R. K.

JAIN
Dy. E.E.
KORADI PROJECT
Sectional view of plant
Boiler key plan
 THERMODYNAMIC ANALYSIS – RANKINE CYCLE
qin

Boiler
T
3
2

3
wtrub,out wturb, out
Water qin
Turbine
wpump,in

2
Pump
4
qout 1 4
qout

wpump, in

1
Condenser S
Boiler circulation
systems
CIRCULATION SYSTEMS

NATURAL CONTROLLED
Water wall design
Rifle tube and smooth tube
Water cycle for 500 MW
BUCK-STAY ARRANGEMENT
Super heater cycle
Divisional panel
Platen SH
 SUPER HEATER & REHEATER
Sr. No. Type Heating surface area
in sq. m
1 Radiant roof, steam cooled wall LTSH horizontal & 9620
pendent
2 SH divisional panel 1361
3 Final SH (platen) 1458
4 RH Radiant wall front & side, front platen, rear 5075
pendent.
Total Heating Surface 17514
RH cycle
Reheater
Features - 500 MW Boiler
1. Controlled circulation by:
 C.C. Pumps.
 Orifice plates in bottom ring headers.
 Rifled tubes in water walls.

2. Divisional superheaters.
3. Pendent coils
4. Wall Reheaters.
5. Two RH coils with crossover tubes.
6. Single main steam, hot reheat & cold reheat lines.
7. Change in ECO link connections.
8. Down comers connection to only bottom front ring header.
9. Eco. Re- circulation connection to bottom ring header rear.
10. 4 Nos. Bisector type Air pre-heaters.
11. 8 Nos. coal mills and feeders.
12. 4 Nos. oil elevations & 8 coal elevations.
13. 4 Nos. I.D. Fans.
14. HEA ignitors.
 TERMINOLOGY USED IN BOILER
1. GIRDING LOOP
2. WRAPPER TUBE
3. LTSH : Low Temperature Super Heater
4. PENDENT COIL
5. STEAM COOLED SPACER
6. MECHANICAL SPACER
7. FLEXIBLE CONNECTORS
8. BUCKSTAY
9. STIRRUP
10. LEVELLER GUIDES
11. SEISMIC GUIDE
12. HEADER GUIDE
13. HEADER TIES
14. GAMMA PLUG/RADIOGRAPHIC PLUG
15. HAND HOLE PLATE
16. SCALLOPAD BAR
17. CROWN PLATE ASSEMBLY
18. CASSETTE BAFFLES
19. RIFLED TUBES
20. HEA IGNITORS : High Energy Arc Ignitors
 BOILER
 CONTROLLED CIRCULATION WITH
Rifled tubing and C.C. pumps
 Radiant Reheat.
 Dry bottom.
 Top supported.
 Design pressure = 204 Kg/ Cm2
 SH outlet pressure = 179 Kg/ Cm2
 FURANCE
 Balanced draft furnace with fusion
welded water walls.
 Furnace width = 18034 mm
Depth = 15289 mm
Volume = 14580 M3
Sr. No. Parameter Rating
1 SH steam flow 1681 tones/ hr
2 RH steam flow 1430.64 tones/ hr
3 Pressure at SH outlet 179 kg/ cm2 (g)
4 Temp. of SH outlet 540 deg. centigrade
5 Pressure at RH inlet 44.88 kg/ cm2 (g)
6 Temp. of RH inlet 342.7 deg. centigrade
7 Pressure at RH outlet 42.68 kg/ cm2 (g)
8 Temp. of RH outlet 540 deg. centigrade
9 Feed water temp. 255 deg. centigrade
10 Ambient air temp. 28 deg. centigrade
11 Combustion air temp. secondary 335 deg. centigrade
12 Fuel quantity 330 tones/ hr
13 Air quantity 2030 tones/ hr
14 Temp. of gas at Boiler exit 142 deg. centigrade
15 Total heat output of system 1076 m Kcal/ hr
AIR PRE- HEATERS
 TYPE B1- sector
 Primary APH – 2 Nos.

Heating surface area= 23190 m2

 Secondary APH – 2 Nos.

Heating surface area= 62270 m2

Air cycle
Flue gas cycle
Sr. Description Type of Blower
No
WB-1E LRD-II E LRD-II E LRD-II E

1 Blower number 1 to 88 89 & 90 91 to 102 103 to 120

2 Travel in mm 305 9200 9200 9200
3 Dead travel in mm - 350 350 350
4 Nozzle size in mm (diameter) 26 32 25 25
5 Blowing pressure in kg/sq. cm (g) 10 12.5 12 9
6 No. of groups 44 1 6 9
7 Blowing time per group (2 blower ) in 1.4 11.42 11.42 11.42
min.
8 Operating time per group (2 blower ) in 1.5 11.87 11.87 11.87
min.

9 Operating time per cycle in Min. 66 11.87 71.22 106.83

10 Blowing rate per group in kg/min 76.5 293.33 176.66 143.3
11 Steam consumption per group in kg 107 3349 2017.45 1636.48
12 Steam consumption per cycle in kg 4708 3349 12105 14728
LOCATION SL. VALVE TAG NO. SET OPEN PRESs. SET CLOSE BLOW DOWN %
NO. (kg/sq.cm) PRESS.
(kg/sq.cm)
Boiler drum 1 SV1 204.00 195.80 4
2 SV2 208.10 197.70 5
3 SV3 210.10 199.60 5
4 SV4 206.00 195.80 5
5 SV5 208.10 197.70 5
6 SV6 210.10 199.60 5
SH outlet 7 SV7 187.90 180.40 4
8 SV8 187.60 180.10 4
ERV on SH outlet 9 SV11 186.00 181.67 2.33
10 SV12 185.70 181.37 2.33
RH inlet 11 SV13 53.00 50.35 5
12 SV14 54.60 51.87 5
13 SV15 53.00 50.35 5
14 SV16 54.60 51.87 5
LOCATION SL. VALVE TAG NO. SET OPEN PRESs. SET CLOSE BLOW DOWN %
NO. (kg/sq.cm) PRESS.
(kg/sq.cm)
RH outlet 15 SV17 49.76 47.27 5
16 SV18 51.87 49.27 5
17 SV19 49.76 47.27 5
18 SV20 51.87 49.27 2
ERV on RH 19 SV23 49.26 48.27 2
outlet
20 SV24 49.26 48.27 2
Soot blower 21 SV29 39.00 37.44 4