SIPAT SUPER THERMAL POWER PROJECTSIPAT SUPER THERMAL POWER PROJECT

SIPAT STAGE # 1 BOILERSIPAT STAGE # 1 BOILER

ECO. JUNTION HEADERS

ECO I/L HDR

ECONOMISER

ECO O

/L

HDR

ECO. O/L LINKS

ECO. MIXING PIECE

BOTTOM RING HEADER

SPIRAL WALL

INTERMITTENT HEADERS

VERTICAL WALL

OUTLET HEADERS

ECONOMISER TO 1 ST PASS TOP HEADERSECONOMISER TO 1 ST PASS TOP HEADERS : :

ECONOMISER ECONOMISER ::

COUNTER FLOWCOUNTER FLOW4 BANKS4 BANKS163 ASSEMBLIES163 ASSEMBLIES4 JUNCTION HEADERS4 JUNCTION HEADERS224 HANGER TUBES224 HANGER TUBESECO OUTLET HEADERECO OUTLET HEADERSA 106 C ; SA 210 CSA 106 C ; SA 210 C

SPIRAL AND VERTICAL WALLSSPIRAL AND VERTICAL WALLS : :TOTAL SPIRAL TUBES : 440 (102X2 FRONT & REAR; 108X2 TOTAL SPIRAL TUBES : 440 (102X2 FRONT & REAR; 108X2

LEFT & RIGHT) LEFT & RIGHT)

SPIRAL TO VERTICAL RATIO = 1:3SPIRAL TO VERTICAL RATIO = 1:3

FRONT VERTICAL TUBES: 336FRONT VERTICAL TUBES: 336SIDE WALL TUBES: 648SIDE WALL TUBES: 648REAR SCREEN TUBES : 280REAR SCREEN TUBES : 280REAR HANGER TUBES : 56REAR HANGER TUBES : 56

TUBES : T22TUBES : T22HEADERS : P12HEADERS : P12

STORAGE TANK

MIXING PIECE FLASH

TANK

CONDENSER

BOILER FILL LINEFEED WATER LINE

TO ECONOMISERBCP

WR ZR

UG

STORAGE TANK

MIXING PIECE FLASH

TANK

CONDENSER

BOILER FILL LINEFEED WATER LINE

TO ECONOMISERBCP

WR ZR

UG

START UP SYSTEMSTART UP SYSTEM : :

SEPERATOR TANKS

1ST PASS ROOF O/L HEADERS

SEPERATORS I/L LINKS

EXTENDED WALLEXTENDED WALL : :22NDND PASS STEAM FLOW PASS STEAM FLOW : :

BACK PASS BOTTOM RING HDR

BACK PASS TOP LHS HDR

BACK PASS TOP RHS HDR

BACK PASS ROOF I/L HDR

EXTENDED WALL HDR

1ST PASS ROOF I/L HDR

EXTENDED WALL

BACK PASS WALLS & HEADERSBACK PASS WALLS & HEADERS : :

FURNACE FRONT ROOF : FURNACE FRONT ROOF : 168168BACK PASS ROOF : 111BACK PASS ROOF : 111BACK PASS REAR WALL : BACK PASS REAR WALL : 111111BACK PASS SIDE WALL : BACK PASS SIDE WALL : 328328BACK PASS FRONT WALL : BACK PASS FRONT WALL : 167167BACK PASS SCREEN : 167BACK PASS SCREEN : 167

TUBES : T12TUBES : T12HEADERS : P12HEADERS : P12

EXTENDED WALLEXTENDED WALL : :

EXTENDED WALL FLOOR : 142EXTENDED WALL FLOOR : 142EXTENDED SIDE WALL : 142EXTENDED SIDE WALL : 142

TUBES : T12TUBES : T12HEADERS : P12HEADERS : P12

FLUID COOLED SPACER TUBES: FLUID COOLED SPACER TUBES: 33

BACK PASS WALLS & HEADERSBACK PASS WALLS & HEADERS : :

LINK PIPES : P12LINK PIPES : P12

SEPERATORS & SEPERATORS & STORAGE TANK : SA STORAGE TANK : SA

302C 302C

START UP SYSTEMSTART UP SYSTEM : :

LINK PIPES : P12LINK PIPES : P12

SEPERATORS & SEPERATORS & STORAGE TANK : SA STORAGE TANK : SA

302C 302C

FROM II nd PASS BOTTOM RING LHS HDR

FROM II nd PASS BOTTOM RING RHS HDR

DIV. PANEL I/L HDR

DIV. PANEL I/L HDR

DIV. PANEL O/L HDR

DIV. PANEL O/L HDR

DIV. PANEL

DIV. PANEL

II ND PASS TOP RHS HDR

II ND PASS TOP LHS HDR

DIVISIONAL PANELDIVISIONAL PANEL : :

SH DIV. PANEL TUBES : 480SH DIV. PANEL TUBES : 480 TUBES : T23; T91TUBES : T23; T91HEADERS : P12; P23HEADERS : P12; P23

FLUID COOLED SPACER TUBES : FLUID COOLED SPACER TUBES : 66

DIV. PANEL O/L HDR

PLATEN I/L HDR

PLATEN O/L HDR

PLATEN COILS

DIV. PANEL I/L HDR

DIV. PANEL I/L HDR

PLATEN TO FINAL SH LINK

DIV. PANEL O/L HDR

FINAL SH I/L HDR

FINAL SH O/L HEADERS

TO HP TURBINE

FINAL SH COILS

DIV. PANEL TO PLATEN LINK

PLATEN AND FINAL SHPLATEN AND FINAL SH : :

PLATEN ASSEMBLIES : 20PLATEN ASSEMBLIES : 20NO OF TUBES : 480NO OF TUBES : 480 TUBES : T12; T23; T91TUBES : T12; T23; T91HEADERS : P12; P23HEADERS : P12; P23

NO OF STAGES : 2NO OF STAGES : 2ASSMBLIES : 2X55ASSMBLIES : 2X55NO OF TUBES : 935 NO OF TUBES : 935

TUBES : T23; T91TUBES : T23; T91HEADERS : P23; HEADERS : P23; P91P91

COUNTER FLOW DIRECTIONCOUNTER FLOW DIRECTION

LTRH O

/L HDR

FINAL R

H I/L HDR

FINAL

RH O

/L HDRS

LTRH BANKS

LTRH

O/L

TO FI

NAL R

H I/L L

INKS

TO IPT

TO IPT

FINAL RH

LTRH

I/L

HDR

FROM CRH

FROM CRH

REHEATERSREHEATERS : :

NO OF BANKS : 3NO OF BANKS : 3NO OF TUBES : 111NO OF TUBES : 111 TUBES : SA 210C; T12; T23TUBES : SA 210C; T12; T23HEADERS : SA 106C; P12HEADERS : SA 106C; P12

NO OF ASSEMBLIES : 41NO OF ASSEMBLIES : 41NO OF TUBES : 615NO OF TUBES : 615 TUBES : T23; T91; SUPER 304HTUBES : T23; T91; SUPER 304HHEADERS : P12; P91HEADERS : P12; P91

HPTIPTLPT

CONDENSER

FEED WATER

FRS

STORAGE TANK

SEPARATOR

BWRP

Spiral w

ater walls

MS LINE

HRH LINE

VERTICAL WW

ECO I/L

ECO JUNCTION

HDR

ECO HGR O/L HDR

FUR LOWER HDR

FUR ROOF I/L HDR

DIV PANELS SH PLATEN SH

FINAL RH

FINAL SH

LTRH

ECONOMISER

290°C, 302 KSC

411°C, 277Ksc

411°C, 275 Ksc

492°C, 260 Ksc

540°C, 255 Ksc

305°

C, 4

9 K

sc

457°C, 49 Ksc

568°C, 47 Ksc

GLPT

FEATURES OF SUPER CRITICAL BOILERFEATURES OF SUPER CRITICAL BOILER : :

1. 1. ONCE THROUGH OPERATIONONCE THROUGH OPERATION : :

FEED WATER PUMP

ECONOMISER WATER WALL/ EVAPORATOR SEPERATOR SUPERHEATER

STORAGETANK

RECIRCULATION

PUMP

CONSTANT WATER WALL FLOWCONSTANT WATER WALL FLOW (below 30% load)(below 30% load)

FEED WATER PUMP

ECONOMISER WATER WALL/ EVAPORATOR SEPERATOR SUPERHEATER

ONCE THROUGH FLOW OPERATION (above 30% ONCE THROUGH FLOW OPERATION (above 30% load)load)

2. CONSTANT PRESSURE OPERATION :2. CONSTANT PRESSURE OPERATION :

Above 90% & below 30% Above 90% & below 30%

3. SLIDING PRESSURE OPERATION :3. SLIDING PRESSURE OPERATION :

B/W 30% & 90% B/W 30% & 90%

1. No additional pressure loss between boiler and turbine

2. Low Boiler Pr. at low loads

- Less fatigue of Pr. part components

- Longer life of all components, Less wear of components

- Less Maintenance

3. Lower thermal stresses in the turbine during load changes

4. Control range of RH temp is extended

5. Overall reduction in power consumption and improved heat rate

ADVANTAGES OF SLIDING PRESSURE OPERATIONADVANTAGES OF SLIDING PRESSURE OPERATION

DESCRIPTIONDESCRIPTION UNITUNIT 660 MW AT BMCR660 MW AT BMCR

S/H STEAM FLOWS/H STEAM FLOW T/HRT/HR 22252225 SH STEAM PRSH STEAM PR KG/CMKG/CM22 256256SH STEAM TEMPSH STEAM TEMP 00CC 540540RH STEAM FLOWRH STEAM FLOW T/HRT/HR 17421742RH STEAM TEMP RH STEAM TEMP INLETINLET 00CC 299299RH STEAM TEMP OUTLETRH STEAM TEMP OUTLET 00CC 568568RH STEAM PRESS RH STEAM PRESS OUTLET OUTLET KG/CMKG/CM22 46.6146.61FEED WATER TEMPFEED WATER TEMP 00CC 289.64289.64SECONDARY AIR FLOWSECONDARY AIR FLOW T/HRT/HR 17321732PRIMARY AIR FLOWPRIMARY AIR FLOW T/HRT/HR 946946TOTAL COAL FLOWTOTAL COAL FLOW T/HRT/HR 472472

660MW PARAMETERS :

FEATURES OF 660 MW- STEAM QUALITY PARAMETERSFEATURES OF 660 MW- STEAM QUALITY PARAMETERS

S.NO.S.NO. PARAMETERPARAMETER

STEAM QUALITY AT STEAM QUALITY AT SG OUTLETSG OUTLET

DURING START UPDURING START UP DURING DURING NORMAL NORMAL

OPERATIONOPERATION11 TDSTDS 2020 2222 SILICASILICA 2020 2233 SODIUMSODIUM 1010 2244 CHLORIDESCHLORIDES 00 2255 COPPERCOPPER 2020 1166 IRONIRON 1010 5577 CATION CATION

CONDUCTIVITYCONDUCTIVITY<0.2 to 0.25 micro <0.2 to 0.25 micro

siemens /cmsiemens /cm<-0.2 micro <-0.2 micro siemens / cm siemens / cm

88 PHPH 6~86~8

COMMISSIONING COMMISSIONING NETWORKNETWORK

ID FAN # 1A TRIAL RUN

FD FAN # 1A TRIAL RUN

SAPH # 1A TRIAL RUN

BRP TRIAL RUN

SACNNER AIR SYSTEM READINESS

FURNACE READINESS

FUEL OIL SYSTEM READINESS

DDCMIS FSSS READINESS

MFT CHECKING

GATES, DAMPERS / VALVES

TG :

SG :

SG ECW SYSTEM

CW SYSTEM READINESS

CHEMICAL CLEANING OF BOILER

MS Line Welding Completion

CRH Line Welding Completion

HRH Line Welding Completion

MS Line Hanger Erection Cold Setting

CRH Line hangers Cold Setting

HRH Line Hangers Cold Setting

MS Line Insulation CRH Line Insulation HRH Line Insulation

MS Line HT CRH Line HT HRH Line HT

COMPRESSED AIR SYSTEM READINESS

AUX PRDS READINESS

ACW System

Temporary Piping Completion

Boiler Light Up & Steam Blowing

MDBFP Trial

CEP Trial

TG ECW System

HOT Well Readiness

LIST OF APPROVED PROCEDURESLIST OF APPROVED PROCEDURES

Boiler Commissioning is carried out based on the guide Boiler Commissioning is carried out based on the guide lines of Corporate commissionin groups. OS) These are the lines of Corporate commissionin groups. OS) These are the list of approved commissioning procedures which are list of approved commissioning procedures which are followed in sipat commissioning activitiesfollowed in sipat commissioning activities

1. BOILER HYDRO TEST1. BOILER HYDRO TEST

2. OIL FLUSHING OF ROTARY MACHINES2. OIL FLUSHING OF ROTARY MACHINES

3. BOILER & DUCTS AIR TIGHTNESS TEST (ATT)3. BOILER & DUCTS AIR TIGHTNESS TEST (ATT)

4. ESP AIR IN LEAK TEST4. ESP AIR IN LEAK TEST

5. ESP GAS DISTRIBUTION (GD) TEST5. ESP GAS DISTRIBUTION (GD) TEST

6. BOILER CHEMICAL CLEANING6. BOILER CHEMICAL CLEANING

7. BOILER COLD AIR VELOCITY TEST7. BOILER COLD AIR VELOCITY TEST

8. CLEAN AIR FLOW TEST8. CLEAN AIR FLOW TEST

9. LDO & HFO SYSTEMS COMMISSIONING9. LDO & HFO SYSTEMS COMMISSIONING

10. BOILER & AUX LINES STEAM BLOWING10. BOILER & AUX LINES STEAM BLOWING

COMMISSIONING MILE STONESCOMMISSIONING MILE STONES1. BOILER HYDRO TEST : HP SYSTEM : Hydro test done on 20.12.2006 HP system hydro test is done at 410 KSC. HP system consists of

Economiser, boiler 1st & 2nd pass, divisional panel, platen & final super heater upto boiler stop valves.

MP SYSTEM : Hydro test done on 26.03.2008 MP system hydro test is done at 80.1 KSC. MP system consists of CRH

isolator to LTRH, Final Reheater upto HRH isolators.2. BURNER TILT, OIL GUNS & IGNITOR CHECKING : Checking is completed on 24.12.2007 Burner tilt checking is done from inside the boiler in which burner

limits +300 & - 300 angles adjusted. Oil guns & ignitors clearances are checked inside the boiler.

3. FD, ID & PA FANS COMMISSIONING : FD Fan # 1A trial run taken on 03.03.2010

ID Fan # 1A trial run taken 15.03.2010 PA Fan # 1A trial run taken 18.03.2010

COMMISSIONING MILE STONESCOMMISSIONING MILE STONES3. FD, ID & PA FANS COMMISSIONING : FD Fan # 1B trial run taken on 22.06.2010

ID Fan # 1B trial run taken 21.06.2010 PA Fan # 1B trial run taken 22.06.2010

Fans commissioning involves following steps: Lube oil flushing of lube oil skid, lube oil lines with flushing oil (32

grade) (bearings bypassed) (Completion criterion is Moisture & Mechanical impurities should be below 100 ppm)

Lube oil flushing through bearings (32 grade) Lube oil flushing through bearings (68 grade oil) Blade pitch commissioning & discharge gate commng. Cooling water lines flushing & charging Fan trial4. AIR PREHEATERS COMMISSIONING : SAPH # 1A trial run taken on 27.03.2010SAPH # 1B trial run taken on 20.04.2010

4. AIR PREHEATERS COMMISSIONING : PAPH # 1A trial run taken on 29.03.2010PAPH # 1B trial run taken on 20.04.2010

Air Preheaters commissioning involves following steps:

Lube oil motors & main motor no load trial

Lube oil flushing of Support & Guide bearings with 32 oil (Completion criterion is Moisture & Mechanical impurities should be below 100 ppm)

Lube oil flushing through bearings (32 grade)

Lube oil flushing through bearings (680 grade oil)

Air motor service air line blowing

Cooling water lines flushing & charging

Air preheater trial with air motor & electrical motor

4. BOILER & DUCT ATT : Secondary air duct ATT is completed on 01.04.2010

Primary air duct ATT is completed on 05.05.2010 Flue gas air duct ATT is completed on 24.04.2010 Furnace ATT completed on

ATT of boiler & ducts is done at 150 mm of water column. Secondary air duct & boiler pressurisation is done by FD Fan. Primary air duct pressurisation is done by PA fan. Flue gas duct pressurisation is done by using temporary blowers

5. ESP COMMISSIONING : ESP Air In Leak test: All passes air in leak test completed on

09.11.2008 The test is done to prove that air in leak into ESP is with in

guaranteed value of 1% of design gas flow rate. ESP Rapping system commng. : All passes rapping systems

commng. completed on 21.07.2010 Each Pass has 18 nos. collecting electrodes rapping system, 18 nos

emitting electrode rapping system & 2 nos. gas distribution plates rapping system.

5. ESP COMMISSIONING : ESP Fields charging ESP GD test completed on 25.08.2010This is done to verify uniform flow distribution inside the ESP Chambers. 6. BOILER CAVT : CAVT (Cold Air Velocity Test) is completed on 03.09.2010This test is done to check flue gas flow patterns inside the boiler.7. AIR BALANCE TEST (ABT): 8. BOILER CHEMICAL CLEANING : Boiler Chemical cleaning is completed on 30.09.2010

Chemical cleaning involves following steps: Flushing Acid Cleaning Rinsing Pre Neutralization Neutralization Passivation

Main chemicals used are formic acid (10%), sorbic acid, coronil 200S Boiler chemical cleaning is completed in 7 days.

9. BRP (Boiler Recirculation Pump) COMMISSIONING : BRP trial completed on 13.10.2010 BRP commissioning involves following steps: Cavity filling line flushing (until Conductivity & Turbidity reaches

required parameters) Flushing through motor cavity & through cooler ECW lines water flushing Pump trial10. BOILER LIGHT UP : Boiler is Lighted Up on 27.10.10Boiler is lighted up with LDO and all 4 corner oil guns were

proven.11. STEAM BLOWING : It has following stepsPRE STEP1: Separator Superheater Main Steam Line Main Stop Valve Temporary Piping Temporary MOV Tailpipe to atmosphereBlowing is done from 40 KSC to 20 KSC

11. STEAM BLOWING : Steam blowing consists of following steps:PRE STEP 2: Separator Superheater Main Steam Line HP Bypass Valve Cold RH line backward flush through drain pot near RH inletheader Temporary Piping tailpipe to atmosphereBlowing is done from 40 KSC to 20 KSCMAIN STEP 1:Separator Superheater Main Steam Line Main Stop Valve Temporary Piping Temporary MOV Non-return Valve ColdReheat Line Reheater Hot Reheat Line IPT Stop Valve Tailpipe to atmosphereBlowing is done from 80 KSC to 40 KSCMAIN STEP 2:Separator Superheater Main Steam Line Main Stop Valve Temporary Piping Temporary MOV Non-return Valve ColdReheat Line Reheater Hot Reheat Line LP Bypass Valve Tailpipe to atmosphereBlowing is done from 80 KSC to 40 KSC

11.PF SYSTEM COMMISSIONING: (a) Seal air fan & its dampers(b) Mills commissioning: Lube oil pumps load trial

Lube oil flushing of oil line with 32 oil bypassing gear box & bearings (Completion criterion is Moisture & Mechanical impurities should be below 100 ppm)

Lube oil flushing through bearings & gear box(32 grade)

Lube oil flushing through bearings (320 grade oil)

Cooling water lines flushing & charging

Roller & Bowl gap adjustment

Spring tension adjustment

P&I checks & Mill solo run.

11.PF SYSTEM COMMISSIONING: (C) RC Feeders Motor checks

P&I checking

Feeder belt trial with clean out conveyor.

(D)Commissioning of gates & dampers Commng of HAD, CAD, HAG, CAG, BIG, MDV from remote

(E) Clean air flow test of mills as per approved procedure

PROBLEMS & PROBLEMS & MODIFICATIONSMODIFICATIONS

1. Provision of manholes in ducts & hoppers 2. Oil gun cleaning system 3. BRP fill line from boiler fill pump 4. FD, ID & PA fans blade pitch local indication 5. Black Start Up line in unit # 16. Additional vents are provided in SGECW system7. Boiler headers & links replacement

BOILER HEADERS REPLACEMENTS

Some of the super heater headers were replaced with higher grade materials.

5 nos. of headers & link pipes of Gr P23 were replaced with Gr P91.

This material replacement is done to avoid probable material failure in the pipes and fittings of the boiler subjected to very high temperature and pressures.