Standard Technical Specification for Sub- critical Thermal Power Project - 2x(500MW or above)

Main Plant Package

Section- 2 (Steam Generator and Auxiliaries)

2.2.4 Air Pre Heaters and Steam Coil Air Pre Heaters

2.2.4.1 Air pre heaters (APHs)

i) In addition to sizing and design criteria requirements elaborated at clause 2.1, the air
preheaters shall be designed to cater to following requirements also:

a) Type Regenerative type.

b) No. of air preheaters Two tri-sector type APH or

per steam generator two bi-sector type APH each for primary air
and secondary air.

c) Air temperature at Adequate to attain the required coal/air mix

APH outlet temperature at burner inlet and to provide
combustion air at required temperature to
furnace at all loads and full range of
specified coals.

ii) Air and flue gas ducts at inlet and outlet of APH shall be of aerodynamic design to
ensure uniform flow distribution across the duct sections at all loads.

iii) The air pre heaters shall be of rotary regenerative, Lungstorm or approved equivalent
type with axis of rotation as vertical. The construction of air pre heaters shall conform
to the following:

a) Heating Elements
• Cold end Corten steel, minimum 1.2 mm thick
• Hot/ intermediate end Carbon steel, minimum 0.8 mm thick
.
b) Bearings (forced lubricated and oil cooled)
• Cold end Spherical roller thrust bearing
• Hot end Radial guide bearing

Only metallic hoses shall be used for bearing cooling and lubrication. Rubber
hoses shall not be acceptable.

c) Air heater seals

• The seals shall be of externally adjustable and easily replaceable type.

• The maximum air-in leakage to flue gas after 3000 hours continuous
operation of the boiler with coal shall be guaranteed and demonstrated. The
contractor shall also demonstrate that the drift in air heater leakage
(percentage change in air-in-leakage) does not exceed 2%, subject to a
maximum air leakage of 12%, one year after demonstration of above
guaranteed air-in-leakage. Within this period of operation till all air heater
leakage demonstrations are completed only external adjustments of seals
without needing any shut down for replacements or internal adjustments
shall be allowed. The seal design/construction shall be such that the above
requirements are satisfied.

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 Standard Technical Specification for Sub- critical Thermal Power Project - 2x(500MW or above)
Main Plant Package

Section- 2 (Steam Generator and Auxiliaries)

• Seals shall have life not less than 2 years (with leakages not exceeding
permitted limits)

d) Air heater drive system

The drive system shall consist of one (1) no. peripheral AC drive with gear box
and automatic clutching/ declutching facility, and one (1) no. independent air
motor drive with its gear box and automatic clutching facility for rotation
during non availability of AC drive system. An air receiver of storage capacity
to cater to 10 minutes (minimum) operational requirement of air motors shall
be provided.

iv) Ash hoppers shall be provided for collection of ash.

v) The rated air temperature exiting the air heater shall be achievable upto 100% BMCR
load with design coal.

vi) Facilities along with the grids for flue gas sampling and gas temperature measurement
on both the inlet and outlet sides of APH(s) shall be provided.

vii) Alarms for failure of drives and lubrication system shall be provided.
viii) Air pre heater rotor standstill sensing device with alarm shall be provided.
ix) Air pre heater off load water washing facilities (including hoppers, water connections
etc.) with drainage connected to station drains shall be provided.
x) Air heater elements shall be arranged in baskets and shall be easily removable in
groups/baskets for maintenance.
xi) Observation ports with vapour proof light shall be provided at air inlet duct for rotor
inspection.
xii) Maintenance facilities:
a) The arrangement of walkways, platform, runway beams, trolley, hoists etc. as
required, shall be provided conveying, lowering and placement of
elements/baskets to ground level.
b) Hinged access doors shall be provided in the housing for internal inspection,
cleaning, maintenance and replacement of elements without dismantling air
heaters.
c) Galleries and platform around air heater and access to observation ports/access
doors etc. shall be provided. Platforms shall be capable of taking load and
storing elements for at least one sector of the air pre heater.
d) Special T&P kit shall be provided for removal of bearings and for replacement
of shaft.
xiii) Permanent firefighting facilities alongwith thermocouple type fire sensing device and
redundant temperature elements shall be provided for each bearing and oil sump. Fire
fighting facilities on cold end and hot end of the air preheaters shall be provided and
the fire fighting facilities shall cover both flue gas sides of air preheaters. Connections
for fire water shall be taken from fire water lines in the purchaser’s scope. Necessary
water draining system, connected to station drains shall also be provided.

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 Standard Technical Specification for Sub- critical Thermal Power Project - 2x(500MW or above)
Main Plant Package

Section- 2 (Steam Generator and Auxiliaries)

2.2.4.2 Steam coil air pre heaters (SCAPHs)

i) SCAPH and connected air ducts shall be designed to handle flows corresponding to
50% BMCR loads with one of the two streams working without any undue noise/
vibration.

ii) Condensate from SCAPH shall be led to intermittent blow down (IBD) tank.

iii) SCAPH shall have modular construction with adequate tube spacing to avoid
chocking by contamination in the entering air.

iv) SCAPH shall be located in the bypass duct at the outlets of each FD fans. For bi-
sector type APH, SCAPH shall also be provided in the bypass duct at the outlet of
each PA fan.

v) Facility shall be provided for complete isolation of SCAPH from the air flow path.

vi) SCAPH should be in service only during startup, low load and under abnormal
conditions. It shall not be in service under all normal operations for the complete
specified range of fuel.

vii) The construction shall be of side entry type to facilitate removal of SCAPH modules
by sliding out of modular frame.

viii) Proper approach to the side entry and adequate facility (platform, runway beam, hoist
etc.) for removal and placement of SCAPH modules on ground level shall be
provided.

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 Standard Technical Specification for Sub- critical Thermal Power Project - 2x(500MW or above)
Main Plant Package

Section- 2 (Steam Generator and Auxiliaries)

2.2.5 Coal Preparation and Firing System

2.2.5.1 General

i) The coal preparation and firing system shall commence with the shut-off valve/ gate
at raw coal bunker outlet and shall include raw coal feeders with shut off gate at inlet,
coal pulverisers, primary air and seal air fans, pulverised coal piping, coal burners and
associated auxiliaries.

ii) The design of coal preparation and firing system shall ensure the following:

a) Complete safety of the plant, equipment and the personnel.

b) Complete compliance with the latest NFPA (USA) requirements and other
requirements specified hereinafter.

2.2.5.2 Coal shut off gates/ valves and coal chutes

i) Bunker shut off gate(s) and coal feeder inlet gate(s) shall be provided with the
following features:

a) Size of gates/valves shall be suitable for round bunker opening of minimum

914.4 mm (36”).

b) Shut off gates/valves shall be motor operated, with double rack and pinion
drive arrangement and shall be of non-jamming type.

c) Gate/ valve design shall ensure dust tight enclosure and shall be of self cleaning
type.

ii) All components coming in contact with coal and the roller bearing shall be of
stainless steel material.

iii) Shut off valves/gates shall be designed to operate with “bunker full of coal” condition
without its motor getting overloaded. Normal motorised as well inching operation of
these shut off gates/valves should be possible from the feeder floor. For manual
operation from feeder floor level, wheel and chain shall be provided for each
gate/valve.

iv) The chutes between bunker outlet gate and inlet to the coal feeder shall not have
internal diameter less than 914.4 mm. The chute between feeder outlet and pulveriser
inlet shall not be of internal diameter less than 600 mm.

v) The chutes shall be of made of minimum 12mm thick SS-410 material and shall be of
fully welded construction. The chute between feeder outlet and pulveriser inlet shall
have a SS lined hopper with suitable reinforcement. The provision shall be made for
the insertion of poke rods in two direction opposite to each other at outlet of the
bunker and inlet of the feeders.

vi) Suitable coupling (Dresser or equivalent) shall be provided for chute connection(s) at
outlet of feeder and pulveriser with SS 410 inner ring.

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 Standard Technical Specification for Sub- critical Thermal Power Project - 2x(500MW or above)
Main Plant Package

Section- 2 (Steam Generator and Auxiliaries)

vii) The arrangement of permanent bunker emptying chute alongwith necessary coal flow
diversion valve shall be provided between each bunker and RC feeder. Necessary
access shall be provided for operation of coal flow diversion valves. The emptying
chute shall enable unloading of bunkers on trucks at ground level. An arrangement
with a temporary chute fitted on the bunker downspout alongwith a permanent chute
from the feeder floor to the ground level shall also be acceptable.

viii) Suitable indicators shall be provided in the downspout between bunker and feeder to
detect presence of coal flow to ensure minimum seal height at inlet to feeder and trip
the feeder if the level of coal tends to be below the seal height.

2.2.5.3 Raw coal (RC) feeders

i) The raw coal feeders shall be of gravimetric, belt type with minimum size of 914.4
mm (36”). Each RC feeder shall be sized for 1.2 times the maximum capacity of coal
pulveriser. The feeder casing shall be designed to withstand an explosion pressure of
3.5 kg/cm2(g).

ii) The RC feeders shall comply with all the stipulations of NFPA.

iii) The feeder belt shall be of multi- ply reinforced rubber of single piece construction
with arrangement for tracking and to prevent spillage. The width of the belt shall have
sufficient margin while operating in conjunction with feeder inlet opening. Suitable
arrangement shall be provided to adjust belt tension.

iv) All components coming in contact with coal (except belt) shall be made of stainless
steel.

v) All site equipment shall be suitable for 700C ambient temperature and other
environment conditions envisaged.

vi) Detection for “No coal” flow shall be provided to stop the feeder when no coal is
detected on the conveyor and when pluggage occur at feeder outlet. Paddle type coal
alarm switch shall be provided for this purpose over the feeder conveyor for
indication of loss of coal flow and near the feeder discharge to stop the feeder in the
event of coal pluggage at the feeder outlet.

vii) The feeder control system shall be microprocessor based. Coal weighing shall be
automatic and shall include local and remote indication for rate of flow and totaliser
counter. The feeder control cabinet shall be located in control equipment room
(CER).

viii) The weighing accuracy of the feeder shall be + 0.5% with repeatability of 0.1%.
Facility for in-built calibration shall be provided.

ix) The following facilities shall be provided for the feeders:

a) Spraying water inside the casing.

b) Providing purge air to the feeder.

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 Standard Technical Specification for Sub- critical Thermal Power Project - 2x(500MW or above)
Main Plant Package

Section- 2 (Steam Generator and Auxiliaries)

x) Feeders shall be provided with adequate number of manholes on for quick and easy
release of the feeder jamming. Easy access to any part of the feeder internals shall be
possible without dismantling the complete casing.

2.2.5.4 Coal pulverisers (mills)

i) Pulveriser type:

The coal pulverizes shall be of vertical spindle type. The pulverisers offered by the
bidder can be of Ball and Race/ Roller/ Bowl/ MPS type or approved equivalent type.

ii) Classifier design:

a) The classifier design shall be of static type and shall be capable of maintaining
rated conditions of fineness under all conditions of operation, load changes and
specified fuels. Further, the classifier vanes shall be adjustable externally and
shall be lined with suitable wear resistant material to ensure the guaranteed
wear life.

b) The classifier shall ensure reduction in particle of 50 mesh without increasing

200 mesh percentage to ensure uniform sizing and distribution of particles.
Fineness adjustment shall be possible while the mills are in service.

c) Outlet of the classifier shall have aerodynamic shape to prevent eddies.

iii) Provision shall be provided in the mill design for future accommodation of rotary
classifier in place of stationary classifier. For this purpose necessary structure,
piping, spare piece etc. shall be provided.

iv) Mill noise level:

The mill noise level shall not exceed the specified values. While selecting lagging,
background noise from adjacent mills, drive system and other secondary and stray
noises shall be taken into account.

v) Mill seal air system:

a) 2x100% seal air fans common for all the mills shall be provided for ach steam
generator unit. The fans shall preferably be located at ground floor.

b) The sealing system shall prevent ingress of any dust into the bearings and
leakage of coal-air mixture to atmosphere.

c) The seal air fans shall take their suction from atmosphere/ PA fan cold air bus.
Silencers shall be provided, if required, at the suction of the fans to restrict
noise level within permissible limits.

vi) Mill gear box:

The gear box shall be planetary type. The gear box design shall ensure that there is
no ingress of coal dust into gear box under all conditions of operation. The gear box
shall give trouble free operation of not less than 100,000 hours of mill operation.

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 Standard Technical Specification for Sub- critical Thermal Power Project - 2x(500MW or above)
Main Plant Package

Section- 2 (Steam Generator and Auxiliaries)

vii) Mill motor capacity:

The mill motors shall be adequately sized and selected motor capacity shall enable
restart of the mill after a trip with mill full of coal. Such restart shall not call for any
emptying of the mill.

viii) Inlet coal pipe between RC feeder and the mill shall not have any reduction in section
throughout the length, including at entry point on top of the mill.

ix) Each mill shall be fed with coal by an independent coal feeder.

x) Materials of construction:

a) The material of construction of wear parts shall be selected taking into account
highly abrasive nature of coal resulting from coal contamination with silica
sand and alpha-quartz.

b) The grinding rings/ race shall be made of material having hardness of minimum
550 BHN at the surface with adequate chilled depth. The grinding balls/ rolls
shall be of material with minimum hardness 350 BHN. Minimum difference
between hardness of rings/race and balls/rolls shall be 100 BHN.

c) The classifier cone shall be lined with minimum 15 mm thick ceramic tiles on
both inside and outside surfaces of the cone. The classifier vanes shall be lined
with suitable material to provide minimum specified wear life.

xi) Lubrication system:

The design of lubrication system shall ensure continuous operation of mill bearings.
Suitable arrangement shall be provided for readily determining the oil level in the
gear box(es) and all other lubricated parts.

xii) Pulverised coal sampling:

a) Tapping points shall be provided on each pulverized coal pipe at mill outlet
and shall be suitable for coal sampling as per ISO 9931. The sampling
provisions shall be complete with screwed plugs, compressed air purging
connections at tapping points, heating arrangement and other requirements as
per ISO 9931.

b) One (1) no. of Rota probe shall be provided for each steam generator for coal
sampling as per ISO 9931. Further, four (4) nos. of Dirty Pitot tubes shall be
provided for steam generator and shall be suitable for measurement of coal-air
velocity in the coal pipes.

c) Convenient approach/access from nearest platform floor shall be provided for

coal sampling/ measurement points.

xiii) Mill outlet temperature control shall be capable of achieving and maintaining rated
temperature for adequately drying the specified coal range for all unit loads.

xiv) The flap of power operated mill discharge valves shall be totally out of coal path
during operation of the mill.

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 Standard Technical Specification for Sub- critical Thermal Power Project - 2x(500MW or above)
Main Plant Package

Section- 2 (Steam Generator and Auxiliaries)

xv) All mill wear parts shall be arranged so as to facilitate easy replacements without total
dismantling of pulveriser(s).

xvi) The mill shall be capable of running at part loads and ensure minimum turn-down
ratio of 2:1.

xvii) Handling of pulveriser parts:

a) The pulveriser shall be designed to facilitate ease of handling of heavy parts for
maintenance purpose.

b) Motorised hoists shall be provided for O&M works of components below

separator top.

c) The gear case shall be accessible and suitable for removing gearing/ removing
upper structure.

xviii) Adequate numbers of access doors/windows with access ladders shall be provided to
facilitate access to various parts of mill. The access doors shall be suitable for on load
inspection and maintenance of the mill. The oil pumps and filters shall be readily
accessible.

xix) Necessary ladders and approach platforms for mill bay hoist shall be provided at one
end/ corner to carry out any maintenance activity on hoists.

2.2.5.5 Pulverised coal pipes

i) In addition to sizing and design requirements elaborated for pulverized coal pipes at
clause 2.1, the following requirements shall also be adhered:

a) The design and arrangement of fuel pipe shall ensure uniform distribution of
coal air mixture between all burners served by one pulveriser under all
conditions of loading.

b) The maximum permissible design stress shall be 67% of yield strength (or 0.2%
proof stress).

c) The coal air mixture velocity in the coal pipes shall not be lower than the critical
fallout velocity under all conditions of mill operation from start up of boiler
onward.

d) The fuel pipe shall preferably have no horizontal run and if horizontal run is
necessitated due to layout constraints it shall tilt either towards mills or burners.

e) The pipe and bend base material thickness wherever liners are provided shall not
be less than 8 mm.

f) The straight unlined pulverized coal pipe length shall be of mild steel having a
thickness not less than 12.7 mm with a minimum wear allowance of 4 mm.

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 Standard Technical Specification for Sub- critical Thermal Power Project - 2x(500MW or above)
Main Plant Package

Section- 2 (Steam Generator and Auxiliaries)

g) Calculated static loading of each support of the pulverized coal pipes shall be
increased by at least 25% to arrive at the design load, to take care of the shock
loading, occurring in the pipe work under abnormal conditions of operation.

ii) The guide plates, wherever provided in the coal pipe, shall be removable and access
to them shall be obtained through detachable cover. The guide plates shall be made
up of suitable abrasion resistant material.

iii) The following pulverized coal piping portions shall be ceramic lined:

a) From mill outlet upto and including 1st bend and two times pipe diameter
straight length down stream of first bend.

b) All bends between 150 and 300 angle and straight length down stream of the
bends equivalent to one pipe diameter.

c) All bends 300 and higher and two times diameter straight length downstream of
the bend.

d) The burner inlet elbow and the pipe piece after the elbow.

e) Pulverised coal pipe from mill to classifier (in case of separate classifier).

The ceramic material shall have alumina content of not less than 90%. The ceramic
lining shall be minimum 15 mm thickness and shall provide guaranteed life of
25000 hrs.

iv) Purge air connections shall be provided after the mill discharge valve to clean
pulverised coal pipes of any deposits etc.

v) Provisions shall be made at suitable locations on pulverized coal piping for sampling
the pulverized coal. Suitable sampling equipment shall also be provided.

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 Standard Technical Specification for Sub- critical Thermal Power Project - 2x(500MW or above)
Main Plant Package

Section- 2 (Steam Generator and Auxiliaries)

2.2.6 Coal Burners

2.2.6.1 Burners design
i) Turn down ratio of coal firing system shall be 2:1 (minimum).

ii) The coal burner design shall ensure a steady log mean density of coal air mixture
distribution as it enters the combustion zone, without allowing the coal dust to settle
down.

iii) The burner design shall minimise erosion.

iv) The burner shall be designed to ensure smooth variation in the fuel flow without
affecting the air to fuel ratio.

v) The air to fuel ratio around the burner shall be optimized to ensure low emission of
NOx. Total NOx emission (fuel as well as thermal NOx) shall not exceed 260 gm/giga
joule of heat input to the boiler.

vi) Burners shall be provided with centralised automatic control with flame scanner and
safety protection.

2.2.6.2 Burners construction

i) Each coal burner shall be served by one separate coal pipe and shall be provided with
one knife edge type gate valve at burner inlet. The valve shall be power operated and
hooked up to burner management system.

ii) Compartmented wind box shall be provided for supply of secondary air for
combustion.

iii) The material and construction of burner shall withstand radiation from the
furnace, and shall not be damaged when not in use.

iv) The parts subjected to high temperature which cannot be protected by other means
shall be made of alloy steel. Further, burners parts subject to abrasion that may
require replacement at frequent intervals shall be easily removable.

v) Burner design shall ensure freedom from deposits and distortion under all operating
condition in the furnace. Further, burners shall not require adjustment to maintain
flame shape.

vi) Minimum operating life of burner parts without requiring any maintenance
and replacement shall be guaranteed for minimum 8000 hours.
vii) Burner shall be removable or replaceable from outside the stream generator without
entry to the furnace.

2.2.6.3 Air register construction shall be such that tangential air vanes are always free to move. The
support bearings shall preferably be located outside. In case the support bearings are
located inside, minimum period of operation shall be 16000 hours without calling for
maintenance of any sort during this period.

2.2.6.4 The angle at confluence between the coal burner primary air and secondary air shall be such
that the inherent carbon monoxide produced is removed by scrubbing action without any
significant reduction in velocities of the air stream.

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 Standard Technical Specification for Sub- critical Thermal Power Project - 2x(500MW or above)
Main Plant Package

Section- 2 (Steam Generator and Auxiliaries)

2.2.7 Primary Air Fans

2.2.7.1 Fan characteristics

The fan shall take suction from atmosphere. The fan characteristics shall be compatible
with pulverized coal system resistance and boiler operation at rated loads, during boiler
start up and low load operation with minimum number of mills. The system resistance
curves shall always be sufficiently below the fan stall line. The best efficiency point of the
fan shall be close to 100% TMCR operating point.

2.2.7.2 Fan control system

i) The system shall be designed to achieve stable and satisfactory operation with air
flow control and air pressure controls.

ii) Fan flow control shall be by blade pitch control. The final control element shall be
electrically/ pneumatically operated and shall not have a backlash or play etc.

iii) The regulating dampers for air pressure control shall operate in the range of 20% to
85% steam generator loads up to BMCR conditions.

iv) The system shall be capable of working on automatic mode for all regimes of
operation in a steady and stable manner.

2.2.7.3 Constructional features

i) Material of construction

a) Fan blades : High strength aluminum alloy with

minimum hardness of BHN-75.

b) Base plate : Cast iron or welded steel.

c) Casing : Sheet steel of suitable thickness.

d) Fan inlet boxes, diffuser : Fabricated with sheet steel of

and intermediate pieces thickness not less than 5 mm.

ii) Special construction features:

a) The fan suction shall be provided with rigid bird and trash screen assembly
and shall have suitable arrangement to prevent rain water from directly
entering the fan.

b) The fan design shall be over hung type. The layout of PA fans shall ensure
interchangeability of impellers. Similar fans shall have same direction of
rotation.

c) The contractor shall submit detailed calculations for purchaser's approval to

confirm compliance with the sizing requirements specified under clause 2.1.

d) Pulsation shall be avoided by suitable design of fan and connecting

ductwork.

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 Standard Technical Specification for Sub- critical Thermal Power Project - 2x(500MW or above)
Main Plant Package

Section- 2 (Steam Generator and Auxiliaries)

iii) Fan bearings:

a) The rotor assembly shall be supported over a oil lubricated bearing assembly
consisting of antifriction/sleeve bearing adequately sized to take care of radial
thrust loads.

b) Bearing housings shall be provided with vibration pad and sensors for remote
monitoring, interlock and protection.

c) In case of oil lubricated bearing, the design shall be such that bearing are
lubricated by external force oil lubricating system in which oil is cooled by
external cooler. In addition, sump lubrication shall also be provided.

d) One number duplex RTD (100 ohm at 00 C) and temperature indicators shall
be provided for local and remote monitoring of the bearing metal temperature
of fans for each bearing.

iv) Fan lubrication system

The lubricating system shall be complete in all respect, compact and frame mounted.
The lube oil pressure shall be higher than cooling water pressure. Each bearing shall
be provided with an oil level indicator and screwed drain plug.

v) Silencers shall be provided to limit the noise level to the specified values.

vi) Fan vibration monitoring pads shall be provided.

vii) Fan housing shall be designed for ease of maintenance and access to the fan wheel or
impeller. The casing shall be split type to provide easy removal of the fan wheel or
impeller for replacement and repairs. Access doors shall be provided in each suction
chambers, casing. The casing section shall have gasketted joints to ensure air-tight
sealing. Drain connections shall be provided at the bottom most point of fan housing.

viii) Fan casing shall be properly stiffened to minimize vibrations and distortions during
operation.

2.2.7.4 Primary air flow measurement

i) PA flow measuring devices shall be provided at air inlet to each mill for total air flow
measurement and control.

ii) Independent tapping points with necessary isolating valves shall be provided for
control, measurement and performance test.

iii) Location, type and design of flow measuring devices shall be subject to purchaser's
approval.

iv) Necessary temperature element points for temperature compensation in the flow
measurement shall also be provided.

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 Standard Technical Specification for Sub- critical Thermal Power Project - 2x(500MW or above)
Main Plant Package

Section- 2 (Steam Generator and Auxiliaries)

2.2.8 Balanced Draft System

2.2.8.1 Both FD and ID fans shall operate with highest possible efficiency which shall be nearly
equal at the 100% TMCR and test block points.

2.2.8.2 Construction features

The construction of FD & ID fans shall comply with the following requirements:

Description FD fans ID fans

(Axial type) (Radial type) (Axial type)
i) Type of fan Stream line, aerofoil Backward curved single Stream line, aerofoil
blade shaped section thickness plate bladed shaped section
type or aerofoil type
ii) Blade High strength Al-alloy 25mm (min.) thick High strength Al-
material and BHN-75 (min) blade plate provided alloy with anti wear
thickness with renewable liners of spray coating/ liners.
wear resistant material
having minimum 10 mm
thickness.
iii) Fan speed Maximum 1500 rpm Maximum 600 rpm Maximum 600 rpm
iv) Air/flue gas Blade pitch control Variable frequency drive Blade pitch control
flow control or hydraulic coupling
v)Fan critical Not less than 125% of Not less than 125% of Not less than 125%
speed fan maximum fan maximum operating of fan maximum
operating speed speed operating speed
vi) Fan To withstand torsional To withstand torsional To withstand
component stresses three times stresses three times the torsional stresses
design the normal full load normal full load motor three times the
motor torque at all torque at all speeds normal full load
speeds The shaft material shall motor torque at all
be 15 Mo3 or better. The speeds
operating stresses shall The shaft material
be limited to 2kg/mm2. shall be 15 Mo3 or
Welded zones shall be better. The operating
suitably stress relieved stresses shall be
and residual stress shall limited to 2kg/mm2.
be considered for design. Welded zones shall
be suitably stress
relieved and residual
stress shall be
considered for
design.
vii) Fan 5 mm (min.) Abrasion resistant high Abrasion resistant
casing BHN Steel 8 mm (min.)/ high BHN Steel 8
material and 12mm (min.) mild steel mm (min.)/ 12mm
plate with liner thickness 6 (min.) mild steel
thickness mm (min.). with liner thickness
6 mm (min.).
viii) Fan Shut off head of the Shut off head of the fan Shut off head of the
housing design fan fan
pressure

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 Standard Technical Specification for Sub- critical Thermal Power Project - 2x(500MW or above)
Main Plant Package

Section- 2 (Steam Generator and Auxiliaries)

Note : a) Fan components along with servo/blade pitch control mechanism shall be
designed to withstand and continuously operate with the maximum air or flue
gas temperature that these fans will be required to handle.

b) ID fan components shall also be designed to withstand the excursions upto

3000C which may persist for about 30 minutes duration.

2.2.8.3 Fan bearings

i) Bearing shall be provided with oil bath to avoid damage in case of complete loss of
plant auxiliary power when the fans must coast down without power.

ii) Oil reservoir in bearings housing shall be sized for maintaining lubrication for
extended periods in case of oil circulation system being out of service.

iii) One number duplex PE-RTD (100 ohm at 00C) and temperature indicator shall be
provided for each bearing.

iv) Bearing housings shall be provided with vibration pads and sensors for remote
monitoring and interlock/ protection.

2.2.8.4 Fan balancing

i) The fans shall be statically and dynamically balanced before. Balancing of each fan
shall be checked and adjusted at site, if necessary.

ii) Natural frequency of fan components shall be established by vibration testing to

ensure that no part of the wheel is adversely exited by any force generated at
operating speeds.

iii) For axial fan cantilever, variable pitch blade shall be subjected to natural frequency.
The other components of ID & FD fan wheels need not be subjected to natural
frequency test if supplier can prove that these component are very rigid and have very
high natural frequency compared to the operating frequency of respective fans giving
justification.

2.2.8.5 Operational requirements

FD & ID fans shall meet the following operational requirements:

Description FD fans ID fans

Mode of operation a) Two fans in parallel a) Two fans in parallel.

b) One fan operation b) One fan operation

(one as well as both (one as well as both
streams in operation) streams in operation)

Fan control a) Capable of operating a) Capable of operating

in automatic mode in automatic mode
for all regimes of for all regimes of
operation in a steady operation in a steady
and stable manner and stable manner

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Section- 2 (Steam Generator and Auxiliaries)

b) The final control element b)The final control element

Vibration monitoring
Bearing metal temperature
monitoring
shall not have any back
lash, plays etc., and shall
operate in the range of
20% to 85% BMCR load.
Suitable pads matching with
vibration pickup shall be
provided on fan bearing housings.
Shall be possible from
remote as well as locally
using adequate nos. of
duplex platinum RTDs
(100 ohms at 00C.)
shall operate in the range
of 20 to 85% BMCR load.
Same as that for FD fans
Shall be possible from
remote as well as locally
using adequate nos. of
duplex platinum RTDs
(100ohms at 00C)

Note :- The fans shall be suitable for parallel operation and sharing the load equally over the
entire range of operation without hunting. Pulsation shall be avoided by suitable
design of fans and connected ductwork.

2.2.8.6 Flow measuring devices

i) The draft plant shall include venturi/ aerofoil type flow elements in the air system for
total air flow measurements and control, each with three pairs of tapping points.
ii) Two nos. duplex temperature element with thermo wells for temperature
compensation shall be provided.

2.2.8.7 Fan casing

i) The fan casing shall be of split type to facilitate easy removal of the fan wheel or
impeller for replacement and repairs.
ii) Access doors shall be provided in each suction chamber casing and diffuser.
iii) The sections shall have gasketed joint to ensure air tight sealing.

2.2.8.8 Fan layout

The layout of FD fans shall ensure interchangeability of the impellers. Similar fans shall
have same direction of rotation.

2.2.8.9 Drain connections

Drain connections shall be provided at bottom most point of the fan housing.

2.2.8.10 Fan suction

i) Silencers shall be provided at the suction of FD fans to limit the noise level to 85
dBA at a distance of 1.0 m.
ii) Fan suction shall be provided with rigid bird and trash screen assembly and shall have
suitable arrangement to avoid rain water from directly entering the FD fan.

iii) Location of FD fan hood shall prevent entry of dusty air into fan.

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 Standard Technical Specification for Sub- critical Thermal Power Project - 2x(500MW or above)
Main Plant Package

Section- 2 (Steam Generator and Auxiliaries)

2.2.9 Fuel Oil System

The fuel oil system shall comprise of fuel oil preparation and firing system for heavy fuel
oil (HFO/LSHS/HPS) and LDO, fuel oil drain system and fuel oil condensate system.

i) Heavy fuel oil firing system

Heavy fuel oil shall be used for initial start-up, low load operation and as secondary
fuel for pulverised coal flame stabilization at the start ups and low load operation.
The scheme as envisaged for firing these oils shall cater to requirements of two units.
The fuel oil shall be drawn from HFO storage tank(s) by fuel oil pressurising pumps
and pumped through steam oil heaters. The oil shall be taken in steam generator
unit(s) and re-circulated back to the storage tanks through oil coolers. The oil
requirement of oil burners of the steam generator shall be tapped off from a ring main
formed at the respective steam generator area. The oil pressure shall be maintained to
the required value in the pressure main by means of automatic pressure regulating
valve(s). Oil temperature shall be controlled by regulating steam flow to fuel oil
heaters. All facilities required for functioning of fuel oil supply to the burners under
certain operating conditions etc. shall be incorporated in the design. For each steam
generator between pressure oil line and return oil line an interconnecting line shall be
provided with automatic control system to maintain the pressure of the oil to the
steam generator at a predetermined value.

ii) LDO firing system

The LDO firing system shall be provided to facilitate start of units when no auxiliary
steam is available from external source. Light diesel oil firing system shall also be
used for cold start up of steam generators and for flushing of heavy fuel oil lines.
Basic scheme for light oil system shall be the same as that discussed above for heavy
fuel oil system, except that the suction for the LDO pressuring pumps shall be from
the LDO tanks and there shall not be any heating requirements. Provision of draining
shall be provided in the LDO system.

iii) Fuel oil drain system

The fuel oil drains from different equipments and piping etc. of a steam generator
shall be brought by gravity to the drain oil tank provided for each steam generator.
The oil collected in these tanks shall be periodically pumped back to the fuel oil
storage tanks (in purchaser’s scope). Drains from the common oil pressurising pump
house area shall be led to another drain oil tank and shall be pumped to fuel oil
storage tanks by 2x100% pumps. Adequate heating arrangement shall be provided for
drain oil tanks.

iv) Oily water drain system

The oily waste water drains from each steam generator area shall be collected and
suitably treated in an oil separator. The treated out let water shall not have oil content
more than 10 ppm. The recovered oil from oil separators shall be led to drain oil
tanks/ waste oil collection tanks. Separated water shall be pumped to effluent
treatment plant (in purchaser’s scope) using sump pumps.

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 Standard Technical Specification for Sub- critical Thermal Power Project - 2x(500MW or above)
Main Plant Package

Section- 2 (Steam Generator and Auxiliaries)

v) Fuel oil condensate system

Condensate from complete fuel oil plant shall be brought to a common condensate
flash tank in fuel oil unloading area. Drains from this condensate tank shall be
connected to station drains.

2.2.9.1 Fuel oil preparation and firing system

i) The fuel oil preparation and firing system shall be designed common for both the
units. The system shall be designed to function in total association with the furnace
safeguard supervisory system (FSSS).

ii) The heavy fuel oil system shall have the following design features:

a) Steam tracing shall be provided for all the heavy fuel oil lines. There shall be
no cooled legs in oil supply and recirculation piping.

b) Relief valves shall be provided on larger section of fuel oil pipes which can be
isolated.

c) Isolation valves shall be provided both on up stream and down stream sides for
all in-line items like pumps, heaters, flow meters, filters, control valves etc.
which are required to be taken out for maintenance.

d) Adequately sized pressure accumulators shall be provided on fuel oil lines to

individual steam generator for maintaining constant oil pressure. Each
accumulator shall be complete with a pressure gauge, stop cock and isolation
valves to ensure maintainability of nitrogen pressure.

e) Facility shall be provided for complete flushing of heavy fuel oil handling
system by LDO. For LDO handling system, steam flushing system shall be
provided for cleaning during commissioning.

iii) Design and sizing of various pumps shall be based on following criteria:

Heavy oil LDO pumps Drain oil pumps Sump pumps

pressuring
pumps

a) Type of fuel to be HFO/HPS/ LDO HFO/HPS/LSHS/ Oil and water

to be handled LSHS LDO

b) Temperature of fuel 900C Atmospheric 900C 50-850C

oil to be handled

c) Pump design and ----------HI Standards, ASTM, ASME or equivalent code) ----------------
construction (subject to purchaser’s approval)

d) No. of pumps 3 (2W+1S) 3 (2W+1S) 2 (1W+1S) 2 (1W+1S)

per unit per unit

e) No. of oil heaters 3 (2W+1S) Nil - -

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 Standard Technical Specification for Sub- critical Thermal Power Project - 2x(500MW or above)
Main Plant Package

Section- 2 (Steam Generator and Auxiliaries)

f) Capacity of each To cater to To cater to 4m3/hr 7.5m3/hr

pump 30% BMCR minimum
requirements 7.5% BMCR
of one steam requirement
generator of one steam
without coal generator
firing plus without any
10%. coal firing
plus 10%.

g) Pump suction Head from Head from (-)1.0 m approx. Flooded

head tank tank suction

h) Pump discharge To suit the To suit the As required to To suit site

head. requirements requirements pump oil from drain requirements
of burners of burners oil tanks to main oil
storage tanks

iv) Construction of heavy fuel oil pressuring pumps, LDO pressuring pumps and drain
oil pumps shall comply with the following:

a) Type of Pump : Rotary, positive displacement, horizontal pump

fitted with relief valves.

b) Pump/motor base plate : Common

c) Type of drive : Constant speed squirrel cage, induction motor with

flexible couplings.
d) Materials
• Casing : Close grained cast iron
• Shaft : Carbon steel

e) Type of bearings : Antifriction

v) Heavy fuel oil heaters shall be designed based on the following:

a) Type and no. of heaters : Three (2 working + 1 standby)

shell and tube type, preferably
with oil through tubes. (oil
through shell also acceptable).

b) Capacity of each heater : To suit the rated capacity of each

heavy fuel oil pressurising pump.

c) Heater inlet fuel oil temp. : 300C

(considered for sizing)

d) Heater outlet temperature : To suit the viscosity requirements

at the fuel oil tips for the grade of
oil (HPS/HFO/LSHS) used.

e) Metal temperature of heater : 2100C (Maximum)

heat transfer surface

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 Standard Technical Specification for Sub- critical Thermal Power Project - 2x(500MW or above)
Main Plant Package

Section- 2 (Steam Generator and Auxiliaries)

f) Heater design and

construction : TEMA, ASME Boiler and
pressure vessel code, HEI
standards, USA. Pipe
connections to heater as per
TEMA class C BEV type.

g) Heater tubes : Seamless (tube bundles shall be

of removable type)

vi) Filters

a) Coarse filter shall be provided at pressuring pumps inlet and fine filter
at oil heater outlet.

b) The maximum pressure drop across filters shall be 0.1 kg/cm2 when
filter is clean and 0.3 kg/cm2 when filter is 50% clogged.
.
c) Material of filtering mesh shall be stainless steel.

d) Aperture size for fine filter shall not exceed 150 μm or shall be at least
30% smaller than smallest oil orifice or passage to the burners.

vii) Trip and nozzle valves

a) Heavy fuel oil and light oil trip valves and nozzle valves shall be
suitable to handle oils at temperature and pressure required at the
burners. Further, these valves shall confirm to ANSI leakage Class-VI
under shut off pressure conditions of respective pumps.

b) The solenoids of trip valves and individual burner nozzle valve shall
be of single coil heavy duty construction having class ‘H’ insulation.

c) The closing time of trip and nozzle valve shall be less than one (1)
second. The valves shall close when de-energised /failure of air supply.

d) The operating voltage shall be as under:

• Trip valve solenoid : 24 volts DC
• Nozzle valves solenoid : 110 volts AC

viii) Oil burners and burner components

Description Heavy fuel oil LDO firing system

firing system

a) Type of burner Steam atomised (steam Air atomised (air

to be tapped off from tapped off from
auxiliary steam the compressed
system) air system)

b) Burner cooling Steam or air Air

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 Standard Technical Specification for Sub- critical Thermal Power Project - 2x(500MW or above)
Main Plant Package

Section- 2 (Steam Generator and Auxiliaries)

c) Burner tip material Resistant to corrosion Resistant to corrosion

(Tips to be fully leak tight) due to fuel oils contai-
due to oil containing ning sodium, vanadium
sodium, vanadium, sulp- sulphur, chloride etc.
hur, chloride etc.

d) Minimum guaranteed ------------ 8000 hours ---------------

life of burner tips, before
needing any maintenance/
replacements.

e) Hardness of atomiser Minimum vickers Minimum vickers

(hardness to be retained hardness number hardness number of 400
even at 4000C) of 400

f) Type of oil ignitor High energy arc High energy arc

ignitors ignitors

ix) Piping shall conform to following codes:

Piping Code

a) Steam and condensate piping IS: 1239 (heavy duty) or ASTM 106
below 20 kg/cm2 pressure Gr. B or approved equivalent.

b) Fuel oil piping : API-5L Gr. B or ASTM-106 Gr.

B in the unloading area.

: IS:1978 or approved equivalent

from discharge of pressurising
pump to the boiler.

Piping, fittings shall be of carbon steel butt welded connection conforming to

ASTM A-234 or approved equivalent. All flanges, where provided, shall
conform to IS :6392 or approved equivalent.

x) Valves shall conform to following:

Parameter Requirement

a) Type of valves (for oil services) Plug type, leak proof, self
lubricating

b) Material of valves on oil lines:

• On pump suction side Cast iron
• On pump discharge side Cast steel

c) Material of valves on steam Cast steel

and condensate lines

Instrument root valves on heavy oil lines shall be of 25 NB size, flanged OS

and Y type with body rating in ASA as per process conditions.

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 Standard Technical Specification for Sub- critical Thermal Power Project - 2x(500MW or above)
Main Plant Package

Section- 2 (Steam Generator and Auxiliaries)

xi) Maintenance facilities to be provided shall include:

a) Burner maintenance trolley along with accessories

b) Fixed drip tray for each oil burner to contain any oil leakage

c) Handling facility (with runway beam, hoist, equivalent structure etc.)

for all pumps and heaters.

d) Oil gun cleaning station and the facility for blow off of the oil guns
using auxiliary steam at each firing floor. For this purpose auxiliary
steam tapping with necessary isolation valves and necessary hose
connection shall be provided.

xii) Operational requirements:

a) Facilities shall be provided for auto start of standby heavy fuel

oil/LDO pressuring pumps in event of tripping of any running pump or
low fuel oil pressure. For drain oil pumps, auto start and shutdown
facility shall be provided in conjunction with level in the drain oil
tanks.

b) Interlock shall be provided for automatic purge before light up and

after failure to first oil burner operation.

c) Separate flame viewing opening/ facility shall be provided for boiler

operation and for flame monitoring at each burner from out side. The
provision shall be made to keep the system cool below 750C and to
keep the optical system clean during firing/non firing by pressurised
air.

d) Adequate instrumentation such as temperature, pressure, differential

pressure, flow transmitters, switches for independent high and low
signalling contacts required for burner management system and other
interlock/alarm shall be provided for interfacing with other systems/
equipments.

e) Adequate potential free contacts shall be provided for status of

individual pumps.

2.2.9.2 Fuel oil drain and condensate system

i) Design and construction of drain oil tank(s) and condensate tank shall
comply with following requirements:

Drain oil tank Condensate flash tank

a) Medium to be Heavy fuel oil Condensate water/

stored (HPSLSHS/HFO) flash steam
and LDO

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 Standard Technical Specification for Sub- critical Thermal Power Project - 2x(500MW or above)
Main Plant Package

Section- 2 (Steam Generator and Auxiliaries)

b) No. of tanks Two (2) in boiler One (1)

area and one (1)
in FO pressurizing
pump house area.

c) Tank capacity 6m3 (each) in SG 6m3

area and 10m3 in
FO pressurizing
pump house area.

d) Design and IS:800 IS: 2825 Class-II

construction code or equivalent

e) Design temperature 1200C (minimum) 2150C (minimum)

f) Tank design pressure - As per applicable code

g) Type of Rectangular Vertical cylindrical

construction with dished ends

h) Material of As per IS:2062 As per IS:2825/

construction ASME Sec. VIII

i) Corrosion allowance 1.8 mm 1.8 mm

j) Insulation Required Required

k) Nominal - Vent pipe of 250 Nb

venting capacity (min.) and 3.5 m height

l) Heater tube 50 Nb tubes as -

material per IS1239
(heavy grade) or
ASTM 106 Gr. B

ii) The design, fabrication, erection, commissioning and testing of the tanks
shall be conform to IS:2825.

iii) Steam coil heaters shall be provided at the bottom of drain oil tanks to
maintain the oil temperature to facilitates its pumping. The heaters shall be
sized considering ambient air temperature of 100C. Total heating surface of
heaters shall not be less than 4 m2 per drain oil tank. Steam for the heaters
shall be drawn from the auxiliary steam supply system.

2.2.9.3 Fuel oil cooler

Oil cooler on the heavy fuel oil return line shall be sized for cooling the return oil
from each unit to the temperature of oil in the fuel oil storage tanks.

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