You are on page 1of 82

NTPC DRG. No.

: 3530-101-01-TR-PVM-W-006
NTPC LIMITED

JOB NO :
STATUS:
DISTRIBUTION

SIMHADRI SUPER THERMAL POWER PROJECT

STAGE-II with
( 2 xElectrostatic
500 MW) Precipitator package"
Modify package name as "Steam Generator
STEAM GENERATOR PACKGE

TO
No. of

REV.
01

Date
13.12.07

ALTD

SS/NR

CHD

APPD

PR

SCS

Predicted performance data for


bottom mills attached

BHARAT HEAVY ELECTRICALS LTD.


UNIT : HIGH PRESSURE BOILER PLANT
TIRUCHIRAPPALLI 620 014

Dept
Code

Name

DRN
DESN
CHD
APPD

Sign

Date

13.12.07
13.12.07
13.12.07

SS/ NR
PR

SCS

TITLE:
PREDICTED PERFORMANCE DATA FOR DESIGN COAL, WORST COAL AND BEST COAL FOR CONSTANT AND
VARIABLE PRESSURE OPREATIONS
DEPT.

SCALE

DRAWING NO.

SIGN.
DATE.

CAUTION:

SHEET

1 OF 82

REV

01

THIS DRAWING IS THE PROPERTY OF BHARAT HEAVY ELECTRICALS LTD., AND IS NOT TO BE REPRODUCED OR USED TO FURNISH ANY INFORMATION FOR
MAKING OF DRAWINGS OR APPARATUS EXCEPT WHERE PROVIDE FOR AGREEMENT WITH SAID COMPANY.

PREDICTED PERFORMANCE DATA


(Design Coal - Constant Pressure)
CONTENTS
SECTION

DESCRIPTION

SHEET No.

FLOW

II

TEMPERATURE

III

PRESSURE (STEAM & WATER)

IV

GAS VELOCITIES

PRESSURES & DRAFTS (AIR & GAS)

VI

FUEL

VII

MILL & BURNER PERFORMANCE

VIII

O2 , CO2 & EXCESS AIR

IX

AMBIENT CONDITIONS

HEAT BALANCE

10

The attached Performance Data are predicted only and are not to be construed as
being guaranteed except where the values coincide with guarantees stated under
the performance guarantee section.

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

Title
: Predicted Performance for Design coal
Doc.No.:
Rev. 01
Sheet 2 of 82

PREDICTED PERFORMANCE DATA


(Design Coal - Constant Pressure)
1. FLOW
Description

HP Heaters in

Unit

HP
heaters
out

BMCR

500
MW

400
MW

300
MW

250
MW

t/h
t/h

1590.0
1358.0

1457.9
1302.1

1167.3
1052.2

887.6
808.3

755.4
656.8

1385.5
1379.0

t/h

1590.0

1432.9

1087.3

796.6

678.4

1297.5

SH spray

t/h

25

80

91

77

88

RH spray

t/h

13

Air
AH Outlet (Primary)

t/h

652

582

445

363

357

626

Tempering air

t/h

15

41

23

10

41

AH Outlet (Secondary)
Total Combustion Air
Gas
Flue gas at RAPH inlet
(Secondary & Primary)
Flue gas at RAPH outlet
(Secondary & Primary)
Inlet PAH
Inlet SAH
Outlet PAH
Outlet SAH
Fuel

t/h
t/h

1155
2024

1067
1855

843
1531

610
1198

464
1033

1157
2026

t/h

2245

2057

1697

1329

1145

2247

t/h

2444

2253

1885

1508

1318

2443

t/h
t/h
t/h
t/h

820

737

601

506

501

800

1425
930
1514

1320
847
1406

1096
709
1176

823
611
897

644
603
715

1447
909
1534

t/h

374

347

286

224

193

376

Steam
Superheater outlet
Reheater outlet
Water
Feed water

Coal

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

Title
: Predicted Performance for Design coal
Doc.No.:
Rev. 01
Sheet 3 of 82

PREDICTED PERFORMANCE DATA


(Design Coal - Constant Pressure)
II.

TEMPERATURE
Description

HP Heaters in

Unit

Steam
Sat. temp. in Drum
LTSH inlet
LTSH outlet
SH Panel inlet
SH Panel outlet
SH Platen inlet
SH Platen outlet
RH Stage-I inlet
RH Stage-I outlet
RH Stage-II inlet
RH Stage-II outlet
Water
Economiser inlet
Economiser outlet
Air
Ambient
AH Outlet (Primary)
AH Outlet (Secondary)
Gas
SH Panel inlet
SH Platen inlet
RH Front inlet
RH Rear inlet
LTSH inlet
Economiser inlet
Airheater inlet
Airheater outlet

HP
Heaters
out

BMCR

500
MW

400
MW

300
MW

250
MW

C
C

362

361

358

355

354

360

365

364

363

362

362

365

C
C
C
C
C
C
C
C
C

397
397
467
467
540
338
487
487
568

395
389
464
464
540
337
492
492
568

398
377
455
455
540
329
494
494
568

398
367
444
444
540
322
499
499
568

400
362
439
439
540
311
502
502
568

406
383
456
456
540
351
502
502
568

C
C

255
318

253
315

243
309

230
305

219
297

169
286

C
C
C

27
313
311

27
309
305

27
294
294

27
275
275

27
262
262

27
269
266

C
C
C
C
C
C
C
C

1383
1128
1029
852
673
549
339
126

1380
1115
1013
836
658
537
332
125

1382
1090
980
799
626
513
314
125

1400
1067
944
756
590
486
293
117

1392
1043
914
726
567
470
279
114

1379
1125
1027
855
678
554
289
110

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

Title
: Predicted Performance for Design coal
Doc.No.:
Rev. 01
Sheet 4 of 82

PREDICTED PERFORMANCE DATA


(Design Coal - Constant Pressure)
III.

PRESSURES (STEAM AND WATER)

Description

HP Heaters in

Unit
BMCR

500
MW

400
MW

300
MW

250
MW

HP
Heaters
out

Pressure
Superheater Outlet
LTSH Outlet
Drum

kg/cm2 (g)

178.0

176.6

174.0

171.9

171.1

175.9

190.0

186.9

180.9

176.1

174.3

185.3

195.0

191.2

183.9

177.9

175.6

189.3

kg/cm (g)
kg/cm (g)

Economiser inlet

kg/cm (g)

200.7

196.4

188.1

181.4

178.8

194.2

Reheater Stage II outlet

kg/cm2 (g)

42.4

40.7

32.7

25.0

20.2

44.1

kg/cm (g)

45.0

43.2

34.8

26.6

21.5

46.7

kg/cm2

17.0

14.6

9.9

6.0

4.5

13.4

2.6

2.5

2.1

1.6

1.3

2.6

5.7

5.2

4.2

3.5

3.2

4.9

Reheater Stage I inlet

Pressure Drop
Superheater system
Reheater system
Economiser including
static head

kg/cm

kg/cm

IV. GAS VELOCITIES IN SH/RH/ECO BANKS


Description

Platen SH
RH Front
RH Rear
LTSH
Economiser

HP Heaters in

Unit

m/s
m/s
m/s
m/s
m/s

BMCR

500
MW

400
MW

300
MW

250
MW

7.4
8.6
9.3
8.9
8.5

6.6
7.7
8.2
7.8
7.4

5.4
6.1
6.5
6.2
5.9

4.1
4.7
4.9
4.7
4.5

3.5
3.9
4.1
3.9
3.8

HP
Heaters
out
7.4
8.6
9.3
8.9
8.5

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

Title
: Predicted Performance for Design coal
Doc.No.:
Rev. 01
Sheet 5 of 82

PREDICTED PERFORMANCE DATA


(Design Coal - Constant Pressure)
V. PRESSURES AND DRAFTS (AIR AND GAS)
Description

Unit

HP Heaters in
BMCR

500 MW

400 MW

300 MW

250 MW

HP
Heaters
out

Primary air
PA Fan inlet

mmwc

-11

-9

-6

-4

-4

-11

PA Fan outlet

mmwc

871

885

853

830

783

853

Air heater inlet

mmwc

858

875

845

825

778

840

Air heater outlet

mmwc

807

832

814

801

754

793

Mill inlet

mmwc

686

712

698

687

644

672

Mill outlet

mmwc

306

323

310

302

277

292

FD fan inlet

mmwc

-14

-12

-8

-5

-3

-14

FD fan outlet

mmwc

177

164

131

105

91

177

Airheater inlet

mmwc

160

149

121

99

87

160

Airheater outlet

mmwc

113

108

94

83

78

115

Windbox pressure

mmwc

70

70

70

70

70

70

mmwc
mmwc
mmwc
mmwc
mmwc

-5
-5
-6
-15

-5
-5
-6
-13

-5
-5
-6
-11

-5
-5
-6
-9

-5
-5
-6
-8

-5
-5
-6
-15

-31

-29

-24

-19

-16

-30

mmwc
mmwc
mmwc
mmwc
mmwc
mmwc

-58
-74
-166
-181
-236

-54
-68
-149
-163
-213

-44
-56
-115
-128
-165

-34
-44
-90
-101
-128

-28
-37
-82
-93
-115

-56
-71
-154
-169
-222

31

28

23

19

17

30

Secondary air

Gas
Furnace
SH Platen inlet
RH Inlet (Platen outlet)
LTSH inlet (RH outlet)
Economiser inlet (LTSH
outlet)
Economiser outlet
Airheater inlet
Airheater outlet
EP inlet
ID fan inlet
ID fan outlet

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

Title
: Predicted Performance for Design coal
Doc.No.:
Rev. 01
Sheet 6 of 82

PREDICTED PERFORMANCE DATA


(Design Coal - Constant Pressure)
VI.FUEL
The fuel data for design coal are as follows:

Description

Unit

Fuel

Design Coal

Proximate Analysis :
Fixed carbon

24

Volatile matter

21

Moisture

14

Ash

41

HGI

55

Higher Heating Value (HHV)

kcal/kg

3300

Size of coal to Mill (Approx.)

mm

50

Carbon

31.70

Hydrogen

3.30

Sulphur

0.28

Nitrogen

0.83

Oxygen

8.54

Carbonates

0.30

Phosphorous

0.05

Moisture

14.00

Ash

41.00

Grindability Index

Ultimate Analysis:

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

Title
: Predicted Performance for Design coal
Doc.No.:
Rev. 01
Sheet 7 of 82

PREDICTED PERFORMANCE DATA


(Design Coal - Constant Pressure)
VII. MILL AND BURNER PERFORMANCE

Description

BMCR

500 MW

400 MW

300 MW

250 MW

HP
Heaters
out

Top 7

Top 6

Top 5

Top 4

Top 4

Top 7

(D-K)

(E-K)

(F-K)

(G-K)

(G-K)

(D-K)

HP Heaters in

Unit

No. of mills in Operation

Mill loading

82.2

89.0

88.0

86.2

74.2

82.6

Air flow per mill

t/h

95.3

97.7

97.2

96.5

91.7

95.3

Air temp. at mill inlet

307

307

272

261

256

254

Mill outlet temperature

66 to 90

Fineness(thru' 200 mesh)

70

Deg

-30 to +30

Burner tilt

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

Title
: Predicted Performance for Design coal
Doc.No.:
Rev. 01
Sheet 8 of 82

PREDICTED PERFORMANCE DATA


(Design Coal - Constant Pressure)
VIII.

O2, CO2 (DRY VOL.) AND EXCESS AIR

Description

HP Heaters in
BMCR

500 MW

400 MW

300 MW

250 MW

HP
Heaters
out

Unit

Oxygen in gas at
Economiser outlet

3.58

3.58

3.58

3.58

3.58

3.58

Carbon-di-oxide in gas
at Economiser outlet

15.00

15.00

15.00

15.00

15.00

15.00

Excess air in gas at


Economiser outlet

20.0

20.0

20.0

20.0

20.0

20.0

IX.AMBIENT CONDITIONS
Ambient temperature
Relative Humidity

Deg.C

27

60

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

Title
: Predicted Performance for Design coal
Doc.No.:
Rev. 01
Sheet 9 of 82

PREDICTED PERFORMANCE DATA


(Design Coal - Constant Pressure)
X. HEAT BALANCE

Description

HP Heaters in
BMCR

500 MW

400 MW

300 MW

250 MW

HP
Heaters
out

Unit

Losses
Dry gas

4.167

4.149

4.213

4.007

4.132

3.484

H2O in fuel, surf. & inherent

2.598

2.596

2.595

2.579

2.570

2.568

H2O from comb. of H2

5.472

5.468

5.467

5.433

5.414

5.409

H2O in air

0.103

0.102

0.104

0.099

0.102

0.086

Radiation

0.216

0.233

0.283

0.362

0.419

0.218

Unburnt Carbon

1.500

1.500

1.500

1.500

1.500

1.500

Unaccounted

0.950

0.952

0.961

0.964

0.969

0.915

Manufacturers margin

0.150

0.150

0.150

0.150

0.150

0.150

Total losses

15.156

15.150

15.273

15.094

15.256

14.330

84.84

84.85

84.73

84.91

84.74

85.67

EFFICIENCY

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

Title
: Predicted Performance for Design coal
Doc.No.:
Rev. 01
Sheet 10 of 82

PREDICTED PERFORMANCE DATA


(Worst Coal - Constant Pressure)
CONTENTS
SECTION

DESCRIPTION

SHEET No.

FLOW

12

II

TEMPERATURE

13

III

PRESSURE (STEAM & WATER)

14

IV

GAS VELOCITIES

14

PRESSURES & DRAFTS (AIR & GAS)

15

VI

FUEL

16

VII

MILL & BURNER PERFORMANCE

17

VIII

O2 , CO2 & EXCESS AIR

18

IX

AMBIENT CONDITIONS

18

HEAT BALANCE

19

The attached Performance Data are predicted only and are not to be construed as
being guaranteed except where the values coincide with guarantees stated under
the performance guarantee section.

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Worst coal


DWG :
Sheet : 11 of 82
Rev.01

PREDICTED PERFORMANCE DATA


(Worst Coal - Constant Pressure)
1. FLOW
Description

HP Heaters in

Unit

HP
heaters
out

BMCR

500
MW

400
MW

300
MW

250
MW

t/h
t/h

1590.0
1358.0

1457.9
1302.1

1167.3
1052.2

887.6
808.3

755.4
656.8

1385.5
1379.0

t/h

1625.0

1440.9

1090.3

799.6

687.4

1286.5

SH spray

t/h

17

77

88

68

99

RH spray

t/h

21

Air
AH Outlet (Primary)

t/h

855

768

625

447

431

832

Tempering air

t/h

34

40

31

26

AH Outlet (Secondary)
Total Combustion Air
Gas
Flue gas at RAPH inlet
(Secondary & Primary )
Flue gas at RAPH outlet
(Secondary & Primary )
Inlet PAH
Inlet SAH
Outlet PAH
Outlet SAH

t/h
t/h

1026
2087

934
1908

701
1562

533
1222

389
1053

1020
2080

t/h

2334

2133

1747

1366

1178

2325

t/h

2536

2329

1934

1543

1353

2524

t/h
t/h
t/h
t/h

1050

953

817

624

614

1027

1284
1164
1372

1180
1065
1264

930
926
1008

742
729
814

564
718
635

1298
1140
1384

t/h

447

412

341

266

230

450

Steam
Superheater outlet
Reheater outlet
Water
Feed water

Fuel
Coal

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Worst coal


DWG :
Sheet : 12 of 82
Rev.01

PREDICTED PERFORMANCE DATA


(Worst Coal - Constant Pressure)
II. TEMPERATURE
Description

HP Heaters in

Unit
BMCR

500
MW

400
MW

300
MW

250
MW

HP
Heaters
out

Steam
Sat. temp. in Drum
LTSH inlet

C
C

362

361

358

355

354

360

365

365

363

362

362

366

LTSH outlet
SH Panel inlet
SH Panel outlet
SH Platen inlet
SH Platen outlet
RH Stage-I inlet
RH Stage-I outlet
RH Stage-II inlet
RH Stage-II outlet

C
C
C
C
C
C
C
C
C

399
399
464
464
540
338
482
482
568

398
392
463
463
540
337
488
488
568

399
382
456
456
540
329
495
495
568

400
369
446
446
540
322
499
499
568

401
364
441
441
540
311
501
501
568

404
381
453
453
540
351
502
502
568

C
C

255
322

253
319

243
312

230
307

219
300

169
295

C
C
C

27
313
318

27
309
314

27
297
298

27
278
277

27
265
264

27
271
276

C
C
C
C
C
C
C
C

1388
1136
1039
862
682
557
345
127

1368
1113
1015
840
665
544
338
126

1354
1079
975
799
630
518
318
126

1356
1048
933
753
592
489
296
123

1347
1024
904
724
569
473
282
122

1383
1133
1036
866
690
564
297
115

Water
Economiser inlet
Economiser outlet
Air
Ambient
AH Outlet (Primary)
AH Outlet (Secondary)
Gas
SH Panel inlet
SH Platen inlet
RH Front inlet
RH Rear inlet
LTSH inlet
Economiser inlet
Airheater inlet
Airheater outlet

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Worst coal


DWG :
Sheet : 13 of 82
Rev.01

PREDICTED PERFORMANCE DATA


(Worst Coal - Constant Pressure)
III.

PRESSURES (STEAM AND WATER)

Description

HP Heaters in

Unit

Pressure
Superheater Outlet

kg/cm2 (g)

LTSH Outlet

BMCR

500
MW

400
MW

300
MW

250
MW

HP
Heaters
out

178.0

176.6

174.0

171.9

171.1

175.9

190.0

186.9

180.9

176.1

174.3

185.3

kg/cm (g)

Drum

kg/cm (g)

195.0

191.2

183.9

177.9

175.6

189.3

Economiser inlet

kg/cm2 (g)

Reheater Stage-II outlet


Reheater Stage-I inlet

200.7

196.4

188.1

181.4

178.8

194.2

42.4

40.7

32.7

25.0

20.2

44.1

kg/cm (g)

45.0

43.2

34.8

26.6

21.5

46.7

kg/cm2

17.0

14.6

9.9

6.0

4.5

13.4

2.6

2.5

2.1

1.6

1.3

2.6

5.7

5.2

4.2

3.5

3.2

4.9

kg/cm (g)

Pressure Drop
Superheater system

Reheater system

kg/cm

Economiser including
static head

kg/cm

IV. GAS VELOCITIES IN SH/RH/ECO BANKS


Description

HP Heaters in

Unit

Platen SH
RH Front
RH Rear
LTSH
Economiser

m/s
m/s
m/s
m/s
m/s

BMCR

500
MW

400
MW

300
MW

250
MW

7.6
8.8
9.6
9.2
8.7

6.7
7.7
8.3
7.9
7.5

5.4
6.2
6.6
6.3
6.0

4.2
4.7
5.0
4.8
4.5

3.5
4.0
4.2
4.0
3.8

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Worst coal


DWG :
Sheet : 14 of 82
Rev.01

HP
Heater
s out
7.6
8.8
9.5
9.2
8.7

PREDICTED PERFORMANCE DATA


(Worst Coal - Constant Pressure)
V. PRESSURES AND DRAFTS (AIR AND GAS)
Description

Unit

HP Heaters in
BMCR

500 MW

400 MW

300 MW

250 MW

HP
Heaters
out

Primary air
PA Fan inlet

mmwc

-17

-14

-11

-6

-6

-17

PA Fan outlet

mmwc

909

900

841

842

793

888

Air heater inlet

mmwc

888

883

828

835

786

868

Air heater outlet

mmwc

813

818

781

804

756

798

Mill inlet

mmwc

683

692

661

687

643

669

Mill outlet

mmwc

302

307

285

299

274

288

FD fan inlet

mmwc

-11

-10

-6

-4

-2

-11

FD fan outlet

mmwc

157

144

112

98

87

155

Airheater inlet

mmwc

143

132

105

93

84

141

Airheater outlet

mmwc

104

99

86

81

76

104

Windbox pressure

mmwc

70

70

70

70

70

70

mmwc
mmwc
mmwc
mmwc
mmwc

-5
-5
-6
-14

-5
-5
-6
-12

-5
-5
-6
-10

-5
-5
-6
-8

-5
-5
-6
-8

-5
-5
-6
-14

-27

-26

-21

-18

-15

-28

mmwc
mmwc
mmwc
mmwc
mmwc
mmwc

-50
-67
-201
-216
-274

-48
-63
-178
-192
-244

-38
-50
-141
-154
-192

-32
-42
-103
-114
-142

-26
-35
-94
-105
-128

-52
-69
-191
-206
-265

33

30

24

19

17

33

Secondary air

Gas
Furnace
SH Platen inlet
RH Inlet (Platen outlet)
LTSH inlet (RH outlet)
Economiser inlet (LTSH
outlet)
Economiser outlet
Airheater inlet
Airheater outlet
EP inlet
ID fan inlet
ID fan outlet

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Worst coal


DWG :
Sheet : 15 of 82
Rev.01

PREDICTED PERFORMANCE DATA


(Worst Coal - Constant Pressure)
VI.FUEL
The fuel data for Worst coal are as follows:
Description

Unit

Fuel

Worst Coal

Proximate Analysis:
Fixed carbon

20

Volatile matter

19

Moisture

16

Ash

45

HGI

50

kcal/kg

2800

mm

50 (Approx.)

Carbon

27.70

Hydrogen

2.60

Sulphur

0.50

Nitrogen

0.52

Oxygen

7.26

Carbonates

0.38

Phosphorous

0.04

Moisture

16.00

Ash

45.00

Grindability Index
Higher Heating Value (HHV)
Size of coal to Mill
Ultimate Analysis:

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Worst coal


DWG :
Sheet : 16 of 82
Rev.01

PREDICTED PERFORMANCE DATA


(Worst Coal - Constant Pressure)
VII. MILL AND BURNER PERFORMANCE

Description

BMCR

500 MW

400 MW

300 MW

250 MW

HP
Heaters
out

Top9

Top8

Top7

Top5

Top5

Top9

(B-K)

(C-K)

(D-K)

(F-K)

(F-K)

(B-K)

HP Heaters in

Unit

No. of mills in Operation

Mill loading

82.2

85.2

80.6

88.0

76.1

82.7

Air flow per mill

t/h

95.4

96.5

94.1

97.4

92.4

95.3

Air temp. at mill inlet

311

307

283

258

249

264

Mill outlet temperature

Fineness (thru '200 mesh)

Burner tilt

Deg

66

to 90
70

-30

to

At this mill inlet temp min. mill outlet temp. of


66 deg may not be achieved. BHEL to
check and change the mill inlet temp
accordingly.

+30

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Worst coal


DWG :
Sheet : 17 of 82
Rev.01

PREDICTED PERFORMANCE DATA


(Worst Coal - Constant Pressure)

VIII. O2, CO2 (DRY VOL.) AND EXCESS AIR


Description

BMCR

500 MW

400 MW

300 MW

250 MW

HP
Heaters
out

HP Heaters in

Unit

Oxygen in gas at
Economiser outlet

3.57

3.57

3.57

3.57

3.57

3.57

Carbon-di-oxide in gas
at Economiser outlet

15.26

15.26

15.26

15.26

15.26

15.26

Excess air in gas at


Economiser outlet

20.0

20.0

20.0

20.0

20.0

20.0

IX.AMBIENT CONDITIONS
Ambient temperature

Deg.C

27

60

Relative Humidity

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Worst coal


DWG :
Sheet : 18 of 82
Rev.01

PREDICTED PERFORMANCE DATA


(Worst Coal - Constant Pressure)

X. HEAT BALANCE

Description

BMCR

500 MW

400 MW

300 MW

250 MW

HP
Heaters
out

HP Heaters in

Unit

Losses
Dry gas

4.257

4.235

4.296

4.197

4.381

3.734

H2O in fuel, surf. & inherent

3.497

3.494

3.493

3.486

3.480

3.466

H2O from comb. Of H2

5.078

5.074

5.073

5.062

5.054

5.034

H2O in air

0.105

0.104

0.106

0.103

0.108

0.092

Radiation

0.214

0.231

0.280

0.358

0.414

0.216

Unburnt Carbon

1.500

1.500

1.500

1.500

1.500

1.500

Unaccounted

1.192

1.192

1.200

1.208

1.216

1.155

Manufacturers margin

0.150

0.150

0.150

0.150

0.150

0.150

Total losses

15.993

15.980

16.098

16.064

16.303

15.347

EFFICIENCY

84.01

84.02

83.90

83.94

83.70

84.65

the total losses are indicated on higher side


than given in the bid and final efficiency is
indicated less than given in the bid. BHEL
to clarify and correct. It is applicable for all
coals.

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Worst coal


DWG :
Sheet : 19 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Best Coal - Constant Pressure)
CONTENTS
SECTION

DESCRIPTION

SHEET No.

FLOW

21

II

TEMPERATURE

22

III

PRESSURE (STEAM & WATER)

23

IV

GAS VELOCITIES

23

PRESSURES & DRAFTS (AIR & GAS)

24

VI

FUEL

24

VII

MILL & BURNER PERFORMANCE

25

VIII

O2 , CO2 & EXCESS AIR

26

IX

AMBIENT CONDITIONS

27

HEAT BALANCE

28

The attached Performance Data are predicted only and are not to be construed as
being guaranteed except where the values coincide with guarantees stated under
the performance guarantee section.

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Best coal


DWG :
Sheet : 20 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Best Coal - Constant Pressure)
1. FLOW
Description

HP Heaters in

Unit

Steam
Superheater outlet

t/h

HP
heaters
out

BMCR

500
MW

400
MW

300
MW

250
MW

1457.9
1302.1

1167.3
1052.2

887.6
808.3

755.4
656.8

1385.5
1379.0

Reheater outlet
Water
Feed water

t/h

1590.0
1358.0

t/h

1625.0

1430.9

1085.3

794.6

676.4

1325.5

SH spray

t/h

27

82

93

79

60

RH spray

t/h

Air
AH Outlet (Primary)
Tempering air

t/h
t/h

461

442

386

329

254

486

71

78

46

14

15

46

t/h
t/h

1252
1986

1119
1841

878
1512

637
1182

550
1021

1250
1984

2179

2021

1659

1298

1120

2177

2376

2212

1843

1472

1289

2370

AH Outlet (Secondary)
Total Combustion Air
Gas
Flue gas at RAPH inlet
(Secondary & Primary )
Flue gas at RAPH outlet
(Secondary & Primary )
Inlet PAH
Inlet SAH
Outlet PAH
Outlet SAH

t/h
t/h
t/h
t/h

615

596

527

456

369

634

1564
722
1654

1425
701
1511

1132
631
1212

842
557
915

751
467
822

1543
739
1631

Fuel
Coal

t/h

287

267

221

173

149

287

t/h
t/h

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Best coal


DWG :
Sheet : 21 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Best Coal - Constant Pressure)

II. TEMPERATURE
Description

HP Heaters in

Unit
BMCR

500
MW

400
MW

300
MW

250
MW

HP
Heaters
out

Steam
Sat. temp. in Drum
LTSH inlet

C
C

362

361

358

355

354

360

365

364

363

362

362

365

LTSH outlet
SH Panel inlet
SH Panel outlet

C
C
C

400
400

394
387

397
375

401
365

401
364

406
387

468

462

454

442

437

459

SH Platen inlet
SH Platen outlet
RH Stage-I inlet
RH Stage-I outlet

C
C
C
C

468
540
338
491

462
540
337
492

454
540
329
494

442
540
322
500

437
540
311
502

459
540
351
499

RH Stage-II inlet

491

492

494

500

502

499

RH Stage-II outlet

568

568

568

568

568

568

C
C

255
315

253
314

243
307

230
302

219
294

169
276

C
C
C

27
312
304

27
307
303

27
291
290

27
271
271

27
257
257

27
262
255

C
C
C
C
C
C
C
C

1390
1127
1026
847
668
543
333
126

1426
1138
1029
843
660
536
328
125

1431
1113
995
804
626
510
310
125

1456
1091
958
761
589
484
289
117

1446
1065
927
730
567
468
275
114

1375
1118
1018
844
668
544
279
110

Water
Economiser inlet
Economiser outlet
Air
Ambient
AH Outlet (Primary)
AH Outlet (Secondary)
Gas
SH Panel inlet
SH Platen inlet
RH Front inlet
RH Rear inlet
LTSH inlet
Economiser inlet
Airheater inlet
Airheater outlet

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Best coal


DWG :
Sheet : 22 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Best Coal - Constant Pressure)
III.

PRESSURES (STEAM AND WATER)

Description

HP Heaters in

Unit

Pressure
Superheater Outlet

kg/cm2 (g)

LTSH Outlet

BMCR

500
MW

400
MW

300
MW

250
MW

HP
Heaters
out

178.0

176.6

174.0

171.9

171.1

175.9

190.0

186.9

180.9

176.1

174.3

185.3

kg/cm (g)

Drum

kg/cm (g)

195.0

191.2

183.9

177.9

175.6

189.3

Economiser inlet

kg/cm2 (g)

Reheater Stage-II outlet


Reheater Stage-I inlet

200.7

196.4

188.1

181.4

178.8

194.2

42.4

40.7

32.7

25.0

20.2

44.1

kg/cm (g)

45.0

43.2

34.8

26.6

21.5

46.7

kg/cm2

17.0

14.6

9.9

6.0

4.5

13.4

2.6

2.5

2.1

1.6

1.3

2.6

5.7

5.2

4.2

3.5

3.2

4.9

kg/cm (g)

Pressure Drop
Superheater system

Reheater system

kg/cm

Economiser including
static head

kg/cm

IV. GAS VELOCITIES IN SH/RH/ECO BANKS


Description

HP Heaters in

Unit

Platen SH
RH Front
RH Rear
LTSH
Economiser

m/s
m/s
m/s
m/s
m/s

BMCR

500
MW

400
MW

300
MW

250
MW

7.3
8.5
9.1
8.7
8.2

6.6
7.6
8.1
7.7
7.3

5.4
6.1
6.4
6.1
5.8

4.1
4.6
4.8
4.7
4.4

3.5
3.9
4.0
3.9
3.7

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Best coal


DWG :
Sheet : 23 of 82
Rev.01

HP
Heaters
out
7.3
8.5
9.1
8.7
8.2

PREDICTED PERFORMANCE DATA


( Best Coal - Constant Pressure)
V. PRESSURES AND DRAFTS (AIR AND GAS)
Description

Unit

HP Heaters in
BMCR

500 MW

400 MW

300 MW

250 MW

HP
Heaters
out

Primary air
PA Fan inlet

mmwc

-7

-7

-5

-4

-2

-7

PA Fan outlet

mmwc

800

797

799

779

773

800

Air heater inlet

mmwc

791

792

793

775

770

791

Air heater outlet

mmwc

758

761

755

743

752

758

Mill inlet

mmwc

645

647

647

647

645

646

Mill outlet

mmwc

289

297

299

301

286

290

FD fan inlet

mmwc

-16

-13

-9

-5

-4

-16

FD fan outlet

mmwc

196

172

134

107

99

193

Airheater inlet

mmwc

176

156

123

101

94

173

Airheater outlet

mmwc

122

111

95

84

81

122

Windbox pressure

mmwc

70

70

70

70

70

70

mmwc
mmwc
mmwc
mmwc
mmwc

-5
-5
-6
-17

-5
-5
-6
-15

-5
-5
-6
-12

-5
-5
-6
-9

-5
-5
-6
-8

-5
-5
-6
-16

-35

-32

-24

-19

-18

-35

mmwc
mmwc
mmwc
mmwc
mmwc
mmwc

-66
-81
-186
-201
-254

-60
-74
-163
-177
-225

-44
-55
-115
-127
-164

-34
-43
-83
-94
-120

-32
-40
-71
-82
-105

-66
-81
-175
-190
-243

30

28

22

18

16

30

Secondary air

Gas
Furnace
SH Platen inlet
RH Inlet (Platen outlet)
LTSH inlet (RH outlet)
Economiser inlet (LTSH
outlet)
Economiser outlet
Airheater inlet
Airheater outlet
EP inlet
ID fan inlet
ID fan outlet

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Best coal


DWG :
Sheet : 24 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Best Coal - Constant Pressure)
VI.FUEL
The fuel data for Best coal are as follows:
Description

Unit

Fuel

Best Coal

Proximate Analysis:
Fixed carbon

32

Volatile matter

24

Moisture

12

Ash

32

HGI

60

kcal/kg

4200

mm

50 (Approx.)

Carbon

41.90

Hydrogen

3.60

Sulphur

0.25

Nitrogen

1.00

Oxygen

8.92

Carbonates

0.27

Phosphorous

0.06

Moisture

12.00

Ash

32.00

Grindability Index
Higher Heating Value (HHV)
Size of coal to Mill
Ultimate Analysis:

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Best coal


DWG :
Sheet : 25 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Best Coal - Constant Pressure)
VII. MILL AND BURNER PERFORMANCE

Description

BMCR

500 MW

400 MW

300 MW

250 MW

HP
Heaters
out

Top6

Top6

Top5

Top4

Top3

Top6

(E-K)

(E-K)

(F-K)

(G-K)

(H-K)

(E-K)

HP Heaters in

Unit

No. of mills in Operation

Mill loading

66.6

62.0

61.5

60.2

69.2

66.6

Air flow per mill

t/h

88.7

86.7

86.4

85.8

89.7

88.7

Air temp. at mill inlet

275

265

264

261

245

242

Mill outlet temp.

Fineness(thru '200
mesh)

Burner Tilt

Deg

66

to

90

70
-30

to

+30

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Best coal


DWG :
Sheet : 26 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Best Coal - Constant Pressure)

VIII. O2, CO2 (DRY VOL.) AND EXCESS AIR


Description

HP Heaters in

Unit
BMCR

500 MW

400 MW

300 MW

250 MW

HP
Heaters
out

Oxygen in gas at
Economiser outlet

3.57

3.57

3.57

3.57

3.57

3.57

Carbon-di-oxide in gas
at Economiser outlet

15.37

15.37

15.37

15.37

15.37

15.37

Excess air in gas at


Economiser outlet

20.0

20.0

20.0

20.0

20.0

20.0

IX.AMBIENT CONDITIONS
Ambient temperature

Deg.C

27

60

Relative Humidity

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Best coal


DWG :
Sheet : 27 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Best Coal - Constant Pressure)

X. HEAT BALANCE

Description

BMCR

500 MW

400 MW

300 MW

250 MW

HP
Heaters
out

HP Heaters in

Unit

Losses
Dry gas

4.238

4.210

4.507

4.287

4.479

3.533

H2O in fuel, surf. & inherent

1.752

1.751

1.749

1.738

1.732

1.732

H2O from comb. Of H2

4.698

4.694

4.689

4.660

4.644

4.644

H2O in air

0.104

0.103

0.111

0.106

0.110

0.087

Radiation

0.221

0.239

0.288

0.369

0.427

0.224

Unburnt Carbon

1.500

1.500

1.500

1.500

1.500

1.500

Unaccounted

0.639

0.642

0.654

0.663

0.674

0.617

Manufacturers margin

0.150

0.150

0.150

0.150

0.150

0.150

Total losses

13.302

13.289

13.648

13.473

13.716

12.487

86.70

86.71

86.35

86.53

86.28

87.51

EFFICIENCY

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Best coal


DWG :
Sheet : 28 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Design Coal - Sliding Pressure)
CONTENTS
SECTION

DESCRIPTION

SHEET No.

FLOW

30

II

TEMPERATURE

31

III

PRESSURE (STEAM & WATER)

32

IV

GAS VELOCITIES

32

PRESSURES & DRAFTS (AIR & GAS)

33

VI

FUEL

34

VII

MILL & BURNER PERFORMANCE

35

VIII

O2 , CO2 & EXCESS AIR

36

IX

AMBIENT CONDITIONS

36

HEAT BALANCE

37

The attached Performance Data are predicted only and are not to be construed as
being guaranteed except where the values coincide with guarantees stated under
the performance guarantee section.

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Design Coal (Sliding Pressure)


DWG :
Sheet : 29 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Design Coal - Sliding Pressure)
1. FLOW
Description
Steam
Superheater outlet

HP Heaters in

Unit

t/h

500 MW

400 MW

300 MW

250 MW

1150.2
1037.1

864.6
787.6

731.4
654.0

Reheater outlet
Water
Feed water

t/h

1452.9
1297.7

t/h

1427.9

1070.2

774.6

639.4

SH spray

t/h

25

80

90

92

RH spray

t/h

Air
AH Outlet (Primary)
Tempering air

t/h
t/h

571

460

369

350

15

26

16

15

AH Outlet (Secondary)
Total Combustion Air
Gas

t/h
t/h

1066
1854

840
1528

604
1191

452
1019

Flue gas at RAPH inlet


(Secondary & Primary )
Flue gas at RAPH outlet
(Secondary & Primary )
Inlet PAH
Inlet SAH
Outlet PAH
Outlet SAH

t/h

2055

1694

1321

1130

2250

1882

1500

1303

t/h
t/h
t/h
t/h

729

614

512

497

1326
839
1411

1080
722
1160

809
617
883

633
600
703

Fuel
Coal

t/h

346

284

221

191

t/h

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Design Coal (Sliding Pressure)


DWG :
Sheet : 30 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Design Coal - Sliding Pressure)
II. TEMPERATURE
Description

HP Heaters in

Unit
500 MW

400 MW

300 MW

250 MW

Steam
Sat. temp. in Drum
LTSH inlet

C
C

357

340

319

307

361

350

337

329

LTSH outlet
SH Panel inlet
SH Panel outlet
SH Platen inlet
SH Platen outlet
RH Stage-I inlet
RH Stage-I outlet
RH Stage-II inlet
RH Stage-II outlet

C
C
C
C
C
C
C
C
C

396
388
463
463
540
340
492
492
568

390
361
450
450
540
341
503
503
568

397
338
430
430
540
344
514
514
568

404
327
423
423
540
342
515
515
568

C
C

253
316

243
305

230
296

221
289

C
C
C

27
310
306

27
294
294

27
274
274

27
260
260

C
C
C
C
C
C
C
C

1364
1105
1006
831
656
536
332
125

1351
1073
967
793
624
509
314
125

1353
1041
924
749
587
479
292
118

1322
1005
885
714
560
458
277
117

Water
Economiser inlet
Economiser outlet
Air
Ambient
AH Outlet (Primary)
AH Outlet (Secondary)
Gas
SH Panel inlet
SH Platen inlet
RH Front inlet
RH Rear inlet
LTSH inlet
Economiser inlet
Airheater inlet
Airheater outlet

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Design Coal (Sliding Pressure)


DWG :
Sheet : 31 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Design Coal - Sliding Pressure)
III.

PRESSURES (STEAM AND WATER)


Description

Pressure
Superheater Outlet
LTSH Outlet

HP Heaters in

Unit

kg/cm2 (g)

500 MW

400 MW

300 MW

250 MW

167.6

134.1

101.7

86.2

178.4

143.1

108.9

92.4

kg/cm (g)

Drum

kg/cm (g)

183.0

146.9

111.9

95.1

Economiser inlet

kg/cm2 (g)

Reheater Stage-II outlet


Reheater Stage-I inlet

188.0

151.1

115.3

98.3

40.5

32.3

24.4

20.1

kg/cm (g)

43.1

34.3

25.9

21.4

kg/cm2

kg/cm (g)

Pressure Drop
Superheater system
Reheater system
Economiser including
static head

15.4

12.8

10.2

8.9

2.6

2.0

1.5

1.3

2.53, refer boiler performance parameters

kg/cm

kg/cm

5.0

4.2

3.4

3.2

IV. GAS VELOCITIES IN SH/RH/ECO BANKS


Description

Platen SH
RH Front
RH Rear
LTSH
Economiser

HP Heaters in

Unit

m/s
m/s
m/s
m/s
m/s

500 MW

400 MW

300 MW

250 MW

6.6
7.6
8.2
8.1
7.4

5.2
6.0
6.4
6.1
5.8

3.9
4.5
4.8
4.6
4.3

3.3
3.7
4.0
3.8
3.6

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Design Coal (Sliding Pressure)


DWG :
Sheet : 32 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Design Coal - Sliding Pressure)
V. PRESSURES AND DRAFTS (AIR AND GAS)
Description

Unit

HP Heaters in
500 MW

400 MW

300 MW

250 MW

Primary air
PA Fan inlet

Mmwc

-9

-6

-4

-4

PA Fan outlet

Mmwc

883

856

831

782

Air heater inlet

Mmwc

873

848

826

777

Air heater outlet

Mmwc

831

816

800

754

Mill inlet

Mmwc

711

700

686

644

Mill outlet

Mmwc

322

312

302

279

FD fan inlet

Mmwc

-12

-7

-5

-3

FD fan outlet

Mmwc

164

131

105

90

Airheater inlet

Mmwc

149

121

99

86

Airheater outlet

Mmwc

108

94

83

77

Windbox pressure

Mmwc

70

70

70

70

Mmwc
Mmwc
mmwc
mmwc
mmwc

-5
-5
-6
-13

-5
-5
-6
-10

-5
-5
-6
-8

-5
-5
-6
-7

-29

-23

-19

-16

-54
-68
-149
-163
-213

-42
-54
-114
-127
-164

-34
-43
-90
-101
-129

-28
-37
-82
-93
-115

28

23

18

16

Secondary air

Gas
Furnace
SH Platen inlet
RH Inlet (Platen outlet)
LTSH inlet (RH outlet)
Economiser inlet (LTSH
outlet)
Economiser outlet
Airheater inlet
Airheater outlet
EP inlet
ID fan inlet
ID fan outlet

mmwc
mmwc
mmwc
mmwc
mmwc
mmwc

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Design Coal (Sliding Pressure)


DWG :
Sheet : 33 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Design Coal - Sliding Pressure)
VI.FUEL
The fuel data for design coal are as follows:

Description

Unit

Fuel

Design Coal

Proximate Analysis:
Fixed carbon

24

Volatile matter

21

Moisture

14

Ash

41

HGI

55

Higher Heating Value (HHV)

kcal/kg

3300

Size of coal to Mill (Approx.)

mm

50

Carbon

31.70

Hydrogen

3.30

Sulphur

0.28

Nitrogen

0.83

Oxygen

8.54

Carbonates

0.30

Phosphorous

0.05

Moisture

14.00

Ash

41.00

Grindability Index

Ultimate Analysis:

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Design Coal (Sliding Pressure)


DWG :
Sheet : 34 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Design Coal - Sliding Pressure)
VII. MILL AND BURNER PERFORMANCE

Description

HP Heaters in

Unit

No. of mills in Operation

500 MW

400 MW

300 MW

250 MW

Top 6

Top 5

Top 4

Top 4

(E-K)

(F-K)

(G-K)

(G-K)

Mill loading

88.7

87.4

85.0

73.5

Air flow per mill

t/h

97.6

97.2

96.3

91.2

Air temp. at mill inlet

303

280

264

251

Mill outlet temp.

66 to 90

Fineness(thru 200
mesh)

70

Deg

-30 to +30

Burner tilt

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Design Coal (Sliding Pressure)


DWG :
Sheet : 35 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Design Coal - Sliding Pressure)

VIII. O2, CO2 (DRY VOL.) AND EXCESS AIR


Description

HP Heaters in

Unit
500 MW

400 MW

300 MW

250 MW

Oxygen in gas at
Economiser outlet

3.58

3.58

3.58

3.58

Carbon-di-oxide in gas
at Economiser outlet

15.00

15.00

15.00

15.00

Excess air in gas at


Economiser outlet

20.0

20.0

20.0

20.0

IX.AMBIENT CONDITIONS
Ambient temperature
Relative Humidity

Deg.C

27

60

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Design Coal (Sliding Pressure)


DWG :
Sheet : 36 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Design Coal - Sliding Pressure)

X. HEAT BALANCE

Description

HP Heaters in

Unit
500 MW

400 MW

300 MW

250 MW

Losses
Dry gas

4.149

4.213

4.052

4.276

H2O in fuel, surf. & inherent

2.596

2.595

2.581

2.576

H2O from comb. Of H2

5.468

5.467

5.437

5.426

H2O in air

0.102

0.104

0.100

0.106

Radiation

0.234

0.285

0.366

0.423

Unburnt Carbon

1.500

1.500

1.500

1.500

Unaccounted

0.952

0.961

0.965

0.976

Manufacturers

0.150

0.150

0.150

0.150

Total losses

15.151

15.275

15.151

15.433

84.85

84.72

84.85

84.57

EFFICIENCY

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Design Coal (Sliding Pressure)


DWG :
Sheet : 37 of 82
Rev.01

PREDICTED PERFORMANCE DATA


(Worst Coal - Sliding Pressure)
CONTENTS
SECTION

DESCRIPTION

SHEET No.

FLOW

39

II

TEMPERATURE

40

III

PRESSURE (STEAM & WATER)

41

IV

GAS VELOCITIES

41

PRESSURES & DRAFTS (AIR & GAS)

42

VI

FUEL

43

VII

MILL & BURNER PERFORMANCE

44

VIII

O2 , CO2 & EXCESS AIR

45

IX

AMBIENT CONDITIONS

45

HEAT BALANCE

46

The attached Performance Data are predicted only and are not to be construed as
being guaranteed except where the values coincide with guarantees stated under
the performance guarantee section.

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Worst Coal (Sliding Pressure)


DWG :
Sheet : 38 of 82
Rev.01

PREDICTED PERFORMANCE DATA


(Worst Coal - Sliding Pressure)
1. FLOW
Description
Steam
Superheater outlet

HP Heaters in

Unit

t/h

500 MW

400 MW

300 MW

250 MW

1150.2
1037.1

864.6
787.6

731.4
654.0

Reheater outlet
Water
Feed water

t/h

1452.9
1297.7

t/h

1418.9

1047.2

744.6

624.4

SH spray

t/h

34

103

120

107

RH spray

t/h

10

Air
AH Outlet (Primary)
Tempering air

t/h
t/h

744

625

461

434

29

36

26

27

t/h
t/h

944
1919

712
1575

537
1226

385
1048

2146

1762

1371

1172

2342

1949

1548

1346

AH Outlet (Secondary)
Total Combustion Air
Gas
Flue gas at RAPH inlet
(Secondary & Primary )
Flue gas at RAPH outlet
(Secondary & Primary )
Inlet PAH
Inlet SAH
Outlet PAH
Outlet SAH
Fuel
Coal

t/h
t/h
t/h
t/h
t/h
t/h

938

817

630

615

1208
1050
1292

945
926
1023

741
735
813

557
720
626

t/h

412

340

266

228

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Worst Coal (Sliding Pressure)


DWG :
Sheet : 39 of 82
Rev.01

PREDICTED PERFORMANCE DATA


(Worst Coal - Sliding Pressure)
II. TEMPERATURE
Description

HP Heaters in

Unit
500 MW

400 MW

300 MW

250 MW

Steam
Sat. temp. in Drum
LTSH inlet

C
C

357

340

319

307

362

351

340

332

LTSH outlet
SH Panel inlet
SH Panel outlet
SH Platen inlet
SH Platen outlet
RH Stage-I inlet

C
C
C
C
C
C

403
388
461
461
540

404
370
446
446
540

414
334
426
426
540

396
320
419
419
540

340

341

344

341

RH Stage-I outlet
RH Stage-II inlet
RH Stage-II outlet

C
C
C

488
488
568

510
510
568

521
521
568

522
522
568

C
C

253
323

243
316

230
304

221
289

C
C
C

27
311
315

27
299
300

27
280
279

27
266
265

C
C
C
C
C
C
C
C

1369
1115
1017
842
666
544
338
126

1356
1081
977
804
636
519
320
126

1357
1049
933
759
598
489
298
122

1325
1012
894
724
570
468
283
122

Water
Economiser inlet
Economiser outlet
Air
Ambient
AH Outlet (Primary)
AH Outlet (Secondary)
Gas
SH Panel inlet
SH Platen inlet
RH Front inlet
RH Rear inlet
LTSH inlet
Economiser inlet
Airheater inlet(SAH)
Airheater outlet

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Worst Coal (Sliding Pressure)


DWG :
Sheet : 40 of 82
Rev.01

PREDICTED PERFORMANCE DATA


(Worst Coal - Sliding Pressure)
III. PRESSURES (STEAM AND WATER)
Description

Pressure
Superheater Outlet
LTSH Outlet

HP Heaters in

Unit

kg/cm2 (g)

500 MW

400 MW

300 MW

250 MW

167.6

134.1

101.7

86.2

178.4

143.1

108.9

92.4

kg/cm (g)

Drum

kg/cm (g)

183.0

146.9

111.9

95.1

Economiser inlet

kg/cm2 (g)

Reheater Stage-II outlet


Reheater Stage-I inlet

188.0

151.1

115.3

98.3

40.5

32.3

24.4

20.1

kg/cm (g)

43.1

34.3

25.9

21.4

kg/cm2

15.4

12.8

10.2

8.9

2.6

2.0

1.5

1.3

5.0

4.2

3.4

3.2

kg/cm (g)

Pressure Drop
Superheater system
Reheater system
Economiser including
static head

kg/cm

kg/cm

IV. GAS VELOCITIES IN SH/RH/ECO BANKS


Description

Platen SH
RH Front
RH Rear
LTSH
Economiser

HP Heaters in

Unit

m/s
m/s
m/s
m/s
m/s

500 MW

400 MW

300 MW

250 MW

6.6
7.7
8.3
7.9
7.5

5.3
6.1
6.5
6.3
5.9

4.1
4.6
4.9
4.8
4.5

3.4
3.8
4.1
3.9
3.7

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Worst Coal (Sliding Pressure)


DWG :
Sheet : 41 of 82
Rev.01

PREDICTED PERFORMANCE DATA


(Worst Coal - Sliding Pressure)
V. PRESSURES AND DRAFTS (AIR AND GAS)
Description

Unit

HP Heaters in
500 MW

400 MW

300 MW

250 MW

Primary air
PA Fan inlet

mmwc

-14

-11

-6

-6

PA Fan outlet

mmwc

871

845

847

792

Air heater inlet

mmwc

858

832

839

785

Air heater outlet

mmwc

807

785

807

758

Mill inlet

mmwc

686

664

691

643

Mill outlet

mmwc

306

287

302

274

FD fan inlet

mmwc

-10

-6

-4

-2

FD fan outlet

mmwc

145

116

99

86

Airheater inlet

mmwc

133

109

94

83

Airheater outlet

mmwc

100

88

81

76

Windbox pressure

mmwc

70

70

70

70

mmwc
mmwc
mmwc
mmwc
mmwc

-5
-5
-6
-12

-5
-5
-6
-10

-5
-5
-6
-8

-5
-5
-6
-7

-26

-21

-18

-15

mmwc
mmwc
mmwc
mmwc
mmwc
mmwc

-48
-63
-176
-191
-243

-38
-50
-140
-153
-192

-32
-42
-103
-114
-142

-26
-35
-94
-105
-128

30

24

19

17

Secondary air

Gas
Furnace
SH Platen inlet
RH Inlet (Platen outlet)
LTSH inlet (RH outlet)
Economiser inlet (LTSH
outlet)
Economiser outlet
Airheater inlet
Airheater outlet
EP inlet
ID fan inlet
ID fan outlet

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Worst Coal (Sliding Pressure)


DWG :
Sheet : 42 of 82
Rev.01

PREDICTED PERFORMANCE DATA


(Worst Coal - Sliding Pressure)
VI.FUEL The fuel data for Worst coal are as follows:

Description

Unit

Fuel

Worst Coal

Proximate Analysis :
Fixed carbon

20

Volatile matter

19

Moisture

16

Ash

45

HGI

50

kcal/kg

2800

mm

50 (Approx.)

Carbon

27.70

Hydrogen

2.60

Sulphur

0.50

Nitrogen

0.52

Oxygen

7.26

Carbonates

0.38

Phosphorous

0.04

Moisture

16.00

Ash

45.00

Grindability Index
Higher Heating Value (HHV)
Size of coal to Mill
Ultimate Analysis :

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Worst Coal (Sliding Pressure)


DWG :
Sheet : 43 of 82
Rev.01

PREDICTED PERFORMANCE DATA


(Worst Coal - Sliding Pressure)
VII. MILL AND BURNER PERFORMANCE

Description

HP Heaters in

Unit

No. of mills in Operation

500 MW

400 MW

300 MW

250 MW

Top 8
(C-K)

Top 7
(D-K)

Top 5
(F-K)

Top 5
(F-K)

Mill loading

85.2

80.3

88.0

75.4

Air flow per mill

t/h

96.6

94.4

97.4

92.2

Air temp. at mill inlet

300

284

267

253

Mill outlet temp.

66 to 90

Fineness(thru '200 mesh)

70

Deg

-30 to +30

Burner tilt

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Worst Coal (Sliding Pressure)


DWG :
Sheet : 44 of 82
Rev.01

PREDICTED PERFORMANCE DATA


(Worst Coal - Sliding Pressure)

VIII. O2, CO2 (DRY VOL.) AND EXCESS AIR


Description

HP Heaters in

Unit
500 MW

400 MW

300 MW

250 MW

Oxygen in gas at
Economiser outlet

3.57

3.57

3.57

3.57

Carbon-di-oxide in gas
at Economiser outlet

15.26

15.26

15.26

15.26

Excess air in gas at


Economiser outlet

20.0

20.0

20.0

20.0

IX. AMBIENT CONDITIONS


Ambient temperature
Relative Humidity

Deg.C

27

60

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Worst Coal (Sliding Pressure)


DWG :
Sheet : 45 of 82
Rev.01

PREDICTED PERFORMANCE DATA


(Worst Coal - Sliding Pressure)

X. HEAT BALANCE

Description

HP Heaters in

Unit
500 MW

400 MW

300 MW

250 MW

Losses
Dry gas

4.235

4.296

4.153

4.381

H2O in fuel, surf. & inherent

3.494

3.493

3.483

3.480

H2O from comb. Of H2

5.074

5.073

5.059

5.054

H2O in air

0.104

0.106

0.102

0.108

Radiation

0.231

0.281

0.358

0.417

Unburnt Carbon

1.500

1.500

1.500

1.500

Unaccounted

1.192

1.200

1.206

1.218

Manufacturers margin

0.150

0.150

0.150

0.150

Total losses

15.980

16.099

16.011

16.308

84.02

83.90

83.99

83.69

EFFICIENCY

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Worst Coal (Sliding Pressure)


DWG :
Sheet : 46 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Best Coal - Sliding Pressure)
CONTENTS
SECTION

DESCRIPTION

SHEET No.

FLOW

48

II

TEMPERATURE

49

III

PRESSURE (STEAM & WATER)

50

IV

GAS VELOCITIES

50

PRESSURES & DRAFTS (AIR & GAS)

51

VI

FUEL

52

VII

MILL & BURNER PERFORMANCE

53

VIII

O2 , CO2 & EXCESS AIR

54

IX

AMBIENT CONDITIONS

54

HEAT BALANCE

55

The attached Performance Data are predicted only and are not to be construed as
being guaranteed except where the values coincide with guarantees stated under
the performance guarantee section.

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Best Coal (Sliding Pressure)


DWG :
Sheet : 47 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Best Coal - Sliding Pressure)
1. FLOW
Description
Steam
Superheater outlet

HP Heaters in

Unit

t/h

500 MW

400 MW

300 MW

250 MW

1150.2
1037.1

864.6
787.6

731.4
654.0

Reheater outlet
Water
Feed water

t/h

1452.9
1297.7

t/h

1409.9

1051.2

764.6

634.4

SH spray

t/h

43

99

100

97

RH spray

t/h

Air
AH Outlet (Primary)
Tempering air

t/h
t/h

441

387

307

243

79
1118
1840

44
869
1502

35
622
1166

24
533
1002

2019

1649

1279

1100

2211

1831

1453

1269

AH Outlet (Secondary)
Total Combustion Air
Gas
Flue gas at RAPH inlet
(Secondary & Primary )
Flue gas at RAPH outlet
(Secondary & Primary )
Inlet PAH
Inlet SAH
Outlet PAH
Outlet SAH

t/h
t/h

t/h
t/h
t/h
t/h

595

526

438

361

1424
701
1510

1123
629
1202

841
539
914

739
459
810

Fuel
Coal

t/h

267

219

170

147

t/h
t/h

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Best Coal (Sliding Pressure)


DWG :
Sheet : 48 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Best Coal - Sliding Pressure)
II. TEMPERATURE
Description

HP Heaters in

Unit
500 MW

400 MW

300 MW

250 MW

Steam
Sat. temp. in Drum
LTSH inlet

C
C

357

340

319

307

361

349

335

327

LTSH outlet
SH Panel inlet
SH Panel outlet
SH Platen inlet
SH Platen outlet
RH Stage-I inlet
RH Stage-I outlet
RH Stage-II nlet
RH Stage-II outlet

C
C
C
C
C
C
C
C
C

395
384
462
462
540
340
493
493
568

388
361
451
451
540
341
499
499
568

387
334
434
434
540
344
506
506
568

395
320
424
424
540
341
511
511
568

C
C

253
316

243
305

230
296

221
289

C
C
C

27
307
303

27
289
289

27
268
267

27
255
255

C
C
C
C
C
C
C
C

1412
1129
1022
839
658
534
328
125

1374
1080
970
790
619
503
308
125

1353
1036
917
740
578
470
285
118

1345
1012
888
712
556
452
272
117

Water
Economiser inlet
Economiser outlet
Air
Ambient
AH Outlet (Primary)
AH Outlet (Secondary)
Gas
SH Panel inlet
SH Platen inlet
RH Front inlet
RH Rear inlet
LTSH inlet
Economiser inlet
Airheater inlet
Airheater outlet

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Best Coal (Sliding Pressure)


DWG :
Sheet : 49 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Best Coal - Sliding Pressure)
III.

PRESSURES (STEAM AND WATER)


Description

Pressure
Superheater Outlet
LTSH Outlet

HP Heaters in

Unit

kg/cm2 (g)

500 MW

400 MW

300 MW

250 MW

167.6

134.1

101.7

86.2

178.4

143.1

108.9

92.4

kg/cm (g)

Drum

kg/cm (g)

183.0

146.9

111.9

95.1

Economiser inlet

kg/cm2 (g)

Reheater Stage-II outlet


Reheater Stage-I inlet

188.0

151.1

115.3

98.3

40.5

32.3

24.4

20.1

kg/cm (g)

43.1

34.3

25.9

21.4

kg/cm2

15.4

12.8

10.2

8.9

2.6

2.0

1.5

1.3

5.0

4.2

3.4

3.2

kg/cm (g)

Pressure Drop
Superheater system
Reheater system
Economiser including
static head

kg/cm

kg/cm

IV. GAS VELOCITIES IN SH/RH/ECO BANKS


Description

Platen SH
RH Front
RH Rear
LTSH
Economiser

HP Heaters in

Unit

m/s
m/s
m/s
m/s
m/s

500 MW

400 MW

300 MW

250 MW

6.6
7.5
8.1
7.6
7.2

5.2
5.9
6.3
6.1
5.7

3.9
4.4
4.7
4.5
4.2

3.3
3.7
3.9
3.7
3.5

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Best Coal (Sliding Pressure)


DWG :
Sheet : 50 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Best Coal - Sliding Pressure)
V. PRESSURES AND DRAFTS (AIR AND GAS)
Description

Unit

HP Heaters in
500 MW

400 MW

300 MW

250 MW

Primary air
PA Fan inlet

mmwc

-7

-5

-4

-2

PA Fan outlet

mmwc

796

788

778

773

Air heater inlet

mmwc

788

782

774

770

Air heater outlet

mmwc

757

755

753

752

Mill inlet

mmwc

647

647

648

645

Mill outlet

mmwc

298

299

303

288

FD fan inlet

mmwc

-13

-8

-5

-4

FD fan outlet

mmwc

172

133

105

98

Airheater inlet

mmwc

156

123

99

93

Airheater outlet

mmwc

111

95

83

81

Windbox pressure

mmwc

70

70

70

70

mmwc
mmwc
mmwc
mmwc
mmwc

-5
-5
-6
-14

-5
-5
-6
-11

-5
-5
-6
-9

-5
-5
-6
-8

-31

-24

-19

-18

mmwc
mmwc
mmwc
mmwc
mmwc
mmwc

-58
-72
-161
-175
-222

-44
-55
-114
-126
-162

-34
-43
-81
-92
-118

-32
-40
-71
-82
-104

28

22

18

16

Secondary air

Gas
Furnace
SH Platen inlet
RH Inlet (Platen outlet)
LTSH inlet (RH outlet)
Economiser inlet (LTSH
outlet)
Economiser outlet
Airheater inlet
Airheater outlet
EP inlet
ID fan inlet
ID fan outlet

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Best Coal (Sliding Pressure)


DWG :
Sheet : 51 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Best Coal - Sliding Pressure)
VI.FUEL
The fuel data for Best coal are as follows:
Description

Unit

Fuel

Best Coal

Proximate Analysis :
Fixed carbon

32

Volatile matter

24

Moisture

12

Ash

32

HGI

60

kcal/kg

4200

mm

50 (Approx.)

Carbon

41.90

Hydrogen

3.60

Sulphur

0.25

Nitrogen

1.00

Oxygen

8.92

Carbonates

0.27

Phosphorous

0.06

Moisture

12.00

Ash

32.00

Grindability Index
Higher Heating Value (HHV)
Size of coal to Mill
Ultimate Analysis :

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Best Coal (Sliding Pressure)


DWG :
Sheet : 52 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Best Coal - Sliding Pressure)
VII. MILL AND BURNER PERFORMANCE

Description

HP Heaters in

Unit

No. of mills in Operation

500 MW

400 MW

300 MW

250 MW

Top 6
(E-K)

Top 5
(F-K)

Top 4
(G-K)

Top 3
(H-K)

Mill loading

62.0

61.0

59.2

68.2

Air flow per mill

t/h

86.7

86.2

85.5

89.0

Air temp. at mill inlet

265

263

244

235

Mill outlet temp.

66 to 90

Fineness(thru '200 mesh)

70

Deg

-30 to +30

Burner tilt

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Best Coal (Sliding Pressure)


DWG :
Sheet : 53 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Best Coal - Sliding Pressure)

VIII. O2, CO2 (DRY VOL.) AND EXCESS AIR


Description

HP Heaters in

Unit
500 MW

400 MW

300 MW

250 MW

Oxygen in gas at
Economiser outlet

3.57

3.57

3.57

3.57

Carbon-di-oxide in gas
at Economiser outlet

15.37

15.37

15.37

15.37

Excess air in gas at


Economiser outlet

20.0

20.0

20.0

20.0

IX. AMBIENT CONDITIONS


Ambient temperature
Relative Humidity

Deg.C

27

60

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Best Coal (Sliding Pressure)


DWG :
Sheet : 54 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Best Coal - Sliding Pressure)

X. HEAT BALANCE

Description

HP Heaters in

Unit
500 MW

400 MW

300 MW

250 MW

Losses
Dry gas

4.210

4.507

4.335

4.635

H2O in fuel, surf. & inherent

1.751

1.749

1.739

1.736

H2O from comb. Of H2

4.694

4.689

4.663

4.654

H2O in air

0.103

0.111

0.107

0.114

Radiation

0.239

0.290

0.375

0.433

Unburnt Carbon

1.500

1.500

1.500

1.500

Unaccounted

0.642

0.654

0.665

0.679

Manufacturers margin

0.150

0.150

0.150

0.150

Total losses

13.289

13.650

13.534

13.901

86.71

86.35

86.47

86.10

EFFICIENCY

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS / NR
PR
SCS

TITLE: Predicted performance for Best Coal (Sliding Pressure)


DWG :
Sheet : 55 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Design Coal Constant Pressure)
(BOTTOM MILLS)
CONTENTS
SECTION

DESCRIPTION

SHEET No.

FLOW

57

II

TEMPERATURE

58

III

PRESSURE (STEAM & WATER)

59

IV

GAS VELOCITIES

59

PRESSURES & DRAFTS (AIR & GAS)

60

VI

FUEL

61

VII

MILL & BURNER PERFORMANCE

62

VIII

O2 , CO2 & EXCESS AIR

63

IX

AMBIENT CONDITIONS

63

HEAT BALANCE

64

The attached Performance Data are predicted only and are not to be construed as
being guaranteed except where the values coincide with guarantees stated under
the performance guarantee section.

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE:
Predicted performance for design coal
DWG :
Sheet : 56 of
82
Rev.01

PREDICTED PERFORMANCE DATA


( Design Coal Constant Pressure)
(BOTTOM MILLS)
1. FLOW
HP Heaters in
Description
Steam
Superheater outlet

Unit

t/h

500 MW

250 MW
755.4
656.8

Reheater outlet
Water
Feed water

t/h

1457.9
1302.1

t/h

1432.9

681.4

SH spray

t/h

25

74

RH spray

t/h

Air
AH Outlet (Primary)
Tempering air

T/h
t/h

582

350

17

t/h
t/h

1067
1855

504
1073

2057

1185

2253

1359

AH Outlet (Secondary)
Total Combustion Air
Gas
Flue gas at RAPH inlet
(Secondary & Primary )
Flue gas at RAPH outlet
(Secondary & Primary )
Inlet PAH
Inlet SAH
Outlet PAH
Outlet SAH
Fuel
Coal

T/h
t/h
t/h
t/h
t/h
t/h

737

489

1320
847
1406

696
592
767

t/h

347

194

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE:
Predicted performance for design coal
DWG :
Sheet : 57 of
82
Rev.01

PREDICTED PERFORMANCE DATA


( Design Coal Constant Pressure)
(BOTTOM MILLS)

II. TEMPERATURE
HP Heaters in
Description

Unit
500 MW

250 MW

Steam
Sat. temp. in Drum
LTSH inlet

C
C

361

354

364

362

LTSH outlet
SH Panel inlet
SH Panel outlet
SH Platen inlet
SH Platen outlet
RH Stage-I inlet
RH Stage-I outlet
RH Stage-II inlet
RH Stage-II outlet

C
C
C
C
C
C
C
C
C

395
389
464
464
540
337
492
492
568

403
364
442
442
540
311
501
501
568

C
C

253
315

219
298

C
C
C

27
309
305

27
263
263

C
C
C
C
C
C
C
C

1380
1115
1013
836
658
537
332
125

1358
1029
908
726
570
473
280
116

Water
Economiser inlet
Economiser outlet
Air
Ambient
AH Outlet (Primary)
AH Outlet (Secondary)
Gas
SH Panel inlet
SH Platen inlet
RH Front inlet
RH Rear inlet
LTSH inlet
Economiser inlet
Airheater inlet
Airheater outlet

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE:
Predicted performance for design coal
DWG :
Sheet : 58 of
82
Rev.01

PREDICTED PERFORMANCE DATA


( Design Coal Constant Pressure)
(BOTTOM MILLS)
III. PRESSURES (STEAM AND WATER)
Description

HP heaters in

Unit
500 MW

250 MW

176.6

171.1

Pressure
Superheater Outlet

kg/cm2 (g)
2

LTSH Outlet

kg/cm (g)

186.9

174.3

Drum

kg/cm2 (g)

Economiser inlet

191.2

175.6

196.4

178.8

kg/cm (g)

Reheater Stage-II outlet

kg/cm (g)

40.7

20.2

Reheater Stage-I inlet

kg/cm2 (g)

43.2

21.5

kg/cm2

14.6

4.5

2.5

1.3

5.2

3.2

Pressure Drop
Superheater system
Reheater system
Economiser including
static head

kg/cm

kg/cm

IV. GAS VELOCITIES IN SH/RH/ECO BANKS


Description

Platen SH
RH Front
RH Rear
LTSH
Economiser

Unit

m/s
m/s
m/s
m/s
m/s

HP heaters in
500 MW

250 MW

6.6
7.7
8.2
7.8
7.4

3.6
4.0
4.3
4.0
3.9

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE:
Predicted performance for design coal
DWG :
Sheet : 59 of
82
Rev.01

PREDICTED PERFORMANCE DATA


( Design Coal Constant Pressure)
(BOTTOM MILLS)
V. PRESSURES AND DRAFTS (AIR AND GAS)
Description

Unit

HP Heaters in
500 MW

250 MW

Primary air
PA Fan inlet

mmwc

-9

-4

PA Fan outlet

mmwc

885

782

Air heater inlet

mmwc

875

777

Air heater outlet

mmwc

832

754

Mill inlet

mmwc

712

648

Mill outlet

mmwc

323

281

FD fan inlet

mmwc

-12

-3

FD fan outlet

mmwc

164

93

Airheater inlet

mmwc

149

89

Airheater outlet

mmwc

108

79

Windbox pressure

mmwc

70

70

mmwc
mmwc
mmwc
mmwc
mmwc

-5
-5
-6
-13

-5
-5
-6
-8

-29

-17

mmwc
mmwc
mmwc
mmwc
mmwc
mmwc

-54
-68
-149
-163
-213

-30
-39
-82
-93
-116

28

17

Secondary air

Gas
Furnace
SH Platen inlet
RH Inlet (Platen outlet)
LTSH inlet (RH outlet)
Economiser inlet (LTSH
outlet)
Economiser outlet
Airheater inlet
Airheater outlet
EP inlet
ID fan inlet
ID fan outlet

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE:
Predicted performance for design coal
DWG :
Sheet : 60 of
82
Rev.01

PREDICTED PERFORMANCE DATA


( Design Coal Constant Pressure)
(BOTTOM MILLS)

VI.FUEL
The fuel data for design coal are as follows:
Description

Unit

Fuel

Design Coal

Proximate Analysis :
Fixed carbon

24

Volatile matter

21

Moisture

14

Ash

41

HGI

55

Higher Heating Value (HHV)

kcal/kg

3300

Size of coal to Mill (Approx.)

mm

50

Carbon

31.70

Hydrogen

3.30

Sulphur

0.28

Nitrogen

0.83

Oxygen

8.54

Carbonates

0.30

Phosphorous

0.05

Moisture

14.00

Ash

41.00

Grindability Index

Ultimate Analysis :

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE:
Predicted performance for design coal
DWG :
Sheet : 61 of
82
Rev.01

PREDICTED PERFORMANCE DATA


( Design Coal Constant Pressure)
(BOTTOM MILLS)

VII. MILL AND BURNER PERFORMANCE

Description

HP Heaters in

Unit

No. of mills in Operation

500 MW

250 MW

Bottom6

Bottom4

(A-F)

(B-E)

Mill loading

89.0

74.6

Air flow per mill

T/h

97.7

91.7

Air temp. at mill inlet

307

252

Mill outlet temp.

66 to 90

Fineness(thru '200 mesh)

70

Deg

-30 to +30

Burner tilt

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE:
Predicted performance for design coal
DWG :
Sheet : 62 of
82
Rev.01

PREDICTED PERFORMANCE DATA


( Design Coal Constant Pressure)
(BOTTOM MILLS)

VIII. O2, CO2 (DRY VOL.) AND EXCESS AIR


Description

HP Heaters in

Unit
500 MW

250 MW

Oxygen in gas at
Economiser outlet

3.58

4.24

Carbon-di-oxide in gas
at Economiser outlet

15.00

14.43

Excess air in gas at


Economiser outlet

20.0

24.6

IX. AMBIENT CONDITIONS


Ambient temperature
Relative Humidity

Deg.C

27

60

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE:
Predicted performance for design coal
DWG :
Sheet : 63 of
82
Rev.01

PREDICTED PERFORMANCE DATA


( Design Coal Constant Pressure)
(BOTTOM MILLS)

X. HEAT BALANCE

Description

HP Heaters in

Unit
500 MW

250 MW

Losses
Dry gas

4.149

4.379

H2O in fuel, surf. & inherent

2.596

2.572

H2O from comb. Of H2

5.468

5.419

H2O in air

0.102

0.108

Radiation

0.233

0.418

Unburnt Carbon

1.500

1.5

Unaccounted

0.952

0.975

Manufacturers margin

0.150

0.150

Total losses

15.150

15.521

84.85

84.48

EFFICIENCY

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE:
Predicted performance for design coal
DWG :
Sheet : 64 of
82
Rev.01

PREDICTED PERFORMANCE DATA


( Worst Coal Constant Pressure )
(BOTTOM MILLS)
CONTENTS
SECTION

DESCRIPTION

SHEET No.

FLOW

66

II

TEMPERATURE

67

III

PRESSURE (STEAM & WATER)

68

IV

GAS VELOCITIES

68

PRESSURES & DRAFTS (AIR & GAS)

69

VI

FUEL

70

VII

MILL & BURNER PERFORMANCE

71

VIII

O2 , CO2 & EXCESS AIR

72

IX

AMBIENT CONDITIONS

72

HEAT BALANCE

73

The attached Performance Data are predicted only and are not to be construed as
being guaranteed except where the values coincide with guarantees stated under
the performance guarantee section.

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE:
Predicted performance for Worst coal
DWG :
Sheet : 65 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Worst Coal Constant Pressure )
(BOTTOM MILLS)
1. FLOW
Description
Steam
Superheater outlet

HP Heaters in

Unit

t/h

500 MW

250 MW
755.4
656.8

Reheater outlet
Water
Feed water

t/h

1457.9
1302.1

t/h

1440.9

685.4

SH spray

t/h

17

70

RH spray

t/h

Air
AH Outlet (Primary)
Tempering air

t/h
t/h

768

431

31

t/h
t/h

934
1908

389
1053

2133

1178

2329

1353

AH Outlet (Secondary)
Total Combustion Air
Gas
Flue gas at RAPH inlet
(Secondary & Primary )
Flue gas at RAPH outlet
(Secondary & Primary )
Inlet PAH
Inlet SAH
Outlet PAH
Outlet SAH

t/h
t/h
t/h
t/h

953

614

1180
1065
1264

564
718
635

Fuel
Coal

t/h

412

230

t/h
t/h

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE:
Predicted performance for Worst coal
DWG :
Sheet : 66 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Worst Coal Constant Pressure )
(BOTTOM MILLS)
II. TEMPERATURE
Description

HP Heaters in

Unit
500 MW

250 MW

Steam
Sat. temp. in Drum
LTSH inlet

C
C

361

354

365

362

LTSH outlet
SH Panel inlet
SH Panel outlet
SH Platen inlet
SH Platen outlet
RH Stage-I inlet
RH Stage-I outlet
RH Stage-II inlet
RH Stage-II outlet

C
C
C
C
C
C
C
C
C

398
392
463
463
540
337
488
488
568

401
364
441
441
540
311
501
501
568

C
C

253
319

219
300

C
C
C

27
309
314

27
265
264

C
C
C
C
C
C
C
C

1368
1113
1015
840
665
544
338
126

1347
1024
904
724
569
473
282
122

Water
Economiser inlet
Economiser outlet
Air
Ambient
AH Outlet (Primary)
AH Outlet (Secondary)
Gas
SH Panel inlet
SH Platen inlet
RH Front inlet
RH Rear inlet
LTSH inlet
Economiser inlet
Airheater inlet
Airheater outlet

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE:
Predicted performance for Worst coal
DWG :
Sheet : 67 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Worst Coal Constant Pressure )
(BOTTOM MILLS)
III.

PRESSURES (STEAM AND WATER)


Description

Pressure
Superheater Outlet
LTSH Outlet

HP Heaters in

Unit

kg/cm2 (g)

500 MW

250 MW

176.6

171.1

186.9

174.3

kg/cm (g)

Drum

kg/cm (g)

191.2

175.6

Economiser inlet

kg/cm2 (g)

196.4

178.8

40.7

20.2

kg/cm (g)

43.2

21.5

Superheater system

kg/cm2

14.6

4.5

Reheater system

kg/cm2

2.5

1.3

5.2

3.2

Reheater Stage-II outlet


Reheater Stage-I inlet

kg/cm (g)

Pressure Drop

Economiser including
static head

kg/cm

IV. GAS VELOCITIES IN SH/RH/ECO BANKS


Description

Platen SH
RH Front
RH Rear
LTSH
Economiser

HP Heaters in

Unit

m/s
m/s
m/s
m/s
m/s

500 MW

250 MW

6.7
7.7
8.3
7.9
7.5

3.5
4.0
4.2
4.0
3.8

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE:
Predicted performance for Worst coal
DWG :
Sheet : 68 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Worst Coal Constant Pressure )
(BOTTOM MILLS)
V. PRESSURES AND DRAFTS (AIR AND GAS)
Description

Unit

HP Heaters in
500 MW

250 MW

Primary air
PA Fan inlet

mmwc

-14

-6

PA Fan outlet

mmwc

900

793

Air heater inlet

mmwc

883

786

Air heater outlet

mmwc

818

756

Mill inlet

mmwc

692

643

Mill outlet

mmwc

307

274

FD fan inlet

mmwc

-10

-2

FD fan outlet

mmwc

144

87

Airheater inlet

mmwc

132

84

Airheater outlet

mmwc

99

76

Windbox pressure

mmwc

70

70

mmwc
mmwc
mmwc
mmwc
mmwc

-5
-5
-6
-12

-5
-5
-6
-8

-26

-15

mmwc
mmwc
mmwc
mmwc
mmwc
mmwc

-48
-63
-178
-192
-244

-26
-35
-94
-105
-128

30

17

Secondary air

Gas
Furnace
SH Platen inlet
RH Inlet (Platen outlet)
LTSH inlet (RH outlet)
Economiser inlet (LTSH
outlet)
Economiser outlet
Airheater inlet
Airheater outlet
EP inlet
ID fan inlet
ID fan outlet

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE:
Predicted performance for Worst coal
DWG :
Sheet : 69 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Worst Coal Constant Pressure )
(BOTTOM MILLS)

VI.FUEL
The fuel data for Worst coal are as follows:
Description

Unit

Fuel

Worst Coal

Proximate Analysis :
Fixed carbon

20

Volatile matter

19

Moisture

16

Ash

45

HGI

50

kcal/kg

2800

mm

50 (Approx.)

Carbon

27.70

Hydrogen

2.60

Sulphur

0.50

Nitrogen

0.52

Oxygen

7.26

Carbonates

0.38

Phosphorous

0.04

Moisture

16.00

Ash

45.00

Grindability Index
Higher Heating Value (HHV)
Size of coal to Mill
Ultimate Analysis :

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE:
Predicted performance for Worst coal
DWG :
Sheet : 70 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Worst Coal Constant Pressure )
(BOTTOM MILLS)

VII. MILL AND BURNER PERFORMANCE

Description

HP Heaters in

Unit

No. of mills in Operation

500 MW

250 MW

BOTTOM 8

BOTTOM 5

(A-H)

(B-F)

Mill loading

85.2

76.1

Air flow per mill

t/h

96.5

92.4

Air temp. at mill inlet

307

249

Mill outlet temperature

66 to 90

Fineness(thru '200 mesh)

70

Deg

-30 to +30

Burner tilt

At this mill inlet temp min. mill


outlet temp. of 66 deg may
not be achieved. BHEL to
check and change the mill
inlet temp accordingly.

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE:
Predicted performance for Worst coal
DWG :
Sheet : 71 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Worst Coal Constant Pressure )
(BOTTOM MILLS)

VIII. O2, CO2 (DRY VOL.) AND EXCESS AIR


Description

HP Heaters in

Unit
500 MW

250 MW

Oxygen in gas at
Economiser outlet

3.57

3.57

Carbon-di-oxide in gas
at Economiser outlet

15.26

15.26

Excess air in gas at


Economiser outlet

20.0

20.0

IX. AMBIENT CONDITIONS


Ambient temperature
Relative Humidity

Deg.C

27

60

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE:
Predicted performance for Worst coal
DWG :
Sheet : 72 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Worst Coal Constant Pressure )
(BOTTOM MILLS)

X. HEAT BALANCE

Description

HP Heaters in

Unit
500 MW

250 MW

Losses
Dry gas

4.235

4.381

H2O in fuel, surf. & inherent

3.494

3.480

H2O from comb. Of H2

5.074

5.054

H2O in air

0.104

0.108

Radiation

0.231

0.414

Unburnt Carbon

1.500

1.500

Unaccounted

1.192

1.216

Manufacturers margin

0.150

0.150

Total losses

15.980

16.303

84.02

83.70

EFFICIENCY

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE:
Predicted performance for Worst coal
DWG :
Sheet : 73 of 82
Rev.01

PREDICTED PERFORMANCE DATA


( Best Coal Constant Pressure )
(BOTTOM MILLS)
CONTENTS
SECTION

DESCRIPTION

SHEET No.

FLOW

75

II

TEMPERATURE

76

III

PRESSURE (STEAM & WATER)

77

IV

GAS VELOCITIES

77

PRESSURES & DRAFTS (AIR & GAS)

78

VI

FUEL

79

VII

MILL & BURNER PERFORMANCE

80

VIII

O2 , CO2 & EXCESS AIR

81

IX

AMBIENT CONDITIONS

81

HEAT BALANCE

82

The attached Performance Data are predicted only and are not to be construed as
being guaranteed except where the values coincide with guarantees stated under
the performance guarantee section.

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE: Predicted performance for Best coal


DWG :
Sheet :
74 of 82

Rev.01

PREDICTED PERFORMANCE DATA


( Best Coal Constant Pressure )
(BOTTOM MILLS)
1. FLOW
Description
Steam
Superheater outlet

HP Heaters in

Unit

t/h

500 MW

250 MW
755.4
656.8

Reheater outlet
Water
Feed water

t/h

1457.9
1302.1

t/h

1430.9

690.4

SH spray

t/h

27

65

RH spray

t/h

Air
AH Outlet (Primary)
Tempering air

t/h
t/h

442

258

78

10

t/h
t/h

1119
1841

652
1122

2021

1222

2212

1393

AH Outlet (Secondary)
Total Combustion Air
Gas
Flue gas at RAPH inlet
(Secondary & Primary )
Flue gas at RAPH outlet
(Secondary & Primary )
Inlet PAH
Inlet SAH
Outlet PAH
Outlet SAH

t/h
t/h
t/h
t/h

596

366

1425
701
1511

856
465
928

Fuel
Coal

t/h

267

149

t/h
t/h

II. TEMPERATURE
PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW
Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE: Predicted performance for Best coal


DWG :
Sheet :
75 of 82

Rev.01

PREDICTED PERFORMANCE DATA


( Best Coal Constant Pressure )
(BOTTOM MILLS)

Description

HP Heaters in

Unit
500 MW

250 MW

Steam
Sat. temp. in Drum
LTSH inlet

C
C

361

354

364

362

LTSH outlet
SH Panel inlet
SH Panel outlet
SH Platen inlet
SH Platen outlet
RH Stage-I inlet
RH Stage-I outlet
RH Stage-II inlet
RH Stage-II outlet

C
C
C
C
C
C
C
C
C

394
387
462
462
540
337
492
492
568

404
366
444
444
540
311
500
500
568

C
C

253
314

219
295

C
C
C

27
307
303

27
262
262

C
C
C
C
C
C
C
C

1426
1138
1029
843
660
536
328
125

1359
1031
913
731
576
476
279
115

Water
Economiser inlet
Economiser outlet
Air
Ambient
AH Outlet (Primary)
AH Outlet (Secondary)
Gas
SH Panel inlet
SH Platen inlet
RH Front inlet
RH Rear inlet
LTSH inlet
Economiser inlet
Airheater inlet
Airheater outlet

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE: Predicted performance for Best coal


DWG :
Sheet :
76 of 82

Rev.01

PREDICTED PERFORMANCE DATA


( Best Coal Constant Pressure )
(BOTTOM MILLS)
III.

PRESSURES (STEAM AND WATER)


Description

Pressure
Superheater Outlet
LTSH Outlet

HP Heaters in

Unit

kg/cm2 (g)

500 MW

250 MW

176.6

171.1

186.9

174.3

kg/cm (g)

Drum

kg/cm (g)

191.2

175.6

Economiser inlet

kg/cm2 (g)

196.4

178.8

40.7

20.2

kg/cm (g)

43.2

21.5

Superheater system

kg/cm2

14.6

4.5

Reheater system

kg/cm2

2.5

1.3

5.2

3.2

Reheater Stage-II outlet


Reheater Stage-I inlet

kg/cm (g)

Pressure Drop

Economiser including
static head

kg/cm

IV. GAS VELOCITIES IN SH/RH/ECO BANKS


Description

Platen SH
RH Front
RH Rear
LTSH
Economiser

HP Heaters in

Unit

m/s
m/s
m/s
m/s
m/s

500 MW

250 MW

6.6
7.6
8.1
7.7
7.3

3.8
4.3
4.4
4.3
4.1

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE: Predicted performance for Best coal


DWG :
Sheet :
77 of 82

Rev.01

PREDICTED PERFORMANCE DATA


( Best Coal Constant Pressure )
(BOTTOM MILLS)
V. PRESSURES AND DRAFTS (AIR AND GAS)
Description

Unit

HP Heaters in
500 MW

250 MW

Primary air
PA Fan inlet

mmwc

-7

-2

PA Fan outlet

mmwc

797

773

Air heater inlet

mmwc

792

770

Air heater outlet

mmwc

761

752

Mill inlet

mmwc

647

645

Mill outlet

mmwc

297

286

FD fan inlet

mmwc

-13

-5

FD fan outlet

mmwc

172

108

Airheater inlet

mmwc

156

102

Airheater outlet

mmwc

111

85

Windbox pressure

mmwc

70

70

mmwc
mmwc
mmwc
mmwc
mmwc

-5
-5
-6
-15

-5
-5
-6
-9

-32

-19

mmwc
mmwc
mmwc
mmwc
mmwc
mmwc

-60
-74
-163
-177
-225

-34
-43
-80
-91
-115

28

17

Secondary air

Gas
Furnace
SH Platen inlet
RH Inlet (Platen outlet)
LTSH inlet (RH outlet)
Economiser inlet (LTSH
outlet)
Economiser outlet
Airheater inlet
Airheater outlet
EP inlet
ID fan inlet
ID fan outlet

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE: Predicted performance for Best coal


DWG :
Sheet :
78 of 82

Rev.01

PREDICTED PERFORMANCE DATA


( Best Coal Constant Pressure )
(BOTTOM MILLS)

VI.FUEL
The fuel data for Best coal are as follows:
Description

Unit

Fuel

Best Coal

Proximate Analysis :
Fixed carbon

32

Volatile matter

24

Moisture

12

Ash

32

HGI

60

kcal/kg

4200

mm

50 (Approx.)

Carbon

41.90

Hydrogen

3.60

Sulphur

0.25

Nitrogen

1.00

Oxygen

8.92

Carbonates

0.27

Phosphorous

0.06

Moisture

12.00

Ash

32.00

Grindability Index
Higher Heating Value (HHV)
Size of coal to Mill
Ultimate Analysis :

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE: Predicted performance for Best coal


DWG :
Sheet :
79 of 82

Rev.01

PREDICTED PERFORMANCE DATA


( Best Coal Constant Pressure )
(BOTTOM MILLS)

VII. MILL AND BURNER PERFORMANCE

Description

HP Heaters in

Unit

No. of mills in Operation

500 MW

250 MW

Bottom 6

Bottom 3

(A-F)

(C-E)

Mill loading

62.0

69.2

Air flow per mill

t/h

86.7

89.3

Air temp. at mill inlet

265

253

Mill outlet temp.

66 to 90

Fineness(thru '200 mesh)

70

Deg

-30 to +30

Burner Tilt

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE: Predicted performance for Best coal


DWG :
Sheet :
80 of 82

Rev.01

PREDICTED PERFORMANCE DATA


( Best Coal Constant Pressure )
(BOTTOM MILLS)
VIII. O2, CO2 (DRY VOL.) AND EXCESS AIR
Description

HP Heaters in

Unit
500 MW

250 MW

Oxygen in gas at
Economiser outlet

3.57

5.16

Carbon-di-oxide in gas
at Economiser outlet

15.37

13.96

Excess air in gas at


Economiser outlet

20.0

31.9

IX. AMBIENT CONDITIONS


Ambient temperature
Relative Humidity

Deg.C

27

60

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE: Predicted performance for Best coal


DWG :
Sheet :
81 of 82

Rev.01

PREDICTED PERFORMANCE DATA


( Best Coal Constant Pressure )
(BOTTOM MILLS)

X. HEAT BALANCE

Description

HP Heaters in

Unit
500 MW

250 MW

Losses
Dry gas

4.210

4.846

H2O in fuel, surf. & inherent

1.751

1.731

H2O from comb. Of H2

4.694

4.642

H2O in air

0.103

0.120

Radiation

0.239

0.425

Unburnt Carbon

1.500

1.500

Unaccounted

0.642

0.679

Manufacturers margin

0.150

0.150

Total losses

13.289

14.093

86.71

85.91

EFFICIENCY

PROJECT : NTPC / SIMHADRI STPP STAGE II 2 x 500 MW


Engineer
Rev. with
Approved by

SS/NR
PR
SCS

TITLE: Predicted performance for Best coal


DWG :
Sheet :
82 of 82

Rev.01