1. MERC TRAINING ACADEMY
BOILER SPEFICATIONS

2. 2.0. STEAM GENERATORS OF TPSII/STAGE-I
2.1. GENERAL DATA :
Boilers designers : M/S. E.V.T Germany
Boiler suppliers : M/S. Trans Electro, Hungary
Boiler capacity : 690 T/hr, 158 ata, 540ºC
Boiler type: Single drum, natural circulation, non-steaming economizer, Single reheat, tangential firing in radiant, dry bottom furnace, balanced draught system with axial profile blading fans, Electro static precipitator with wet Ash disposal system static precipitator with wet Ash disposal system

3. 2.2. BOILER PERFORMANCE AT 100% MCR CONDITION (210 MW)
Feed water temperature : 241.6ºC – 304.5ºC
Steaming rate : 656 T/hr
Circulation ratio : 7
Superheated steam pressure : 157 kg/cm²
Superheated steam temperature : 540ºC
Reheated steam flow : 594 T/hr
Reheated steam pressure : 36.9 kg/cm²
Reheated steam temperature : 540ºC
Fuel consumption : 207 T/hr
Exit gas temperature : 149ºC
Efficiency(NCV BASIS) : 89.33%

4. 2.3. BOILER FUELS
a) Furnace oil
b) Lignite

5. S.No Description Furnace oil Lignite
1 Gross calorific value kcal/kg
2 Net calorific value kcal/kg
3 Carbon %
4 Hydrogen %
5 Sulphur % max
6 Nitrogen %
Oxygen %
Ash % max
9 Moisture % traces
Sediments %
11 Pour point ºC
12 Flash point ºC
13 Fire point ºC
14 Density at 15ºC
15 Kinematicviscosity(CST)at 100ºC
16 Fixed carbon
17 Volatile Matter
18 Hard groove index
19 Grindability

6. OIL HANDLING SYSTEM Decanting pump suction strainers
Decanting pump house
Oil storage tank
SUCTION HEATER
OIL PRESSURIZING PUMP
FUEL OIL PUMP
FILTER BEFORE DRAIN OIL PUMP
DRAIN OIL TANK

7. 2.5. OIL FIRING SYSTEM General: 1 . Impulse Ignitor 2. Flame Scanner
Capacity :30% MCR
Number of Burner/Boiler :4
Type of Burner :Steam Atomizer Type 2
Make :EVT W. Germany
Turn down ratio : 4:1
Location :20 metre elevation
Oil pressure max/min : 16/6 bar
Oil temp. max/min : 130ºC/90ºC
Viscosity : 12 – 15 CST
Atomising steam pressure : 10 bar
Atomising steam Temperature : 230ºC
Atomising steam flow : 240 kg/hr
Purge steam pressure :16 bar
Purge steam Temperature : 230ºC
Purge steam flow duration :1 min
Compressed air pressure : 7 bar
Compressed air consumption : 0.06 Nm³/Travel
EQUIPMENTS USED IN THE OIL FIRING SYSTEM :
1 . Impulse Ignitor
2. Flame Scanner
3. Scanner air Fan

8. LIGNITE FIRING SYSTEM 1. Bunker 2. Plate Belt Feeder
3. Scraper Under Plate Belt Feeder
4. Paddle Wheel
5. Conveyor Belt Feeders
6. Resuction Duct
7. Beater Wheel Mill
8. Classifier
9. Pulverised fuel burners

9. AIR CIRCUIT
1. Forced Draught Fan 2. Lub & Control Oil system 3. Steam Coil Air preheater 4. Regenerative Air preheater 5. Regenerative Air preheater motor 6. Regenerative Air preheater lub oil system 7. Air distribution

10. GAS CIRCUIT 2. After Burning Grate 3. Grease pump
1. Furnace
2. After Burning Grate
3. Grease pump
4. ELECTROSTATIC PRECIPITATOR
5. Induced draught fan
6. Lub oil system
7. Air blowers
8. Chimney
9.Wind strakes
10.
LOCATION Gas temp. ºc Vacuum mbar Gas velocity
Before SH
After SH
After SH
After RH
After SH
After RH
After ECO bottom bank
After ECO middle bank
After ECO Top Bank

11. ASH DISPOSAL SYSTEM 1. Slag Conveyor 2. Seal water pit at ADPH
3. Seal water pumps
4. HP/LP Water sump pit
5. HP water pump
6. LP Water pump
7. Ash Mixing vessel
8. Ash slurry pits
9. Ash slurry pumps
10. Channels
11. Drain pump

12. FEED AND CIRCULATION SYSTEM
1. Economizer
2. Drum
3. Number of Cyclone separators
4. Down comers
5. Evaporator
6. Intermediate Headers
7. Top Header
8. No. of Roof Header
9. Over Flow Pipes
10. Saturated steam Pipes

13. SUPER HEATERS DESUPERHEATERS 1. Super heater 1 2. Super heater 2
1 Desuperheater 1A, 1B
2. Desuperheater 2A, 2B

14. REHEATERS
Reheater 1
Reheater 2
RH Desuperheater A, B

15. MAIN STEAM LINES Cold reheat lines Hot reheat lines
Number of lines : Two
Size : Φ ID 240 mm X 34/31 mm
Cold reheat lines
Number of lines : Two
:From HP Turbine outlet to Reheater Inlet header.
size : Φ 532 mm X 16 mm
Hot reheat lines
Number of lines : Two
:From Reheater outlet header to IP Turbine inlet.
Size : Φ 488 mm X 24mm

16. SAFETY VALVES Total number of safety valves : 6
Type : Spring loaded direct acting
type aided with pneumatic
power actuation
Description Blow off pressure Relieving capacity
kg/cm² T/hr
Superheater 10% safety valve
Superheater 50% safety valve
Reheater 50% safety valve

17. DRAIN HEADERS
1.Water side drain header 2. Superheater drain header 3. Reheater drain header

18. BLOW DOWNS 1. Continuous blow down
2. Continuous blow down expander tank
3. Emergency blow down
4. Intermittent Blow down tank
5. Condensate storage tank
6. Boiler fill pump
7. Hot well make pump

19. PHOSPHATE DOZING PUMP 1. Hydrazene dozing pump Number of pumps : Two
Capacity : 65 litres/hr
Delivery pressure : 210 kg/cm²
Drive motor : 3Φ,415 V, 1.5 KW, 1410 rpm
1. Hydrazene dozing pump
Number of pumps : Two
Capacity : 150 m³/hr
Delivery pressure : 5.0 kg/cm²
Drive motor : 3Φ,415 V, 1.1 KW, 2920 rpm

20. SOOT BLOWERS WATER SOOT BLOWERS STEAM SOOT BLOWERS
Numbers : 42
Type : Short retractable
Locations : From 16.0 ML to 37.4 ML
Blowing medium : Service water
Blowing pressure : 12 bar
Drive for blower : 3Φ,415 V, 0.37 KW
Operating time : 720 seconds/blower
Water soot blower pumps
STEAM SOOT BLOWERS
Numbers : 42
Provision for additional Blowers : 18
Type : Long retractable
Locations : From 45.4 ML to 71.3 ML
Blowing medium : superheated steam
Blowing medium pressure/
Temperature : 12 kg/cm²/200ºC Drive for blower : 3Φ,415 V, 0.55 KW/915 rpm
Operating time : 543 seconds/blower
STEAM TO STEAM SOOT BLOWER

21. AIR COMPRESSORS AIR DRYERS Number of dryers : 3 Type : Adsorption
Total number of compressors : 12 Type : T-BTD-J2M Capacity : m³/hr (1000 Nm³/hr) Delivery pressure : 8.1 kg/cm² Delivery air temperature : 45ºC Drive : 3Φ,415 V, 135 KW/1500 rpm Number of compressors for Service air : 3/3 boilers Number of compressors for instrument air : 3 per boiler(total 9 compressors
Number of dryers : 3
Type : Adsorption
Capacity : m³/hr
Heater : 3Φ,415 V, 30 KW
Drying medium : Silica gel