Power house specifications & operations

BPL

Bilt Power House

POWER HOUSE

46 Kg/ cm2 pressure and 35 TPH Babcock and wilcox spreader stoker Boiler X 1 NO

85 Kg/ cm2 pressure and 35 TPH x 03 nos (IJT)

TG Turbine 1 x 18 mw

46 Kg/ cm2 pressure and 25 TPH Heat recovery Boiler X 1 NO (JMW)

BTH TURBINE 6.25 MW X 1 NO (BRITISH THOMSON HOUSTEN)

46 Kg/ cm2 pressure and 25 TPH Heat recovery Boiler X 1 NO (ABL)

Ash handling plant

Coal handling plant

Boiler No. Units

7 1 2 3

Type of boiler

Water Tube

Water Tube

Make IJT IJT

Designed Capacity

t/hr 35 35

Designed efficiency

% 81 81

Operating Capacity

t/hr 30 to 40

30 to 40

Operating efficiency

% 77 to 80

77to 80

Fuel used coal coal

Boiler No. Units 7 1 2 3

Steam pressure

kg/cm2 46 85 85 85

Steam temperature

ºC 404 490 490 490

Blow down %

% 4-5 5-6 5-6 5-6

Pollution control device used

(ESP, cyclone)

ESP ESP ESP ESP

Water tube

IJT

35

81

30 to 40

77 to 80

Coal

Water Tube

B&W

35

78

10 to 35

75-77

coal

BOILER SPECIFICATIONS BOILER PARAMETERS

:

1.FEEDING SCREEN 2.VIBRATOR

3.COAL CRUSHER OR GRANULATOR (HAMMER TYPE)4.CONVEYER BELTS

5.ROLLERS 6.COAL BUNKER

Details of belt conveyor:Belt conveyer 1 [ 800 x 34, 263 long ]Belt conveyer 2 [ 600 x 14, 362 long ]Belt conveyer 3 [ 600 x 126,267 long]Belt conveyer 4 [ 600 x 21, 168 long ]Belt conveyer 5a & 5b [ 800 x 32, 500 long ]

Vibrating feeder [ 915 wide x 1500 long ]Coal size ¾ inches ( 15 – 20 mm )

Grade of coal BCalorific value of coal 4500- 5000 kcal/kg

COAL HANDLING LAY OUT

MakeTRF/GB

Capacity, tons /hr 80/40

1

2Coal charge

m

coalcrusher

1- gear ratio : 30:12- : 30:13- :20 :14- :20:15a : :30:15b : :30:1

COAL HANDLING LAY OUT

crusher

TRF

ELECON

OPP

me

crusher

3

45A

5B

OPP

800x

800x

450

trolley

Type: V1000

Type: 10.5 FSM

Type : V 800

Type: 7

sfm

FLUE GAS PATH HP BOILER

BOILER 1 ST CYCLON 2 ND CYCLON 3RD CYCLON

SECONDARY AIR

TO GRATE

ECONOMISERAIR PREHEATER

FD AIR

HOT AIR OUT

ESP

SCREW CONVEYERS

TO SUBMURGED ASH BELT

FLUE GAS PATH MP BOILER

econ

ID 90 KW

ID 200 KW

GRN

ESP

The flue gas laden with fly ash is sent through pipes having negatively charged plates which give the particles a negative charge. The particles are then routed past positively charged plates, or grounded plates, which attract the now negatively-charged ash particles. The particles stick to the positive plates until they are collected. The air that leaves the plates is then clean from harmful pollutants. Just as the spoon picked the salt and pepper up from the surface they were on, the electrostatic precipitator extracts the pollutants out of the air.

WORKING OF ESP

ASH HANDLING PLANT MAIN EQUIPMENTS:1.ASH BELT CONVEYER2.SUBMERGE BELTS3.SCREW CONVEYERS (SMALL AND LONG)4.ASH HOPPERS5.RIDDLING HOPPERS6. ROLLERS

ASH HANDLING LAY OUT

SB1 SB3 SB3

ABC 1

ABC 2

ABC 3

ABC 3 BYPASS

INC

LIN

ED

BE

LT

Impact rollersplain rollers

SkirtingScrapper

To main ash Hooper

ReturnPla

in r

etu

rn

Carrying idlerImpact

Carrying idlerTrough

ASH HANDLING LAY OUT

IB

HB

SB

SB1

SB2

SB3

BELT 1

BELT 2

BELT 3

ABC 3 BYPASS

BL 7 ESP

ESPAPHECO

APH

ESP

RH

FAH

FAH

RAH

ASH HANDLING PRE CAUTIONS

If inclined belt trips, Horizontal and submerged belt will automatically stopsOPP Submerged belt bypass : Trolley is used to transfer ash when it is bypassed.Inclined belt : Bypass ABC 3 with in 3-5 minutes

Horizontal belt : ESP Hooper bypass NPP Submerged belt has two bypass.

ABC 3 bypass

Pull cord switch

( Belt 1,Belt 2, Belt 3 (ABC 3by pass) ,horizontal belt, Inclined belt, submerged belts (3 in NPP and 1 in OPP). Only horizontal belt in OPP is having chain drive.

P C S

Z S S

B S S

AB

LD

AR

E.

OT

DEAERATOR

PDM

ABLFP

ABLSTEAMFP

85 KGSTEAMFP

EFP1EFP2

LAY OUT FEED WATER (HP) SYSTEM

TOHP BOILERS

TOABL BOILERS

ABLdeae. pump

Suction

Suction

FEED PUMP SPECIFICATIONS

ABL STEAM FP

85 KG SFP

ELECT FP 1

ELECT FP 2

ABL FP

MAKE KSB MATH & PLATT

MATH & PLATT

MATH & PLATT

KSB

TYPE HAD 50/15

4/6 BFO

9 CHR

4/6 BFO

9 CHR

4/6 BFO

9 CHR

HAD 50/15

FLOW 25.3 145 145 145 25.3

HEAD 747MLC 1068 M 1068 M 1068 M 747 MLC

RPM 2960 2980 2980 2980 2950

KW/HP ------- ------- 700/938 700/938 100/134

NE

W P

OW

ER

P

LA

NT

Over head tank

Condtank

Deaerat

or

STST M

46 KG

Ex

h Ex

h

suction

MAINDIRECT

Prv

outlet

Prv

outlet

Prv

outlet

Ve

nt Ve

nt

BL 7 FEED PUMP LINES

Cond. F

rom

plant

3 KG

BL 7 FEED PUMP AREA PRE CAUTIONS

Condensate pump running indication by bulbs.

ABL feed pumps running indication by bulbs.

Inside feed pump attendants room electric feed pump running indication bulb

OT Level 10.5 feet indication bulb

OCT and NCT Level gauges (OCT-0-50-100 %=0-0.25-0.50 LEVEL), (NCT-0-50-100 % = 0-0.20-0.4 LEVEL) Inform DM plant if OCT level falls below 20 %)

OT level graphical indication also

Alarm will ring when any of the above condition is not satisfied.

Electric feed pump Amps above 370 Amps (OL on 380), Immediately steam feed pump to be taken in service. Or if demand is more, inform NPP to start supply from their end for ABL boiler in case BL 7 is running.

If any pump stops or trips immediately standby pump to be started.

Deaerator bypass system always in lineBalancing pressure should be within operating range to maintain the thrust clearanceThere are 2 supplies for ABL/Condensate / Deaerator pump viz. BTH / TG

Incase 2nd extraction pressure is more in BTH , Steam pump extraction line valve required to be operate if instructed from BTH

Gland cooling line is to be continuously observed, There are two valves which are of 55 & 150 hp , and if this is not available third one which comes from emergency tank , valve to be opened

When JMW & BL 7 are in operation, ABL boiler feed water supply to be stopped and ABL condensate pump to be started. (Valve near ABL boiler stairs entry). If only JMW boiler is running feed water supply is from BL 7 feed pump.

JMW boiler feed water heater out temperature 130 deg. Cel. Maximum and steam outlet temperature 405 deg. Cel. Maximum (Runs max 450 deg. Cel. )

No steam / water valve should be opened till the written memo is received and physical check for drain, or isolation is confirmed

BL 7 FEED PUMP AREA PRE CAUTIONS

Direct

MAIN

RTD

TO STEAM DRUM

ECO IN

ECO OUT

TI

BL 7 FEED PUMP LINES

JMW FEED WATER LINES

To Boiler Drum

Direct3 kg steam

Condensate to NCT

Eco in

Feed water heater Mai

n

Sr no Parameter O V Alarm Trip

1 Condensate pump load 30-32 A

2 Deaerator water temperature 105

3 Deaerator pump load 15-17 A

4 Deaerator discharge pressure 2-2.5

5 Electric feed pump load 350 370 380

6 Suction pressure 1.5-2

7 Discharge pressure 58-60

8 Balancing pressure 3 6

9 Oil level

10 Overhead tank level ABOVE 10.5 FT

10.5

11 OCT LEVEL Above 30 % 30 % Below 20%

12 NCT Level Above 50 % 50 % Below 40 %

FE

ED

PU

MP

OP

ER

AT

ING

PA

RA

ME

TE

RS

FEED PUMP

Make: M & P

Type: V.G PLUROVANE

Head : 1980 ft. (600 m)

Size : 6” x 4”Discharge : 349 GPM

92 M3/HR

Motor : 322 HP 430 KW

RPM :SP 1 : 3850SP 2 : 3740EFP : 2960

CONDENSATE TANKS AND PDM

TG condensate goes to PDM tank and from PDM tank to HP deaerator

BTH turbine,PM4, SPL machine condensate to NCT, then it is pumped to DM plant for polishing, back to PDM tank

Remaining condensate from clo2,PM1,PM2,Pulp mill, S/R plant, chemical house comes in OCT

From OCT it is pumped to Overhead feed tank of Boiler no 7 and other pump for ABL overhead tank

OCT & NCT are inter connected ,OCT being on height than NCT. Level is maintained by DM plant, still if OCT level drops to 25 – 20 % verbally to be inform to DM plant SE.Hydrazine + Ammonia –LP Dosing & Nalcol 2518 + Caustic – HP DosingPOLISHING: NCT Charcoal filter Iron filter DM tank

PDM Tank Secondary mixed bed

PDM PUMP

Total head:45 m

Flow : 416.7 lps BEFORE START UP OF BL 7, DM PLANT TO BE IMFORMED

Attempt. Line

pg

85 kg st pum

p

TO

T

G

Range v/v

BL1

Range v/v

BL2

Range v/v B

L 3

85/46

46 KG

H

EA

DE

R

46 kg to TG

E

jector

To A

BL st

pump

85/46 STEAM HEADER

Condensate tank pump ( 1 and 3) and 2Raw water pump 1 and 3Type: 4 U P3 (Double extraction)Size : 150 x 100Capacity : 40 lps (144 m3 / hr)Head : 40 mHP : 50RPM : 1450

46 KG/CM2 FROM 85/46 PRV

AB

L 46

Location: JMW

46/3 PRV

JMW

46 O

LD

46

46/17/7

Ste

am f

eed

pum

p B

TH

BTH TURBINE

46/3 STEAM HEADER

When condensate flow to TG condenser is less ,46/3 PRV is required to be charged. Control of opening of this valve is in TG Control room.

It is assumed that steam flow from this line is 5 Tons Per Hour.

46/17/7

46 HEADER SOOTING JMW

BTH 7

Not in use

Chem house

650/250/100

Pulp millBladecoating

From 10/7 TG

17

7

7/3 PRV

Supplim. For PM1

7 / 3 PRV

PM 2 Supplim

3 kg

PM1 , PM2 LINES

From BTH

PM 1 Supplim

PM1

PM2

10 KGTG

PULP MILL

7 KG BTH

rail clo2

SM

OPP office10KG STEAM HEADER

PRV 10/7

Dorr plant JMW APH

From

46/17/7 prv

ABL

LIME KLIN

PM

4

PM

1.2

3 KG NETWORK

BT

H 7

K

G

SR EVAP

CH

PU

LP

M

ILL

DE

AE

RA

TO

R

SPL M/CF

P E

XH

L

INE

DE

AE

RA

TO

R

CLO2

DORR

JMW FW HEATER

85 KG SFP

10 KG

ABL

SMCLO2

PMC4

MP STEAM VALVE LOCATIONS

Sr. No.

Customer Pr.

Kg/cm2

Location

1 PM 5 10 Back side of CT

2 STARCH MILL 10 Railway gate

3 ABL 10 Railway gate

4 PULP MILL 10 Behind TG room platform

5 CLO2 10 Behind OPP Office

6 PULP MILL 7 Wooden bridge Boiler & BTH

7 CHEMICAL HOUSE 7 BTH header chain valve

8 BLADE COATING 17 Wooden bridge Boiler & BTH

9 FEED PUMP 46 ASH plant

LP STEAM VALVE LOCATIONS

Sr. No.

Customer Pr.

Kg/cm2

Location

1 CHEMICAL HOUSE 3 Above MW section TR 18 (Toilet)

2 PM 1 3 Platform in front of PM 1

3 PM2 3 Platform in front of PM 2

4 PM1 SUPPLM.VALVE 3 BTH house

5 PM2 SUPPLM.VALVE 3 In front of BTH between 2 tanks

6 S/R EVAPORATOR 3 Near 46/3 PRV STAIRS

7 PM 5 / 6 / 7 3 Above BL 7 Control room

8 PM4 3 Near BL 1 FD fan area

9 DORR PLANT 3 Near JMW ESP Stairs

10 HP DEAERATOR 3 Hp deaerator

11 ABL DEAERATOR 3 ABL deaerator

12 BL 7 DEAERATOR 3 BL 7 feed pump area

13 PULP MILL 3 Rail gate + 46/10 PRV

14 MC NO 4 3 From BTH also

15 CLO2 3 Above BL 7 Control room

BOILER NO 7

FR

ON

TRE

AR

RIGHT

LEFT

CO

AL F

EE

DE

R S

IDE

FRONT AND REAR TUBES GOES TO STEAM DRUM

RIGHT & LEFT END TUBES FORM HEADER ,THEN GOES TO STEAM DRUM

REAR END

LEFT ENDRIGHT END

FRONT END

MUD DRUM

BL NO 7 WATER WALLS

BOILER NO 7,8 MOUNTINGS AND FITTINGSDrum safety valvesSH stop valveSH safety valveDrum gauge glassRange valveBlow down valve (04 + 02)Economizer safety valveSteam flow meterWater flow meterHi and LO Whistle

RGG

DOSING

COOLING TOWERS

MAKE : PAHARPUR COOLING TOWERS (Induced draft )

. TUBE WELL SUPPLY:

CHEMICALS USED:

H2SO4 - PH CONTROL 70022718: 75007000: CHLORINE

Total fans :9 nosCurrent : 36 ampsCirculation rate: 2900 m3/hrEvaporation lass : 16 m3/hr

BTH

Fans : 02 nosCurrent : Fan 1 VFD 45 amps

Fan 2 65 ampsCirculation rate : 3200 m3/hrEvaporation loss: 32 m3/hr

3,4,8,16,20,22. 10,12,14,15,17 18,19 1,21

TG

150 HP PUMP HOUSE

12345

PM 4 & OLDPH

TO HYDRANT

OLD PH PULP MILLNOT IN USE

TANK LEVEL 12 FEET SCALEREADING -------FEET EMPTY

Pump 1 current: 25 AVFD 40 HZ

3,4,8,16,20,22. 10,12,14,15,17 18,19 1,21TUBE WELL LINES:

150 HP PUMP HOUSE ELECTRICAL SUPPLY

PUMP NO 1 IS HAVING VFD.

PUMP NO 2 IS HAVING COS FROM DB2 (BTH AND TG).

PUMP NO 3 IS HAVING BTH SUPPLY

PUMP NO 4 AND 5 HAS COS FROM DB2.

FROM 150 HP PUMP HOUSE COS DB2 AND COS DB1 SUPPLY IS GIVEN.

PUMP NO 1 RUNS NORMALLY IN 150 HP PUMP HOUSE

PUMP NO 4 – HYDRANT

55 HP PUMP HOUSE

5421

TANK LEVEL 5 FEET SCALEREADING -------FEET FULL

MC 1,4 NOT IN USE COATING PLANT

NOT IN USE

NOT IN USE

MC 1,4 / DM/ DORR/ SR/ PH/ CH/ NPP

Pump 5 current: 82-84 A

3,4,8,16,20,22. 10,12,14,15,17 18,19 1,21TUBE WELL LINES:

55 HP PUMP HOUSE

BFW PUMPSGLAND

EMERGENCY GLANDFILLING TANK

DM PLANTTUBE WELL NO 6 / 9 CONNECTION

BTH DRINKING/WASHING

BTH OIL / AIR COOLER

PM

C 1

, 2

DORR / SR/NPP BFW PUMPSGLAND

SR/NPP

CH

FROM SPL PUMP

BTH SUMP

FR

OM

SP

LIT

Y P

UM

P

HO

US

E

55

55 HP PUMP HOUSE ELECTRICAL SUPPLY

PUMP NO 5 IS HAVING VFD.

SUPPLY FROM PANEL NO 2

DB1 SUPPLY TO TUBE WELL NO 1 AND 2 ,AND TO SERVICE PUMP NO 4.

COS IS FOR ABOVE. (Main supply from 150 HP pump house)

SUPPLY FOR PUMP NO 1 FROM PANEL NO 1.

COS FOR DB2 IS FOR SERVICE PUMP NO 1 , 2 , AND 5.

PUMP NO 5 RUNS NORMALLY.

FIRE PUMP DETAILS

At four location Fire pump stations are available

Main fire pump house at S/R area (4 Pumps)

At ETP (2 Pumps, One electric driven and other Diesel 12 cyl driven )

At Yard sump Electric pump

At 150 HP pump house , pump no 4.

From main fire pump house, pump no 4 runs normally

Yard fire pump some times used when sump level to be make up

All three supply available

Fire hydrant circuit 1 (cooling pond)Pump 1 (Pump no 3)Make : Mather and PlattType : 7.2 ST MEDICapacity: 1000 gpmHead : 290 ftHP : 190 RPM : 1450

Pump 2Make Mather and greevesType: 8/8 MHLCapacity: 1500 gpmHead : 290 ftHP : 200 RPM: 1450

Pump 2B (ETP)Make : KirloskarType: SVA 8Size: 8 x 8Capacity : 1400 gpmHead : 225 ftHP : 200 RPM : 1450

Diesel engine driven pump :8/8 MHL Mather and plattCapacity : 1500 gpmHead : 290 ftRPM : 1450Diesel engine make: MWMType: TD – 237 – VIZBHP : 200RPM : 1500

Fire hydrant circuit 3 ( Chipper yard)

Pump no 3:Make : Mather and PlattCapacity : 1500 gpmHead : 290 ftHP : 200 RPM : 1440Reservoir capacity : 2 lacs gallon

FIRE PUMP DETAILS

FIRE PUMP HOUSE

3421

Sometimes pump no 2 is started for CH increased consumption

66 A / 2.5 K/c2

SPECIALITY PUMP HOUSE DETAILS

1 RUNNING 1 RUNNINGSHUT

250 M3/HR4 K/C285 A

M3/HR2-2.5 K/C265-70 A

3,4,8,16,20,22. 10,12,14,15,17 18,19 1,21TUBE WELL LINES:

CO

AT

ING

PL

AN

T

AIR

CO

MP

RE

SS

OR

TW NO 9 / 6

55/ 150 LINE

NEW POWER HOUSE

PU

LP

MIL

L

AIR COMPRESSORS

Air compressors in power house are situated as follows

1) 2 nos at old power plant

2) 2 nos at new power plant

3) 4 nos at specialty machine area

cooler

PROCESS

2.5 kg/cm2

Coating plant5 kg/cm2

AD AD

cooler

RECIEVERTANK

cooler

cooler

Pulp mill , spl machines , Clo2 plant, power house

5 kg/cm2

Air comp no 2,6,4,5

Motor load: 230-250 A

AIR COMPRESSORS

NPP : KG KHOSLA MAKEDouble stage3H Y2TCERRPM : 650Pr. : 7 kg/cm2Cap : 5.89 m3/minPr 1 st stage : 2 kg/cm2pr 2 nd stage : 5.5 kg/cm2oil pr. : 2.5 kg/cm2

SPL : KG KHOSLA MAKEDouble stageAir comp no 4,5,6RPM : 800Pr. : 7 kg/cm2Cap : 51.41 m3/minPr 1 st stage : 2 kg/cm2pr 2 nd stage : 5.5 kg/cm2oil pr. : 2.5 kg/cm2

SPL : KG KHOSLA MAKESingle stageAir comp no 2RPM : 560Pr. : 7 kg/cm2Cap : 11.01 m3/minoil pr. : 2.5 kg/cm2

Air is distributed from new power plant air compressors to POWER HOUSE Air compressors in Old Power House are standby.

In case of air pressure drop or compressor trip, SPL pump house air compressor valve can be opened which is at NPP electrical panel room.

Also one line from S/R plant air compressors is available for the same purpose but it is rarely used.

Air compressors in Old Power Plant can be started in emergencies, can be put in Auto mode .One will be Auto and other will be stand by.

AIR COMPRESSORS PRE CAUTIONS

TUBE WELL NETWORKTUBE WELL NO

LOCATION SUPPLY CHANGE OVER

1 CHAIR REPAIR WORK SHOP 55 HP PUMP HOUSE

2 COATING PLANT (BEHIND 55 HP PUMP HOUSE) 55 HP PUMP HOUSE

3 TI CLUB NEAR TUBE WELL 8

4 RAMLEELA STAGE NEAR TUBE WELL 8

5 DOES NOT EXSISTS -------

6 BEHIND DM PLANT SAME LOCATION

7 DISPENSARY NO 5 NEAR TUBE WELL 8

8 TR BUILDING NEAR TEMPLE NEAR TUBE WELL 8

9 GHEE PLANT FROM BOILER HOUSE DB

10 GATE NO 9 NEAR TUBE WELL 10

11 DOES NOT EXSISTS -------

12 ETP MACHINE NO 5 / 7

13 DOES NOT EXSISTS -------

14 200 QTR NEW GATE SAME LOCATION

15 GATE NO 8 NEAR TUBE WELL 10

16 CHUNA BHATTI NEAR DR BUILDING

17 NANGAL POWER HOUSE

18 PUNJAB MILL NANGAL NO CCHANGE OVER

19 PUNJAB MILL NANGAL NO CHANGE OVER

20 TR BUILDING GROUND NEAR TUBE WELL 8

21 NEAR TRAFFIC DEPT. Location

22 DR BUILDING OLD NEAR DR BUILDING

INS

IDE

1,2,6,7,9,10,12,14,15,17,21

OU

T S

IDE

3,4,8,16,20,22

PU

NJA

B

18,19