Birla Copper Part 1

TITLE : INTRODUCTION
A0-0-0-0
INTRODUCTION
BIRLA COPPER – B008 1

A1.0.0.0 INTRODUCTION
In ever growing industrialisation 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, pulverised coal fired 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) Sulphur dioxide, Hydrogen chloride, Hydrogen fluoride released during

combustion are retained in the ash with the help of Limestone.
c) Due to low combustion temperature and combustion in stages there is only

a little development of Nitrogen monoxide.
Thus reduction of gaseous pollutants produced during combustion is achieved by

combustion process itself, which is speciality 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 Circofluid system and
thus eliminate additional efficiency losses.

The advantages of stationary fluidised 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 fluidised bed
firing system which are:
• High firing efficiency

• High sulphur retention with low limestone consumption
• Lower NOx formation helped by staged firing.
CFBC technology also offers highly reliable means of steam generation burning
wide range of fossil fuels without any problems.

TITLE : SYSTEM AND FUNCTION DESCRIPTION
B0 - 0 - 0 - 0
SYSTEM AND FUNCTION DESCRIPTION

TITLE : CFBC FIRING SYSTEM
B1 - 0 - 0 - 0
CFBC FIRING SYSTEM

TITLE : CFBC FIRING SYSTEM
B1.0.0.0 CFBC FIRING SYSTEM
In the CFBC firing system about 50% of the combustion of lignite and/or coal 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.
Mixture of 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 420ºC depending on the boiler load. Subsequently it is separated from the
flue gas flow in cyclone separators connected in parallel. Ash collected in
cyclones drops in the siphons. Nozzles in siphon fluidise this ash and it spills
over into the chutes where mixture of fuel and limestone (if required) is added
before it returns to fluidised bed.
The cyclone ash circulation causes isothermal combustion to take place in wide
area of bed at temperatures in the range of 840 - 880ºC for Coal. An optimum
desulphurisation reaction takes place in this temperature range, which is
facilitated by the inherent content of calcium compounds in the lignite, and/or any
additionally fed limestone.
The cyclone ash circulation with flue gases, substantially contribute in heat
transfer from the fluidised bed to the heating surfaces of Screen, Evaporators,
Superheater and part of Economiser.
The high ash load of the flue gases facilitates intensive heat transfer by means of
radiant heat emission.

TITLE : PROCESS AND PLANT STRUCTURE
B2 - 0 - 0 - 0
PROCESS & PLANT STRUCTURE

B2.0.0.0 PROCESS & PLANT STRUCTURE
The plant basically consists of two boiler passes, electrostatic precipitator, one
induced draft fan, one primary air fan, one secondary air fan and 2 hot gas
generators. Cyclones and siphons are provided for circulating the ash.
The equipment for fuel transport, limestone feeding (not included for this project)
and ash removal are located on the periphery of the plant. The ash removal is
divided into removal systems for bed, cyclone and ESP ash.
Generally, 60% of air required for combustion, is supplied by primary air fans at
about 1500mmWG pressure. Primary air, flows through tubular air heater, wind-
box and enters the combustor simultaneously fluidising the bed ash during
normal operation of the boiler. Air heater is provided with by-pass arrangement
for start up.
Secondary fan supplies air at about 450 mmWG, which forms the remaining 40%
of the combustion air, i.e the secondary and tertiary air. This fan is also equipped
with suction and discharge dampers like P.A. fan and the air, flows through air
heater. Air splitting - secondary and tertiary takes place after air heater outlet.
Secondary air enters combustor through nozzles located at lower elevation than
that for tertiary air. This method is known as "air staging". Secondary and
primary air has independent paths through air heater.
Fuel (coal or lignite) with grain size <8.0 mm (fines i.e. <1.0 mm not exceeding
40%) falls in combustor mixed with circulating ash through fuel chutes from
siphon. The location where fuel-ash mixture enters combustor is partly immersed
in fluidised bed.
In the stationary state, approximately 800 to 1000 mm thick layer of ash (initially
bed material) is lying in the bottom of combustor. This mass is fluidised 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
mmWG per 15 mm height of bed material) from nozzles to the top of the bed.
Fuel percentage in bed during combustion is roughly 2 to 3%.

In combustion process, fines are carried away upwards from fluidised bed with
flue gas. Secondary air and tertiary air is pushed through number of nozzles at
10.3 m and 13.8 m elevation respectively to provide plenty of oxygen and burn
them in free board during upward flow of flue gas with ash. Flue gas temperature
in free board may be around 1000ºC depending on volatiles and quantity of fines
in fuel.
Heating surfaces of Screen, Superheaters, Evaporator and Economiser II absorb

heat from flue gases travelling upwards and approximate temperature of flue
gases entering cyclone is 420ºC. In cyclones, ash (grain size approximate 0.8
mm) is separated from flue gas and drops into siphons in course of its travel back
to combustor. Flue gas enters Economiser I and water flowing through its coils
absorb heat. Flue gas temperature at air heater inlet is approximately 260ºC. Air
from primary and secondary fans gain heat in air heater and the flue gas further
loses heat in turn with AH exit temp around 145ºC.
Circulating cyclone ash not only helps heat transfer to pressure parts, but it also
substantially controls the bed temperature. Higher circulating ash from cyclones
(400ºC) reduces the bed temperature and vice-versa.
Primary air from air heater enters combustor through hot gas generator (during
start up or otherwise), wind box and large number of specially designed air
nozzles. I.D. fan is designed to handle flue gases for 100% MCR steam
generation maintaining balance draft in free board area.
Hot gas generators, which are attached to the wind box are provided for cold start
up. HSD oil is used in the oil burners, which get combustion air and dilution air
from Primary air fans. Hot flue gas generated by HGG mainly assists to raise bed
temperature, to a level, which is slightly higher than ignition temperature of fuel.
During cold start up, flue gas temperature at air heater outlet is generally below
the acid dew point and therefore air is pushed through air heater by-pass
duct/damper arrangement to avoid cold end corrosion.

TITLE : CONTROL FUNCTIONS
B3 - 0 - 0 – 0
CONTROL FUNCTIONS

B3.0.0.0 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
B3.1.0.0 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.
B3.2.0.0 BOILER INTERLOCKS:
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.
B3.3.0.0 AUTO CONTROLS:
The steam generator is normally expected to maintain operating parameters at

desired levels from approximately 35% MCR to 100% MCR by tuning the
standard control loops as described below:

B3.3.1.0 THREE – ELEMENT CONTROL:
Steam flow, feed water flow (including attemperation) and drum level are
conventional parameters which form the operating circuit to regulate feed water
flow to maintain the drum level at a steady state. In specific application, basic
elements are pressure and temperature compensated.
The steam generator is normally expected to maintain operating parameters at

desired levels from approximately 35% MCR to 100% MCR by tuning the
standard control loops as described below :
B3.3.2.0. FURNACE DRAFT CONTROL:
Usually, furnace draft is measured from a point few metres below the screen and
fed in control circuit to maintain it at a steady desired value by regulating Induced
draft MLPB Suction dampers. Some anticipatory signals from total air may help
controlling furnace draft better.
B3.3.3.0 STEAM TEMPERATURE CONTROL:
At higher load say above 60% MCR, mass flow of flue gases and heat absorption
in superheater, reaches a stage when it is possible not only to achieve final
steam temperature, but at times it becomes necessary to cool the steam in
stages to maintain superheater outlet steam temperature within few degrees from
rated temperature. Spray attemperator is interposed between SH I & SH II such
that SH I outlet steam is cooled by water spray to enter SH II at the desired
temperature. Attemperation is further provided between SH II and SH III to control
the Final SH Outlet Steam temperature to the desired value.

STEAM TEMPERATURE CONTROL
SH 1
Outet
Spray Attemperator – 1
Inlet
SH 2
Outlet
Spray Attemperator – 2
Outlet M MS Outlet
SH3
Inlet

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, instead of very fine
particles (atomisation) of water, to achieve quick evaporation, big drops may
come off causing adverse effect on life of attemperator. Multi spray nozzle
system incorporated in CFBC boiler ensures spray of water within specific limits
through each nozzle.
B3.3.4.0 BED TEMPERATURE CONTROL:
To regulate the emission of pollutants such as CO and NOx it is necessary to

control the bed temperature. Also if desulphurisation of fuel with Limestone is
required, such reaction takes place in the bed and the effectiveness depends on
the temperature of the bed ash.
Normally bed temperature for coal is around 840 to 880°C. The ash temperature
at cyclone outlet is approximately 4000C and therefore increase or decrease of
cyclone circulating ash quantity (at 4000C) 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 will help control the bed
temperature. It is therefore speed regulation of cyclone ash screw, which will
govern bed temperature effectively.
Bed temperature is one of the important parameters in boiler protection. Main

fuel cannot be charged, unless bed attains minimum set value of ignition
temperature. Similarly in case, the bed temperature increases beyond safe limit
e.g. 940°C approximately, the boiler should be tripped.

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 20°C above ignition temperature of
main fuel. Approximately 3 to 4 hours will suffice to raise the bed temperature to
ignition value in cold starts through HGG.
B3.3.5.0. BED HEIGHT CONTROL:
Ash generated during combustion has three outlet/ extraction points namely bed
drain, cyclone ash screw and fly ash from ESP hoppers. Almost 85 to 95% of
ash is removed through cyclone ash coolers and ESP hoppers put together and
remaining portion gets gradually accumulated in bed. Static head required for
fluidising will increase with increase in bed ash and therefore bed ash is drained
intermittently (say once in a shift). This is purely remote - manual operation. Bed
ash screw cooler is started from control room and gate valves are opened to
drain excessive ash accumulated. Soon after bed differential drops to minimum
desired value, bed ash drain is stopped by closing the gate valves.
B3.3.6.0. STEAM PRESSURE CONTROL :
The control room operator sets the desired pressure of final steam for automatic
controls. Steam flow signal is used for feed flow in derivative action. The signal
thus generated is command signal for firing normally called as Load signal.
B3.3.7.0. COAL FLOW CONTROL :
Coal flow signal is compared with total primary air flow. The output of this
controller is compared with the load signal to develop set point to coal controller.
The summation of coal feeder (actual) speeds is worked out and compared with
coal controller set point to determine/change the actual value of coal controller.
Control room operator may modify the set point of the coal controller, after
observing the O2 content of flue gas.

B3.3.8.0. AIR FLOW CONTROL:
The ratio of total air to boiler load can be changed by the control room operator.
The load dependant total air (including excess air) is impressed on the output
signal. The signal receives an absolute and fuel dependant minimum value
limitation.
Command signal for primary air is generated in similar fashion with a difference
that a portion of a coal signal is of significance for fuel dependant minimum value
limitation. Pressure and temperature corrected actual (total) P.A flow is compared
with lead P.A. flow and controller sends output to reposition the P.A. suction
vanes.
The difference between total air and P.A. is command signal for secondary +
tertiary air. The ratio of secondary air to tertiary air is pre-determined by control
room operator. However, free board temperature control can trim this ratio in
favour of tertiary air i.e. increase in tertiary air quantity to a limited extent when
free board temperature is too low.
The secondary air set point is deducted from common set point i.e. sum of
secondary + tertiary air. The remaining value is for tertiary air.

TITLE : CONSTRUCTIONAL FEATURES
C-0-0-0–0
CONSTRUCTIONAL FEATURES

TITLE : BOILER DATA AND EQUIPMENT SPECIFICATIONS
C1 - 0 - 0 – 0
BOILER DATA AND EQUIPMENT SPECIFICATIONS

C1.0.0.0 BOILER DATA AND EQUIPMENT SPECIFICATIONS
C1.1.0.0 TYPE
Natural Circulation, Single Drum, Top Supported, Balanced Draft, Tower Type,
Membrane Panel Constructed, Outdoor Unit Equipped with Two Cyclones,
having Economiser and Tubular Air-Preheater as back end heat traps and 1 x
100% Draught Plant (Primary Air fan, Secondary Air Fan and Induced Draught
Fan).
C1.2.0.0 GENERAL INFORMATION
Steam Flow : MCR 150 TPH

Steam Pressure at outlet of Steam Stop Valve : 96 kg/cm2 (g)
Steam Temp at outlet of Steam Stop Valve : 535+50C
(60to100%MCR)
Feed Water Temp at inlet of Economiser : 2200C
Design Pressure : 114 Kg/cm²g
C1.3.0.0 PERFORMANCE GUARANTEE
MCR : 150 TPH

Final Steam Pressure : 96Kg/cm²g
Final Steam Temp. : 535 + 50C
Efficiency at MCR based on GCV of design fuel (Coal) : 87.9 + 1%
Performance Test will be carried out as per ASME PTC 4.1
(Indirect abbreviated method).
Thermal efficiency on GCV of design coal as evaluated w.r.t. an ambient

temp. of 30°C and 60% relative humidity.

C1.4.0.0 PLANT DETAILS :

C1.4.1.0 Site Data :
Avg. Max. Min.
Ambient air temperature °C 30

Ambient air temperature Design. °C 30
Ambient air temperature (for motors) 50
Ambient air temperature 47
(Fans & thermal Insulation)
Relative Humidity % 60 100 20
Altitude 285 M above MSL
Wind Velocity Km/hr 7.2 2.2
Horizontal Seismic Coefficient as per IS-1893 - Zone III
C1.4.2.0 Electrical Supply :
Variations : Voltage + 10%

Frequency + 5%
Combined + 10%
HT : 3.3 KV /50 HZ(above160 KW rating)
LT : 415V / 50 HZ for LT motors
Instrumentation : 230 V AC system, single phase

C1.4.4.0 Compressed Air :
Pressure Kg/cm²(g)
Normal
Instrument air supply pr.(dry)free from

moisture, traces of oil and other impurities 7.0
Service air supply pr. free from moisture,
traces of oil content 7.0
C1.4.4.1 Cooling Water
Pressure : 4.5 kg/cm2(g)

Temperature : 33°C
C1.5.0.0 INPUTS FROM BIRLA COPPER
Range Design
C1.5.1.0 Fuel Analysis (Coal)
Proximate Analysis :
Fixed Carbon % 25-35 29.8

Volatile Matter % 22-29 27.4
Ash % 35-42 35.9
Moisture % 4-9 6.9
GCV KCal/Kg. 4100
Grindability Index HGI 64-69 69

Ultimate Analysis:
Carbon % 43.3
Hydrogen % 2.7
Nitrogen % 1.0
Sulphur % 0.6
Oxygen % 9.6
Ash % 35.9
Moisture % 6.9
Coal Size :
a) 100 % < 8.0 mm
b 40 % (max.) < 1.0 mm (fines)
C1.5.2.0 Ash Analysis:
SiO2 % 58.6
Fe2O3 % 4.1
TiO2 % 1.8
Al2O3 % 26.3
CaO % 1.4
MgO % 0.9
SO3 % Traces
P2O5 % 2.4
Alkalies (by difference) 4.5
C1.5.3.0 Start-up Fuel :
Type of fuel : HSD

GCV : 10000 Kcal/kg

C1.5.4.0 Feed Water (as per Vd TUV/VGB directive)

1. Boiler working pressure > 80 kg/cm2(g)
2. General requirement Clear and colourless
3. Specific electrical conductivitiy at 25°C Guide values of boiler water
are to be respected.
1. Hardness mVal/kg Not detectable

2. Total Iron mg/kg <0.02
3. Total Copper mg/kg <0.003
4. Total silica mg/kg <0.02
5. Oxygen mg/kg <0.02
6. PH at 25°C >9
8. Permanganate mg/kg <5
(possible consumption)
Total carbonic acid
9. Total Co2
10. Oil mg/kg <0.5
C1.5.4.1 Boiler Water
P Value m Val/kg <0.3

pH value at 25°C 9 – 10.5
Silica SiO2 mg/kg <4.0
In case of phosphate injection PO4 mg/kg 2-6
Conductivity at 25°C s/cm <300

C1.6.0.0 MAJOR EQUIPMENT SPECIFICATIONS

C1.6.1.0 Fan
C1.6.1.1 Primary Air Fan
Quantity : One No.

Make : TLT Engg.(I) Pvt. Ltd.
Volume Flow : 11.4 Nm³/sec per fan
Static Pressure : 2000 mmwg
Temperature : 50°C
Speed : 1480 RPM
Damper Control : Inlet Vane Control
C1.6.1.2 Secondary Air Fan
Quantity : One No.

Volume Flow : 10.3 Nm³/sec per fan
Static Pressure : 820 mmwg
Temperature : 50°C
Speed : 1480 RPM
Damper Control : Inlet Vane Control
C1.6.1.3 Induced Draught Fan
Quantity : One No.

Volume Flow : 22.8 Nm3/sec per fan
Static Pressure : 645 mmWC
Temperature : 160°C
Speed : 980 RPM
Damper Control : Inlet MLPB Damper

C1.6.2.0 Roots Blowers
Quantity : 2 nos.(1Working+ 1Standby)

Make : Kulkarni Engg. Asso. Ltd.
Volume Flow : 1529 Nm3/Hr
Discharge Pressure : 468m bar (at blower outlet)
Temperature : 50°C
Control : Variable Speed.
C1.6.3.0 Coal Feeders
Quantity : 2 nos.
Make : Methods
Capacity : 25 TPH
Width : 800 mm
Conveying speed : 0.07 m/sec (max)
Turn Down : 1:5
Control : Variable Speed.
Particle size distribution : 100 % < 8mm
max. 40% < 1mm
Bulk Density : 800 kg/m³ - Coal

C1.6.5.0 Safety Valves :
Quantity : 03 nos
Make : F.M.C. SANMAR Ltd..
SET PRESSURE
Drum-1 : 113 kg/cm²g (60 TPH)
Drum-2 : 112 kg/cm²g (60 TPH)
Super-heater : 100.8 kg/cm² g (30 TPH)
EMRV : 100.3 kg/cm2 (30 TPH)
C1.6.6.0 Start-up Vent
Quantity : 1 no.
Make : BHEL
Type : Globe, regulating
Size : 100 mm
C1.6.7.0 ESP
Number of streams : 2
Make : ACC
Volume of Flow of flue gases : 45.6 Nm3/sec
Temperature of glue gases : 160°c
Dust loading at ESP inlet : 100 gm/Nm3
Dust loading at ESP outlet : 150 mg/Nm3
System pressure : -480 mmWC
Max. permissible pressure drop : 25 mm
SO2 content in flue gas : 0.000948 kg/kg
H2O content in flue gas : 0.0534 kg/kg

C1.6.8.0 Hot Gas Generators
Quantity : 2 nos
Make : Coen Bharat
Fuel oil : HSD
Max. Fuel oil Consumption : 900kg/hr
Gas temp. at HGG outlet : 850o C at outlet.
Turn Down : 1:5
C1.6.9.0 Fuel Oil Pumps
Fuel oil : HSD

Flow rate : 1700 kgs/hr
Discharge Pressure : 8.0 kgs/cm2(g)
C1.6.10.0 Cyclone Ash Cooling System
C1.6.10.1 Cyclone Ash Screw Feeder
Quantity : 2 nos.
Make : Methods
Arrangement : Horizontal
Trough Dia. : 300 mm - U
Conveying length : 2225 mm.
Temperature : 450o C at inlet max.
350 - 375°C at outlet.
Capacity : 3 TPH
Jacket cooling water pressure : 4.5kg/cm² at inlet (max.)
Turn down : 1:5

C1.6.11.0 Bed Ash Screw Cooler.
Capacity : 0.6 TPH

Inlet temp of ash : 850°C
Outlet temp of ash : 300°C
Inlet temp of water : 30°C
Outlet temp of water : 39°C
C1.6.12.0 Chemical Dosing System
C1.6.12.1 HP Dosing System
a) Tank Dosing Tank
i) No. of tanks : One

ii) Capacity (Litres) : 400
b) Pumps
i) Quantity : 2 x 100%
ii) Make : V.K. Pump. Bombay
iii) Type / mode : Positive Displacement / PR-10
iv) Max. dosing reqd. : 20 LPH
v) Discharge Pr. at full stroke : 85 kg/cm2g
vi) No. of strokes/min. : 185

C1.6.12.2 Hydrazine L.P. Dosing System
a) Tank Dosing Tank
i)) No. of tanks One

ii) Capacity (Litres) 400
b. Pumps
i) Quantity : 2 nos x 100%
ii) Make : V.K. Pumps, Bombay
iii) Type/Model : Positive displacement / PR-10
iv) Max. Dosing : 20 LPH
v) Discharge pressure : 6 kg/cm2(g)
vi) No. of strokes/min : 185
C1.6.12.3 Cyclo Hexamin L.P. Dosing System
a) Tank Dosing Tank
i)) No. of tanks One

ii) Capacity (Litres) 400
b. Pumps
i) Quantity : 2 nos x 100%
ii) Make : V.K. Pumps, Bombay
iii) Type/Model : Positive displacement / PR-10
iv) Max. Dosing : 20 LPH
v) Discharge pressure : 6 kg/cm2(g)
vi) No. of strokes/min : 185

SCHEDULE OF PRESSURE PARTS
Sr. No. Description Sizes Material Specification
1 Steam drum
Shell 1810 O.D x 75 thk BS 1501-224 Gr. 490 B
Dished Ends 70 mm thk BS 1501-224 Gr. 490 B
2 Furnace
F.W. membrane panels 44.5 O.D x 5 thk BS3059 PII GR440
R.W memrane panels 44.5 O.D x 5 thk BS3059 PII GR440
L.H side wall memrane panels 44.5 O.D x 5 thk BS3059 PII GR440
R.H side wall memrane panel 44.5 O.D x 5 thk BS3059 PII GR440
Roof panel 44.5 O.D x 5 thk BS3059 PII GR440
Air box 44.5 O.D x 5 thk BS3059 PII GR440
3 Furnace headers
Front wall bottom header 219.1O.D X 23 thk SA 106 Gr B
Rear wall bottom header 219.1O.D X 23 thk SA 106 Gr B
S.W bottom header Right 219.1O.D X 23 thk SA 106 Gr B
S.W bottom header Left 219.1O.D X 23 thk SA 106 Gr B
Side wall top header 219.1O.D X 23 thk SA 106 Gr B
Front & rear wall top header 219.1O.D X 23 thk SA 106 Gr B
4 Screen Panels 38.1 O.D x 5 thk 15 Mo 3

Screen tube inlet header 273 O.D x 25.4 thk SA 106 Gr B
5 SH1,SH2,SH3 supporting tubes 44.5 O.D x 5 thk BS3059 PII GR440
6 EVAP. supporting tubes 44.5 O.D x 5 thk BS 3059 PII Gr 440
7 ECO 2 supporting tubes 44.5 O.D x 5 thk BS3059 PII GR440
8 Supporting tubes above ECO-2 44.5 O.D x 5 thk BS3059 PII GR440
9 Outlet header for supporting tubes 273 X 25.4 thk SA 106 Gr B
10 Main downcomer 298 O.D X 28 thk SA 106 Gr B
11 Main downcomer header 298 O.D X 28.6 thk SA 106 Gr B
12 Evporator inlet & outlet header 273 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 219.1 O.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 3.6 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 3.6 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 13 Cr Mo 44
3)Superheater 1 coil 31.8 O.D X 4 thk 15 Mo 3
31.8 O.D X 4 thk 13 Cr Mo 44
18 Superheater 2
1)Superheater 2 inlet header 219.1O.D X 20 thk 15 Mo 3
2)Superheater 2 outlet header 273 O.D X 32 thk 13 Cr Mo 44
3)Superheater 2 coil 31.8 O.D X 5 thk 10 Cr Mo 910
19 Superheater 3
1)Superheater 3 inlet header 273O.D X 32 thk 15 Mo 3
2)Superheater 3 outlet header 273 O.D X 45 thk 13 Cr Mo 44
3)Superheater 3 coil 31.8 O.D X 5 thk 10 Cr Mo 910
20 Interconnecting piping from ECO1 168.3 O.D X 14.3 thk SA 106 Gr B

to ECO 2.
21 Piping from SH1 outlet to ATTEMP 219.1 O.D X 20 thk 13 Cr Mo 44

1 & from ATTEMP 1 to SH2 inlet
23 Piping from Saturated steam header 219.1 O.D X 23 thk SA 106 Gr B

to SH-1 inlet header
24 Riser tubes from header to drum 88.9 O.D X 6.3 thk BS3059 PII GR440
25 Connecting tubes from downcomer 88.9 O.D X 6.3 thk BS3059 PII GR440
to membrane wall bottom header
26 Connecting tubes from drum to 88.9 O.D X 6.3 thk BS3059 PII GR440
evap. inlet header and to drum
27 Tubes from ECO2 to drum 88.9 O.D X 6.3 thk BS3059 PII GR440
28 Tubes from drum to saturated 88.9 O.D X 6.3 thk BS3059 PII GR440
steam header


29 Connecting tubes from drum to 88.9 O.D X 6.3 thk BS3059 PII GR440
screen tube inlet header
30 Feed water line upto feed control 168.3 O.D x 14.3 thk SA106 Gr B
station & to ECO-1
31 Spray Attemperator – 1st Stage 210.1 O.D X 20 thk 13 Cr Mo 44
32 Spray Attemperator – 2nd Stage 273 O.D X 32 thk 13 Cr Mo 44

SCHEDULE OF VALVES
Sl. Item NB H/ End Class Matl Valve Duty / Remarks Tag No.
No. mm M Conn. Qty.
A : GATE VALVES
1 outlet of CBD. TANK 50 H SW 800 A105 2 CBD. level control 50-V-140
2 EMSV 65 H BW 900 WC9 1 Isolation 65-V-154
For downstream
isolation(100NB valve with
3 30 % FCV 80 H BW 600 WCB 1 80-V-143
ends suitable for 80NB
pipe)
For upstream
isolation(100NB valve with 80-V-144-
4 30 % FCV 80 M BW 900 WCB 1
ends suitable for 80NB MO
pipe)
5 Start up vent 100 H BW 900 WC9 1 For isolation 100-V-154
6 30-100 %FCV 150 H BW 600 WCB 1 For downstream isolation 150-V-143
7 Economiser inlet 150 H BW 600 WCB 1 For feed Isolation 150-V-143
8 On FCV bypass line 150 H BW 600 WCB 1 For downstream isolation 150-V-143
150-V-
9 30-100 %FCV 150 M BW 900 WCB 1 For upstream isolation
144-MO
150-V-
10 On FCV bypass line 150 M BW 900 WCB 1 For upstream isolation
144-MO
With integral bypass both 200-V-
11 Mainsteam stop 200 M BW 900 WC9 1
motorised 154-MO
Total no. of Gate Valves : 12
B : GLOBE VALVES
12 On CBD.& IBD tank 15 H SW 800 A105 2 PG. isolation 15-V-240
For pr. measurement on
13 Instrument isolations 15 H SW 800 A105 6 15-V-240
upstream of fcs
For flow measurement on
upstram of fcs
For pr.measurement on
feedwater line eco inlet
Feedwater/Dearator For isolation, at Eco1
16 15 H SW 800 A105 6 15-V-240
sampling inlet& for deaerator
drum
18 HP dosing line 15 H SW 800 A105 2 For isolations 15-V-240
19 W.L.I. drains 15 H SW 800 A105 4 Drain 15-V-240
20 sat steam sampling 15 H SW 800 A105 3 ISOLATION 15-V-240
21 Blow down sampling 15 H SW 800 A105 3 For isolations 15-V-240
spray line
For flow measurement on
spray line

Sl. NB H/ End Valve
Item Class Matl Duty / Remarks Tag No.
No. mm M Conn. Qty.
Root valves for flow
24 Instrument isolation 15 H SW 1500 F22 8 measurement.(main 15-V-255A
steam)
Root valves for pr.
25 Instrument isolation 15 H SW 1500 F22 6 measurement.(msl to 15-V-255A
turbine)
26 Main steam sampling 15 H SW 1500 F22 3 For isolation 15-V-255A
27 Eco vent 25 H SW 800 A105 2 On header 25-V-240
28 FCV Vent 25 H SW 800 A105 6 On header 25-V-240
For level measurement on
drum
30 Sat steam header vent 25 H SW 800 A105 2 Vent 25-V-240
31 N2 Capping 25 H SW 800 A105 2 For isolations 25-V-240
32 On CBD. tank 25 H SW 800 A105 2 Isolation on LG 25-V-240
sample cooler cooling
33 Sample cooler 25 H SW 800 A105 11 25-V-240
water
34 On CBD. tank 25 H SW 800 A105 2 LT. isolation 25-V-240
IBD. tank outlet &
35 oulet of IBD. tank 25 H SW 800 A105 2 effluent discharge pump 25-V-240
inlet
Att.control valve drain line
36 25 H SW 800 A105 4 Drain 25-V-240
isolation
Attemp.stn bypass
37 32 H SW 800 A105 2 Upstream & downstream 32-V-240
isolation
32-V-240-
38 Attemp. station 32 M SW 800 A105 1 For upstream
MO
Bypass, Regulating
32-V-
39 Attemperator bypass 32 M SW 800 A105 1 type,inching with position
240B-MI
transmitter
32-V-240-
40 Attemp. station 32 M SW 800 A105 1 For downstream
MO
32-V-
41 Att.#1 spray nozzle 32 M SW 1500 F22 2 For isolation
255A-MO
Drain
42 0-30% FCV 40 H SW 800 A105 4 40-V-240
upstream/downstream
Drain
43 30-100% FCV 40 H SW 800 A105 4 40-V-240
upstream/downstream
44 Filling line 40 H SW 800 A105 2 For upstream 40-V-240
45 Eco2 drain 40 H SW 800 A105 2 Drain 40-V-240
46 Eco1 drain 40 H SW 800 A105 2 Drain 40-V-240
47 FCV bypass drain 40 H SW 800 A105 4 Drain 40-V-240
48 FCV drain line 40 H SW 800 A105 2 Drain 40-V-240
Evap bdl,wall,screen
49 40 H SW 800 A105 5 For isolations 40-V-240
drain
50 Evap drain hdr to IBD 40 H SW 800 A105 1 For isolations 40-V-240
51 Main downcomer to IBD 40 H SW 800 A105 1 For isolation 40-V-240

Sl. NB H/ End Valve
Item Class Matl Duty / Remarks Tag No.
No. mm M Conn. Qty.
52 Soot blower isolation 40 H SW 800 A105 2 Line inlet to superheater-2 40-V-240
53 Emergency Blowdown 40 H SW 800 A105 1 Isolation 40-V-240
54 CBD valve 40 H SW 800 A105 1 ISOLATION 40-V-240
40-V-240-
55 Main downcomer to IBD 40 M SW 800 A105 1
MO
Block Valve(CLIENT TO 40-V-240-
56 Spray water line 40 M SW 800 A105 1
CONFIRM) MO
Regulating type,inching 40-V-
57 Emergency Blowdown 40 M SW 800 A105 1
with position transmitter 240B-MI
Regulating type blow down 40-V-
58 CBD line 40 M SW 1500 A105 1 valve,inching,with position 245A-MI-
transmitter CBD
Evap bdl,wall,screen
59 40 H SW 1500 F22 7 For isolations 40-V-255A
drain
60 SH drain hdr to IBD 40 H SW 1500 F22 1 Drain 40-V-255A
61 SH1 drains 40 H SW 1500 F22 2 Drain 40-V-255A
62 SH2 drain 40 H SW 1500 F22 2 Drain 40-V-255A
63 Main steam piping drain 40 H SW 1500 F22 2 Drain 40-V-255A
64 S.H. # 2 header 50 H SW 1500 F22 2 Vent 50-V-255A
bypass, Regulating
50-V-
65 CBD. level control 50 M SW 800 A105 1 type,inching with
240B-MI
position transmitter
Regulating type, inching 100-V-
66 Start up vent 100 M BW 1500 WC9 1
with position transmitter 255-MI
bypass, Regulating type,
150-V-
67 On FCV bypass line 150 M BW 2500 WCB 1 inching with position
246-MI
transmitter
Total no. of Globe Valves : 191
C : NRV
68 HP dosing 15 --- SW 800 A105 1 Feed check valve 15-V-340
69 On spray att. #1 32 --- SW 1500 F22 1 Feed check valve 32-V-355A
70 Spray water line 40 -- SW 800 A105 1 Feed check valve 40-V-340
71 Filling line 40 --- SW 800 A105 1 Feed check valve 40-V-340
72 Economiser inlet 150 --- BW 1500 WCB 1 Feed check valve 150-V-345
73 Main steam 200 --- BW 1500 WC9 1 Feed check valve 200-V-355
Total no. of NRVs : 6
Total no. of Valves : 209

SCHEDULE OF ELECTRICAL EQUIPMENTS
SR. TAG NO. ITEM MOTOR RPM FIXED / FLC REMARKS

NO. RATING VAR. Amp
(kW) SPEED
A) H.T.MOTORS (3.3kV +/- 10%, 50Hz -5% to +5%)
1 PA-FN-001 P.A.FAN # 1 400 1480 F
2 PA-FN-002 P.A.FAN # 2 400 1480 F
3 ID-FN-001 I.D.FAN # 1 360 980 F
4 ID-FN-002 I.D.FAN # 2 360 980 F
B) L.T.MOTORS (415V +/- 10%, 50Hz -5% to +5%)

1 RB-001 ROOTS BLOWER #1 22 1500 V
2 RB-002 ROOTS BLOWER #2 22 1500 V
3 CL-F-001 COAL FEEDER #1 5.5 750 V
4 CL-F-002 COAL FEEDER #2 5.5 750 V
5 BA-SC-001 BED ASH COOLER #1 7.5 750 V
6 BA-SC-002 BED ASH COOLER #2 7.5 750 V
7 CA-SF-001 CYCL ASH SCREW FEEDER #1 3.7 1480 V
8 CA-SF-002 CYCL ASH SCREW FEEDER #2 3.7 1480 V
9 SA-FN-001 S.A.FAN # 1 160 1480 F

10 SA-FN-002 S.A.FAN # 2 160 1480 F
11 LDO-P-001 LDO PUMP #1 3.7 1440 F
12 LDO-P-002 LDO PUMP #2 3.7 1440 F
13 BDT-P-001 BLOWDOWN TRANSFER 1.5 1480 F
PUMP#1
14 BDT-P-002 BLOWDOWN TRANSFER 1.5 1480 F
PUMP#2
C) FRACTIONAL H.P. MOTORS (415V +/- 10%, 50Hz +/- 5%)

1 SB-001 SOOT BLOWER #1 0.1 1480 F ↑
2 SB-002 SOOT BLOWER #2 0.1 1480 F |
3 SB-003 SOOT BLOWER #3 0.1 1480 F Future provision.
4 SB-004 SOOT BLOWER #4 0.1 1480 F |
5 SB-005 SOOT BLOWER #5 0.1 1480 F |
6 SB-006 SOOT BLOWER #6 0.1 1480 F ↓
7 SB-007 SOOT BLOWER #7 0.1 1480 F

NO. RATING VAR. Amp
(kW) SPEED
8 SB-008 SOOT BLOWER #8 0.1 1480 F ↑
9 SB-009 SOOT BLOWER #9 0.1 1480 F |
10 SB-010 SOOT BLOWER #10 0.1 1480 F Future provision.
11 SB-011 SOOT BLOWER #11 0.1 1480 F |
12 SB-012 SOOT BLOWER #12 0.1 1480 F ↓
13 HPD-P-001 H.P. DOSING PUMP #1 0.75 1480 F
14 HPD-P-002 H.P. DOSING PUMP #2 0.75 1480 F
15 HPD-ST-001 STIRRER 0.37 1480 F
16 CHD-P-001 CYCLOHEXAMINE DOSING 0.37 1480 F
PUMP #1
17 CHD-P-002 CYCLOHEXAMINE DOSING 0.37 1480 F
PUMP #2
18 CHD-ST-001 STIRRER 0.37 1480 F
19 LPD-P-001 L..P. DOSING PUMP #1 0.75 1480 F
20 LPD-P-002 L..P. DOSING PUMP #2 0.75 1480 F
21 LPD-ST-001 STIRRER 0.37 1480 F
D) MOTORISED ACTUATORS FOR VALVES
1 100-V-255 START UP VENT REGLN. 2.2 1480 modulating, inching

2 200-V-154 MAIN STEAM STOP VALVE 5 1480 on / off
ISLN.
3 200-V-154- MAIN STEAM STOP VALVE 0.12 1480 on / off
BY BYP.
4 40-V-240 QUICK SHUT OFF VALVE 0.12 1480 on / off

5 32-V-255- ATTEMP.-1 NOZZLE ISOLN. 1.1 1480 on / off
001 VALVE # 1
6 32-V-255- ATTEMP.-1 NOZZLE ISOLN. 1.1 1480 on / off

002 VALVE # 2
7 32-V-240- ATTEMP FCS BYPASS 0.12 1480 Modulating inching

001 MODULATING
8 32-V-240- ATTEMP FCS UPSTREAM 0.12 1480 on / off

002 ISOLATION
9 32-V-240- ATTEMP FCS DOWNSTREAM 0.12 1480 on / off

003 ISOLATION
10 40-V-CBD CONTINUOUS BLOW DOWN 0.55 1480 modulating, inching

VALVE # 1
11 40-V-240- EMERGENCY BLOW DOWN 0.12 1480 modulating, inching
001 VALVE(EBD) MODULATING
12 80-V-144 30 % FCV UPSTREAM 1.1 1480 on / off

ISOLATION

NO. RATING VAR. Amp
(kW) SPEED
13 150-V-144- 30 TO 100 % FCV UPSTREAM 1.1 1480 on / off
001 ISOLATION
14 150-V-144- 100 % FCV BYPASS UPSTREAM 1.1 1480 on / off

002 ISOLATION
15 150-V-24_ 100 % FCV BYPASS 4 1480 modulating, inching

MODULATING
16 40-V-240- MAIN DOWNCOMER TO CBD 0.12 1480 on / off
002 ISOLATION
17 50-V-240 CBD LEVEL CONTROL BYPASS 0.12 1480 on / off

VALVE
E) MOTORISED ACTUATERS FOR

DAMPERS
1 PA-DMP-209 HGG # 1 AIR BYPASS DAMPER 0.5 1480 F
2 PA-DMP-212 HGG # 2 AIR BYPASS DAMPER 0.5 1480 F
3 CL-G-001 SLIDE GATE AT BUNKER # 1 O/ L 1.0 1480 F
4 CL-G-002 SLIDE GATE AT BUNKER # 2 O/ L 1.0 1480 F
5 CL-G-003 SLIDE GATE AT FEEDER # 1 O / L 1.0 1480 F
6 CL-G-004 SLIDE GATE AT FEEDER # 2 O / L 1.0 1480 F
7 PA-DMP-205 AH BYPASS DAMPER #1 1.0 1480 F
8 PA-DMP-206 AH BYPASS DAMPER #2 1.0 1480 F
F) MISCELLANEOUS
1 HGG PANEL 2.0 KVA
2 SOOT BLOWER PANEL 0.5 KVA Future provision should be made in LT MCC for these
feeders.
3 ANALYSER 0.65KVA
4 SOLENOID VALVES 0.7 KVA
5 BUNKER LEVEL SWITCHES 1 KVA
6 ESP SYSTEM 450 KVA
7 OTHER INSTRUMENTS 4 KVA
G) SPARES
1 SPARE 1 1 1480 F
2 SPARE 2 1 1480 F
3 SPARE 3 1 1480 F
4 SPARE 4 1 1480 F C

NO. RATING VAR. Amp
(kW) SPEED
5 SPARE 5 1 1480 F C
6 SPARE 6 1 1480 F C
7 SPARE 7 1 1480 F C
8 SPARE 8 1 1480 F C
NOTE : 1) Roots blowers will be 1 working & 1 standby.

2) V - variable speed , F- fixed speed motors.

SCHEDULE OF DAMPERS
Sl.No. Item Description Medium Size in mm Tag No. Operation Type
1 PA fan # 1 suction air dia 800 PA-DMP-201 Pneumatic control

2 PA fan # 2 suction air dia 800 PA-DMP-202 Pneumatic control
3 PA fan # 1discharge air 1000x1000 PA-DMP-203 Manual Isolation
4 PA fan # 2 discharge air 1000x1000 PA-DMP-204 Manual Isolation
5 Air Heater bypass air 1700x850 PA-DMP-206 Motorised Isolation
6 PA to Air Heater air 2092x850 PA-DMP-205 Motorised Isolation
7 Combustion air HGG # 1 air 765x765 PA-DMP-210 Pneumatic control
8 Dilution air HGG # 1 air 560x700 PA-DMP-211 Pneumatic control
9 Bypass HGG # 1 air 1700x850 PA-DMP-212 Motorised Isolation
10 Combustion air HGG # 2 air 765x765 PA-DMP-207 Pneumatic control
11 Dilution air HGG # 2 air 560x700 PA-DMP-208 Pneumatic control
12 Bypass HGG # 2 air 1700x850 PA-DMP-209 Motorised Isolation
13 SA fan # 1 suction air dia 950 SA-DMP-201 Pneumatic control
14 SA fan # 2 suction air dia 950 SA-DMP-202 Pneumatic control
15 SA fan # 1discharge air 900x900 SA-DMP-203 Manual Isolation
16 SA fan # 2discharge air 900x900 SA-DMP-204 Manual Isolation
17 SA near Furnace air 1010x1520 SA-DMP-205 Pneumatic control
18 TA near Furnace air 1520x600 TA-DMP-201 Pneumatic control
19 ESP # 1 to ID fan # 1 inlet flue gas 1550x1550 FG-DMP-205 Manual Isolation
20 ESP # 2 to ID fan # 2 inlet flue gas 1550x1550 FG-DMP-206 Manual Isolation
21 ID fan # 1 discharge flue gas 1550x1550 FG-DMP-209 Manual Isolation
22 ID fan # 2 discharge flue gas 1550x1550 FG-DMP-210 Manual Isolation
23 ID fan # 1 suction flue gas 840x 2300 FG-DMP-207 Pneumatic control
24 ID fan # 2 suction flue gas 840x 2300 FG-DMP-208 Pneumatic control
25 ID Fans Cross-over Duct flue gas 1550 x 1550 FG-DMP-…... Manual Isolation
26 ESP # 1inlet flue gas 1200 x 1200 FG-DMP-201 Manual Isolation
27 ESP # 2 inlet flue gas 1200 x 1200 FG-DMP-202 Manual Isolation
28 ESP # 1 outlet flue gas 1550 x 1784 FG-DMP-203 Manual Isolation
29 ESP # 2 outlet flue gas 1550 x 1784 FG-DMP-204 Manual Isolation

TITLE : WATER STEAM CIRCUIT
C2 - 0 - 0 – 0
WATER STEAM CIRCUIT

C2.0.0.0 NATURAL CIRCULATION STEAM GENERATION
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 Pass II 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
downcomers 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 upto 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 downcomers. 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.
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.
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.
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.

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 and Superheater – II and
Superheater – II and 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.
After superheater I there is spray-type attemperator I followed by superheater

II which is similarly arranged on the flue gas side in the parallel flow for
regulating the superheater outlet temperature. Attemperator – II is placed
between SH-II Outlet header and SH- III Inlet Header. This attemperator is
used to adjust the Final SH Steam temperature so that the temperature can be
maintained at a constant set point. SH – III bank tubes are also arranged in
the flue gas path above SH – II bank tubes in parallel flow.
Final steam at around temperature of 535ºC & pressure of 96kg/cm²(g) 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 bye pass as well as non-return valves, are
located close to SH III outlet header.
The steam generator is fitted with a safety valve system and electrically
operated start up vent valve.

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.

WATER AND STEAM CIRCUIT

BASIC CIRCUIT DIAGRAM NATURAL CIRCULATION TYPE STEAM

GENERATOR

TITLE : STRUCTURAL DESIGN AND SPECIAL FEATURES
C3 - 0 - 0 – 0
STRUCTURAL DESIGN AND SPECIAL FEATURES

C3.1.0.0 SUSPENSION SYSTEM
The entire boiler load of the Ist pass, the 2nd pass to the expansion joint and
the cyclone is taken up by the suspension beams at the top of boiler structure.
Cup springs are provided on four water cooled walls of combustor (Ist 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.
2nd 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 Ist 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 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 Ist
and 2nd passes.

C3.3.0.0 2ND PASS
The 2nd pass consists of 2 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 2nd 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.
Airheater 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 2nd pass, the theoretical fixed point for the horizontal
expansion is at the centre of the 2nd pass front wall. The lateral expansion of
air heater is therefore sideways and towards rear side.

C3.4.0.0 SPECIAL FEATURES OF DESIGN - IST PASS
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 forces arising, 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 1st 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 - 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
minimises 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 top side of economiser I.

In order to minimise 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 pressurisation
of furnace.
Wind box 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 3 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".
Roots blower 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.
C3.5.0.0 SPECIAL FEATURES OF DESIGN - 2ND PASS
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.
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.
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
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
stand pipes 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 (per cyclone) :
Boilers Load Unit
Fuel - Coal 30% MCR 100% MCR

Gas mass flow at inlet Kg/sec 7.0 23
Gas temperature at inlet Deg.C 300 440
Inlet dust loading Kg/NM3 2.4 2.4
Draft loss MMWC 13 130

CYCLONE

TITLE : COMBUSTION - AIR FLUE GAS SYSTEMS
C4 - 0 - 0 – 0
COMBUSTION - AIR FLUE GAS SYSTEMS

C4.0.0.0 COMBUSTION AIR FLUE GAS SYSTEMS
C4.1.0.0 AIR PATH
The entire combustion air comprises of

- Ignition air for burners of the hot gas generators.
- Primary air
- Dilution air (through hot gas generators)
- Secondary air
- Tertiary air
The combustion air required for the fluidised bed combustion is admitted from
primary air fans and secondary air fans, and supplied to the furnace. The air-
flow is adjusted to the respective requirement through radial vane control
(RVC) at the fan suction.
Individual suction ducts of both primary and secondary air direct the fresh air
to the respective fans. The flow off ducts, come to a junction on discharge
side before entering air pre-heater.
Air flows through the tubular air heater in 4 stages on the primary, secondary
and tertiary air side and is heated in the cross flow pattern. After the tubular
air heater, 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 fluidized bed via the P.A. 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 air pre-heater. The secondary air is injected
into the boiler by means of 16 nozzles located above the fluidised bed. The
tertiary air is supplied to the boiler through 16 nozzles, located above the
secondary air nozzles.
This staged combustion air supply and low combustion temperature are
responsible for largely preventing the formation of thermal NOx.
To the extent that they are required, access doors and various pressure and
temperature & flow monitoring points are provided over the entire primary and
secondary/tertiary air path.
C4.2.0.0 FLUE GAS PATH
The flue gas-side pressure in the freeboard, above the fluidised bed is around
- 30 mmwg. From here, the fly ash charged flue gases from combustion are
conveyed to induced-draught fan. In the first boiler pass flue gas passes over
screen, the final-stage, superheater (SH3), superheater (SH2), superheater
(SH1), evaporator and Eco 2 reaching the 2nd boiler pass via cyclone
separators. The cyclone separator recirculate the ash discharged from the
fluidised bed a number of times. Approximately 95% of the ash contained in
the flue gases is being separated in the cyclones.
In the second boiler pass, the flue gases first flow through Eco 1 and then the
tubular air heater. The primary air and secondary/tertiary air is heated here.

On leaving the tubular air heater the flue gases, now only charged with
extremely fine dust, reach electrostatic percipitator where, depending on the
dust load, their dust is precipitated.
The induced-draft fan directs the flue gas coming from the electrostatic
precipitator to the stack.
The damper control at the suction of the induced-draft fan 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.

TITLE : COAL FEEDING SYSTEM
C5 - 0 - 0 – 0
COAL FEEDING SYSTEM

TITLE : COAL FEEDING SYSTEM
C5.1.0.0 COAL FEEDING SYSTEM
Internal coal feeding system in the scope of TKIIPL starts, with two rod type
cut off gates fitted just below the bunkers of 700 mt3 capacity for continuous
feeding of coal to boiler. Plate type cut off gate each 2050mm x 750 mm is
located below the rod type cut off gate for isolation purpose. This ensures a
flooded section of coal at the entry to both coal feeders fitted under the
isolation gates.
The coal feeders are equipped with chain tension adjusting arrangement, no
coal flow alarm, chain scrapping arrangement, and coal bed height adjustment.
The last of these is of manual type and for the purpose of commissioning. The
electric prime mover drives the coal feeder with variable speed control through
gearbox and chain drive.
Downstream end of coal feeder is feeding the coal straight into "Y" piece fitted
under the siphon. Here also, plate type electrically operated cut off gates are
interposed.
Emergency gates 600mm x 600mm provided on each coal feeder chutes fixed
on underside of each coal feeder facilitates loading on transport truck directly.
Provision of "on line" sampling of coal/lignite is also available.

TITLE : ASH HANDLING SYSTEM
C6 - 0 - 0 – 0
ASH HANDLING SYSTEM

C6.0.0.0 ASH HANDLING SYSTEM
C6.1.0.0 REQUIREMENTS ON THE ASH HANDLING SYSTEM
In contrast to ash handling systems in conventional power plants the ash

conveying system in fluidised bed boilers has - apart from performing removal
functions - to meet boiler-specific requirements. These include:
a) At all boiler loads the corresponding ash quantities in the fluidised bed
must be capable of being maintained between two limit values, i.e. it
must be possible to remove the oversize portion of the fuel ash not
elutriated with the flue gas from the fluidised bed. The control criteria
are the pressure drops through the fluidised bed between the air
distribution grid and freeboard; this ash handling system is described in
the following under the heading "Bed Ash Handling System".
b) It must be possible to reduce the circulating cyclone ash flow via a lock
facility. In practice, this means that the cyclone ash collecting efficiency
can be adjusted to the varying ash quantities and properties of the fuel
range.
The system should be capable of varying the recirculating ash for regulating
the bed temperature. Portion of the ash separated in cyclones, therefore has
to be extracted, cooled and transported to storage silos.
These ash handling systems are explained in the following under the
headings "Cyclone Ash Circulation and Cyclone Ash Extraction".

C6.2.0.0 BED ASH HANDLING SYSTEM
The bed ash handling system is designed for intermittent operation. In the
process, the bed ash is drained from the fluidised bed through two drain
pipes.
The two bed ash drain systems, are shut off by pneumatically operated gates,
directly below the wind box.
The expansion joints below the cut off gates are designed to accommodate
total downward thermal expansion of furnace.
Below each bed ash discharge pipe, a cooling screw cooler serving as
discharge device is arranged. In the water-cooled screw cooler, the bed ash
is cooled down from about 850°C to about 300°C. The screw coolers are
provided with variable speed drives. The speed variation is based on the feed
back signal from bed ash level.
Note:
Dismantling of the bed ash system is only allowed during boiler downtime.
Since hot ash may be in the drain pipes, between fluidised bed bottom and
cut off gates, utmost care and caution should be exercised.

C6.3.0.0 CYCLONE ASH CIRCULATION
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 roots
blowers (air blowers) is admitted to the siphons. The air flow is adjusted to
the operating conditions prevailing in each case via the variable speed of the
roots blowers. The cyclone ash passes from the outlet of the siphon into the
mixing chamber.
The area of the cyclone outlet up to and including the mixing chamber is
provided with a heat insulation for 4500C and the coal / ash pipes downstream
of the siphons up to the inlet of the steam generator with a heat insulation for
about 6000C.
C6.4.0.0 CYCLONE ASH EXTRACTION
To control the fluidised bed temperature the mass flow of the circulating
cyclone ash has to be changed. For this purpose cyclone ash can be
extracted from two loop seals. To lower the fluidised bed temperature the
extraction quantity is reduced; to raise the temperature the extraction flow is
increased.

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TITLE : INTRODUCTION

BIRLA COPPER – B008 1

In ever growing industrialisation of developed and developing nations, electric

b) Sulphur dioxide, Hydrogen chloride, Hydrogen fluoride released during

c) Due to low combustion temperature and combustion in stages there is only

Thus reduction of gaseous pollutants produced during combustion is achieved by

BIRLA COPPER – B008 2

The advantages of stationary fluidised bed firing system such as:

• Low investment cost.

• High firing efficiency

BIRLA COPPER – B008 3

SYSTEM AND FUNCTION DESCRIPTION

BIRLA COPPER – B008 4

CFBC FIRING SYSTEM

BIRLA COPPER – B008 5

B1.0.0.0 CFBC FIRING SYSTEM

BIRLA COPPER – B008 6

PROCESS & PLANT STRUCTURE

BIRLA COPPER – B008 7

B2.0.0.0 PROCESS & PLANT STRUCTURE

BIRLA COPPER – B008 8

Heating surfaces of Screen, Superheaters, Evaporator and Economiser II absorb

BIRLA COPPER – B008 9

BIRLA COPPER – B008 10

B3.0.0.0 CONTROL FUNCTIONS

Instrumentation and control philosophy of CFBC boiler incorporates control loops,

B3.1.0.0 BOILER PROTECTION:

B3.2.0.0 BOILER INTERLOCKS:

B3.3.0.0 AUTO CONTROLS:

The steam generator is normally expected to maintain operating parameters at

BIRLA COPPER – B008 11

B3.3.1.0 THREE – ELEMENT CONTROL:

The steam generator is normally expected to maintain operating parameters at

B3.3.2.0. FURNACE DRAFT CONTROL:

B3.3.3.0 STEAM TEMPERATURE CONTROL:

BIRLA COPPER – B008 12

STEAM TEMPERATURE CONTROL

BIRLA COPPER – B008 13

B3.3.4.0 BED TEMPERATURE CONTROL:

To regulate the emission of pollutants such as CO and NOx it is necessary to

Bed temperature is one of the important parameters in boiler protection. Main

BIRLA COPPER – B008 14

B3.3.5.0. BED HEIGHT CONTROL:

B3.3.6.0. STEAM PRESSURE CONTROL :

B3.3.7.0. COAL FLOW CONTROL :

BIRLA COPPER – B008 15

B3.3.8.0. AIR FLOW CONTROL:

BIRLA COPPER – B008 16

BIRLA COPPER – B008 17

BOILER DATA AND EQUIPMENT SPECIFICATIONS

BIRLA COPPER – B008 18

C1.0.0.0 BOILER DATA AND EQUIPMENT SPECIFICATIONS

C1.2.0.0 GENERAL INFORMATION

Steam Flow : MCR 150 TPH

C1.3.0.0 PERFORMANCE GUARANTEE

MCR : 150 TPH

Thermal efficiency on GCV of design coal as evaluated w.r.t. an ambient

BIRLA COPPER – B008 19

C1.4.0.0 PLANT DETAILS :

Ambient air temperature °C 30

C1.4.2.0 Electrical Supply :

Variations : Voltage + 10%

BIRLA COPPER – B008 20