Updated Boiler and Auxiliaries2

Boiler
TROMBAY THERMAL POWER STATION

PLANT LAYOUT

BOILER
Water and Steam circuit

H.
R.
M.S C.R.H H
Feed water from BFP DISH

RE HEATER CIRCUIT
NON DRAINABLE PORTION
DRAINABLE PORTION

SALIENT FEATURES OF 500 MW BOILER
With increase in demand of power in India, new power projects are being
constructed with higher capacity and advanced technology for the better
economy and reliability of operation. Compared to other lower capacity
Boilers supplied by BHEL, these 500 MW capacity boiler have
incorporated certain special technical features which are detailed in the
next slides.

UNIT 5 BOILER SPECIFICATIONS
Manufactured by - BHEL
1) Fuel Used - Coal/Oil/Gas
LSHS - Carbon - 84.07%, Hydrogen - 11.85%, Nitrogen - 0.16%, Sulpfur - 0.13%, Ash - 0.07%,
Oxygen - 3.72%, HHV(High heating value) - 10808 Kcal/Kg.
Coal - (Fixed carbon) FC-8.36% volatile matter - 31% Moisture - 8%, Ash - 25% Sulfur - 0.7%,
Ash fusion temperature - 1400 o C HHV - 5125 Kcal/Kg. Grindability - 52 HGI. Size or
coal to mill 20mm.
Gas - Natural gas, Sp Gr. - 0.6 at 0 o C HHV 105550 Kcal/NCum (Raw gas) 9433 Kcal/NCum for
methane rich gas supply pressure - 5 Kg/Cm2
2) Steam Pressure - Design - 204 Kg/Cm2 (g)

SH output - 178 Kg/Cm2(g)
3) Superheater -
Type Heating Surface M2
Stage 1 Pendant 3450
LTSH Horizontal 9250
Stage II Pendant Panel 1640
Pendant Platen 1890
Stage III Pendant Finishing 2200
Total 18430
Superheater Desuperheater -
Type - Spray
No. of stages - One
Medium of spray - Water

UNIT 5 BOILER SPECIFICATIONS
4) Reheater : Type - Radiant wall and pendant
Total HS (Heating Surface) - 7420 m2
Control 1) Coal - Burner tilt
2) Oil - GR & Burner tilt.
5) Economizer : Type - Bare tube

Total HS - 12840 M2
No. of blocks – Two
6) Furnace : Type - Fusion Welded

Width - 17653 mm
Depth - 15289 mm
EPRS - 7710 m2
Volume - 15520 m3
Fuel heat input - coal - 1232 Mcal/hr.
7) Air heater : Type - LJUNSTROM - Regenerative type Make BHEL

1)Steam coiled air heater - Two (Not present)
2)RAPH (Trisector) - Two

CONTROLLED CIRCULATION SYSTEM
This is achieved by three/four numbers of glandless pump and wet

motor installed in the down comer line after the suction manifold.
These pump motor assemblies have single suction and double
discharge introduction of these pumps in the boiler system have led
to the designing of a furnace with lesser diameter tubes and high
parameters operating characteristics.

ADVANTAGES OF THE CONTROLLED
CIRCULATION
Uniform drum cooling and heating. In controlled circulation boilers this is

possible because of arrangement of relief tubes inlets to the drum and
the internal baffles of the drum from both sides. The internal base plates
are arranged in such a way that it guides the steam water mixture from
the relief tubes along the whole circumference of the drum. The drum is
therefore uniformly heated and cooled.

NATURAL CIRCULATION SYSTEM
The arrangement of relief tubes and baffle plates is only on one side of the drum
and this imposes a constraint on uniform heating of drum. Similar arrangement of
relief as in controlled circulation boiler does not exist in natural circulation (NC)
boiler because in that case the relief required to be taken over the drum and fed
from both sides. This shall increase the pressure losses in the riser tubes and also
the hot static head requirement for start up. Since the available head in NC Boiler
is very less; efforts are always made to reduce the pressure loss and improve the
circulation. Second reason is to commence flow in the riser tubes immediately after
light up hot static head is kept as minimum as possible.

USE OF RIFLE TUBES FOR FURNACE
CONSTRUCTION
This is one of the extraordinary features of 500 MW capacity boilers. Because of

the excessive heat release in the burner zone of the furnace, the metal tubes
constituting the furnace at that zone are exposed to the maximum temperature.
This being a water-cooled furnace, the steam water mixture inside the tubes
should effectively carry the heat from the burner zone of the furnace. In this zone,
the tubes have an internally cut spiral like a rifle bore so that when water flows
through the tubes, due to hot static heat, it takes a screwed path and attains a
certain degree of spin by which the wetness of the tube is always maintained. This
prevents the tubes form departure from Nucleate boiling (DNB) under all operating
condition of the boiler and increases the circulation ratio.

OVER FIRE AIR SYSTEM FOR NOX
(OXIDES OF NITROGEN) CONTROL
In the 500 MW capacity boiler design, this aspect has been given due importance and
certain technical improvements have been incorporated. These are tilting tangential
firing and over fire air system. Tangential firing helps in keeping the temperature of the
furnace low so that NOX emission is reduced considerably.
In addition to the above the over fire air is provided which is used as combustion
process adjustment technically for keeping the furnace temperature low and thereby
low Nox formation. Each corner of the burner windbox is provided with two numbers of
separate over fire air compartments, kept one above the other and the over fire air is
admitted tangentially into the furnace. The over fire air nozzles has got tilting
arrangement and compartment flow control dampers for working in unison with the
tilting tangential type burner system for effective control of Nox formation.
OF2 OPENING STARTS AT 50% OPEN FULL AT 75% OF BOILER LOAD

BOILER LOAD (250MW) (375MW)
OF1 OPENING STARTS AT 75% OPEN FULL AT 100% OF BOILER LOAD

BOILER LOAD 3750MW) (500MW)

Damper Logic
 Lower Aux damper : Generally remains open 20%.
 Fuel air damper: AB,BC,CD,DE,EF

 Close: if boiler load>30% and elevation o/s.
 Open: Proportional to burner pressure if elevation i/s and boiler load>30%.
 Modulates: As furnace to WB delta P if boiler load <30% and elevation o/s.
 Open: Open to pre-determined value of 30% if SU i/s.
 Auxiliary air damper: A,B,C,D,E,F

 Close: After purging and associated elevation o/s. Control remains in PROG
mode.
 Modulates: On furnace to WB delta P if associated elevation is i/s.
 Auxiliary air damper AA:

 Close: 1) MFT not present.
2) AB elevation o/s.
3) Boiler load >30%.
 Modulates: Furnace to delta P if any of above condition are not satisfied.

AIR PRE-HEATER SYSTEM
As compared to trisector air pre-heater in 200 MW units, 500 MW units

have been incorporated with bisector and trisector air pre-heaters. This
has been done for optimum utilisation of space and also improved
system layout. This has resulted in the flexibility and efficient operation
and maintenance of the air pre-heaters and the boiler as a whole.

PRIMARY AIR SYSTEM
The primary air system delivers air to the mills for coal drying and
transportation of coal powder to furnace. The 500 MW units have two
stage axial flow primary fans as compared to radial fans in 200 MW
units. By introducing axial flow fans, the system efficiency has gone up
as the axial flow fans consistently high efficiency at all operating loads.

MILLING SYSTEM
In the 500 MW units bowl mills have been installed. These are
similar to the 200 MW mills except that 500 MW mills have vane
wheel surrounding the bowl and external lubrication unit. Introduction
of vane wheel has led to uniform distribution of primary air within the
mill and less rejects. These mills are also supplied with weld overlay
technology, which has increased the minimum wear life of grinding
parts to 6000 hrs.

ELECTROSTATIC PRECIPITATORS
Electro static precipitators are installed in the 500 MW units for

minimising the particulate emission from the stack flue gases. There
are four ESP passes for one unit of 500 MW and each is
independently operated. The emitting electrodes are charged at high
-ve voltage DC and the gas while crossing this charged path gets
ionised. The ionised ash particles of the gas are attracted towards
the collecting electrode, which is maintained at high +ve voltage. The
ash collects at the collecting electrode by rapping motor. The ash
falls into the hopper, which is evacuated by the ash handling system
and taken out as slurry.

TECHNICAL SPECIFICATION OF 500 MW BOILER
Sr.
Specification Parameter
No.
1 Manufacturer M/s BHEL (C.E. Design)
Balanced Draft, Dry bottom, Single

2 Type of Boiler
drum, Controlled Circulation.
3 Type of Firing Tangential firing

FURNACE SPECIFICATION
Sr.
No.
1 Wall Water Steam cooled
2 Bottom Dry
3 Tube arrangement Membrane
Explosion/Implosion
4 +/- 660
withstand capacity
Residence time for fuel
5 particles in the furnace. 3 second
Height from furnace bottom

6 ash hopper to 63.65 Mtr
furnace roof (M)
7 Depth (M)/Width (M) 15.28/15.04

DRUM SPECIFICATION
Sr
No
1 Material specification SA-299
2 Design pressure Kg/cm2 (ABS) 204.9
3 Design metal temp OC 366
4 Max operating pressure Kg/cm2 (ABS) 192.4
Max permissible temp differential
5 between any 50
two parts of the drum (oC).
6 Drum wt. with internals (tonnes) 237.00

DRUM DESCRIPTION
Connections at both ends to the chemical clean pipe work, and at three points along
its length to feed individual circulation pump suctions. Water will flow from the
pumps through two discharge pipes into the front leg of the water wall inlet headers
at the bottom of the furnace. Each discharge pipe is fitted with circulating pump
discharge stop/check valves, which are controlled via sequence equipment to open
and close as the pump is taken in and out of service. If, however all three pumps
are out of service, all of the valves will open to enable thermosyphonic circulation to
take place. Initiating any pump to restart will cause them all to close again then
continue with the in and out of service regime. Controls for the pumps are located in
the Control room and comprise a SEQUENCE pushbutton, ammeter and a
DUTY/STANDBY selector. Pump status is indicated on RUN/STOP lamps on the
Firemen's Aisle Panel.

DRUM INTERNALS

DRUM INTERNALS
The saturated steam/water mixture enters the steam drum on both sides
behind a watertight inner plate baffle which directs the mixture around the
inside surface of the drum to provide uniform heating of the drum shell.
This eliminates thermal stresses from temperature differences through the
thick wall of the drum, between the submerged and unsubmerged portions.
Having travelled around this baffle the mixture enters two rows of steam
enter the outer edge of the separator where it is separated from the steam.
Nearly dried steam leaves the separators and passes through four rows of
corrugated plate baskets where by low velocity surface contact the
remaining moisture is removed.

Safety valves
Safety valves on the superheater main steam lines set below the low set drum safety
valve, provide another means of protection by assuring adequate flow through the
superheater if the steam demand should suddenly and unexpectedly drop Reheater
safely valves, located on the hot and cold reheat piping serve to protect the reheater if
steam flow through the reheater is suddenly interrupted.
A power control valve (Electro magnetic relief vlv) on the superheater main steam line
set below the low set
superheater safety valve is provided as a working valve to given an initial indication of

excessive steam pressure. This valve is equipped with a shut off valve to permit
isolation for maintenance. The relieving capacity of the Power Control Valve is not
included in the total relieving capacity of the safety valves required by the Boiler Code.
During all start-ups, care must be taken not to overheat the superheater or reheater
elements. The firing rate must be controlled to keep the furnace exit gas temperature
from exceeding 5400C. A thermocouple probe normally located the upper furnace
sidewall should be used to measure the furnace exit gas temperatures.
DESUPERHEATERS
Desuperheaters are provided in the superheater-connecting link and the

reheater inlet leads to permit reduction of steam temperature when
necessary and to maintain the temperatures at design values within the
limits of the nozzle capacity. Temperature reduction is accomplished by
spraying water into the path of the steam through a nozzle at the entering
end of the desuperheater. The spray water comes from the boiler
feedwater system. It is essential that the spray water be chemically pure
and free of suspended and dissolved solids, containing only approved
volatile organic treatment material, in order reheater and carry-over of
solids to the turbine.

DESUPERHEATERS
During start up of the unit, if desuperheating is used to match the outlet steam
temperature to the turbine metal temperatures, care must be exercised so as not
to spray down below a minimum of 100 C above the saturation temperature at the
existing operating pressure. Desuperheating spray is not particularly effective at
the low steam flows of start up. Spray water may not be completely evaporated but
be carried through the heat absorbing sections to the turbine where it can be the
source of considerable damage. During start up alternate methods of steam
temperature control should be considered. The location of the desuperheaters
helps to ensure against water carry - over to the turbine. It also eliminates the
necessity for high temperature resisting materials in the desuperheater
construction.

DESUPERHEATERS
Super heater & Reheater temp Control
SUPER HEATER ATTEMPRATOR
Type : Spray.
Spray water taken from U:5 BFP Header
U6:BFP Kicker stage.
Stage : One (Unit 5)/Two (Unit 6)
Position in steam circuit : Between LT pendants
and SH panels. (inlet to divisional panel)
Specification of material. : SA335 P12
Spray tube material : SA-213 T11
REHEATER ATTEMPERATOR
TYPE : Spray.
Spray water taken from U:5 BFP Header.
U6:BFP 2nd stage.
No. of stages of attemperator : One
Position in the steam circuit : Before RH Radiant wall
Specification of the Material : SA-106 Gr-B
Spray nozzle Material : SA-213T & SS Tips
HP & LP BYPASS SYSTEM
The function of HP bypass is to ensure that the maximum permissible pressure levels
between the turbine and the boiler are not exceeded and that no abrupt pressure surges
occur/develop during variable pressure operation of the unit.
The function of LP bypass is to control the pressure in the reheat system under certain
operating conditions like.
a) Start up & shutdown of turbine.
b) On partial load below the boiler minimum load.
c) In occurrence of fault like load rejection, unit trip out etc.
The HP-LP bypass system permits operators to increase boiler firing rate, boiler
steam flow and thus boiler outlet temperature to a higher level thereby providing more
suitable restart conditions for a hot turbine, within shortest possible time.

It should be noted that high boiler steam temperatures are desired only if the turbine is hot
(say above 400o C). The operation of HP-LP bypass may not be desirable for cold start-
ups.
During the load rejection which may occur due to electrical disturbances, turbine
governing system rapidly closes the steam admission valves. In such event, HP-LP
bypass has a capability of bypassing a large fraction of steam generated in boiler. This
can reduce the impact on boiler and the need to trip the fire.
The application of HP-LP bypass system reduces the solid particle erosion (also called as
silica purging during start up). Also, continuous cooling steam flow through superheater
and reheater tubes reduces the formation of oxide layer on the inner surface of the tubes.

The HP bypass is designed for 60% capacity having maximum steam flow of 270
Kg/second with -
1) upstream steam condition = 164.3 bar, 538 oC
2) downstream steam conditions = 27.3 bar, 337.8 oC
injection water conditions = 188 bar, 245/118 oC (max/min).
LP bypass has capacity corresponding to HP bypass max - steam flow i.e. 384 Kg/s with
1) upstream steam conditions = 41 bar, 538 o C.
2) downstream (before dumping device) steam conditions = 24.6 bar, 538oC
spray water quantity = 15306 Kg/s at CEP discharge pressure.

The HP bypass station is located at 29 M elevation above the TG building

arranged between main steam and cold reheat streamline, bypassing HP
turbine. In unit it consist of two (2) electrically operated steam converting
valves and electrical controllers having normal and high speed motor drives.
Operation time of motor drives

1) Normal speed - 45 sec.
2) High speed (on protection) - 5.6 sec.
Unit 6 HP bypass is hydraulically operated.

The H.P. Bypass system in co-ordination with LP-Bypass enables boiler operation and
loading independent of the turbine. This allows quick raising of steam parameters to a level
acceptable to turbine for rolling during start up. Steam is Bypassed from main steam line to
cold reheat line through HP-Bypass and from hot reheat line to condenser through LP
Bypass. The HP Bypass valve can handle a maximum of 60% of the full load turbine steam
flow.
The possible phases of operation of HP Bypass station can broadly be classified as follows:
 Boiler start-up with TG set on Barring Gear.
 Raising of steam parameters to a level acceptable for T.G. rolling, at a relatively
faster rate than otherwise is possible.
 Turbine loading while steam flow gets transferred to the turbine.
 Parallel operation with turbine on load rejection.
 Allowing boiler operation following turbine trip-out provided boiler load is less than
60 %.
 Preventing safety valves opening at raised steam pressures.

OVERRIDES AND INTERLOCKS

1. HP Bypass valve PCV opening less than 2 % will automatically close the spray water
pressure control valve (BD valve).
2. It opening of either of the Bypass valves PCV1 or PCV2 is above 2 %, the control of
spray temperature control valves TCV1 & TCV 2 shall be changed to ‘AUTO’ mode
irrespective of their initial conditions.
3. If PCV position drops 2 % open, it will receive an auto close command to ensure
positive shut-off.
4. If the steam temperature downstream of the PCV becomes 380 deg C, the closing
signal for these valves are initiated accompanied with an alarm. In this case, the
PCV controller will transfer itself from AUTO to MANUAL.
5. PCV closes on MFT
6. If spray water pressure less than 12 bar PCV will close.
The following will activate the ‘Fast Opening’ Signal :-

7. Generator breaker open.
8. Turbine load shedding relay operated
9. Pressure controller deviation more (+) 10 %.
10. Depressing of the ‘FAST OPEN’ push button
LP BYPASS SYSTEM
Low pressure Bypass system enables to establish an alternative pass for dumping the
steam from reheater outlet directly into condenser at suitable steam parameters. The
controls for LP-BYPASS system are essentially a combination of electrical and hydraulic
system. Electro-hydraulic converter provides the necessary link between hydraulic
actuators and the electrical system. The control of LP Bypass system is hooked up by the
same control which is used for turbine governing system.
The LP Bypass valves are two in number. the LP Bypass stop and control valves are
combined in a common body. The double shut-off arrangement separates the reheater from
the condenser during normal operation. In addition to these, two steam pressure control
valves, four injection water valves are provided for desuperheating purpose. This injection
water is taken from the discharge of the condensate extraction pumps.

LP BYPASS SYSTEM

LP BYPASS SYSTEM
LP BYPASS CONTROL SYSTEM
CONDENSER TEMPERATURE PROTECTION
The purpose of the condenser temperature protection is to protect the condenser from
excessively high steam inlet temperatures. Thermocouples output temperature signals are
passed to an interlock circuit which locks out the LP turbine Bypass station. Protective Closing
Of Bypass System (Condenser Back-Up Protection)
The LP Bypass valves will close automatically under the following normal conditions to prevent
damage to the condenser.
1. If the steam pressure downstream of LP Bypass valves is greater than 19 kg/cm2.

2. Condenser vacuum is low (0.4 kg/cm2 abs)
3. Spray water pressure is low (10 kg/cm2
4. Condenser wall temperature is high (90OC)- Only alarm.

STEAM GENERATOR WATER CIRCULATING
PUMP CONSTRUCTION
Each Boiler Water Circulation pump consists of a single stage

centrifugal pump on wet stator induction motor mounted within a
common pressure vessel. The vessel consists of three main parts a
pump casing, motor housing and motor covers. The motor is
suspended beneath pump casing and is filled with boiler water at full
system pressure. No seal exists between the pump and motor, but
provision is made to thermally isolate the pump from the motor in the
following respect:
Thermal Conduction: To minimize heat conduction, a simple

restriction in the form of thermal neck is provided.

PUMP CONSTRUCTION
Hot Water Diffusion:
To minimize diffusion of boiler water, a narrow annulus surrounds the rotor shaft,
between the hot and cold regions. A baffle ring restricts solids entering the
annulus.
Motor Cooling: The motor cavity is maintained at a low temperature by a heat
exchanger and a closed loop water circulation system, thus extracting the heat
conducted form the pump.
In addition, this water circulates through the stator and rotor bearings extracting
the heat generated in the windings and also provide bearing lubrication. An
internal filter is incorporated in the circulation system. In emergency conditions, if
low-pressure coolant to the heat exchanger fails, or is inadequate to cope with
heat flow from pump case, a cold purge can be applied to the bottom of the motor
to limit the temperature rise.

PUMP CONSTRUCTION

Pump:
The pump comprises a single suction and dual discharge branch casing. The case is welded
into the boiler system pipe work at the suction and discharge branches with the suction upper
most. Within the pump cavity rotates a key driven, fully shrouded, mixed flow type impeller,
mounted on the end of the extended motor shaft. Renewable wear rings are fitted to both the
impeller and pump case. The impeller wear ring is the harder component to prevent galling.
Motor:
The motor is a squirrel cage, wet stator, induction motor, the stator, wound with a special
watertight insulated cable. The phase joints and lead connections are also moulded in an
insulated material. The motor is joined to the pump casing by a pressure tight flange joint and
a motor cover completes the pressure tight shell. The motor shell contains all the moving
parts, except for the impeller. Below the impeller is situated an integral heat baffle which
reduces the heat flow, a combination of convection and conduction, down the unit. A baffle
wear ring-cum sleeve above the baffle forms a labyrinth with the underside of the impeller to
limit sediment penetration into the motor. Should foreign matter manage to pass the labyrinth
device into the motor enclosure, a filter located at the base of the cover end bearing housing
strains it out.

AUXILIARY COOLING CIRCUIT
The motor is provided with its own auxiliary cooling circuit, which besides cooling the motor
lubricates the bearings. The water is continuously circulated through the bearings, motor
windings and the external heat exchanger, (cooler), by an auxiliary impeller (thrust disc) at the
thrust bearing end of the motor shaft. When the motor is stationary, thermo-syphonic
circulation takes place to remove conducted heat from the pump end of the motor.
BEARINGS
The motor rotor shaft is supported by water lubricated tilting pad type radial and thrust
bearings mounted on the stator shell, thus making the motor internals into a separated
construction independent of the motor pressure vessel.
INTER FILTER
A stainless steel woven wire strainer, fitted at the base of the reverse thrust plate, filters the
liquid in the motor before it is circulated through the bearings after passing through the heat
exchanger (cooler). The filter should be cleaned at normal maintenance periods, removing
any accumulation of foreign matter in the motor cover.

HEAT EXCHANGER
A heat exchanger (cooler) is fitted to dissipate the heat generated by the motor
winding. Brackets are provided on the motor case to mount the heat exchanger.
High-pressure outlet and inlet-raised facings are situated bottom and top of the
motor case respectively for connection to high-pressure heat exchanger/motor
case stub pipes. Inter - connecting pipe work is short and direct with the heat
exchanger mounted as high as possible to promote good thermo syphonic
circulation when the unit is on hot standby.

PUMP SPECIFICATIONS
Make HAYWARD TYLER LIMITED

Type Single suction double discharge
Design Pressure 207.55 Kg/cm2
Design temp 366.2oC
Suction Pressure 193.27 Kg/cm2
Suction temp. 348.9oC
Specific gravity at pump Suction 0.5993
Qty. pumped 47994.2 lit/min
Differerential HEAD 28.65 M (94.00 ft)
Differential Pressure 1.708 Kg/cm2
Minimum NPSH required above 16.15 M (53 ft)
Vapour Pressure
Pump efficiency 84% Hot duty

Motor SPECIFICATIONS
Type Wet Stator -Squirrel Cage induction motor
Output 400 H.P.
Service factor 1.0
Motor case design temp 343.34OC
Motor efficiency 86%(Hot Duty), 88% ( Cold Duty)
K.W. Input 187 (Hot duty),302(Cold duty)
Power factor 0.7 (Hot duty), 0.805(Cold duty)
Overall efficiency 72.2% (Hot duty), 74.3%(Cold Duty)
Full load speed 1450 rpm

FILL AND PURGE OF CCW PUMP
ACW dish P/p
Raw wtr p/p
ACW O/H Tank
Fill and purge supply is from

1) BFP Dish, 2) CEP dish, 3) HMP

EMERGENCY COOLING WATER SUPPLY
V1
Normal ACW pumps disch.
Pr. Sw.
V3 SGWCP
Raw Water HEAT
EXCHANGER
V5
Emergency supply from
ACW overhead tank Maint. Door
V2
Normal return line
to ACW system
V4
To waste

TATA POWER TROMBAY
Air and Flue Gas System

DRAFT SYSTEM

What is the difference between
Fans, Blowers & Compressor ?

FANS
AXIAL FANS RADIAL FANS

Types of Fans
Axial Fans

RADIAL FANS
Control Dampers
Impeller
Rotor
Bearings
Casing

EQUIPMENTS IN AIR PATH

EQUIPMENT IN FLUE GAS PATH

A B ID FAN C D
ESP
FD
PA 5A A FAN
B PA 5B
RAPH-5A RAPH-5B
GR 5A GR 5B
RAPH

RAPH

RAPH

SECONDARY AIR CIRCUIT
350 DEG
S 35 degR
C SD SD
A
AIR FROM ATMOS SD- 2 A
P
P 8.1 10.1
H
H 8.2 10.2
B
B
FD B
SD-6
FROM GRF - B
-10 mm
• FURNACE
FROM GRF - A
SD-5
S SD R
SD-1
C
7.1 A SD
A P 9.1
P 7.2 H 9.2
AIR FROM ATMOS
H A
FD A A 35 DEG C 350 DEG
IGNITOR AIR
FAN

Flue gas system
ESP GD GD-19
GD- GD- GD-7 GD-15 GD-23
R 3.1 11A
5A ID A
3.2 11B
A
GD 29.1 29.2
P
H 20
8 12A 16 24
A 5B ID B GD
12B
27.1
27.2
Stack
GD 30.1 30.2 GD
GD 5.1 5.2
28.1
28.2
9
13A
R 5C 13B 17 ID C 25
A 21
P GD 31.1 31.2
GD
H GD-
4.1 14A
5D ID D
B 4.2 14B
GD- GD-10 GD-18 GD-26
GD-22

FD FANS

FD Fans LO System
 Control Oil  Fan Brg.  Motor Brg.
 12 Bar Norm  2.5 Bar Norm  2.5 Bar Norm
 8.0 Bar Alarm  0.8 Bar Alarm  0.8 Bar Alarm
 6.5 Bar Trip  0.5 Bar Trip  0.5 Bar Trip
ACCM
Filter A
FS
Cooler A
Cooler B
Filter B

WIND BOX
OF2
OF1
AA
Scanners Ignitors
A
AB
BC
CD
DE
EF
FG
GH
HH

PA FANS

PA Fans LO System
 Control Oil  Fan Brg.  Motor Brg.

 12 Bar Norm  2.5 Bar Norm  2.5 Bar Norm
 8.0 Bar Alarm  0.8 Bar Alarm  0.8 Bar Alarm
 6.5 Bar Trip  0.5 Bar Trip  0.5 Bar Trip
ACCM
Filter A
FS
Cooler A
Cooler B
Filter B

ID FANS

ID Fans LO System
 Fan Brg.  Motor Brg.

 2.5 Bar Norm  2.5 Bar Norm
 0.8 Bar Alarm  0.8 Bar Alarm
 0.5 Bar Trip  0.5 Bar Trip
ACCM
Filter A
Cooler A
Cooler B
Filter B

GR FANS

Igniter Air Fans
To Igniters Windbox
Auto changeover
Damper
Igniters Air Fan 5A Igniters Air Fan 5B
From FD fan Interconnection Damper

Scanner Air Fans
To Scanners To Scanners
Auto changeover
Damper
Scanner Air Scanner Air

Fan 5A Fan 5B
Suction From Atmosphere
From Igniter air fan discharge

SECONDARY AIR CIRCUIT
350 DEG
S 35 degR
C SD SD
A
AIR FROM ATMOS SD- 2 A
P
P 8.1 10.1
H
H 8.2 10.2
B
B
FD B
SD-6
FROM GRF - B
-10 mm
• FURNACE
FROM GRF - A
SD-5
S SD R
SD-1
C
7.1 A SD
A P 9.1
P 7.2 H 9.2
AIR FROM ATMOS
H A
FD A A 35 DEG C 350 DEG
IGNITOR AIR
FAN

TATA POWER TROMBAY
Stotiometric Air & Excess Air
• Air is required for combustion process

which is supplied by 2 No. of FD Fans.
• Flue gases generated by combustion
process are removed by 4 No. of ID fans.
• Excess air is maintain for complete
combustion.

What is an ESP???

Principle behind ESP
•
BOILER FUEL SYSTEM

TANGENTIAL FIRING
2 3
1 4
4
4

BOILER SPECIFICATION
Unit 5: (100% MCR) Unit 6: (100% MCR)
• Drum pressure - 191 bar • Drum pressure - 184 bar
• Steam flow - 423 Kg/Sec

• Steam flow - 446 Kg/Sec
• Main steam Temp- 541 ºC • Main steam Temp- 541 ºC
• Reheat Temp • Reheat Temp - 568 ºC

- 541 ºC

BOILER FUEL SYSTEM

BOILER FUEL SYSTEM

FUEL OIL TANK FARM

IGNITION OIL PUMPS

LC OIL PUMPS

BOILER FUEL OIL SYSTEM

Ignition Oil CPRV

IGNITOR AIR AND SCANNER AIR
SYSTEM
• Ignitor Air system provides combustion air
to Ignitors
• Scanner air system is used for providing
cooling air for Flame Scanners
• Secondary air system should be
established prior to taking Ignitor air
system and Scanner air system in service

Unit 5
LC trip
Valve LC Oil
Control
V/V
Coal Mills
•
Coal Mills and Coal Feeders
•
LUBRICATION SYSTEM OF COAL
MILL
•
SEAL AIR SYSTEM
•
BOILER LIGHT UP

BOILER LIGHT UP

BOILER TRIP

BOILER TRIP


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Boiler

TROMBAY THERMAL POWER STATION

TROMBAY THERMAL POWER STATION

TROMBAY THERMAL POWER STATION

Feed water from BFP DISH

TROMBAY THERMAL POWER STATION

TROMBAY THERMAL POWER STATION

2) Steam Pressure - Design - 204 Kg/Cm2 (g)

TROMBAY THERMAL POWER STATION

5) Economizer : Type - Bare tube

6) Furnace : Type - Fusion Welded

7) Air heater : Type - LJUNSTROM - Regenerative type Make BHEL

TROMBAY THERMAL POWER STATION

This is achieved by three/four numbers of glandless pump and wet

TROMBAY THERMAL POWER STATION

Uniform drum cooling and heating. In controlled circulation boilers this is

TROMBAY THERMAL POWER STATION

TROMBAY THERMAL POWER STATION

This is one of the extraordinary features of 500 MW capacity boilers. Because of

TROMBAY THERMAL POWER STATION

OF2 OPENING STARTS AT 50% OPEN FULL AT 75% OF BOILER LOAD

OF1 OPENING STARTS AT 75% OPEN FULL AT 100% OF BOILER LOAD

TROMBAY THERMAL POWER STATION

 Fuel air damper: AB,BC,CD,DE,EF

 Auxiliary air damper: A,B,C,D,E,F

 Auxiliary air damper AA:

TROMBAY THERMAL POWER STATION

As compared to trisector air pre-heater in 200 MW units, 500 MW units

TROMBAY THERMAL POWER STATION

TROMBAY THERMAL POWER STATION

TROMBAY THERMAL POWER STATION

Electro static precipitators are installed in the 500 MW units for

TROMBAY THERMAL POWER STATION

1 Manufacturer M/s BHEL (C.E. Design)

Balanced Draft, Dry bottom, Single

3 Type of Firing Tangential firing

TROMBAY THERMAL POWER STATION

Height from furnace bottom

TROMBAY THERMAL POWER STATION

TROMBAY THERMAL POWER STATION

TROMBAY THERMAL POWER STATION

TROMBAY THERMAL POWER STATION

TROMBAY THERMAL POWER STATION

superheater safety valve is provided as a working valve to given an initial indication of

Desuperheaters are provided in the superheater-connecting link and the

TROMBAY THERMAL POWER STATION

TROMBAY THERMAL POWER STATION

TROMBAY THERMAL POWER STATION

TROMBAY THERMAL POWER STATION

TROMBAY THERMAL POWER STATION

The HP bypass station is located at 29 M elevation above the TG building

Operation time of motor drives

Unit 6 HP bypass is hydraulically operated.

TROMBAY THERMAL POWER STATION

TROMBAY THERMAL POWER STATION

OVERRIDES AND INTERLOCKS

The following will activate the ‘Fast Opening’ Signal :-

TROMBAY THERMAL POWER STATION

TROMBAY THERMAL POWER STATION