x 6.35 mm
5) Stress calculation : Inlet 72.5 kg/cm² / 378 °C, Outlet 21 kg/cm² / 378 °C
6) leakage class : FCI 70-2-2006 class V
24.0 Annexure - 1 - Sizing calculations
MDL Document reference
S.no Document Title
number
1 Process calculation report for boiler efficiency calculation 9571-102-PVM-U-0018
2 Heat Duty Calculation Report 9571-102-PVM-U-0006

3 Gas & Weight Calculation Report 9571-102-PVM-U-0007
Furnace Performance and Sizing & Residence Time Calculation
4 9571 - 102 - PVM - U 0022
Report
5 Summary of pressure drop in economizer, separator, superheater 9571-102-PVM-U-0044
6 Summary of Pressure Drop in RH 9571-102-PVM-U-0045

7 NOx Calculation Report 9571-102-PVM-U-0024
8 Data Sheet of Distance between buckstays 9571-102-PVM-Y-0027
Data Sheet for Design of the combustion air and flue gas cross
9 9571-102-PVM-Y-0059
sections (up to chimney)
10 Design Report Boiler Pressure Part and Auxiliaries 9571-102-PVM-U-0048
11 Design Data Sheet Boiler Condensate Pumps 9571-102-PVM-F-1481
12 Design Data Sheet Boiler Flash Tank 9571-102-PVM-V-0293
13 Design Data Circulation Pump 9571-102-PVM-Y-0186
14 FD Fan Sizing Calculation 9571-102-PVM-U-0367
15 ID Fan Sizing Calculation 9571-102-PVM-U-0368
16 PA Fan Sizing Calculation 9571-102-PVM-U-0369
17 Seal Air Fan - Sizing Calculation 9571-102-PVM-U-0373
18 Design Criteria for APH selection 9571-102-PVM-U-0298
19 Design Criteria for SCAPH Selection 9571-102-PVM-U-0255
20 Mill Selection (Attachment to Design Report MPS® Mill) 0360-102-PVM-U-0374
21 Feeder Sizing Calculation 9571-102-PVM-U 0375
22 Safety Valves Sizing & Selection 9571-102-PVM-Y-0047
23 Design Report Steam Soot Blowers 9571-102-PVM-U-0959
24 Insulation thickness calculation 9571-102-PVM-U-0295
25 Cycling loading capability of boiler 9571-102-PVM-Y-0001
26 Evaporator Stability Analysis Report 9571-102-PVM-U-0695
Fuel oil system sizing (incl.HFO/LDO pumps, HFO heaters, coolers,

27 9571-102-PVM-U-0504
drain oil system etc.) and pressure drop calculations
28 PRDS station sizing calculation 9571-102-PVM-U-0402

29 Design Data Sheet of HP Drainage Control Valves 9571-102-PVI-Y-0682
24.0 Annexure - 1 - Sizing calculations
MDL Document reference
S.no Document Title
number
30 Design Data Sheet of RH Drainage Control Valves 9571-102-PVI-Y-0683
31 Design Data Sheet of HP Attemperator Control Valve 9571-102-PVI-Y-0685
32 Design Data Sheet of RH Attemperator Control Valve 9571-102-PVI-Y-0686
33 Design Data Sheet of Steam Sootblower Control Valves 9571-102-PVI-Y-0688
34 Design Data Sheet of Air Heater Sootblower Control Valves 9571-102-PVI-Y-0689
35 Design Data Sheet of Steam Sootblower Throttle Valves 9571-102-PVM-Y-0184
36 Design Data Sheet of Air Heater Sootblower Throttle Valves 9571-102-PVM-U-0185
37 Sizing Criteria of NPSH Control Valve 9571-102-PVI-Y-0684
38 Design Data Sheet of Recirculation Control Valve 9571-102-PVI-Y-0681
39 Design Data Sheet of Discharge Valves 9571-102-PVM-Y-0183
40 Design Data Sheet of HP Throttle Valves 9571-102-PVI-Y-0687
41 Design of pipes - HFO/LDO 9571-102-PVM-Y-0066
42 Data sheet of fuel oil control valves including their GA 9571-102-PVI-Y-0525
43 Data Sheet for Burner Design Data 9571-102-PVM-Y-0065
44 Technical datasheet of Oxygen dosing System 9571‐102‐PVM‐Y‐0460
45 Technical datasheet of Hydrazine dosing System 9571-102-PVM-Y-0939
46 Technical datasheet of Ammonia dosing System 9571-102-PVM-Y-0944
47 Design Data Unheated Pressure Parts 9571-102-PVM-Y-0028
Compliance Sheet
Doc.-Title : Boiler Design Dosier

Doc.-No. : BBX-0001-01-S-H__-IB02-00021
NTPC Doc.-No. : 9571-102-PVM-X-0344
Sl.
No. NTPC-Comments BGRB-Replies
Solapur - NTPC Written comments dated – 14.06.2016
1 Refer comments marked up Noted
It is seen that only scope related to BGRB & HPE is
covered, however ceratin area like fuel oil sizing and
eqpt data related to FUEL OIL PUMP HOUSE, Included.
2
aux.PRDS sizing and major valves of boiler integral Please refer revised
Fuel oil equipment like fuel document.
oil skids in boiler area,main
mechanical and control valves in boiler area,
piping etc. are not covered. This may also be suitably accumulator (LDO&HFO), drain oil pump and fuel oil
included. condensate tank in boiler area are not covered. Also
include details of oil burner,HFO steam atomizing skids,
Preliminary comments given. Other comments,shall be LDO air atomizing skids,Burner valves etc.Please
3 Noted
given shortly. Please include details of coal firing system, coal burner, include the same
soot blowing details,gates and dampers, SH&RH spray
Please includesystem
all performance related data
and control valves,separator for major
and atmospheric
instrumentation, C&I equipment coming pump
flash tank, condensate flash tank, condensate inside
details, expansion joints,oxygen dosing system etc.
furnace and related to measurment and control for
boiler like all coal and oil flame scanners,acoustic
Included.
4 pyrometers, ASLD, flame viewing camera etc. similar
Please refer revised document.
to data covered for furnace temeprature probe ,which
are important measurment and control tools inside
furnace and pressure parts in general ,whether they
are in scope of HPE OR BGRB or BGRE
Please note that there is no new data
provided in this document. The data
provided in this document is an
extract from approved MDL
5 Document to be veted by QSGM
document.
Hence vetting of QSGM is not

envisaged.
Solapur - NTPC Marked Up comments dated – 14.06.2016

BGR/HPE to also include the following as part of this
The aim of Design Dossier is to
document itself:
provide quick glance of the Design
A) sizing calculations/data
Parameters of Boiler & its Auxiliaries.
1. Boiler efficiency calculations
2. Heat duty calculations
It is not meant to be a compilation of
6 3. Air & gas weight calculations
all the MDL documents.
4. Furnace sizing calculations
5. SH, RH and economiser pressure drop & summary
Please refer dedicated MDL document
of pressure drop in circulation sytem
for sizing calculation.
6. NOx calculation report
7. Buckstay sizing calculation
8 Duct sizing calculation/design data
9. Design report -boiler pressure part & auxiliaries(doc All reference drg/doc. to be
no.9571-102-PVM-U-048)covering sizing of start up
included in boiler design dossier
drain system,flash tank,drain system etc.
10. Design data sheet of condensate tank,condensate
pump,boiler flash tank
11. Design data boiler circulation pump
12. PA,FD,ID &Seal air fan sizing calculation
13. APH sizing calculation/selection data
14. SCAPH selection data
15. Mill selection data &feeder sizing/selection data
including correction curves
16. Safety valve sizing/selection data
17. Soot blower selection data
18. Insulation thickness calculation
19. Cyclic loading capability
20. Evaporator stability report
21. Fuel oil sizing calculation related to FOPH &
BOILER AREA (doc no.9571-102-PVM-U-504)&HPE
DOCUMENT
22. Auxiliary PRDS calculations
23. Design data sheet of major steam &water valves
like HP&RH Drainage valves,HP&RH attemperator
control valves,Soot blower control and throttle valves,
NPSH control valve,recirculation control valve,water
vessel discharge valve,feed water economiser inet
NRV,HP throttle valves etc.
24. Design data of HFO-LDO pipes,design data of fuel
oil control valves and other mech valves
25. Burner design data
26. Ooxygen dosing
27. Design data of unheated pressure parts
B) Further some final vendor data sheet/parameters
of equipment to be included
1. Furnace diagram sketch
2. General boiler diagram showing average flue gas
velocities
3. Schedule of gates and dampers
4. Schedule of expansion joints for entre boiler upto
chimney
5. Safety valve setting and GADRG OF SAFETY
VALVES including EMRV
7 Please refer reply of poiny no. 6
6. GADrg of soot blowers
7. GAdrg of FD,PA,ID and Seal air fan
8. GAdrg of PAPH,SAPH & primary &sec. SCAPH
9. Predicted performance of blended coal condition
10. Vvendor drg of separator,flash tank,HP&RH spray
attemperator
11. PF piping arrangement
12. MILL GA
13. Unit operating philosophy including boiler
correction curves
Further it is seen that data related to equipments in
HPE/BGRB scope of supply have been included.
Included.
8
BGR/HPE to also include data for equipments under
BGRE scope of supply for ensuring completeness of
the document.
Kindly correct the values as per approved Site
Conditions Data Sheet (NTPC Doc. No. 9571-102- Replaced the data with approved “Site
9
PVM-Y-0005) and Climatological table as included in Conditions Data Sheet”.
the specification.
Please include flow, pressure drop data also for Flow in t/h, inlet & outlet pressure in
10 various conditions Kg/cm2 are mentioned in the
document. Please refer the same.
Please include predicted perf.data for blended coal
conditions also
Also parameters for blended coal combinations may
be included for information.
Included.
13 Reference drawing no. to be included.
14 Include mill correction curves Please refer reply of poiny no. 6
Include design data of boiler flash
tank,separator,vessel, boiler condensate tank, etc.
Besides furnace temp.probe,Please include all
performance related data for major instrumentation,
C&I equipment coming inside furnace and related to
measurement and control for boiler like all coal and oil
flame scanners,acoustic pyrometers,ASLD , flame Included.
16
viewing camera etc. similar to data covered for Please refer revised document.
furnace temperature probe ,which are important
measurement and control tools inside furnace and
pressure parts in general ,whether they are in scope
of HPE OR BGRB or BGRE
Compliance Sheet

Doc.-No. : BBX-0001-01-S-H__-IB02-00021 NTPC
Doc.-No. : 9571-102-PVM-X-0344 – Rev 01
Sl.
1 Refer comments marked up Noted
It is seen that BGR/HPE has not included much The performance data and specific
information as commented in last revision. It is seen boiler drawings for the respective
that BGR has not included all boiler related sizing components have been already
2 calculations, performance related data, specific furnished in the revised document.
boiler drgs and vendor related boiler auxiliaries GA The sizing calculations, and vendor
drg.,as commented earlier ,which are essentially to related boiler auxiliaries GA drg
be a part of boiler design dossier.This has been have already been covered in the
followed by other SG contractors also for SG respective MDL document .
packages, including BHEL. Refer earlier comments
marked up at rev0.
Some other comments on boiler related pressure

3 parts, performance data shall also be sent
Noted. The comments are not yet
received.
separately.
BGR/HPE to include all the data and then only re-
4 submit the document. Noted
The requirement of the QSGM approval

are already met with the respective MDL
5 To be vetted by QSGM
documents. Hence vetting of QSGM is
not envisaged.
Site Conditions - Check the value The value is in line with the Site
condition data sheet.
6 Rainfall in month – Maximum 518.8 mm
7 Type of Control - Hydralic Hydraulic - Typographic error has been

corrected in the revised document.
Please include data for mill seal air fan and also
Details Included.
8 for Seal air fan for ID FAN
12.0 Oil Firing Datas for Plug valves, control valves &
9 trip valves can be referred from the
Please include data for plug valves, control Respective MDL document.
valves,trip valves etc.in FOPH &firing floor
12.1 LDO Firing System Details Details for drain oil tank has been
included. The reference of vendor drgs
Please include data for drain oil pump, drain oil & datas of accumulators, plug valves,
10 tank in boiler area with reference of vendor drgs. strainers and steam traps can be
data of accumulators, plug valves, strainers, referred from the respective MDL
steam traps in boiler area supplied by document.
BGRB/HPE.
HFO/HPS/LSHS PUMPS & DRAIN OIL PUMPS
11 Please include capacity at max.& min. viscosity in Details Included.

LPM as indicated in data sheet. Please include
min and max. viscosity range separately.
12 Please include details of fuel oil condensate tank, Details Included.

drain oil tank in FOPH area
FORWARDING HEATERS – HFO/HPS/LSHS

13 Details Included.
Please include flow rate for all grade of oil
i.e.HFO/HPS/LSHS as given in GA DRG of HFO
heater
14 Please include steam flow rate also Details Included.
15 Please include safety relief valve set pressure for

Details Included.
oil side and steam side also
RETURN OIL COOLERS – HFO/HPS/LSHS
Please include cooling water flow rate also for
different grade of oils
17 Please include safety relief valve set pressure for

oil side Details Included.
Please include design pressure &design

temperature
SUMP PUMP
19 Please include capacity in LPM also Details Included.
SUMP PUMP MOTOR
Please include frame size also Details Included.
20
Please include reference drg of all equipment in
FOPH i.e. DS/GA drg of LDO pump, HFO pump, Applicable drawings of all equipment in
HFO heaters &coolers, Drain oil pump, sump pump FOPH can be referred from the
21
and their respective motors, strainers etc. respective MDL documents.
ACCUMULATOR
22 Please include qty provided for HFO&LDO Details Included.
accumulators in FOPH& firing floor.
STEAM TRAPS
Details Included.
23 Please include qty provided
Boiler Circulation pump
1. Please include design temperature and 1. Details Included.

24 pressure as covered in data sheet of pump
2. Operating Temperature is 20°C & it
2. Operating Temperature – 40 as per data sheet is inline as per the data sheet.
instead 20 Deg C.
3. Value updated.
3. Density 1000 kg/m3 instead 998 kg/m3
Boiler Condensate Transfer pump
25 1. Please also include pump BKW liquid in cold

condition also. Details Included.
2. Please include hot condition at density and temp
of 105 deg.c
Boiler Safety Valve and EMRV
Please include valve and actuator type whether Details Included.

26
elec./pneumaticaly,EH type operated and also
model no.
Dosing System
Please check whether now vendor is changed and
The given datas are as per the new
27 whether data given is specific to new vendor vendor.
or it is related to earlier vendor.
Solapur – NTPC Comments on compliance sheet – 30.11.2016
BGR to note that this document also contain inputs

from other documents where QSGM vetting remark Please refer reply of point no. 5
28 was given by NTPC. Hence, this document need to
be vetted by QSGM.
The purpose of design dossier is to have ready
reference of all sizing documents of boiler and its
auxiliaries and performance related data, which has
to be covered in design dossier. Accordingly, as Please refer reply of point no. 2
29 commented please include the same for ready
reference instead of referring different sizing
documents covered elsewhere. This practice has
been followed by other SG contractors including
BHEL
The aim of design dossier is also to understand as

to how equipment have been designed & selected Sizing calculations, Basis for equipment
which primarily depends on sizing calculations. selection are already available in the
30
Hence, sizing calculations need to be included as applicable MDL documents and the
part of Design Dossier. This is in line with the same can be referred.
practice followed by all other SG Contractors.
As commented earlier, please include all boiler

pressure parts, performance related data and
vendor specific GA drg and schedule of expansion Please refer reply of point no. 30
31
joints, gates& damper which gives summary of
performance related data of boiler.
Please note that Valve Schedule, Gates & Dampers

Schedule etc. also contain the details of parameters The details can be referred from the
such as Temperatures, pressures & flow across the respective MDL documents.
32
respective equipments. Hence, the same need to
be included as part of this document itself.
Please include relevant sizing data and Please refer reply of point no. 2
33 also refer our response to point no.6 above.
In general it may be noted that all data except data Noted.

34 to be included in O&M Manuals shall be a part of
Boiler Design Dossier.
Compliance Sheet

Doc.-No. : BBX-0001-01-S-H__-IB02-00021 NTPC
Doc.-No. : 9571-102-PVM-X-0344 – Rev 02
Sl.
1 Refer to comments marked up. All required informations are already

It is seen that BGR/HPE has still not included furnished in this document. Please note
information as commented in last revision. that sizing calculations, Performance
BGR/HPE to include all the data and then only re- datas, Boiler drgs etc. can be referred
submit the document. As commented earlier,please from the MDL document.
ensure all boiler related sizing
calcualtions,performance related data,specific
boiler drgs and vendor related boiler auxilaries GA
drg.,as commented earlier ,which are essentaially
to be a part of boiler design dossier are covered in
this document.This has been followed by other SG
contractors also for SG packages, including BHEL.
Further, document to be vetted by QSGM
2 To be reviewed and approved byQSGM The requirement of the QSGM approval

are already met with the respective MDL
documents. Hence vetting of QSGM is
not envisaged.
3 Will the same be covered in the O&M Manual? O&M Manual covers only the boiler
operational procedures. Sizing
Calculations, Basis for Equipment
selection can be referred from the
respective MDL Documents.
4 As commented earlier, BGR/HPE to also include the
following as part of this document itself: Required details can be referred from
A) sizing calculations/data the respective MDL documents which is
1. Boiler efficiency calculations listed in Annexure – 1 (24.0 Sizing
2. Heat duty calculations Calculations)
3. Air & gas weight calculations
4. Furnace sizing calculations
5. SH, RH and economiser pressure drop & summary
of pressure drop in circulation sytem
6. NOx calculation report
7. Buckstay sizing calculation
8 Duct sizing calculation/design data
9. Design report -boiler pressure part & auxiliaries(doc
no.9571-102-PVM-U-048)covering sizing of start up
drain system,flash tank,drain system etc.
10. Design data sheet of condensate tank,condensate
pump,boiler flash tank
11. Design data boiler circulation pump
12. PA,FD,ID &Seal air fan sizing calculation
13. APH sizing calculation/selection data
14. SCAPH selection data
15. Mill selection data &feeder sizing/selection data
including correction curves
16. Safety valve sizing/selection data
17. Soot blower selection data
18. Insulation thickness calculation
19. Cyclic loading capability
20. Evaporator stability report
21. Fuel oil sizing calculation related to FOPH &
BOILER AREA (doc no.9571-102-PVM-U-504)&HPE
DOCUMENT
22. Auxiliary PRDS calculations
23. Design data sheet of major steam &water valves
like HP&RH Drainage valves,HP&RH attemperator
control valves,Soot blower control and throttle valves,
NPSH control valve,recirculation control valve,water
vessel discharge valve,feed water economiser inet
NRV,HP throttle valves etc.
24. Design data of HFO-LDO pipes,design data of fuel
oil control valves and other mech valves
25. Burner design data
26. Ooxygen dosing
27. Design data of unheated pressure parts
5 To be complied All relevant datas are complied in this

document.

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AC 09.06.2017 M.

Charles See compliance sheet Bhavannarayana

NTPC Limited SING

(A Government of India Enterprise) H Date: 2017.06.30

CHENNAI – HYDERABAD – MUMBAI - NOIDA

BGR BOILERS PRIVATE LIMITED

DOC. NO. BBX-0001-01-S-H__-IB02-00021

TITLE: Boiler Design Dossier

SIZE SCALE NTPC DOCUMENT NO. REV.

1.0 Design Parameters

2.0 Project Details

3.0 Process Details

4.0 Pressure Parts Details

9.0 Raw coal (RC) Feeder

12.0 Oil Firing

13.0 Boiler Circulation Pump

14.0 Boiler Condensate Transfer Pump

15.0 Safety Valve & EMRV

16.0 Soot Blower

17.0 Furnace Instrumentation

18.0 Control & Instrumentation

19.0 Control Valves

20.0 Equipment Cooling Water System

21.0 Dosing System

22.0 Compressed Air System

23.0 PRDS System

24.0 Annexure - 1- Sizing Calculations

1.1 Boiler Parameters

1.2 Fuel Analysis

 Pressure Part Arrangement

 Evaporator - Spiral + Vertical walls

 Air & Flue Gas System

 Fuel Preparation and Firing System

 MPS Mills, 8 no., arranged on both sides of the Boiler

Sl. No. Description Units 100% BMCR VWO 100% TMCR

2 Pressure at Turbine Inlet kg/cm²(a) 247.0 247.0 247.0

5 Steam Flow to Reheater T/hr 1717.3 1729.7 1612.6

Feed Water Temperature

Reference Documents: Data Sheet Basic Boiler Performance Parameter (9571-102-

Description Design Coal Worst Coal Best Coal

Reference Documents: Fuel Analysis Data Sheet (9571-102-PVM-Y-0003, Rev-04)

Site Conditions Minimum Design Maximum Unit

Level above Mean Sea 479 m

Rainfall in 24h 191 mm

Rainfall in month 518.8 mm

Basic wind speed at 39 m/s

Risk coefficient K 1.06

Additional site information Comments

Reference Documents: Site Conditions Data Sheet ( 9571-102-PVM-Y-0005,Rev-AB)

Ersteller / Prepared by Geprüft / Checked by: Datum /Date: Rev.:

3.1 Predicted Performance

3.2 Start Up Curves (Cold, Warm & Hot)

3.3 Shut Down Diagram

3.5 Sliding Pressure Curves (HP&RH)

Design Coal Worst Coal Best Coal

Design Coal Worst Coal Best Coal

Design Coal Worst Coal Best Coal

Design Coal Worst Coal Best Coal

NTPC_DRG_NO. Dok.-Nr. / Doc.-No. Seit e / page

HP steam bypass system closed xx % open on control stand by

LP steam bypass system closed xx % open on control stand by

SH and RH drains controlled closing

120 330 720