500 MW Boiler of Chandrapur T. P. S.

– Salient Features
500MW Boiler at C.S.T.P.S. is supplied by B.H.E.L. The boiler is described as:
Controlled Circulation with rifled tubing, single drum, balanced draft, radiant reheat, dry
bottom, coal fired boiler, top supported.
It is a tangentially fired boiler with tilting burners. The salient features of this
boiler (compared with 210 MW BHEL Boilers) are-
1) Maximum Continuous Rating: 550 MW
2) Sub critical operating pressure: The operating drum pressure at 90% MCR is
188.8 Kg/ cm²
3) Controlled Circulation of Feed Water in Water Walls with the help of 3 Nos. of
Boiler Circulating Water Pumps installed on Downcomers.
4) Rifled bore water wall tubes as against smooth bore tubes in 210 MW boilers.
5) Provision of Orifices for equal distribution of water in water wall tubes from
Bottom ring headers.
6) All downcomers are connected to front header of the bottom ring header.
7) Design coal: Volatile Matter: 24%, Moisture 8%, Ash 40%, Sulphur 0.4%,
Ash fusion temperature 1200° C, High Heating Value of 3750 Kcal/ Kg.
8) 4 Nos. of Bisector air heaters, two for Primary air and two for secondary air.
9) 8nos. XRP 1043 Bowl Mills,
10)4 I.D. fans, 2 F.D. fans and 2 P.A. Fans
11)4 E. S. P. Passes
12)H.P. / L. P. Bypass system having capacity of 60% of Full Load Steam flow.
Controlled circulation system is the most features of this boilers (compared with
existing 210 MW boilers operated by M.S.E.B.) Due to the sub critical operating pressure
of 500 MW Boilers, difference in density of Water and Steam is very low and hence
natural circulation is not possible. Hence three pumps are provided in the downcomers
of 500 MW Boilers for circulation of water through Water walls. Tubes are rifled bore as
against smooth bore tubes used in Boilers operating on Natural Circulation Due to
swirling and highly turbulent flow in rifled bore tubes, boundary layer thickness of the
fluid flowing through tubes is very small, thus enhancing the convective heat transfer
rate. The disadvantage is high frictional resistance offered to fluid.
Important Auxiliaries of the Boiler are:
Auxiliary Important Data Motor Rating Nos.
per
boiler
F. D. fan Type: Radial, 1750 KW, 3.3 KV, Squirrel cage 2
Capacity 249 M³/ sec: induction motor, 990 RPM
Head Developed: 430 mmWc
Fan Regulation: Inlet Guide
vanes
P. A. Fan Type: Radial 2800 KW, 11 KV, 990 RPM, 2
Capacity: 169 M³/ sec Squirrel Cage induction motor
Head developed: 1270 mmWc
Regulation: Inlet guide vane
I. D. Fan Type: NDZV-33 S 1800 KW, 11 KV, 740 RPM, 4
Capacity: 255 M³/ sec: Squirrel Cage induction motor
Head Developed: 480 mmWc
Regulation: Inlet guide vane
Coal Mills Type: Pressurized Bowl Mill with 600 KW, 3.3 KV, 1000 RPM 8
classifier

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R.S.Kulkarni, E.E (G) KTC
Prepared By Page 1 of 7 Approved By
 Size: XRP 1043
Base Capacity: 72.1 T/Hr for
pulverized fuel fineness of 70%
through 200 mesh, with raw coal
of grindability index of 50HG,
total moisture not more than 8%
Mill shaft RPM: 35.47
Coal Volumetric feeder, Belt type. D.C. shunt wound, totally 8
Feeder Inlet Diameter: 914 mm enclosed, fan cooled, variable
Capacity: Min; 15 TPH speed motor.
Max: 85 TPH Maximum RPM 1750
Min RPM: 100
Motor rating: 5.6 KW
Gear reduction: 203: 1
Voltage 240 Volts D.C.
B.C.W. Type: Single suction, double Wet stator, squirrel cage 3
Pump discharge induction motor
Design Pressure: 208.5 Kg/ cm² Insulation: XLP
Design temperature: 366° C Motor Case Design temp:
Suction Pressure: 195.6 Kgf/cm² : 343° C
Suction temp: 349.4° C Motor case design pressure:
Sp. Gravity of Water at suction: 206.5 Kgf/cm²
0.5993
Quantity Pumped: 47990
Lits/min
Differential pressure: 2.8 Kgf \
cm²
Minimum NPSH required: 16.15
meters above vapor pressure
Power absorbed:
160.1 KW hot duty
267.17 KW cold duty
Other important parameters of the Boiler are as follows:
Parameter Value at 500 MW Generation Unit
Main steam flow 1524.27 Tons / Hour
Reheat Steam Flow 1372.64 Tons / Hour
Pressure at Superheater outlet 177.2 Kg / cm²,gage
Temperature at Superheater outlet 540° C
Pressure at Reheater Outlet 41.0 Kg / cm²,gage
Temperature at Reheater outlet 540° C
Pressure at Reheater Inlet 43.0 Kg / cm², gage
Temperature at Reheater Inlet 342° C
Feed water inlet temperature 253° C
Secondary air temperature 326° C
Coal Flow rate 300 Tons / Hr
Total Combustion Air 1853 Tons / Hour
Furnace Draft -4 mm WC
Temp. of Flue gas at Boiler outlet 136° C
Efficiency based on HCV 88.10 %
O I flue gas at Economiser Inlet 3.59 %

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 Excess Air 20 %
Boiler performance Data
Dry Gas Loss 4.64 %
H0 and H in fuel 5.60 %
H0 in Air 0.18 %
Unburnt Carbon 0.60 %
Radiation 0.19 %
Unaccounted + Manufacturer’s 0.90 %
margin
Total Losses 12.11 %
Heat Credit 0.21 %
Efficiency 88.10 %
Boiler External Piping System:
Main steam system: It consists of two steam lines from superheater outlet. These two
lines join at a Tee connection out side boiler front and runs as a single line to turbine
Hall. Similarly one single line is used for CRH steam and HRH steam from boiler to
turbine. The sizes of these pipes are:
Live Steam Pipe: Two lines of 330.2 mm I.D. χ 79.0 mm thickness
One line of 442 mm I. D. χ 109.15 mm thickness
HRH Pipes : Two lines of 596 mm I. D. χ 33.22 mm thickness
One line of 812.8 mm I. D. χ 44.94 mm thickness
CRH Pipes : Two lines of 762.00 mm I.D. χ 18.71 mm thickness
One line of 864 mm I. D. χ 21.08 mm thickness
Safety Valves:
Location Numbers Relieving Capacity, T/ Hr Set Pressure Kg/ cm²
gage
Drum 6 208, 210, 212, 212, 255, 204, 206, 208, 208,
255 210, 210
SH Outlet 2 Safety valves 187, 187 188.5, 188.5
2 ERV 130,130 186.6, 186.6
RH Outlet 4 Safety valves 165,165, 173, 173 49.96, 52.61
2 ERV 125, 125 49.46
RH inlet 4 208, 208, 215,215 53.0, 54.6

Waterwall Sootblowers : 104 Nos., LRSB : 128 Nos.

Fuel Firing Equipment:
Type and disposition Nos.
Coal Burners Tilting Tangential, on 8 elevations * 4 burners per elevation,
Corner Nomenclature: A, B, C, D, E, F, G, H
HFO Burners Tilting Tangential, on 4 elevations * 4 burners per elevation
Corner Nomenclature: AB, CD, EF, GH
L.D.O. Burners Tilting Tangential, on One elevation * 4 burners per elevation
Corner Nomenclature: AB

Economiser:
Plain tube Economiser, Total H. S. 14948 M², No. of blocks – 3

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Each block consists of 130 parallel tube elements arranged in Horizontal manner in
Second pass of Boiler.
Superheaters:
It is in three stages, composed of 1) finishing pendant platen 2) Divisional Panel
and 3) Low temperature super heater.
The finishing platan is located on horizontal gas path, above furnace real arch tubes and
consists of 47.63 / 54 mm I.D. assemblies spaced on 762 centers. Total Heat Transfer
surface area is 1458 M².
The divisional panel is having H.S. Area of 1362 M². It is located in the furnace between
front wall and Pendant Platan section. It is composed of 6 front and 6 rear panel
assemblies made from 44.5 mm O.D. tubes.
Low temperature super heater is located in the second pass above economiser, consist
of 116 assemblies of 51 O.D. tubes spaced on 152. 4 mm centers across the width of
furnace. Total H. S. Area is 9620 M².
Reheater:
Total heating surface is 5075 M² and is composed of three sections. Finishing
section is located above furnace arch and consists of 46 Nos. of 54mm O.D. tubes. The
front and side radiant wall sections are composed of 60.3 mm O.D. tubes spaced on
63.5 mm centers across furnace width.
Furnace wall:
It is composed of 51-mm O.D tubes spaced on 63.5 mm centers. The space
between the tubes is fusion welded to form gas tight seals.
Circulating Water Pumps:
Hayward Taylor Circulating Water Pumps are glandless pumps and consists of a
single stage centrifugal pump, 3.3 KV wet stator induction motor, which are mounted
within common pressure vessel. Motor is suspended beneath the pump casing and is
filled with boiler drum water to the drum pressure. No seal exist between pump and
motor. Motor is thermally isolated from pump by:
a) Thermal Conduction: The pump temperature is very high (340º C) and motor
temperature should not exceed 54º C. To prevent heat conduction from pump to
motor, a restriction in the form of ‘Neck’ is provided.
b) Hot Water Diffusion: To minimize diffusion of boiler water, a narrow annulus
surrounds the rotor shaft, between hot and cold regions. A baffle ring restricts entry
of solids from boiler water in to the motor casing.
c) Motor Cooling: Motor cavity is maintained at low temperature by a cooler through
which cavity water circulates. Separate pumps, installed at Boiler zero elevation,
supply the ACW water to the cooler. The pump delivery pressure is 10 – 12 Kg/ cm².
An overhead ACW tank is installed at 72- meter elevation, which supplies cooling
water to these coolers in case of non-availability of the cooling water pumps for 45
minutes.
d) Cold Water Purging: In emergency, if temperature of motor cavity water increases,
cold water can be admitted in to the motor casing from bottom of motor. The water
for purging is obtained from B. F. P. Discharge or Boiler Fill Pump discharge. A
separate cooler is provided to cool the purge water.
The figures 1 and 2 show the arrangement of cooling water and schematic of B.C.W.
pump.

Electrostatic Precipitators:
Design gas flow rate 750 m³ / s

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 Design temp of gas at ESP inlet 123°C
Inlet Dust concentration: 54.61 gms/ Nm³,
No. of gas paths per boiler 4
N0. Of fields in each gas peth 6
Guaranteed Collection efficiency 99.87%, with one field out of service
Velocity of gas in electrode zone 0.895 m/s
Treatment time 25.2 s
Total No. of Ash Hoppers for ESP 72
Storage capacity of hopper 8 Hrs of ash collection
Gas distribution at inlet By perforated plates.
Gas distribution at outlet U shaped thin sheets, located with
600mm pitch
No. of rows of collecting electrodes / field 57
Nominal height of collecting electrodes 12.5 m
Specific collecting area with one field out of 167.96 m²/ m³/ s
service
No. of collecting electrode plates per field 342
Emitting electrode type Spiral, with hooks
Emitting electrode wire diameter 2.7 mm
No. of Emitting electrode per field 3024
No. of Emitting electrode per row frame 324
No. of Rappers for collecting electrodes One drop hammer per row of collecting
electrodes having collecting area of
112.5 m²
Rapper size 4.9 Kg
Frequency of rap for collecting electrodes 15 raps to 2 raps per hour,
No. of Rappers for emitting electrodes One drop hammer for two rows
Size of Rappers for emitting electrodes 3.0 Kg
Frequency of rap for emitting electrodes 10 raps / hour
No. of rectifiers 48
Rectifier rating 70 KV, 1000 mAmps
No. of motors for Emitting electrode 48 nos
No. of motors for Collecting electrode 24 nos.
ESP Control With microprocessor controlled EPMS
and ICE C control equipment
ESP Manufacturer M/s BHEL

Auxiliary P.R.D.S:
Steam for Auxiliary P.R.D.S. is obtained from Boiler outlet before boiler outlet
valves. For control of Steam Temperature and Pressure, pneumatic valves are provided.
Spray water is obtained from BFP discharge header. Steam pressure in maintained at 16
Kg/ cm² and temperature at 220°C. P.R.D.S. steam is used for :
1) Turbine Gland Sealing , 2) T.D. B.F.P. turbine warm up
3) Deaerater Heating 4) Wet steam washing of turbine
5) Coal Mill inerting system, ( used for extinguishing coal mill fire)
6) F.O. atomization and burner scavenging, 7) SCAPH in Primary air as well as
Secondary air, 8) F.O. line tracing, 8) Oil handling plant

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