JSW Energy (Vijayanagar) LimitedTCE CONSULTING ENGINEERS LTD BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU, BELLARY DESIGN BASIS REPORT FOR BTG MECHANICAL PART DOCUMENT NO. 50-F271C-J01-01 REV.1 SHANGHAI ELECTRIC GROUP CORPORATION,LTD 3669 Jindu Road,Shanghai,China SOUTHWEST ELECTRIC POWER DESIGN INSTITUTE 18 Dongfeng Road,Chengdu,China . PDF created with pdfFactory Pro trial version www.pdffactory.com Design Basis Report for BTG Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU, BELLARY DOCUMENT CONTROL SHEET PROJECT: BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU, BELLARY CLIENT: JSW ENERGY (Vijayanagar) LIMITED /SHANGHAI ELECTRIC GROUP CORPORATION,LTD DOCUMENT TITLE: DESIGN BASIS REPORT FOR BTG MECHANICAL PART DOCUMENT NO.: 50-F271C-J01-01 REV. NO. : 1 ENDORSEMENTS 1 10.11. Revised as per 2006 MOM of second coordination meeting 刘翔 胡毅 杨强 吴东梅 张静 任家驰 1 08.200 6 刘翔 胡毅 杨强 吴东梅 张静 任家驰 REV. DATE DESCRIPTION PREP. BY NO. REVW. BY APPD BY SIGN.(INITIAL) SIGN.(INITIAL) SIGN.(INITIAL) SOUTHWEST ELECTRIC POWER DESIGN INSTITUTE 18dongfengRoad,chengdu,China DOCUMENT NO.: 50-F271S-J01-01 REV.1 Page 1 PDF created with pdfFactory Pro trial version www.pdffactory.com Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU, BELLARY CONTENTS 1 GENERAL 1.1 Major design principle 1.2 Boiler 1.2.1 Introduction 1.3.1 General 1.3.2 Turbine HBD 1.4 Generator 1.4.1 General 2 FUEL 2.1 Fuel characteristics 1 1 2 2 3 4 6 6 7 7 3 COMBUSTION SYSTEM AND SELECTION OF AUXILIARY EQUIPMENT 11 3.1 Boiler Fuel Consumption 3.2 Design principle of Flue gas and air system & pulverized coal 11 system 11 3.3 System Description 3.4 Calculation results 3.5 Major Auxiliary Equipments Selection 3.6 Pyrites handling system 11 16 18 23 4 THERMAL SYSTEM AND SELECTION OF AUXILIARY EQUIPMENT 25 4.1 Design principle of Thermal System 4.2 System Description 4.2.1 Main steam, reheat steam and bypass system 4.2.2 Feed-water system 4.2.3 Extraction steam system 4.2.4 Condensate water system 4.2.5 Heater drains and vents system DOCUMENT NO.: 50-F271C-J01-01 REV.1 Page 2 25 26 26 30 34 35 36 PDF created with pdfFactory Pro trial version www.pdffactory.com 2.2.8 Vacuum system 4.pdffactory.4 Vacuum pump 4.3.2.2.9 Condenser tube cleaning system 4.2.3 Major Auxiliary Equipment Selection 4.10 Boiler blowdown and drain system 4.5 Condenser 4.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.6 Auxiliary steam system 4.3.: 50-F271C-J01-01 REV.1 Page 3 PDF created with pdfFactory Pro trial version www.11 Steam turbine lube oil and Lube oil handling system 4.4 Table of economic index 5 INSULATING MATERIAL 37 39 39 39 40 41 41 45 45 51 64 66 67 72 73 DOCUMENT NO.3 Condensate extraction pump 4. BELLARY 4.2 Heaters 4.3.2.3.1 Feed-water pump 4.com .3.12 Lubrication Oil System 4.10 Closed cycle DM water system 4.2. 5) Code for design of thermal power plant steam/water piping. 2) ASME Test codes.) 1) American society of testing & materials. with nominal generator output capacity of 2X300MW.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. 6) Guaranteed availability of each unit is higher than 85%.1 Page 1 PDF created with pdfFactory Pro trial version www.: 50-F271C-J01-01 REV. Warm and Hot start respectively.<4 Hr.pdffactory. <1.5 Hr for Cold.5 Hr. 3) Technical code for designing fossil fuel power plant 4) Technical code for design of thermal power plant air & flue gas ducts/raw coal & pulverized coal piping. Main design basis codes and standards will be international codes & standards. DOCUMENT NO. IBR or equivalent standards subject to owner’s approval as below (refer to contract technical specification.com .1 Major design principle This project is designed to be the coal-fired power plant located in India. BELLARY 1 GENERAL 1. 7) Unit start-up time from ignition to full load <7. The light diesel oil will be designed for 10 % BMCR load and mechanical atomization. Also.pdffactory.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.5Hz. 1.1 Page 2 PDF created with pdfFactory Pro trial version www. for all equipments.5Hz to 51. The minimum load without oil support is 30 % BMCR with design coal and 40 % BMCR with worst coal with two adjacent mill in service. dry bottom type water-cooled. The steam generator shall be designed for firing heavy fuel oil up to 30 % BMCR load.2.1 Introduction The boiler is a natural circulation. The HFO will be steam atomization. BELLARY 8) Plant makeup water≤3%. balanced draft furnace and is designed with tangential firing arrangement of burners.com . Double pass) arrangement and full pendant steel structure. 1. There are six pulverizers with 24 coal nozzles in different elevations in the furnace zone of the boiler.2.2 Boiler capacity and main parameters Items Unit BMCR DOCUMENT NO. Light diesel oil will be used for start-up. It is semi outdoor arranged and has a single furnace of reverse u-form (∏-type. 9) The steam turbine. noise level measured at a distance of 1 m from the equipment will not exceed 85dBA except for places as mentioned below: TG unit in which case it will not exceed 88 dBA. turbine generator and all equipments and auxiliaries are suitable for continuous operation in the frequency range of 47.2 Boiler 1. subcritical pressure with single steam drum and single reheat.: 50-F271C-J01-01 REV. 622 323 541 279 88.77 % 1 1.3. and axial flow type with steam exhausting from one double flow low-pressure cylinder to condenser.7 3.(a) °C t/h Mpa(a) Mpa(a) ℃ ℃ ℃ 1015 17.57 541 840.com . The unit will be capable of producing rated output of 300mw when operating with rated steam conditions and design ambient conditions.1 General The steam turbine will be of a tandem compound. single reheat.1 Page 3 PDF created with pdfFactory Pro trial version www.3 Steam turbine 1.pdffactory.: 50-F271C-J01-01 REV.816 3. Continuous rating (BMCR) Superheater outlet steam pressure Superheater outlet steam temperature Reheat steam flow Reheater inlet steam pressure Reheater outlet steam pressure Reheater inlet steam temperature Reheater outlet steam temperature Economizer inlet feed water temperature Efficiency(Based on higher heating value of the design fuel) t/h MPa. Main specification DOCUMENT NO.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. BELLARY Items Unit BMCR Boiler Max. Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.a ℃ ℃ t/h t/h kPa(a) ℃ ℃ VWO 312.com .1 Page 4 PDF created with pdfFactory Pro trial version www.67 538 538 966. Two cylinder.8 33 1 DOCUMENT NO. BELLARY Type: Subcritical.2 Turbine HBD Type： N300－16.05 277. Tandem compound. Reheat.970 16.3.623 798.67/538/538 (K156) 1) VWO (valve wide open) condition 1 Items Maximum output Steam pressure at the inlet of MSV Steam temperature at the inlet of MSV Reheat steam temperature at combined valves Steam flow for main steam Steam flow for hot reheat steam Back pressure of condenser Final feed water temperature Circulate cooling water Unit MW MPa.pdffactory.881 10. Condensing Rated Power (TMCR Condition): 300MW Rated Speed: 3000r/min Direction of Rotation: Clockwise viewing from Governing End Steam Inlet Pressure: 16.67MPa(a) STEAM INLET TEMPERATURE 538℃ STEAM REHEAT TEMPERATURE538℃ 1.: 50-F271C-J01-01 REV. Double flow. 078 16.624 761.(a) ℃ 300. BELLARY 2) Heat Rate Guarantee Condition Items Unit Heat Rate Guarantee Rate output Steam pressure at the inlet of MSV Steam temperature at the inlet of MSV Reheat steam temperature at combined valves Steam flow for main steam Steam flow for hot reheat steam Back pressure of condenser Final feed water temperature Circulate cooling water guaranteed heat rate MW MPa.5 33 1909.6 1 3) All HP Heater out of service Condition All HP Heater out Items Unit of service Rate output Steam pressure at the inlet of MSV Steam temperature at the inlet of MSV MW MPa.115 16.67 538 DOCUMENT NO.pdffactory.1 Page 5 PDF created with pdfFactory Pro trial version www.67 538 ℃ 538 t/h t/h kPa(a) ℃ ℃ Kcal/Kwh 913.com .: 50-F271C-J01-01 REV.(a) ℃ 300.05 274.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.991 10. BELLARY All HP Heater out Items Unit of service Reheat steam temperature at combined valves Steam flow for main steam Steam flow for hot reheat steam Back pressure of condenser Final feed water temperature Circulate cooling water ℃ t/h t/h KPa(a) ℃ ℃ 538 796.6 33 1.1 General The generator is a two-pole.4. Generator type: Rated output Rated voltage Rated current Power factor Speed Frequency No.4 Generator 1.pdffactory. cylindrical rotor type synchronous machine.005 10.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.: 50-F271C-J01-01 REV. of phase Cooling method Stator winding Rotor winding Direct Water cooled Direct Hydrogen cooled QFSN-300-2 353MVA/300 MW 20 kV 10189 A 0.1 Page 6 PDF created with pdfFactory Pro trial version www. directly coupled with steam turbine.85 (Lagging) 3000 r/min 50 Hz 3 DOCUMENT NO.851 778.05 178.com . 1 Fuel characteristics The fuel and its characteristic data is listed below. BELLARY Exciter method Class of insulation Brushless excitation system Class F with temperature rise limited to class B ± 5% .pdffactory.5 m 1 Permissible variation in voltage Permissible variation in frequency Max cooling inlet H2 temperature Noise level 2 FUEL 2. 2.com .1 Coal Analysis DOCUMENT NO.0% to + 3.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.: 50-F271C-J01-01 REV.1 Page 7 PDF created with pdfFactory Pro trial version www.5.0% 48 deg C 88 dBA at 1.1. 01 23.82 23.No Proximate Analysis Design coal 1 2 3 4 5 Fixed Carbon % Volatile Matter % Moisture % Ash % High Heating Value Kcal/Kg 54.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.64 4.com .12 6300 5977(LHV) Worst Coal 41.30 2.40 15.09 15.94 11.12 53 49.02 11.59 20.: 50-F271C-J01-01 REV. BELLARY Sl.1 Page 8 PDF created with pdfFactory Pro trial version www.04 11.pdffactory.00 23. C 1180 10 11 12 13 Hemispherical TEMP.91 <1400 <1400 Ash charactorisics %/Wt DOCUMENT NO. C Crucibie swelling index (FSI) Bulk Density 1240 1290 >1 0.24 0.24 5. Fluid Deg.75 0.46 1.19 4.31 5000 4679(LHV) 1 2 3 4 5 6 7 8 Carbon % Hydrogen % Sulphur % Nitrogen % Oxygen % Moisture % Ash % Grindability index (HGI) 64.32 45 9 Initial Deformation TEMP.04 11.39 6. 0 45.27 0.1 Sieve analysis +60 Mesh +120 Mesh +200 Mesh -200 Mesh Un-burnt % 02-0.3 4.69 0.30 0.7 920 66 C DOCUMENT NO.0-18. 1995 Viscosity at 40o C Density at 15o C Flash point. BELLARY Design coal 1 2 3 4 5 6 7 8 9 Silico Alumina Ferric Oxide Calclum Oxide Magnesium Oxide Sodium Oxide Potassium Oxide Tilanium Oxide Phosphate pent Oxide 10 11 Sulphur Trioxide Undetemined 0.1 LIGHT DIESEL OIL ANALYSIS LIGHT DIESEL OIL (LDO) ANALYSIS AS PER IS 1460.7 1.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.40 1.com .: 50-F271C-J01-01 REV.2 0.29 1.3 35.5% 8-11% 80-90% 4.50 0.1.67 0.1.1 Page 9 PDF created with pdfFactory Pro trial version www.pdffactory.4% 2.40 53. Min Cst kg/m3 o 2.2.8 10.08 0.5-6.2 Fuel Oil 2.5 to 15.0 2.0 2.94 1.44 0.50 1.30 Worst coal 37. 8. 4. Deg. % max.2 40.. Pour point Ash content by weight Free Water content by volume Sediments by weight Total sulphur by weight Calcium Sodium Lead content Vanadium Carbon residence (Rams bottom) Approximate gross calorific value SP gravity at 150C Max. C min.02 9950Kcal/kg 2. Cst 0C % max.pdffactory. Water content.74 10.25 4. Particulars Unit Grade MV2 (IS : 1593) 1. 3. 5.2. Sediment. 9.2 HEAVY FUEL OIL ANALYSIS Furnace Oil Sl.0 30. Max. BELLARY Pour point.933 DOCUMENT NO.05 1. Gross calorific value 12o C 21 o C % vol. 11. 15 Flash point Viscosity @ 150C Maxi. % max.50 7. 14. 6.5 10 0. Max. 10.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. % wt % wt % wt (Approximate) for Winter for summer 0. 12.1 Page 10 PDF created with pdfFactory Pro trial version www.No. 7. PPM PPM PPM PPM % wt Kcal/kg 66 180 21 01 1. Sulphur. Ash content.com . Max.25 0.1. Max. 2.: 50-F271C-J01-01 REV. Max.000 0.8 0.0 0. % max. 2 Design principle of Flue gas and air system & pulverized coal system Considering the high volatile matter and easy burning character of the raw coal. pulverized coal system with MSM will be adopted in this project.8t/h (worst coal) per unit at boiler maximum operation condition (BMCR).Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.6t/h (design coal) and 146.3. There are four (4) pulverized coal pipes on each separator connected to four corners of boiler burners in the same layer. and has suitable margin.1 Pulverized Coal System Direct firing.9t/h for worst coal per unit.3 t/h for design coal and 131. electric gravimetric coal feeders (EGCF) and raw coal bunkers will be matched with each boiler. At TMCR condition it is 103.1 Page 11 PDF created with pdfFactory Pro trial version www. Six (6) sets of MSMs correspond to six (6) layer burners of each DOCUMENT NO. 3. pressurized cold primary air.: 50-F271C-J01-01 REV.com . Six (6) sets of HP863 (not finalized) type MSMs.1 Boiler Fuel Consumption The fuel consumption is about 112. Raw coal from raw coal bunker via EGCF will be pulverized and dried in the MSM.pdffactory. and has suitable margin.3 System Description 3. 3. BELLARY 3 COMBUSTION SYSTEM AND SELECTION OF AUXILIARY EQUIPMENT 3. medium speed mill (MSM) (positive pressure)& direct-firing pulverizing system with cold primary air fan will be adopted based on heat calculation of coal pulverizing system. The output of four (4) MSMs will meet the requirement of boiler capacity at BMCR with design coal. the output of five MSMs will meet the requirement of boiler capacity at BMCR with worst coal. then be separated in the MSM separator. and each boiler will be equipped with two (2) axial flow forced draft fans (FDF) with adjustable moving-blade. coal flow monitor etc. direct pulverized coal tangential fired.1 Page 12 PDF created with pdfFactory Pro trial version www.2 Flue Gas and Air System Direct firing. During operation. The EGCFs have alarms of coal flow break and block. At the outlet of the bunker there is a motor operated rack & pinion gate. BELLARY boiler.pdffactory. Each MSM will be equipped with one EGCF.: 50-F271C-J01-01 REV. System design scope will include raw coal pipe and pulverized coal pipe. Inlet and outlet motor operated coal gates with good seal of the feeder can endure the exploding pressure of 0.35MPa. The boiler manufactured by Shanghai Boiler Works Co. Six (6) bunkers will be set for each boiler. single reheat. two (2) centrifugal primary air fans (PAF) and two (2) sealing air fans. balance draft.3. Diameter adjustable device will be placed at pulverized coal pipes. so that operator can handle emergency and ensures safe operation. The coal bunkers are designed and supplied by JSW. two (2) centrifugal induced draft fans (IDF) with hydraulic coupling. dry bottom. Flue gas from the furnace shall be induced to atmosphere. DOCUMENT NO. 3. so that the resistance of each pipe is the same.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. water tube. and have the function of self-clean. double pass. and the bunker emptying chute will be equipped between the two gates. pressurized cold primary air system with MSM shall be adopted in the project. drum type. Ltd (SBWL) in China shall be of natural circulation. The capacity of series of bunkers per each unit will be normal sufficient to provided 16 hours requirement at boiler maximum continuous rate with worst coal firing.com . pressurized air shall be forced into furnace. 1 Primary air system Main function of the system is to feed pulverized coal and primary hot air heated by air preheater to MSMs. and be sent to MSMs via common manifold. motorized damper on the cold duct will be also closed immediately. 3.3. When one MSM failure happens and shuts down. Pressurized cold air from PAFs will be regarded as regulating temperature for MSMs. To avoid primary hot air enter into the duct of primary cold air. and cold primary air to MSMs (boosted by sealing air fan) and EGCFs will be acted as seal medium.1 Page 13 PDF created with pdfFactory Pro trial version www. the corresponding pneumatic damper on primary hot air duct shall be closed immediately. When air preheater failure happen.pdffactory. Mixed air flow measurer will be installed on the mixed duct. the damper will be closed. The pressurized cold air will be mixed with hot primary air. BELLARY Online vibration monitoring system and bearing metal temperature measurement system shall be provided for all fans and their drive motors . DOCUMENT NO.com .2. The air velocity in air ducts will be 10-12m/s for cold air and 15-25m/s for hot air.: 50-F271C-J01-01 REV. Primary air will be heated in air preheater. The inlet vanes of centrifugal primary air fan can adjust air flow and pressure automatically.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. Mixed air can meet the temperature requirement of coal dried in the MSM and pulverized coal at the MSM outlet. Primary air damper will be placed at air preheater inlet and outlet. Primary hot air will be acted as dry medium. Cold air from FDFs shall be forced into trisector regenerative air preheater. hot air flow to the boiler four corners will be almost equal. Damper and air flow measurer shall be placed at hot air duct of air preheater outlet. and hot air shall be sent into secondary air box and be distributed to furnace for combusting. filters. the damper shall be closed automatically.3.1 Page 14 PDF created with pdfFactory Pro trial version www. DOCUMENT NO. Two (2) FDFs will be equipped for each boiler. so that stable combusting and reasonable temperature field in the furnace can be ensured. when one FDF out of operation. and will reduce temperature deviation at two sides of boiler. which connect two ducts between FDFs downstream. when air preheater is out of operation. water washing system and fire protection system and soot blowing system will be equipped for GAH. and associated piping/ accessories) is provided for air preheater. The hot air liaison duct arranged at air preheater outlet. Two trisector regenerative air preheater will be equipped which primary and secondary air will be heated in it.pdffactory.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. The air velocity in air ducts will be 10-12m/s for cold air and 15-25 m/s for hot air.2. Forced lubrication oil system (with 2x100% capacity pumps.: 50-F271C-J01-01 REV.com . BELLARY 3. Cold air liaison duct.2 Secondary air system The system shall provide air for furnace combusting. Also. Secondary hot air box is special design. one in operation and another standby. BELLARY 3. six electric-fileds. Two (2) ID fans are in operating.2.1 Page 1 15 PDF created with pdfFactory Pro trial version www. Each boiler will be equipped with two ESPs. the filter will clean itself via pressure difference. When emergency happens to one air preheater. When IDF failure happens.com . IDF & chimney will be vented into atmosphere. the damper will be opened or closed.2.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.4 Flue gas system The system consists of two ESPs and two centrifugal induced draft fans (IDF) with hydraulic coupling. another’s inlet damper is closed.3. 3.3 Sealing air system 2x100% centrifugal sealing air fans will be equipped in the system. the respective damper will be closed. Sealing air from cold primary air manifold will be sent into MSMs via seal fan boost. Flue gas from economizer will enter into two (2) air preheaters. During air preheater start up or shut down. Fluel gas via ESP. each one isolating damper will set at the inlet and outlet of each air preheater. At sealing air fans inlet. it will be overhauled after the dampers closed. when one fan is in operation.: 50-F271C-J01-01 REV. air filters and motorized control dampers will be arranged. Flue gas from air preheater enters into ESP with double path. If pressure difference of the filter inlet & outlet reaches to setting value.pdffactory. the damper will be opened or closed. 1 Isolating dampers will be placed at IDF inlet & outlet.3. During IDFs starting up or shutting down. Isolating Guillotine type gates will be placed at ESP inlet & outlet. DOCUMENT NO. 79(design coal) DOCUMENT NO.1 Pulverized coal system 1 Value NO.4.: 50-F271C-J01-01 REV.6 53 <32 4 Fineness of coal powder % 70 Medium 5 Medium speed 4/6(design coal) （operate/install） speed mill quantity （operate/install） / set 5/6(worst coal) 6 Medium speed mill operating output BF1 t/h 38. 3.1 Page 16 PDF created with pdfFactory Pro trial version www.pdffactory. 3.4 Calculation results The results are based on design coal for one boiler at MCR and it can adapt the characteristic data range of the coal. BELLARY The GAH outlet flue gas velocity in gas ducts will be 10-20m/s. Item Symbol Unit (For one unit) 1 2 3 Boiler coal consumption (BMCR) Hard grove grindability index Maximum Size of raw coal at inlet of mill Bg HGI dmax mesh 200 mill quantity / set t/h / mm 112.com .Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. Item Symbol Unit (For one unit) 36. Item (one unit) Symbol Unit Value DOCUMENT NO.pdffactory.4.1 Page 17 PDF created with pdfFactory Pro trial version www.05 14 Effective volume of each raw coal bunker Duration for boiler burning at BMCR condition with worst coal– bunker storage Refer to TCE related 15 h documents 3. BELLARY Value NO.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.2 Flue gas and air system (BMCRl) 1 NO.28(design coal) 2.: 50-F271C-J01-01 REV.com .12 306 214(design coal) 239(worst coal) 10 Air temperature at inlet of medium speed mill t1 1 11 Ratio of air and coal mass at inlet of medium speed mill / kg/kg 2.72(worst coal) 7 8 9 Medium speed mill max output Medium speed mill rated inlet air flow Primary air temperature at outlet of GAH BSJ Qv tkr t/h t/h °C °C 43.31(worst coal) Temperature at outlet of medium speed 12 mill Mill reject rate tm °C % m3 80 13 <0.1 72. 2988 Nm3/kg 6.5.92 466.5 Major Auxiliary Equipments Selection 3. DOCUMENT NO.com .18 7 Apy / 1.1 Pulverized coal system Six (6) medium speed mills and six (6) coal feeders will be furnished for each boiler. five (5) mills will be in operation and one (1) will be standby.: 50-F271C-J01-01 REV. and when firing the worst coal.8174 Vy t 'kg tⅠky Nm3/kg 8.283 1. together with its associated feeders. four (4) mills will be in operation and two (2) will be standby. two (2) sealing air fan are furnished to supply the sealing air to avoid the powder leaking.7713 6.2 6 Vy m3/s 455.3 137. Because of the positive pressure in the mill and coal feeder. In other words.283 3.pdffactory. BELLARY Design coal 1 2 Theoretical air volume for combustion (per kg coal) Volume of combustion result at the outlet of furnace 3 Air temperature at inlet of GAH V° ° Worst coal 5.9371 °C 35 35 4 Air temperature at outlet of GAH Flue gas temperature at outlet of GAH ( corrected) Flue gas volume at outlet of GAH Flue gas excess air coefficient at outlet of GAH °C 304 302 5 tpy °C 138. when firing the performance coal.1 Page 18 PDF created with pdfFactory Pro trial version www. These will be of sufficient capacity to attain the MCR of the steam generator when boiler firing any specified coal with any one mill out of service.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. 04% 70% 43.1 TPH corresponding to 53 HGI.04 %.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.6 9 10 11 12 13 14 kPa ℃ ℃ Kg/Kg r/min KW 250 4.8 11.12 10. BELLARY The maximum capacity of mill shall be 43.com .31 DOCUMENT NO. 70% through 200 mesh) mesh 200 t/h HGI 53 HP863 45 15 70% 40. 70% through 200 mesh and moisture content 11.78 65.2 71.28 38.5 72.: 50-F271C-J01-01 REV.pdffactory. resistance Inlet temperature of mill Outlet temperature of mill Inlet air/ inlet coal Rotary speed Shaft power of mill (BMCR) t/h % t/h 10. air flow rate Max. Value NO.7 274 239 80 2. Item Unit Design coal 1 2 3 4 5 Worst coal Type of MSM Grindability Index Moisture(AR) Powder fineness Maximum capacity of mill(HGI=53.1 1 6 7 8 Minimum capacity of mill Mill loading Max.1 Page 19 PDF created with pdfFactory Pro trial version www.5 214 80 2. Item Unit Design coal Worst coal 1 Primary air fan (2x60%BMCR) Double suction centrifugal A Type DOCUMENT NO. Under normal operation.5. The fans sizing are based on the flow and total pressure at BMCR conditions with a specific margin as below: Value NO.FDF and IDFwill be in operation.6 40 2200 3. all of PAF.2 Flue gas and air system Each boiler will be furnished with two (2) sets of primary air fan，two (2) sets of forced draft fan and two (2) sets of induced draft fan.1 Page 20 PDF created with pdfFactory Pro trial version www.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.: 50-F271C-J01-01 REV. BELLARY Value NO. Item Unit Design coal 15 16 17 18 Worst coal Rated power of motor Voltage Gravimetric coal feeder Coal feed distance (from feeder inlet to feeder outlet) KW KV t/h mm 400 6.pdffactory. These fans will be designed for outdoor installation.com . Item Unit Design coal Worst coal QBMCR（100％BMCR with 35 degree B ambient temperaturel） PBMCR QTB (test block.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.: 50-F271C-J01-01 REV.1 Page 21 PDF created with pdfFactory Pro trial version www. 60％BMCR with 5 m3/s 46.6 E margin，design coal) Speed rpm kW kV F G Motor ( with 15 % margin) Voltage Primary air fan (2x60%BMCR) 2 Adjustable movingA Type blade axial flow QBMCR（100％BMCR with 35 degree B ambient temperaturel） PBMCR m3/s 109.8 C Pa 3179 3043 DOCUMENT NO.7 57.9 99.pdffactory.3 C Pa 10907 11913 73. considering 30% m3/s / 1 Pa / 15934 ≤1500 later 6.5 D degree above maximum ambient temperature） PTB(test block.com . BELLARY Value NO. Item Unit Design coal Worst coal QTB (test block.: 50-F271C-J01-01 REV. considering 30% 148 1 Pa 4133 / E margin.design coal) Speed Motor ( with 15 % margin) Voltage Sealing air fan (2x100%BMCR) F G H rpm kW kV Later later 6.pdffactory. 60％BMCR with 5 D / m /s 3 degree above maximum ambient temperature） PTB(test block.415 B C D E Rated flow Rated head Motor Voltage Induced draft fan (2x60%BMCR) 4 A Type Double suction centrifugal type DOCUMENT NO. BELLARY Value NO.6 3 A Type m3/h Pa kW kV Double suction centrifugal 42221 6382 132 0.com .1 Page 22 PDF created with pdfFactory Pro trial version www.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. 60％BMCR with 15 m3/s 239 244 C Pa 3738 3775 1 D degree above flue gas temperature margin) m3/s / 329 E PTB(test block. considering 30% margin) Motor (The motor rating shall be arrived at considering 15% margin over the duty point input or 10% over Pa / 4908 G the maximum demand of the driven equipment.6 Two (2) electrostatic precipitators (double-pass.pdffactory.com . six electric field) are equipped for each boiler. considering frequency) whichever highest is higher. system later H I J Speed Motor Voltage rpm kW kV later 2240 6.: 50-F271C-J01-01 REV.1 Page 23 PDF created with pdfFactory Pro trial version www.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. Item Unit Design coal Worst coal QBMCR（100％BMCR with 35 degree B ambient temperature） PBMCR QTB (test block. BELLARY Value NO. The ESP remove particulate from the boiler flue gas to achieve a guaranteed outlet emission of less than 75 mg/Nm3 with all fields in service.and 100 mg/Nm3 with one field out of service when fired with specified coal range. DOCUMENT NO. design ) flue gas temperature(including 10℃ 3 145.3 Boiler Igniting and Fire Stabilizing Oil System The oil of the boiler igniting is diesel oil and fire stabilizing is HFO.design coal) 4 5 6 A B Inlet dust concentration Outlet dust concentration Efficiency of ESP With (n-1) field in service With n field in service 10. Value No Value Electrostatic precipitator Unit (design coal) (worst coal) 1 Double-pass. The system will be furnished with two 200m3 HFO daily oil tank. the capacity and quantity of tanks will be finalized by JSW/TCE ).2 75 % % / / / / 3.: 50-F271C-J01-01 REV.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. 1 Page 24 DOCUMENT NO.9 145.5 75 / 29. one 50m3 LDO daily tank for both units. and the boiler ignition mode is high-energy ignition. electric fields Flue gas flow (including 10% m3/s 522 per unit ℃ g/Nm3 mg/Nm3 534 2 margin and 10℃ margin.com .4 margin. BELLARY Air in leakage through ESP of the total gas flow is less than 3 %.pdffactory.1 PDF created with pdfFactory Pro trial version www.5. (These oil tanks are in the scope of JSW. pyrites discharged from each mill will be hold in pyrites hopper for unloading to chain conveyor by screw conveyor.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. 1 4 THERMAL SYSTEM AND SELECTION OF AUXILIARY EQUIPMENT 4.com . volume of each bunker is about 20m3. Three motor-driven LDO oil transfer pumps and other associated equipments are common for two boilers.pdffactory.1 Design principle of Thermal System DOCUMENT NO.4 t/h H≈290m (Total 4 sets for two units) 3.: 50-F271C-J01-01 REV.6 Pyrites handling system Pyrites quantity(not finalized): Quantity(t/h) 1X300MW 2X300MW 0.22 Mechanical system will be used for pyrites handling. For details please see drawing 50-F127C1-J01-36 “ Pyrites Handling System Diagram”.1 Page 25 PDF created with pdfFactory Pro trial version www. All these equipments are arranged centralized and located nearly the oil tank area. Mechanical system will operate about one(1) hour each eight(8) hours. BELLARY Two motor-driven HFO oil transfer pumps per unit (one operation and another standby).11 0. Chain conveyor is located below ground. In each shift. Light diesel oil pump capacity: Q≈8 t/h H≈450m (Total 3 sets for two units) Heavy fuel oil pump capacity: Q≈25. each chain conveyor’s capacity is 10-15t/h. Pyrites will be conveyed out of the boiler by chain conveyor then to be lifted to pyrites bunker by bucket elevator to make pyrites discharge into a truck for further transportation to ash yard. pdffactory. DOCUMENT NO. 1) A Motor operated Main steam isolation valve with motor operated integral bypass valve is set on main steam pipe near boiler outlet for boiler hydraulic test as well as for normal operation.com .2. when steam turbine at 100% TGMCR guarantee point : pressure drop in main steam line from superheater outlet to steam turbine stop valve is about 5.1 Main steam system Main steam system will convey superheated steam from the superheater outlet to the HP main steam stop valve.1 Page 26 PDF created with pdfFactory Pro trial version www.1.2.5 bar. Main steam flow through single pipe from outlet of boiler superheater header. Main steam is unit system. reheat steam and bypass system The pipe sizing shall be as per ASME B31.: 50-F271C-J01-01 REV. In addition to above.1 Main steam. and then divided into two branches and connects to left and right main HP steam stop valve separately.1 and velocities shall be limited to the values mentioned in specification. BELLARY The thermal system will ensure the security. overall pressure drop between HP turbine exhaust and IP turbine interceptor valves for reheater circuit shall be less than 10% of HP turbine exhaust pressure 4. economy and flexibility of the unit.2 System Description 4. All of the systems are unit system except auxiliary steam system.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. 4. pdffactory. then connect to two inlets of boiler reheater header separately. and divided into two pipes again in front of turbine.com . All drains including drain pot shall be checked with respect to ASME TDP guideline for turbine water damage protection. 3) To prevent water from entering turbine. A pneumatic drain valve and a hand-operated valve are set on drain pipe of each drain point. Two hot reheat steam pipes are connected at two end of outlet header of boiler reheater and join one pipe at front of boiler. drain system is set to discharge condensate water of main steam pipe during warm-up and shut-down. Drain water is led to drain flash tank.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.2 Reheat steam system Reheat steam system will convey cold-reheat steam from HP casing exhaust spout to inlet of boiler reheater and convey hot-reheat steam from outlet of reheater to IP main steam stop valve.2. Drain points are set at the lowest points on main steam pipe. another branch leads to auxiliary steam header when the cold reheat pipe pressure is inadequate or not available. then connect with left and right IP steam stop valve.: 50-F271C-J01-01 REV. Two solenoid PCVs and two motorized venting valves are set on main steam pipe near superheater outlet. Reheat steam is unit system. 4) Two spring safety valves. DOCUMENT NO. 4.1 Page 27 PDF created with pdfFactory Pro trial version www. One cold reheat steam pipe is connected from turbine HP casing exhaust pipe and divided into two pipes in front of boiler. BELLARY 2) One branch leads to gland steam system as HP steam source when normal gland steam pressure is too low and one branch leads to turbine casing steam heating header as heating steam source before turbine startup.1. to adjust steam temperature of reheater outlet under emergency condition. 2) Desuperheaters are set on the pipe of reheater inlet. A pneumatic valve is set on drain pipe to automatically control drain water into condenser in time. 6) A hydraulic test valve is set on hot-reheat main pipe to make sure that the pressurized water is stopped during boiler reheater hydraulic test and can’t enter into the hot reheat pipes. 3) Hydraulic test valve is set on each cold-reheat steam pipe near reheater inlet to prevent pressurized water entering cold-reheat pipe during hydraulic test of boiler.1 Page 28 PDF created with pdfFactory Pro trial version www. BELLARY 1) To prevent steam from flowing back into turbine. Desuperheating water come from intermediate stage extraction of BFP. 7) One pipe connecting the outlet of HP bypass valve and the inlet of LP bypass valve is set to form the heat circuit by pressure difference which is able to warm the outlet of HP bypass valve and pipe. one pneumatic check valves is provided on cold-reheat pipes. the inlet of LP bypass valve and pipe. one drain pot is set on the pipe near HP casing exhaust spout. 5) One spring safety valve are set on each cold-reheat pipe near reheater inlet separately. 8) Three spring safety valves are set on hot-reheat pipe near reheater outlet.pdffactory.com .: 50-F271C-J01-01 REV.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. 4) To prevent water entering turbine. its DOCUMENT NO. 2) LP-bypass system is connected with HP-bypass system in series to achieve the function of whole bypass system.pdffactory. HP-LP bypass system will open automatically. 4. one control valve and one isolation valve are set on desuperheating water pipe. One upstream and one downstream DOCUMENT NO.com . 9) Drain points are set on hot-reheat steam pipe branches after tee to remove condensate water during startup and shut-down. TG set is capable of operating on house load during sudden total export load throw-off and in the event of turbine trip and generator breaker open. This system can convey main steam bypass HP-casing to cold-reheat piping and convey hot-reheat steam bypass IP&LP-casing to condenser when unit startup.1.3 Bypass steam system The capacity of bypass system is 60% BMCR.1 Page 29 PDF created with pdfFactory Pro trial version www. Drain water enters into condenser. so the former will open before the later when over pressure happens to ensure enough steam through reheater and avoid over heating of reheater. The leakage class of valves shall be minimum class V. BELLARY set pressure is lower than the spring safety valve on cold-reheat steam pipe near reheater inlet. HP & LP bypass valves shall be of angle type and combined throttle cum spray valve. bypass valves and spray control valves are hydraulic operated valves.: 50-F271C-J01-01 REV.2. A pneumatic valve and a hand-operated valve are set on each drain pipe. shutdown and other various operating modes.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. 1) Desuperheating water of HP bypass is from feed water system. For Spray valve Trim exit velocity of liquid shall not exceed 30m/s. There are three 50% capability motorized variable speed feedwater pump in this system.225 A672B70CL32 φ558.2.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.pdffactory. A pneumatic valve is set on each drain pipe.8 3 Cold reheated steam pipe φ812.3×41.275 ID273. Feed water is heated to the given temperature in HP-heaters by turbine extraction steam to improve heat efficiency of the units. during DOCUMENT NO.8×22. Table 4. 4) Desuperheating water of LP-bypass is from condensate water system.2. 3) One drain pot is set at the lowest point downstream of LP-bypass valve.1 Item 1 Name Main steam pipe Diameter ID368.2 Feed-water system HP feedwater system is unit system. BELLARY isolation valves are provided for LP bypass spray control valve.com .5X32 ID508×24.1 Page 30 PDF created with pdfFactory Pro trial version www.: 50-F271C-J01-01 REV. The function of this system is to pump deaerated feed-water from deaerator water tank to inlet header of boiler economizer.8×16 A672B70CL32 4.05x30 Material A335P91 A335P91 A335P22 A335P22 Velocity (m/second) 50 45 67 60 33 35 2 Hot reheated steam pipe ID679. Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. the orifice valve can be reduce openning by manual remotely in control room when boiler load is <60%MCR. 30% BMCR bypass control valve is provided for low load operation and startup.pdffactory. BELLARY normal operation. DOCUMENT NO. two pumps work and one pump is standby.17% Chrome steel (Material shall be non-galling type with differential hardness not less than 100 BHN) e) Stuffing box bushing & Stuffing box f) Pump shaft g) Shaft sleeves h) Base plate i) Diffuser / Volute j) Strainer k) Hydraulic Coupling 1) Make 2) Coupling wheels & casing 3) Scoop tube l) Balancing drum 13% chrome steel 13% Forged chrome steel Stellite on 13% chrome steel Structural steel 13% chrome steel Stainless steel mesh Voith Alloy steel Stainless steel ASTM A 182 Grade F6 a One full flow motorized orifice valve and one full flow motorized gate valve is located in major feedwater pipe. Two motorized isolating valve are located in boiler filling bypass pipe.com . When the orifice valve in operation. The main boiler feed pump and booster boiler feed pump shall be manufactured of following or superior materials a) Outer casing b) Inner casing c) Impellers d) Wearing rings Forged Carbon steel ASTM A743 CA 6 NM ASTM A743 CA 6 NM 13 .1 Page 31 PDF created with pdfFactory Pro trial version www.: 50-F271C-J01-01 REV. Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. DOCUMENT NO. All bypass and isolation valves will be motor operated. There are motorized valve and strainer on each pipe.: 50-F271C-J01-01 REV. When startup. impurities etc. which were accumulated in feedwater tank. Bypass piping will be provided to divert feedwater flow around any of the high-pressure heater for heater isolation of the respective each unit.1 Page 32 PDF created with pdfFactory Pro trial version www. and LP feedwater pipes during erection and maintenance to protect feedwater booster pumps. Feedwater system can be divided into three parts: LP feedwater.pdffactory. Each pipe has a flow metering nozzle to measure the feedwater flow at the inlet of feedwater pump in order to control opening and closing of minimum flow unit at the outlet of feedwater pump.. 3) HP feedwater pipes Pipes between the outlets of feedwater pumps and inlet header of boiler economizer are called “HP feedwater pipes”. the strainer can separate the welding slag. IP feedwater. which pass through HP heaters. BELLARY There are three HP heaters. HP heaters are horizontal type. 2) IP feedwater pipes Pipes between the outlets of booster pumps and the inlets of feedwater pumps are called “IP feedwater pipes”. 1) LP feedwater pipes Pipes between the outlets of feedwater tank and the inlets of booster pumps are called “LP feedwater pipes”. and HP feedwater pipes. There are also filters in these pipes in order to protect feedwater pumps.com . 1 Page 33 PDF created with pdfFactory Pro trial version www. DOCUMENT NO.: 50-F271C-J01-01 REV.pdffactory. One check valve is located at inlet pipe of economizer. two manual valves and one check valve. In order to prevent cavitation of booster pump. The former adjust superheating steam temperature and the latter adjust main steam temperature to cold reheat steam system. Another pipe is branched for HP bypass control valve.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. one recirculation pipe is extracted from the feedwater pipe and connected to the deaerator which has one minimum flow unit including a pneumatic control valve. Signal of the minimum flow unit comes from the flow metering nozzle at the outlet of booster pipe. One pipe is branched from outlet manifold of feedwater pumps and connected to boiler superheater primary and secondary spray attemperator.com . The capacity of bypass is 30% rated feedwater flow which adjusts feedwater flow when unit startup and low load operation. The interstage extractions from each feedwater pump are collected together and flow to the reheater attemperator as emergency desuperheating water to adjust steam temperature of reheater. Each feedwater pump has a recirculation pipe which is connected to deaerator. One full flow motorized orifice valve and one full flow motorized gate valve is located in major feedwater pipe. The feedwater control station is located between outlet of HP heaters and inlet header of boiler economizer. BELLARY There are one check valve and one motorized gate valve at the outlet of each feedwater pump. extraction No.: 50-F271C-J01-01 REV. Extraction No. Extraction No.4&3&2&1 supply steam to four (4) LP heaters. Pneumatic-driven check valve and motor-driven isolation valve are set in each DOCUMENT NO.pdffactory. BELLARY Two motorized isolating valve are located in boiler filling bypass pipe. LP heaters No.3 1 4.3 Extraction steam system The system extracts steam from steam turbine to specified heating device and increases the temperature of condensate water and feed-water so as to raise thermal efficiency of the power plant.2 Item 1 Name HP feed water common pipe Diameter φ355.6×30 Material 15NiCuMoNb5-6-4 (EN10216-2) (DIN17175-79) 2 HP feed water branch pipe φ244.2.5 supplies steam to deaerator.8&7&6 supply steam to three (3) HP heaters.1 are combined heaters which are located at neck of condenser.5x20 15NiCuMoNb5-6-4 (EN10216-2) (DIN17175-79) 4.1 Page 34 PDF created with pdfFactory Pro trial version www. There are 8 stages non-adjustable extraction of the steam turbine.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. Table 4.2 and No.8 velocity(m/s) 5. One pipe is branched from the economizer inlet heater to drum as the economizer recirculating water pipe.2.com . the system also provides desuperheating water.pdffactory. make-up cooling water and other miscellaneous water requirements. Beside these. To prevent condensate water entering into steam turbine to harm it during startup.1 LP heater to ensure water level control of DOCUMENT NO. 7 extraction pipe No. Item 1 2 3 4 5 6 Name No.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. 3 extraction pipe Diameter φ194×10 φ219×7 φ273×9 φ377×10 φ426×9 φ530×9 Material 12Cr1MoV 20 12Cr1MoV 20 20 20 Velocity (m/second) 41 39 36 36 51 45 4. drain water pipe is set at the low point of each extraction pipe.com . 4 extraction pipe No.2.: 50-F271C-J01-01 REV. 6 extraction pipe No. auxiliary control valve and their bypass valve are set on condensate water pipe before No. 5 extraction pipe No.1 Page 35 PDF created with pdfFactory Pro trial version www. The system is unit system. There are two (2) 100% capability vertical Condensate extraction pumps in the system. 8 extraction pipe No. shutdown & low load. near the valves. BELLARY extraction pipe except No2&1 extraction pipes. Main control valve.4 Condensate water system The system conveys condensate water from hot well of condenser to deaerator through gland steam condenser and four LP heaters to ensure safe operation and improve circulation heat efficiency. The normal cascade HP heater drain pipes from No.No.1 Page 36 PDF created with pdfFactory Pro trial version www. 4.: 50-F271C-J01-01 REV. LP heater drain pipes from No. No.4.No. Emergency drain pipe from each HP heater to emergency drain flash tank which DOCUMENT NO. recovering condensed water of LP heater and gland steam condenser. Pipe is set to generator stator cooling water tank and vacuum pump startup make-up water from condensate water. LP heaters and deaerator.pdffactory. BELLARY deaerator under all kinds of condition. Return water pipe to condenser make-up water tank (surge tank) from the outlet of condensate extraction pump is set for collecting water when the condenser hot well water level is high.3. LP-bypass desuperheater.2.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. HP emergency drain flash tank. third-stage pressure and temperature reducer.4 LP header outlet pipe is set to discharge unqualified water during startup.2 and No. and also the make-up water pipe of closed circuit cooling water expansion tank. removing noncondensable gas in HP heaters.7 and No.1 LP heater to condenser.5 Heater drains and vents system The functions of the system is recovering condensed water from heating steam of each HP heater and overflow & drain water of the deaerator.6 HP heater to deaerator. One water discharge pipe branches from No. There are branches at the low pressure desuperheating water pipe such as desuperheating water pipe to fuel oil sweeping steam desuperheater turbine gland steam desuperheater.com .8. Recirculation pipe at the gland steam condenser outlet pipe is set for the minimum flow when Condensate extraction pump is startup or the unit runs at the low load. LP casing spray. DOCUMENT NO. Normal drain water from LP heaters cascade to condenser. Non-condensable gas pipes from each HP heaters to deaerator and from each LP heaters to condenser and from deaerator vent to atmosphere. and LP heaters to condenser. low-load and trip. Control valve is designed in each drain pipe to control water level. 4. provide steam to turbine gland steam system when start-up and standby.pdffactory. Emergency drain pipes are set for each heater and respectively led to emergency drain flash tank or deaerator in order to ensure smooth drain and keep normal level in case that high water level in HP heaters appears or HP heater is out of service. Multi-stage water sealing device is set in the drain piping of gland steam condenser to ensure smooth drain to main condenser in all operating conditions. provide steam to soot-blower when air preheater start-up.2. Over flow pipe will maintain normal water level of feed-water tank and discharge pipe can empty water in case of maintenance.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. BELLARY attach to condenser.6 Auxiliary steam system Auxiliary steam system provide steam to deaerator when start-up.com .: 50-F271C-J01-01 REV. and provide steam to mill inerting steam and fuel oil system.1 Page 37 PDF created with pdfFactory Pro trial version www. provide steam to boiler bottom heating. Normal drain water from HP heaters cascade to deaerator. Control valve is designed in each drain pipe of HP&LP heaters to control water level. Pipes for emergency drain water of each LP heater can ensure smooth drain to condenser when water level in LP heater is high or at low load or its downstream LP heater(s) is (are) out of service. The terminal point location shall be 1m from the turbine building Column -1 between B-C row. The source of auxiliary steam come from cold reheat steam pipe at normal condition and main steam pipe when unit startup.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. make-up water for vacuum pump and etc. During unit startup. and complement water to hot well when operating. Beside these. 4. DOCUMENT NO. shutdown and when cold reheat pipe pressure is inadequate. 1 One auxiliary steam header is provided for each unit. it can drain condensed water of header to condenser.: 50-F271C-J01-01 REV.2. JSW/TCE indicated that the parameters of the steam from the existing unit will be about 9.20MPa and temperature is about 320 0C in normal operation. make-up water for HVAC system. Two safety valves are set on the header with different pressure setting. The pressure of auxiliary steam header is about 1. so the auxiliary steam can be provided when one unit is startup and another is in service. BELLARY Auxiliary steam is taken from cold reheat pipe at normal operation. shutdown or cold reheat pipe pressure is inadequate.7 Condensate make-up water system Condensate make-up water system will fill condenser and boiler and deaerator with water before the starting of unit. start-up steam will be provided from the existing 2*130MW thermal power plant.1 Page 38 PDF created with pdfFactory Pro trial version www. auxiliary steam source shall be arranged by JSW.com . When the unit start up. There is a interconnection of auxiliary steam headers between the two units. Steam header has continuous drain pipes. the steam is taken from main steam pipe.pdffactory.0 bar (g) and 280 Deg C at the terminal point. However if steam is required for pre commissioning/ commissioning of first unit. the system will supply sealing water for condensed pump. Before unit startup. turbine lube oil cooler. generator stator water cooler. two pumps will operate in parallel to establish vacuum as fast as possible (17 minutes reach to 35KPa). Uncondensed gas There is one vacuum breaker pipe at neck of condenser. During the unit load rejection.10 Closed cycle DM water system Closed cooling water shall be used to turbine auxiliary equipments and boiler auxiliary equipments such as generator hydrogen cooler.2.2. 4. The vacuum will be break to protect turbine during emergency. one pump is in operation and another is standby.9 Condenser tube cleaning system JSW not adopt. Two vacuum pumps are set in this system.com .2.8 Vacuum system The function of this system is extracting the non-condensable gas from condenser and maintain rated vacuum in condenser during normal operating condition.pdffactory. 4.1 Page 39 1 PDF created with pdfFactory Pro trial version www. air admission valve will be opening to break vacuum in condenser and decrease rotating speed of turbine.: 50-F271C-J01-01 REV. then shorten time of turning by inertia to protect turbine. Under normal operation.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. BELLARY 4. etc The closed cooling water for auxiliary equipments is demineralized water. This will be used only in emergency case. 1 Mixture of steam and air is extracted from exhaust to atmosphere. BFP motor cooler. the bearing of equipments. condenser. DOCUMENT NO. The water tank will be arranged at a high place to gives the closed cooling water pump sufficient NPSH.pdffactory. 3x50% CCW pumps and 2x50% PHEs shall be provided for CCW system. An expansion water tank with volume 10m3 is set to meet the needs of volume change of cooling water caused by water temperature. this bypass can also be used to increase continuous blowdown water flow. Demineralized water will be sent to the equipments and return to the inlet of the cooling water pumps. 2) Boiler intermittent blowdown system According to quality of boiler water. 4.1 Page 40 PDF created with pdfFactory Pro trial version www. The make-up water is led to expansion water tank with control valve for water tank level set in the pipe. If quality of boiler water is getting worse.10 Boiler blowdown and drain system 1) Continuous blowdown system Drum will continuously blowdown some unqualified boiler water to continuous blowdown tank to separate steam and water.: 50-F271C-J01-01 REV.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. blowdown water will flow through bypass to intermittent blowdown flash tank directly. The demineralized water is pumped by the closed cooling water pumps and is sent to the heat exchanger in which the demineralized water is cooled by the Aux.com . When continuous blowdown flash tank is failure during operation.2. BELLARY Chemical department will guarantee the water quality. steam flow into deaerator and water is discharged to intermittent blowdown flash tank. cooling water. Make-up water of the system is from outlet of condensate water pump in normal condition and from condensate make-up water system in emergency condition. the water accumulated in bottom headers of DOCUMENT NO. 4. oil coolers etc. BELLARY boiler with some deposits will be discharged intermittently.com . with main oil tank.2.1 Page 41 PDF created with pdfFactory Pro trial version www. Provide oil to lubricate the thrust bearing Provide oil to lubricate the turning gear . and then water is discharged to boiler intermittent blowdown flash tank. The water in intermittent blowdown flash tank then discharge to a concrete pit underground and mixed with cooling water there. Provide oil pressure for the governor system The lubrication oil system is a closed system using oil stored in a reservoir which DOCUMENT NO.pdffactory. Provide oil pressure for the generator hydrogen seal oil system .11 Steam turbine lube oil and Lube oil handling system Steam turbine lube oil system will supply lube oil to the bearing of steam turbine and generator. After steam water separate in tank. 3) Drainage and discharge system Drainage and discharge pipes of each header would collect together to drainage manifold in boiler house during startup and shutdown. oil pumps. steam is exhausted to atmosphere. then discharged out. This water will be discharged to intermittent blowdown flash tank directly. 4.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.12 Lubrication Oil System The function of the lubrication system is to : Provide oil to lubricate the turbine and generator journal bearings .2.: 50-F271C-J01-01 REV. Strainers on the oil DOCUMENT NO.Motor-driven pumps are used when the main oil pump and oil ejector cannot supply sufficient oil pressure.A shaft-driven pump in the turbine governor pedestal . The system uses two oil coolers to regulate the temperature of the lubricating oil system for the turbine generator unit consists of the following major components: Lubrication oil reservoir : Turbine shaft driven main oil pump oil ejector Auxiliary motor driven oil pumps Vapor extractors oil coolers Oil piping Protective devices Bearing lift oil system The lubrication oil reservoir is a steel tank in which the lubrication oil is stored. BELLARY is pumped to various points of use. the lubrication system uses both shaft-driven and motor-driven pumps .pumps the oil when the turbine is operating at or near rated speed .1 Page 42 PDF created with pdfFactory Pro trial version www.the oil ejector uses high-pressure oil from the main oil pump discharge to pick up oil from the reservoir when the unit is operating at or near rated speed .Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.together with oil ejector in the reservoir .: 50-F271C-J01-01 REV. pressure transducers.com . Mounted on the reservoir are the auxiliary motor driven pumps. level sensors.pdffactory. and pressure gages . vapour extraction system. com .: 50-F271C-J01-01 REV.and oil return drain help to prevent particle contaminants from circulating through the system. BELLARY ejector intake . the oil is directed through the oil coolers to the turbine generator bearings. During startup.auxiliary oil pump suctions . The main oil pump is a volute-type centrifugal pump mounted horizontally on the turbine extension shaft in the governor pedestal area. horizontally DOCUMENT NO. vertically mounted on the top of plate of the oil reservoir which is used at startup and shutdown.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. The emergency oil pump (EOP) is a DC motor-driven centrifugal pump which is identical to the BOP except for the motor.pdffactory. the BOP is placed in service before the unit is put on turning gear operation. the main oil pump supplies all of the oil requirements of the lubrication system. One outlet. The bearing oil pump (BOP) is an AC motor-driven centrifugal pump. The inlet is supplied with highpressure oil from the discharge of the main oil pump when the turbine generator is at or near rated speed. The other outlet supplies the inlet side of the mail oil pump with oil. It stays in service until the main oil pump can satisfy the system oil requirements.1 Page 43 PDF created with pdfFactory Pro trial version www. At or near rated turbine speed. The EOP serves as a backup to the BOP in case of AC power failure. The oil ejector is mounted inside the oil reservoir. The Reservoir is provided with man way access openings on the top of the shell and a drain connection on the bottom. The seal oil backup pump (SOB) is an AC motor-driven gear pump. Provide oil pressure for the governor system and provides two source of backup for the generator hydrogen seal oil system. BELLARY mounted on the top of the oil reservoir which is used during startup and shutdown of the turbine generator when main oil pump discharge pressure is too low to meet the oil pressure for the governor system and the generator seal system high-pressure oil backup requirements. Valves between the two coolers direct oil flow from reservoir to the selected cooler. The hourly conditioning capacity shall be equivalent to 20 percent of the combined capacity of the main oil tank at operating level plus the oil in the lubricator system that flows back into the main oil tank during a shutdown of the turbine each hour. oil reservoir.pdffactory. Turbine unit oil purification system shall be of centrifuge type.023 m2 of free oil surface for each lpm of normal oil flow. Design basis of oil system The Main oil tank capacity shall provide a minimum of 8 minutes retention time. The oil DOCUMENT NO.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. The coolers are identical in construction.com . The lubrication oil system includes two full-size oil coolers to maintain an acceptable temperature range of oil to the bearings while the system is in operation. Two vapor extractors are supplied for the reservoir. The main function is to remove oil vapors and maintain a slight vacuum at the turbine pedestal. The equipment shall be designed to meet all lube oil purity requirements established by the turbine generator manufacturer and ASME Standard 118. bearing housings. and oil guard piping system. One cooler is used during normal operation and the other cooler is kept on standby.: 50-F271C-J01-01 REV. one vapor extractor is normally operating and the other vapor extractor is on standby.1 Page 44 PDF created with pdfFactory Pro trial version www. There shall be a minimum of 0. two convey pump. so a 48m3 dirty oil tank and a 48m3 clean oil tank is set in this system. Clean oil tank.1 Page 45 PDF created with pdfFactory Pro trial version www.3 Major Auxiliary Equipment Selection 4.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. In addition to unit oil purification ( centrifuge type) . 4. Three booster pumps are set for each feedwater pump. Purification system. a common turbine oil purification system for both unit comprising of Dirty oil tank. The pumps furnished for each installation is operate satisfactorily both in two DOCUMENT NO. one cleaning oil pump and one dirty oil pump set will be provided. The capacity of the pumps is regulated by throttling pump discharge across a feedwater regulator.: 50-F271C-J01-01 REV. The pumps are capable of operating satisfactorily at deliveries ranging from minimum recirculation flow to the maximum specified. Two pumps are working at normal operation and one pump is standby.pdffactory.com .1 Feed-water pump Each unit will be furnished with three 50% capacity motor-driven variable speed feed-water pump with hydraulic coupling. The lube oil volume of steam turbine is 32m3. BELLARY conditioning equipment shall be designed to provide for removal of particulate matter greater than 10 microns absolute and all free water in accordance with ASME. Lube oil handling system will handle the unqualified lube oil before unit startup or under normal operation. with water coalescer type oil purifier and lube oil transfer pump.3. : 50-F271C-J01-01 REV.593 42 42 3 4 DOCUMENT NO. Boiler feed pumps design is based on 110% feed water flow at BMCR.593 BFP 2 gland seal G2 t/h 2 2 discharge and injection flow difference Interstage flow for RH spray Total suction flow of BFPs Data from G3 t/h Shanghai boiler works Co. Pump and motor are provided with online vibration monitoring system and bearing metal temperature measurement.1 Page 46 PDF created with pdfFactory Pro trial version www. when the variable speed drive cannot provide the required feedwater flow control. The low load regulating valve is bypassed.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.5 Hz during normal operation.com .5 to 51. Pump is designed for complete frequency range of 47.ltd G4 t/h G4=G1*110%+ G2+G3 1160.5 964. BELLARY pump parallel operation and single pump operation and when bringing in or taking a pump out of service with one or two other pumps in service.pdffactory. BFP SIZING DATA SHEET No Name Symbo l Unit Calculation & Remark BMCR TMCR (3%MU) Technical evaluatio n sheet A BFP inlet suction flow HBD from 1 Maximun steam flow G1 t/h Shanghai steam turbine works 1015 920. During startup and low load operation. a low load regulating valve is used. 3 539.734 b Equipment pressure drop HP heaters △PEQUI P Mpa 0.876 0.66 580.25 649.66 482.001119 893.001119 893.5 30 550 9 B 1 BFP booster pump suction flow BFP head Q2 m3/h Pipe and equipments pressure drop Pipe pressure drop from △PLP＋ △PIP+△PHP Considering 20 Mpa ％ margin 1.1 Page 47 PDF created with pdfFactory Pro trial version www.7 550 Feedwater density Capacity of each BFP BFP suction flow 8 Interstage flow of BFP Q1=G3*υ*1000 Q1 m3/h m3/h /2 23.5 30 650 23.pdffactory. BELLARY Technical evaluatio n sheet No Name Symbo l specific υ ρ G Q Unit Calculation & Remark According to BMCR TMCR (3%MU) 5 6 7 Feedwater volume m3/kg kg/m3 t/h m3/h m3/h HBD ρ=1/υ G=G4/2 Q=G*υ*1000 0.3 650 0.3 0.411 1.3 Mpa Total pressure drop from deaerator tank outlet to ecoonmizer inlet △P1 Mpa ％ margin △PPIPE+△PEQUI P 0.051 0.181 DOCUMENT NO.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.881 a deaerator tank outlet to economizer inlet △PPIPE Mpa 0.com .1*3 (3 HP heaters) Considering 20 0.36 1.: 50-F271C-J01-01 REV. pdffactory. 1 BFP flow Name Symbol Unit Calculation W kg/s SG BMCR condition Data 294.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.224 C BFP sizing result Head Suction flow △P Q mH2o m /h 3 2454 650 2200 550 1 Note: all these data is primary data for the selection of BFP.78 From HBD △P=△P1+△P 2+△P3+△P4 -0.487 19.814 -0. BELLARY Technical evaluatio n sheet No Name Symbo l Unit Calculation & Remark BMCR TMCR (3%MU) Water pressure 2 economizer differential between inlet and △P2 Mpa (29.com .: 50-F271C-J01-01 REV.8)*9.524.778 Mpa 21.45 feedwater pressure at MCR condition 4 Rated working pressure of deaerator(neagative) Total head of BFP △P4 △P Mpa 18.041 deaerator tank normal water level Drum relieving Total pressure drop from economizer drum Economizer inlet inlet to safety valve According to △P3 Mpa data sheet from boiler works 20.041 0.81/υ 0.200 1 DOCUMENT NO. NPSH calculation for BFP No.4 3 1 0.1 Page 48 PDF created with pdfFactory Pro trial version www. 44 55.09 Total weight of water Pipe length of BFP booster pump B b) LP feedwater pipe Water weight of one meter in pipe Total weight of water Pipe length of BFP booster pump C LP feedwater pipe Water weight of one meter in pipe Total weight of water Water weight from deaerator to d) BFP booster pump Water weight in condensate pipe from No.9 72.1185×(Gi+Gc+Gcf) L×Q1 Φ325*8 weight: 62. 4 4 LP heater inlet Pipe length from No. 4 LP heater to deaerator Water weight in condensate pipe from No.542kg/m×L Data of manufactory Data of manufactory 71.3 69.55 4958.1185 kg kg Valve handbook Gs1+Gs2+0.02 3727.com .24 16380 12820 3560 0. 3 LP heater inlet Pipe length from No.62 67.1185 1600 10756. 2 LP heater outlet to No.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.06 10513.59 37. BELLARY 2 a) Water weight from deaerator to BFP booster pump Pipe length of BFP booster pump A LP feedwater pipe Water weight of one meter in pipe L1 Q1 G1 L3 Q3 G3 L2 Q3 G2 MS m kg/m Φ325X8 kg m kg/m Φ325X8 kg m kg/m Φ325*8 kg kg Q3×L2 Normal operation is two BFP. 4 LP heater to 3 deaerator a) Pipe length Water weight of one meter in pipe Total weight of water Total weight of metal Operation weight of No.11 L2-3 L3-4 Q1 Gs1 m m kg/m Φ325*8 kg (L2-3+L3-4)×Q1 89 56. 4 LP b) heater Total metal weight of No.02 2388.1 Page 49 PDF created with pdfFactory Pro trial version www.pdffactory.: 50-F271C-J01-01 REV. 4 LP heater Total water weight of No.64 67.65 6214. Ms= G3+G2 L3XQ3 L3XQ3 35. 3 LP heater b) outlet to No.02 2486.1 67.55 DOCUMENT NO. 2 LP heater a) outlet to No. 4 LP heater inlet c) Water weight of one meter in pipe Water weight of L2-3 and L3-4 c) L Q1 Gs1 Gi Gb Gc Gs2 Gs3 Gcf ML m kg/m Φ325*8 kg kg kg kg kg Convert coefficient: C'=0.92 4459. 4 LP heater Convert coefficient of metal Weight of valve Water weight in condensate pipe c) from No. 85 63. 3 LP e) heater Total metal weight of No.1185*(Gi+Gc6+Gc7+Gcf ) 32777. 3 LP heater Total water weight of No.88 14920 11850 3070 Data of manufactory Data of manufactory 48345 36320 12025 C'=0.pdffactory.1 PDF created with pdfFactory Pro trial version www.6 192. 3 LP heater Operation weight of No.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.4 LP heater outlet when load 7 rejection Condensater water enthalpy of 8 condensor 9 Calculation time after load rejection c) Gi Gb3 Gc3 Gs2 Gb2 Gc2 Gs3 C' Gcf kg kg kg kg kg kg kg Φ325×8 weight: 62.5 10 Kind of downcomer 11 NPSH（25% margin） Level difference from calculation water elevation of deaerator to BFP booster pump C 12 Hj m Page 50 21. 1&2 LP 6) heater Total metal weight of No.25 589.05 HO kJ/kg VWO 736.20 Data of manufactory Data of manufactory 180 73300 1. 4 LP heater inlet 5 a) Water weight of deaerator Cubage of deaerator water tank Metal weight of deaerator water b) tank Radius of deaerator water tank Center elevation of deaerator water d) tank The lowest water level elevation of e) deaerator water tank Water weight of the lowest water f) level in deaerator water tank Water calculation weight of the lowest water level in deaerator Saturation water enthalpy of deaerator when transient load 6 rejection Condensate water enthalpy of No. 1&2 LP heater Convert coefficient of metal Weight of valve Water weight in condensate pipe from No.6*1.com .955 DOCUMENT NO.1185 3200 Mc Q Gj R V V1 Gs M kg m3 kg m m m kg kg Gs1+Gs2+Gs3+0.1185 kg Valve handbook 0.8 23.233m3 Gs+C'*Gj 56511 65197. BELLARY d) Metal weight of L2-3 and L3-4 Operation weight of No.55 22.3 HL HC TS N Nr kJ/kg VWO kJ/kg VWO S m standard 3. 2 LP heater outlet to No.2 300 1 4. 1&2 LP heater Total water weight of No.: 50-F271C-J01-01 REV.542kg/m*(L2-3+L3-4) Data of manufactory Data of manufactory 9124. 5 11.55.589.62 11.36 147.1 4. one deaerator.1 PL VV DN L kPa m3/kg VWO: 173.2.2 0.2.147.300. and one gland steam condenser.3.20.62 3.2.36.5 ； Motorized gate valves Inlet resistance cofficient of downcomer Total resitance coefficient of pipe 18 Flow of each downcomer Available NPSH of load ejection result condition Originality data for calculation program 294.2-1 E.DN300 查 P180 附表 E.62 13 Resistance of strainer Specific volume of BFP booster 14 pump inlet 15 Inner diameter of downcomer 16 Calculatiom length of downcomer Part resistance coefficient of 17 downcomer Outside diameter of pipe Thickness of pipe Inner diameter of pipe Equivalence roughness of pipe Friction coefficient of pipe Length of pipeline Friction coefficient of pipeline Part resistance coefficient of pipeline Elbow：90° total 11.955.6214.3.32777.2.1 0.1-1 1/(1.2.21.237 4.2 Heaters The extraction system of each unit will be set with three HP heaters.8 2.0.2-16 PN2.09.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.192.001119 0.11.2.10756.5.: 50-F271C-J01-01 REV.pdffactory.875 2.18482 ζ1 ζ2 ζ3 ζ G ZH kg/s m E. four LP heaters.14+2*logDi/ε) m λ*L/（Di/1000) 2 325 8 309 0.65197 736.309.5.309 55.001119 0.6.com .1 Page 51 PDF created with pdfFactory Pro trial version www. DOCUMENT NO.2-14 2.01769 55.2. BELLARY 20 0.9°C m [325-（2×8)]/1000 m The max DW S Di ε λ L ζA mm mm mm DW-2*S E. no change of phase. Deaerator shall remove dissolved oxygen from the condensate in excess of 0.e. feedwater heaters also help to reduce thermal pollution. The deaerator has enough volume to ensure the boiler working at the maximum operation condition for about 10 minutes. Since the work lost by extracting the steam is derived from sensible heat.com .: 50-F271C-J01-01 REV. A special insert DOCUMENT NO. The resultant heating of the feed water aids in avoiding thermal shock to the boiler and reduces the fuel consumption required to convert the feedwater to steam. Without a feedwater heater.005 cc per liter at any load from 5 percent to and including rated capacity. i. They are arranged indoors. The deaerator storage tank is also sized in conjunction with the deaerator outlet piping and height to provide a storage volume which allow adequate transient NPSH for the boiler feed due to a sudden full load rejection and prevent flashing at the pump suction. the much greater latent heat recovered in the feedwater heater by changing phase from steam to water result in a net energy gain.1 Page 52 PDF created with pdfFactory Pro trial version www. Shell wall thickness shall be determined in accordance with the ASME code utilizing the allowable stress value for the shell material at the design pressure and temperature.pdffactory. The high pressure heater is essentially an all-welded assembly. HP heaters: Closed feedwater heaters are used in a regenerative steam cycle to improve the thermodynamic gain.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. This is accomplished by extracting system at various points from the turbine and condensing kit using boiler feedwater. BELLARY All of the heaters are horizontal type and are designed in accordance with HEI standard. Therefore. Two LP heaters are arranged at the neck of condenser. the latent heat is wasted or thrown out in the main condenser or cooling tower. 069 MPa Page 53 DOCUMENT NO. No 1 DESCRIPTION Tube side Sort Parameter Shell side Unit Class 3rd pressure Class 2nd pressure vessel vessel JG-1370 1370 27.1 <0.5 279.com .2145 393.5 295 27. BELLARY is assembled in the inlet end of every heater-transfer U tube. When accident has taken place.5 6. automatic regulating of drain level can fast bypass high pressure heater.pdffactory.1 PDF created with pdfFactory Pro trial version www.4/277. Each high pressure heater has indicating.9 MPa(a) o C 9 Max. On tube side.58 420/295 7. 8 DATA SHEET SL.e.58 m2 MPa(a) o 2 3 4 5 6 Type Heating area Design pressure Design temperature Max. (i. Each high pressure heater contains three zones.: 50-F271C-J01-01 REV. HP HEATER Nos.5 7. The welded seams are radiographed to insure the quality of the joint. desuperheating zone. relief valve is provided to prevent excessive pressure. Stainless steel impingement plates have been installed in these heaters of steam and other drains inlets to avoid direct impingement of steam and drains upon the tubes to prevent tube erosion. pressure drop <0. condensing zone and subcooling zone). pressure operating C MPa(a) 7 8 Operating pressure Operating temperature 21. Heater shell is provided with relief valves to protect the shell in case of tube failure. regulating and alarming devices of level.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. 25 Parameter Shell side 80. No 1 DESCRIPTION Tube side Sort Parameter Shell side Unit Class 3rd pressure Class 2nd pressure vessel vessel JG-1575 1575 27. BELLARY SL.5 265 4.37 1 Unit T/h MPa(a) 15 Estimated weight Net weight Operating weight Flooded weight Manhole weight 64956 70861 82717 120 Kg Kg Kg Kg m3 m3 m3 m3 16 Estimated Volume Volume of water in sub-cooler zone at normal water level Volume of water in shell at normal water level outside sub-cooler zone Volume of steam in shell operating Volume of tube side 12.: 50-F271C-J01-01 REV. 7 DATA SHEET SL.pdffactory. No 10 11 12 13 14 DESCRIPTION Tube side Flow Medium Weld coefficient Test pressure Corrosion allowable 1015 Water 1 41.com .1 3.81 360/265 m o 2 2 3 4 5 Type Heating area Design pressure Design temperature MPa(a) C DOCUMENT NO.1 Page 54 PDF created with pdfFactory Pro trial version www.78 0.86 1.40 HP HEATER Nos.785 Steam & Water 1 11.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. BELLARY SL.9 4.3 1. pressure operating 27.6542 324/245 MPa(a) o C 9 10 11 12 13 14 Max.: 50-F271C-J01-01 REV.27 2.5 245 3. No 6 DESCRIPTION Tube side Max.1 1015 Water 1 1 41.042 Steam & Water 1 MPa T/h 7.069 68. 5 Parameter Shell side 4.25 <0.215 MPa(a) 15 Estimated weight Net weight Operating weight Flooded weight Manhole weight 62121 69767 81407 120 Kg Kg Kg Kg m3 m3 m3 m3 16 Estimated Volume Volume of water in sub-cooler zone at normal water level Volume of water in shell at normal water level outside sub-cooler zone Volume of steam in shell operating Volume of tube side 11.com .N o DESCRIPTION Tube side Parameter Shell side Page 55 Unit DOCUMENT NO.81 Unit MPa(a) 7 8 Operating pressure Operating temperature 21.pdffactory. pressure drop Flow Medium Weld coefficient Corrosion allowable Test pressure <0. 6 DATA SHEET SL.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.23 HP HEATER Nos.1 PDF created with pdfFactory Pro trial version www. 915 455/207.: 50-F271C-J01-01 REV.069 37.07 m2 MPa(a) o 2 3 4 5 6 Type Heating area Design pressure Design temperature Max. pressure drop Flow Medium Weld coefficient Corrosion allowable Test pressure <0.105 MPa(a) 15 Estimated weight Net weight Operating weight Flooded weight Manhole weight 48739 55961 69272 120 Kg Kg Kg Kg 3 16 Estimated Volume Volume of water in sub-cooler zone at normal water level Volume of water in shell at normal water level outside sub-cooler zone 1.55 m DOCUMENT NO. BELLARY SL. 5 2.1 Page 56 PDF created with pdfFactory Pro trial version www.799 Steam & Water 1 MPa T/h 3.1 1015 Water 1 1 41.07 470/215 2. pressure operating C MPa(a) 7 8 Operating pressure Operating temperature 21.6 1.pdffactory. 5 215 27.com .N o 1 DESCRIPTION Tube side Sort Parameter Shell side Unit Class 3rd pressure Class 2nd pressure vessel vessel JG-1230 1230 27.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.32 m3 2.25 <0.5 207.6 MPa(a) o C 9 10 11 12 13 14 Max. b) Shell: Carbon steel ASTM SA516Gr70. The low-pressure feedwater heaters shall increase the temperature of the condensate in stages by the use of extraction steam.: 50-F271C-J01-01 REV. class II: 1. BELLARY SL. Heat transfer tubes are stainless steel U-tubes.1 Page 57 PDF created with pdfFactory Pro trial version www. The high-pressure feedwater heaters shall be manufactured of following materials or superior materials:- a) Channel: Carbon steel ASTM A516 Gr 70.pdffactory. LP Heaters: The low pressure heater system adopts single string arrangement. The low pressure heaters contain two zones(condensing zone and subcooling zone). d) Tubes: Stainless steel ASTM SA688TP304N e) Tubesheet: forged steel ASTM SA 350 Gr LF 2 with SS Cladding 1 Feed pump hydraulic coupling shall be rated up to lower operating range of 20% of the maximum output speed.6 3. which consists of four low pressure feedwater heaters. c) Shell skirt: Carbon steel ASTM A516 Gr 70.N o DESCRIPTION Tube side Volume of steam in shell operating Volume of tube side Parameter Shell side 13.com .50 Unit m3 m3 Note: class III: 10 to 100MPa.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.6 to 10MPa. Heater DOCUMENT NO. LP heaters 1 & 2 are located in the neck of the condenser.1 <0.583 Steam & Water 0.0235 62. 1 & 2 DATA SHEET SL.0738 90.pdffactory. 6 15.: 50-F271C-J01-01 REV. 6 33.com .206 JD-740-2-2 740 3. Type Heating area Design pressure Design temperature Max.206 m2 MPa(a) o C operating MPa(a) 1. relief valve is provided to prevent excessive pressure.92 130 3.33 0.345 Steam & Water 0.1 <0.79 0.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.1 PDF created with pdfFactory Pro trial version www.0156 MPa 791.206 130 0. pressure 7 8 Operating pressure Operating temperature 9 Max.85 1 Page 58 Shell side #1 Tube side #2 Shell side Unit JD-840-2-1 840 3. Each channel of low pressure heaters consists of a cylindrical shell and an ellipsoidal head. No 1 2 3 4 5 6 Parameter DESCRIPTION Tube side Heater No.92 0.11 MPa(a) o C <0.56 1.724 87. The maximum tube side flow shall be the condensate flow at turbine valves wide open and a design margin of no less than 10 percent. LP HEATERS Nos.92 130 3. BELLARY shell is provided with relief valves to protect the shell in case of tube failure.206 130 0.0055 <0. pressure drop across heater 10 11 Flow Medium 791. On tube side.85 T/h Water 1 Water 1 12 13 Weld coefficient Corrosion allowance DOCUMENT NO.724 59.92 0. 3 DATA SHEET SL.92 JD-530-1-2 530 0.24 m3 m3 level outside sub-cooler 3.88 Shell side 0. No 1 DESCRIPTION Tube side Sort 2nd Class pressure vessel 2 3 4 5 6 Type Heating area Design pressure Design temperature Max.2 6. BELLARY SL.31 Tube side 5.48 m2 MPa(a) o Parameter Shell side 1st Class pressure vessel Unit C MPa(a) DOCUMENT NO.92 LP HEATER No.pdffactory.31 MPa(a) Unit 15 Estimated weight Net weight Operating weight Flooded weight Heaters #1 & #2 combined 41100 48345 69555 Kg Kg Kg m3 m3 16 Estimated Volume Volume of water in sub-cooler zone at normal water level Volume of water in shell at normal water zone Volume of steam in shell operating Volume of tube side 21. pressure 7 Operating pressure 1.88 Shell side 0.158 MPa(a) operating 3.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.com . No 14 Parameter DESCRIPTION Tube side Test pressure 5.: 50-F271C-J01-01 REV.1 Page 59 PDF created with pdfFactory Pro trial version www.86 1.724 0.48 266/138 0.92 138 3. 6 Water 1 1 5.com .77 0.88 26.37 LP HEATER No. pressure drop across heater <0.85 T/h 0.2 2.1 Page 60 PDF created with pdfFactory Pro trial version www.9/111.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.1 <0.948 Steam & Water 0.72 MPa(a) 16 Estimated weight Net weight Operating weight Flooded weight Manhole weight 14000 17070 23130 275 Kg Kg Kg Kg m3 m3 m3 m 3 17 Estimated Volume Volume of water in sub-cooler zone at normal water level Volume of water in shell at normal water level outside sub-cooler zone Volume of steam in shell operating Volume of tube side 6.4 Unit o C 9 Max.pdffactory.: 50-F271C-J01-01 REV. BELLARY SL.019 MPa 10 11 12 13 15 Flow Medium Weld coefficient Corrosion allowable Test pressure 791. 4 DATA SHEET SL. No DESCRIPTION Tube side Parameter Shell side Unit DOCUMENT NO. No 8 DESCRIPTION Tube side Operating temperature 108.6 Parameter Shell side 155.00 0. No 1 DESCRIPTION Tube side Sort Parameter Shell side 1st Class pressure vessel JD-580-6-4 580 3.com . pressure operating m2 MPa(a) o C MPa(a) 7 8 Operating pressure Operating temperature 1.85 T/h 1.7 MPa(a) o C 9 Max.029 MPa(a) 15 Estimated weight Net weight Operating weight Flooded weight Manhole weight 15400 18960 25200 275 Kg Kg Kg Kg m3 16 Estimated Volume Volume of water in sub-cooler zone at normal water level 0.: 50-F271C-J01-01 REV. pressure drop across heater <0.1 Page 61 PDF created with pdfFactory Pro trial version www.724 139.9 0.88 40.1 <0.686 332/164 0.92 164 3.pdffactory.92 0.65 DOCUMENT NO.0344 MPa 10 11 12 13 14 Flow Medium Weld coefficient Corrosion allowable Test pressure 791. BELLARY SL.6 Water 1 1 5.686 2nd Class pressure vessel Unit 2 3 4 5 6 Type Heating area Design pressure Design temperature Max.58 Steam & Water 0.4104 256/142.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. 70. No DESCRIPTION Tube side Parameter Shell side 0.1 to 1. The low-pressure feedwater heaters shall be manufactured of following materials or superior materials:- a) Channel: Carbon steel ASTM SA516 Gr.005 cc/l. BELLARY SL.1 Page 62 PDF created with pdfFactory Pro trial version www. 6. etc.com . The boiler water is to reduce oxygen content below 0.36 2. 70. 1 b) Shell: Carbon steel ASTM A516 Gr. In addition. 1 Deaerator: The horizontal deaerator is one of the main auxiliary equipment in feedwater regenerative system for steam generating units. class I: 0.pdffactory. The primary use of deaerator is to remove noncondensable gases such as oxygen. 70 c) Shell skirt: Carbon steel ASTM A515 Gr.6MPa. carbon dioxide.6 to 10MPa.: 50-F271C-J01-01 REV.16 10% Design margin shall be kept. with DOCUMENT NO. d) Tubes: Stainless steel ASTM SA688 TP 304 e) Tubesheet: carbon steel ASTM SA350 Gr LF2.84 Unit m3 m3 m3 Volume of water in shell at normal water level outside sub-cooler zone Volume of steam in shell operating Volume of tube side Note: class II: 1.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. : 50-F271C-J01-01 REV.com .N o 1 2 3 4 5 DESCRIPTION Sort Type Design pressure Design temperature Max.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. The deaerator can store a definite amount of saturated water at deaerator pressure and conform to the standard of oxygen content to meet the needs of the boiler and guarantee its safe operation.1 Page 63 PDF created with pdfFactory Pro trial version www.2 Steam & Water 0.pdffactory.2 o Parameter Deaerator Class 1st pressure vessel GC-1080/ GS-180 1.19/full vacuum 365 0. capacity t/h pressure 180 257 1080 1 3. BELLARY extraction on the intermediate pressure side of the turbine and other residual steam and drain. pressure 6 Working temperature 7 8 9 10 11 12 13 Effective Volume Total volume Rated capacity Weld coefficient Corrosion allowable Medium Nozzle drop 14 Max.954 Unit MPa(a) o C working MPa(a) C DOCUMENT NO. DEAERATOR AND TANK DATA SHEET SL.05 MPa mm m3 m3 t/h 356. the deaerator shall heat the boiler feedwater to saturated temperature under operating pressure of deaerator so as to raise the thermal efficiency of the unit. 3.12. B or equivalent Stainless steel to SS 304 SA . if any Vent orifice Carbon steel to SA 516 Gr.pdffactory.: 50-F271C-J01-01 REV.12.5 6.6 6. Each Condensate extraction pump shall be sized to supply 110 percent of the flow requirements at VWO operation with 3% makeup for each unit.9 6. 70 or equivalent Stainless steel to SS 304 / SS 431 Stainless steel to SS 304 Stainless steel to SS 304 Carbon steel to SA 106 Gr.12. The Condensate extraction pump & motor shall be provided with online vibration DOCUMENT NO.3 Condensate extraction pump Two 100% capacity constant speed motor driven Condensate extraction pumps are set for each unit. BELLARY Parameter 15 Set pressure of MPa(a) safety valve 16 Others The deaerator shall be manufactured of following materials or superior materials: 6.193 B7 or equivalent SA . 70 or equivalent Carbon steel to SA 516 Gr.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. The Condensate extraction pump is “can” type with single suction impeller and with derivational stage.12.10 6.3 6.2 6.1 6.194 2H or equivalent CAF 40 Stainless steel to SS 304 Stainless steel to SS 304 4.12.12.4 6.12.12.12.12.12.11 6.7 6.12.8 6.com .1 Page 64 PDF created with pdfFactory Pro trial version www.12 Deaerating shell & heads Feed water storage tank shell & heads Trays Tray enclosure Spray valves / sprayer assembly Steam distribution pipe (Internal) / Nozzles / Condensate pipes Splash plates & Baffle plates Bolts Nuts Gaskets Internal bolting. one operate and one standby. 1 Page 65 PDF created with pdfFactory Pro trial version www.8 2 G2 " " " " " " 3 G3 t/h 29 27.00101 901.2 125.3 117.00101 786.6 910 0.com .6 4 G4 t/h 50 50 5 G' t/h G'=G1+G2+G3+G4 811. BELLARY measurement system and bearing metal temperature measurement system.pdffactory.: 50-F271C-J01-01 REV.5 778.7 6 CEP Condensate water G υ Q' Q t/h m3/K g m3/h m3/h G=1.1*G' According to HBD Q=G*υ*1000 892.82 0.6 0.5 795 7 8 specific volume CEP flow B CEP head Pipe pressure drop 1 from condenser hotwell outlet to deaerator inlet △P1 Mpa Calculation result 0.74 DOCUMENT NO.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.3 583. CEP SIZING DATA SHEET No Name Symbo l Unit Calculation & Remark VWO TMCR (3%MU) Technical evaluatio n sheet A 1 Capacity of CEP Condensate steam flow at VWO Normal drain to condenser Normal makeup water to condenser Other flow to condenser Maximum condensate flow Capacity of each G1 HBD from Shanghai t/h t/h steam turbine works 607.617 Mpa Considering 20％ margin 0.984 0. 088 0.3.582 5 Mpa 0. 4 VWO TMCR (3%MU) 2 Equipments pressure drop Mpa LP heaters & spring nozzle 0.1 Page 66 PDF created with pdfFactory Pro trial version www.088 6 Mpa 3.06 C 1 2 CEP sizing result Discharge pressure Flow H Q Mpa m3/h 3.2701 0.com . Two pumps will be in operation for establish vacuum in condenser fast to shorten the start-up DOCUMENT NO.: 50-F271C-J01-01 REV. 4.05 △P=△P1+△P2+ △P3+△P4 1.485 Mpa Water differential pressure between 3 deaerator inlet and condenser hotwell lowest water level 4 Deaerator max.25 margin 735x133.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.pdffactory.14 0.2701 0.662)(water level of condenser well) *1. BELLARY Technical evaluatio n sheet No Name Symbo l Unit Calculation & Remark Including GSC.06 910 795 Note: all these data is primary data for the selection of CEP. To counter the surging effect on hotwell 100 m3 size surge tank is provided.35(inlet of deaerator condensater water)-(0.4 Vacuum pump 2X100% capacity vacuum pumps will be furnished in the system.3/100010. working pressure Condenser highest vacuum CEP discharge head △P3 △P4 △P Mpa △P2 Mpa Considering 20％ margin 26.9120(no margin) 0.485 0. with both pumps working in parallel. at CW temperature of 33 Deg.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.4 m/sec. the pump capacity is also such that at starting. BELLARY time before the unit starting.5 Condenser 4.1 Page 67 PDF created with pdfFactory Pro trial version www. 3.1 Structural Characteristic DOCUMENT NO.com . and are sized in accordance with HEI standards. The pumps shall not cavitate under all operating conditions including part loads and design point.2 Heat Exchangers : a) Shell b) Tubes c) Tube sheet d) Baffle and tie rod cage 4.pdffactory. The vacuum pumps are of liquid ring type.5. The design capacity of each pump shall be selected to meet the above requirements with a margin of 10%.C.1 Vacuum pumps a) Casing b) Shaft c) Impeller d) Shaft sleeves Cast iron Carbon steel EN-8 SS SS Carbon steel Stainless Steel Carbon steel with epoxy coating as required SS 3. Besides. Each vacuum pump designed capacity is of 80Kg/h approximately of dry air plus associated water vapor to saturate at 1 inch (25. During normal operation.: 50-F271C-J01-01 REV. it is possible to create within 20 minutes vacuum (about 35 KPa) in the condenser.10.3.3.) Hg atm.10. one operates for maintain the vacuum in condenser and another standby. BELLARY The condenser is designed in the form single shell. waterbox. The condenser is connected to turbine exhaust hood with expansion joint. divided water boxes Two pass and installed in transversal arrangement.3. Water screen spray protection device is equipped inside neck.: 50-F271C-J01-01 REV. All extraction lines are equipped with stainless steel waveform expansion joints to absorb thermal expansion in the lines. exhaust expansion joint and so on. T-type beam steel are applied inside each sideplate of neck to increase transversal rigidity of sideplates so that the complete neck could be rigid enough.3.pdffactory. 4. DOCUMENT NO.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. Each fixed base support with three slot holes is connected to the foundation with M36 anchor bolt in order to satisfy the requirements of condenser expansion.3 Shell Shell made of full welded structure is the main part of condenser and possesses reliable tightness. Extraction lines go through neck.5.com . 4.1 Page 68 PDF created with pdfFactory Pro trial version www. In order to protect abnormal higher temperature caused by turbine bypass inlet steam. Four fixed base supports are arranged at the four angles at bottom of the condenser. shell. so that the complete condenser can steadily upon the eight base supports.2 Neck Condenser neck is made of welded carbon steel plates and steel plate is applied for inside supporting and ribbed plates for reinforcement.5. The condenser mainly consists of neck. Stainless steel lagging is adopted to cover the outside of extraction lines in order to avoid erosion. Four sliding base supports are arranged at middle at the bottom of the condenser. Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU, BELLARY Two tube bundles are set up in shell. Triangular conventional layout is adopted for the arrangement of tube bundle. All tubes are seam welded. Air extracting line in cooling area are evenly distributed at cooling water entrance. Support plates are distributed between front and back tube sheets to support cooling tubes. So that tubes could contact support plates closely to improve the vibration property of tubes and avoid resonance. Tube sheets are welded to two ends of shell and thinner steel plate is applied for flexible transition to compensate thermal expansion difference between cooling the and shell. Proper access manhole and other connections are provided on the shell. An access manhole is provided on the tube bundle. Access openings or manhole is provided on the interior of the condenser to provided access to the tube support plates. In some place where steam of water enters the condenser shell provided suitable approved baffle to prevent impingement on the tube and shell, and proper distribution of condensate and steam. Hot well is designed below tube bundles with enough space so that subcooling could be minimized in the process for reheating transfer and raise deaerating effect as well. The hotwell has enough space for the requirements of condensate level change. Two flash box is for absorbing drain. In this way, draining water can be temperature-reduced and pressure breakdown and then drained into condenser so that tube bundle could be protected from erosion of steam and water higher DOCUMENT NO.: 50-F271C-J01-01 REV.1 Page 69 PDF created with pdfFactory Pro trial version www.pdffactory.com Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU, BELLARY temperature and pressure. 4.3.5.4 Waterboxes Waterboxes are designed in the form of semicircle and cone-type. Thus resulting in good rigidity of the hole waterbox body, lightweight and favorable flowing property of cooling water. The water box is provided cathodic protection equipment. Inside of this condenser safety ladder is assembled to the inside wall of waterbox and both vacuum extracted outlet and air vent displaced at the top of waterbox. Manhole is equipped outlet the lower part of waterbox for maintenance personnel easy access. The type of water box connection to condenser is hinged connection. 1 Sufficient tube extract space shall be kept in the front of tubesheets for taking out of tubes if tubes are required to be taken out. 4.3.5.5 Exhaust expansion joint Stainless steel waveform expansion joint is arranged at the exhaust expansion joint to absorb thermal expansion from turbine low pressure exhaust cylinder and condenser at vertical centerline direction of flow pressure exhaust cylinder. The surface condenser is a double pass design with divided water boxes which will facilitate operation of one half of the condenser while the other half is under maintenance. The bottom of the condenser serves as a hot well for condensate storage. Design Basis: DOCUMENT NO.: 50-F271C-J01-01 REV.1 Page 70 PDF created with pdfFactory Pro trial version www.pdffactory.com Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU, BELLARY The thermal design of surface condenser is based on HEI standard considering 33°C cooling water temperature for a temp rise of 10°C corresponding to heat load for VWO, 3% makeup and 10.05KPa(a)back pressure. The condenser hot well minimum storage capacity at the normal water level shall be 4 minutes of condensate storage when operating at the turbine valves wide open. The oxygen content of the condensate leaving the hot well shall not exceed 0.015 cc per liter at all conditions CONDENSER DATA SHEET Sl.No Description Parameter Unit 1 Type N-17000 2 Model Single pressure divided two passes surface 3 Condenser effective surface area 17000m2 4 Condenser back pressure 10.05 KPa(a) 5 Condenser design pressure Shell side 0.1/Full vacuum MPa(g) Waterbox side 0.343 MPa(g) DOCUMENT NO.: 50-F271C-J01-01 REV.1 Page 71 PDF created with pdfFactory Pro trial version www.pdffactory.com pdffactory.No Description Parameter Unit Waterbox side test pressure 0.com .h) DOCUMENT NO. inlet temperature of cooling water 33 36 °C °C 9 10 11 12 13 14 Design flow of cooling water Cleanliness factor Water velocity in condenser tubes Tube thickness Tube plugging margin Tube sheet material 35000 0. BELLARY Sl.15 0.: 50-F271C-J01-01 REV.5 5% TP304+SA516Gr70 t/h m/s mm 4.4 Table of economic index 7995 KJ/kW.6 Kcal/kw.525 MPa(g) 6 Condenser design temperature Shell side 121 o C Waterbox side 60 o C 7 8 Inlet temperature of cooling water Max.h Heat consumption rate of turbine (1909.85 2.7 & 0.1 Page 72 PDF created with pdfFactory Pro trial version www.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. 032+0.1 Page 73 PDF created with pdfFactory Pro trial version www. 33 Deg CCW inlet temp & 10.00018tm W/m·℃ 2) Temperature under 350 degree’s equipments and pipes will adopt rock wool or glass wool material.05 kPa(a) back pressure of condenser.00015tm W/m·℃ aluminium silicate: conductivity factor λ=0. rock wool: conductivity factor λ＝0. Turbine cycle heat rate is 1909.h based on with 0% makeup.00018 tm W/m·℃ 3) Valves will adopt insulating material and abnormities will adopt slurry of silicate and aluminum for protecting layer.pdffactory.: 50-F271C-J01-01 REV. Silicate: conductivity factor λ＝0. 5 INSULATING MATERIAL According to different temperature and pressure. different layout of equipments and pipes in the BTG. DOCUMENT NO. BELLARY Guarantee efficiency of boiler (high heating value) 88. the insulation material is considering as following (Code for designing insulation and painting of fossil and fuel power plant DL/T 50721997) taking care of the following design data: a) Design ambient temperature: 30℃ b) Maximum cladding temperature: 60 ℃ 1) Temperature over 350 degree’s equipments and pipes will adopt silicate or aluminium silicate material.8% Note：The above results are based on TMCR (Heat Rate Guarantee) condition.031+0.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU.6 Kcal/kW.035+0.com . DOCUMENT NO.: 50-F271C-J01-01 REV.com . BELLARY 4) Aluminum material will adopt for protecting layer.Design Basis Report for Mechanical Part BTG PACKAGE FOR 2×300MW COAL BASED THERMAL POWER STATION AT TORANAGALLU. the thickness will satisfy the IS requirement.1 Page 74 PDF created with pdfFactory Pro trial version www.pdffactory.