DBR 300 MW PDF JSW Energy

.
TCE CONSULTING ENGINEERS LTD

BTG PACKAGE FOR 2300MW COAL
BASED THERMAL POWER STATION AT
TORANAGALLU, BELLARY

DESIGN BASIS REPORT

FOR BTG MECHANICAL PART

DOCUMENT NO. 50-F271C-J01-01 REV.1

SHANGHAI ELECTRIC GROUP
CORPORATION,LTD
3669 Jindu Road,Shanghai,China

J SW Energy (Vijayanagar) Limited
SOUTHWEST ELECTRIC
POWER DESIGN INSTITUTE
18 Dongfeng Road,Chengdu,China
PDF created with pdfFactory Pro trial version www.pdffactory.com

Design Basis Report for
BTG Mechanical Part
BTG PACKAGE FOR
2300MW COAL BASED
THERMAL POWER
STATION AT
TORANAGALLU,
BELLARY

DOCUMENT NO.: 50-F271S-J01-01 REV.1 Page

1

DOCUMENT CONTROL SHEET

PROJECT: BTG PACKAGE FOR 2300MW COAL BASED THERMAL POWER
STATION AT TORANAGALLU, BELLARY

CLIENT: JSW ENERGY (Vijayanagar) LIMITED
/SHANGHAI ELECTRIC GROUP CORPORATION,LTD

DOCUMENT TITLE: DESIGN BASIS REPORT FOR BTG MECHANICAL PART

DOCUMENT NO.: 50-F271C-J01-01

REV. NO. : 1

ENDORSEMENTS

1 10.11.
2006

Revised as per
MOM of second
coordination
meeting
! "# $% &'( )* +,-
1 08.200
6

! "# $% &'( )* +,-
REV.
NO.
DATE DESCRIPTION PREP. BY
SIGN.(INITIAL)
REVW. BY
SIGN.(INITIAL)
APPD BY
SIGN.(INITIAL)
SOUTHWEST ELECTRIC POWER DESIGN INSTITUTE
18dongfengRoad,chengdu,China

Mechanical Part
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THERMAL POWER
STATION AT
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DOCUMENT NO.: 50-F271C-J01-01 REV.1 Page

2
CONTENTS
1 GENERAL 1
1.1 Major design principle 1
1.2 Boiler 2
1.2.1 Introduction 2
1.3.1 General 3
1.3.2 Turbine HBD 4
1.4 Generator 6
1.4.1 General 6
2 FUEL 7
2.1 Fuel characteristics 7
3 COMBUSTION SYSTEM AND SELECTION OF AUXILIARY EQUIPMENT
11
3.1 Boiler Fuel Consumption 11
3.2 Design principle of Flue gas and air system & pulverized coal
system 11
3.3 System Description 11
3.4 Calculation results 16
3.5 Major Auxiliary Equipments Selection 18
3.6 Pyrites handling system 23
4 THERMAL SYSTEM AND SELECTION OF AUXILIARY EQUIPMENT 25
4.1 Design principle of Thermal System 25
4.2 System Description 26
4.2.1 Main steam, reheat steam and bypass system 26
4.2.2 Feed-water system 30
4.2.3 Extraction steam system 34
4.2.4 Condensate water system 35
4.2.5 Heater drains and vents system 36

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4.2.6 Auxiliary steam system 37
4.2.8 Vacuum system 39
4.2.9 Condenser tube cleaning system 39
4.2.10 Closed cycle DM water system 39
4.2.10 Boiler blowdown and drain system 40
4.2.11 Steam turbine lube oil and Lube oil handling system 41
4.2.12 Lubrication Oil System 41
4.3 Major Auxiliary Equipment Selection 45
4.3.1 Feed-water pump 45
4.3.2 Heaters 51
4.3.3 Condensate extraction pump 64
4.3.4 Vacuum pump 66
4.3.5 Condenser 67
4.4 Table of economic index 72
5 INSULATING MATERIAL 73


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1
1 GENERAL

1.1 Major design principle

This project is designed to be the coal-fired power plant located in India, with
nominal generator output capacity of 2X300MW.

Main design basis codes and standards will be international codes & standards,
IBR or equivalent standards subject to owner!s approval as below (refer to
contract technical specification.)

1) American society of testing & materials;

2) ASME Test codes;

3) Technical code for designing fossil fuel power plant

4) Technical code for design of thermal power plant air & flue gas ducts/raw coal
& pulverized coal piping;

5) Code for design of thermal power plant steam/water piping.

6) Guaranteed availability of each unit is higher than 85%.

7) Unit start-up time from ignition to full load <7.5 Hr,<4 Hr, <1.5 Hr for Cold,
Warm and Hot start respectively.


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8) Plant makeup water.3%.

9) The steam turbine, turbine generator and all equipments and auxiliaries are
suitable for continuous operation in the frequency range of 47.5Hz to 51.5Hz.
Also, for all equipments, noise level measured at a distance of 1 m from the
equipment will not exceed 85dBA except for places as mentioned below:
TG unit in which case it will not exceed 88 dBA;

1.2 Boiler

1.2.1 Introduction

The boiler is a natural circulation, subcritical pressure with single steam drum
and single reheat. It is semi outdoor arranged and has a single furnace of
reverse u-form (-type, Double pass) arrangement and full pendant steel
structure, dry bottom type water-cooled, balanced draft furnace and is designed
with tangential firing arrangement of burners. There are six pulverizers with 24
coal nozzles in different elevations in the furnace zone of the boiler. Light diesel
oil will be used for start-up. The light diesel oil will be designed for 10 % BMCR
load and mechanical atomization. The steam generator shall be designed for
firing heavy fuel oil up to 30 % BMCR load. The minimum load without oil
support is 30 % BMCR with design coal and 40 % BMCR with worst coal with
two adjacent mill in service. The HFO will be steam atomization.

1.2.2 Boiler capacity and main parameters

Items Unit BMCR

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Items Unit BMCR
Boiler Max. Continuous rating (BMCR) t/h 1015
Superheater outlet steam pressure MPa.(a) 17.57
Superheater outlet steam temperature C 541
Reheat steam flow t/h 840.7
Reheater inlet steam pressure Mpa(a) 3.816
Reheater outlet steam pressure Mpa(a) 3.622
Reheater inlet steam temperature 323
Reheater outlet steam temperature 541
Economizer inlet feed water temperature 279
Efficiency(Based on higher heating value of the design
fuel)
%
88.77

1.3 Steam turbine
1.3.1 General
The steam turbine will be of a tandem compound, single reheat, and axial flow
type with steam exhausting from one double flow low-pressure cylinder to
condenser.

The unit will be capable of producing rated output of 300mw when operating with
rated steam conditions and design ambient conditions.
Main specification
1

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Type: Subcritical, Reheat, Tandem compound, Two cylinder, Double flow,
Condensing
Rated Power (TMCR Condition): 300MW
Rated Speed: 3000r/min
Direction of Rotation: Clockwise viewing from Governing End
Steam Inlet Pressure: 16.67MPa(a)
STEAM INLET TEMPERATURE 538/
STEAM REHEAT TEMPERATURE538/

1.3.2 Turbine HBD
Type0 N300116.67/538/538 (K156)
1) VWO (valve wide open) condition

Items Unit VWO
Maximum output MW 312.970
Steam pressure at the inlet of MSV MPa.a 16.67
Steam temperature at the inlet of MSV 538
Reheat steam temperature at combined valves 538
Steam flow for main steam t/h 966.623
Steam flow for hot reheat steam t/h 798.881
Back pressure of condenser kPa(a) 10.05
Final feed water temperature 277.8
Circulate cooling water 33

1
1

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2) Heat Rate Guarantee Condition

Items Unit Heat Rate Guarantee
Rate output MW 300.078
Steam pressure at the inlet of MSV MPa.(a) 16.67
Reheat steam temperature at combined
valves
538
Back pressure of condenser kPa(a) 10.05
guaranteed heat rate Kcal/Kwh 1909.6
3) All HP Heater out of service Condition
Items Unit
All HP Heater out
of service
Rate output MW 300.115
Steam pressure at the inlet of MSV MPa.(a) 16.67
1

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Items Unit
All HP Heater out
of service
Reheat steam temperature at combined valves 538
Back pressure of condenser KPa(a) 10.05

1.4 Generator
1.4.1 General
The generator is a two-pole, cylindrical rotor type synchronous machine, directly
coupled with steam turbine.
Generator type: QFSN-300-2
Rated output 353MVA/300 MW
Rated voltage 20 kV
Rated current 10189 A
Power factor 0.85 (Lagging)
Speed 3000 r/min
Frequency 50 Hz
No. of phase 3
Cooling method
Stator winding Direct Water cooled
Rotor winding Direct Hydrogen cooled

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Exciter method Brushless excitation system
Class of insulation Class F with temperature rise limited to class B
Permissible variation in voltage " 5%
Permissible variation in frequency - 5.0% to + 3.0%
Max cooling inlet H2 temperature 48 deg C
Noise level 88 dBA at 1.5 m

2 FUEL

2.1 Fuel characteristics
The fuel and its characteristic data is listed below.
2.1.1 Coal Analysis
1

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Sl.No Proximate Analysis
Design coal Worst Coal
1 Fixed Carbon % 54.82 41.59
2 Volatile Matter % 23.02 20.09
3 Moisture % 11.04 15.01
4 Ash % 11.12 23.31
5 High Heating Value
Kcal/Kg
6300
5977(LHV)
5000
4679(LHV)

1 Carbon % 64.64 49.19
2 Hydrogen % 4.75 4.24
3 Sulphur % 0.30 0.46
4 Nitrogen % 2.24 1.39
5 Oxygen % 5.94 6.40
6 Moisture % 11.04 15.00
7 Ash % 11.12 23.32
8 Grindability index
(HGI)
53 45
9 Initial Deformation
TEMP. C
1180
10 Hemispherical TEMP. 1240 <1400
11 Fluid Deg. C 1290 <1400
12 Crucibie swelling index (FSI) >1
13 Bulk Density 0.91

Ash charactorisics %/Wt


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Design coal Worst coal
1 Silico 53.3 37.0
2 Alumina 35.3 45.8
3 Ferric Oxide 4.0 10.7
4 Calclum Oxide 2.2 1.69
5 Magnesium Oxide 0.50 0.44
6 Sodium Oxide 0.30 0.08
7 Potassium Oxide 0.50 0.29
8 Tilanium Oxide 1.40 1.27
9 Phosphate pent
Oxide
1.30 0.67
10 Sulphur Trioxide 0.40 0.94
11 Undetemined 1.1
Sieve analysis
+60 Mesh 02-0.4%
+120 Mesh 2.5-6.5%
+200 Mesh 8-11%
-200 Mesh 80-90%
Un-burnt % 4.0-18.0

2.1.2 Fuel Oil
2.1.2.1 LIGHT DIESEL OIL ANALYSIS
LIGHT DIESEL OIL (LDO) ANALYSIS AS PER IS 1460, 1995
Viscosity at 40o C Cst 2.5 to 15.7
Density at 15
o
C kg/m
3
920
Flash point, Min
o
C 66

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Pour point, Max.
12
o
C
21
o
C
for Winter
for summer
Water content, Max. % vol. 0.25
Sediment, Max. % wt 0.05
Sulphur, Max. % wt 1.8
Ash content, Max. % wt 0.02
Gross calorific value (Approximate) 9950Kcal/kg

2.1.2..2 HEAVY FUEL OIL ANALYSIS

Sl . No. Parti cul ars Uni t
Furnace Oi l
Grade MV2
(I S : 1593)
1. Flash point Deg. C min. 66
2. Viscosity @ 150C Maxi. Cst 180
3. Pour point 0C 21
4. Ash content by weight % max. 01
5. Free Water content by volume % max. 1.0
6. Sediments by weight % max. 0.25
7. Total sulphur by weight % max. 4.0
8. Calcium PPM 30.5
9. Sodium PPM 10
10. Lead content PPM 0.2
11. Vanadium PPM 40.50
12. Carbon residence (Rams bottom) % wt 7.74
14. Approximate gross calorific value Kcal/kg 10,000
15 SP gravity at 150C Max. 0.933


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3 COMBUSTION SYSTEM AND SELECTION OF AUXILIARY EQUIPMENT
3.1 Boiler Fuel Consumption

The fuel consumption is about 112.6t/h (design coal) and 146.8t/h (worst coal)
per unit at boiler maximum operation condition (BMCR). At TMCR condition it is
103.3 t/h for design coal and 131.9t/h for worst coal per unit.

3.2 Design principle of Flue gas and air system & pulverized coal system
Considering the high volatile matter and easy burning character of the raw coal,
medium speed mill (MSM) (positive pressure)& direct-firing pulverizing system
with cold primary air fan will be adopted based on heat calculation of coal
pulverizing system.

3.3 System Description

3.3.1 Pulverized Coal System

Direct firing, pressurized cold primary air, pulverized coal system with MSM will
be adopted in this project. Six (6) sets of HP863 (not finalized) type MSMs,
electric gravimetric coal feeders (EGCF) and raw coal bunkers will be matched
with each boiler. The output of four (4) MSMs will meet the requirement of boiler
capacity at BMCR with design coal, and has suitable margin, the output of five
MSMs will meet the requirement of boiler capacity at BMCR with worst coal, and
has suitable margin.

Raw coal from raw coal bunker via EGCF will be pulverized and dried in the
MSM, then be separated in the MSM separator. There are four (4) pulverized
coal pipes on each separator connected to four corners of boiler burners in the
same layer. Six (6) sets of MSMs correspond to six (6) layer burners of each

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boiler. Diameter adjustable device will be placed at pulverized coal pipes, so that
the resistance of each pipe is the same.
Each MSM will be equipped with one EGCF. Inlet and outlet motor operated coal
gates with good seal of the feeder can endure the exploding pressure of
0.35MPa, and have the function of self-clean. At the outlet of the bunker there is
a motor operated rack & pinion gate, and the bunker emptying chute will be
equipped between the two gates. The EGCFs have alarms of coal flow break
and block, coal flow monitor etc, so that operator can handle emergency and
ensures safe operation.

Six (6) bunkers will be set for each boiler. The capacity of series of bunkers per
each unit will be normal sufficient to provided 16 hours requirement at boiler
maximum continuous rate with worst coal firing. The coal bunkers are designed
and supplied by JSW.

System design scope will include raw coal pipe and pulverized coal pipe.

3.3.2 Flue Gas and Air System

Direct firing, pressurized cold primary air system with MSM shall be adopted in
the project. The boiler manufactured by Shanghai Boiler Works Co. Ltd (SBWL)
in China shall be of natural circulation, drum type, double pass, water tube,
direct pulverized coal tangential fired, dry bottom, single reheat, balance draft,
and each boiler will be equipped with two (2) axial flow forced draft fans (FDF)
with adjustable moving-blade, two (2) centrifugal induced draft fans (IDF) with
hydraulic coupling, two (2) centrifugal primary air fans (PAF) and two (2) sealing
air fans. During operation, pressurized air shall be forced into furnace. Flue gas
from the furnace shall be induced to atmosphere.

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Online vibration monitoring system and bearing metal temperature measurement
system shall be provided for all fans and their drive motors .

3.3.2.1 Primary air system

Main function of the system is to feed pulverized coal and primary hot air heated
by air preheater to MSMs. Primary hot air will be acted as dry medium, and cold
primary air to MSMs (boosted by sealing air fan) and EGCFs will be acted as
seal medium. The inlet vanes of centrifugal primary air fan can adjust air flow
and pressure automatically.

Primary air will be heated in air preheater, and be sent to MSMs via common
manifold. Primary air damper will be placed at air preheater inlet and outlet.
When air preheater failure happen, the damper will be closed.

Pressurized cold air from PAFs will be regarded as regulating temperature for
MSMs. The pressurized cold air will be mixed with hot primary air. Mixed air can
meet the temperature requirement of coal dried in the MSM and pulverized coal
at the MSM outlet.

When one MSM failure happens and shuts down, the corresponding pneumatic
damper on primary hot air duct shall be closed immediately. To avoid primary hot
air enter into the duct of primary cold air, motorized damper on the cold duct will
be also closed immediately. Mixed air flow measurer will be installed on the
mixed duct.

The air velocity in air ducts will be 10-12m/s for cold air and 15-25m/s for hot air.

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3.3.2.2 Secondary air system

The system shall provide air for furnace combusting. Cold air from FDFs shall be
forced into trisector regenerative air preheater, and hot air shall be sent into
secondary air box and be distributed to furnace for combusting.

Two (2) FDFs will be equipped for each boiler. Cold air liaison duct, which
connect two ducts between FDFs downstream; The hot air liaison duct arranged
at air preheater outlet. Secondary hot air box is special design, when one FDF
out of operation, hot air flow to the boiler four corners will be almost equal, so
that stable combusting and reasonable temperature field in the furnace can be
ensured, and will reduce temperature deviation at two sides of boiler.

Damper and air flow measurer shall be placed at hot air duct of air preheater
outlet, when air preheater is out of operation, the damper shall be closed
automatically.

Two trisector regenerative air preheater will be equipped which primary and
secondary air will be heated in it. Also, water washing system and fire protection
system and soot blowing system will be equipped for GAH.

Forced lubrication oil system (with 2x100% capacity pumps, filters, and
associated piping/ accessories) is provided for air preheater.

The air velocity in air ducts will be 10-12m/s for cold air and 15-25 m/s for hot
air.


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3.3.2.3 Sealing air system

2x100% centrifugal sealing air fans will be equipped in the system, one in
operation and another standby. Sealing air from cold primary air manifold will be
sent into MSMs via seal fan boost. At sealing air fans inlet, air filters and
motorized control dampers will be arranged, when one fan is in operation,
another!s inlet damper is closed. If pressure difference of the filter inlet & outlet
reaches to setting value, the filter will clean itself via pressure difference.

3.3.2.4 Flue gas system

The system consists of two ESPs and two centrifugal induced draft fans (IDF)
with hydraulic coupling.
Flue gas from economizer will enter into two (2) air preheaters, each one
isolating damper will set at the inlet and outlet of each air preheater. When
emergency happens to one air preheater, the respective damper will be closed.
During air preheater start up or shut down, the damper will be opened or closed.

Flue gas from air preheater enters into ESP with double path, six electric-fileds.
Each boiler will be equipped with two ESPs. Isolating Guillotine type gates will
be placed at ESP inlet & outlet. Fluel gas via ESP, IDF & chimney will be vented
into atmosphere.

Isolating dampers will be placed at IDF inlet & outlet. When IDF failure happens,
it will be overhauled after the dampers closed. During IDFs starting up or
shutting down, the damper will be opened or closed.

Two (2) ID fans are in operating.
1
1

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The GAH outlet flue gas velocity in gas ducts will be 10-20m/s.

3.4 Calculation results
The results are based on design coal for one boiler at MCR and it can adapt the
characteristic data range of the coal.

3.4.1 Pulverized coal system

NO. Item Symbol Unit
Value
(For one unit)
1 Boiler coal consumption (BMCR) Bg t/h 112.6
2 Hard grove grindability index HGI / 53
3 Maximum Size of raw coal at inlet of mill dmax mm <32
4 Fineness of coal powder
mesh
200
% 70
Medium speed mill quantity
2operate/install3
/ set
4/6(design
coal)
5
Medium speed mill quantity
2operate/install3
/ set 5/6(worst coal)
6 Medium speed mill operating output B
F1
t/h
38.79(design
coal)
1

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NO. Item Symbol Unit
Value
(For one unit)
36.72(worst
coal)
7 Medium speed mill max output B
SJ
t/h 43.1
8 Medium speed mill rated inlet air flow Qv t/h 72.12
9 Primary air temperature at outlet of GAH t
kr
C 306
10 Air temperature at inlet of medium speed mill t1 C
214(design coal)
239(worst coal)
11
Ratio of air and coal mass at inlet of medium
speed mill
/ kg/kg
2.28(design coal)
2.31(worst coal)
12
Temperature at outlet of medium speed
mill
t
m
C 80
13 Mill reject rate % <0.05
14 Effective volume of each raw coal bunker m
3

15
Duration for boiler burning at BMCR condition
with worst coal# bunker storage
h
Refer to TCE
related
documents

3.4.2 Flue gas and air system (BMCRl)

NO. Item (one unit) Symbol Unit Value
1
1

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Design
coal
Worst
coal
1
Theoretical air volume for combustion
(per kg coal)
V Nm
3
/kg 6.8174 5.2988
2 Volume of combustion result at the
outlet of furnace
V
y

Nm
3
/kg 8.7713 6.9371
3
Air temperature at inlet of GAH t
'
kg

C
35 35
4 Air temperature at outlet of GAH t
!ky
C 304 302
5
Flue gas temperature at outlet of
GAH ( corrected)
t
py
C 138.3 137.2
6 Flue gas volume at outlet of GAH Vy m
3
/s 455.92 466.18
7
Flue gas excess air coefficient at
outlet of GAH
Apy / 1.283 1.283

3.5 Major Auxiliary Equipments Selection
3.5.1 Pulverized coal system

Six (6) medium speed mills and six (6) coal feeders will be furnished for each
boiler. These will be of sufficient capacity to attain the MCR of the steam
generator when boiler firing any specified coal with any one mill out of service. In
other words, when firing the performance coal, four (4) mills will be in operation
and two (2) will be standby, and when firing the worst coal, five (5) mills will be in
operation and one (1) will be standby, together with its associated feeders.
Because of the positive pressure in the mill and coal feeder, two (2) sealing air
fan are furnished to supply the sealing air to avoid the powder leaking.

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The maximum capacity of mill shall be 43.1 TPH corresponding to 53 HGI,
70% through 200 mesh and moisture content 11.04 %.

Value
NO. Item Unit
1
Type of MSM
HP863
2
Grindability Index
HGI 53 45
3
Moisture(AR)
11.04% 15
4
Powder fineness
mesh 200 70% 70%
5
Maximum capacity of mill(HGI=53,
70% through 200 mesh)
t/h 43.1 40.8
6
Minimum capacity of mill
t/h 10.78 10.2
7
Mill loading
% 65.5 71.6
8
Max. air flow rate
t/h 72.12
9 Max. resistance kPa 4.5
10 Inlet temperature of mill / 214 239
11
Outlet temperature of mill
/ 80 80
12
Inlet air/ inlet coal
Kg/Kg 2.28 2.31
13
Rotary speed
r/min 38.7
14
Shaft power of mill (BMCR)
KW 250 274
1

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Value
NO. Item Unit
15
Rated power of motor
KW 400
16
Voltage
KV 6.6
17
Gravimetric coal feeder
t/h 40
18
Coal feed distance (from feeder
inlet to feeder outlet)
mm 2200

3.5.2 Flue gas and air system

Each boiler will be furnished with two (2) sets of primary air fan4two (2) sets of
forced draft fan and two (2) sets of induced draft fan. These fans will be
designed for outdoor installation. Under normal operation, all of PAF,FDF and
IDFwill be in operation. The fans sizing are based on the flow and total pressure
at BMCR conditions with a specific margin as below:

Value
NO. Item Unit
1 Primary air fan (2x60%BMCR)
A Type
Double suction
centrifugal

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Value
NO. Item Unit
B
Q
BMCR
21005BMCR with 35 degree
ambient temperaturel3
m
3
/s 46.7 57.3
C P
BMCR
Pa 10907 11913
D
Q
TB
(test block, 605BMCR with 5
degree above maximum ambient
temperature3
m3/s /
73.5
E
P
TB
(test block, considering 30%
margin4design coal)
Pa / 15934
Speed rpm 1500
F Motor ( with 15 % margin) kW later
G Voltage kV 6.6
2 Primary air fan (2x60%BMCR)
A Type
Adjustable moving-
blade axial flow
B
Q
BMCR
ambient temperaturel3
m
3
/s 109.9 99.8
C P
BMCR
Pa 3179 3043
1

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Value
NO. Item Unit
D
QTB (test block, 605BMCR with 5
degree above maximum ambient
temperature3
m
3
/s 148
/
E
PTB(test block, considering 30%
margin,design coal)
Pa 4133 /
F Speed rpm Later
G Motor ( with 15 % margin) kW later
H Voltage kV 6.6
3 Sealing air fan (2x100%BMCR)
A Type
Double suction
centrifugal
B Rated flow m
3
/h 42221
C Rated head Pa 6382
D Motor kW 132
E Voltage kV 0.415
4 Induced draft fan (2x60%BMCR)
A Type
Double suction
centrifugal type
1

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Value
NO. Item Unit
B
Q
BMCR
ambient temperature3
m
3
/s 239
244
C P
BMCR
Pa 3738 3775
D
Q
TB
(test block, 605BMCR with 15
degree above flue gas temperature
margin)
m3/s / 329
E
P
TB
(test block, considering 30%
margin)
Pa / 4908
G
Motor (The motor rating shall be
arrived at considering 15% margin
over the duty point input or 10% over
the maximum demand of the driven
equipment, whichever is higher,
considering highest system
frequency)
later
H Speed rpm later
I Motor kW 2240
J Voltage kV 6.6

Two (2) electrostatic precipitators (double-pass, six electric field) are equipped
for each boiler, The ESP remove particulate from the boiler flue gas to achieve a
guaranteed outlet emission of less than 75 mg/Nm3 with all fields in service,and
100 mg/Nm3 with one field out of service when fired with specified coal range.
1

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Air in leakage through ESP of the total gas flow is less than 3 %.

No Electrostatic precipitator Unit
Value
(design coal)
Value
(worst coal)
1 Double-pass, electric fields
2
Flue gas flow (including 10%
margin and 10/ margin,design )
m
3
/s
per unit
522 534
3
flue gas temperature(including 10/
margin,design coal)
145.9 145.4
4 Inlet dust concentration g/Nm
3
10.5 29.2
5 Outlet dust concentration mg/Nm
3
75 75
6 Efficiency of ESP /
A With (n-1) field in service % / /
B With n field in service % / /

3.5.3 Boiler Igniting and Fire Stabilizing Oil System

The oil of the boiler igniting is diesel oil and fire stabilizing is HFO, and the boiler
ignition mode is high-energy ignition.

The system will be furnished with two 200m
3
HFO daily oil tank, one 50m
3
LDO
daily tank for both units. (These oil tanks are in the scope of JSW, the capacity
and quantity of tanks will be finalized by JSW/TCE ).
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Two motor-driven HFO oil transfer pumps per unit (one operation and another
standby); Three motor-driven LDO oil transfer pumps and other associated
equipments are common for two boilers. All these equipments are arranged
centralized and located nearly the oil tank area.
Light diesel oil pump capacity: Q68 t/h H6450m (Total 3 sets for two units)
Heavy fuel oil pump capacity: Q625.4 t/h H6290m (Total 4 sets for two units)

3.6 Pyrites handling system

Pyrites quantity(not finalized):

Quantity(t/h)
1X300MW 0. 11
2X300MW 0. 22

Mechanical system will be used for pyrites handling. For details please see
drawing 50-F127C1-J01-36 $ Pyrites Handling System Diagram%.
In each shift, pyrites discharged from each mill will be hold in pyrites hopper for
unloading to chain conveyor by screw conveyor. Pyrites will be conveyed out of
the boiler by chain conveyor then to be lifted to pyrites bunker by bucket elevator
to make pyrites discharge into a truck for further transportation to ash yard.
volume of each bunker is about 20m
3
. Chain conveyor is located below ground,
each chain conveyor!s capacity is 10-15t/h. Mechanical system will operate
about one(1) hour each eight(8) hours.

4 THERMAL SYSTEM AND SELECTION OF AUXILIARY EQUIPMENT

4.1 Design principle of Thermal System

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The thermal system will ensure the security, economy and flexibility of the unit.
All of the systems are unit system except auxiliary steam system.

4.2 System Description

4.2.1 Main steam, reheat steam and bypass system

The pipe sizing shall be as per ASME B31.1 and velocities shall be limited to the
values mentioned in specification.

In addition to above, when steam turbine at 100% TGMCR guarantee point :
pressure drop in main steam line from superheater outlet to steam turbine stop
valve is about 5.5 bar; overall pressure drop between HP turbine exhaust and IP
turbine interceptor valves for reheater circuit shall be less than 10% of HP
turbine exhaust pressure

4.2.1.1 Main steam system

Main steam system will convey superheated steam from the superheater outlet
to the HP main steam stop valve. Main steam is unit system. Main steam flow
through single pipe from outlet of boiler superheater header, and then divided
into two branches and connects to left and right main HP steam stop valve
separately.

1) A Motor operated Main steam isolation valve with motor operated integral
bypass valve is set on main steam pipe near boiler outlet for boiler hydraulic test
as well as for normal operation.


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2) One branch leads to gland steam system as HP steam source when normal
gland steam pressure is too low and one branch leads to turbine casing steam
heating header as heating steam source before turbine startup, another branch
leads to auxiliary steam header when the cold reheat pipe pressure is
inadequate or not available.

3) To prevent water from entering turbine, drain system is set to discharge
condensate water of main steam pipe during warm-up and shut-down. Drain
points are set at the lowest points on main steam pipe. A pneumatic drain valve
and a hand-operated valve are set on drain pipe of each drain point. Drain water
is led to drain flash tank. All drains including drain pot shall be checked with
respect to ASME TDP guideline for turbine water damage protection.

4) Two spring safety valves, Two solenoid PCVs and two motorized venting
valves are set on main steam pipe near superheater outlet.

4.2.1.2 Reheat steam system

Reheat steam system will convey cold-reheat steam from HP casing exhaust
spout to inlet of boiler reheater and convey hot-reheat steam from outlet of
reheater to IP main steam stop valve. Reheat steam is unit system.
One cold reheat steam pipe is connected from turbine HP casing exhaust pipe
and divided into two pipes in front of boiler, then connect to two inlets of boiler
reheater header separately.

Two hot reheat steam pipes are connected at two end of outlet header of boiler
reheater and join one pipe at front of boiler, and divided into two pipes again in
front of turbine, then connect with left and right IP steam stop valve.

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1) To prevent steam from flowing back into turbine, one pneumatic check valves
is provided on cold-reheat pipes;

2) Desuperheaters are set on the pipe of reheater inlet, to adjust steam
temperature of reheater outlet under emergency condition. Desuperheating
water come from intermediate stage extraction of BFP.

3) Hydraulic test valve is set on each cold-reheat steam pipe near reheater inlet
to prevent pressurized water entering cold-reheat pipe during hydraulic test of
boiler.

4) To prevent water entering turbine, one drain pot is set on the pipe near HP
casing exhaust spout. A pneumatic valve is set on drain pipe to automatically
control drain water into condenser in time.

5) One spring safety valve are set on each cold-reheat pipe near reheater inlet
separately.

6) A hydraulic test valve is set on hot-reheat main pipe to make sure that the
pressurized water is stopped during boiler reheater hydraulic test and can!t enter
into the hot reheat pipes.

7) One pipe connecting the outlet of HP bypass valve and the inlet of LP bypass
valve is set to form the heat circuit by pressure difference which is able to warm
the outlet of HP bypass valve and pipe, the inlet of LP bypass valve and pipe.

8) Three spring safety valves are set on hot-reheat pipe near reheater outlet, its

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set pressure is lower than the spring safety valve on cold-reheat steam pipe near
reheater inlet, so the former will open before the later when over pressure
happens to ensure enough steam through reheater and avoid over heating of
reheater.

9) Drain points are set on hot-reheat steam pipe branches after tee to remove
condensate water during startup and shut-down. Drain water enters into
condenser. A pneumatic valve and a hand-operated valve are set on each drain
pipe.

4.2.1.3 Bypass steam system

The capacity of bypass system is 60% BMCR. HP & LP bypass valves shall be
of angle type and combined throttle cum spray valve, bypass valves and spray
control valves are hydraulic operated valves. This system can convey main
steam bypass HP-casing to cold-reheat piping and convey hot-reheat steam
bypass IP&LP-casing to condenser when unit startup, shutdown and other
various operating modes. TG set is capable of operating on house load during
sudden total export load throw-off and in the event of turbine trip and generator
breaker open, HP-LP bypass system will open automatically. The leakage class
of valves shall be minimum class V. For Spray valve Trim exit velocity of liquid
shall not exceed 30m/s.

1) Desuperheating water of HP bypass is from feed water system, one control
valve and one isolation valve are set on desuperheating water pipe.

2) LP-bypass system is connected with HP-bypass system in series to achieve
the function of whole bypass system. One upstream and one downstream

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isolation valves are provided for LP bypass spray control valve.

3) One drain pot is set at the lowest point downstream of LP-bypass valve. A
pneumatic valve is set on each drain pipe.

4) Desuperheating water of LP-bypass is from condensate water system.

Table 4.2.1

Item Name Diameter Material Velocity (m/second)
1 Main steam pipe ID368.341.275 A335P91 50
ID273.05x30 A335P91 45
2 Hot reheated steam pipe ID679.5X32 A335P22 67
ID50824.8 A335P22 60
3 Cold reheated steam pipe 7812.822.225
A672B70CL32
33
7558.816
A672B70CL32
35

4.2.2 Feed-water system

HP feedwater system is unit system. The function of this system is to pump
deaerated feed-water from deaerator water tank to inlet header of boiler
economizer. Feed water is heated to the given temperature in HP-heaters by
turbine extraction steam to improve heat efficiency of the units. There are three
50% capability motorized variable speed feedwater pump in this system, during

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normal operation, two pumps work and one pump is standby.
The main boiler feed pump and booster boiler feed pump shall be manufactured
of following or superior materials

a) Outer casing Forged Carbon steel
b) Inner casing ASTM A743 CA 6 NM
c) Impellers ASTM A743 CA 6 NM
d) Wearing rings 13 - 17% Chrome steel (Material shall be non-galling
type with differential hardness not less than 100 BHN)
e) Stuffing box bushing & Stuffing box 13% chrome steel
f) Pump shaft 13% Forged chrome steel
g) Shaft sleeves Stellite on 13% chrome steel
h) Base plate Structural steel
i) Diffuser / Volute 13% chrome steel
j) Strainer Stainless steel mesh
k) Hydraulic Coupling
1) Make Voith
2) Coupling wheels & casing Alloy steel
3) Scoop tube Stainless steel
l) Balancing drum ASTM A 182 Grade F6 a

One full flow motorized orifice valve and one full flow motorized gate valve is
located in major feedwater pipe. When the orifice valve in operation, the orifice
valve can be reduce openning by manual remotely in control room when boiler
load is <60%MCR.
30% BMCR bypass control valve is provided for low load operation and startup.
Two motorized isolating valve are located in boiler filling bypass pipe.


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There are three HP heaters. HP heaters are horizontal type. Bypass piping will
be provided to divert feedwater flow around any of the high-pressure heater for
heater isolation of the respective each unit. All bypass and isolation valves will
be motor operated.

Feedwater system can be divided into three parts: LP feedwater, IP feedwater,
and HP feedwater pipes.

1) LP feedwater pipes

Pipes between the outlets of feedwater tank and the inlets of booster pumps are
called $LP feedwater pipes%. There are motorized valve and strainer on each
pipe. When startup, the strainer can separate the welding slag, impurities etc.,
which were accumulated in feedwater tank, and LP feedwater pipes during
erection and maintenance to protect feedwater booster pumps.

2) IP feedwater pipes

Pipes between the outlets of booster pumps and the inlets of feedwater pumps
are called $IP feedwater pipes%. Each pipe has a flow metering nozzle to
measure the feedwater flow at the inlet of feedwater pump in order to control
opening and closing of minimum flow unit at the outlet of feedwater pump. There
are also filters in these pipes in order to protect feedwater pumps.

3) HP feedwater pipes

Pipes between the outlets of feedwater pumps and inlet header of boiler
economizer are called $HP feedwater pipes%, which pass through HP heaters.

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There are one check valve and one motorized gate valve at the outlet of each
feedwater pump. In order to prevent cavitation of booster pump, one
recirculation pipe is extracted from the feedwater pipe and connected to the
deaerator which has one minimum flow unit including a pneumatic control valve,
two manual valves and one check valve. Signal of the minimum flow unit comes
from the flow metering nozzle at the outlet of booster pipe. Each feedwater pump
has a recirculation pipe which is connected to deaerator.

The interstage extractions from each feedwater pump are collected together and
flow to the reheater attemperator as emergency desuperheating water to adjust
steam temperature of reheater.

One pipe is branched from outlet manifold of feedwater pumps and connected to
boiler superheater primary and secondary spray attemperator. Another pipe is
branched for HP bypass control valve. The former adjust superheating steam
temperature and the latter adjust main steam temperature to cold reheat steam
system.

The feedwater control station is located between outlet of HP heaters and inlet
header of boiler economizer.

One full flow motorized orifice valve and one full flow motorized gate valve is
located in major feedwater pipe. One check valve is located at inlet pipe of
economizer.

The capacity of bypass is 30% rated feedwater flow which adjusts feedwater flow
when unit startup and low load operation.

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Two motorized isolating valve are located in boiler filling bypass pipe.

One pipe is branched from the economizer inlet heater to drum as the
economizer recirculating water pipe.

Table 4.2.2
Item Name Diameter Material velocity(m/s)
1 HP feed water common pipe 7355.630 15NiCuMoNb5-6-4
(EN10216-2)
(DIN17175-79)
5.3
2 HP feed water branch pipe 7244.5x20 15NiCuMoNb5-6-4
(EN10216-2)
(DIN17175-79)
4.8

4.2.3 Extraction steam system
The system extracts steam from steam turbine to specified heating device and
increases the temperature of condensate water and feed-water so as to raise
thermal efficiency of the power plant.

There are 8 stages non-adjustable extraction of the steam turbine. Extraction
No.8&7&6 supply steam to three (3) HP heaters, extraction No.5 supplies steam
to deaerator. Extraction No.4&3&2&1 supply steam to four (4) LP heaters. LP
heaters No.2 and No.1 are combined heaters which are located at neck of
condenser.

Pneumatic-driven check valve and motor-driven isolation valve are set in each
1

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extraction pipe except No2&1 extraction pipes. To prevent condensate water
entering into steam turbine to harm it during startup, shutdown & low load, drain
water pipe is set at the low point of each extraction pipe, near the valves.

Item Name Diameter Material Velocity (m/second)
1 No. 8 extraction pipe 719410 12Cr1MoV 41
2 No. 7 extraction pipe 72197 20 39
3 No. 6 extraction pipe 72739 12Cr1MoV 36

4.2.4 Condensate water system

The system conveys condensate water from hot well of condenser to deaerator
through gland steam condenser and four LP heaters to ensure safe operation
and improve circulation heat efficiency. Beside these, the system also provides
desuperheating water, make-up cooling water and other miscellaneous water
requirements.

The system is unit system. There are two (2) 100% capability vertical
Condensate extraction pumps in the system.
Main control valve, auxiliary control valve and their bypass valve are set on
condensate water pipe before No.1 LP heater to ensure water level control of

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deaerator under all kinds of condition.
Recirculation pipe at the gland steam condenser outlet pipe is set for the
minimum flow when Condensate extraction pump is startup or the unit runs at the
low load. One water discharge pipe branches from No.4 LP header outlet pipe is
set to discharge unqualified water during startup.

Return water pipe to condenser make-up water tank (surge tank) from the outlet
of condensate extraction pump is set for collecting water when the condenser
hot well water level is high.

There are branches at the low pressure desuperheating water pipe such as
desuperheating water pipe to fuel oil sweeping steam desuperheater turbine
gland steam desuperheater, LP-bypass desuperheater, third-stage pressure and
temperature reducer, LP casing spray, HP emergency drain flash tank; and also
the make-up water pipe of closed circuit cooling water expansion tank.

Pipe is set to generator stator cooling water tank and vacuum pump startup
make-up water from condensate water.

4.2.5 Heater drains and vents system

The functions of the system is recovering condensed water from heating steam
of each HP heater and overflow & drain water of the deaerator, recovering
condensed water of LP heater and gland steam condenser, removing non-
condensable gas in HP heaters, LP heaters and deaerator. The normal cascade
HP heater drain pipes from No.8, No.7 and No.6 HP heater to deaerator, LP
heater drain pipes from No.4,No.3,No.2 and No.1 LP heater to condenser.
Emergency drain pipe from each HP heater to emergency drain flash tank which

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attach to condenser, and LP heaters to condenser. Non-condensable gas pipes
from each HP heaters to deaerator and from each LP heaters to condenser and
from deaerator vent to atmosphere. Over flow pipe will maintain normal water
level of feed-water tank and discharge pipe can empty water in case of
maintenance. Control valve is designed in each drain pipe to control water level.

Normal drain water from HP heaters cascade to deaerator. Emergency drain
pipes are set for each heater and respectively led to emergency drain flash tank
or deaerator in order to ensure smooth drain and keep normal level in case that
high water level in HP heaters appears or HP heater is out of service.
Normal drain water from LP heaters cascade to condenser; Pipes for emergency
drain water of each LP heater can ensure smooth drain to condenser when water
level in LP heater is high or at low load or its downstream LP heater(s) is (are)
out of service.

Control valve is designed in each drain pipe of HP&LP heaters to control water
level.

Multi-stage water sealing device is set in the drain piping of gland steam
condenser to ensure smooth drain to main condenser in all operating conditions.

4.2.6 Auxiliary steam system

Auxiliary steam system provide steam to deaerator when start-up, low-load and
trip, provide steam to boiler bottom heating, provide steam to turbine gland
steam system when start-up and standby, provide steam to soot-blower when air
preheater start-up, and provide steam to mill inerting steam and fuel oil system.


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Auxiliary steam is taken from cold reheat pipe at normal operation. During unit
startup, shutdown and when cold reheat pipe pressure is inadequate, the steam
is taken from main steam pipe. When the unit start up, start-up steam will be
provided from the existing 2*130MW thermal power plant. JSW/TCE indicated
that the parameters of the steam from the existing unit will be about 9.0 bar (g)
and 280 Deg C at the terminal point. The terminal point location shall be 1m from
the turbine building Column -1 between B-C row. There is a interconnection of
auxiliary steam headers between the two units, so the auxiliary steam can be
provided when one unit is startup and another is in service. Steam header has
continuous drain pipes, it can drain condensed water of header to condenser.

One auxiliary steam header is provided for each unit. The pressure of auxiliary
steam header is about 1.20MPa and temperature is about 320
0
C in normal
operation. Two safety valves are set on the header with different pressure
setting.

The source of auxiliary steam come from cold reheat steam pipe at normal
condition and main steam pipe when unit startup, shutdown or cold reheat pipe
pressure is inadequate. However if steam is required for pre commissioning/
commissioning of first unit, auxiliary steam source shall be arranged by JSW.

4.2.7 Condensate make-up water system

Condensate make-up water system will fill condenser and boiler and deaerator
with water before the starting of unit, and complement water to hot well when
operating. Beside these, the system will supply sealing water for condensed
pump, make-up water for HVAC system, make-up water for vacuum pump and
etc.
1

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4.2.8 Vacuum system

The function of this system is extracting the non-condensable gas from
condenser and maintain rated vacuum in condenser during normal operating
condition. The vacuum will be break to protect turbine during emergency. Two
vacuum pumps are set in this system. Before unit startup, two pumps will operate
in parallel to establish vacuum as fast as possible (17 minutes reach to 35KPa).
Under normal operation, one pump is in operation and another is standby.

Mixture of steam and air is extracted from condenser. Uncondensed gas
exhaust to atmosphere.

There is one vacuum breaker pipe at neck of condenser. During the unit load
rejection, air admission valve will be opening to break vacuum in condenser and
decrease rotating speed of turbine, then shorten time of turning by inertia to
protect turbine. This will be used only in emergency case.

4.2.9 Condenser tube cleaning system
JSW not adopt.

4.2.10 Closed cycle DM water system

Closed cooling water shall be used to turbine auxiliary equipments and boiler
auxiliary equipments such as generator hydrogen cooler, turbine lube oil cooler,
generator stator water cooler, BFP motor cooler, the bearing of equipments, etc

The closed cooling water for auxiliary equipments is demineralized water.
1
1

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Chemical department will guarantee the water quality. The demineralized water
is pumped by the closed cooling water pumps and is sent to the heat exchanger
in which the demineralized water is cooled by the Aux. cooling water. 3x50%
CCW pumps and 2x50% PHEs shall be provided for CCW system.
Demineralized water will be sent to the equipments and return to the inlet of the
cooling water pumps. An expansion water tank with volume 10m
3
is set to meet
the needs of volume change of cooling water caused by water temperature. The
water tank will be arranged at a high place to gives the closed cooling water
pump sufficient NPSH. Make-up water of the system is from outlet of condensate
water pump in normal condition and from condensate make-up water system in
emergency condition. The make-up water is led to expansion water tank with
control valve for water tank level set in the pipe.

4.2.10 Boiler blowdown and drain system

1) Continuous blowdown system

Drum will continuously blowdown some unqualified boiler water to continuous
blowdown tank to separate steam and water, steam flow into deaerator and
water is discharged to intermittent blowdown flash tank. When continuous
blowdown flash tank is failure during operation, blowdown water will flow through
bypass to intermittent blowdown flash tank directly. If quality of boiler water is
getting worse, this bypass can also be used to increase continuous blowdown
water flow.

2) Boiler intermittent blowdown system

According to quality of boiler water, the water accumulated in bottom headers of

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boiler with some deposits will be discharged intermittently. This water will be
discharged to intermittent blowdown flash tank directly. After steam water
separate in tank, steam is exhausted to atmosphere. The water in intermittent
blowdown flash tank then discharge to a concrete pit underground and mixed
with cooling water there, then discharged out.

3) Drainage and discharge system

Drainage and discharge pipes of each header would collect together to drainage
manifold in boiler house during startup and shutdown, and then water is
discharged to boiler intermittent blowdown flash tank.

4.2.11 Steam turbine lube oil and Lube oil handling system

Steam turbine lube oil system will supply lube oil to the bearing of steam turbine
and generator, with main oil tank, oil pumps, oil coolers etc.

4.2.12 Lubrication Oil System

The function of the lubrication system is to :

Provide oil to lubricate the turbine and generator journal bearings .
Provide oil to lubricate the thrust bearing
Provide oil to lubricate the turning gear .
Provide oil pressure for the generator hydrogen seal oil system .
Provide oil pressure for the governor system

The lubrication oil system is a closed system using oil stored in a reservoir which

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is pumped to various points of use. the lubrication system uses both shaft-driven
and motor-driven pumps .A shaft-driven pump in the turbine governor
pedestal ,together with oil ejector in the reservoir ,pumps the oil when the turbine
is operating at or near rated speed .Motor-driven pumps are used when the main
oil pump and oil ejector cannot supply sufficient oil pressure. The system uses
two oil coolers to regulate the temperature of the lubricating oil system for the
turbine generator unit consists of the following major components:
Lubrication oil reservoir :

Turbine shaft driven main oil pump oil ejector

Auxiliary motor driven oil pumps

Vapor extractors

oil coolers

Oil piping

Protective devices

Bearing lift oil system

The lubrication oil reservoir is a steel tank in which the lubrication oil is stored.
Mounted on the reservoir are the auxiliary motor driven pumps, vapour extraction
system, level sensors, pressure transducers, and pressure gages .the oil ejector
uses high-pressure oil from the main oil pump discharge to pick up oil from the
reservoir when the unit is operating at or near rated speed .Strainers on the oil

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ejector intake ,auxiliary oil pump suctions ,and oil return drain help to prevent
particle contaminants from circulating through the system. The Reservoir is
provided with man way access openings on the top of the shell and a drain
connection on the bottom.

The main oil pump is a volute-type centrifugal pump mounted horizontally on the
turbine extension shaft in the governor pedestal area. At or near rated turbine
speed, the main oil pump supplies all of the oil requirements of the lubrication
system. Provide oil pressure for the governor system and provides two source of
backup for the generator hydrogen seal oil system.

The oil ejector is mounted inside the oil reservoir. The inlet is supplied with high-
pressure oil from the discharge of the main oil pump when the turbine generator
is at or near rated speed. One outlet, the oil is directed through the oil coolers to
the turbine generator bearings. The other outlet supplies the inlet side of the
mail oil pump with oil.

The bearing oil pump (BOP) is an AC motor-driven centrifugal pump, vertically
mounted on the top of plate of the oil reservoir which is used at startup and
shutdown. During startup, the BOP is placed in service before the unit is put on
turning gear operation. It stays in service until the main oil pump can satisfy the
system oil requirements.

The emergency oil pump (EOP) is a DC motor-driven centrifugal pump which is
identical to the BOP except for the motor. The EOP serves as a backup to the
BOP in case of AC power failure.

The seal oil backup pump (SOB) is an AC motor-driven gear pump, horizontally

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mounted on the top of the oil reservoir which is used during startup and
shutdown of the turbine generator when main oil pump discharge pressure is too
low to meet the oil pressure for the governor system and the generator seal
system high-pressure oil backup requirements.

Two vapor extractors are supplied for the reservoir, one vapor extractor is
normally operating and the other vapor extractor is on standby. The main
function is to remove oil vapors and maintain a slight vacuum at the turbine
pedestal, bearing housings, oil reservoir, and oil guard piping system.

The lubrication oil system includes two full-size oil coolers to maintain an
acceptable temperature range of oil to the bearings while the system is in
operation. The coolers are identical in construction. One cooler is used during
normal operation and the other cooler is kept on standby. Valves between the
two coolers direct oil flow from reservoir to the selected cooler.

Design basis of oil system

The Main oil tank capacity shall provide a minimum of 8 minutes retention time.
There shall be a minimum of 0.023 m
2
of free oil surface for each lpm of normal
oil flow.

Turbine unit oil purification system shall be of centrifuge type. The hourly
conditioning capacity shall be equivalent to 20 percent of the combined capacity
of the main oil tank at operating level plus the oil in the lubricator system that
flows back into the main oil tank during a shutdown of the turbine each hour. The
equipment shall be designed to meet all lube oil purity requirements established
by the turbine generator manufacturer and ASME Standard 118. The oil

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conditioning equipment shall be designed to provide for removal of particulate
matter greater than 10 microns absolute and all free water in accordance with
ASME.

In addition to unit oil purification ( centrifuge type) , a common turbine oil
purification system for both unit comprising of Dirty oil tank, Clean oil tank,
Purification system, two convey pump, one cleaning oil pump and one dirty oil
pump set will be provided.

Lube oil handling system will handle the unqualified lube oil before unit startup
or under normal operation. The lube oil volume of steam turbine is 32m
3
, so a
48m
3
dirty oil tank and a 48m
3
clean oil tank is set in this system, with water
coalescer type oil purifier and lube oil transfer pump.

4.3 Major Auxiliary Equipment Selection

4.3.1 Feed-water pump

Each unit will be furnished with three 50% capacity motor-driven variable speed
feed-water pump with hydraulic coupling. Two pumps are working at normal
operation and one pump is standby. Three booster pumps are set for each feed-
water pump.

The capacity of the pumps is regulated by throttling pump discharge across a
feedwater regulator. The pumps are capable of operating satisfactorily at
deliveries ranging from minimum recirculation flow to the maximum specified.
The pumps furnished for each installation is operate satisfactorily both in two

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pump parallel operation and single pump operation and when bringing in or
taking a pump out of service with one or two other pumps in service.

During startup and low load operation, when the variable speed drive cannot
provide the required feedwater flow control, a low load regulating valve is used.
The low load regulating valve is bypassed.

Boiler feed pumps design is based on 110% feed water flow at BMCR. Pump is
designed for complete frequency range of 47.5 to 51.5 Hz during normal
operation. Pump and motor are provided with online vibration monitoring system
and bearing metal temperature measurement.

BFP SIZING DATA SHEET
No Name
Symbo
l
Unit
Calculation &
Remark
BMCR
TMCR
(3%MU)
Technical
evaluatio
n sheet
A BFP inlet suction flow

1 Maximun steam flow G1
t/h
HBD from
Shanghai
steam turbine
works
1015 920.593

2
BFP gland seal
discharge and injection
flow difference
G2 t/h 2 2
3
Interstage flow for RH
spray
G3 t/h
Data from
Shanghai boiler
works Co.ltd
42 42

4
Total suction flow of
BFPs
G4 t/h
G4=G1*110%+
G2+G3
1160.5 964.593


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No Name
Symbo
l
Unit
Calculation &
Remark
BMCR
TMCR
(3%MU)
Technical
evaluatio
n sheet
5
Feedwater specific
volume & m3/kg
According to
HBD 0.001119 0.001119

6 Feedwater density
' kg/m3 '=1/& 893.66 893.66

7 Capacity of each BFP
G t/h G=G4/2 580.25 482.3

Q m3/h Q=G*&*1000 649.3 539.7

BFP suction flow
m3/h 650 550

8 Interstage flow of BFP
Q1 m3/h
Q1=G3*&*1000
/2 23.5 23.5

m3/h 30 30

9
BFP booster pump
suction flow
Q2 m3/h

650 550

B BFP head

1 Pipe and equipments pressure drop

a
Pipe pressure drop from
deaerator tank outlet to
economizer inlet
"P
PIPE
Mpa
P "
LP
P "
IP
+ P "
HP

0.876 0.734

Mpa
Considering 20
" margin
1.051 0.881

b Equipment pressure drop

HP heaters
P "
EQUI
P

Mpa
0.1*3 (3 HP
heaters)
0.3 0.3

Mpa
Considering 20
" margin
0.36

Total pressure drop from
deaerator tank outlet to
ecoonmizer inlet
P1 " Mpa
P "
PIPE
+ P "
EQUI
P

1.411 1.181


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No Name
Symbo
l
Unit
Calculation &
Remark
BMCR
TMCR
(3%MU)
Technical
evaluatio
n sheet
2
Water differential
pressure between
economizer inlet and
deaerator tank normal
water level
P2 " Mpa
(29.5-
24.8)*9.81/&
0.041 0.041

3
Drum safety valve
relieving
"P3 Mpa
According to
data sheet from
boiler works
20.4

Total pressure drop from
economizer inlet to
drum
0.45

Economizer inlet
feedwater pressure at
MCR condition
18.78

4
Rated working pressure
of deaerator(neagative)
"P4 Mpa
From HBD -0.814 -0.778

Total head of BFP "P
Mpa
P= P1+ P " " "
2+ P3+ P4 " " 21.487 19.224

C BFP sizing result

Head "P mH
2
o 2454 2200
Suction flow Q m
3
/h 650 550
Note: all these data is primary data for the selection of BFP.

NPSH calculation for BFP
No. Name Symbol Unit Calculation Data
1 BFP flow W kg/s SG BMCR condition 294.200
1
1
1

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2
Water weight from deaerator to
BFP booster pump

a)
Pipe length of BFP booster pump
A LP feedwater pipe L
1
m

35.64

Water weight of one meter in pipe Q
1
kg/m 8325X8 67.02

Total weight of water G
1
kg L
3
XQ
3
2388.59
b)
Pipe length of BFP booster pump B
LP feedwater pipe L
3
m

37.1

Water weight of one meter in pipe Q
3
kg/m 8325X8 67.02

Total weight of water G
3
kg L
3
XQ
3
2486.44
c)
Pipe length of BFP booster pump C
LP feedwater pipe L2 m

55.62

Water weight of one meter in pipe Q3 kg/m 8325*8 67.02

Total weight of water G2 kg Q3!L2 3727.65
d)
Water weight from deaerator to
BFP booster pump MS kg Normal operation is two BFP, Ms= G3+G2 6214.09
3
Water weight in condensate pipe
from No. 4 LP heater to
deaerator

a) Pipe length L m

71.3


Total weight of water Gs1 kg L!Q1 4958.92

Total weight of metal Gi kg 8325*8 weight: 62.542kg/m!L 4459.24
b)
Operation weight of No. 4 LP
heater Gb kg Data of manufactory 16380

Total metal weight of No. 4 LP
heater Gc kg Data of manufactory 12820

Total water weight of No. 4 LP
heater Gs2 kg

3560

Convert coefficient of metal Gs3

Convert coefficient: C'=0.1185 0.1185

Weight of valve Gcf kg Valve handbook 1600
c)
from No. 4 LP heater to deaerator ML kg Gs1+Gs2+0.1185!(Gi+Gc+Gcf) 10756.11
4
from No. 2 LP heater outlet to No.
4 LP heater inlet

a)
Pipe length from No. 2 LP heater
outlet to No. 3 LP heater inlet L2-3 m

89
b)
Pipe length from No. 3 LP heater
outlet to No. 4 LP heater inlet L3-4 m

56.9

c) Water weight of L2-3 and L3-4 Gs1 kg (L2-3+L3-4)!Q1 10513.55

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d) Metal weight of L2-3 and L3-4 Gi kg 8325!8 weight: 62.542kg/m*(L2-3+L3-4) 9124.88
e)
Operation weight of No. 3 LP
heater Gb3 kg Data of manufactory 14920

Total metal weight of No. 3 LP
heater Gc3 kg Data of manufactory 11850

Total water weight of No. 3 LP
heater Gs2 kg

3070
6)
Operation weight of No. 1&2 LP
heater Gb2 kg Data of manufactory 48345

Total metal weight of No. 1&2 LP
heater Gc2 kg Data of manufactory 36320

Total water weight of No. 1&2 LP
heater Gs3 kg

12025

Convert coefficient of metal C'

C'=0.1185 0.1185

Weight of valve Gcf kg Valve handbook 3200

from No. 2 LP heater outlet to No.
4 LP heater inlet Mc kg
Gs1+Gs2+Gs3+0.1185*(Gi+Gc6+Gc7+Gcf
) 32777.20
5 Water weight of deaerator

a) Cubage of deaerator water tank Q m
3
Data of manufactory 180
b)
Metal weight of deaerator water
tank Gj kg Data of manufactory 73300
c) Radius of deaerator water tank R m

1.8
d)
Center elevation of deaerator water
tank V m

23.55
e)
The lowest water level elevation of
deaerator water tank V1 m

22.85
f)
Water weight of the lowest water
level in deaerator water tank Gs kg 63.233m
3
56511

Water calculation weight of the
lowest water level in deaerator M kg Gs+C'*Gj 65197.05
6
Saturation water enthalpy of
deaerator when transient load
rejection H
O
kJ/kg VWO 736.3
7
Condensate water enthalpy of No.4
LP heater outlet when load
rejection H
L
kJ/kg VWO 589.6
8
Condensater water enthalpy of
condensor H
C
kJ/kg VWO 192.2
9 Calculation time after load rejection T
S
S
standard
300
10 Kind of downcomer N

1
11 NPSH225% margin3 N
r
m 3.6*1.25 4.5
12
Level difference from calculation
water elevation of deaerator to
BFP booster pump C H
j
m

21.955

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13 Resistance of strainer PL kPa

20
14
Specific volume of BFP booster
pump inlet VV m
3
/kg VWO: 173.9"C 0.001119
15 Inner diameter of downcomer DN m [325-22!8)]/1000 0.309
16 Calculatiom length of downcomer L m The max 55.62
17
Part resistance coefficient of
downcomer

Outside diameter of pipe DW mm

325

Thickness of pipe S mm

8

Inner diameter of pipe Di mm DW-2*S 309

Equivalence roughness of pipe 9

E.2.1-1 0.2

Friction coefficient of pipe :

1/(1.14+2*logDi/#)
2
0.01769

Length of pipeline L m

55.62

Friction coefficient of pipeline ;
A

:*L/2Di/1000) 3.18482

Part resistance coefficient of
pipeline

Elbow090" total 11.5 < ;
1

E.2.2-1 2.875

Motorized gate valves ;
2

E.2.2-16 PN2.5;DN300 2.8

Inlet resistance cofficient of
downcomer ;
3

=P180 >?E.2.2-14 2.5

Total resitance coefficient of pipe ;

11.36
18 Flow of each downcomer G kg/s

147.1
result
Available NPSH of load ejection
condition ZH m

0.237

Originality data for calculation
program

294.2,6214.09,10756.11,32777.2,65197
736.3,589.6,192.2,300,1
4.5,21.955,20,0.001119
0.309,55.62
11.36,147.1

4.3.2 Heaters

The extraction system of each unit will be set with three HP heaters, four LP
heaters, one deaerator, and one gland steam condenser.


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All of the heaters are horizontal type and are designed in accordance with HEI
standard. Shell wall thickness shall be determined in accordance with the ASME
code utilizing the allowable stress value for the shell material at the design
pressure and temperature. They are arranged indoors. Two LP heaters are
arranged at the neck of condenser.

The deaerator has enough volume to ensure the boiler working at the maximum
operation condition for about 10 minutes. The deaerator storage tank is also
sized in conjunction with the deaerator outlet piping and height to provide a
storage volume which allow adequate transient NPSH for the boiler feed due to
a sudden full load rejection and prevent flashing at the pump suction.
Deaerator shall remove dissolved oxygen from the condensate in excess of
0.005 cc per liter at any load from 5 percent to and including rated capacity.

HP heaters:

Closed feedwater heaters are used in a regenerative steam cycle to improve the
thermodynamic gain. This is accomplished by extracting system at various points
from the turbine and condensing kit using boiler feedwater. The resultant heating
of the feed water aids in avoiding thermal shock to the boiler and reduces the
fuel consumption required to convert the feedwater to steam. Since the work lost
by extracting the steam is derived from sensible heat, i.e. no change of phase,
the much greater latent heat recovered in the feedwater heater by changing
phase from steam to water result in a net energy gain. Without a feedwater
heater, the latent heat is wasted or thrown out in the main condenser or cooling
tower. Therefore, feedwater heaters also help to reduce thermal pollution.

The high pressure heater is essentially an all-welded assembly. A special insert

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is assembled in the inlet end of every heater-transfer U tube. Each high pressure
heater has indicating, regulating and alarming devices of level. When accident
has taken place, automatic regulating of drain level can fast bypass high
pressure heater. Heater shell is provided with relief valves to protect the shell in
case of tube failure. On tube side, relief valve is provided to prevent excessive
pressure. Each high pressure heater contains three zones, (i.e. desuperheating
zone, condensing zone and subcooling zone).

The welded seams are radiographed to insure the quality of the joint.

Stainless steel impingement plates have been installed in these heaters of
steam and other drains inlets to avoid direct impingement of steam and drains
upon the tubes to prevent tube erosion.

HP HEATER Nos. 8 DATA SHEET
Parameter SL.
No
DESCRIPTION
Tube side Shell side
Unit
1 Sort Class 3rd pressure
vessel
Class 2nd pressure
vessel

2 Type JG-1370
3 Heating area 1370 m
2

4 Design pressure 27.5 7.58 MPa(a)
5 Design temperature 295 420/295
o
C
6 Max. operating
pressure
27.5 7.58 MPa(a)
7 Operating pressure 21.5 6.2145 MPa(a)
8 Operating
temperature
279.5 393.4/277.9
o
C
9 Max. pressure drop <0.1 <0.069 MPa


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Parameter SL.
No
DESCRIPTION
Unit
10 Flow 1015 80.785 T/h
11 Medium Water Steam & Water

12 Weld coefficient 1 1

13 Test pressure 41.25 11.37 MPa(a)

14 Corrosion allowable 1

15 Estimated weight

Net weight 64956 Kg
Operating weight 70861 Kg
Flooded weight 82717 Kg

Manhole weight 120 Kg
16 Estimated Volume
Volume of water in sub-cooler zone at
normal water level
1.40 m
3

Volume of water in shell at normal water
level outside sub-cooler zone
0.86 m
3

Volume of steam in shell operating 12.1 m
3

Volume of tube side 3.78 m
3

Parameter SL.
No
DESCRIPTION
Unit
vessel
Class 2nd pressure
vessel

2 Type JG-1575
2

o
C

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Parameter SL.
No
DESCRIPTION
Unit
6 Max. operating
pressure
27. 5 4.81 MPa(a)
8 Operating
temperature
245 324/245
o
C

10 Flow 1015 68.042 T/h




15 Estimated weight

Net weight 62121 Kg

16 Estimated Volume
normal water level
2.23 m
3

1.27 m
3

3

3

Parameter SL.N
o
DESCRIPTION
Unit

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Parameter SL.N
o
DESCRIPTION
Unit
vessel
Class 2nd pressure
vessel

2 Type JG-1230
2

4 Design pressure 27. 5 2.07 MPa(a)
o
C
6 Max. operating
pressure
27. 5 2.07 MPa(a)
8 Operating
temperature
207.6 455/207.6
o
C

10 Flow 1015 37.799 T/h




15 Estimated weight

Net weight 48739 Kg

16 Estimated Volume
normal water level
2.55 m
3

1.32 m
3


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Parameter SL.N
o
DESCRIPTION
Unit
3

3

Note: class III: 10 to 100MPa, class II: 1.6 to 10MPa.

The high-pressure feedwater heaters shall be manufactured of following
materials or superior materials:-

a) Channel: Carbon steel ASTM A516 Gr 70.

b) Shell: Carbon steel ASTM SA516Gr70.

c) Shell skirt: Carbon steel ASTM A516 Gr 70.

d) Tubes: Stainless steel ASTM SA688TP304N

e) Tubesheet: forged steel ASTM SA 350 Gr LF 2 with SS Cladding

Feed pump hydraulic coupling shall be rated up to lower operating range of 20%
of the maximum output speed.

LP Heaters:

The low pressure heater system adopts single string arrangement, which
consists of four low pressure feedwater heaters. The low-pressure feedwater
heaters shall increase the temperature of the condensate in stages by the use of
extraction steam. The low pressure heaters contain two zones(condensing zone
and subcooling zone). Heat transfer tubes are stainless steel U-tubes. Heater
1

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shell is provided with relief valves to protect the shell in case of tube failure. On
tube side, relief valve is provided to prevent excessive pressure. Each channel
of low pressure heaters consists of a cylindrical shell and an ellipsoidal head. LP
heaters 1 & 2 are located in the neck of the condenser.

The maximum tube side flow shall be the condensate flow at turbine valves wide
open and a design margin of no less than 10 percent.
LP HEATERS Nos. 1 & 2 DATA SHEET
Parameter
SL.
No
DESCRIPTION Tube
side
Shell
side
Tube
side
Shell
side
Unit
1 Heater No. #1 #2
2 Type JD-840-2-1 JD-740-2-2
3 Heating area 840 740 m
2

4 Design pressure 3.92 0.206 3.92 0.206 MPa(a)
5 Design temperature 130 130 130 130
o
C
6 Max. operating
pressure
3.92 0.206 3.92 0.206 MPa(a)
7 Operating pressure 1.724 0.0235 1.724 0.0738 MPa(a)
8 Operating
temperature
59.79 62.56 87.33 90.11
o
C
9
Max. pressure drop
across heater
<0.1 <0.0055 <0.1 <0.0156 MPa

10
Flow
791. 6 15.345 791. 6 33.583 T/h

11 Medium
Water
Steam &
Water
Water
Steam &
Water

12 Weld coefficient 1 0.85 1 0.85

13 Corrosion allowance 1


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Parameter
SL.
No
DESCRIPTION Tube
side
Shell
side
Tube
side
Shell
side
Unit
14 Test pressure 5.88 0.31 5.88 0.31 MPa(a)

15 Estimated weight Heaters #1 & #2 combined

Net weight 41100 Kg
16 Estimated Volume
Volume of water in sub-cooler
zone at normal water level
1.92 m
3

Volume of water in shell at normal
water level outside sub-cooler
zone
3.86 m
3

3

3

LP HEATER No. 3 DATA SHEET
Parameter SL.
No
DESCRIPTION
Unit
1 Sort 2
nd
Class pressure
vessel
1
st
Class pressure
vessel

2 Type JD-530-1-2
2

o
C
6 Max. operating
pressure
3.92 0.48 MPa(a)

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Parameter SL.
No
DESCRIPTION
Unit
8 Operating
temperature
108.6 155.9/111.4
o
C
9
Max. pressure drop
across heater
<0.1 <0.019 MPa

10
Flow
791. 6 26.948 T/h


12 Weld coefficient 1 0.85



16 Estimated weight

Net weight 14000 Kg

17 Estimated Volume
normal water level
0.37 m
3

0.77 m
3

3

3

LP HEATER No. 4 DATA SHEET
Parameter SL.
No
DESCRIPTION
Unit

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Parameter SL.
No
DESCRIPTION
Unit
1 Sort 2
nd
Class pressure
vessel
1
st
Class pressure
vessel

2 Type JD-580-6-4
2

o
C
6 Max. operating
pressure
3.92 0.686 MPa(a)
8 Operating
temperature
139.9 256/142.7
o
C
9
Max. pressure drop
across heater
<0.1 <0.0344 MPa

10
Flow
791.6 40.58 T/h


12 Weld coefficient 1 0.85



15 Estimated weight

Net weight 15400 Kg

16 Estimated Volume
normal water level
0.65 m
3


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Parameter SL.
No
DESCRIPTION
Unit
0.84 m
3

3

3

Note: class II: 1.6 to 10MPa, class I: 0.1 to 1.6MPa.

10% Design margin shall be kept.

The low-pressure feedwater heaters shall be manufactured of following materials
or superior materials:-

a) Channel: Carbon steel ASTM SA516 Gr. 70.

b) Shell: Carbon steel ASTM A516 Gr. 70

c) Shell skirt: Carbon steel ASTM A515 Gr. 70.

d) Tubes: Stainless steel ASTM SA688 TP 304

e) Tubesheet: carbon steel ASTM SA350 Gr LF2.

Deaerator:

The horizontal deaerator is one of the main auxiliary equipment in feedwater
regenerative system for steam generating units. The primary use of deaerator is
to remove noncondensable gases such as oxygen, carbon dioxide, etc. The
boiler water is to reduce oxygen content below 0.005 cc/l. In addition, with
1
1

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extraction on the intermediate pressure side of the turbine and other residual
steam and drain, the deaerator shall heat the boiler feedwater to saturated
temperature under operating pressure of deaerator so as to raise the thermal
efficiency of the unit. The deaerator can store a definite amount of saturated
water at deaerator pressure and conform to the standard of oxygen content to
meet the needs of the boiler and guarantee its safe operation.

DEAERATOR AND TANK DATA SHEET
Parameter SL.N
o
DESCRIPTION
Deaerator
Unit
1 Sort Class 1st pressure vessel
2 Type GC-1080/ GS-180
3 Design pressure 1.19/full vacuum MPa(a)
4 Design temperature 365
o
C
5 Max. working
pressure
0.954 MPa(a)
6 Working
temperature
356.2
o
C
7 Effective Volume 180 m
3
8 Total volume 257 m
3

9 Rated capacity 1080 t/h

10 Weld coefficient 1

11 Corrosion allowable 3.2 mm

12 Medium Steam & Water

13 Nozzle pressure
drop
0.05 MPa

14 Max. capacity t/h

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Parameter
15 Set pressure of
safety valve
MPa(a)
16 Others
The deaerator shall be manufactured of following materials or superior materials:

6.12.1 Deaerating shell & heads Carbon steel to SA 516 Gr. 70
or equivalent
6.12.2 Feed water storage tank shell & heads Carbon steel to SA 516 Gr. 70
or equivalent
6.12.3 Trays Stainless steel to SS 304 / SS
431
6.12.4 Tray enclosure Stainless steel to SS 304
6.12.5 Spray valves / sprayer assembly Stainless steel to SS 304
6.12.6 Steam distribution pipe (Internal) /
Nozzles / Condensate pipes
Carbon steel to SA 106 Gr. B
or equivalent
6.12.7 Splash plates & Baffle plates Stainless steel to SS 304
6.12.8 Bolts SA - 193 B7 or equivalent
6.12.9 Nuts SA - 194 2H or equivalent
6.12.10 Gaskets CAF 40
6.12.11 Internal bolting, if any Stainless steel to SS 304
6.12.12 Vent orifice Stainless steel to SS 304

4.3.3 Condensate extraction pump

Two 100% capacity constant speed motor driven Condensate extraction pumps
are set for each unit, one operate and one standby. The Condensate extraction
pump is $can% type with single suction impeller and with derivational stage.

Each Condensate extraction pump shall be sized to supply 110 percent of the
flow requirements at VWO operation with 3% makeup for each unit.

The Condensate extraction pump & motor shall be provided with online vibration

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measurement system and bearing metal temperature measurement system.

CEP SIZING DATA SHEET
No Name
Symbo
l
Unit
Calculation &
Remark
VWO
TMCR
(3%MU)
Technical
evaluatio
n sheet
A Capacity of CEP

1
Condensate steam
flow at VWO
G1
t/h
HBD from Shanghai
steam turbine works 607.2 583.3
2
Normal drain to
condenser
G2 t/h
" "
125.3 117.8
3
Normal makeup
water to condenser
G3 t/h
" "
29 27.6

4
Other flow to
condenser
G4 t/h
" "
50 50

5
Maximum
condensate flow
G' t/h G'=G1+G2+G3+G4 811.5 778.7

6
Capacity of each
CEP G t/h G=1.1*G' 892.6
7
Condensate water
specific volume
&
m3/K
g
According to HBD 0.00101 0.00101

8 CEP flow Q' m3/h Q=G*&*1000 901.6 786.5
Q m3/h 910 795

B CEP head
1
Pipe pressure drop
from condenser
hotwell outlet to
deaerator inlet
"P1 Mpa Calculation result 0.82 0.617

Mpa
Considering 20"
margin 0.984 0.74

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No Name
Symbo
l
Unit
Calculation &
Remark
VWO
TMCR
(3%MU)
Technical
evaluatio
n sheet
2
Equipments
pressure drop

Mpa
Including GSC, 4
LP heaters & spring
nozzle 0.485 0.485

Mpa
Considering 20"
margin 0.582
3
Water differential
pressure between
deaerator inlet and
condenser hotwell
lowest water level
"P2 Mpa
26.35(inlet of
deaerator
condensater water)-(-
0.662)(water level of
condenser well)
0.2701 0.2701

4
Deaerator max.
working pressure
"P3 Mpa *1.25 margin 1.14
0.9120(no
margin)
5
Condenser highest
vacuum
"P4 Mpa
735x133.3/1000-
10.05
0.088 0.088

6
CEP discharge
head
"P Mpa
P= P1+ P2+ " " "
P3+ P4 " "
3.06

C CEP sizing result
1 Discharge pressure H Mpa 3.06
2 Flow Q m3/h 910 795
Note: all these data is primary data for the selection of CEP.

To counter the surging effect on hotwell 100 m
3
size surge tank is provided.

4.3.4 Vacuum pump

2X100% capacity vacuum pumps will be furnished in the system. Two pumps will
be in operation for establish vacuum in condenser fast to shorten the start-up

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time before the unit starting. During normal operation, one operates for maintain
the vacuum in condenser and another standby.

The vacuum pumps are of liquid ring type, and are sized in accordance with HEI
standards. Each vacuum pump designed capacity is of 80Kg/h approximately of dry
air plus associated water vapor to saturate at 1 inch (25.4 m/sec.) Hg atm. Besides,
the pump capacity is also such that at starting, with both pumps working in parallel, it
is possible to create within 20 minutes vacuum (about 35 KPa) in the condenser.

The design capacity of each pump shall be selected to meet the above
requirements with a margin of 10%.

The pumps shall not cavitate under all operating conditions including part loads
and design point, at CW temperature of 33 Deg.C.

3.10.1 Vacuum pumps
a) Casing Cast iron
b) Shaft Carbon steel EN-8
c) Impeller SS
d) Shaft sleeves SS
3.10.2 Heat Exchangers :
a) Shell Carbon steel
b) Tubes Stainless Steel
c) Tube sheet Carbon steel with epoxy coating
as required
d) Baffle and tie rod cage SS

4.3.5 Condenser
4.3.5.1 Structural Characteristic

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The condenser is designed in the form single shell, divided water boxes Two
pass and installed in transversal arrangement. The condenser mainly consists of
neck, shell, waterbox, exhaust expansion joint and so on.
Four fixed base supports are arranged at the four angles at bottom of the
condenser. Each fixed base support with three slot holes is connected to the
foundation with M36 anchor bolt in order to satisfy the requirements of
condenser expansion. Four sliding base supports are arranged at middle at the
bottom of the condenser, so that the complete condenser can steadily upon the
eight base supports. The condenser is connected to turbine exhaust hood with
expansion joint.

4.3.5.2 Neck

Condenser neck is made of welded carbon steel plates and steel plate is applied
for inside supporting and ribbed plates for reinforcement. T-type beam steel are
applied inside each sideplate of neck to increase transversal rigidity of
sideplates so that the complete neck could be rigid enough. Extraction lines go
through neck. Stainless steel lagging is adopted to cover the outside of
extraction lines in order to avoid erosion. All extraction lines are equipped with
stainless steel waveform expansion joints to absorb thermal expansion in the
lines.
In order to protect abnormal higher temperature caused by turbine bypass inlet
steam. Water screen spray protection device is equipped inside neck.

4.3.5.3 Shell

Shell made of full welded structure is the main part of condenser and possesses
reliable tightness.

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Two tube bundles are set up in shell. Triangular conventional layout is adopted
for the arrangement of tube bundle. All tubes are seam welded. Air extracting
line in cooling area are evenly distributed at cooling water entrance.

Support plates are distributed between front and back tube sheets to support
cooling tubes. So that tubes could contact support plates closely to improve the
vibration property of tubes and avoid resonance. Tube sheets are welded to two
ends of shell and thinner steel plate is applied for flexible transition to
compensate thermal expansion difference between cooling the and shell.
Proper access manhole and other connections are provided on the shell.

An access manhole is provided on the tube bundle. Access openings or manhole
is provided on the interior of the condenser to provided access to the tube
support plates.

In some place where steam of water enters the condenser shell provided
suitable approved baffle to prevent impingement on the tube and shell, and
proper distribution of condensate and steam.

Hot well is designed below tube bundles with enough space so that subcooling
could be minimized in the process for reheating transfer and raise deaerating
effect as well. The hotwell has enough space for the requirements of condensate
level change.

Two flash box is for absorbing drain. In this way, draining water can be
temperature-reduced and pressure breakdown and then drained into condenser
so that tube bundle could be protected from erosion of steam and water higher

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temperature and pressure.

4.3.5.4 Waterboxes

Waterboxes are designed in the form of semicircle and cone-type. Thus resulting
in good rigidity of the hole waterbox body, lightweight and favorable flowing
property of cooling water. The water box is provided cathodic protection
equipment. Inside of this condenser safety ladder is assembled to the inside wall
of waterbox and both vacuum extracted outlet and air vent displaced at the top of
waterbox. Manhole is equipped outlet the lower part of waterbox for maintenance
personnel easy access. The type of water box connection to condenser is
hinged connection.

Sufficient tube extract space shall be kept in the front of tubesheets for taking
out of tubes if tubes are required to be taken out.

4.3.5.5 Exhaust expansion joint

Stainless steel waveform expansion joint is arranged at the exhaust expansion
joint to absorb thermal expansion from turbine low pressure exhaust cylinder and
condenser at vertical centerline direction of flow pressure exhaust cylinder.

The surface condenser is a double pass design with divided water boxes which
will facilitate operation of one half of the condenser while the other half is under
maintenance. The bottom of the condenser serves as a hot well for condensate
storage.

Design Basis:
1

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The thermal design of surface condenser is based on HEI standard considering
33C cooling water temperature for a temp rise of 10C corresponding to heat
load for VWO, 3% makeup and 10.05KPa(a)back pressure.
The condenser hot well minimum storage capacity at the normal water level shall
be 4 minutes of condensate storage when operating at the turbine valves wide
open. The oxygen content of the condensate leaving the hot well shall not
exceed 0.015 cc per liter at all conditions

CONDENSER DATA SHEET
Sl.No Description Parameter Unit
1 Type N-17000
2 Model Single pressure divided two
passes surface

3 Condenser effective surface area 17000m
2

4 Condenser back pressure 10.05 KPa(a)
5 Condenser design pressure
Shell side 0.1/Full vacuum MPa(g)
Waterbox side 0.343 MPa(g)

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Sl.No Description Parameter Unit
Waterbox side test pressure 0.525 MPa(g)
6 Condenser design temperature
Shell side 121
o
C
Waterbox side 60
o
C
7 Inlet temperature of cooling water 33 C
8 Max. inlet temperature of cooling
water
36 C
9 Design flow of cooling water 35000 t/h
10 Cleanliness factor 0.85
11 Water velocity in condenser tubes 2.15 m/s
12 Tube thickness 0.7 & 0.5 mm
13 Tube plugging margin 5%
14 Tube sheet material TP304+SA516Gr70

4.4 Table of economic index
Heat consumption rate of turbine
7995 KJ/kW.h
(1909.6 Kcal/kw.h)

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Guarantee efficiency of boiler (high heating value) 88.8%

Note0The above results are based on TMCR (Heat Rate Guarantee) condition.
Turbine cycle heat rate is 1909.6 Kcal/kW.h based on with 0% makeup, 33 Deg
CCW inlet temp & 10.05 kPa(a) back pressure of condenser.

5 INSULATING MATERIAL
According to different temperature and pressure, different layout of equipments
and pipes in the BTG, the insulation material is considering as following (Code
for designing insulation and painting of fossil and fuel power plant DL/T 5072-
1997) taking care of the following design data:

a) Design ambient temperature: 30

b) Maximum cladding temperature: 60

1) Temperature over 350 degree!s equipments and pipes will adopt silicate or
aluminium silicate material.
Silicate: conductivity factor (@0.031+0.00015tm W/m)
aluminium silicate: conductivity factor (=0.035+0.00018tm W/m)

2) Temperature under 350 degree!s equipments and pipes will adopt rock wool
or glass wool material.
rock wool: conductivity factor (@0.032+0.00018 tm W/m)
3) Valves will adopt insulating material and abnormities will adopt slurry of
silicate and aluminum for protecting layer.

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4) Aluminum material will adopt for protecting layer, the thickness will satisfy the
IS requirement.


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