Technical Diary [PDF]

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TRNEPL Technical Diary©

TRN ENERGY PVT LTD, RAIGARH

Technical Diary© A Technical Diary is a proper blend of all the specifications of mechanical & electrical equipments and provides generic descriptions of equipments associated with power generation.

Prepared By: Operation Team 06/03/2020

TRNEPL Technical Diary© FOREHEAD

Shri C.P.Malik COO - TRNEPL

Hearty congratulation to you and your entire team for this marvellous team work of preparing TRNEPL technical diary. This could be possible due to untiring and sincere efforts of you and your team. Technical Diary is a most effective document to broaden the knowledge base of the young engineers and gives them confidence and precision in their day today working at their workplace. I express my sincere thanks to all other departments & their HODs for providing you the details and valuable inputs for preparation and compilation of diary. Special thanks to Mr. Upadhyaya & Mr. Prahlad for their constant guidance & motivation to you and the whole team of TRNEPL for shaping it to be strong, skilled and dependable team. Their guidance will be a great asset to all the young engineers in their professional growth, elevation in career and enabling them to groom them as technically and sound professionals in future.

TRNEPL Technical Diary© FOREHEAD

Shri. D.N.Patel Head – Operation

I am extremely happy to learn that TRN Energy Pvt. Ltd operation team has compiled the equipment’s Technical Diary for 2X330 MW TPP. I am sure this document would be of great utility for trouble free operation & maintenance of the unit. I congratulate the entire operation team for this excellent timely work which signifies the spirit of knowledge sharing and good team spirit that would go long way in building this organization surpassing the promoter’s expectations.

TRNEPL Technical Diary© INDEX TITLE Boiler & Auxiliaries Boiler General Specification Predicted Performance with Design Coal Coal Firing Excess Air Steam & Water Purity Furnace Specifications Water Walls Boiler Drum Superheaters Reheaters Superheater & Reheater Temp Control/ Economiser

PAGE TITLE Boiler’s Soot Blower 1 PRDS 1 Steam & Water Analysis

37

3 4 5 6 7 8 9 10 11

Aux. Boiler Turbine & Auxiliaries Main Turbine Specifications Load & Critical Speed Parameter Control Turbine Extractions Barring Gear & Lube Oil System JOP & Lube Oil Cooler

38

Vapour Extractor & EH Oil System

45

Safety Valves Setting

12

Lube Oil Transfer Pump

46

FD Fan FD Fan Motor’s Details & Lub. System ID Fan

13 14

Centrifuge System Fire Resistant Fluid Specification

47 48

15

Condenser

49

ID Fan Motor’s Details & Lub. System PA Fan PA Fan Motor’s Details & Lub. System Seal Air Fan Regenerative Air Pre Heater APH Gear Box, Air Motor & Soot Blower Scanner Cooling Air Fan & Coal Mill

16 17 18 19 20 21

50 51 52 53 54 55

Mill Performance Data Dynamic Classifier & Mill Fire Fighting System Lubrication System for Mill/Raw Coal Feeder Coal Specifications Coal & Oil Burners

23 24

Condensate Extraction Pump Gland Steam Condenser LP Heaters LP Heater Drain Pump & Deaerator BFP & Auxiliaries Hydraulic Coupling of BFP Thrust & Journal Gearing & PHE of BFP Booster Pumps HP Heaters

25

Vacuum Pump

59

26 27

60 61

Actuators for Nozzles

28

HP Bypass System LP Bypass System Operating Parameters of HP/LP Bypass Valves OCCW System CCCW System Boiler Fill Pump

Oil Firing FOPH Electro Static Bag Precipitator

2

1

PAGE 34 36

22

29 29-32 33

39 40 41 42 43 44

56 57 58

62 63 64 65

1

TRNEPL Technical Diary© INDEX TITLE Hotwell Make Up Pump Chemical Feeding System Stator Water System Seal Oil & H2 System Coolant & Lube Oil Hydrogen Dryer Cooling Tower CW Pump Transformer Compressor Air Dryer & Receiver

PAGE TITLE PAGE 66 DM Plant Equipment Details 104-109 67 Coal Handling Plant Truck Unloading Complex & 69-70 110 Crusher House 71-72 JNT#2 111-112 73 Stacker Cum Reclaimer 113-114 74 BCN-4A/4B 115 Ash Handling Plant 75 103 Grinder/BA Overflow Pump 76 Clinker 116 77 BA Drain Pit & Eco Water Pump 117 Transport Air Compressor & BA LP 78 118 Pump

Generator & Auxiliaries General Specifications

79

Main Exciter

80

Generating & Station Transformer UAT, Generator Circuit Breaker & AVR Generator Metering & Sync Panel HT Switch Gear & Boiler MCC Turbine MCC & Battery Charger Switch Yard Battery Charger, CT Transformer DM Plant Transformer CHP/AHP Transformer Stacker Cum Reclaimer, TAC, Unit, Station Transformer ESP Transformer & Rectifier Transformer FOPH Transformer & DG Set Generator Engine Spec. UPS Balance of Plant 88 PT Plant & Chemical Dosing System

81

Lime Dosing Pump Poly Dosing Pump Cascade Aerator, Distribution Chamber Clarifier & Pump House

82 83 84 85 86 87 88 89

BA HP & Compressor Cooling Water Pump Water Ash Conditioner Water Pump & HCSD LP Water Pump Seal Water Pump & Slurry Pump Seal Water Over Flow Pit Pump/Emergency Flushing Pump GEHO Pump (Sac) Pump & Ash Mixer Charge Screw Conveyor & Ash Conditioner (Dgst) Fly Ash Silo Bag Filter/Air Oil Convertor System Chemical House Alum/Lime Dosing Pump Poly Solution & Recovery Water Pump

119 120 121 122 123 124 125 126 127 128

90

Clariflocculator/Sludge Pump

129

91 92 93

130 131 132 133

96 97

Hydrogen Plant Cell/Electrolyser Rectifier/Hydrogen Compressor Drying System of H2 Caustic Recirculation Pump & H2SO4 Storage Tank CW Chemical Dosing System Scale Inhibitor/Bio Dispersant Pump

98

400 kV Switchyard

95

99-103 Circuit Breaker, CT & CVT

134 135 136

137

TRNEPL Technical Diary© INDEX TITLE PAGE Metal Oxide Surge Arrestor/Line Trap 138 Solid Core Post Insulator 139 Effluent Treatment Plant Sludge Transfer/Poly Dosing Pump 140 141 Poly Agitator/Flash Miser Tube Settler Pump 142 Sewage Treatment Plant Air Blower 143 Hypo Dosing & Treated Water Pump 144 Chiller System Treated Water Pump & Compressor 145 Chilled Water Pump & Air Washery 146 Blower Start-up & Characteristics Curves Cold Start-up Curve For Boiler 148 Warm Start-up Curve For Boiler 149 Hot Start-up Curve For Boiler 150 Super-Hot Start-up Curve For Turbine 151 Cold Start-up Curve For Turbine 152 Start-up Curve after 40 hrs of shut 153 down Start-up Curve after 09 hrs of shut 154 down Start-up Curve after 01 hrs of shut 155 down Generator Capability Curve 156 Characteristics Curves For PA Fan 157 Characteristics Curves For FD Fan 158 Steam Table Saturated Steam Properties 160 Superheated Steam Properties 162

TRNEPL Technical Diary© BOILER GENERAL SPECIFICATIONS Manufacturer Type

M/s. China Western Power Corporation, CHINA HX1052/18.2 Subcritical, natural circulation, drum type, single reheat, balance draft, dry bottom, and membrane water tube on the roof.

Tangential firing with four corners arranged, horizontal heavy thin burner (All nozzles could tilt vertically in the range of 30º) Pressure 18.2 MPa. g °C Temperature 543 Flow 1052 TPH Rating RH outlet pressure 4.1 MPa.(g) RH outlet temperature 543°C Feed water temperature 262.4°C Minimum load at which steam generator can be operated continuously with complete flame stability without oil support (% MCR) with oil support (% MCR) 50% 30 Economizer 70 M3 Drum 53 M3 Total water content of the steam generator Water Wall 140 M3 for hydraulic test Reheater 115 M3 Super Heater 183 M3 Total 561 M3 Economizer 70 M3 Drum 23 M3 Normal operating water volume of Boiler Water Wall 140 M3 Total 233 M3 Total heating surface area of boiler pressure parts (M2) = 37978.3 M² Water Wall 2164 Low Temperature Super Heater 14608.7 Division Platen Super Heater 842.3 Rear Platen Super heater 1331.6 Final Super Heater 3524.5 Roof Super Heater 208.9 Enclosure Super Heater 537 Wall Re heater 500.3 Intermediate Re heater 2326 Final Re heater 2019 Economizer 9916 Total 37978.3 Type of Firing

%

Page 1 of 162

TRNEPL Technical Diary© Predicted Performance Data with Design Coal 100% BMCR

100% TMCR

60% BMCR

Steam flow from super heater, T/hr Super heater outlet pressure, (MPa, g) Super heater outlet temperature, °C Steam flow through Re heater, T/hr

1052 18.30 543 934.7

973 18.24 543 884.4

595 11.68 543 550.3

Reheater inlet pressure, (MPa, g)

4.43

4.19

2.63

Reheater outlet pressure, (MPa, g)

4.20

3.99

2.48

343.9/543

337/543

348/543

Feed water temperature, °C

262.4

259

233

Coal consumption, T/hr

234.8

215.98

140.14

Load Data

Reheater Inlet/outlet temperature, °C

Excess air, % Super heater 1ST DE superheating spray water flow, T/hr. Super heater 2ND DE superheating spray water flow, T/hr. Reheater Desuperheater heating spray water flow, T/hr Circulation Ratio

20 20.02

12.01

13.35

8.01

19.35

11.61

3.859

Flue Gas Data; Load Data Divisional platen outlet Rear platen super heater outlet Intermediate reheater temp. outlet High temp reheater outlet High temp super heater outlet LTSH outlet Economizer outlet RAPH outlet ESP outlet

100% BMCR 1066 992 872 790 685 429 332 147 140

Page 2 of 162

100% TMCR 1022 954 845 770 674 426 328 142 140

60% BMCR 908 855 770 711 635 409 304 133.1 120

TRNEPL Technical Diary© Coal Firing; 100% BMCR With Design Coal T/Hr With Worst Coal T/Hr FD fan outlet air m³/sec PA fan outlet air m³/sec ID fan inlet flue gas Tempering air for each pulverizer Total air to each pulverizer

100% TMCR

234 268.39 155 84.49 346 0 95

60% BMCR 140 161 93 50.69 207.6 0 57

Steam/Water Pressure & Pressure Drops, Mpa (g) Steam at Superheater outlet Pressure drop in Superheater (s) Steam in Boiler Drum Pressure drop in Economizer (without static head) Water at Economizer inlet (with static head) Steam at Reheater inlet Pressure drop through Reheater(s) Steam at Reheater outlet

18.2

17.2

10.92

20.7

12.42

4.23 0.23 4.1

2.53 0.13 2.46

Steam/Water Temperature, °C Steam at Superheater outlet Steam at Reheater outlet Steam at Reheater inlet Water at Economizer inlet Water at Economizer outlet

545 545 342 262 332

540 540 336.9 262 331

545 545 342 262 332

Air Temperature, °C FD fan inlet PA fan inlet Air at RAPH Inlet Air at RAPH Outlet Primary/Secondary Secondary air at burner inlet Primary air at pulverizer inlet Coal air mixture at pulverizer outlet Coal air mixture at burner inlet

35 35 35 303/310.6 303 300 70-80 70-80 Page 3 of 162

35 35 35 303/310.6 303 268 70-80 70-80

TRNEPL Technical Diary© Excess Air (%)

At Burners At Furnace Exit At APH Inlet At APH Outlet At ESP Inlet At ESP Outlet At ID fan Inlet At Chimney Inlet

100% BMCR

100% TMCR

1.2

1.2

60% BMCR

1.334

Flue Gas Velocities m/sec. In Superheater Section In Reheater Section In Economizer Section

14.5 20 5.0

Percentage of Oxygen in Flue Gas Item At Furnace exit At Economizer outlet At RAPH outlet

Design Coal

Energy Quantities Kcal/hr. Energy to Steam & Water Energy to Reheated Steam Heat output of unit Heat input from fuel Net heat input per m3 of Furnace volume, Kcal/hr./m3 Maximum net heat input per m2 of furnace plan area, Kcal/hr/m2 Maximum Burner Zone heat release rate, Kcal/hr./m2

Page 4 of 162

Worst Coal

Best Coal

TRNEPL Technical Diary© Pulverizer Total number offered Number required for operation with -

a) Design Coal b) Worst Coal

6

100% BMCR

100% TMCR

60% BMCR

4 5

4 5

3 4

Steam & Water Purity (μg/kg) Silica (SiO2) Oxygen Hydrazine pH Oil Conductance Sodium Chlorides Copper Iron Percentage load change per minute without exceeding the limits on unburnt combustibles or NOX while maintaining safe flame conditions Time required for draining the complete steam generator

Page 5 of 162

≤20 ≤7 10 ~ 30 9.0 – 9.5 300 ≤ 0.3 μ Si/cm