7. INTRODUCTION OF BOILER

10. Introduction to Adani Power 660 MW Boiler Description Unit Value Type Supercritical, Once Through Type, Sliding Pressure, Single Furnace, New Tangential Type, Single Reheat, Balanced Draft, Dryed Slag Discharge, Complete Steel Structure, Complete Hanging Construction, Double Gas Passes. Manufacturer HARBIN BOILER COMPANY, CHINA Design Code For Pressure Parts ASME, GB9222-88, IBR

13. SUPER CRITICAL BOILER CYCLE WITH SH, RH & Regeneration of ADANI 5 x 660 MW 256 Kg/cm2 0 100 200 300 400 500 600 540’C 568’C Steam flow :2225 T/Hr Steam temp : 540 ‘c Steam Pres : 256 kg/cm2 RH pre : 51.6 Kg/cm2 RH Temp : 568’c Feed water Temp : 291’c ENTROPY TEMP

15. SH DRUM ECO HTR BFP W/WALL DOWN COMER RISERS Natural Circulation Boiler W/WALL BFP HTR ECO SH SEPERATOR ONCE THROUGH SYSTEM

16. FLOW DIAGRAM OF SIPAT SUPER-CRITICAL BOILER

18. Spiral wall outlet temp at BMCR (front wall) Spiral Wall Evaporator Configuration of Evaporator panel Spiral wall : Vertical wall = 3 : 1 Supercritical Boiler Technology

19. spiral wall spiral wall and windbox WALL OF BOILER

20. 660 MW PLANT BOILER

21. LTSH COILS ECONOMISER COILS ECONOMISER I/L HEADER ECONOMISER O/L HEADER

22. AIR PREHEATER

28. Air Preheater, main technical specifications and list of master drawings

30. Isometric view of Air Preheater

36. ASH HANDLING PLANT

39. Silos for collection of FLY-ASH

42. LOCATION OF ESP ESP CHIMNEY APH ECO

44. ESP PROCESS STEPS Collecting electrode, grounded Rapping mechanism Discharge electrode with Negative high tension (20-60kV) 4.dust collection 4 Dust layer 1 1.Electron emission 2 2.Dust particle charging 3 3.Migration 5 5.Rapping

45. ESP Flue gas Emitter coil Gas distribution plate Collector plate

46. ESP TECHNICAL SPECIFICATIONS Description Unit Value Nos. of Gas Stream / ESP Double Nos. of Parallel Path per Stream Nos. 38 Nos. of electrical fields in series Nos. 5 Total active treatment length per stream m 3.5 Treatment Time Seconds 15

47. Description Unit Value Total Number of Electrode Nos. 3192 x 2 Total numbers of Rappers per Unit Nos. 7 Total Nos. of Transformer Rectifier Unit Nos. 20 Capacity of Transformer Rectifier Unit Each KVA 1.6A/72 KV Total No. of Dust Hoppers Nos. 40

48. FUEL OIL SYSTEM

57. COAL MILL

60. COAL MILL

61. A B C D E F ESP PASS A ID-A ID-B PA-B FD-B PA-A FD-A FURNACE WIND BOX SCAPH SA PA FG SA PA FG SCAPH ESP PASS B ESP PASS C ESP PASS D WIND BOX ESP I/L X – OVER DUCT ESP O/L X – OVER DUCT SA –X-OVER DUCT COLD PA HOT PA FLUE GAS COLD SA HOT SA CHIMNEY MILL LOCATION APH APH MILL 27ºC 324ºC 320ºC 1165ºC ECO I/L 493ºC 351ºC 136ºC 134ºC 129ºC 126ºC

66. Coal Pulverisers Description Unit Value Type of Design & Construction Medium Speed Mill Number (Each Unit) Nos. 6 Capacity of each pulveriser for the design coal TPH 70 Min. load of Pulverisers % 25 Mill Speed Rpm 33 Driver Speed Rpm 982 Rated Power Kw 900 Avg. life of Rollers/Grind Roll & Bottom Race Liners before Replacement Hrs. 12000

67. ID, FD & PA FAN

68. FURNACE PRIMERY AIR HEATER SECONDRY AIR HEATER MILLS FD FAN A PA FAN B PA FAN A FD FAN B ESP ID FAN A ID FAN B CHIMNEY Atmospheric air Atmospheric air

70. Induced Draught Fan

73. Forced Draught Fan

76. primary air fan

78. Fans Description Unit FD PA ID Fan Model Axial Fan Axial Fan Axial Fan Rated Power of Motor kW 2000 3150 4500 Rotational Speed of Fan r/min 990 1490 990 Volume flow of fan inlet m^3/s 230.1 112.9 538.4 Temperature of fan inlet ˚C 47.8 47.8 137 Fan total pressure Pa 3871 12671 3989 Total efficiency % 87 88 85.5 External Diameter of Blade mm 2880 2100 3349 Diameter of Impeller mm 1600 1400 1884 Blade No. of Each Grade Nos. 26 22 18

79. COOLING TOWER

82. COOLING TOWER

84. Principle of cooling Tower operation In COOLING TOWER - Water is split up into small droplets & brought into intimate contact with air. - In doing so a small quantity of water is evaporated. - The EVAPORATION brings about the 75 % of the cooling effect. - Balance 25 % of the cooling is due to sensible heat transfer.

85. Evaporation Heat Load Blowdown Recirculating Pump Cooling Tower

87. FIRE FIGHTING SYSTEM

88. Water spray fire fighting system HVWS System & Automatic alarming ,Automatic/Manual startup To spray fire fighting system(300 nb) hydro pneumatic tank(80nb) 1 4 2 2 2000 m3 fresh water reservoir 2000 m3 fresh water reservoir 3 3 1 Automatic sprinkler driven F.F Q-410,H=115,N=220,1nos 2 Automatic sprinkler F.F jockey pump,Q-18,H-115,N-13.5-2nos 3 Air compressor-2nosX100%Type-ww-0.7/25V=170LN=11kw No Description 4 Automatic sprinkler motor drive F.F pump,Q-410,H-115,N-220 - Coal conveyor - 3#juction house - 2#juction house - 1#juction house - Crusher room - switch yard control building 10.40m cable spreader room -10.4 m cable mezzanine MVW -Bunker bay Steam driven pump lube oil system, category-B' Steam driven pump lube oil system, category-B' Hydrogen seal oil device, category-B Turbine lube oil tank, category-B Medium layer oil device, category-B Mill lube oil system, category-B Air pre-heater, category-B Boiler burner, category-B Diesel generator room, category-B outdoor oil storage tanks, category-B Station transformers, category-A Unit auxiliary transformers, category-A Generator transformers, category-A

89. Hydrant fire fighting system hydro pneumatic tank(80nb) To fire hydrant fire fighting system 5 10 6 9 7 7 5,6 Hydrants Diesel- drive F.F pump,Q-273,H-125,N-160 9,10 Hydrants Motor- drive F.F pump,Q-273,H-125,N-160 7 Hydrants F..F jockey pump 8 Air compressor-2nosX100%Type-ww-0.7/25V=170LN=11kw No Description 2000 m3 fresh water reservoir Crusher room Junction house-3nos Junction house-2nos Junction house-1nos Coal yard area Cooling tower area of Unit-5& 6 Water clarifiers area fuel oil storage area Waste water treatment building area D.M water treatment plant area ESP& stack area Central control building Boiler house-6 unit Boiler house-5 unit Dearetor & bunker bay Main turbine house-6 unit Main turbine house-5 unit 2000 m3 fresh water reservoir 8 8

90. COAL HANDLING PLANT

92. LAYOUT OF COAL HANDLING PLANT TT-1 TT-3 TT-2 TT-4 CRUSHER HOUSE BUNKER

97. Coal conveyor

100. Stacker & Reclaimer

101. TURBINE

102. TURBINE MAKE:- Dong Fang Steam Turbine Works Nominal Capacity- 660 MW Type- N660-24.2/566/566

104. REACTION TURBINE IMPULSE TURBINE PRESSURE AND VELOCITY PROFILE THROUGH THE BLADES

106. HPT IPT LPT A LPT B CPP Condensor (HP) Condenser (LP) 1 HPH - 1 HPH - 2 HPH -3 EXT From CRH LPH -5 LPH -6 LPH -7A LPH -7B LPH -8A LPH -8B 3 Deaerator BFBP TDBFP Boiler CEP 3x50% 2x50% FCS 5 5 6 6 2x50% From Reheater Economiser 1482 TPH 1994 TPH (MD BFP 1x35%) (MD BFBP 1x35%) 7 8 7 8 8 7 7 8 8 6 2x7 2x7 HPH-1 – Extr from 6 th stage HPH-2 – From CRH HPH-3 – From 11 th stage Deaerator – From 14 th stage LPH-5 – Extr from 16 th stage LPH-6 – From 17 th stage LPH-7 – From 18 th stage LPH-8 – From 19 th stage GSC

107. TURBINE SPECIFICATION HPT IPT LPT Pressure (bar) 242 44.9 11.6 Temp (Deg C) 566 566 383.5 Steam Flow (tph) 1994.25 No of Stop valves 2 2 No of Control valves 4 2 Steam Admission Parameters at Turbine Inlet

111. SEA WATER SYSTEM

112. Mechanical accelerated clarifier Sea water in take pump house Sea water reservoir Cooling tower Evaporative losses Drift losses D.M plant waste water(43m3/hr) Effluent plant 440m3/hr 156m3/hr 2200m3/hr 43m3/hr 8806m3/hr 8806m3/hr 8366m3/hr 6121m3/hr 6611m3/hr Water balance diagram Sea water 124 cum/hr from fresh water sys.

113. Over view of water system of phase-III Desalination plant (PMC scope) Intake Water Reservoir (sea water) Make water system service water system Water spray fire fighting system Hydrant fire fighting system Potable water supply system D.M water system Recirculation water system 381 m3/hr 8806 m3/hr

115. service water system Consume & stand by water(30m3/hr) Wash water for car & floor(2m3/hr) Ash handling air compressor cooling water(60m3/hr) Mechanical air compressor cooling water(100m3/hr) Industrial waste water treatment system(1m3hr loss) For HAVAC system- (8m3/hr) Wash water for coal handling system(2m3/hr) Moistening water for dry ash(9m3/hr) Wash water for clinker floor(2m3/hr loss) SSC Seal water(3m3/hr ) Coal water treatment system(6m3/hr) Bottom ASH hopper seal water(3 m3/hr) Coal storage area spray water(6m3/hr) Spray water for bunker wheel machine(3m3/hr) 2000 m3 fresh water reservoir 2000 m3 fresh water reservoir Make up water to cooling tower basin128m3/hr) Service water pump,Q-150m3/hr,H-60Mtr,N-40Kw To service Water(198m3/hr,250nb)

117. Waste water treatment System 1. Sanitary sewage treatment system This system function is to send the sewage to the sewage treatment equipment, in which the sewage is treated to remove the suspended solid, colloidal substance, soluble organic matter and to eliminate the pathogenic bacteria 2. Coal wastewater treatment system Storm water runoff from the coal handling area and Coal Handling Plant is collected in a set of coal settling pond. Coal fines, which accumulate in the basin over time, must be periodically removed. These are stacked-out adjacent to the pond for dewatering, and returned to the coal pile. The rain water will be pumped into the coal wastewater treatment system and will be reused in the plant. 3. Industrial wastewater treatment system Industrial wastewater system collects variety of wastewater, which is produced in the course of daily life and production activities. The water will be treated by the Industrial wastewater treatment system and then be reused.

119. DM PLANT

121. Cation exchanger precision filter Q=110m3/hr High pressure pump Q=110m3/hr,H=1.35Mpa Reverse osmosis Q=80m3/hr Fresh water tank V=300m3 Fresh water pump Q=90m3/hr,H=0.3Mpa Decarbonator Intermediate water pump Q=90m3/hr,H=0.4Mpa Mixed ion exchanger Ø2200,H cation- 500mm, H anion -500mm Anion exchanger D.M water tank Condenser storage tank ,V=300m3 DM water pump Q=120m3/hr,H=0.4Mpa-2nos Q=300m3/hr,H=0.5Mpa-1nos Reducing agent dosing Cleaning agent dosing Acid dosing caustic dosing Caustic & acid dosing D.M plant flow diagram Inlet water quality PH- 5-6 T.D.S - <500ppm T.S.S=Nil Sodium+ potassium=<150ppm Sulphate=<20ppm Chloride<250ppm Silica=<1ppm Outlet water quality PH= 8 to 7.2 Turbidity<1NTU Free chlorine Nil Conductivity <0.1Micromhos/cm Sodium as Na= <1ppm Free CO2<5ppm Total silica <0.02ppm

124. Sodium Hypochlorite Dosing Tank Sodium Hypochlorite Dosing Pump-I (1W+1S) Sodium Hypochlorite Dosing Pump-II (1W+1S) Pressure Sand Filter ( 2W+1S) Activated Carbon Filter ( 2W+1S) Strong Acid Cation Exchanger Degasser Tower Degassed Water Transfer Pump (3W+1S) [ Degasser Storage tank Weak Base Anion Exchanger Strong Base Anion Exchanger Mixed bed Exchanger DM Water Storage Tank Condensate Water Transfer Pumps (1W+1S) DM Regeneration Pumps (1W+1S) Condensate Storage Tank Acid Measuring Tank for MB Service Water Overhead Tank Bulk Acid Storage Tank Acid Unloading & Transfer Pump (1W+1S) Caustic Measuring Tank for SBA Bulk Caustic Storage Tank Caustic Unloading Pump (1W+1S) Acid Measuring Tank for SAC Caustic Measuring Tank for MB Process Flow Diagram for Conventional DM Plant for Adani Power Ltd. , Mundra SEZ 60m 3 /hr 60m 3 /hr 60 m 3 /hr 60m 3 /hr 60m 3 /hr Water Storage Tank DM Water Supply Pumps (3W+1S) Filter water B/W Tank 30% HCl for regeneration Degasser Blower (1W+1S) 45% NaOH for regeneration Mixed Bed Blower (1W+1S) Neutralization Pit (2) ETP Effluent Transfer Pumps (1W+1S) Air Scouring Blower (1W+1S)

125. DM PLANT

126. TDBFP & MDBFP SYSTEM

128. Boiler Feed Pump Options Available 1X100% TDBFP & 1X100% MDBFP 2X50% TDBFP & 1X50% MDBFP 3X33% TDBFP & 1X33% MDBFP To pump feed water from Deaerator to boiler through HP Feed water heaters. Requirement:

130. THE BOILER FEED WATER PUMP

131. Efficiency of generator = 98% (Say) Efficiency of UAT= 97% (Say) Efficiency of Elect. system = 98% (Say) Efficiency of BFP Motor = 97% (Say) Efficiency of Hyd. coupling = 87% (Say) Total percentage utilisation when MDBFP used= 78.6% (0.98 X 0.97 X 0.98 X0.97 X 0.87 = 0.786) Power consumed by two TDBFP = 15 MW (approx.) ?? Saving in MW when TDBFP used = 3.21 MW (15 X (1-0.786) = 3.21 MW) Reasons for Selection of TDBFP Over MDBFP for Normal Operation

136. TDBFP

138. MDBFP

139. THANK YOU