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Boiler

TROMBAY THERMAL POWER STATION


PLANT LAYOUT

TROMBAY THERMAL POWER STATION


BOILER
Water and Steam circuit

TROMBAY THERMAL POWER STATION


H.
R.
M.S C.R.H H

Feed water from BFP DISH


RE HEATER CIRCUIT
NON DRAINABLE PORTION
DRAINABLE PORTION

TROMBAY THERMAL POWER STATION


SALIENT FEATURES OF 500 MW BOILER

With increase in demand of power in India, new power projects are being
constructed with higher capacity and advanced technology for the better
economy and reliability of operation. Compared to other lower capacity
Boilers supplied by BHEL, these 500 MW capacity boiler have
incorporated certain special technical features which are detailed in the
next slides.

TROMBAY THERMAL POWER STATION


UNIT 5 BOILER SPECIFICATIONS

Manufactured by - BHEL
1) Fuel Used - Coal/Oil/Gas
LSHS - Carbon - 84.07%, Hydrogen - 11.85%, Nitrogen - 0.16%, Sulpfur - 0.13%, Ash - 0.07%,
Oxygen - 3.72%, HHV(High heating value) - 10808 Kcal/Kg.
Coal - (Fixed carbon) FC-8.36% volatile matter - 31% Moisture - 8%, Ash - 25% Sulfur - 0.7%,
Ash fusion temperature - 1400 o C HHV - 5125 Kcal/Kg. Grindability - 52 HGI. Size or
coal to mill 20mm.
Gas - Natural gas, Sp Gr. - 0.6 at 0 o C HHV 105550 Kcal/NCum (Raw gas) 9433 Kcal/NCum for
methane rich gas supply pressure - 5 Kg/Cm2

2) Steam Pressure - Design - 204 Kg/Cm2 (g)


SH output - 178 Kg/Cm2(g)

3) Superheater -
Type Heating Surface M2
Stage 1 Pendant 3450
LTSH Horizontal 9250
Stage II Pendant Panel 1640
Pendant Platen 1890
Stage III Pendant Finishing 2200
Total 18430
Superheater Desuperheater -
Type - Spray
No. of stages - One
Medium of spray - Water

TROMBAY THERMAL POWER STATION


UNIT 5 BOILER SPECIFICATIONS
4) Reheater : Type - Radiant wall and pendant
Total HS (Heating Surface) - 7420 m2
Control 1) Coal - Burner tilt
2) Oil - GR & Burner tilt.

5) Economizer : Type - Bare tube


Total HS - 12840 M2
No. of blocks – Two

6) Furnace : Type - Fusion Welded


Width - 17653 mm
Depth - 15289 mm
EPRS - 7710 m2
Volume - 15520 m3
Fuel heat input - coal - 1232 Mcal/hr.

7) Air heater : Type - LJUNSTROM - Regenerative type Make BHEL


1)Steam coiled air heater - Two (Not present)
2)RAPH (Trisector) - Two

TROMBAY THERMAL POWER STATION


CONTROLLED CIRCULATION SYSTEM

This is achieved by three/four numbers of glandless pump and wet


motor installed in the down comer line after the suction manifold.
These pump motor assemblies have single suction and double
discharge introduction of these pumps in the boiler system have led
to the designing of a furnace with lesser diameter tubes and high
parameters operating characteristics.

TROMBAY THERMAL POWER STATION


ADVANTAGES OF THE CONTROLLED
CIRCULATION

Uniform drum cooling and heating. In controlled circulation boilers this is


possible because of arrangement of relief tubes inlets to the drum and
the internal baffles of the drum from both sides. The internal base plates
are arranged in such a way that it guides the steam water mixture from
the relief tubes along the whole circumference of the drum. The drum is
therefore uniformly heated and cooled.

TROMBAY THERMAL POWER STATION


NATURAL CIRCULATION SYSTEM

The arrangement of relief tubes and baffle plates is only on one side of the drum
and this imposes a constraint on uniform heating of drum. Similar arrangement of
relief as in controlled circulation boiler does not exist in natural circulation (NC)
boiler because in that case the relief required to be taken over the drum and fed
from both sides. This shall increase the pressure losses in the riser tubes and also
the hot static head requirement for start up. Since the available head in NC Boiler
is very less; efforts are always made to reduce the pressure loss and improve the
circulation. Second reason is to commence flow in the riser tubes immediately after
light up hot static head is kept as minimum as possible.

TROMBAY THERMAL POWER STATION


USE OF RIFLE TUBES FOR FURNACE
CONSTRUCTION

This is one of the extraordinary features of 500 MW capacity boilers. Because of


the excessive heat release in the burner zone of the furnace, the metal tubes
constituting the furnace at that zone are exposed to the maximum temperature.
This being a water-cooled furnace, the steam water mixture inside the tubes
should effectively carry the heat from the burner zone of the furnace. In this zone,
the tubes have an internally cut spiral like a rifle bore so that when water flows
through the tubes, due to hot static heat, it takes a screwed path and attains a
certain degree of spin by which the wetness of the tube is always maintained. This
prevents the tubes form departure from Nucleate boiling (DNB) under all operating
condition of the boiler and increases the circulation ratio.

TROMBAY THERMAL POWER STATION


OVER FIRE AIR SYSTEM FOR NOX
(OXIDES OF NITROGEN) CONTROL
In the 500 MW capacity boiler design, this aspect has been given due importance and
certain technical improvements have been incorporated. These are tilting tangential
firing and over fire air system. Tangential firing helps in keeping the temperature of the
furnace low so that NOX emission is reduced considerably.

In addition to the above the over fire air is provided which is used as combustion
process adjustment technically for keeping the furnace temperature low and thereby
low Nox formation. Each corner of the burner windbox is provided with two numbers of
separate over fire air compartments, kept one above the other and the over fire air is
admitted tangentially into the furnace. The over fire air nozzles has got tilting
arrangement and compartment flow control dampers for working in unison with the
tilting tangential type burner system for effective control of Nox formation.

OF2 OPENING STARTS AT 50% OPEN FULL AT 75% OF BOILER LOAD


BOILER LOAD (250MW) (375MW)

OF1 OPENING STARTS AT 75% OPEN FULL AT 100% OF BOILER LOAD


BOILER LOAD 3750MW) (500MW)

TROMBAY THERMAL POWER STATION


TROMBAY THERMAL POWER STATION
Damper Logic
 Lower Aux damper : Generally remains open 20%.

 Fuel air damper: AB,BC,CD,DE,EF


 Close: if boiler load>30% and elevation o/s.
 Open: Proportional to burner pressure if elevation i/s and boiler load>30%.
 Modulates: As furnace to WB delta P if boiler load <30% and elevation o/s.
 Open: Open to pre-determined value of 30% if SU i/s.

 Auxiliary air damper: A,B,C,D,E,F


 Close: After purging and associated elevation o/s. Control remains in PROG
mode.
 Modulates: On furnace to WB delta P if associated elevation is i/s.

 Auxiliary air damper AA:


 Close: 1) MFT not present.
2) AB elevation o/s.
3) Boiler load >30%.
 Modulates: Furnace to delta P if any of above condition are not satisfied.

TROMBAY THERMAL POWER STATION


AIR PRE-HEATER SYSTEM

As compared to trisector air pre-heater in 200 MW units, 500 MW units


have been incorporated with bisector and trisector air pre-heaters. This
has been done for optimum utilisation of space and also improved
system layout. This has resulted in the flexibility and efficient operation
and maintenance of the air pre-heaters and the boiler as a whole.

TROMBAY THERMAL POWER STATION


PRIMARY AIR SYSTEM

The primary air system delivers air to the mills for coal drying and
transportation of coal powder to furnace. The 500 MW units have two
stage axial flow primary fans as compared to radial fans in 200 MW
units. By introducing axial flow fans, the system efficiency has gone up
as the axial flow fans consistently high efficiency at all operating loads.

TROMBAY THERMAL POWER STATION


MILLING SYSTEM

In the 500 MW units bowl mills have been installed. These are
similar to the 200 MW mills except that 500 MW mills have vane
wheel surrounding the bowl and external lubrication unit. Introduction
of vane wheel has led to uniform distribution of primary air within the
mill and less rejects. These mills are also supplied with weld overlay
technology, which has increased the minimum wear life of grinding
parts to 6000 hrs.

TROMBAY THERMAL POWER STATION


ELECTROSTATIC PRECIPITATORS

Electro static precipitators are installed in the 500 MW units for


minimising the particulate emission from the stack flue gases. There
are four ESP passes for one unit of 500 MW and each is
independently operated. The emitting electrodes are charged at high
-ve voltage DC and the gas while crossing this charged path gets
ionised. The ionised ash particles of the gas are attracted towards
the collecting electrode, which is maintained at high +ve voltage. The
ash collects at the collecting electrode by rapping motor. The ash
falls into the hopper, which is evacuated by the ash handling system
and taken out as slurry.

TROMBAY THERMAL POWER STATION


TECHNICAL SPECIFICATION OF 500 MW BOILER

Sr.
Specification Parameter
No.

1 Manufacturer M/s BHEL (C.E. Design)

Balanced Draft, Dry bottom, Single


2 Type of Boiler
drum, Controlled Circulation.

3 Type of Firing Tangential firing

TROMBAY THERMAL POWER STATION


FURNACE SPECIFICATION

Sr.
Specification Parameter
No.
1 Wall Water Steam cooled
2 Bottom Dry
3 Tube arrangement Membrane
Explosion/Implosion
4 +/- 660
withstand capacity
Residence time for fuel
5 particles in the furnace. 3 second

Height from furnace bottom


6 ash hopper to 63.65 Mtr
furnace roof (M)
7 Depth (M)/Width (M) 15.28/15.04

TROMBAY THERMAL POWER STATION


DRUM SPECIFICATION

Sr
Specification Parameter
No
1 Material specification SA-299
2 Design pressure Kg/cm2 (ABS) 204.9
3 Design metal temp OC 366
4 Max operating pressure Kg/cm2 (ABS) 192.4
Max permissible temp differential
5 between any 50
two parts of the drum (oC).
6 Drum wt. with internals (tonnes) 237.00

TROMBAY THERMAL POWER STATION


DRUM DESCRIPTION

Connections at both ends to the chemical clean pipe work, and at three points along
its length to feed individual circulation pump suctions. Water will flow from the
pumps through two discharge pipes into the front leg of the water wall inlet headers
at the bottom of the furnace. Each discharge pipe is fitted with circulating pump
discharge stop/check valves, which are controlled via sequence equipment to open
and close as the pump is taken in and out of service. If, however all three pumps
are out of service, all of the valves will open to enable thermosyphonic circulation to
take place. Initiating any pump to restart will cause them all to close again then
continue with the in and out of service regime. Controls for the pumps are located in
the Control room and comprise a SEQUENCE pushbutton, ammeter and a
DUTY/STANDBY selector. Pump status is indicated on RUN/STOP lamps on the
Firemen's Aisle Panel.

TROMBAY THERMAL POWER STATION


DRUM INTERNALS

TROMBAY THERMAL POWER STATION


DRUM INTERNALS

The saturated steam/water mixture enters the steam drum on both sides
behind a watertight inner plate baffle which directs the mixture around the
inside surface of the drum to provide uniform heating of the drum shell.
This eliminates thermal stresses from temperature differences through the
thick wall of the drum, between the submerged and unsubmerged portions.
Having travelled around this baffle the mixture enters two rows of steam
enter the outer edge of the separator where it is separated from the steam.
Nearly dried steam leaves the separators and passes through four rows of
corrugated plate baskets where by low velocity surface contact the
remaining moisture is removed.

TROMBAY THERMAL POWER STATION


Safety valves
Safety valves on the superheater main steam lines set below the low set drum safety
valve, provide another means of protection by assuring adequate flow through the
superheater if the steam demand should suddenly and unexpectedly drop Reheater
safely valves, located on the hot and cold reheat piping serve to protect the reheater if
steam flow through the reheater is suddenly interrupted.

A power control valve (Electro magnetic relief vlv) on the superheater main steam line
set below the low set

superheater safety valve is provided as a working valve to given an initial indication of


excessive steam pressure. This valve is equipped with a shut off valve to permit
isolation for maintenance. The relieving capacity of the Power Control Valve is not
included in the total relieving capacity of the safety valves required by the Boiler Code.
During all start-ups, care must be taken not to overheat the superheater or reheater
elements. The firing rate must be controlled to keep the furnace exit gas temperature
from exceeding 5400C. A thermocouple probe normally located the upper furnace
sidewall should be used to measure the furnace exit gas temperatures.
TROMBAY THERMAL POWER STATION
DESUPERHEATERS

Desuperheaters are provided in the superheater-connecting link and the


reheater inlet leads to permit reduction of steam temperature when
necessary and to maintain the temperatures at design values within the
limits of the nozzle capacity. Temperature reduction is accomplished by
spraying water into the path of the steam through a nozzle at the entering
end of the desuperheater. The spray water comes from the boiler
feedwater system. It is essential that the spray water be chemically pure
and free of suspended and dissolved solids, containing only approved
volatile organic treatment material, in order reheater and carry-over of
solids to the turbine.

TROMBAY THERMAL POWER STATION


DESUPERHEATERS

During start up of the unit, if desuperheating is used to match the outlet steam
temperature to the turbine metal temperatures, care must be exercised so as not
to spray down below a minimum of 100 C above the saturation temperature at the
existing operating pressure. Desuperheating spray is not particularly effective at
the low steam flows of start up. Spray water may not be completely evaporated but
be carried through the heat absorbing sections to the turbine where it can be the
source of considerable damage. During start up alternate methods of steam
temperature control should be considered. The location of the desuperheaters
helps to ensure against water carry - over to the turbine. It also eliminates the
necessity for high temperature resisting materials in the desuperheater
construction.

TROMBAY THERMAL POWER STATION


DESUPERHEATERS
Super heater & Reheater temp Control
SUPER HEATER ATTEMPRATOR

Type : Spray.
Spray water taken from U:5 BFP Header
U6:BFP Kicker stage.
Stage : One (Unit 5)/Two (Unit 6)
Position in steam circuit : Between LT pendants
and SH panels. (inlet to divisional panel)
Specification of material. : SA335 P12
Spray tube material : SA-213 T11

REHEATER ATTEMPERATOR

TYPE : Spray.
Spray water taken from U:5 BFP Header.
U6:BFP 2nd stage.
No. of stages of attemperator : One
Position in the steam circuit : Before RH Radiant wall
Specification of the Material : SA-106 Gr-B
Spray nozzle Material : SA-213T & SS Tips
TROMBAY THERMAL POWER STATION
HP & LP BYPASS SYSTEM

The function of HP bypass is to ensure that the maximum permissible pressure levels
between the turbine and the boiler are not exceeded and that no abrupt pressure surges
occur/develop during variable pressure operation of the unit.

The function of LP bypass is to control the pressure in the reheat system under certain
operating conditions like.
a) Start up & shutdown of turbine.
b) On partial load below the boiler minimum load.
c) In occurrence of fault like load rejection, unit trip out etc.

The HP-LP bypass system permits operators to increase boiler firing rate, boiler
steam flow and thus boiler outlet temperature to a higher level thereby providing more
suitable restart conditions for a hot turbine, within shortest possible time.

TROMBAY THERMAL POWER STATION


HP & LP BYPASS SYSTEM

It should be noted that high boiler steam temperatures are desired only if the turbine is hot
(say above 400o C). The operation of HP-LP bypass may not be desirable for cold start-
ups.

During the load rejection which may occur due to electrical disturbances, turbine
governing system rapidly closes the steam admission valves. In such event, HP-LP
bypass has a capability of bypassing a large fraction of steam generated in boiler. This
can reduce the impact on boiler and the need to trip the fire.

The application of HP-LP bypass system reduces the solid particle erosion (also called as
silica purging during start up). Also, continuous cooling steam flow through superheater
and reheater tubes reduces the formation of oxide layer on the inner surface of the tubes.

TROMBAY THERMAL POWER STATION


HP & LP BYPASS SYSTEM

The HP bypass is designed for 60% capacity having maximum steam flow of 270
Kg/second with -
1) upstream steam condition = 164.3 bar, 538 oC
2) downstream steam conditions = 27.3 bar, 337.8 oC
injection water conditions = 188 bar, 245/118 oC (max/min).

LP bypass has capacity corresponding to HP bypass max - steam flow i.e. 384 Kg/s with
1) upstream steam conditions = 41 bar, 538 o C.
2) downstream (before dumping device) steam conditions = 24.6 bar, 538oC
spray water quantity = 15306 Kg/s at CEP discharge pressure.

TROMBAY THERMAL POWER STATION


HP & LP BYPASS SYSTEM

The HP bypass station is located at 29 M elevation above the TG building


arranged between main steam and cold reheat streamline, bypassing HP
turbine. In unit it consist of two (2) electrically operated steam converting
valves and electrical controllers having normal and high speed motor drives.

Operation time of motor drives


1) Normal speed - 45 sec.
2) High speed (on protection) - 5.6 sec.

Unit 6 HP bypass is hydraulically operated.

TROMBAY THERMAL POWER STATION


HP & LP BYPASS SYSTEM

The H.P. Bypass system in co-ordination with LP-Bypass enables boiler operation and
loading independent of the turbine. This allows quick raising of steam parameters to a level
acceptable to turbine for rolling during start up. Steam is Bypassed from main steam line to
cold reheat line through HP-Bypass and from hot reheat line to condenser through LP
Bypass. The HP Bypass valve can handle a maximum of 60% of the full load turbine steam
flow.
The possible phases of operation of HP Bypass station can broadly be classified as follows:
 Boiler start-up with TG set on Barring Gear.
 Raising of steam parameters to a level acceptable for T.G. rolling, at a relatively
faster rate than otherwise is possible.
 Turbine loading while steam flow gets transferred to the turbine.
 Parallel operation with turbine on load rejection.
 Allowing boiler operation following turbine trip-out provided boiler load is less than
60 %.
 Preventing safety valves opening at raised steam pressures.

TROMBAY THERMAL POWER STATION


HP & LP BYPASS SYSTEM

OVERRIDES AND INTERLOCKS


1. HP Bypass valve PCV opening less than 2 % will automatically close the spray water
pressure control valve (BD valve).
2. It opening of either of the Bypass valves PCV1 or PCV2 is above 2 %, the control of
spray temperature control valves TCV1 & TCV 2 shall be changed to ‘AUTO’ mode
irrespective of their initial conditions.
3. If PCV position drops 2 % open, it will receive an auto close command to ensure
positive shut-off.
4. If the steam temperature downstream of the PCV becomes 380 deg C, the closing
signal for these valves are initiated accompanied with an alarm. In this case, the
PCV controller will transfer itself from AUTO to MANUAL.
5. PCV closes on MFT
6. If spray water pressure less than 12 bar PCV will close.

The following will activate the ‘Fast Opening’ Signal :-


7. Generator breaker open.
8. Turbine load shedding relay operated
9. Pressure controller deviation more (+) 10 %.
10. Depressing of the ‘FAST OPEN’ push button
TROMBAY THERMAL POWER STATION
LP BYPASS SYSTEM

Low pressure Bypass system enables to establish an alternative pass for dumping the
steam from reheater outlet directly into condenser at suitable steam parameters. The
controls for LP-BYPASS system are essentially a combination of electrical and hydraulic
system. Electro-hydraulic converter provides the necessary link between hydraulic
actuators and the electrical system. The control of LP Bypass system is hooked up by the
same control which is used for turbine governing system.

The LP Bypass valves are two in number. the LP Bypass stop and control valves are
combined in a common body. The double shut-off arrangement separates the reheater from
the condenser during normal operation. In addition to these, two steam pressure control
valves, four injection water valves are provided for desuperheating purpose. This injection
water is taken from the discharge of the condensate extraction pumps.

TROMBAY THERMAL POWER STATION


LP BYPASS SYSTEM

TROMBAY THERMAL POWER STATION


LP BYPASS SYSTEM

LP BYPASS CONTROL SYSTEM

CONDENSER TEMPERATURE PROTECTION

The purpose of the condenser temperature protection is to protect the condenser from
excessively high steam inlet temperatures. Thermocouples output temperature signals are
passed to an interlock circuit which locks out the LP turbine Bypass station. Protective Closing
Of Bypass System (Condenser Back-Up Protection)

The LP Bypass valves will close automatically under the following normal conditions to prevent
damage to the condenser.

1. If the steam pressure downstream of LP Bypass valves is greater than 19 kg/cm2.


2. Condenser vacuum is low (0.4 kg/cm2 abs)
3. Spray water pressure is low (10 kg/cm2
4. Condenser wall temperature is high (90OC)- Only alarm.

TROMBAY THERMAL POWER STATION


STEAM GENERATOR WATER CIRCULATING
PUMP CONSTRUCTION

Each Boiler Water Circulation pump consists of a single stage


centrifugal pump on wet stator induction motor mounted within a
common pressure vessel. The vessel consists of three main parts a
pump casing, motor housing and motor covers. The motor is
suspended beneath pump casing and is filled with boiler water at full
system pressure. No seal exists between the pump and motor, but
provision is made to thermally isolate the pump from the motor in the
following respect:

Thermal Conduction: To minimize heat conduction, a simple


restriction in the form of thermal neck is provided.

TROMBAY THERMAL POWER STATION


STEAM GENERATOR WATER CIRCULATING
PUMP CONSTRUCTION
Hot Water Diffusion:
To minimize diffusion of boiler water, a narrow annulus surrounds the rotor shaft,
between the hot and cold regions. A baffle ring restricts solids entering the
annulus.
Motor Cooling: The motor cavity is maintained at a low temperature by a heat
exchanger and a closed loop water circulation system, thus extracting the heat
conducted form the pump.
In addition, this water circulates through the stator and rotor bearings extracting
the heat generated in the windings and also provide bearing lubrication. An
internal filter is incorporated in the circulation system. In emergency conditions, if
low-pressure coolant to the heat exchanger fails, or is inadequate to cope with
heat flow from pump case, a cold purge can be applied to the bottom of the motor
to limit the temperature rise.

TROMBAY THERMAL POWER STATION


STEAM GENERATOR WATER CIRCULATING
PUMP CONSTRUCTION

TROMBAY THERMAL POWER STATION


Pump:
The pump comprises a single suction and dual discharge branch casing. The case is welded
into the boiler system pipe work at the suction and discharge branches with the suction upper
most. Within the pump cavity rotates a key driven, fully shrouded, mixed flow type impeller,
mounted on the end of the extended motor shaft. Renewable wear rings are fitted to both the
impeller and pump case. The impeller wear ring is the harder component to prevent galling.

Motor:
The motor is a squirrel cage, wet stator, induction motor, the stator, wound with a special
watertight insulated cable. The phase joints and lead connections are also moulded in an
insulated material. The motor is joined to the pump casing by a pressure tight flange joint and
a motor cover completes the pressure tight shell. The motor shell contains all the moving
parts, except for the impeller. Below the impeller is situated an integral heat baffle which
reduces the heat flow, a combination of convection and conduction, down the unit. A baffle
wear ring-cum sleeve above the baffle forms a labyrinth with the underside of the impeller to
limit sediment penetration into the motor. Should foreign matter manage to pass the labyrinth
device into the motor enclosure, a filter located at the base of the cover end bearing housing
strains it out.

TROMBAY THERMAL POWER STATION


AUXILIARY COOLING CIRCUIT
The motor is provided with its own auxiliary cooling circuit, which besides cooling the motor
lubricates the bearings. The water is continuously circulated through the bearings, motor
windings and the external heat exchanger, (cooler), by an auxiliary impeller (thrust disc) at the
thrust bearing end of the motor shaft. When the motor is stationary, thermo-syphonic
circulation takes place to remove conducted heat from the pump end of the motor.

BEARINGS
The motor rotor shaft is supported by water lubricated tilting pad type radial and thrust
bearings mounted on the stator shell, thus making the motor internals into a separated
construction independent of the motor pressure vessel.

INTER FILTER
A stainless steel woven wire strainer, fitted at the base of the reverse thrust plate, filters the
liquid in the motor before it is circulated through the bearings after passing through the heat
exchanger (cooler). The filter should be cleaned at normal maintenance periods, removing
any accumulation of foreign matter in the motor cover.

TROMBAY THERMAL POWER STATION


HEAT EXCHANGER

A heat exchanger (cooler) is fitted to dissipate the heat generated by the motor
winding. Brackets are provided on the motor case to mount the heat exchanger.
High-pressure outlet and inlet-raised facings are situated bottom and top of the
motor case respectively for connection to high-pressure heat exchanger/motor
case stub pipes. Inter - connecting pipe work is short and direct with the heat
exchanger mounted as high as possible to promote good thermo syphonic
circulation when the unit is on hot standby.

TROMBAY THERMAL POWER STATION


STEAM GENERATOR WATER CIRCULATING
PUMP SPECIFICATIONS

Make HAYWARD TYLER LIMITED


Type Single suction double discharge
Design Pressure 207.55 Kg/cm2
Design temp 366.2oC
Suction Pressure 193.27 Kg/cm2
Suction temp. 348.9oC
Specific gravity at pump Suction 0.5993
Qty. pumped 47994.2 lit/min
Differerential HEAD 28.65 M (94.00 ft)
Differential Pressure 1.708 Kg/cm2
Minimum NPSH required above 16.15 M (53 ft)
Vapour Pressure
Pump efficiency 84% Hot duty

TROMBAY THERMAL POWER STATION


STEAM GENERATOR WATER CIRCULATING
Motor SPECIFICATIONS

Type Wet Stator -Squirrel Cage induction motor

Output 400 H.P.

Service factor 1.0

Motor case design temp 343.34OC

Motor efficiency 86%(Hot Duty), 88% ( Cold Duty)

K.W. Input 187 (Hot duty),302(Cold duty)

Power factor 0.7 (Hot duty), 0.805(Cold duty)

Overall efficiency 72.2% (Hot duty), 74.3%(Cold Duty)

Full load speed 1450 rpm

TROMBAY THERMAL POWER STATION


FILL AND PURGE OF CCW PUMP

ACW dish P/p

Raw wtr p/p

ACW O/H Tank

Fill and purge supply is from


1) BFP Dish, 2) CEP dish, 3) HMP

TROMBAY THERMAL POWER STATION


EMERGENCY COOLING WATER SUPPLY

V1
Normal ACW pumps disch.
Pr. Sw.

V3 SGWCP
Raw Water HEAT
EXCHANGER

V5
Emergency supply from
ACW overhead tank Maint. Door

V2
Normal return line
to ACW system

V4
To waste

TROMBAY THERMAL POWER STATION


TATA POWER TROMBAY

Air and Flue Gas System

TROMBAY THERMAL POWER STATION


DRAFT SYSTEM

TROMBAY THERMAL POWER STATION


What is the difference between
Fans, Blowers & Compressor ?

TROMBAY THERMAL POWER STATION


FANS

AXIAL FANS RADIAL FANS

TROMBAY THERMAL POWER STATION


Types of Fans

Axial Fans

TROMBAY THERMAL POWER STATION


RADIAL FANS

Control Dampers

Impeller

Rotor

Bearings

Casing

TROMBAY THERMAL POWER STATION


EQUIPMENTS IN AIR PATH

TROMBAY THERMAL POWER STATION


EQUIPMENT IN FLUE GAS PATH

TROMBAY THERMAL POWER STATION


A B ID FAN C D

ESP

FD
PA 5A A FAN
B PA 5B

RAPH-5A RAPH-5B

GR 5A GR 5B
TROMBAY THERMAL POWER STATION
RAPH

TROMBAY THERMAL POWER STATION


RAPH

TROMBAY THERMAL POWER STATION


RAPH

TROMBAY THERMAL POWER STATION


SECONDARY AIR CIRCUIT
350 DEG
S 35 degR
C SD SD
A
AIR FROM ATMOS SD- 2 A
P
P 8.1 10.1
H
H 8.2 10.2
B
B
FD B

SD-6

FROM GRF - B

-10 mm

• FURNACE
FROM GRF - A

SD-5

S SD R
SD-1
C
7.1 A SD
A P 9.1
P 7.2 H 9.2
AIR FROM ATMOS
H A
FD A A 35 DEG C 350 DEG

IGNITOR AIR
FAN

TROMBAY THERMAL POWER STATION


Flue gas system
ESP GD GD-19
GD- GD- GD-7 GD-15 GD-23
R 3.1 11A
5A ID A
3.2 11B
A
GD 29.1 29.2
P
H 20
8 12A 16 24
A 5B ID B GD
12B
27.1
27.2

Stack
GD 30.1 30.2 GD
GD 5.1 5.2
28.1
28.2
9
13A
R 5C 13B 17 ID C 25
A 21
P GD 31.1 31.2
GD
H GD-
4.1 14A
5D ID D
B 4.2 14B
GD- GD-10 GD-18 GD-26
GD-22

TROMBAY THERMAL POWER STATION


FD FANS

TROMBAY THERMAL POWER STATION


FD Fans LO System
 Control Oil  Fan Brg.  Motor Brg.
 12 Bar Norm  2.5 Bar Norm  2.5 Bar Norm
 8.0 Bar Alarm  0.8 Bar Alarm  0.8 Bar Alarm
 6.5 Bar Trip  0.5 Bar Trip  0.5 Bar Trip
ACCM

Filter A
FS

Cooler A

Cooler B

Filter B

TROMBAY THERMAL POWER STATION


WIND BOX
OF2

OF1

AA
Scanners Ignitors
A

AB

BC

CD

DE

EF

FG

GH

HH

TROMBAY THERMAL POWER STATION


PA FANS

TROMBAY THERMAL POWER STATION


PA Fans LO System

 Control Oil  Fan Brg.  Motor Brg.


 12 Bar Norm  2.5 Bar Norm  2.5 Bar Norm
 8.0 Bar Alarm  0.8 Bar Alarm  0.8 Bar Alarm
 6.5 Bar Trip  0.5 Bar Trip  0.5 Bar Trip
ACCM

Filter A
FS

Cooler A

Cooler B

Filter B

TROMBAY THERMAL POWER STATION


ID FANS

TROMBAY THERMAL POWER STATION


ID Fans LO System

 Fan Brg.  Motor Brg.


 2.5 Bar Norm  2.5 Bar Norm
 0.8 Bar Alarm  0.8 Bar Alarm
 0.5 Bar Trip  0.5 Bar Trip
ACCM

Filter A

Cooler A

Cooler B

Filter B

TROMBAY THERMAL POWER STATION


GR FANS

TROMBAY THERMAL POWER STATION


TROMBAY THERMAL POWER STATION
Igniter Air Fans

To Igniters Windbox

Auto changeover
Damper

Igniters Air Fan 5A Igniters Air Fan 5B

From FD fan Interconnection Damper


TROMBAY THERMAL POWER STATION
Scanner Air Fans

To Scanners To Scanners

Auto changeover
Damper

Scanner Air Scanner Air


Fan 5A Fan 5B

Suction From Atmosphere

From Igniter air fan discharge


TROMBAY THERMAL POWER STATION
SECONDARY AIR CIRCUIT
350 DEG
S 35 degR
C SD SD
A
AIR FROM ATMOS SD- 2 A
P
P 8.1 10.1
H
H 8.2 10.2
B
B
FD B

SD-6

FROM GRF - B

-10 mm

• FURNACE
FROM GRF - A

SD-5

S SD R
SD-1
C
7.1 A SD
A P 9.1
P 7.2 H 9.2
AIR FROM ATMOS
H A
FD A A 35 DEG C 350 DEG

IGNITOR AIR
FAN

TROMBAY THERMAL POWER STATION


TATA POWER TROMBAY

Stotiometric Air & Excess Air

• Air is required for combustion process


which is supplied by 2 No. of FD Fans.
• Flue gases generated by combustion
process are removed by 4 No. of ID fans.
• Excess air is maintain for complete
combustion.

TROMBAY THERMAL POWER STATION


TROMBAY THERMAL POWER STATION
What is an ESP???

TROMBAY THERMAL POWER STATION


Principle behind ESP


TROMBAY THERMAL POWER STATION
TROMBAY THERMAL POWER STATION
BOILER FUEL SYSTEM

TROMBAY THERMAL POWER STATION


TANGENTIAL FIRING

2 3

1 4
4
4

TROMBAY THERMAL POWER STATION


BOILER SPECIFICATION

Unit 5: (100% MCR) Unit 6: (100% MCR)

• Drum pressure - 191 bar • Drum pressure - 184 bar

• Steam flow - 423 Kg/Sec


• Steam flow - 446 Kg/Sec

• Main steam Temp- 541 ºC • Main steam Temp- 541 ºC

• Reheat Temp • Reheat Temp - 568 ºC


- 541 ºC

TROMBAY THERMAL POWER STATION


BOILER FUEL SYSTEM

TROMBAY THERMAL POWER STATION


BOILER FUEL SYSTEM

TROMBAY THERMAL POWER STATION


FUEL OIL TANK FARM

TROMBAY THERMAL POWER STATION


IGNITION OIL PUMPS

TROMBAY THERMAL POWER STATION


LC OIL PUMPS

TROMBAY THERMAL POWER STATION


TROMBAY THERMAL POWER STATION
BOILER FUEL OIL SYSTEM

TROMBAY THERMAL POWER STATION


Ignition Oil CPRV

TROMBAY THERMAL POWER STATION


TROMBAY THERMAL POWER STATION
IGNITOR AIR AND SCANNER AIR
SYSTEM
• Ignitor Air system provides combustion air
to Ignitors
• Scanner air system is used for providing
cooling air for Flame Scanners
• Secondary air system should be
established prior to taking Ignitor air
system and Scanner air system in service

TROMBAY THERMAL POWER STATION


Unit 5

LC trip
Valve LC Oil
Control
V/V
TROMBAY THERMAL POWER STATION
TROMBAY THERMAL POWER STATION
TROMBAY THERMAL POWER STATION
TROMBAY THERMAL POWER STATION
Coal Mills


TROMBAY THERMAL POWER STATION
Coal Mills and Coal Feeders


TROMBAY THERMAL POWER STATION
LUBRICATION SYSTEM OF COAL
MILL


TROMBAY THERMAL POWER STATION
TROMBAY THERMAL POWER STATION
SEAL AIR SYSTEM


TROMBAY THERMAL POWER STATION
BOILER LIGHT UP

TROMBAY THERMAL POWER STATION


BOILER LIGHT UP

TROMBAY THERMAL POWER STATION


BOILER TRIP

TROMBAY THERMAL POWER STATION


BOILER TRIP

TROMBAY THERMAL POWER STATION


TROMBAY THERMAL POWER STATION

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