Air compressors Pump house Steam header Feed water System Operating Parameters Fuel Gas path Ash content vs fuel efficiency Operating alarms operating instruments on panel

1. HP BOILERS

2. HP BOILERS
Sr Parameter OV Unit alarm Sr Parameter OV unit alar
no no m
1 Main steam pressure/Drum 85 Kg/cm2 22 Primary SH before Attmpt. 354 0c
pressure
23 ESP outlet flue gas 129 0c
2 Main steam temperature 463 0c
3 Drum level 336 Mmwc 24 ESP 1A 20/135 Ma
4 Oxygen 8.56 % 25 ESP 1B 40/160 Ma
OPERATING PARAMETERS
5 FD air 36.5 M3/hr 26 85/46 PRV open % 15
6 Furnace draft 0 Mmwc
27 PDM tank temperature 50 0c
7 ID Suction draft 26 Mmwc
28 PDM tank level
8 FD Discharge dreaft 27 Mmwc
29 Instrument air pressure
9 Pressure under grate 14 Mmwc
30 Ash Hooper level
10 Draft Eco in 5 Mmwc
31 Deaerator level
11 Draft eco out 40 Mmwc
32 85/46 pressure 42.5 Kg/c2
12 Draft dust coo outlet 55 Mmwc
13 Secondary air pressure 33 CBD Conductivity
14 Load ID 185 Amps 34 Deaerator water conductivity
15 Load FD 24 Amps 35 Feed water Ph
16 FW temperature before Eco 131 0c
17 FW temperature after Eco 218 0c
18 Boiler outlet gas 377 0c
19 Eco outlet gas 197 0c
20 A 143 0c

3. AIR COMPRESSORS
NPP : KG KHOSLA MAKE SPL : KG KHOSLA MAKE
Double stage Double stage
3H Y2TCER Air comp no 4,5,6
RPM : 650 RPM : 800
Pr. : 7 kg/cm2 Pr. : 7 kg/cm2
Cap : 5.89 m3/min Cap : 51.41 m3/min
Pr 1 st stage : 2 kg/cm2 Pr 1 st stage : 2 kg/cm2
pr 2 nd stage : 5.5 kg/cm2 pr 2 nd stage : 5.5 kg/cm2
oil pr. : 2.5 kg/cm2 oil pr. : 2.5 kg/cm2
SPL : KG KHOSLA MAKE
Single stage
Air comp no 2
RPM : 560
Pr. : 7 kg/cm2
Cap : 11.01 m3/min
oil pr. : 2.5 kg/cm2

4. AIR COMPRESSORS
 Air compressors in power house are situated as follows Motor load: 230-250 A
1) 2 nos at old power plant
2) 2 nos at new power plant
3) 4 nos at specialty machine area
cooler 2.5 kg/cm2
Air comp no 2,6,4,5 PROCESS
cooler
Coating plant
5 kg/cm2
AD AD
cooler
5 kg/cm2 Pulp mill , spl machines ,
RECIEVER Clo2 plant, power house
TANK
cooler

5. SPECIALITY PUMP HOUSE DETAILS
250 M3/HR
4 K/C2
TW NO 9 / 6 85 A
COATING PLANT
NEW POWER HOUSE
AIR COMPRESSOR
M3/HR
55/ 150 LINE
2-2.5 K/C2
65-70 A
PULP MILL
SHUT 1 RUNNING 1 RUNNING
TUBE WELL LINES: 3,4,8,16,20,22. 10,12,14,15,17 18,19 1,21

6. OPP office
10KG STEAM HEADER rail clo2
SM PULP MILL
ABL
PRV 10/7 10 KG
TG
LIME KLIN
From 46/17/7 prv
Dorr plant JMW APH 7 KG BTH

7. PDM
DEAERATOR
OT Suction
TO
HP
BOILERS
TO
ABL
BOILERS
DARE.
ABL
Suction
ABL EFP1 85 KG ABL
FP EFP2 STEAM STEAM
FP FP
ABL
deae. pump LAY OUT FEED WATER (HP) SYSTEM

8. HP BOILER AND ABL FEED WATER
HP BOILER 3 HP BOILER 2 HP BOILER 1
ECO ECO ECO
FROM ABL PUMP
ABL

9. OPERATING PARAMETRES
Sr Parameter OV Sr Parameter OV
no no
ABL FEED PUMP HP FEED PUMP
1 SUCTION PR 2.7
STEAM
2 DISCHARGE PR 70 78 1 RPM 2600
3 BALACING PR 3.0 2 CONTROL OIL PR 2.3
4 ABL DEAERATOR WATER TEMP 100 3 LUB OIL TEMP 44
5 DEAERATOR PUMP PR 4 INLET STEAM PR 54
6 DEAERATOR PUMP LOAD 13.5 5 EXH STEAM PR 1.6-
2.0
7 BEARING TEMP MAX 60
6 MOTOR LOAD 110
HP FEED PUMP 7 BOILER WATER COND 60-70 55 75
1 WATER TEMP 108
2 FEED WATER COND 5-6
3 FEED WATER PH 9 -10
4 FEED PUMP SUC PR 1.3
5 DISCHARGE PR 100
6 BALANCING PR 1.4
7 PUMP NDE BEARING 40-45 70
8 PUMP DE BEARING TEMP 40-45 105
9 MOTOR WINDING 30-35
MOTOR BEARING DE 35-40 85
MOTOR NDE 90
21

10. FLUE GAS PATH HP BOILER
SECONDARY AIR
BOILER 1 ST CYCLON 2 ND CYCLON 3RD CYCLON
TO GRATE
HOT AIR OUT
AIR PRE
ESP ECONOMISER
HEATER
FD AIR
SCREW CONVEYERS
TO SUBMURGED ASH BELT
RATED FLOW RATE: ID FAN :97524 M3/HR AND FD FAN : 51876 M3/HR (AIR DENSITY 1.20 KG/M3 AT 20 DEG CEL)

11. ASH CONTENT V/S EXPECTED BOILER EFFICIENCY
Sr ASH CONTENT % COMUSTIBLE IN REFUSE INDIRECT BOILER
no00 EFFICIENCY
1 15 8-9 79.8-80.8
2 20 5-6 83-83.6
SULP
HER
3 25 4.5-5 83.6-84.1 %
4 30 5.4-6.4 82.4-83.4 1.8
5 35 8-9.5 79.3-80
6 40 9.6-11.6 77.2-79
7 45 12-14 74.2-74.8
18

12. SAFETY VALVES SETTINGS
JMW BOILER: 51 , 50 , 48 (RHS,LHS,SUPER HEATER)
BOILER NO 1,2,3: 94.8, 93.6, 91.2 (RHS,LHS,SUPER HEATER)
BOILER NO 7: 51, 50, 48.5 (RHS,LHS,SUPER HEATER)
ABL BOILER

13. OPERATING ALARMS ON PANEL
Sr Parameter OV Sr Parameter O
no no V
HP BOILER 1,2,3 DRUM LEVEL HIGH
1 EMERGENCY TRIP 1 MAIN STEAM TEMP HIGH
2 ID FAN TRIPPED 2 MAIN STEAM TEMP LOW
3 FD FAN TRIPPED 3 AIR FLOW LESS THAN 30 %
4 SA FAN TRIPPED 4 FUEL PR LOW
5 COAL FEEDER 1 TRIPPED 5 AIR COMP 1 STOPPED
6 COAL FEEDER 2 TRIPPED 6 AIR COPMPRESSOR 2 STOPPED
7 COAL FEEDER 3 TRIPPED 7 DEAERATOR LEVEL LOW
COAL FEEDER 4 TRIPPED EICM CERM RELAY MOTOR O/L
1 STOKER TRIPPED 1 ESP1 FIELD 1 A TRIPPED
2 COAL FEEDRE NO 1 SPEED LOW 2 FIELD 1 B TRIPPED
3 COAL FEEDRE NO 2 SPEED LOW 3 ASH HOOPER LEVEL HIGH
4 COAL FEEDRE NO 3 SPEED LOW 4 RALV SC TRIPPED
5 COAL FEEDRE NO 4 SPEED LOW 5 ESP FIELD 1A 1B WORKING ALARM
6 INST AIR PRESSURE VERY LOW 6 O2 HIGH EXCESS AIR
7 DRUM PR HIGH 7
8 DRUM PR VERY LOW 8
9 DRUM LEVEL VERY LOW 9

14. OPERATING ALARMS ON PANEL
Sr Parameter Sr Parameter
no no
HP BOILER 1,2,3 ABL BOILER
1 EMERGENCY TRIP
1 MAIN STEAM HEADER PR LOW
2 DRUM LEVEL LOW
2 86/46 LINE PR LOW
3 DRUM LEVEL HIGH
3 PDM PUMP 1 STOP
4 FURNACE PRESSURE HIGH
4 PDM PUMP 2 STOP 5 FURNACE PRESSURE LOW
5 CBD1 COND LOW 6 OVERHEAD TANK LEVEL LOW
6 CBD 2 COND LOW 7 DRUM LEVEL LOW
7 CBD 3 COND LOW DRUM LEVEL VERY LOW
DEAERATOR COND HIGH 1 DRUM LEVEL HIGH
1 FEED WATER PH LOW 2 AIR FLOW LESS THAN 30 %
3 C
2 FEED WATER PH HIGH
3
4
5
6
7
8
9

15. OPERATING INSTRUMENTS ON PANEL
Sr Parameter Sr Parameter
no no
HP BOILER 1,2,3 DEAERATOE PRESSURE
CONTROLLER
1 ID SUCTION DRAFT MMWC 1 DEAERATOR LEVEL CONTROLLER
2 FD DISCHARGE DRAFT MMWC 2
3 APH INLET DRAFT MMWC 3
4 AIR PH OUTLET 4
5 ECON IN 5
6 ECON OUT 6
7 SA FAN 7
DEAERATOR LEVEL
1 APH OUTLET GAS TEMP 1
2 FURNACE DRAFT CONTROLLER 2
3 FEED WATER FLOW INTIGRATOR 3
4 STEAM FLOW INTIGRATOR 4
5 MAIN STEAM TEMP 5
CONTROLLER
6
6 STEAM PR CONTROLLER
7
7 OXYGEN CONTROLLER
8
8 AIR FLOW CONTROLLER
9
9 DRUM LEVEL FEED WATER
CONTROLLER