Jaypee Nigrie Super Thermal

L&T-MHI BOILERS PVT.

Power Project, 2 x 660 MW
LIMITED
Nigrie, Singraulli, MP
Steam Generator and Technical Diary
Auxiliaries Package

OF
JAYPEE NIGRIE SUPER THERMAL POWER
PROJECT, 2 X 660 MW STEAM GENERATOR
AND AUXILIARIES PACKAGE

Issued For Information Dharmesh Srivastava Sanjeev Padhy Ajay Kumar Jain 12th March 2012 1
Description Prepared By Checked By Approved By Dated Page No.
 Jaypee Nigrie Super Thermal
L&T-MHI BOILERS PVT.
Power Project, 2 x 660 MW
LIMITED
Nigrie, Singraulli, MP
Steam Generator and Technical Diary
Auxiliaries Package

CONTENTS
SR. NO. ITEM DESCRIPTION PAGE NO.
1. BOILER SPECIFICATION 3
2. WATER-WALL TUBES 4
3. WATER SEPARATOR 4
4. WATER SEPARATOR DRAIN TANK 4
5. ROOF TUBES 5
6. BACK PASS AND PASSAGE WALL TUBES 5
7. PRIMARY SUPERHEATER 5
8. SECONDARY SUPERHEATER 6
9. TERTIARY SUPERHEATER 6
10. PRIMARY REHEATER 7
11. SECONDARY REHEATER 7
12. DE-SUPERHEATERS 7
13. ECONOMIZER (SPIRAL FINNED TUBE) 8
14. ECONOMIZER (HANGER TUBE) 8
15. WATER HOLDING CAPACITY 8
16. SPECIFICATION OF HEADERS (To Be Revise)* 9
17. BOILER CIRCULATION PUMP SPECIFICATION 10
18. REGENERATIVE AIR PREHEATER 10 & 11
19. INDUCED DRAFT FAN (ID FAN) 11
20. FORCED DRAFT FAN (FD FAN) 11
21. PRIMARY AIR FAN (PA FAN) 12
22. PULVERIZER SEAL AIR FAN 12
23. FLAME DETECTOR COOLING AIR FAN 12
24. LIGHT DIESEL OIL (LDO) BURNER 13
25. HEAVY FUEL OIL (HFO) BURNER 13
26. COAL BURNER 13
27. COAL FEEDER 13
28. PULVERIZER 14
29. COAL SILO 14
30. AUXILIARY BOILER SPECIFICATION 15 To 22
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.

Issued For Information Dharmesh Srivastava Sanjeev Padhy Ajay Kumar Jain 12th March 2012 2
Description Prepared By Checked By Approved By Dated Page No.
 Jaypee Nigrie Super Thermal
L&T-MHI BOILERS PVT.
Power Project, 2 x 660 MW
LIMITED
Nigrie, Singraulli, MP
Steam Generator and Technical Diary
Auxiliaries Package

BOILER SPECIFICATION

Subject Specifications
Boiler Designer Mitsubishi Heavy Industries Ltd., Japan
Boiler Maker Larsen & Toubro Ltd., India
Boiler Maker No. LMB 0001 & LMB 0002
Supercritical, Sliding Pressure Operation, Once
Boiler Type
Through Boiler and Single Reheat Cycle
Main Steam Flow 2,322 TPH
Reheater Steam Flow 1886 TPH
Design Pressure at Super heater Outlet 269 Kg/cm² (26.40 MPa)
Superheated Outlet Pressure (at BMCR) 256 Kg/cm² (25.12 MPa)
Design Temperature of Super-Heater 571 °C
Superheated Outlet Temperature (at BMCR) 568 °C
Design Pressure of Cold Reheat Inlet 73 Kg/cm² (7.20 MPa)
Cold Reheat Inlet Pressure (at BMCR) 63 Kg/cm² (6.1 Mpa)
Cold Reheat Inlet Temperature (at BMCR) 350 °C
Design Pressure of Hot Reheat Outlet 71 Kg/cm² (7.0 MPa)
Hot Reheat Outlet pressure (at BMCR) 60 Kg/cm² (5.93 MPa)
Design Temperature of Re-Heater 604 °C
Hot Reheat Outlet Temperature (at BMCR) 596 °C
Feed Water Temperature at Economizer Inlet 312 °C
Enthalpy of Superheated Steam at 256 Kg/cm²
810 Kcal/Kg
(Pressure) and 568 °C (Temp.)
Excess Air at BMCR 15%
Drafting System Balance Draft
Ambient Temperature Average in Winter 25.0 °C
Ambient Temperature Average in Summer 48.0 °C
Changing Point Between Wet & Dry Operation 30% MCR
Fuel Coal (Diesel Oil Start-up and Support)
Grade of Automatic Operation Fully Automated on Boiler Operation
Total Heating Surface Area 83357 m²
Water Wall (Radiant Zone) 4827 m²
Water Wall (Convective Zone) 5426 m²
Economizer 23306 m²
Primary Super Heater 12434 m²
83357 m²
Secondary Super Heater 5410 m²
Tertiary Super Heater 2192 m²
Primary Re-Heater 24012 m²
Secondary Re-Heater 5750 m²

Issued For Information Dharmesh Srivastava Sanjeev Padhy Ajay Kumar Jain 12th March 2012 3
Description Prepared By Checked By Approved By Dated Page No.
 Jaypee Nigrie Super Thermal
L&T-MHI BOILERS PVT.
Power Project, 2 x 660 MW
LIMITED
Nigrie, Singraulli, MP
Steam Generator and Technical Diary
Auxiliaries Package

WATER-WALL TUBES

Subject Specifications
Type Membrane Wall
Furnace Width 27.278 m
Furnace Depth 13.267 m
Furnace Height (Furnace Lower Header to Roof) 61.050 m
Furnace Volume 20649 m³
Effective Projected Radiation Surface (EPRS) 5437 m²
Tube OD 28.6 mm
Operating Pressure (WS Outlet) 26.8 MPa (BMCR)
Pitch 44.5 mm
Tube Material SA-213T12

WATER SEPARATOR

Subject Specifications
Outside Diameter 1000 mm
Thickness 120 mm
Height (Shell End to End) 3.31 m
Shell Material SA182F12-2
Design Pressure 28.4 MPa
Design Temperature 450 °C
Shell Material SA387F11-2
Operating Medium Steam/Water

WATER SEPARATOR DRAIN TANK

Subject Specifications
Outside Diameter 1000 mm
Thickness 120 mm
Height (Shell End to End) 14.7 m
Shell Material SA387F11-2
Design Pressure 28.4 MPa
Design Temperature 450 °C
Operating Medium Water
No. of Water Separator Drain Tank Per Boiler 02 (Two)

Issued For Information Dharmesh Srivastava Sanjeev Padhy Ajay Kumar Jain 12th March 2012 4
Description Prepared By Checked By Approved By Dated Page No.
 Jaypee Nigrie Super Thermal
L&T-MHI BOILERS PVT.
Power Project, 2 x 660 MW
LIMITED
Nigrie, Singraulli, MP
Steam Generator and Technical Diary
Auxiliaries Package

ROOF TUBES

Type Membrane Panel

Design Pressure 29.8 MPa
Heating Surface Area 1130.7 m²

No. Of Tube Size (mm)

Tube Material Tube Pitch (mm)
Tubes OD Thickness
Roof Front 408 SA213-T12 45.0 10.4 66.75
Roof Rear 204 SA213-T12 57.1 8.9 133.50

BACK PASS AND PASSAGE WALL TUBES

Type Fin Welded Panels

Design Pressure 29.30 MPa
Heating Surface Area 5426.34 m²

No. Of Tube Size (mm)

Tube Material Tube Pitch (mm)
Tubes OD Thickness
2ry Pass Front Wall
-Lower 204 SA213-T12 38.1 9.9 133.5
-Screen 102 SA213-T12 45.0 8.4 267.0
2ry Pass Rear Wall - Upper 203 SA213-T12 38.1 9.9 133.5
2ry Pass Side Left & Right
2x116 SA213-T12 38.1 9.9 111.25
Side Wall
2ry Pass Division Wall
-Screen 136 SA213-T12 45.0 7.4 200.25
-Lower 272 SA213-T12 38.1 9.9 100.125
Passage Left & Right Side
2x83 SA213-T12 38.1 9.9 89
Wall

PRIMARY SUPERHEATER

Type Panel, Drainable

Design Pressure 28.1 MPa (I/L) & 27.8 MPa (O/L)
Heating Surface Area 12,434 m²

Panel Pitch No. Of Tube Size (mm) Tube Pitch

Description Material
(mm) Panels OD Thickness (mm)
Upper 133.5 204 SA213-T12 45.0 6.9 80.0
Lower 133.5 204 SA213-T12 45.0 6.9 80.0

Issued For Information Dharmesh Srivastava Sanjeev Padhy Ajay Kumar Jain 12th March 2012 5
Description Prepared By Checked By Approved By Dated Page No.
 Jaypee Nigrie Super Thermal
L&T-MHI BOILERS PVT.
Power Project, 2 x 660 MW
LIMITED
Nigrie, Singraulli, MP
Steam Generator and Technical Diary
Auxiliaries Package

SECONDARY SUPERHEATER

Type Platen, Non-Drainable

Design Pressure 27.8 MPa
Heating Surface Area 5410.03 m²

Panel Pitch No. Of Tube Size (mm)

Material Tube Pitch (mm)
(mm) Panels OD Thickness
SA213-T12 31.8 7.9/7.4 54.5
ASME Code Case 2328-1 45.0 5.9 54.5
ASME Code Case 2328-1 45.0 5.4 54.5
ASME Code Case 2328-1 45.0 6.9/8.4 54.5
1602 16 SA213-T12 38.1 6.4 54.5
SA213-T12 31.8 5.9 54.5
SA213-T12 31.8 6.4 54.5
SA213-T91 45.0 9.4 54.5
SA213-T22 45.0 9.9 -
ASME Code Case 2328-1 45.0 6.9 -
Supporting
- SA213-T12 45.0 6.9 -
Tube
SA213-T91 45.0 5.4 -

TERTIARY SUPERHEATER

Type Pendent, Non-Drainable

Design Pressure 27.3 MPa
Heating Surface Area 2,192 m²

Panel Pitch No. Of Tube Size (mm)

Material Tube Pitch (mm)
(mm) Panels OD Thickness
ASME Code Case 2328-1 45.0 4.9 54.5
ASME Code Case 2328-1 45.0 5.4 54.5
534 50 ASME Code Case 2328-1 45.0 5.9 54.5
SA213-T91 31.8 5.4 54.5
SA213-T91 45.0 8.9 -
ASME Code Case 2328-1 45.0 6.9 -
Supporting SA213-T12 45.0 6.9 -
-
Tube SA213-T12 31.8 5.9 -
SA213-T91 45.0 6.4 -

Issued For Information Dharmesh Srivastava Sanjeev Padhy Ajay Kumar Jain 12th March 2012 6
Description Prepared By Checked By Approved By Dated Page No.
 Jaypee Nigrie Super Thermal
L&T-MHI BOILERS PVT.
Power Project, 2 x 660 MW
LIMITED
Nigrie, Singraulli, MP
Steam Generator and Technical Diary
Auxiliaries Package

PRIMARY REHEATER

Type Panel, Drainable

Design Pressure 7.2 MPa
Heating Surface Area 24,012 m²

Panel Pitch No. Of Tube Size (mm) Tube Pitch

Description Material
(mm) Panels OD Thickness (mm)
Upper 133.5 204 SA213-T22 57.1 3.5/4.5 115
Middle Upper 133.5 204 SA213-T12 57.1 3.5/4.5 115
Middle Lower 133.5 204 SA213-T12 57.1 3.5/4.5 115
Lower 133.5 204 SA213-T12 57.1 3.5/4.5 115
Terminal 267 102 ASME Code Case 2328-1 57.1 3.5 115

SECONDARY REHEATER

Type Pendant, Non-Drainable

Design Pressure 7.2 MPa
Heating Surface Area 5,750 m²

Panel Pitch No. Of Tube Size (mm)

Material Tube Pitch (mm)
(mm) Panels OD Thickness
267 100 ASME Code Case 2328-1 57.1 3.5 115

DE-SUPERHEATERS
Design Design Spray
OD ID Thickness Quantity
Description Material Pressure Temp. Capacity
(mm) (mm) (mm) (Nos.)
MPa(g) (°C) (TPH)
Primary SH SA335-
508.0 362 73 27.8 468 160* 2
De-SH P12
Secondary SA335-
508.0 362 73 27.3 573 40* 2
SH De-SH P91
Re heater SA335-
711.0 613 49 7.2 529 33* 2
De-SH P12

Issued For Information Dharmesh Srivastava Sanjeev Padhy Ajay Kumar Jain 12th March 2012 7
Description Prepared By Checked By Approved By Dated Page No.
 Jaypee Nigrie Super Thermal
L&T-MHI BOILERS PVT.
Power Project, 2 x 660 MW
LIMITED
Nigrie, Singraulli, MP
Steam Generator and Technical Diary
Auxiliaries Package

ECONOMIZER (SPIRAL FINNED TUBE)

Design Pressure 31.7 MPa

Design Temperature 371 °C*
Heating Surface Area 23,306 m²

Panel Pitch No. Of Tube Size (mm) Tube Pitch

Location Material
(mm) Panels OD Thickness (mm)
Re-Heater Pass
96 282 SA210-C 45.0 6.9 90
(Lower Section)
Super-Heater Pass
96 282 SA210-C 45.0 6.9 90
(Lower Section)
Super-Heater Pass
96 282 SA210-C 45.0 6.9 90
(Upper Section)

ECONOMIZER (HANGER TUBE)

Design Pressure 31.7 MPa

Design Temperature 371 °C*

Panel Pitch No. Of Tube Size (mm) Tube Pitch

Location Material
(mm) Panels OD Thickness (mm)
Re-Heater Pass 102 SA210-C 50.8 7.9
267 -
(Upper/Lower) 102 SA210-C 57.1 8.4
Super-Heater Pass 102 SA210-C 50.8 7.9
267 -
(Upper/Lower) 102 SA210-C 63.5 9.4

WATER HOLDING CAPACITY

Item Water Holding (m³)

Economizer 137
Furnace/Secondary Pass 173
Super-Heater 155
Re-Heater 374

Issued For Information Dharmesh Srivastava Sanjeev Padhy Ajay Kumar Jain 12th March 2012 8
Description Prepared By Checked By Approved By Dated Page No.
 Jaypee Nigrie Super Thermal
L&T-MHI BOILERS PVT.
Power Project, 2 x 660 MW
LIMITED
Nigrie, Singraulli, MP
Steam Generator and Technical Diary
Auxiliaries Package

SPECIFICATION OF HEADERS (To Be Revise)*

Design Design
S. OD & Thick.
Description Material Pres. Temp.
No. (mm)
(MPa) (°C)
1. Furnace Inlet Header (Front) SA-106C Ø 267.4x52 30.6 371
2. Furnace Lower Header (Rear) SA-106C Ø 267.4x52 30.6 371
3. Furnace Lower Header (Side) SA-106C Ø 267.4x52 30.6 371
4. Furnace Intermediate Header (Front) SA-335P12 Ø 298.5x53 30.6 428
5. Furnace Intermediate Header (Rear) SA-335P12 Ø 298.5x53 30.6 428
6. Furnace Intermediate Header (Side) SA-335P12 Ø 298.5x53 30.6 428
7. Furnace 2nd Intermediate Header (Front) SA-335P12 Ø 298.5x53 30.6 428
8. Furnace 2nd Intermediate Header (Rear) SA-335P12 Ø 298.5x53 30.6 428
9. Furnace 2nd Intermediate Header (Side) SA-335P12 Ø 298.5x53 30.6 428
10. Furnace Outlet Header (Front) SA-335P12 Ø 355.6x61 28.9 437
11. Furnace Outlet Header (Rear) SA-335P12 Ø 355.6x53 28.9 437
12. Furnace Outlet Header (Side) SA-335P12 Ø 298.5x66 28.9 437
13. Rear Wall Hanger Inlet Header SA-335P12 Ø 355.6x44 28.9 437
14. Rear Wall Hanger Outlet Header SA-335P12 Ø 216.3x42 28.9 437
15. Passage Side Wall Inlet Header SA-335P12 Ø 216.3x42 28.9 437
16. Passage Side Wall Outlet Header SA-335P12 Ø 216.3x42 28.9 437
17. Roof Inlet Header SA-335P12 Ø 216.3x37 28.9 437
18. Roof Outlet Header SA-335P12 Ø 584.2x111 28.9 441
19. Back Pass Inlet Header (Front) SA-335P12 Ø 216.3x42 28.6 437
20. Back Pass Inlet Header (Rear) SA-335P12 Ø 216.3x42 28.6 437
21. Back Pass Inlet Header (Side) SA-335P12 Ø 216.3x42 28.6 437
22. Back Pass Outlet Header (Front) SA-335P12 Ø 216.3x42 27.6 445
23. Back Pass Outlet Header (Rear) SA-335P12 Ø 355.6x61 27.6 445
24. Back Pass Outlet Header (Side) SA-335P12 Ø 216.3x42 27.6 445
25. Back Pass Inlet Header (Division Wall) SA-335P12 Ø 216.3x42 28.6 437
26. Back Pass Outlet Header (Division Wall) SA-335P12 Ø 216.3x42 27.6 445
27. Primary SH Inlet Header SA-335P12 Ø 368.3x70 27.6 464
28. Primary SH Outlet Header SA-335P12 Ø 393.7x71 27.3 478
29. Secondary SH Inlet Header SA-335P12 Ø 318.5x59 27.3 470
30. Secondary SH Outlet Header CASE-2199-1 Ø 339.7x58 26.9 517
31. Tertiary SH Inlet Header CASE-2199-1 Ø 457.2x78 26.9 501
32. Tertiary SH Outlet Header CASE-2199-1 Ø533.4x100 26.3 550
33. Primary RH Inlet Header SA-106C Ø 546.1x27 5.5 371
34. Primary RH Outlet Header SA-106C Ø 711.2x45 5.5 500
35. Secondary RH Inlet Header SA-106C Ø 635.0x35 5.1 412
36. Secondary RH Outlet Header CASE-2199-1 Ø 711.2x51 5.1 555
37. Economizer Inlet Header SA-106C Ø 355.6x66 30.6 371
38. Economizer Intermediate Header (RH Pass) SA-106C Ø 216.3x40 30.6 371
39. Economizer Intermediate Header (SH Pass) SA-106C Ø 216.3x40 30.6 371
40. Economizer Outlet Header SA-106C Ø 419.1x65 30.0 371

Issued For Information Dharmesh Srivastava Sanjeev Padhy Ajay Kumar Jain 12th March 2012 9
Description Prepared By Checked By Approved By Dated Page No.
 Jaypee Nigrie Super Thermal
L&T-MHI BOILERS PVT.
Power Project, 2 x 660 MW
LIMITED
Nigrie, Singraulli, MP
Steam Generator and Technical Diary
Auxiliaries Package

BOILER CIRCULATION PUMP

Subject Specifications
Manufacturer TORISHIMA
Quantity One (01) Set
Type Spherical Casing, Centrifugal Closed Impeller
Model HLAV250-570/1K
Capacity 890 m³/h
Total Head 110 m
Minimum Flow TBA m³/h
Warming Flow 70 m³/h
Suction Temperature 287.3 °C
Design Pressure 289.60 Kg/cm³ (28.40 MPa)
Design Temperature 359 °C
Operating Medium Boiler Water
Drive Motor Details 380 KW, 3300 V, 1465 RPM, 50 Hz
Heat Barrier Normal / Emergency Water Flow Rate 30 L/min – 18 L/min
Motor Cooler Cooling Water Flow Rate 158 L/min
Cooling Water Inlet Temperature 36 °C

REGENERATIVE AIR PREHEATER

DESCRIPTION DETAILS
Number of Air Pre-Heaters Two (02) Sets
Equipment Number 01HLD01AC101/102
Type Regenerative, Tri-Sector
Inlet Gas Flow 2721 TPH (BMCR, Design Coal)
Primary Air Entering / Leaving Temperature 35 °C / 307.2 °C
Secondary Air Entering / Leaving Temperature 29 °C / 317.2 °C
AH Gas I/L Temperature 352 °C
AH Gas O/L Temperature 131.2 °C (Uncorrected)
Cold End Metal Temperature 81 °C
Pressure Differential (Hot Side)
Primary Air to Secondary Air 949 mmAq
Secondary Air to Gas 351 mmAq
Primary Air to Gas 1026 mmAq

Continued to Next Page....................

Issued For Information Dharmesh Srivastava Sanjeev Padhy Ajay Kumar Jain 12th March 2012 10
Description Prepared By Checked By Approved By Dated Page No.
 Jaypee Nigrie Super Thermal
L&T-MHI BOILERS PVT.
Power Project, 2 x 660 MW
LIMITED
Nigrie, Singraulli, MP
Steam Generator and Technical Diary
Auxiliaries Package

Pressure Drop
Primary Air Side 24 mmAq
Secondary Air Side 55.8 mmAq
Gas Side 64.1 mmAq
Air Leakage 6.0% (Max.)
Heating Surface Area 54,605 m²
Heating Element
Hot End Layer Depth 300 mm/ Material Mild Steel
Interim Layer Depth 970 mm/ Material Mild Steel
Cold End Layer Depth 300 mm/ Material Corten (CRLS/LACR) Steel
Electric Drive Details 18.50 KW, 415 V, 3 Phase AC
Air Motor Details 7 KW, 975 RPM

INDUCED DRAFT FAN (ID FAN)

DESCRIPTION DETAILS
Number of Fans Two (02) Sets
Equipment Number 01HNC01AN101/102
Type Axial Flow, Horizontal
Capacity 30,936 m³/min
Inlet Air Temperature 137 °C
Inlet Static Pressure -331 mmAq
Discharge Static Pressure 13 mmAq
Control System Variable Blade Pitch Control
Driving Motor 5,000 KW

FORCED DRAFT FAN (FD FAN)

DESCRIPTION DETAILS
Number of Fans Two (02) Sets
Equipment Number 01HLB01AN101/102
Type Axial Flow, Horizontal
Capacity 15,326 m³/min
Inlet Air Temperature 25 °C
Inlet Static Pressure -48 mmAq
Discharge Static Pressure 324 mmAq
Control System Variable Blade Pitch Control
Driving Motor 2,800 KW

Issued For Information Dharmesh Srivastava Sanjeev Padhy Ajay Kumar Jain 12th March 2012 11
Description Prepared By Checked By Approved By Dated Page No.
 Jaypee Nigrie Super Thermal
L&T-MHI BOILERS PVT.
Power Project, 2 x 660 MW
LIMITED
Nigrie, Singraulli, MP
Steam Generator and Technical Diary
Auxiliaries Package

PRIMARY AIR FAN (PA FAN)

DESCRIPTION DETAILS
Number of Fans Two (02) Sets
Equipment Number 01HFE11AN101/102
Type Axial Flow, Horizontal
Capacity 6,062 m³/min
Inlet Air Temperature 25 °C
Inlet Static Pressure -49 mmAq
Discharge Static Pressure 1,095 mmAq
Control System Variable Blade Pitch Control
Driving Motor 3,000 KW

PULVERIZER SEAL AIR FAN

DESCRIPTION DETAILS
Number of Fans Two (02) Sets
Equipment Number 01HFW01AN101/102
Type Centrifugal, Overhung, Backward Curved
Capacity 1,000 m³/min
Inlet Air Temperature 37 °C
Head Developed By Fan 5500 Pa (Static)
Driving Motor 132 KW / 4 Pole

FLAME DETECTOR COOLING AIR FAN

DESCRIPTION DETAILS
Number of Fans Two (02) Sets (01 AC Driven & 01 DC Driven)
Equipment Number 01HXA01AN101/102
Type Centrifugal, Horizontal
Capacity 185.7 m³/min
Inlet Air Temperature 25 °C
Head Developed By Fan 3.24 KPa
Driving Motor 132 KW (Each)

Issued For Information Dharmesh Srivastava Sanjeev Padhy Ajay Kumar Jain 12th March 2012 12
Description Prepared By Checked By Approved By Dated Page No.
 Jaypee Nigrie Super Thermal
L&T-MHI BOILERS PVT.
Power Project, 2 x 660 MW
LIMITED
Nigrie, Singraulli, MP
Steam Generator and Technical Diary
Auxiliaries Package

LIGHT DIESEL OIL (LDO) BURNER

DESCRIPTION DETAILS
Number of Burners Eight (08) (1 Elevation x 8 Corners)
Type Air Atomising M-Jet Type
Light Diesel Oil Combustion Rate 16,500 kg/hr
Burner Inlet Pressure 12 Kg/cm²
Operation Oil Temperature 25 °C
Ignitor Type and Total nos. Of Ignitor HEA (High Energy Arc) Ignitor, 8 nos.

HEAVY FUEL OIL (HFO) BURNER

DESCRIPTION DETAILS
Number of Burners Twenty Four (24) (3 Elevation x 8 Corners)
Type Steam Atomising M-Jet Type
Heavy Fuel Oil Combustion Rate 49,100 kg/hr
Burner Inlet Pressure 10.5 Kg/cm²
Operation Oil Temperature 115 °C
Ignitor Type and Total nos. Of Ignitor HEA (High Energy Arc) Ignitor, 24 nos.

COAL BURNER

DESCRIPTION DETAILS
Number of Burners Forty Eight (48) (6 Elevation x 8 Corners)
Type A-PM
Capacity 10.8 TPH
Pulverized Coal Temperature 75 °C

COAL FEEDER

DESCRIPTION DETAILS
Number of Coal Feeders Six (06), 04 Working & 02 Standby
Equipment Number 01HFB01-06AF101
Model No. EG3651
Type Gravimetric-36” Stock Coal Feeder
Capacity 106 TPH
Belt Drive Motor 5.5 KW
Cleanout Drive Details 0.25 KW

Issued For Information Dharmesh Srivastava Sanjeev Padhy Ajay Kumar Jain 12th March 2012 13
Description Prepared By Checked By Approved By Dated Page No.
 Jaypee Nigrie Super Thermal
L&T-MHI BOILERS PVT.
Power Project, 2 x 660 MW
LIMITED
Nigrie, Singraulli, MP
Steam Generator and Technical Diary
Auxiliaries Package

PULVERIZER

DESCRIPTION DETAILS
Number of Coal Feeders Six (06), 04 Working & 02 Standby
Equipment Number 01HFC01-06AJ101
Model No. MVM28RL
Type Vertical Roller Mill
Base Capacity 78 TPH
70 % Through 200 mesh Pass
Fineness
98 % Through 50 mesh Pass
Classifier Rotary Type
Roller Loading Method Hydraulic Loading
Gear Reducer Planetary Type
Pulverizer Motor 840 KW
Rotary Separator Motor 55 KW
Coal Design Coal Worst Coal Best Coal
Total Coal Flow (TPH) 345.374 372.035 307.220
No of Operating Pulverizers 4 5 4
Coal Flow TPH/Pulverizer 86.343 74.407 76.805
Moisture in Coal % 7.0 7.2 7.4
HGI 63 60 65
Fineness (200 Mesh Pass) 70 70 70
Pulverizer Capacity Load % 84.8 75.1 73.5

COAL SILO

DESCRIPTION DETAILS
Number of Coal Silos Six (06)
Diameter on Top Side 9.6 m
Diameter on Bottom Side 0.9 m
Capacity of Each Coal Silo 166 MT

Issued For Information Dharmesh Srivastava Sanjeev Padhy Ajay Kumar Jain 12th March 2012 14
Description Prepared By Checked By Approved By Dated Page No.
 Jaypee Nigrie Super Thermal
L&T-MHI BOILERS PVT.
Power Project, 2 x 660 MW
LIMITED
Nigrie, Singraulli, MP
Steam Generator and Technical Diary
Auxiliaries Package

AUXILIARY BOILER SPECIFICATION

General

Number of boilers 1

Manufacturer Thermax Babcock & Wilcox

Bi-drum, water tube, natural

Type of boiler
circulation, site Assembled.

Model FM 220

Net continuous rating TPH 90

Steam pressure at main steam stop valve outlet Bar (g) 16

Design pressure Bar (g) 26

Steam temperature at outlet of main steam stop

°C 305 +/-5
valve

Feed water temperature at boiler inlet °C 135

Main fuel LDO

Guarantee fuel LDO

Thermal efficiency of the boiler at MCR based on

LHV and reference conditions of 25°C & 53%
% 88
relative humidity on LDO firing as specified in Basis
of Design

Design Blow down % 3

Operating blowdown % <1

Intermittment blowdown Once in 8 hrs.

1. Design codes
Boiler pressure parts IBR

Piping ANSI B 31.1, 31.3

Furnace protection system NFPA 85

FD Fan Vendor Standard

Pumps Vendor Standard

Issued For Information Dharmesh Srivastava Sanjeev Padhy Ajay Kumar Jain 12th March 2012 15
Description Prepared By Checked By Approved By Dated Page No.
 Jaypee Nigrie Super Thermal
L&T-MHI BOILERS PVT.
Power Project, 2 x 660 MW
LIMITED
Nigrie, Singraulli, MP
Steam Generator and Technical Diary
Auxiliaries Package

Electrical motors IEC

Process valves Vendor Standard

Permitted Exposure to sound levels OSHA

Others Vendor standard

Boiler performance testing ASME PTC 4.1 Indirect

abbreviated heat loss method
2. Materials
Boiler pressure parts IBR

Structurals/ Plates IS 2062

Others Vendor standard

3. Boiler pressure parts

Steam Drum

Internal diameter mm 1500

Shell thickness mm 32

Material of construction SA516Gr70

Water Drum

Internal diameter mm 960

Shell thickness mm 32

Material of construction SA516Gr70

Furnace

Type Water wall construction

Side wall, roof, floor Membrane

Tube OD x thickness mmXmm 76.2 X 4.06

Material BS 3059 ERW.

Rear wall Membrane

Tube OD x thickness mmXmm 76.2 X 4.06

Material BS 3059 ERW...

Issued For Information Dharmesh Srivastava Sanjeev Padhy Ajay Kumar Jain 12th March 2012 16
Description Prepared By Checked By Approved By Dated Page No.
 Jaypee Nigrie Super Thermal
L&T-MHI BOILERS PVT.
Power Project, 2 x 660 MW
LIMITED
Nigrie, Singraulli, MP
Steam Generator and Technical Diary
Auxiliaries Package

Baffle wall Membrane

Tube OD x thickness mmXmm 76.2 x 4.06

Material BS 3059 ERW.

Front wall Refractory

Furnace flat projected area EPRS 2 180

m

Volume 3 220
m

Furnace dimensions

mm 6166
• Height (average)
mm 3857
• Width
mm 9730
• Depth
Superheater

Inverted loop, convective, fully

Type
drainable

Tube OD x thickness mmxmm 50.8 x 4.5 / 5

Material SA 210 Gr A1/ SA 213 T11

Header OD x thickness mmxmm 355.6 x Sch 120

Header material SA 335 P11

Desuperheater

Type Direct contact spray

Convection Bank

Type Inline

Tube OD x thickness mmxmm 50.8 x 3.25

Material BS 3059 ERW..

4. Mountings & fittings

Safety Valves Drum 1 Drum 2 SH

Capacity TPH 44 44 27.5

Issued For Information Dharmesh Srivastava Sanjeev Padhy Ajay Kumar Jain 12th March 2012 17
Description Prepared By Checked By Approved By Dated Page No.
 Jaypee Nigrie Super Thermal
L&T-MHI BOILERS PVT.
Power Project, 2 x 660 MW
LIMITED
Nigrie, Singraulli, MP
Steam Generator and Technical Diary
Auxiliaries Package

Set Pressure Barg 25 26 20

Temperature °C Sat Sat 305

Level gauges Drum Drum

Bicolor
Type
type

Numbers 2

Ducts Air duct Gas Duct

Thickness mm 5 6

Material IS 2062/CS IS 2062/CS

Burner

Make of burner TBW

Numbers per boiler 2

Burner capacity 100% capacity

Type of ignitor HEA ignitor

Type of atomiser Air/steam atomised

Location Front wall

Air temperature °C Ambient

Turndown ratio on Fuel oil 4:1

Forced draft fan

No. One

Type Centrifugal

Design capacity kg/sec 41

Design head mm wg 405

Design temperature °C 47.8

Fan RPM rpm 1500 synchronus

Type of control Inlet vane control

Issued For Information Dharmesh Srivastava Sanjeev Padhy Ajay Kumar Jain 12th March 2012 18
Description Prepared By Checked By Approved By Dated Page No.
 Jaypee Nigrie Super Thermal
L&T-MHI BOILERS PVT.
Power Project, 2 x 660 MW
LIMITED
Nigrie, Singraulli, MP
Steam Generator and Technical Diary
Auxiliaries Package

Forced draft fan drive motor

No. One

Type TEFC SCR

Motor RPM rpm 1500

Power KW 270

Protection IP-55

Insulation Class B

Insulation

Lightly resin bonded mineral

Type wool with one side GI wire
netting

Density 3 120
Kg/m

Wind velocity for thickness calculation m/s 3

skin temperature °C 60

Cladding

For boiler block

Type Ribbed Aluminium

Thickness SWG 20

For other surfaces

Type Plain Aluminium

Thickness SWG 22

Sample coolers OP

Numbers 4

Type Shell & tube

Material of shell CS

Material of coil SS

Issued For Information Dharmesh Srivastava Sanjeev Padhy Ajay Kumar Jain 12th March 2012 19
Description Prepared By Checked By Approved By Dated Page No.
 Jaypee Nigrie Super Thermal
L&T-MHI BOILERS PVT.
Power Project, 2 x 660 MW
LIMITED
Nigrie, Singraulli, MP
Steam Generator and Technical Diary
Auxiliaries Package

Drum water, steam, feed water,

Duty
Saturated steam

HP Chemical Dosing Unit

Number 1

Storage tank

Capacity Liters 300

Material of construction MSRL

Pump

Type Reciprocating plunger

Numbers 2

Design Capacity liters/hr 10

Design Head barg 31

Speed RPM 3000

Drive Motor

Type of coupling Flexible

Power KW 0.37

Protection IP 55

Insulation Class B

LP Chemical Dosing Unit

Number 1

Storage tank

Capacity Liters 300

Material of construction SS 304

Pump

Type Reciprocating plunger

Numbers 2

Issued For Information Dharmesh Srivastava Sanjeev Padhy Ajay Kumar Jain 12th March 2012 20
Description Prepared By Checked By Approved By Dated Page No.
 Jaypee Nigrie Super Thermal
L&T-MHI BOILERS PVT.
Power Project, 2 x 660 MW
LIMITED
Nigrie, Singraulli, MP
Steam Generator and Technical Diary
Auxiliaries Package

Design Capacity liters/hr 10

Design Head barg 6.3

Speed RPM 3000

Drive Motor

Type of coupling Flexible

Power KW 0.37

Protection IP 55

Insulation Class B

PH Chemical Dosing Unit

Number 1

Storage tank

Capacity Liters 300

Material of construction SS 304

Pump

Type Reciprocating plunger

Numbers 2

Design Capacity liters/hr 10

Design Head barg 6.3

Speed RPM 3000

Drive Motor

Type of coupling Flexible

Power KW 0.37

Protection IP 55

Insulation Class B

Boiler feed water pumps

Numbers 2

Issued For Information Dharmesh Srivastava Sanjeev Padhy Ajay Kumar Jain 12th March 2012 21
Description Prepared By Checked By Approved By Dated Page No.
 Jaypee Nigrie Super Thermal
L&T-MHI BOILERS PVT.
Power Project, 2 x 660 MW
LIMITED
Nigrie, Singraulli, MP
Steam Generator and Technical Diary
Auxiliaries Package

Type Centrifugal

Design capacity 3 132.7

m /hr

Design head mlc 337

Speed RPM 3000

Feed water temperature °C 135

Boiler feed water pumps drive motor

Type TEFC SCR

Power KW 180

Protection IP 55

Insulation Class B

Stack

Height M 35

ID mm 2400

Atmospheric blowdown tank

Type Vertical cylindrical

Numbers 1

Design pressure barg atmospheric

ID mm 1200

Height mm 2000

Issued For Information Dharmesh Srivastava Sanjeev Padhy Ajay Kumar Jain 12th March 2012 22
Description Prepared By Checked By Approved By Dated Page No.
 Jaypee Nigrie Super Thermal
L&T-MHI BOILERS PVT.
Power Project, 2 x 660 MW
LIMITED
Nigrie, Singraulli, MP
Steam Generator and Technical Diary
Auxiliaries Package

Issued For Information Dharmesh Srivastava Sanjeev Padhy Ajay Kumar Jain 12th March 2012 23
Description Prepared By Checked By Approved By Dated Page No.