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JADEJA
& TECCHNOLOGY,AHMEDABAD.
CONTENTS
1) INTRODUCTION OF BOILER 2) AIR PREHEATER 3) ASH HANDLING PLANT 4) FUEL OIL SYSTEM 5) COAL MILL 6) ID, FD & PA FAN 7) COOLING TOWER 8) FIRE FIGHTING SYSTEM 9) COAL HANDLING PLANT 10) TURBINE 11) SEA WATER SYSTEM 12) DM PLANT 13) TDBFP & MDBFP SYSTEM
10%
26%
59%
Coal
Hydro
Gas
Nuclear
Others
INTRODUCTION OF BOILER
Boiler
Manufacturer
1.
4. High Strength material application 5. Economic and safe low load and startup system by circulating pump
3. Proven and economic heating surface arrangement 6. Burner tilting for reheater steam temperature control 7. Low Nox Tangential Burner
CRITICAL CONDITION Definition CRITICAL is a thermodynamic expression describing the state of a substance beyond which there is no clear distinction between the liquid and gaseous phase. The critical pressure & temperature for water are Pressure = 225.56 Kg / cm2 Temperature = 374.15 C
TEMP
540C
568C
SUPER CRITICAL BOILER CYCLE WITH SH, RH & Regeneration of ADANI 5 x 660 MW
Steam flow Steam temp Steam Pres RH pre RH Temp Feed water Temp :2225 T/Hr : 540 c : 256 kg/cm2 : 51.6 Kg/cm2 : 568c : 291c
0
ENTROPY
SH
RISERS
W/WALL
W/WALL
BFP
HTR
ECO
STORAGE TK
- Horizontal - SIDE (SPIRAL & VERT.) - Pendant - FRONT & REAR (SPIRAL & VERT.)
- FUR. ROOF
- B/P. ROOF - B/P. FRONT & REAR DIVISION - B/P SDIDE (R.L) - EXT. FLOOR & SIDE(R.L)
- PLATEN
- FINAL
LT R/H
HT R/H (Coil)
B Y O T H ER
- PLATEN
- FINAL
B Y O T H ER D S B Y O T H ER D S
HP TB
DS
IP TB
B Y O T H ER
LP TB
GENERATO R
BWR P
B Y O T H ER
CONDENSO R
CW in CW
WALL OF BOILER
spiral wall
LTSH COILS
ECONOMISER COILS
AIR PREHEATER
The Air Preheater absorbs waste heat from flue gas, and then transfers this heat to incoming cold air by means of continuously rotating heat transfer elements of specially formed metal plates.
2. Recuperative
1) Regenerative APH are also known as storage type heat exchangers, have an energy storage medium, called the matrix, which is alternately exposed to the hot and cold fluids. When the hot flue gases flow through the matrix in the first half of the cycle, the matrix is heated and the gas is cooled. In the next half of the cycle when air flows through the matrix, air gets heated and the matrix is cooled. The cycle repeats itself.
2) Recuperative APH, heat is directly transferred from the hot gases to the air across the heat exchanging surface. They are commonly tubular, although some plate types are still in use. Tubular units are essentially counter-flow shell-and-tube heat exchangers in which the hot gases flow inside the vertical straight tubes and air flows outside. Baffles are provided to maximize air contact with the hot tubes.
PA
SA
SA
PA
FG
FG
Chimney
1 General arrangement of Air Preheater. 2. Rotor assembly 3. Rotor radial seal assembly 4. Rotor module assembly. 5. Rotor post and trunnion assembly. 6. Hot end and hot intermediate layer elements and element baskets. 7. Cold end element and element basket. 8. Rotor housing assembly. 9. Hot end primary center section assembly. 10. Cold end primary center section assembly. 11. Hot end connecting plate assembly. 12. Cold end connecting plate assembly. 13. Guide bearing assembly. 14. Support bearing assembly. 15. Static seal assembly (hot end and cold end). 16. Axial and by-pass seal assembly. 17. Rotor drive assembly. 18. Sector plate assembly (hot end and cold end). 19. Air seal pipe, observation port and vapor or dust proof light assembly. 20. Stationary water washing device (hot end and cold end) and fire fighting device 21. Special tools and spare parts.
Support bearing/ guide bearing lubricating oil pumps RUNNING and lubricating oil coolers are CHARGED. Bearing temperature NOT HIGH (less than 60oC) Electrical supply to APH motor is AVAILABLE. Local operation - Isolating valves of air motors are 'OPEN' and bypass valves of air motor solenoids are 'CLOSED'. 'Air motors' lubricating oil level ADEQUATE Service air pressure is ADEQUATE (> 5 Kg/cm2)
INTRODUCTION
Ash is a waste product of coal and solid fuel combustion. It contains many harmful elements which can contaminate sub-soil water of water is allowed to seep through ash into soil. Further, percentage of ash present in Indian coals is large. As a result, disposal of ash also uses up considerable area of land, which could otherwise be put to better use. Therefore, it is desirable to put ash to use so that the problem of providing land area for its disposal is solved. All out efforts are being made for finding uses of ash. Presently, only negligible amount of total ash produced in the country is put to use. However, ash being a good landfill material can be used in bulk in projects like highway construction. This is being done to as large an extent as possible. Pollution Control Regulations have made it mandatory to dispose ash in dry form only so that harmful elements do not find ingress in the subsoil water
FLY ASH HANDLING SYSTEM The fly ash handling plant will remove fly ash from Electro static precipitator (ESP) hoppers and transport it to the storage silos. This will be carried out by pressure pneumatic conveying system on a continuous, cyclic basis. One boiler unit will be provided with one pneumatic conveying system for handling fly ash collected in the ESP hopper. The system layout and the conveying pipeline configuration will be designed and constructed to enable evacuation of fly ash at maximum design rate. The output of the system will be not less than 200% of actual ash amount. The capacity of each set of system will be 30t/h.
ELECTROSTATIC PRECIPATATOR
It is a device which captures the dust particles from the flue gas thereby reducing the chimney emission.
Precipitators function by electrostatically charging the dust particles in the gas stream. The charged particles are then attracted to and deposited on plates or other collection devices. When enough dust has accumulated, the collectors are shaken to dislodge the dust, causing it to fall with the force of gravity to hoppers below. The dust is then removed by a conveyor system for disposal or recycling
LOCATION OF ESP
ECO
APH
ESP
CHIMNEY
Dust layer
1
3.Migration
5.Rapping 4 4.dust collection 5
Rapping mechanism
ESP
Collector plate Emitter coil
Flue gas
Treatment Time
Seconds 15
Description Total Number of Electrode Total numbers of Rappers per Unit Total Nos. of Transformer Rectifier Unit Capacity of Transformer Rectifier Unit Each Total No. of Dust Hoppers
There are two types of fuels are used for ignition in combustion chamber. 1) Heavy fuel oil(HFO). 2) Light diesel oil (LDO).
BOILER LIGHT-UP
"HFO" inlet and re-circulation flow start increasing "HFO header pressure very low" alarms clear off. HFO temperature in the HFO header increases up to 110 oC. OPEN Ignitor oil trip valve Ignitor oil trip valve opens up. Ignitor air fans A & B, start automatically. Ignitor oil and ignitor air pressure increase up to 23 Kg/cm2 and 400 mm wcl, respectively. "Ignitor air to furnace DP low & "Ignitor oil/Atomising air pressure low" & "Ignitor oil/HFO trip valve closed" alarms clear off. CHECK these parameters are within their operation limits. Drum level normal (-60 mm. to 0, preferably on lower side).
BOILER LIGHT-UP
HFO temp. 110 oC . (Min. temp. required is 95 oC). HFO atomising steam pressure 8.75 Kg/cm2 Light oil pressure more than 15 Kg/cm2. Ignitor atomising air pressure 5 to 7 Kg/cm2 Wind box pressure between 35 to 40 mm wcl ADJUST HFO header pressure set point to 50%(13 Kg/cm2) and TRANSFER its control to auto. HFO pressure controller transfers to auto and modulates to maintain the set HFO header pressure. CLOSE heavy fuel oil re-circulation valve. HFO re-circulation flow valve closes. HFO re-circulation flow comes to minimum position
COAL MILL
INTODUCTION
As coal powder is the most important fuel in the power plant, the plant owners need coal mill or coal pulverizer to grind the coal to micro powders. Raw coal (crushed) is fed through hopper at the top of the coal pulverizer and falls down to grinder ring to be pressed, crushed and milled into pieces by rollers. After the first crush, coal powder fall into the second and third layer. The pumping of the high-pressure centrifugal blower put the outside air into the coal mill. The coarse coal powder will be brought into the classifier.
TYPES OF MILLS
1) Ball mill 2) Ball and Race mill 3) Impact or Hammer mill 4) Bowl mill
COAL MILL
MILL LOCATION
PA-A FD-A
MILL
A
134C
351C
B
1165C
ESP I/L X OVER DUCT WIND BOX SA X-OVER DUCT
ESP PASS A
129C
CHIMNEY
SA FG
136C
C D E
320C
ESP PASS B
ID-A ID-B
SCAPH
FURNACE
SCAPH
324C
ESP PASS C
WIND BOX
SA FG PA APH
ESP PASS D
F
27C
COLD SA HOT SA
COLD PA HOT PA
PA-B
FD-B
FLUE GAS
126C
APH PA
Milling System
PRE START CHECKS (Typical: Raymond Bowl Mill) Local Ensure R.C. Bunker level satisfactory. R.C. feeder and mill properly boxed up and no maintenance staff working. Gear box oil level normal. lubricating oil coolers charged. Pulveriser START PERMIT is AVAILABLE. (Boiler total airflow is < 40% and all burners are HORIZONTAL). Alternatively, if anyone coal feeder is proven then start permit will come from the proven feeder. Tramp iron gate open. Cold air gate 100 % open. Hot air gate closed. Mill outlet valve open. Seal air valve 100 % open. "No unsuccessful start" permissive for pulveriser is ON. Mill fire fighting system ready.
Milling System
PRE START CHECKS (Typical: Raymond Bowl Mill) UCB Ensure no PTW pending. Ensure at least one P.A. fan and a seal air fan is in service. Check the header pressure for both primary and seal air is normal. Check that mill ignition energy is O.K. (Minimum 3 out of 4 gun nozzle valves in adjacent elevation are open and elevation oil flow is more than 30% OR adjacent feeder speed is more than 50% and boiler load is more than 30%. Check that mill start permissive as per FSSS are satisfied Ensure E.P. zones have been charged (for first mill). Get the electrical supply for the mill. Inform the local operator to be near mill for start up. Start the mill
Milling System
POST START CHECKS Local -Check there is no abnormal sound from mill. Check return oil flow from upper bearing is satisfactory. Check all the rollers are rotating and the rate of reject is normal (after the mill is loaded). U.C.B.-Check mill starting time and current. Ensure that they are normal. Open hot air gate. Warm up the mill. Start the RC feeder and load the mill gradually. Keep the air flow through mill - 54 T/hr. Keep watch on mill differential to avoid mill choking. Maintain mill outlet temperature between 75C to 80C. As the pressure, temperature of main steam shoots up with coal firing proper check should be kept on these parameters. (Especially for first mill).
Milling System
MILL SHUTDOWN PROCEDURE TRANSFER mill feeder and fuel master controller to manual. Fuel master and feeder control transfer to manual. REDUCE feeder speed to minimum, gradually. Coal flow to mill starts coming down. Other running feeders start loading up, to maintain boiler loading, if on auto. STOP the mill feeder. Hot air gate closes with a time delay of 30 sec approx. Mill current and differential pressure start reducing as the mill becomes empty, gradually. EVACUATE the mill reject chamber locally and STOP the mill. Mill temperature comes down to less than 500C. Mill CAD goes to <5% open Airflow to furnace drops slightly.
Coal Pulverisers
Description Type of Design & Construction Unit Value Medium Speed Mill
Number (Each Unit) Capacity of each pulveriser for the design coal Min. load of Pulverisers
Mill Speed Driver Speed Rated Power Avg. life of Rollers/Grind Roll & Bottom Race Liners before Replacement
Nos. TPH
% Rpm Rpm Kw Hrs.
6 70
25 33 982 900 12000
FURNACE
CHIMNEY
MILLS
ID FAN A
ID FAN B
The outlet guides are fixed in between the case of the diffuser and the casing. These guide vanes serve to direct flow axially and to stabilize the draft-flow caused in the impeller. These outlet blades are removable type from outside. During operation of the fan itself These blades can be replaced one by one. Periodically the outlet blades can be removed one at a time to find out the extent of wear on the blade.
The centrifugal and setting forces of the blades are taken up by blade bearing. The blade shaft is placed in combined radial and axial antifriction bearing which are sealed off to the outside The rotor is accommodated in cylindrical roller bearing and an inclined ball bearing at the drive side absorbs the axial thrust. Lubrication and cooling of these bearing is assured by a combined oil level and circulating lubrication system.
The special feature of the fan is that it is provided with inlet guide vane control with a positive and precise link mechanism. Fan can develop high pressures at low and medium volumes and can handle hot air laden with dust particles.
Fans
Description
Fan Model Rated Power of Motor Rotational Speed of Fan Volume flow of fan inlet Temperature of fan inlet Fan total pressure Total efficiency External Diameter of Blade Diameter of Impeller Blade No. of Each Grade kW r/min m^3/s C Pa % mm mm Nos.
Unit
FD
Axial Fan 2000 990 230.1 47.8 3871 87 2880 1600 26
PA
Axial Fan 3150 1490 112.9 47.8 12671 88 2100 1400 22
ID
Axial Fan 4500 990 538.4 137 3989 85.5 3349 1884 18
COOLING TOWER
INTRODUCTION
Cooling towers cool the warm water discharged from the condenser and feed the cooled water back to the condenser. They, thus, reduce the cooling water demand in the power plant.
COOLING TOWER
A B C
E
F
A=Mechanical equipment B=Drift eliminator C=Water distribution D=Fill packing E=Air in late louvers F=Cold water basin
- The EVAPORATION brings about the 75 % of the cooling effect. - Balance 25 % of the cooling is due to sensible heat transfer.
Blowdown
Evaporation
Cooling Tower Heat Load
Recirculating Pump
Wet cooling towers have a hot water distribution system that showers or sprays water evenly over a lattice of horizontal slats or bars called fill or packing. The fill thoroughly mixes the falling water with air moving through the fill as the water splashes down from one fill level to another by gravity. Outside air enter the tower through louvers on the side of the tower. Intimate mixing of water and air enhances heat and mass transfer (evaporation), which cools the water. More the water evaporates; more will be the cooling since the latent heat of evaporation is taken from the water itself (evaporation cooling). Cold water is collected in a concrete basin at the bottom of the tower, from where it is pumped back to the condenser. Hot and moist air leaves the tower from the top.
Water spray fire fighting system HVWS System & Automatic alarming ,Automatic/Manual startup
Generator transformers, category-A Unit auxiliary transformers, category-A Station transformers, category-A outdoor oil storage tanks, category-B Diesel generator room, category-B Boiler burner, category-B Air pre-heater, category-B Mill lube oil system, category-B Medium layer oil device, category-B Turbine lube oil tank, category-B
2000 m3 fresh water reservoir 2000 m3 fresh water reservoir
1
2 2
No
Description
Automatic sprinkler driven F.F Q410,H=115,N=220,1nos Automatic sprinkler F.F jockey pump,Q-18,H-115,N-13.5-2nos Air compressor-2nosX100%Typeww-0.7/25V=170LN=11kw Automatic sprinkler motor drive F.F pump,Q-410,H-115,N-220
2
3 4
10
Description
Hydrants Diesel- drive F.F pump,Q-273,H-125,N-160
5,6
9,10
7
8
INTRODUCTIO
Coal Handling System and plant shall comprise of following: (a) Track Hopper and paddle Feeders (b) Roller Screens with Single Drive (c) Crushers (d) Stacker & Reclaimer (e) Conveying System (f) Transfer Tower
TT-3
CRUSHER HOUSE
TT-4
TT-1
TT-2
BUNKER
General:
The track hopper together with coal handling facility (to supply coal for units), capable of continuous, efficient, and reliable operation with minimum maintenance under the environmental and operating conditions pertaining to area adjacent to power plant site. Track hopper complex together with Coal Handling System shall be designed for continuous duty of 24 hour/day.
The entire coal handling plant (CHP) facility shall comply with currently applicable statutes, regulation & safety codes related to design, construction & operation of the CHP. The CHP will supply coal from the track hopper up to and including the bunker fill system. The conveying and handling of coal from the above ground coal stockyard to the main plant boiler bunkers;
The plant will be designed to handle with the whole range and condition of coal that may be delivered to the site in a safe, reliable, economic and environmentally acceptable manner
Conveyor System:
(a) Each conveyor will be fitted with a centrifugal speed switch for use in the sequential starting and tripping interlock scheme and for ensuring that the driving motor will be shut down automatically in the event of the belt slipping or breaking. Start-up and shutdown of each conveyor will be by remote control with provision for local control.
(b) Plant will be designed for ease and flexibility of operation including. All conveyors and transfer towers will be totally enclosed with a central access walkway, maintenance walkways at each side of conveyors. Adequate access will be provided for cleaning all conveyors. Transfer points will be designed to give good material flow and central loading of conveyors without spillage. Access will be provided for chute cleaning. High quality belt scrapers will be provided. They will be positioned and chutes designed such that all scrapings fall into the main chute, to merge with the main flow of material. All operational areas will be well-lit with special lighting provided where the interiors of chutes, hoppers and bunkers must be inspected frequently.
Coal conveyor
TURBINE
IMPULSE TURBINES
REACTION TURBINES
IMPULSE TURBINE
REACTION TURBINE
Economiser
8 6 2x7 2x7
FCS
HPT
3
1
IPT
8
7
LPT A
5 6 7
LPT B
8 8
7 5 6 7
HPH - 1
HPH - 2
Deaerator
Condensor (HP)
Condenser (LP)
BFBP
2x50%
LPH-5 Extr from 16th stage LPH-6 From 17th stage LPH-7 From 18th stage
TDBFP 2x50%
(MD BFP 1x35%) 1994 TPH
CEP
3x50%
HPH-1 Extr from 6th stage HPH-2 From CRH HPH-3 From 11th stage stage Deaerator From 14th
GSC
CPP
1482 TPH
LPH -5
LPH -6
TURBINE SPECIFICATION
Steam Admission Parameters at Turbine Inlet HPT Pressure (bar) Temp (Deg C) Steam Flow (tph) 242 566 1994.25 IPT 44.9 566 LPT 11.6 383.5
No of Stop valves
No of Control valves
2
4
2
2
TURBINE CONSTRUCTION
Thrust Bearing Type Max shaft vibration & bearing housing Type of Coupling
Tapered-land type
TURBINE CONSTRUCTION
FEATURES OF 660 MW TURBINE
Combined HP & IP Section Shorter Turbine Length Reduced No.of Bearings thereby Mech losses Reduced No. of Packing segments thereby reduced leakage loss & Smooth Distribution of Temp Gradient Thrust force balanced Easier. maintenance
1X100 % AC Driven Jacking Oil Pump 1X100 % DC Driven Jacking Oil Pump
8366m3/hr
124 cum/hr from fresh water sys. Drift losses
Evaporative losses
8806m3/hr
Mechanical accelerated clarifier (Q=1800m3/hr-6nos) According to the sea water quality ,chemical dose such as aluminum sulfate & polyacry lamide (PAM) will be added to the clarifier in order to effectually remove the suspended solids. The chlorinator equipment will be used for disinfection.
8366m3/hr 440m3/hr Mechanical draft cooling tower Blow down water 6121m3/hr
Effluent pit
To service Water(198m3/hr,250nb)
Wash water for car & floor(2m3/hr) Ash handling air compressor cooling water(60m3/hr) Mechanical air compressor cooling water(100m3/hr)
Coal storage area spray water(6m3/hr) Spray water for bunker wheel machine(3m3/hr)
Sea water
Sea water in take reservoir
6611m3/hr
Vertical turbine pump, Q=5285m3/hr,H=18m,P= 400Kw,3-nos
Sea water
8806m3/hr Mechanical accelerated clarifier (Q=1800m3/hr-6nos) 8366m3/hr Blow down water 6121m3/hr 43380m3/hr C.W pump,Q-43380m3/hr, H-29.82mP-4800kw,3nos Auxiliary equipment cooling water Condenser cooling water 440m3/hr
C.W pump,Q43380m3/hr,H29.82mP4800kw,3nos
Effluent pit
DM PLANT
What is DM Water?
Demineralization of water is removal of cautions & anions known as TDS( Total dissolved solids ) of all minerals.
PH= 8 to 7.2 Turbidity<1NTU Free chlorine Nil Conductivity <0.1Micromhos/cm Sodium as Na= <1ppm Free CO2<5ppm Total silica <0.02ppm
Decarbonator
Acid dosing
Cation exchanger
Process Flow Diagram for Conventional DM Plant for Adani Power Ltd. , Mundra SEZ
Bulk Acid Storage Tank
60m3 /hr
60m3 /hr
60 m3/hr
Degasser Tower
Acid Measuring Tank for MB Neutralization Pit (2) Caustic Measuring Tank for MB
Effluent Transfer Pumps (1W+1S)
60m3 /hr
60m3 /hr
ETP
45% NaOH for regeneration
DM PLANT
Requirement To pump feed water from deaerator to Boiler Type of BFP Horizontal Barrel type outer casing Multistage Configuration of BFP For 500MW 2x50% TDBFP & 1x50% MDBFP For 200MW 3x50% MDBFP
Requirement: To pump feed water from Deaerator to boiler through HP Feed water heaters.
Options Available
Incase one running TDBFP is out, full unit load can be maintained with 50% MDBFP.
Can facilitate cold as well as hot unit start ups Unit Start up is faster. Better availability and Operational flexibility.
TD BFP
TD BFP Turbine Parameters
TD BFP
Discharge Pressure
NPSH Required Pump Efficeincy
Kg/Cm2
mlc %
250(a)
36 82
Numbers Rated Capacity Suction Pressure Discharge Pressure NPSH Required Pump Efficeincy
Motor Rating
kw
540
TDBFP
MD BFP
MDBFP
NOS
1X35%
Motor Capacity
Kw
12000
MDBFP