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INTRODUCTION In ever growing industrialization of developed and developing nations, electric power generation through boilers of thermal power

station have played very important role over a century. Coal, lignite, fuel oil, natural gas etc. are some of the fuels available as natural resources and these are being consumed for steam generation. Combustion in conventional stoker fired, pulverized coalfired as well as oil /gas fired boilers release pollutants like SOx, NOx, CO etc invariably in much larger quantities which are harmful to human life. This aspect has been attracting more and more attention of governments as well as people and the main focus is now on generation of steam with environmentally friendly system of firing in boilers. "CFBC Boiler" offers valuable solution to reduce ill effects of pollution. Salient advantages of this system are: a) Fuel of different types/origin and quality can be burnt without any problems at high degree of efficiency. b) Pollutants such as Sulphur dioxide, Hydrogen chloride, Hydrogen fluoride released during combustion are retained in the ash with the help of Limestone dosing. c) Due to low combustion temperature and staged combustion formation of nitrogen oxide is substantially reduced. Thus reduction of gaseous pollutants produced during combustion is achieved by combustion process itself, which is specialty of this technology and process steps are integrated into firing system. Flue gas cleaning systems, which are unavoidable in conventional boilers, are not necessary in CFBC system and thus eliminate additional efficiency losses. TITLE: INTRODUCTION The advantages of stationary fluidized bed firing system such as: Low investment cost. Simple and reliable firing arrangement. Easy fuel processing. Short start up periods Are combined with advantages of circulating fluidized bed firing system which are: High combustion efficiency High Sulphur retention with low limestone consumption Lower NOx formation helped by staged firing The Cold Cyclone CFBC technology therefore offers a highly reliable means of steam generation burning wide range of fossil fuels effectively and incorporating best of both fixed and circulating fluid bed technologies. COLD CYCLONE CFBC FIRING SYSTEM In the CFBC firing system about 50% of the combustion of solid fuel is effected in a stationary fluidised bed of coarse bed ash and about 50% in the fine, circulating ash above the fluidised bed, in the so called freeboard. The exact split of the combustion can be influenced by means of controllable stages of the combustion air supply with regard to primary, secondary and tertiary air.
The Circulating ash and flue gases flow upwards and pass over the radiant and convection heating surfaces of the 1st pass and is thereby cooled down to 270 to 450C depending on the boiler load. Subsequently ash is separated from the flue gas flow in two cyclone separators connected in parallel. Ash collected in cyclones drops in the siphons. Nozzles in siphon fluidize this ash and it spills over into the chutes where mixture of fuel and limestone (if required) is added before it returns to fluidized bed. There is a provision for ESP First and second Field Ash re-circulation back to the Boiler where the ESP ash is collected in a intermediate silo placed near the bunkers and the ash from this intermediate silo circulated back to the boiler bed vide a screw conveyor outlet of which is connected to the fuel Feeder outlet chute. This ESP ash recirculation helps in controlling the bed temperature in case of low ash coals.The cyclone ash circulation causes isothermal combustion to take place in wide area

of bed at temperatures in the range of 800 - 960C. An optimum desulphurization reaction takes place in this temperature range, which is felicitated by inherent content of calcium compounds in fuel and/or any additional fed limestone. The cyclone ash recirculation furthermore substantially contribute in heat transfer from the fluidized bed to the heating surfaces wherein the high ash load of the flue gases facilitates intensive heat transfer by means of radiant heat emission.

PROCESS & PLANT STRUCTURE


The plant basically have two boilers, each consisting of two boiler passes, electrostatic precipitator, two induced draft fan, two primary air fan, two secondary air fan, and two hot gas generators. Two Cyclones and siphons are provided for circulating the ash. The equipment for fuel transport, limestone feeding and ash removal are located on the periphery of the plant. The ash removal is divided into removal systems for bed, cyclone, Air-preheater Ashand ESP ash. In air circuit 50-60% of air required for combustion, is supplied by primary air fan at about 1770mmWC pressure. Primary Air Fans are fitted with VFDs (for air flow control through speed variation). Primary air, flows through tubular air heater, wind-box and enters the combustor simultaneously fluidizing the bed during normal operation of the boiler. Air side bypass arrangement required during start up is provided. Remaining 40-50% of the combustion air (secondary and tertiary air) is supplied by Secondary air fans at pressure of 515mmWC.These fans are equipped with VFD control (for air flow control through speed variation). This air flows through air heater and gets heated. Air splitting -secondary and tertiary takes place after air heater outlet. This air enters freeboard through nozzles located at two levels above the fluidized bed. This method is known as "air staging". Secondary and primary air has independent paths through air heater due to their different pressure. In the stationary state, approximately 600-800 mm thick layer of ash (bed material) is lying in the bottom of combustor. This mass is fluidized by the force of incoming air from primary air nozzles (fitted on the distribution plate) inflating the height of bed. Primary air pressure reduces more or less linearly (10 mmWC per 10mm height of bed material) from nozzles to the top of the bed. Fuel is fed via four lateral chutes arranged above the bed into the fluidized bed where it is burned (corresponding to % PA air fed) and converted into flue gases simultaneously releasing heat at same time. Remaining Fuel Fines along with ash is carried away upwards from fluidized bed along with flue gas. To burn this fuel Secondary Air is fed at height of 4m and Tertiary Air is fed at height of 7.5 m through number of nozzles located at lateral boiler wall. Consequently combustion of this share of fuel takes place in free board during its upward flow. Flue gases after sufficient dwell period in the free board enter the heating surface banks (Screen, Superheaters, Evaporator and Economiser-II ) where they are cooled down to about 400-450C before they leave first pass and enter the cyclones. After passing through cyclone flue gas enters Second pass where the flue gases enter heating surface bank (Economiser-1) and the temperature is reduced to temperature about 320C. Flue gas then enters the Airpreheater where in flue gas heat is transferred to combustion air passing through Airpreheater and consequently lowering the flue gas exit temperature to around 140C. Flue gases further passes through electrostatic precipitator, Induced draft fan, chimney and finally to released to atmosphere. In cyclones, coarse ash is separated from the flue gas and drops into the siphons in course of its travel back to combustor. Circulating cyclone ash not only enhances heat transfer to pressure parts, but it also substantially controls the bed temperature. Higher the quantity of ash being recirculated (which is at around 400-450C) lesser will be the bed temperature and vice-versa. In order to obtain better burnout and to make

better us of limestone (if added) filter ash from ESP first field is re-circulated back to the bed via siphon. Low cyclone ash temperature also has following advantages: The cyclone diameter remains relatively small due to the small flue gas volume. Thereby for a given pressure loss and grain spectrum a high degree of separation is obtained. Thick brick lining of cyclone is not necessary. A refractory cladding is sufficient as wear protection with standard external insulation. The absence of brickwork permits short starting up periods of about three (3) hours during cold start. The fuel feeding system is designed suitably for feeding fuels as specified in manual elsewhere. Fuel charged with limestone (if necessary) is fed into the siphon where it is mixed with re-circulated cyclone ash and than flows into the bed. For startup process, two number Hot Gas Generators (HGG) are provided which are attached to he Airbox. HSD is used in the oil burners, which gets combustion air and dilution air from PA fans. Hot flue gas generated by the HGG mainly assists to raise the bed temperature, to a temperature, which is slightly higher than ignition temperature of fuel. During cold start up, flue gas temperature at Airpreheater outlet is generally below the acid dew point. Therefore Airpreheater is bypassed using bypass-duct & damper arrangement to avoid cold end corrosion of Airpreheater tubes. Primary air enters combustor through Airpreheater, Hot Gas, Airbox and large number of specially designed air nozzles. I.D. fans are designed to handle flue gases for 100% MCR steam generation maintaining the balanced draft in the free board area.One number Deaerator and Feed water storage tank common for two boilers is provided. Deaerator is a mechanical device that removes dissolved gases from Boiler Feed-Water by deaeration. During the deaeration process in the deaerator, concentration of the dissolved Carbon Dioxide and Oxygen is reduced to a level where corrosion is minimized; hence the steam generation system is protected from the harmful effects of corrosive gases. In order to prevent corrosion in steam generation systems working with a pressure more than 20 Kg/cm2, a dissolved Oxygen level of around 7ppb is required. Steam from 2nd extraction of both the turbines is supplied to the deaerator to heat the water to full saturation temperature corresponding to the Aux steam pressure in the deaerator and to carry away dissolved gases. In the deaeration Tank, water is heated and agitated by steam bubbling through water. Steam is cooled by the incoming water and condensed at the Vent condenser. Non- Condensable gases and steam are released through the Vent.

CONTROL FUNCTIONS Instrumentation and control philosophy of CFBC boiler incorporates control loops, which are mostly common with other conventional boiler control systems. Broadly total scheme can be split into (1) Boiler Protection (2) Boiler Interlock (3) Auto Control (1) BOILER PROTECTION
During cold or hot start up of the boiler as also normal operation of the unit, certain parameters e.g. drum level, final steam temperature, bed temperature etc. are monitored on continuous basis and ensures that unit will be pulled out of service in cases of deviations beyond set limits. The unit will be restarted only after normal values are established.

(2) BOILER INTERLOCK In order to start the boiler smoothly safely and in a desired sequence, certain interlocks are provided. The contacts / sources to achieve sequential start are drawn from MCC, transmitters,

actuators etc. The unit can also be shut down safely as per desired sequence and same contacts will mostly be useful in normal shut down sequence.

(3) AUTO CONTROLS


The steam generator is normally expected to maintain operating parameters at desired levels from approximately 30% MCR to 100% MCR by tuning the standard control loops as described below:

DRUM LEVEL (THREE-ELEMENT CONTROL) The drum level control is executed as conventional three element control system and designed to keep the level in the boiler drum constant at all load conditions. For steam flow upto 30% of the MCR flow drum level control is executed as single element control. For steam flow above 30% of the MCR flow drum level control is executed as three elements control. The three elements of three element control system are steam flow, drum level and feed water flow. Temperature correction is applied for feed water flow, temperature and pressure compensation applied for steam flow, pressure correction is applied for drum level. Load changes, which becomes apparent as changes in steam flow rate as drawn by the turbine, are feed forwarded to the boiler drum level controller as disturbance variables. The set point signal for the feed water flow control comes from the drum level controller. Feed water controller output then adjusts feed flow control valve to maintain drum level at the desired point. When the drum level maintained at the desired set value that time feed water flow and steam flow will match with feed flow slightly high because of blow down. Feed water control valve is provided with another pneumatically operated control valve as a bypass. In case of failure of main Control Valve this bypass control valve will be in operation to maintain the Drum Level.
From three separate level transmitters high, low, low-low, high-high alarms are generated. The maximum and minimum levels in the boiler drum are monitored as soon as level in the drum drops below low-low level, boiler must be tripped. An emergency blow down is provided in case the drum level goes high-high for restoring the normal water level. Two nos. drum level transmitters are used for drum level measurement and average value being used for control. The two Drum Level Transmitter outputs will be monitored to provide an alarm signal if excessive error occurs between the two Transmitters output. 3 Nos Drum Level Transmitters are used for Drum level Very High/Very Low Tripping and Drum Level High/Low Alarm. One set drum level high-high and low-low trip signal will be obtained from each drum level transmitter and 2 out of 3 Logic will be used for tripping the Boiler. One set drum level high and low alarm signal will be obtained from each drum level transmitter and 2 out of 3 Logic will be used for Drum Level High and Low alarm.

FURNACE DRAFT CONTROL Three Pressure Transmitters will be used to measure the furnace pressure with the average value being used for control. The two furnace pressure inputs will be monitored to provide an alarm signal if excessive errors occur between any two measured values. The average value of furnace pressure signal is compared with a manually preset furnace pressure desired value. Furnace pressure controller output via its associated automatic/ manual station is given to adjusting VFD position, which will vary fan speed thereby to maintain the desired furnace pressure. A feed forward signal, derived from Air flow signal is input to the furnace pressure controller. If an excessive deviation occurs between the furnace pressure measured value and the desired value, the auto manual station will be tripped to manual.
One set of furnace pressure high-high and low-low signal will be generated from each pressure transmitter and 3 off high-high signal, which via a 2 out of 3 logic selected, are used to trip the boiler. 3 off low-low signal, which via a 2 out of 3 logic selected, are used to trip the boiler. One set of furnace pressure high and low signal will be generated from each pressure

transmitter. 3 off high signal, which via a 2 out of 3 logic selected, are used for furnace pressure high alarm. 3 off low signal, which via a 2 out of 3 logic selected, are used for furnace pressure low alarm.

STEAM TEMPERATURE CONTROL Final superheater steam temperature is controlled by modulation of the spray water control valves to the two stages of attemperation. First stage attemperator is located between SH1 & SH2 while the second stage between SH2 & SH3. Each stage of attemperation utilizes a cascade control system. SH2 outlet steam temperature is used as a measured value to SH2 outlet controller with desired value (Remote Set point) is determined from the addition module adding 10 Deg C above the Final Super heater inlet temperature. For Local Set point operation, desired value is being manually set by the operator. Output of this controller being the set point of SH2 inlet steam temperature controller via a high selector relay which compares the output to the saturation temperature limit derived from the drum pressure signal.SH2 inlet steam temperature is used as the measured value to the SH2 inlet steam temperature controller. The controller output is supplied to the Stage 1 attemperator spray valve. Final super heater SH3 outlet steam temperature is used as the measured value to the final superheater outlet controller with the desired value being manually set. The output of this controller is used as the desired value of the SH3 inlet controller.
SH3 inlet steam temperature is measured to become the measured value of the SH3 inlet steam temperature controller. Output of this controller is used to modulate the stage 2 attemperator control valve to maintain the final superheater steam temperature. In each stage, main spray water control valve is provided with another pneumatically operated control valves as Bypass. In case of failure of main Control Valve this bypass control vale will be in operation to maintain the Steam Temperature. As the load increases, the quantity of water spray also increases. In the event of only one spray nozzle, it is likely that at higher water flow, atomization of water may not be proper, which may adversely effect on life of Attemperator. However, multi-spray nozzle system incorporated in Cold Cyclone CFBC boiler ensures fine spray of water, within specific limits through each nozzle, to achieve quick evaporation.

BED TEMPERATURE CONTROL To regulate the emission of pollutants, such as CO and NOx, it is necessary to control the bed temperature. If de-sulphurisation of fuel, using limestone dosing, is required to be done then the effectiveness such chemical reaction depends upon the temperature of the bed where the reaction actually takes place. Normally, bed temperature for coal is around 850 C and for lignite is 800C. The ash temperature at cyclone outlet is approximately 400-450O C and therefore increases or decrease in the cyclone ash quantity being circulated will decrease or increase the bed temperature from its present level. In other words, quantity of cyclone ash put back in circulation through siphon or a portion of it extracted through cyclone ash screw feeder will help to control the bed temperature. It is, in turn, speed regulation of cyclone ash screw feeder, which will govern the bed temperature effectively. Bed temperature is one of the important parameters in boiler protection. During cold start-up, main fuel i.e. fuel cannot be charged unless bed material attains minimum ignition temperature. Similarly in case, the bed temperature increases beyond safe limit e.g. 940 C approximately, the boiler must be tripped. Thermocouples (4 Nos.) are used to measure bed temperature at various points. The average output of the all thermocouples is used as measured variable for the bed temperature controller.
Fluidized bed temperature control is achieved by re-circulating cyclone ash. For this purpose the ash circulation is either decreased or increased to control the bed temperature. Without changing of disturbance variables such as load, fuel flows, ash contents and fuel heat value; during normal operation (at constant load) the bed temperature in principle is steady and

nearly constant. In this case, cyclone ash discharge will stay at constant value, depending upon the actual fuel parameters. Whenever the bed temperature increases the discharge of the cyclone ash is to be reduced by reducing the speed of the cyclone ash screw feeder and vice versa. To avoid the useless swinging of the discharge conveyors speed, the speed is changed only if the difference of the actual bed temperature to bed temperature set point is more than 5 C. As long as bed temperature is less than ignition temperature of fuel, HGGs have to be pressed in service. After a short shut down, main fuel may be charged directly when bed temperature is at least 20C above ignition temperature of main fuel i.e. coal. Approximately 4 to 5 hours of HGG operation will suffice to raise the bed temperature to ignition value during cold start-up.

BED HEIGHT CONTROL Ash generated during combustion has four (4) extraction points, namely, bed ash, cyclone ash, Airpreheater ash and fly ash from ESP hoppers. Almost 85 to 95% of ash is collected at cyclone ash hopper, Airpreheater ash hopper & ESP ash hoppers and remaining portion gets gradually accumulated in bed. Static head required for fluidizing the bed will increase with increase in bed ash and therefore bed ash is drained intermittently (say once in a shift).
When in Auto Control, bed height is calculated according to the formula given below: Bed height = (Air box pressure) (Delta P across the nozzle) Delta P across the nozzle = Constant X (PA Mass flow) 2 Density of air at Air box temperature Pressure transmitters (3 Nos.) are used for Airbox pressure measurement. Median value of the three (3) transmitters is taken as Airbox pressure measured value. When Airbox pressure exceeds 1200 mmWC, the solenoid valve of bed ash gate will be energized and the gate will open. When the Airbox pressure drops below 800 mmWC the solenoid will de-energize and the gate will be closed. Airbox pressure also acts as a guideline for bed height.

BOILER LOAD CONTROL The final steam pressure signal is used for the boiler master pressure controller measured value and is derived from the average value of the pressure transmitter signals from the main steam outlet. The difference between the two pressure signals is measured and if an excessive deviation occurs an alarm will be annunciated. The desired value is manually adjustable to the required operating pressure. The load demand signal from the turbine control system, i.e. Main steam flow is used as feed forward input to the boiler master controller.The output of the boiler master pressure controller is used as the set point for the fuel control, PA control, SA control, etc. FUEL FLOW CONTROL The signal from boiler master control is fed to a function generator. The output being the desired value of fuel flow for all load condition. The output of function generator is fed to a low signal selector. The other output of the signal selector is max. Coal feeding The output of the low signal selector is fed to another low signal selector. The other input to the low signal selector is the (Total Airflow) X (Air-To-Coal Ratio). The first low selector ensures that during full load, feeder speed should not go beyond certain limit as second low selector ensures that during load increases combustion airflow must increase first before the fuel flow increases, so that combustion airflow is sufficient. The output of the second low signal limiter is the desired fuel demand. The sum of the two coal feeders speed is the MV of the coal flow controller. Coal flow controller output signal is divided by no. of feeder in service before feeder to the VFD panel. VFD panel will then adjust the coal feeder speed to feed the correct amount of coal flow for the combustion requirement.

AIR FLOW CONTROL


Primary Air (PA) Flow The boiler master controls will fed a function generator. The output being the desired value of PA flow for all load condition. The function generator output is fed to a high signal selector 1 with the other inputs of the signal selector are a) total coal flow X Primary air to coal ratio and b) desired value, minimum limit to ensure that an adequate air flow is maintained for proper fluidization during low load Output of high signal selector 1 is fed to a low signal selector 2. Other input is a PA flow maximum limit to ensure that PA flow never exceeds maximum PA limit under any circumstances. Output of the second low signal selector is the desired value signal (Remote set point) to the PA flow controller. For local set point operation desired value is manually adjustable to the required PA flow. One no flow transmitter is used to measure PA flow for each HGG. Sum of the PA Flow of the two HGG is the total PA Flow to the Boiler. The total PA Flow to Boiler will be the MV of the PA flow controller. PA flow controller output will vary PA fan speed though VFD to maintain the desired PA flow. Secondary Air (SA) Flow The boiler master control output will feed a function generator. The output being the desired value of SA flow for all load condition. The function generator output is fed to a high signal selector with the other input of the signal selector is desired value minimum limit to ensure that an adequate secondary air flow is maintained for proper combustion during low load. Output of the high signal selector is fed to a low signal selector; other input of the low signal selector is max SA flow. The Output of Low signal selector is the desired value signal(Remote set point) to the SA flow controller. For local set point operation desired value is manually adjustable to the required SA flow. One no. flow transmitter is used to measure SA flow. The signal of the Flow transmitter will be the MV of the SA flow controller. SA flow controller output will vary SA fan speed though VFD to maintain the desired SA flow. Secondary air flow to the boiler LHS and RHS is adjusted by two regulating duty motorized dampers. The damper opening/closing can be adjusted from DCS. Position Feedbacks are also available in CRT. Tertiary air flow to the boiler is adjusted through regulating duty motorized damper. Damper opening/closing adjusted from DCS. Position Feedback is also available in CRT.

DEAERATOR LEVEL CONTROL: Three nos. level transmitters are used for Deaerator level measurement and median value being used as measured value to the Deaerator Level Controller and Deaerator Overflow Controller. Desired values for both the controller is set by the operator. Output of the Deaerator Level controller is fed to the Deaerator Level control valve to maintain Deaerator Level and output of the Overflow Controller is fed to the Solenoid operated valve on Deaerator overflow line to ensure that the Deaerator Level never reaches maximum level. Deaerator Level control valve is provided another pneumatically operated control valve as Bypass. In case of failure of main Control Valve this bypass valve will be in operation to maintain the Deaerator Level. Deaerator Level very Low for BFP tripping will be obtained from the median value of 3 Level transmitters. Deaerator Level low and high Alarm will be obtained from the each of 3 Level transmitters. DEAERATOR PRESSURE CONTROL:

Deaerator pressure measured by the pressure transmitter will become the measured value to the Pressure Controller. Desired value is set by the operator. Output of the controller is fed to the pressure control valve to maintain Deaerator Pressure. Deaerator Pressure control valve is provided with Inching Type Motorised Bypass valve. In case of failure of main Control Valve this Inching Type Motorised valve will be operated from the CRT to maintain the Deaerator Pressure. From the Pressure transmitter signal High / Low alarms will be generated in the CRT.

BOILER DATA AND EQUIPMENT SPECIFICATIONS TYPE OF BOILER Natural Circulation, Single Drum, Top Supported, Balanced Draft, Tower Type, Membrane Panel Constructed, Outdoor Unit Equipped with Two Cyclones, having Economiser and Tubular Airpreheater as back end heat traps and 2 x 60% Draught Plant (Primary Air fan, Secondary Air Fan and Induced Draught Fan). BOILER PARAMETERS Parameter Unit Value Number of Boilers Nos Two (2) Steam Flow (100% BMCR) with Indian Coal TPH 115 Steam Pressure at outlet of Steam Stop Valve Ata 100 Steam Temp. at outlet of Steam Stop Valve Deg.C 540 5 Feed Water Temp at inlet of Economiser Deg.C 210 Design Pressure Ata 120 BOILER DATA AND EQUIPMENT SPECIFICATIONS PERFORMANCE GUARANTEE 1. Super heater outlet steam condition at 100% BMCR - Flow (t/hr) : 115- Pressure in (ata) : 100 - Temperature (C) : 540 + 5 2. Guaranteed thermal efficiency of boiler (%) : 87+ 0.5 (as per ASME PTC 4.0) 3. Unburnt combustibles in fly ash at ESP inlet (Avg.) at MCR condition. : <2 % for Indian Coal 4. Flue gas outlet temp. at air heater outlet (OC) : 140 5. SOx at stack sampling at MCR condition (ppm) : 750 NOx emission in flue gases : 200 6. ESP out dust concentration MCR condition : <30mg/Nm3 with all field in service 7. ESP outlet dust concentration with one ESP field out of service (mg / NM3) : <50 8. Load range for which SH outlet steam temperature at MS stop valve outlet shall be maintained (% BMCR) : 60-100% 9. HSD consumption (Lt/hr) for initial start-up (Approx.) start-up period considered Note: Boiler Performance Test will be carried out as per ASME PTC 4.0 Boiler Thermal efficiency based on GCV with Indian Coal having GCV 4000kcal/kg as evaluated w.r.t. an ambient temperature of 30C and 60% relative humidity and feed water inlet temp 210deg.c. Fuel Sizing shall be 100% < 8mm (fines below 1mm limited to 30%). COMPRESSED AIR Two (2) Nos. (1 W + 1 S), oil free, non-oil lubricated, Screw type air compressors of 1220Nm3/hr capacity each are provided to meet all process air and instrument air requirement of 2 x 25 MW (plus 5 %VWO) TPP including requirement of fuel and limestone handling system, ash handling system (except air for ash conveying), and all accessories like dust collectors, pneumatic actuators, common auxiliaries etc. Three (3) Nos. (2W + 1S), Lubricated, Screw type air compressors, each having capacity of 24m3/min are provided to meet the requirement of conveying air in Ash handling system for 2 x 25 MW TPP. The compressors shall be located in the air compressor house at 0.00m level in ESP building. COOLING WATER

Cooling water requirement of 2 x 25MW TPP is satisfied by closed loop cooling water system comprising of one no. multicell, RCC, induced draft, counter flow cooling tower with all equipment & accessories and Auxiliary cooling water pumps. The cooling tower have three (3) cells (2 W +1S) of 375M3/Hr capacity each to meet the requirement of 1 x 25 MW power plant. The cooling tower will be with splash type fills. Water at 32 C from cooling tower forebay will be circulated to various auxiliaries with the help of three nos (2W +1S) auxiliary cooling water pumps, each having capacity of 375M3/hr. Cooling water return at 42 C will re-circulated back to cooling tower.

FUEL ANALYSIS Details Unit PETCOKE LIGNITE INDIAN COAL A Proximate Analysis Base Fuel 1. Ash % 0.5 4 -7 42.53 2. Volatile matter % 9 - 11 25 -30 25.13 3. Fixed Carbon % 81.5 - 84.5 18-22 30.73 4. Moisture (Inherent) % 0.2 -0.5 1.5 -3 5. Sulphur (org) % 6.5 -7.5 3 - 4 0.7 - 0.9 Moisture (Total) % 10 - 18 45 - 50 10 - 18 B. Ultimate Analysis 1. Ash % 0.5 4.61 41.9 2. Carbon % 81 29.82 38 3. Hydrogen % 3 2.41 2.7 4. Sulphur % 7.5 2.06 0.6 5. Nitrogen % 1 0.41 0.9 6. Oxygen (by diff.) % - 10.69 5 7. Moisture (As receipt) % 8 - 11 45-50 10-20 C Gross Calorific Value Kcal / kg 4000 (adb: base fuel) Maximum 8250 (adb) 3000 (adb) 5600 (adb) with 30% ash Minimum 8100 (adb) 2800 adb) 2600 (adb) with 60% ash D Grindability index - - 42- 45S E Ash Deformation temperature - - F Size / Sieve analysis - - (-1mm)<30 % G Ash analysis - - H Caking / Swelling Index - - SOLID FUEL PARTICLE SIZE DISTRIBUTION a) 100 % < 8.0 mm b) 35 % (Max.) < 1.0 mm (fines) LIMESTONE ANALYSIS CaCo3 - 73.5 (%) MgCo3 - 1.5-1.8 (%) Sio2 - 13.2 -13.6 (%) Al2o3 - 2.1 2.3 (%) Fe2o3 - 1.0 -1.1 (%) Potassium (Free) - 0.25 (%) Sulphur (free) - 0.1 0.2 (%) Bulk Density - 1400 (kg/m3) Particle size - 60 mm Extent of fines (-1mm) presentin limestone - 20 (%) Start up Fuel for Boiler HSD HSD Oil -Only during Startup operation of the boiler
ASTM Spec ASTM D .396 Grade 2 GCV 10000 kcal/kg Temperature 75-80 deg.c Pressure 15.0 kg/cm2g Flash point 100 deg.c Kinematic Viscosity 3.4cst max. Sulphur 0.55% max Carbon Residue 0.35% max Moisture & Sediment 0.05 % Vol

FEED WATER (As per VD TUV/VGB directive) Sl. No. Parameter Unit Value 1. Boiler working pressure kg/cm2(g) > 90 2. General requirement - Clear and colourless

3. Specific Electrical Conductivity at 25C -Guide values of boiler water to be respected 4. Hardness mVal/kg Not detectable 5. Total Iron mg/kg <0.02 6. Total Copper mg/kg <0.003 7. Total silica mg/kg <0.02 8. Oxygen mg/kg <0.02 9. PH at 25C - >9 10. Potassium Permanganate (possible consumption) mg/kg <5 11. Total carbonic acid mg/kg 12. Total Co2 mg/kg 13. Oil mg/kg <0.5

BOILER WATER (BLOW DOWN) 1. P Value mVal/kg < 0.3 2. pH value at 25C - 9 10.5 3. Silica SiO2 mg/kg < 4.0 4. In case of phosphate injection PO4 mg/kg 2-6 5. Conductivity at 25C s/cm < 300 MAJOR EQUIPMENT SPECIFICATIONS Note: - Quantities indicated below are for one boiler PRIMARY AIR (PA) FAN Quantity : 2 X 60% Make : TLT Ltd. Design Volume Flow : 9.71 Nm/sec Design Static Pressure : 1770 mmWC Temperature : 45 C Speed : 1480 RPM Flow Control : VFD SECONDARY AIR (SA) FAN Quantity : 2 x 60% Make : TLT Ltd. Design Volume Flow : 7.84 Nm/sec Design Static Pressure : 511 mmWC Temperature : 45 C Speed : 1480RPM Flow Control : VFD INDUCED DRAUGHT (ID) FAN Quantity : 2 x 60% Make : TLT Ltd. Design Volume Flow : 19.83 Nm3/sec Design Static Pressure : 497mmWCTemperature : 160CSpeed : 980 RPMFlow Control : VFD. FUEL FEEDERS Quantity : 2 Nos.Make : Mahindra Engineering & Chemical Products Ltd. Capacity per feeder : 45 TPH Max. Width : 750mm Conveying speed : 7.5 m/min Turn Down : 1:5 Control : Variable Speed. Particle size distribution : +10mm-10%, -8mm to 1mm- 80% -1mm 40% Bulk Density (Coal) : 800 kg/m SAFETY VALVES Quantity : 04 nosMake : Tyco Sanmar Ltd. Set Pressure Drum-1 : 113 kg/cmg (46 TPH) Drum-2 : 114 kg/cmg (46 TPH) Super heater : 106.5 kg/cmg (23TPH) EMSV : 105.5 kg/cm2g (17.25 TPH) START-UP VENT Quantity : 1 no. Make : Babcock Power Espana, S.A. Type : Regulating duty motorized control valve Size : 100 mm ELECTROSTATIC PRECIPITATOR (ESP) Number of streams : One (1) Make : ETS-ELEX (India) Pvt. Ltd. Design Flow of flue gases : 39.66 Nm3/sec With 100% Lignite) Temperature of glue gases : 160c Dust loading at ESP inlet : 136 gm/Nm3 (With 100% Coal) Dust loading at ESP outlet : 30 mg/Nm3 (With all fields working) System pressure : (-) 497 mmWC Max. Permissible pressure drop : 25 mm HOT GAS GENERATOR (HGG)

Quantity : 2 Nos. Make : Coen Bharat Ltd., Mumbai Fuel oil : HSD Heat Release rate : 9 Mkcal/hr Max. Fuel oil Consumption : 900 kg/hr Gas temp. at HGG outlet : 850o C at outlet Turn Down : 1: 5 HSD Pressure at oil pipe Inlet : 9 kg/cm2g

ESP ASH RECIRCULATION SCREW FEEDER Quantity : 1 Nos. Make : Powercon Equipments Arrangement : Horizontal Trough Dia. : 8mm thk. 382 mm U-Trough Conveying length : 2350mm. (C/C) Temperature : 160 oC Capacity : 8TPH CYCLONE ASH SCREW FEEDER Quantity : 2 Nos. Make : Powercon Equipments Arrangement : Horizontal Trough Dia. : 8mm thk. 382 mm U-TroughConveying length : 3022 mm. (C/C) Temperature : 450 oC (Max) Capacity : 6 TPH Jacket cooling water pressure : 6.0 kg/cm at inlet (max.) Turn down : 1:5 LIME STONE SCREW FEEDER Quantity : 1 Nos. Make : Powercon Equipments Arrangement : Horizontal Trough Dia. : 8mm thk. 432 mm U-Trough Conveying length : 8575mm. (C/C) Temperature : Ambient Capacity : 14 TPH PETCOKE SCREW FEEDER Quantity : 1 Nos. Make : Powercon Equipments Arrangement : Horizontal Trough Dia. : 8mm thk. 432 mm U-Trough Conveying length : 8825 mm. (C/C) Temperature : Ambient Capacity : 12TPH FLUIDISED BED ASH COOLER Make : ThyssenKrupp Industries India Pvt. Ltd. Number of Coolers : 2.0 Capacity each : 2.9 TPH Inlet temp of ash : 850C Outlet temp of ash : 200C Inlet temp of air : 45C0 Outlet temp of air : 250C BOILER FEED PUMP (Common For Two Boilers) Make : KSB PUMPS LTD. Number of Pumps : 3 nos (2W + 1S) Model : HGC-4-11 Pump Type : Horizontal Centrifugal Ring Section. Water Temperature : 155 C Normal Flow/pump at MCR : 126.6 CuM/Hr. Rated Flow/Pump Design : 138.7 CuM/Hr. Differential Head At MCR Condition : 1476 mmWC Differential Head At Design Condition : 1445.6 mmWC Effective Speed : 2980 RPM No. Of Stages : 11 Motor Rating : 750 KW DEAERATOR (Common for Two Boilers) Make : GEA ENERGY SYSTEMS (INDIA) LTD. Quantity : One Type : Spray cum Tray Counter Flow Pressure of Steam at turbine extraction : 5.54 ata Deaerator Capacity : 275 TPH Operating Pressure : 5.54 Kg/cm2 (a) Temperature of Incoming Water : 60-61 oC Temperature of Deaerated Water : 155 oC Dissolved O2 in Deaerated Water : 7 ppb Normal Water Level Ref. bottom of Tank : 2053 mm Design Pressure : 6.5 Kg/cm2 (g) & full vacuum. RAW WATER TRANSFER PUMPS Make : Mather + Platt (I) Ltd. Number of Pumps : 3 nos (2W + 1S) Model : ET - ISO 21 Pump Type : End Suction Water Temperature : 32 C Rated Flow : 70 CuM/Hr Diff. Head at Design Condition : 50 m Motor rating : 22KW Rated Speed : 1480 RPM DM WATER TRANSFER PUMPS Make : Mather + Platt (I) Ltd. Number of Pumps : 3 nos (2W + 1S) Model : PN - ISO 8 Pump Type : End suction Water Temperature : 32 C Rated Flow Design : 15 CuM/Hr. Diff. Head at Design Condition : 25 m Motor rating : 3.7KW Rated Speed : 1480 RPM AUXILIARY COOLING WATER PUMPS

Make : Mather + Platt (I) Ltd. Number of Pumps : 3 nos (2W + 1S) Model : 6/8 CME Pump Type : Horizontal Split Case Water Temperature : 34 C Rated Flow : 375 CuM/Hr Diff. Head at Design Condition : 60 m Motor rating : 90KW Rated Speed : 1480 RPM

H.P. CHEMICAL DOSING SYSTEM (Tri sodium Phosphate) a. Tank No. Of tanks : One Capacity (Liters) : 1000 b. Pumps Quantity : 3 Nos (2W + 1S) Make : SWELORE Type/Model : Reciprocating Plunger type Capacity : 0 - 20 LPH Discharge pressure : 125 kg/cm2 (g) Stroke range : 0-100% Adjustable (Manual) Stroking speed : 50SPM Motor Rating : 1.0HP, 1440 RPM, CGL L.P. DOSING SYSTEM (HYDRAZINE) a. Tank No. Of tanks : One Capacity (Liters) : 1000 b. Pumps Quantity : 2 Nos (1W + 1S) Make : SWELORE Type/Model : Reciprocating Plunger type Capacity : 0 - 40 LPH Discharge pressure : 10 kg/cm2 (g) Stroke range : 0-100% Adjustable (Manual) Stroke speed : 50SPM Motor Rating : 0.5HP, 1440 RPM, CGL SCHEDULE OF PRESSURE PARTS
Description Sizes Material Specification

1 Steam drum 1) Shell 1598 OD x 60 thk 15NiCuMoNb5 2) Dished Ends 60 thk 15NiCuMoNb5 2 Furnace 1) F.W. membrane panels 44.5 O.D x 5 thk BS3059 PII GR440 2) R.W membrane panels 44.5 O.D x 5 thk BS3059 PII GR440 3) L.H side wall membrane panels 44.5 O.D x 5 thk BS3059 PII GR440 4) R.H side wall membrane panel 44.5 O.D x 5 thk BS3059 PII GR440 5) Roof panel 44.5 O.D x 5 thk BS3059 PII GR440 6) Air box 44.5 O.D x 5 thk BS3059 PII GR440 3 Furnace headers 1) Front wall bottom header 219.1O.D X 23 thk SA 106 Gr B 2) Rear wall bottom header 219.1O.D X 23 thk SA 106 Gr B 3) S.W bottom header Right 219.1O.D X 23 thk SA 106 Gr B 4) S.W bottom header Left 219.1O.D X 23 thk SA 106 Gr B 5) Roof header 273O.D X 28.6 thk SA 106 Gr B 6) Front & rear wall top header 219.1O.D X 23 thk SA 106 Gr B 7) Front & rear wall bottom header 219.1O.D X 23 thk SA 106 Gr B 4 Screen 1) Screen Panels 38.1 O.D x 5 thk 15 Mo 3 2) Screen tube inlet header 273 O.D x 25.4 thk SA 106 Gr B 5 SH1, SH2, SH3 supporting tubes 38.1 O.D x 5 thk BS3059 PIIGR440/15M03 6 EVAP. supporting tubes 38.1 O.D x 5 thk BS3059 PIIGR440/15M03 7 ECO2 supporting tubes 38.1 O.D x 5 thk BS3059 PIIGR440/15M03 8 Supporting tubes above ECO2 38.1 O.D x 5 thk BS3059 PIIGR440 9 Outlet header for supporting tubes 273 O.D x 25.4 thk SA 106 Gr B 10 Main Downcomer 273 O.D X 18.2 thk SA 106 Gr B 11 Main Downcomer header 273 O.D X 28.6 thk SA 106 Gr B 12 Evaporator inlet & outlet header 273 O.D X 28.6 thk SA 106 Gr B 13 Evaporator coils 44.5 O.D x 4.5 thk BS3059 PII GR440

14 Saturated steam header 219.1O.D X 23 thk SA 106 Gr B 15 Economiser-1 1) Economiser-1 inlet header 219.1O.D X 23 thk SA 106 Gr B 2) Economiser-1 outlet header 219.1O.D X 23 thk SA 106 Gr B 3) Economiser-1 coil 38.1O.D X 4.0 thk BS3059 PII GR440 16 Economiser-2 1) Economiser-2 inlet header 219.1 O.D X 23 thk SA 106 Gr B 2) Economiser-2 outlet header 219.1 O.D X 23 thk SA 106 Gr B 3) Economiser-2 coils 38.1O.D X 4.0 thk BS3059 PII GR440 17 Superheater-1 1) Superheater-1 inlet header 219.1 O.D X 23 thk SA 106 Gr B 2) Superheater-1 outlet header 219.1 O.D X 23 thk SA 335 Gr P11 3) Superheater-1 coil 31.8 O.D X 4.0 thk SA 213 T11 18 Superheater-2 1) Superheater-2 inlet header 219 O.D x 20.6 thk SA 335 Gr P11 2) Superheater-2 outlet header 273 O.D X 36 thk SA 335 Gr P22 31.8 O.D X 4.0 thk SA 213 T11 3) Superheater-2 coil 31.8 O.D X 5.6 thk SA 213 T22 19 Superheater-3 1) Superheater-3 inlet header 273 O.D X 28.6 thk SA 335 Gr P22 2) Superheater-3 outlet header 273 O.D X 40 thk SA 335 Gr P22 3) Superheater-3 coil 31.8 O.D X 4.5 thk SA 213 T91 20 Interconnecting piping from ECO1 to ECO2 168.3 O.D X 14.3 thk SA 106 Gr B 21 Piping from SH1 outlet to Attemp1 & fromAttemp1 to SH2 inlet 219.1 O.D X 23 thk SA 335 Gr P11 22 Piping from SH2 outlet to Attemp2 & fromAttemp2 to SH3 inlet 273 O.D X 36 thk SA 335 Gr P22 23 Piping from Saturated steam header to SH1inlet header 219 O.D X 18.2 thk SA 106 Gr B 24 Riser tubes from header to drum 88.9 O.D X 7.1 thk BS3059 PII GR440 25 Connecting tubes from Downcomer tomembrane wall bottom header 88.9 O.D X 7.1 thk BS3059 PII GR440 26 Connecting tubes from drum to Evap. inletheader and to drum 88.9 O.D X 7.1 thk BS3059 PII GR440 27 Tubes from ECO2 to drum 88.9 O.D X 7.1 thk BS3059 PII GR440 28 Tubes from drum to sat. steam header 88.9 O.D X 7.1 thk BS3059 PII GR440 29 Connecting tubes from drum to screen tubeinlet header88.9 O.D X 7.1 thk BS3059 PII GR440 30 Feed water line up to feed control station & toECO1 168.3 O.D x 14.3 thk SA106 Gr B 31 Spray Attemperator-1 219.1 O.D X 23 thk SA 335 Gr P11 32 Spray Attemperator-2 273 O.D X 36 thk SA 335 Gr P22
I. Boiler MCC IA. Boiler MCC - Bus - 1 1 Coal Chain Feeder 2 2 0 7.500 VFD 2 Lime Stone / Pet Coke Screw Feeders 2 2 0 5.500 VFD 3 Cycle Ash Screw Feeder 2 2 0 3.750 VFD 4 ESP Ash Recirculation Feeder 1 1 0 3.700 VFD 5 HP Dosing Pump 3 2 1 0.750 DOL 6 Stirrers 1 1 0 0.370 DOL 7 LP Dosing Pump 2 1 1 0.370 DOL 8 Stirrers 1 1 0 0.370 DOL Actuators for Valves 9 Start up vent regulation valve (modulating with inching) 1 1 0 1.500 RDOL(I) 10 Start up vent isolation valve 1 1 0 1.500 RDOL(NI)

11 12 13 14 15 16 17 18 19 20

Main Steam Stop Valve Isolation 1 1 0 5.500 RDOL(NI) Main Steam Stop Valve Bypass 1 1 0 0.180 RDOL(NI) Main Attemperator Line 1 1 0 0.120 RDOL(NI) Attemperator # 1,2 Nozzle Isolation 3 3 0 0.060 RDOL(NI) Attemperator # 1,2 FCV Upstream Isolation 2 2 0 0.060 RDOL(NI) Attn. # 1, 2 FCV Bypass Valves 2 2 0 0.060 RDOL(NI) Continuous Blow Down Valve # 1 (modulating with inching) 1 1 0 0.250 RDOL(I) Emergency Blow Down Valve (EBD) Modulating (modulating with inching) 1 1 0 0.750 RDOL(I) 0 - 40% FCV Upstream Isolation 1 1 0 1.500 RDOL(NI) 30 - 100% FCV Upstream Isolation 3 3 0 3.000 RDOL(NI)

Actuators for Dampers 21 Air Dampers (Modulating with inching) 4 4 0 0.550 RDOL(I) 22 Air Dampers (Modulating with inching) 3 3 0 0.250 RDOL(I) 23 Air cooler Dampers (Modulating with inching) 4 4 0 0.550 RDOL(I) 24 Guillotene Dampers for Fans (ON/OFF) 4 4 0 1.100 RDOL(NI) 25 Guillotene Dampers for Fans (ON/OFF) 4 4 0 0.370 RDOL(NI) Slide gates 26 Slide Gates at coal chain conveyor outlet 2 2 0 0.370 RDOL 27 HGG Pumping Filtering Unit 2 2 0 3.750 DOL IB. Boiler MCC - Bus - 2 1 Coal Chain Feeder 2 2 0 7.500 VFD 2 Lime Stone / Pet Coke Screw Feeders 2 2 0 5.500 VFD 3 Cycle Ash Screw Feeder 2 2 0 3.750 VFD 4 ESP Ash Recirculation Feeder 1 1 0 3.700 VFD Actuators for Valves 5 Start up vent regulation valve (modulating with inching) 1 1 0 1.500 RDOL(I) 6 Start up vent isolation valve 1 1 0 1.500 RDOL(NI) 7 Main Steam Stop Valve Isolation 1 1 0 5.500 RDOL(NI) 8 Main Steam Stop Valve Bypass 1 1 0 0.180 RDOL(NI) 9 Main Attemperator Line 1 1 0 0.120 RDOL(NI) 10 Attemperator # 1,2 Nozzle Isolation 3 3 0 0.060 RDOL(NI) 11 Attemperator # 1,2 FCV Upstream Isolation 2 2 0 0.060 RDOL(NI) 12 Attn. # 1, 2 FCV Bypass Valves 2 2 0 0.060 RDOL(NI) 13 Continuous Blow Down Valve # 1 (modulating with inching) 1 1 0 0.250 RDOL(I) 14 Emergency Blow Down Valve (EBD) Modulating (modulating with inching) 1 1 0 0.750 RDOL(I) 15 0 - 40% FCV Upstream Isolation 1 1 0 1.500 RDOL(NI) 16 30 - 100% FCV Upstream Isolation 3 3 0 3.000 RDOL(NI) Actuators for Dampers 17 Air Dampers (Modulating with inching) 4 4 0 0.550 RDOL(I) 18 Air Dampers (Modulating with inching) 3 3 0 0.250 RDOL(I) 19 Air cooler Dampers (Modulating with inching) 4 4 0 0.550 RDOL(I) 19 Guillotine Dampers for Fans(ON/OFF) 4 4 0 1.100 RDOL(NI) 20 Guillotine Dampers for Fans(ON/OFF) 4 4 0 0.370 RDOL(NI) Slide gates 21 Slide Gates at coal chain conveyor outlet 2 2 0 0.370 RDOL 22 230V AC Supply for Instruments 1 1 0 1.000 O/G(230V AC) 23 HGG Pumping Filtering Unit 2 2 0 3.750 DOL 1 Belt Conveyor - 1 (LPBC-1) 1 1 0 75.000 CONVEYOR 2 Belt Conveyor - 2 (LPBC-2) 1 1 0 11.000 CONVEYOR 3 Belt Conveyor - 3 (LPBC-3) 1 1 0 7.500 CONVEYOR 4 Belt Conveyor - 4 (LPBC-4) 1 1 0 15.000 CONVEYOR 5 Belt Conveyor - 5 (LPBC-5) 1 1 0 15.000 CONVEYOR 6 Belt Conveyor - 6 (FLBC-6) 1 1 0 18.500 CONVEYOR 7 Belt Conveyor - 8 (FLBC-8) 1 1 0 15.000 CONVEYOR 8 Belt Conveyor - 9 (FLBC-9) 1 1 0 18.500 CONVEYOR 9 Belt Conveyor - 10 (FLBC-10) 1 1 0 15.000 CONVEYOR 10 Belt Conveyor - 11 (FLBC-11) 1 1 0 18.500 CONVEYOR 11 Belt Conveyor - 15 (FLBC-15) 1 1 0 5.500 CONVEYOR 12 Belt Conveyor - 16 (FLBC-16) 1 1 0 30.000 CONVEYOR

13 BE - 01 1 1 0 15.000 O/G 14 Crusher - 1 (CR-1) 1 1 0 132.000 RDOL 15 Crusher - 2 (CR-2) 1 0 1 132.000 RDOL 16 Vibrating Screen - 1 1 1 0 2x3.7 DOL 17 Vibrating Screen - 2 1 0 1 2x3.7 DOL 18 Vibrating Feeder - 1 (VS-1) 1 1 0 2x0.75 DOL 19 Vibrating Feeder - 2 (VS-2) 1 0 1 2x0.75 DOL 20 Vibrating Feeder - 3 (VS-3) 1 1 0 2x1.7 DOL 21 Vibrating Feeder - 4 (VS-4) 1 0 1 2x1.7 DOL 22 Vibrating Feeder - 5 (VS-5) 1 1 0 2x1.7 DOL 23 Vibrating Feeder - 6 (VS-6) 1 0 1 2x1.7 DOL 24 Vibrating Feeder - 7 (VS-7) 1 0 1 2X0.75 DOL 25 Vibrating Feeder - 8 (VS-8) 1 1 0 2X0.75 DOL 26 Vibrating Feeder - 9 (VS-9) 1 0 1 2X0.75 DOL 27 Flap Gate - 1 1 1 0 2.200 RDOL 28 Flap Gate - 2 1 1 0 1.500 RDOL 29 Flap Gate - 3 1 1 0 1.500 RDOL 30 Flap Gate - 4 1 1 0 1.500 RDOL 31 Flap Gate - 5 1 1 0 1.500 RDOL 32 R & P Gates - 1 1 1 0 2.200 RDOL 33 R & P Gates - 2 1 1 0 2.200 RDOL 34 R & P Gates - 3 1 1 0 2.200 RDOL 35 R & P Gates - 4 1 1 0 2.200 RDOL 36 Magnetic Separator 1 1 0 11.000 O/G 37 Hoist - 1 1 1 0 5.500 O/G 38 Hoist - 2 1 1 0 5.500 O/G 39 Dust Extraction System (DE-1)-LCP 1 1 0 5.500 O/G 40 Dust Extraction System (DE-2)-LCP 1 1 0 22.370 O/G 41 Dust Extraction System (DE-3)-LCP 1 1 0 55.370 O/G 42 Dust Extraction System (DE-4)-LCP - - - 43 Dust Extraction System (DE-5)-LCP 1 1 0 15.370 O/G 44 Dust Extraction System (DE-6)-LCP 1 1 0 30.370 O/G 45 Dust Extraction System (DE-7)-LCP 1 1 0 30.370 O/G 46 Dust Extraction System (TT-1)-LCP 1 1 0 5.500 O/G 47 Dust Extraction System (TT-2)-LCP 1 1 0 5.500 O/G 48 Dust Extraction System (TT-3)-LCP 1 1 0 5.500 O/G 49 Dust Extraction System (TT-4)-LCP 1 1 0 15.370 O/G 50 Dust Supervision System (DS1)-LCP 1 1 0 2.200 O/G 51 Lime Sampling Unit - 1-LCP 1 1 0 1.100 O/G 52 Lime Sampling Unit - 2-LCP 1 1 0 1.100 O/G 53 Sample Collection System 1 1 0 0.750 O/G 54 Metal Detector 1 1 0 0.150 230V AC Single Phase Loads. Shall be fed by providing suitable control transformers 55 Belt Weigher - 1 1 1 0 0.250 56 Belt Weigher - 2 1 1 0 0.250 57 Belt Weigher - 3 1 1 0 0.250 58 Solenoid Valve DE 61 61 0 0.050 59 Solenoid Valve Air Blast 16 16 0 0.100 60 Plough 19 4 15 0.100 61 230V AC Supply for Instruments 1 1 0 0.500 O/G(230V AC) III ACC (Air Cooled Condensor) MCC IIIA. ACC (Air Cooled Condensor) MCC - Bus - 1 1 Hotwell Transfer Pump - 1 & 2 2 1 1 3.700 DOL 2 Condensate Extraction Pump - 1 & 2 2 1 1 75.000 DOL 3 Motor for High Pressure Pump - Cleaning System 1 1 0 37.000 DOL 4 Geared Motor for cleaning device 1 1 0 0.500 DOL

5 Motorised Valve for Vacuum Breaker 1 1 0 0.550 RDOL(NI) 6 Motorised Valve for CEP Discharge - 1 & 2 2 2 0 1.100 RDOL(NI) 7Motorised Valve for LCV 101 & 103 Upstream Isolator 1 1 0 1.100 RDOL(NI) IIIB. ACC (Air Cooled Condensor) MCC - Bus - 2 1 Hotwell Transfer Pump - 1 & 2 2 1 1 3.700 DOL 2Condensate Extraction Pump - 1 & 2 2 1 1 75.000 DOL 3Motor for High Pressure Pump - Cleaning System 1 1 0 37.000 DOL 4 Geared Motor for cleaning device 1 1 0 0.500 DOL 5 Motorised Valve for Vacuum Breaker 1 1 0 0.550 RDOL(NI) 6 Motorised Valve for CEP Discharge - 1 & 2 2 2 0 1.100 RDOL(NI) 7 Motorised Valve for LCV 101 & 103 Upstream Isolator 1 1 0 1.100 RDOL(NI) IV STG MCC IVA STG MCC - Bus - 1 1 Main Oil Reservoir Oil Mist Fan Motor 1 1 0 1.500 DOL 2 GSVC Vapour Extraction Fan Motor 2 1 1 3.000 DOL 3 Generator Space Heater 1 1 0 4.000 HEATER 4 Generator Exciter Space Heater 1 1 0 0.350 HEATER 5 Oil Reservoir Heater 8 8 0 8.000 HEATER 6 Lube Oil Purifier Motor 1 1 0 1.500 DOL 7Lube Oil Purifier Motor (Transfer Pump) 1 1 0 2.000 DOL 8 Lube Oil Purifier Heater 1 1 0 46.500 HEATER 9 HP heater Unit 1 condensate inlet 1 1 0 3.000 RDOL(NI) 10 HP heater Unit 1 condensate outlet 1 1 0 3.000 RDOL(NI) 11 HP heater Unit 1 condensate bypass 1 1 0 3.000 RDOL(NI) 12 HP heater Unit 2 condensate inlet 1 1 0 3.000 RDOL(NI) 13 HP heater Unit 2 condensate outlet 1 1 0 3.000 RDOL(NI) 14 HP heater Unit 2 condensate bypass 1 1 0 3.000 RDOL(NI) 15 LP heater Unit 1 condensate inlet 1 1 0 1.100 RDOL(NI) 16 LP heater Unit 1 condensate outlet 1 1 0 1.100 RDOL(NI) 17 LP heater Unit 1 condensate bypass 1 1 0 1.100 RDOL(NI) 18 LP heater Unit 2 condensate inlet 1 1 0 1.100 RDOL(NI) 19 LP heater Unit 2 condensate outlet 1 1 0 1.100 RDOL(NI) 20 LP heater Unit 2 condensate bypass 1 1 0 1.100 RDOL(NI) 21 MOV in BFP discharge 3 3 0 3.000 RDOL(NI) 22 MOV in Main steam line to TG 2A isolation (Near Turbine) 1 1 0 5.500 RDOL(NI) 23 MOV in Main steam line to TG 2A isolation valve (2AMAS-31) integralbypass 1 1 0 0.180 RDOL(NI) 24 HP Heater extraction steam line 1 1 0 1.100 RDOL(NI) 25 LP Heater extraction steam line isolation (Unit-2A) 1 1 0 1.100 RDOL(NI) 26 Deaerator steam from extraction line PCV main & bypass upstream isolation (Unit-2A) 2 2 0 1.100 RDOL(NI) 27 CSDH Drains second isolation 2 2 0 0.060 RDOL(NI) 28 Deaerator pegging steam PRDS spray water control valve main & bypass upstream isolation 2 2 0 0.060 RDOL(NI) 29 Deaerator pegging steam PRDS steam pressure control valve main & bypass upstream isolation 2 2 0 1.500 RDOL(NI) 30 Main steam from boiler-2A to CSDH inlet isolation 1 1 0 5.500 RDOL(NI) 31 Main steam from boiler-2A to CSDH inlet isolation valve integral bypass 1 1 0 0.180 32 Main steam from boiler-2B to CSDH inlet isolation 1 1 0 5.500 RDOL(NI) 33 Main steam from boiler-2B to CSDH inlet isolation valve integral bypass 1 1 0 0.180 34 Main steam from boiler-2A to CSDH line drains second isolation 3 3 0 0.060 RDOL(NI) 35 Main steam from boiler-2B to CSDH line drains second isolation 3 3 0 0.060 RDOL(NI) 36 Main steam from CSDH outlet to TG-2A isolation 1 1 0 5.500 RDOL(NI) 37 Main steam from CSDH outlet to TG-2A isolation valve integral bypass 1 1 0 0.180 38 Main steam from CSDH outlet to TG-2B isolation 1 1 0 5.500 RDOL(NI) 39Main steam from CSDH outlet to TG-2B isolation valve integral bypass 1 1 0 0.180 40 Main steam from CSDH outlet to TG-2A line drains second isolation 2 2 0 0.060 RDOL(NI)

41 Main steam from CSDH outlet to TG-2B line drains second isolation 2 2 0 0.060 RDOL(NI) 42 Main steam from CSDH outlet to TG-2A drain first isolation (Near Turbine) 1 1 0 0.060 RDOL(NI) 43 Main steam from CSDH outlet to TG-2B drain first isolation (Near Turbine) 1 1 0 0.060 RDOL(NI) IVB STG MCC - Bus 2 1 Main Oil Reservoir Oil Mist Fan Motor 1 1 0 1.500 DOL 2 GSVC Vapour Extraction Fan Motor 2 1 1 3.000 DOL 3 Generator Space Heater 1 1 0 4.000 HEATER 4 Generator Exciter Space Heater 1 1 0 0.350 HEATER 5 Oil Reservoir Heater 8 8 0 8.000 HEATER 6 Lube Oil Purifier Motor 1 1 0 1.500 DOL 7 Lube Oil Purifier Motor (Transfer Pump) 1 1 0 2.000 DOL 8 Lube Oil Purifier Heater 1 1 0 46.500 HEATER 9 Turbine-2A Warm up vent second isolation 1 1 0 0.060 RDOL(NI) 10 Turbine-2B Warm up vent second isolation 1 1 0 0.060 RDOL(NI) 11 MOV in main steam line to TG 2B isolation (Near Turbine) 1 1 0 5.500 RDOL(NI) 12MOV in Main steam line to TG 2B isolation valve (2BMAS-31) integral bypass 1 1 0 0.180 RDOL(NI) 13 Auxiliary steam 100/15 ata PCV up stream main & bypass isolation (Unit-2A) 2 2 0 0.060 RDOL(NI) 14Auxiliary steam 100/15 ata PCV up stream main & bypass isolation (Unit-2B) 2 2 0 0.060 RDOL(NI) 15Steam from Turbine extraction to Auxiliary stream 22/15 ata PCV stream isolation (Unit-2A) 1 1 0 0.120 DOL(NI) 16 Steam from Turbine extraction to Auxiliary stream 22/15 ata PCV stream isolation (Unit-2B) 1 1 0 0.120 RDOL(NI) 17 Auxiliary stream PRDS spray control valve main & Bypass up stream isolation (Unit-2A) 2 2 0 0.060 RDOL(NI) 18Auxiliary stream PRDS spray control valve main & Bypass up stream isolation (Unit-2B) 2 2 0 0.060 RDOL(NI) 19HP Heater normal and emergency drain lines main & bypass control valve up stream isolation (Unit-2A) 4 4 0 0.120 RDOL(NI) 20 HP Heater normal and emergency drain lines main & bypass control valve up stream isolation (Unit-2B) 4 4 0 .120 RDOL(NI) 21 LP Heater drain line main & bypass control valve upstream isolation (Unit-2A) 2 2 0 0.120 RDOL(NI) 22 LP Heater drain line main & bypass control valve upstream isolation (Unit-2B) 2 2 0 0.120 RDOL(NI) 23 Overhead Surge Tank to CRT make up line LCV upstream isolation (Unit- 2A) 2 2 0 0.120 RDOL(NI) 24 Overhead Surge Tank to CRT make up line LCV upstream isolation (Unit- 2B) 2 2 0 0.120 RDOL(NI) 25 Condensate excess dump to overhead surge tank LCV upstream isolation (Unit-2A) 2 2 0 1.100 RDOL(NI) 26 Condensate excess dump to overhead surge tank LCV upstream isolation (Unit-2B) 2 2 0 1.100 RDOL(NI) 27 HP Heater extraction steam line isolation (Unit-2B) 1 1 0 1.100 RDOL(NI) 28 LP Heater extraction steam line isolation (Unit-2B) 1 1 0 1.100 RDOL(NI) 29 Deaerator steam from extraction line PCV main & bypass upstream isolation (Unit- 2B) 2 2 0 1.100 RDOL(NI) 30 Steam Interconnection line isolation 1 1 0 5.500 RDOL(NI) 31 Interconnection steam PRDS spray water control valve main & bypass upstream isolation 2 2 0 0.060 RDOL(NI) 32 CSDH outlet to existing steam line interconnection isolation 1 1 0 5.500 RDOL(NI) 33 CSDH outlet to existing steam line interconnection valve integral bypass 1 1 0 0.180 34 230V AC Supply for Instruments 1 1 0 1.000 O/G(230V AC) V AC & Ventilation MCC TG Building 1 Centrifugal Blower Motor inside TG Hall @ 15.0 M lvl 4 4 0 30 DOL 2 Viscous Filter Motor inside TG Hall @ 15.0

M Lvl 8 8 0 0.75 DOL 3 ECU Pump Motors inside TG Hall @ 15.0 M lvl 4 4 0 1.5 DOL 4 Exhaust Fan Motor for TG hall @ 0.0 M Level 5 5 0 0.75 DOL 5 Exhaust Fan Motor for Cable Cellar @ 0.0 M Level 3 3 0 1.5 DOL 6 Exhaust Fan Motor for TG hall PCC MCC @ 3.5 M Level 3 3 0 2.2 DOL 7 Exhaust Fan Motor for TG hall @ 5.0 M Level 5 5 0 0.55 DOL 8 Exhaust Fan Motor for TG hall @ 10.0 M Level 5 5 0 2.2 DOL 9 Exhaust Fan Motor for TG hall Battery room@ 10.0 M Level 2 2 0 0.18 DOL 10 Packaged Air Conditioning 17 TR Unit for VFD room @ 3.5 M Level inside TG hall 1 1 0 153.18 O/G 11 Packaged Air Conditioning 11 TR Unit for IO and Control room @ 10.0 M Level inside TG hall 1 1 0 94.68 O/G 12 Hi wall Split units inside Conference room @ 10.0 M Level inside TG Hall 6 6 0 3.7 O/G 13 Hi wall Split units inside office room @ 10.0 M Level inside TG Hall 5 5 0 3.7 O/G 14 Hi wall Split units inside UPS Battery Charger room @ 10.0 M Level inside TG Hall 5 5 0 3.7 O/G ESP Building 1 Exhaust Fan Motor for ESP Cable cellar @ 0.0 M Level 3 3 0 0.55 DOL 2 Exhaust Fan Motor for ESP Compressor room @ 0.0 M Level 2 2 0 0.55 DOL 3 Exhaust Fan Motor for ESP PCC MCC @ 4.0 M Level 3 3 0 0.55 DOL

TITLE: BOILER DATA AND EQUIPMENT SPECIFICATIONS


Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 55 of 85 W.O. No. : 2M0003

4 Hi wall Split units inside Control room @ 4.0 M Level inside ESP building 6 6 0 3.7 O/G 5 Hi wall Split units inside SWAS ESP @ 0.0 M Level inside ESP building 3 3 0 3.7 O/G

6 Hi wall Split units inside Instrument lab @ 4.0 M Level inside ESP Building 3 3 0 3.7 O/G 7 Centrifugal Blower Motor @ 8.5 M Level 2 2 0 7.5 DOL 8 Viscous Filter Motor @ 8.5 M level 1 1 0 0.75 DOL 9 ECU Pump Motors @ 8.5 M level 2 2 0 1.2 DOL WTP Building 1 Exhaust Fan Motor for WTP PCC MCC @ 0.0 M Level 3 3 0 0.55 DOL 2 Exhaust Fan Motor for Mufle furnace and hot oven @ 0.0 M Level 1 1 0 0.55 DOL 3 Exhaust Fan Motor for Chemical storage @ 0.0 M Level 1 1 0 0.55 DOL 4 Exhaust Fan Motor for WTP Plant equipment room @ 0.0 M Level 2 2 0 0.55 DOL 5 Hi wall Split units inside WTP Lab @ 0.0 M Level 3 3 0 3.7 O/G 6 Hi wall Split units inside WTP DCS O/s @ 0.0 M Level 3 3 0 3.7 O/G 7 Hi wall split units inside WTP MCC Room 9 9 0 3 O/G Fire Pump House 1 Exhaust Fan Motor for Fire pump house @ 0.0 M Level 1 1 0 0.55 DOL 2 Hi wall Split units inside Fire water MCC Panel @ 0.0 M Level 2 2 0 3.7 O/G Raw Water Gas Chlorination Builing 1 Exhaust Fan Motor for @ 0.0 M Level 1 1 0 0.55 DOL Cooling Water Gas Chlorination Builing 1 Exhaust Fan Motor for @ 0.0 M Level 1 1 0 0.55 DOL Coal Handling MCC Room 1 Hi-Wall Split Unit 8 8 0 3.7 O/G VI ESP MCC (See Note - 3) VIA ESP MCC - Bus - 1 1 TR Set - 1 to 5 5 5 0 78.480 MCCB 2 Insulator Heaters 1 1 0 15.000 HEATER 3 Hopper Heaters 5 5 0 2.600 HEATER 4 Collecting Electrode Rapping Motor 5 5 0 0.120 DOL 5 Discharge Electrode Rapping Motor 5 5 0 0.180 DOL 6 Purge Air Fan 2 1 1 11.000 DOL 7 Electrical Hoist 1 1 0 4.070 MCCB VIB ESP MCC - Bus - 2 1 TR Set - 1 to 5 5 5 0 78.480 MCCB 2 Insulator Heaters 1 1 0 15.000 HEATER 3 Hopper Heaters 5 5 0 2.600 HEATER 4 Collecting Electrode Rapping Motor 5 5 0 0.120 DOL 5 Discharge Electrode Rapping Motor 5 5 0 0.180 DOL

TITLE: BOILER DATA AND EQUIPMENT SPECIFICATIONS


6 Purge Air Fan 2 1 1 11.000 DOL 7 Electrical Hoist 1 1 0 4.070 MCCB VII Emergency MCC

VIIA Emergency MCC - Bus - 1 1 Main Oil Pump Motor (TG - 1) 1 1 0 75.000 DOL
Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 56 of 85 W.O. No. : 2M0003

2 Auxiliary Oil Pump Motor (TG - 2) 1 0 1 75.000 DOL 3 Barring Gear Motor (TG - 1) 1 1 0 22.000 DOL 4 Generator Jacking Oil Pump Motor (TG - 1) 1 1 0 1.500 DOL 5 UPS 1 1 0 20.000 O/G 6 Emergency Lighting Distribution Board 1 1 0 10.000 O/G 7 Battery Charger 1 1 0 25.000 O/G 8 Welding Receptacle 1 1 0 5.000 O/G VIIB Emergency MCC - Bus - 2 1 Main Oil Pump Motor (TG - 2) 1 1 0 75.000 DOL 2 Auxiliary Oil Pump Motor (TG - 1) 1 0 1 75.000 DOL 3 Barring Gear Motor (TG - 1) 1 1 0 22.000 DOL 4 Generator Jacking Oil Pump Motor (TG - 1) 1 1 0 1.500 DOL 5 UPS 1 1 0 20.000 O/G 6 Battery Charger 1 1 0 25.000 O/G VIII Compressor & Ash Handling MCC 1 Instrument cum Service Air Compressor - A & B 2 1 1 185.00 O/G 4 RCC Fly ash silo Unloading panal-1 (with motor starter) 1 1 0 30.80 O/G 5 RCC Fly ash silo Unloading panal-2 (with motor starter) 1 1 0 30.80 O/G 6 RCC Bed ash silo Unloading panal(with motor starter) 1 1 0 12.35 O/G 7 Vent Filter Fan Motor (Bed Ash Silo) 1 1 0 2.20 DOL 8 Vent Filter Fan Motor (Fly Ash Silo) 2 2 0 4.00 DOL 9 Vent Filter Fan Motor (Bed Ash Recirculating Hopper) 2 2 0 0.75 DOL 10 Vent Filter Fan Motor (Fly Ash Re-circulating Hopper) 2 2 0 0.75 DOL 11 230V Supply for instruments 1 1 0 1.000 O/G(230V AC) 12 Ash Conveying Compressors 3 2 1 150.00 O/G 13 Air cooled air dryer 3 2 1 7.00 O/G IX CW & WTP MCC COOLING TOWER 1 Cooling Tower Fan - A, B & C 3 2 1 18.750 DOL 2 Chlorine Dosing Pump (CWCT) - A & B 2 1 1 0.370 DOL 3 Scale Inhibitor Chemical Dosing Pump (CWCT) - A & B 2 1 1 0.370 DOL 4 Corrosion Inhibitor Chemical Dosing Pump (CWCT) - A & B 2 1 1 0.370 DOL 5 Spare Dosing Pump (CWCT) - A & B 2 1 1 0.370 DOL 6 Dynamic Deposit Monitor (CWCT) 1 1 0 1.000 DOL 7 Air Blower for Cooling Tower Gas

chlorination System 1 1 0 5.500 DOL 8 Air Blower for Raw Water gas chlorination system 1 1 0 5.500 DOL

TITLE: BOILER DATA AND EQUIPMENT SPECIFICATIONS


9 ACW Pump (Connected to PCC) 3 2 1 90.000 DOL 10 DM Water Transfer Pump - A, B & C 3 2 1 3.700 DOL 11 DM Water Transfer Pump - D & E 2 1 1 18.500 DOL 12 Raw Water Transfer Pump - A, B & C 3 2 1 22.000 DOL 13 Filter Feed Pump - A & B 2 1 1 15.000 DOL 14 Blowdown transfer pump - A & B 2 1 1 7.500 DOL 15 Cooling Tower make-up water pump - A, 3 2 1 2.200 DOL
Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 57 of 85 W.O. No. : 2M0003

B&C 16 Effluent Transfer Pump - A & B 2 1 1 11.000 DOL 17 Neutralised Effluent Transfer Pump - A & B 2 1 1 15.000 DOL 18 MOV in ACW pump Discharge 3 3 0 0.060 RDOL(NI) 19 MOV in Raw Water Pump Discharge 3 3 0 0.060 RDOL WATER TREATMENT PLANT 1 MGF Back Wash Pump 2 1 1 5.500 DOL 2 Back Flush Pump 3 2 1 3.700 DOL 3 Fast Flush Pump 3 2 1 5.500 DOL 4 RO Feed Pump 2 1 1 5.500 DOL 5 High Pressure Pump 3 2 1 7.500 DOL 6 Cleaning Solution Pump 1 1 0 9.300 DOL 7 Degassed Water Pump 2 1 1 11.000 DOL 8 Acid Unloading Pump 2 1 1 1.500 DOL 9 Caustic Unloading Pump 2 1 1 1.100 DOL 10 MGF Air Blower 2 1 1 3.700 DOL 11 Degasser Air Blower 2 1 1 0.750 DOL 12 MB Air Blower 2 1 1 2.200 DOL 13 Agitator for SMBS D.T 2 1 1 0.028 DOL(**) 14 Agitator for Antiscalant D.T 2 1 1 0.028 DOL(**) 15 Agitator for CST 1 1 0 1.500 DOL 16 Agitator for CST 1 1 0 0.370 DOL 17 Agitator for CDT 1 1 0 0.028 DOL(**) 18 Agitator for pH Correstion D.T 2 1 1 0.028 DOL(**) 19 Agitator for Alum D.T 2 1 1 0.028 DOL(**) 20 NaOCL Dosing Pump 2 1 1 0.100 DOL(**) 21 Alum Dosing Pump 2 1 1 0.100 DOL(**) 22 SMBS Dosing Pump 2 1 1 0.100 DOL(**) 23 Antiscalant Dosing Pump 2 1 1 0.100 DOL(**) 24 Acid Dosing Pump 2 1 1 0.100 DOL(**) 25 pH Correction Dosing Pump 2 1 1 0.100 DOL(**) 26 Air Blower for Side Stream Filter 2 1 1 0.370 DOL EFFLUENT TREATMENT PLANT 1 Neutralised Water Transfer Pump 2 1 1 1.500 DOL 2 Effluent Water Transfer Pump 2 1 1 7.500 DOL 3 Sludge Transfer Pump 2 1 1 1.500 DOL 4 PSF Feed Pump 2 1 1 15.000 DOL 5 PSF Back Wash Pump 2 1 1 11.000 DOL 6 Back Flush Pump 2 1 1 9.300 DOL 7 Fast Flush Pump 2 1 1 15.000 DOL 8 RO-2 Feed Pump 2 1 1 7.500 DOL 9 High Pressure Pump 2 1 1 22.000 DOL

10 PSF Air Blower 2 1 1 3.700 DOL

TITLE: BOILER DATA AND EQUIPMENT SPECIFICATIONS


11 12 13 14 15 16 17 18 Agitator for Caustic D.T 2 1 1 0.370 DOL Agitator for Coagulant Preparation Tank 1 1 0 0.370 DOL Agitator for Polymer Preparation Tank 1 1 0 0.370 DOL Agitator for SMBS D.T 2 1 1 0.028 DOL(**) Agitator for Antiscalant D.T 2 1 1 0.028 DOL(**) Turbine Drive 1 1 0 0.750 DOL Rake Drive 1 1 0 0.370 DOL Acid Dosing Pump(HCL) 2 1 1 0.370 DOL

Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 58 of 85 W.O. No. : 2M0003

19 Caustic Dosing Pump 2 1 1 0.100 DOL(**) 20 NaOCL Dosing Pump 2 1 1 0.100 DOL(**) 21 Coagulant Dosing Pump 2 1 1 0.100 DOL(**) 22 Polymer Dosing Pump 2 1 1 0.370 DOL 23 HCL Dosing Pump 2 1 1 0.370 DOL 24 NaOCL Dosing Pump 2 1 1 0.370 DOL 25 SMBS Dosing Pump 2 1 1 0.100 DOL(**) 26 Antiscalant Dosing Pump 2 1 1 0.100 DOL(**) 27 HCL Dosing Pump 2 1 1 0.100 DOL(**) 28 230V Supply for instruments 1 1 0 1.000 O/G(230V AC) X Fire Water System 1 Electrical Motor Driven Pump 2 2 0 110.000 DOL 2 Electrical Motor Driven Pump 1 1 0 15.000 DOL XI MPDB 300.000 (#) XII Lighting Loads 120.000 (#) XIII Miscellaneous Loads EOT Crane 1 1 0 46.200 O/G Lifts 2 2 0 11.000 O/G Hoists 20 20 0 5.500 O/G LEGENDS

DOL - DIRECT ON LINE STARTER DOL(**) - DIRECT ON LINE STARTER - SINGLE PHASE TYPE CONVEYOR - CONVERYOR - UNIDIRECTIONAL HEATER - HEATER OUTGOING FEEDER RDOL - REVERSIBLE DIRECT ON LINE STARTER RDOL(I) - REVERSIBLE DIRECT ON LINE STARTER (Inching Duty) RDOL(NI) REVERSIBLE DIRECT ON LINE STARTER (Non-Inching Duty) O/G - SIMPLE FUSE / MCCB OUTGOING FEEDER

TITLE: BOILER DATA AND EQUIPMENT SPECIFICATIONS


1. SCHEDULE OF DAMPERS (PER BOILER) Sr. No. Service Description Type Tag No. Qty. in No(s). Type of Duty Type of Operation

Duct Size in mm (W x H)

(Inside, Clear)
Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 59 of 85 W.O. No. : 2M0003

Sr. No. Service Description Type Tag No. Qty. in No(s). Type of Duty Type of Operation Duct Size in mm (W x H)
(Inside, Clear)

1. PA Line to APH Multilouvre 2A-DPR-305 1 Regulating Motorized 1300 x 1300 2. PA bypass line to APH Multilouvre 2A-DPR-306 1 Regulating Motorized 1120 x 1120 3. PA Fan Discharge damper Guillotine 2A-DPR301/302 2 ON/OFF Motorized 1300 x 650 4. HGG-1 combustion air damper Multi-vane - 1 Regulating Pneumatic 765 x 765 5. HGG-1 dilution air damper Multi-vane - 1 Regulating Pneumatic 700 x 560 6. HGG-1 bypass air damper Multilouvre 2A-DPR-310 1 Regulating Motorized 1700 x 850 7. HGG-2 combustion air damper Multi-vane - 1 Regulating Pneumatic 765 x 765 8. HGG-2 dilution air damper Multi-vane - 1 Regulating Pneumatic 700 x 560 9. HGG-2 bypass air damper Multilouvre 2A-DPR-311 1 Regulating Motorized 1700 x 850 10. SA line near furnace Multilouvre 2A-DPR307/308 2 Regulating Motorized 880 x 880 11. TA Line near furnace Multilouvre 2A-DPR-309 1 Regulating Motorized 1520 x 620 12.ID fan Suction Line Guillotine 2A-DPR312/314 2 ON/OFF Motorized 2938 x 1000 13.ID fan discharge Guillotine 2A-DPR313/315 2 ON/OFF Motorized 1700 X 1700 14. SA fan Discharge damper Guillotine 2A-DPR303/304 2 ON/OFF Motorized 1200 x 600
Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 60 of 85 W.O. No. : 2M0003

TITLE: WATER & STEAM CIRCUIT

C2 - 0 - 0 - 0 WATER & STEAM CIRCUIT

Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 61 of 85 W.O. No. : 2M0003

TITLE: WATER & STEAM CIRCUIT C2.1.0.0 NATURAL CIRCULATION STEAM GENERATION

Feed water from feed pump is supplied to Economiser-I via feed control station where piping and valves layout is such that alternative/ facility (with proper isolation) is available to allow feed water through main line (100%), or its by pass or low feed line or its by pass. Economiser-I is located in upper portion of second Pass and interconnecting piping takes feed water to inlet header of Economiser-II in upper portion of combustor. Drum receives feed water from Economiser-II. Drum is connected to bottom headers of combustor via Downcomer and supply pipes for feeding water. The furnace walls headers located in upper portion of combustor convey mixture of steam and water to drum through riser tubes. Initially water is filled up to drum and thus entire water circuit is filled with water. Water level in the drum is kept approximately 100 mm below NWL prior to lighting up of boiler. Soon after boiler is lit up, furnace walls, Economiser etc start heat absorption and heat up water in system. The water becomes lighter. In the other words, difference in density gives rise to circulation of water in the entire system. As the water in furnace walls rises, its place is taken by denser/colder water from Downcomer. Thus, natural circulation is established and continues. As the water-steam mixture flowing upwards through furnace tubes, top water wall headers and risers enters the drum, separation of steam from water takes place. Steam from upper portion of drum flows to saturation steam header located slightly above the steam drum. Steam then flows through Superheater-I, Superheater-II and Superheater-III absorbing the heat from outgoing flue gases of combustor. The water, separated from water-steam mixture, obviously mixes with water in lower portion of drum and process of natural circulation continues. Feed water regulating system ensures water in the integral parts and maintains desired water level in the drum. There is no circulation of water in the absence of density variation caused by heat absorption.
Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 62 of 85 W.O. No. : 2M0003

TITLE: WATER & STEAM CIRCUIT C2.2.0.0 SCREEN Screen coils are placed above the free board and below Superheater coils to have more heating surface and proper heat balance. Inlet header is provided for feeding water to these screen tubes. Water is fed to this inlet header from drum. The outlet tubes of screen form the support tubes on which Superheater; evaporator and Economiser-II coils rest and maintain proper distance (Pitch) between them. Water flows upwards in evaporator and flue gases also flow upwards. In the other words it is parallel flow of flue gas and water. C2.3.0.0 EVAPORATOR These coils are placed above Superheater section. Feed water from drum enters at inlet header of evaporator. Mixture of water and steam proceeds to drum via evaporator outlet header C2.4.0.0 ECONOMISER-I In Economiser-I, flue gases from cyclones flow downwards towards air heater whereas the feed water moves upwards. The Economiser coils are suspended from steel structure. Economiser-I is counter-flow type heat exchanger and of plain tube configuration. C2.5.0.0 ECONOMISER-II

The flue gases flow upwards through gaps between Economiser II coils. The water also moves upwards to Economiser outlet header. Feed water flows from Economiser-II outlet header to drum through nozzles with thermal sleeves. Inside the steam drum, perforated feed pipes ensure even distribution of feed water. Economiser-II is parallel-flow type heat exchanger and of plain tube configuration.
Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 63 of 85 W.O. No. : 2M0003

TITLE: WATER & STEAM CIRCUIT C2.6.0.0 FURNACE Rear wall forms the roof of furnace. Right, left and front sides of rectangular furnace have virtually upright walls. Riser tubes carry water steam mixture to drum and impact deflection plate inside the drum separates the steam from water. Saturated steam tubes, evenly spaced along the length of drum, ensures uniform steam conveyance to saturated steam header and from here, the steam goes to Superheater-I inlet header through connecting pipe.
Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 64 of 85 W.O. No. : 2M0003

TITLE: WATER & STEAM CIRCUIT C2.7.0.0 SUPERHEATERS Superheaters are so arranged in the first pass that fairly flat characteristic is ensured. Also, the steam velocities and internal heat transfer are such that even on partial load, the metal temperature of all Superheaters are well within the acceptable limits. Constant Superheater outlet steam temperature from 60% MCR onwards can be maintained by cooling the steam by the two spray Attemperators placed between Superheater-I / Superheater-II and between SuperheaterII / Superheater-III respectively. The saturated steam extracted evenly along the whole length of the drum flows via connecting pipes to the Superheater-I bank, which is arranged on the flue gas side in the counter flow. Attemperator-I is placed between Superheater-I Outlet header and Superheater-II Inlet Header. This Attemperator is used to control the outlet temperature of Superheater-I steam so that it can be fed to Superheater-III at desired set point. Superheater-I & Superheater-II is arranged in the flue gas path in counter-flow fashion. Attemperator-II is placed between Superheater-II Outlet header and Superheater-III Inlet Header. This Attemperator is used to adjust the final Superheater Steam temperature so that it can be maintained at a constant set point. Superheater-III bank tubes are arranged in the flue gas path below Superheater-II bank tubes in parallel-flow fashion. Final steam is fed via a pipe into the steam mains and supplied to the users. (Turbine-Alternator set or process) A main steam stop valve with integrated bypass valve and a non-return valve is located close to Superheater-III outlet header. The steam generator is fitted with a safety valve system and electrically operated start up vent valve.
Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 65 of 85 W.O. No. : 2M0003

TITLE: WATER & STEAM CIRCUIT C2.8.0.0 ATTEMPERATORS Under even and good combustion conditions, the level of the steam temperature changes with the boiler load. Additional influences on the final superheated steam temperature amongst others,

from varying fuel compositions, oscillations in the excess air and alternating fouling of the heating surfaces are a common experience. Maintaining the superheated steam temperature is therefore only possible by using auxiliary equipment. This is the reason why Attemperators are arranged between the individual Superheater sections. By spraying in water, they keep the steam at a reasonably constant temperature.
Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 66 of 85 W.O. No. : 2M0003

TITLE: WATER & STEAM CIRCUIT SCHEMATIC DIAGRAM OF WATER & STEAM CIRCUIT

Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 67 of 85 W.O. No. : 2M0003

TITLE: WATER & STEAM CIRCUIT BASIC CIRCUIT DIAGRAM FOR NATURAL CIRCULATION TYPE STEAM GENERATOR
Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 68 of 85 W.O. No. : 2M0003

TITLE: STRUCTURAL DESIGN AND SPECIAL FEATURES

C3 - 0 - 0 - 0 STRUCTURAL DESIGN AND SPECIAL FEATURES


Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 69 of 85 W.O. No. : 2M0003

TITLE: STRUCTURAL DESIGN AND SPECIAL FEATURES C3.1.0.0 SUSPENSION SYSTEM The entire pressure part weight in the boiler first pass, second pass up to the expansion joint below Economiser- and Cyclones is taken up by the suspension beams at the top of boiler structure. Cup springs are provided on four water-cooled walls of combustor (First pass). Pre-compressed cup springs to installation load adequately accommodate the sagging of main suspension beams due to static loads, any possible fouling of Ist pass water walls, Superheaters, Economiser-II and Evaporators. Second pass is separated from first pass by using expansion joints. Entire air heater (tubular type) is supported on Boiler Steel Structural members. Besides, fouling is not expected in view of relatively low temperature of flue gases. Cup springs are therefore not deemed necessary in the second pass with smooth plain sheet casing. Over 70% of supporting tubes used to position Superheater and Economiser coils in first pass do not need any special springs due to insignificant differential expansion between water wall and roof. The vertical water walls of the 1st pass and the smooth plate casing of the 2nd pass are able to take up the entire load without any additional reinforcement. C3.2.0.0 CYCLONES The cyclones are of a self-supporting plate constructional design complete with wear protection. Expansion joints offset any difference in expansion between the two boiler passes. The theoretical fixed point for the vertical expansion is at the centre of the cyclones for the horizontal expansion. Expansion joints, at the connecting ducts of the boiler passes, accommodate any difference in expansion, between the cyclones and the first and second passes. Ash laden flue gas enters from combustor exit into cyclones. The raw gas passes via the raw gas

duct into the raw gas spiral. At this entry, the flue gas is centrifugally deflected. Due to the centrifugal forces the ash particles are flung out from the gas flow towards shell of cyclone
Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 70 of 85 W.O. No. : 2M0003

TITLE: STRUCTURAL DESIGN AND SPECIAL FEATURES They overcome the flow resistance, which is caused by the sinking flow to the immersion pipe inlet. At the cyclone shell, the ash moves downwards into the standpipes and finally in the siphon. The clean gases leave the cyclone via a centrally arranged immersion pipe. The cyclone does not require special maintenance. During long outages ash deposits should be removed. Technical Data of Cyclone for Indian Coal (per Cyclone) Sl. No. Parameter Unit 100% MCR 1. Gas mass flow at inlet kg/sec 21.0 2. Gas temperature at inlet Deg.C 415 3. Inlet dust loading kg/Nm3 2.0 4. Draft loss mmWC ~130 Sketch of Cyclone
Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 71 of 85 W.O. No. : 2M0003

TITLE: STRUCTURAL DESIGN AND SPECIAL FEATURES C3.3.0.0 BOILER FIRST PASS - SPECIAL FEATURES OF DESIGN The boiler body is constructed in self-supporting manner without any support from constant hangers. This avoids any compressive strains in the walls. For taking up the gas-side pressures and any explosion/implosion forces arising out of it, the boiler is provided with buckstays following the course of vertical expansion. Clamping angles connect the buckstays with the channel secured on the walls. The clamping angles permit a horizontal differential expansion between the buckstays and the channels fixed to the wall. However, they transfer forces acting on the attendant wall to the buckstays and direct these same forces via corner connections to the adjacent walls. The entire boiler first pass is designed to attain fully leak proof arrangement for flue gas. All bank heating surfaces, at the wall penetrations are welded directly into the membrane wall using protection sleeves. All the other wall penetrations are sealed off on the flue gas side by employing sheet metal cases or fillers. Lowest tubes of Superheater-I, Superheater-II, Superheater-III, Screen and Economiser-II are fitted with stainless steel flats, also known as "Armour". Similar arrangement is given to top tubes of Economiser-I. This prevents erosion of tubes facing flue. Gas diversion plate assemblies are fixed to furnace walls in spaces between screen, Superheaters, evaporator and Economiser-II. This minimizes the "stack effects" or erosion due to continuous ash mass flow through spaces between furnace wall and ends of heating surfaces. Similar arrangement of gas diversion plate is on the topside of Economiser-I. In order to minimize the difference in thermal expansion between combustor water walls and evaporator/ Superheater / Economiser-II coils; the latter is supported from support tubes. The headers and the interconnecting pipes of Superheater / Economiser-II are supported from combustor walls. Buckstays are used at various levels with corner connections as well as anchor points for more rigidity against bowing due to suction or pressurization of furnace.

Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 72 of 85 W.O. No. : 2M0003

TITLE: STRUCTURAL DESIGN AND SPECIAL FEATURES Airbox or air box form the bottom portion of combustor. It is also a membrane construction having top portion fitted with primary air nozzles (made of high temperature resistant cast steel) for fluidising the bed comprised of ash, coal and limestone mixture effectively. Hot gas generator is connected to air box. The lower section of the combustor water walls is provided with "SiC" refractory. This is done for mainly following reasons: a. To prevent erosion damage, due to the circulating fluidised bed. b. Regulating heat transfer. c. Preventing damage at the evaporator tubes due to the sub- stoichiometrical mode of operation in the lower section of the evaporator. Low cement castable refractory is also applied on all combustor walls just above "SiC" and below screen tubes for technical reasons similar to application of "SIC". Air is tapped from PA Fan Common discharge duct which supplies air through nozzles located inside siphon for fluidising the ash coming from cyclones and pushing it into the bed through coal chutes. Drop pipe with one end approximately 50 mm above the top of primary air nozzle, passing through air box and terminating (with expansion joint) on the underside of air box is used for draining bed ash occasionally. There is of course proper sealing with air box at entry and exit points. C3.4.0.0 BOILER SECOND PASS - SPECIAL FEATURES OF DESIGN The second pass consists of two parts (Economiser upper section and tubular air heater lower section) separated by means of expansion joints to accommodate thermal expansion. Whilst the Economiser-II (convection pass) is hung from the boiler roof, the tubular air heater is propped up in the steel support structure. The second pass tubular air heaters are each propped up in the support structure by means of sliding bearings, permitting of horizontal thermal expansion. The course of thermal expansion in each instance is upwards to the expansion joint.
Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 73 of 85 W.O. No. : 2M0003

TITLE: STRUCTURAL DESIGN AND SPECIAL FEATURES Airpreheater is comprised of four banks of primary air and four banks of secondary air. Steel structure supports upper and lower sections separately. However, metallic expansion joints interposed between them, accommodates thermal expansion. For all parts of the second pass, the theoretical fixed point for the horizontal expansion is at the centre of the second pass front wall. The lateral expansion of air heater is therefore sideways and towards rear side. In view of the lower flue gas temperature at Economiser-I inlet, unlike furnace water-cooled walls, plain casing suffices to enclose Economiser-I. Tubular slings are used to suspend Economiser-I coils from roof.
Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 74 of 85 W.O. No. : 2M0003

TITLE: COMBUSTION AIR & FLUE GAS SYSTEM

C4 - 0 - 0 - 0

COMBUSTION AIR & FLUE GAS SYSTEM


Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 75 of 85 W.O. No. : 2M0003

TITLE: COMBUSTION AIR & FLUE GAS SYSTEM C4.1.0.0 AIR PATH The entire combustion air comprises of During Start-up - Combustion air for burners of the Hot Gas Generators - Dilution air (through Hot Gas Generators) During Normal operation - Primary air (including Siphon air) - Secondary air - Tertiary air The combustion air required for the fluidised bed combustion is admitted from primary air fan and secondary air fan, and supplied to the furnace. The airflow is adjusted to the respective requirement through speed control for PA Fan, SA & ID Fan. Individual suction ducts of the PA and SA Fan direct the fresh air to the respective fan. Discharge side ducts of both fans enter the Airpreheater. Primary air (PA) and Secondary/Tertiary air (SA/TA) flows through the tubular Airpreheater in 4 stages and is heated in the cross flow pattern. After the tubular Airpreheater, primary air bifurcates in two branches for two hot gas generators. Further split up into combustion air, dilution air and HGG bypass is arranged in the vicinity of the individual hot gas generator. The primary air is blown into the fluidised bed via PA nozzles. Generally, primary air is routed through combustion air, dilution air during cold start up and then switch over to HGG by-pass path. Secondary air is further split into secondary and tertiary air ducts with isolation/control dampers after Airpreheater. The secondary air is injected into the boiler by means of nozzles located above the fluidised bed. The tertiary air is supplied to the boiler through nozzles, located above the secondary air nozzles. This staged combustion air supply and low combustion temperature will largely assist in reducing the formation of thermal NOx. Adequate no. of access doors and various pressure and temperature & flow monitoring points are provided over the entire air path at appropriate locations.
Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 76 of 85 W.O. No. : 2M0003

TITLE: COMBUSTION AIR & FLUE GAS SYSTEM C4.2.0.0 FLUE GAS PATH The flue gas-side pressure in the freeboard, above the fluidised bed is around (-) 30 to (-) 50 mmWC. From here, the fly ash charged flue gases from combustion are conveyed to induceddraught fan. In the first pass of boiler, flue gas passes over screen, the final-stage i.e. Superheater-3, Superheater-2, Superheater-1, Evaporator and Econimizer-2 reaching the second boiler pass via cyclone separators. The cyclone separator re-circulates the ash discharged from the fluidised bed a number of times. Approximately 95-97% of the ash contained in the flue gases is being separated in the cyclones. In the second pass of boiler, the flue gases pass through Economizer-1 and then the tubular Airpreheater. The primary air and secondary/tertiary air is heated here. On leaving the tubular Airpreheater, the flue gases, now only charged with extremely fine dust,

reach Electrostatic Precipitator (ESP) where, depending on the dust load, the dust gets precipitated from the dust laden flue gases in each field of the ESP. Induced Draft (ID) fan directs the flue gas coming from the electrostatic precipitator to the stack. The VFD controls the speed of the induced-draft fan, which adjusts the flue gas flow/furnace pressure to the respective requirements. Adequate inspection/access doors and various pressure and temperature monitoring points are provided over the whole of the flue gas path.
Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 77 of 85 W.O. No. : 2M0003

TITLE: FUEL FEEDING SYSTEM

C5 - 0 - 0 - 0 FUEL/LIMSTONE FEEDING SYSTEM


Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 78 of 85 W.O. No. : 2M0003

TITLE: FUEL FEEDING SYSTEM C5.1.0.0 FUEL FEEDING SYSTEM Coal / lignite from existing JT-2 is transferred to TH-1 by 150TPH belt conveyors with some modifications in the existing chute. Fuel from TH-1 will be conveyed to TH-2 and then to TH-4. Fuel from TH-4 will be conveyed to fuel bunkers. For redundancy coal / lignite is also tapped from Tripper of existing boiler with some modifications and then transferred to TH-3. Fuel from TP-3 will be conveyed to TH-4 then to fuel bunkers. Limestone will be tapped from existing transfer point (TP-109). One flap gate is provided on existing conveyors for transferring the limestone to 1000m3 storage silo-1 with the help of 600TPH capacity belt conveyors. From storage silo limestone will be fed to Crusher house using 80TPH capacity belt conveyors. Crushed limestone then will be transferred to screen house, rejected material by screen will be again fed to crusher house. Required size of limestone from screen will be transferred to storage silo2 (750m3) and then transferred to limestone bunker though 150TPH belt conveyors. Two (2) Fuel bunkers, each having total 400 m3 (water volume) capacity, are supplied for continuous fuel feeding to the boiler. Each bunker has one outlet with manual operated Plate type cut-off gate located below rod type cut-off gate for isolation purpose. This ensures a flooded section of Fuel at the entry to both Fuel feeders which are fitted below the isolation gates. The Fuel feeders are equipped with chain tension adjusting arrangement, NO-FUEL-FLOW alarm, chain scrapping arrangement and fuel bed height adjustment. Fuel bed height shall be set manually during commissioning. Fuel feeder drive arrangement comprises electric motor with VFD (for 1:5 speed controls), gearbox and finally chain drive at fuel feeder shaft. One limestone bunker of capacity 250 m3 (water volume) and one pet coke bunker of capacity 300 m3 (water volume) are supplied. One VFD controlled screw feeder is provided at outlet of both the bunkers. A change to the conveying capacity can only be effected by regulating the continuously adjustable drive of the proportioning conveyor. Outlet of screw feeders are connected to each drag

chain feeder. Downstream end of coal feeder is feeding the coal straight into "Y" piece fitted under the Siphon. Fuel along with limestone will reach at mixing chambers -siphons at the end of the drop pipes. Fuel Lime mixture from each siphon goes to combustion chamber vide the "Y" piece fitted under each Siphon. Each outlet of fuel feeder is provided with Motor operated cut-off gate to isolate the supply of fuel/ lime to the mixing chamber (siphon) and consequently to combustion chamber.
Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 79 of 85 W.O. No. : 2M0003

TITLE: FUEL FEEDING SYSTEM Each fuel feeder is provided with an Emergency gate and a chute up to ground level, which facilitates fast evacuation and easy loading to a truck in case of emergency as well as during maintenance. Based on the fuel feeder configuration and speed, fuel flow in TPH shall be computed in the DCS as an on-line monitoring system.
Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 80 of 85 W.O. No. : 2M0003

TITLE: ASH HANDLING SYSTEM

C6 - 0 - 0 - 0 ASH HANDLING SYSTEM


Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 81 of 85 W.O. No. : 2M0003

TITLE: ASH HANDLING SYSTEM C6.1.0.0 REQUIREMENTS OF ASH HANDLING SYSTEM In contrast to ash handling systems in conventional power plants, the ash handling system in CFBC boiler takes care of following specific requirements. a) At all boiler loads, the corresponding ash quantities in the fluidised bed must be maintained between two limit values. It must be possible to remove the oversize portion of the ash, not carried away with the flue gas, from the fluidised bed. The control criterion is the bed height derived from air pressure in the Airbox. This ash handling system is described in next section "Bed Ash Handling System". b) It must be possible to decrease or increase the quantity of ash being collected and recirculated to the combustor via a cyclone ash handling system to suit various fuel qualities. In practice, this means that the cyclone ash re-circulation rate, in turn extraction rate of ash, can be adjusted by varying the speed of ash screw feeder provided below cyclone. The system should be capable of varying the re-circulating ash for regulating the bed temperature. Portion of the ash separated in cyclones, therefore has to be extracted, cooled and transported to storage silos. Total Ash generated during combustion is extracted through four (4) extraction points namely, bed ash(BA), cyclone ash(CA), Air preheater ash(APH) and ESP ash from ESP hoppers. Almost 90% of the total ash is collected as fly ash and remaining 10% is collected as bed ash. This ash will be transferred to respective silos with the hellp of ash handling system. Detail system description of AHS is as below.
Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 82 of 85 W.O. No. : 2M0003

TITLE: ASH HANDLING SYSTEM

C6.2.0.0 BED ASH HANDLING SYSTEM

Bed ash handling system is designed for intermittent operation to drain the bed ash from fluidised bed through two drainpipes. The two (2) bed ash drains are provided below Airbox with a pneumatically operated shut-off gate on each drain point. Fabric expansion joint is provided to accommodate high downward thermal expansion of furnace w.r.t. bottom-supported fluidised bed ash cooler. One (1) refractory lined air-cooled ash cooler is provided, below each bed ash discharge pipe, which cools the bed ash to about 200C. Each bed ash cooler outlet is provided with pneumatically operated shut off gate. Signal for opening the pneumatic slide gate will come from temperature element located on bed ash cooler. The denseveyors are provided below the each bed ash cooler along with pneumatically operated slide gates. The bed ash collected in the respective denseveyor of both the boilers will be conveyed to bed ash silo through MS pipes. The silo is of RCC type construction having 110m3 effective capacity. Proper vent filters with exhaust fans are provided at the top of silo for controlling the dust generated in the silo. The silo has three discharge outlets, under one outlet pneumatic knife gate valve and motor operated Rotary vane feeder and telescopic chutes are provided for disposal of the ash through bulk tankers. Under the second outlet, a pneumatic knife gate valve and ash conditioner is provided to moisten the ash with water so as to discharge in the open trucks. A third outlet shall be provided with manually operated knife gate valve for emergency unloading
One 10m3 Bed material silo is provided near the bunker. Ash from outlet of bed ash cooler can also be transferred to this silo by using switch valve. Ash stored in this silo can be used as bed material in the boiler.

Note: Dismantling of the bed ash system is only allowed during boiler downtime. Since hot ash may be present in the drainpipes above cut-off gates, utmost care and caution should be exercised.
Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 83 of 85 W.O. No. : 2M0003

TITLE: ASH HANDLING SYSTEM C6.3.0.0 CYCLONE ASH HANDLING SYSTEM Cyclone ash handling system can be divided in to two parts: a. Cyclone Ash Re-circulation System b. Cyclone Ash Extraction & Cooling System C6.3.1.0 CYCLONE ASH RE-CIRCULATION SYSTEM The cyclone ash circulation system comprises the path of the cyclone ash through the first pass of the steam generator, through the cyclones and via siphons back to the fluidised bed. The cyclone ash separated from the flue gas in the cyclones flows downwards by gravity through vertical gravity pipes to the siphons. A siphon is assigned to each cyclone separator. The function of the siphon is to isolate the area of the fluidised bed under positive pressure from the negative pressure area of the cyclones.

To ensure optimum ash flow through the siphon, fluidising air from the common PA discharge duct is admitted to the siphons. The airflow is adjusted to the operating conditions prevailing, in each case via the manual valves provided in the airline. The cyclone ash passes from the outlet of the siphon into the mixing chamber. Cyclone outlet area, up to and including the mixing chamber and downstream pipes up to steam generator is provided with thermal insulation for 450O C.
Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 84 of 85 W.O. No. : 2M0003

TITLE: ASH HANDLING SYSTEM C6.3.2.0 CYCLONE ASH EXTRACTION & COOLING SYSTEM Bed temperature is controlled by the regulation of ash mass flow in the combustor, by collecting it in the cyclone and re-circulated to the combustor via siphon. To reduce the bed temperature, more cyclone ash is fed back to the combustor through a siphon, which is provided below each cyclone. This is achieved by reducing the extraction quantity of ash by reducing the speed of screw feeder, thereby achieving more re-circulation of ash. To increase the bed temperature, lesser cyclone ash is fed back to the combustor by extracting more quantity of ash by increasing the speed of screw feeder, thereby achieving lesser recirculation of ash. The extracted ash is then collected in the water-cooled hopper and then conveyed to the ash storage silo. U Trough and variable pitch type screw feeder is provided with water-jacketed trough to handle ash at around 400 Deg C. The drive arrangement comprises of electric motor, gearbox and VFD. Variable speed of screw feeder is achieved by means of VFD, which is governed by the feedback of bed temperature.
Project: 2 x 25 MW TPP AT Chittorgarh, Rajasthan Customer: Grasim Industries Ltd. Aditya Cement Unit-II Page 85 of 85 W.O. No. : 2M0003

TITLE: ASH HANDLING SYSTEM C6.4.0.0 FLY ASH-HANDLING SYSTEM: The fly ash is collected at Outlet of static cooler, ESP, and APH etc. through surge hoppers. Below the surge hoppers manually operated knife / plate valves and expansion joints are provided. The fly ash collected in the respective denseveyor of both the boilers is conveyed to two nos. of fly ash silos (500m3 capacity) through MS pipes. The silos are of RCC type construction. Vent filters with exhaust fan are provided at the top of silo for controlling the dust generated in the silo. The silo has three discharge outlets, under one outlet pneumatic knife gate valve and motor operated Rotary vane feeder and telescopic chutes shall be provided for disposal of the ash through bulk tankers. Under the second outlet, a pneumatic knife gate valve and motor operated rotary vane feeder and ash conditioner is provided to moisten the ash with water so as to discharge in the open trucks. A third outlet is provided with manually operated knife gate valve for emergency unloading. One 20m3 fly ash recirculation silo is provided near the bunker. Ash from the first two fields can be transferred to this silo by using switch valve provided in ash conveying piping. Ash stored in this

silo is circulated back to boiler to control the un-burnt carbon loss.

C6.5.0.0 SECONDARY STAGE ASH-HANDLING SYSTEM: Two numbers of pressure developing ash-conveying pumps of 15TPH capacity are provided to transport ash from fly ash silo to Cement plant ash silo with all piping, valves, interconnection arrangement, instrumentation etc. P.D. Pump located below fly ash silo #1 and #2 shall be both working in tandem.