D 1.1 SG Writeup-4783a150506

JSW ENERGY (VIJAYANAGAR) LIMITED
NO.
TCE-4857A-C-
2 x 300MW COAL BASED THERMAL POWER STATION AT

TORANAGALLU, BELLARY (KARNATAKA)
VOLUME II Part IISECTION: D1.1
SHEET 1 OF 25
STEAM GENERATOR AND AUXILIARIES
1.0
DESIGN REQUIREMENTS
General
1.1
The steam generator shall be designed for SGMCR capacity specified in

Data sheet A1 and for burning 100% coal. The Bidder shall offer drum
type steam generator of proven design.
1.2
The steam generator and its auxiliaries shall be designed for outdoor
installation.
1.3
The steam generator unit shall be capable of operating either on constant

pressure or sliding pressure mode. The load range for the sliding pressure
unit operation would be from 30% steam generator maximum continuous
rating (SGMCR) to 100% TGMCR.
1.4
The steam generator shall be designed to meet the Indian Boiler

Regulations (IBR) requirement. Wherever IBR is not specific about material,
design manufacture, inspection and testing requirements, ASME code shall
be used.
Steam Generator Structure
1.5
The steam generator structure shall be designed to support all loads

located on the structure. In addition, other loadings may be introduced on
the structure from piping, enclosures, adjacent structures and equipment.
Furnace
1.6
The furnace shall be designed such that the heat release rates shall not
exceed the values specified in Data Sheet-A1 at 100% steam generator
maximum continuous rating (SGMCR) condition. The distance between
centre line of bottom most coal burner and furnace hopper working point
shall be not less than 3 metres. The configuration of the furnace shall be
such that flame impingement on any section of the furnace is avoided over
the entire load range.
1.7
The furnace shall have hopper bottom with stainless steel seal plates
suitable for connection to a water impounded ash hopper. A suitable sealing
arrangement for connecting to a water impounded ash hopper shall also be
provided. The clear width of the hopper throat shall not be less than
1100mm. The distance between furnace opening and the grade level shall
be 7.5 m.
1.8
Field welds in large diameter thick walled headers or pipes shall be avoided
to the extent possible.
1.9
Provision shall be made for the future installation of additional soot blowers
in the furnace.
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1.10
Observation ports shall be designed to prevent infiltration of air into the

unit.
Casing
1.11
A gas tight enclosure shall be designed for the entire steam generator from
the lower furnace to the economiser exit. In areas where welded wall
construction is used, no skin casing is required, but skin casing of steel
plates shall be used for all enclosures and behind all wide spaced tubes
where refractory is used. Frames shall be furnished around all openings in
the steam generator, designed to allow for expansion between the welded
wall or inner skin casing and an outer aluminum lagging. The aluminum
shall be of ribbed type and shall be minimum 1.2 mm thick.
Steam and Water System
1.12
The steam and water system shall be as per enclosed scheme no.
TCE.4857A-510-SK-001.The system shall be designed for a continuous
operating capability as specified in Data Sheet-A1. The Bidder shall clearly
bring out the design features to minimise the peak tube metal temperature,
unit temperature variation between adjacent enclosure tubes and prevent
departure from nucleate boiling.
Steam Generator Water Circulation
1.13
The circulation system shall ensure adequate circulation ratio during rapid
start-ups and load changes to prevent overheating of the water wall tubes
with maximum possible heat flux in the furnace. This shall be ensured by
suitable sizing the steam drum, down comers and water wall tubes. The
steam generator water circulation shall be natural circulation type.
1.14
The circulation ratio shall be checked for adequacy under different

operating conditions vz., start-up,abnormal operating conditions,etc.
Suitable allowances shall be provided for all the water wall tubes to counter
the erosion conditions.
Steam Drum
1.15
The design of the drum internal shall be such as to guarantee the steam
quality required for the steam turbine (greater than or equal to 99.9 5), over
the entire load range.
1.16
All nozzles shall be of the long body type so that the same will extend
through the steam generator lagging. The ends of nozzles smaller than 50
mm shall have plane ends for socket welding and the nozzles 50 mm and
larger shall have beveled ends for butt-welding.
1.17
The distribution and placement of furnace water wall tube inlets to the drum ISSUE
shall be designed to permit uniform heating of the drum metal during start- R0
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SHEET 3 OF 25
up, shutdown and load changes. The CONTRACTOR shall specify in the
tender, the maximum permissible drum metal temperature differential and
the corresponding maximum permissible rate of pressure and temperature
changes during start-up, shutdown and load changes.
Superheater and Reheater
1.18
The superheater and reheater shall be of proven design and shall be

designed to maintain superheat and reheat steam temperatures at
superheater and reheater outlet over the entire steam temperature control
range (i.e. from 60% TGMCR to 100% SGMCR rating) as specified in Data
Sheet-A1 under the following conditions:
-With the steam generator heat absorption surface condition varying
from clean upto normally expected and permissible fouling limits;
-With minimum possible use of de-superheating spray;
-
With permissible and normally expected unbalance or stratification in

flue gas flow;
With all specified modes of fuel burning.
1.19
The superheater and reheater elements shall be arranged to ensure the

uniform steam distribution and steam temperature variation of not greater
than 10oC across the width of the steam generator at all operating
conditions and loads.
1.20
The attemperators are to be of spray type fitted with an inner removable

lining, so arranged that the lining could be removed readily without
recourse to extensive cutting of the construction welds. Ample provision
shall be allowed to enable internal inspection of the vessel by means of the
intrascope.
Complete superheater and reheater temperature control
system with necessary piping; block, control, isolation and check valves
and instrumentation & controls shall be provided.
1.21
The superheater and reheater supports or hangers exposed to hot gases

within the setting shall be of a heat-resisting material suitable for long life
under the service condition.
1.22
Auxiliary steam tap-off connection for soot blowing shall be either from
intermediate superheater header or from cold reheat line or from auxiliary
steam header. In case the steam is tapped off from the cold reheat line or
from auxiliary steam header, the CONTRACTOR shall furnish a list of
installation where such systems are in vogue and also the same shall be
reflected appropriately in the turbine cycle heat balance diagrams.
Suitable allowance shall be provided for the superheater and reheater
tubes to counter the erosion condition.
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SHEET 4 OF 25
Economiser
1.23
It shall be ensured that the economiser design pressure exceeds the steam
generator design pressure by an amount of at least equal to the pressure
drop (friction and static) through the economiser at the 100% SGMCR
condition.
1.24
The economiser shall be of non-steaming type and shall have provision for
recirculation of water while starting the unit. The economiser tube banks
shall be of in line design. The design of the economiser shall be such that
the tube elements can be easily replaced when necessary. Suitable
allowance shall be provided for the economiser tubes to counter the
erosion.
Headers
1.25
All headers in high temperature gas path shall be located outside the gas
path. The handhole openings in headers shall be so located as to provide
suitable access to maintenance and inspection. All handhole plates shall be
designed for seal welding.
1.26
The header vents, drains, pressure gauges, steam and safety valve
connections shall be of weld-end type. Instrument as required including test
connections shall be provided.
1.27
All headers shall be thoroughly cleaned and be free of scale by shot

blasting on the inside.
1.28
All valves that require operation during start-up or shutdown of the steam
generator shall be electric motor operated, except as specifically stated
otherwise. All motor actuators shall be designed to meet the torque
requirement due to maximum differential pressure. In addition to these
motorised valves, any other service, which calls for motor operation, shall
be motorised and those motorised valves shall be listed in the bid.
1.29
Drains from steam drum, headers, gauge

steam generator shall be terminated into
headers which will be connected to IBD
liberally sized to avoid pressurisation and
above the steam generator roof.
1.30
Facility for draining the steam drum during emergency when the steam
generator is in operation shall be provided. The valves shall be furnished
with motor drive. The drain shall be led to IBD through a drain collection
header. The tap off point for emergency drain should be at normal drum
level. All blowdown valves shall be suitable for passage of acid wash during
acid cleaning.
glasses and integral piping of

one or more drain collection
tank. IBD tank vent shall be
shall be terminated 3 meters
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SHEET 5 OF 25
1.31
The drain valve capacity shall be sufficient to permit draining of the unit
under atmospheric pressure in one (1) hour.
1.32
For nitrogen (N2) blanket and N2 preservation, suitable connections for N2

supply shall be provided. The N2 system shall include all the piping, valves,
vents and drains, pipe supports etc to make the system complete.
Air and Flue Gas System
1.33
The air and flue gas system shall be as per enclosed scheme no.
TCE.4857A-510-SK-0003
1.34
The air and flue gas system shall be designed to meet the requirements of
100% SG MCR conditions and for using the coals specified. The system
shall also be suitably designed for burning heavy furnace oil (HFO) and
light diesel oil (LDO) as specified.
1.35
The air and flue gas system shall consist of two (2) 60% capacity FD fans
of axial blade pitch controlled, two (2) 60% capacity PA fans of axial blade
pitch controlled (the Bidder can offer centrifugal fans with techno economic
justification), two (2) 60% capacity centrifugal ID fans with variable
frequency drives and inlet guide vane control 2 x 60% capacity trisector
regenerative air preheater (RAPH), with associated drive motors, cold air,
hot air, tempering and flue gas ducting and dampers to handle the steam
generator requirements.
1.36
The general design requirements for the fans shall be as follows:
1.36.1
The rotor shall be over-speed tested to at least 10% above the maximum
operating speed and shall be dynamically balanced. The fan shafts are to
be supported in bearings on either side independent of the casings.
Overhung impellers will not be acceptable.
1.36.2
All fans shall be designed for under-frequency operation up to 47.5 Hz

without any reduction in its performance.
1.36.3
Forced oil lubrication system for the fans and motors shall consist of 2 x
100% oil pumps each with motor, 2 x 100% oil coolers and filters; one (1) oil
tank and electric heater with thermostat etc.
1.36.4
The flow-induced pulsation should be avoided by suitable design of fan and

connecting ductwork.
1.36.5
Suitable design of shaft sealing shall be provided to prevent ingress of

atmospheric air.
1.37
Each bearing is to be provided with oil level indicator and a screwed drain
plug. Adequate sealing arrangement shall be provided at each end of the
bearing housing to prevent leakage of lubricating oil.
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SHEET 6 OF 25
1.38
Silencer shall be provided at the inlet of FD and PA fans with weather hood
and inlet screen.
1.39
Suitable braking arrangement shall be provided to ID fan so that with the

driving motor switched-off, the fan continues to turn at low speed under the
influence of chimney draught.
1.40
An adequate number of interconnecting, isolating and control dampers with

drives shall be provided on all cold air, hot air, seal sir and flue gas ducting
before and after equipment on these systems to permit proper operations.
The control dampers shall be pneumatically operated and isolation dampers
shall be electrically operated.
1.41
The gas and air ducts shall be designed for wind loads as specified for the
steam generating unit proper and their own weight including fly ash load
which may get deposited at the duct bottom, insulation and lining. The top
of the ducts shall be crowned to ensure proper drainage.
1.42
The ductwork shall be free to expand, but it shall be rigid against wind and
seismic disturbances. Adequate provision shall be made for all expected
expansion or contraction.
1.43
All gas and air ducts shall be designed to ensure uniform distribution of gas
and airflow to the various portions of the unit. These ducts shall consist of
turning vanes / baffle plates, stiffening devices, expansion joints, interior
bracings, access doors and brackets, support structures and hangers as
necessary.
1.44
Aerofoils shall be provided in the air ducts for the measurement of total
airflow.
1.45
Locking devices shall be provided to dampers to permit locking in both open

and shut positions.
1.46
Electrical operated guillotine type isolation dampers along with drives shall
be provided as specified in Data sheet-A1. The inlet dampers for ID fans
shall be located in horizontal duct of main inlet duct to avoid fly ash build up
when in closed position(the same will be take care suitably during detailed
engineering by SEC).
1.47
The flue gas duct layout shall be designed considering the following
aspects:
The change of direction of flue gas duct shall be gradual to avoid
ash collection at the bottom of the duct and also to prevent erosion
by local concentration of fly ash.
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The number of direction changes of the flue gas duct shall be

minimal to minimise the ash collection points.
However, the air preheater, economiser and duct hoppers shall

have provision for removal of fly ash during maintenance period
when the steam generator is out of operation. To facilitate such fly
ash removal, a 100% gas tight isolation gate near the hopper
bottom shall be provided. The hopper bottom shall be blanked with
a blind chute suitable for unloading fly ash from all the above
mentioned hoppers.
Dust Precipitation and Collection System

1.48
One electrostatic precipitator (ESP) shall be provided for the steam

generator. The electrostatic precipitator shall be designed to limit the dust
concentration as specified in Data Sheet A1. ESP shall be complete with
supporting structural frames, collecting and discharge electrodes, shaft
insulators, bush insulators, independent rapping system for collecting and
discharge electrodes with automatic rapping controls, high voltage
transformers, rectifiers, bus sections with sectionalising and grounding
switches and controls, fly ash collecting hoppers with accessories etc. An
Energy Management System (EMS) shall be provided to optimise the
power consumption. The Bidder shall furnish the details of EMS.
1.49
Access doors and platforms and corresponding interior walkways shall be

provided on each side of the casing before and after each of the fields in
series at the bottom and mid point elevations of the collecting electrodes in
order to facilitate maintenance and inspection of each of the fields.
1.50
For personnel protection, key interlocks shall be provided to prevent the

opening of any inspection and/or access doors until after de-energising of
all high voltage equipment that can be reached and/or made contact with,
through the inspection and/or access door.
1.51
Each hopper shall be provided with a conveniently located 150 mm (6 inch)

pipe nipple fitted with a quick removable hinged cap located near hopper
outlets to facilitate emergency poking.
1.52
If the MANUFACTURERs standard design is such that the roof is pierced

with rapper rods, high voltage support insulators, or other components
which would require external insulation and weather-proofing be installed,
he shall provide a penthouse/weather enclosure to be erected on
precipitator roof. He shall also provide aluminium gutters and a 100 cm high
2-rail safety handrail.
1.53
Penthouse/weather enclosures shall be ventilated by electric motor driven ISSUE

fans. The transformer rectifier sets, controls etc., must be kept within R0
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SHEET 8 OF 25
acceptable temperature limits under all operating conditions with maximum

ambient temperature. The fans shall be wall mounted, exhaust from inside
the penthouse to the outside and be protected with rain louvers.
1.54
1.55
1.56
The hoist to permit easy removal of each transformer-rectifier from its

operating position to grade level shall be provided.
The rapping system shall be designed for selective remote automatic or
manual operation at adjustable intervals. Necessary rapping arrangement
with controls shall be provided for perforated gas distribution plate at inlet
to and outlet from the ESP.
Electrical System of ESP
Transformer Rectifier Equipment
1.56.1
These shall be suitable for indoor/outdoor installation. The transformer

rectifier assemblies shall be designed for electrostatic precipitator service
and shall be for single-phase energisation with silicon rectifiers connected
for pulsating negative polarity double, halfwave operation. Means shall be
provided for changing to full wave operation, if found desirable, for any
reason through external switching. The access door to the links, required
for changing the high voltage connections, or the high voltage switch
operating mechanism or cover should be arranged for locking with a
padlock. Key interlocking shall be provided on access door or cover to the
links required for changing the high voltage connections, or the high
voltage switch operating mechanism to prevent access while the
transformer-rectifier is energised.
1.56.2
Primary taps shall be included on the transformer. The transformer shall

have electrostatic shielding between primary and secondary windings and
shall have suitable shielding of the high voltage coil to accomplish proper
voltage division in the transformer when unit is subjected to surge
conditions encountered in electrostatic fly ash precipitator application.
1.56.3
Each output leg of each transformer-rectifier set shall serve one bus
section and both bus sections served by each transformer-rectifier set shall
be in the same field.
1.56.4
The transformer rectifier assemblies shall be mounted in a heavy gauge

welded steel tank designed for a minimum of 0.5 Kg/cm 2 test pressure and
full vacuum. Insulating and cooling medium shall be non-flammable
insulating fluid. Unit shall be adequately sealed to prevent contamination of
insulation and cooling medium. Outdoor type construction shall be used
except for the high voltage bushings, which shall be enclosed by the bus
duct.
1.56.5
Each transformer-rectifier tank shall be provided with an indicating

thermometer, pressure-vacuum gauge, liquid-level gauge, top fills hole,
drain valve with liquid, sampling connections and weather-proof terminal ISSUE
box with gasketed removable cover. The terminal box shall contain R0
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transformer primary connections, rectifier positive terminals and ground

terminal. A catch basin is provided in the event of a tank failure.
1.56.6
All silicon rectifier cells shall be conservatively rated for compatibility with
maximum circuit load and demands requirements.
1.56.7
If required suitable low-loss impedance shall be included in the high voltage

circuit to limit circuit capacitance discharge current to values compatible
with current rating of the rectifying elements used.
1.56.8
Two high voltage bushings, negative polarity, shall be connected to the

output of the rectifier and mounted on top of the tank cover. Bushings shall
be conservatively rated for the operating conditions and test, and shall
have suitable connections to support connection arrangement of bus or
cable.
1.56.9
High voltage bus runs shall be adequately supported and protected by

ducts. A 150-mm x 200-mm minimum opening with gasketed cover shall be
provided at the transformer rectifier high voltage terminals for grounding
these terminals during inspection and maintenance. Facility for clearly
seeing the grounding switch contacts at the high voltage terminals before
removing the cover shall be provided.
1.56.10 In the event of arcing, the filter voltage shall be switched off for several half
cycles to ensure a satisfactory extinction of the arc. If dust bridging or metal
short circuits occur in the precipitator, the precipitator short circuit current
shall be limited to the rated current of the installation and disconnected
completely after the expiration of a given time.
1.56.11 Supporting insulators shall be located in heated compartments that are
maintained above the dew point of the flue gas. They shall be located out
of the dirty gas stream. These shall be protected from weather by either a
common top housing or individual compartments. A steel shroud below the
insulator may be provided which will further inhibit dust diffusion. Each
compartment shall be pressurised and ventilated by heated filtered air
furnished by one or motor driven blowers. Contactors and strip heaters with
control thermostats for heating the air, blower motors, and blower motor
contactors and control for each compartment as required, for complete
hand automatic operation with alarm contacts for high and low
temperatures and loss of pressure shall be provided. The filters shall be of
the washable type, adequately sized for use in dusty atmosphere.
1.56.12 If strip heaters are used, the wiring to the strip heater terminals shall be
nickel-plated copper with 600-volt teflon-glass insulation.
Control Cubicles
1.56.13 Automatic control cubicles shall be furnished for indoor mounting. Units
shall be of the high-speed silicon controlled rectifier or magnetic-amplifier
type designed to maintain the optimum Precipitator voltage and current for ISSUE
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SHEET 10 OF 25
variations in rate of gas flow and particle content and with simultaneous
supply voltage variations of plus or minus 10%. The automatic controls
shall have full control from 10% of the power set rating to full rating.
The control system should be capable of:
a)
Evaluating sparking by intensity and wave shape.
b)
Regulate power at the threshold of sparkling.
c)
Break a power arc within around ten- (10) milli sec of its occurrence.
d)
Automatically control the arc response so that power is restored within

around one hundred twenty (120) milli secs. And
e)
Modify the current wave shape permitting greater power input prior to
reaching spark over threshold.
Control cubicles shall generally confirm to Specification as specified.

1.56.14 Complete control and interlock system to automatically regulate and
monitor for safe operation of the ESP shall be provided.
1.56.15 Provision shall be made in each cubicle for auto-manual operation. The
control circuit shall be so arranged that when the latter switch is in manual
position the ESP control room operator shall be able to control the electrical
performance of the ESP by means of a control switch, potentiometer or
variable transformers. When the switch is in the auto position, the
automatic regulator unit located in the control cubicle shall control the
performance of the ESP in accordance with its requirements and settings of
the regulator. Manual adjustments of high voltage set points shall be
provided.
1.56.16 Adequate numbers of indicating instruments shall be provided on the
control cubicles for the purpose of correct monitoring of the performance of
ESP and accessories.
1.56.17 Sufficient numbers of alarms shall be provided on the control cubicles.
1.56.18 Rapper control system for each bus section or pairs of bus sections
served by a single transformer-rectifier shall :
a)
Provide manual adjustments of the timing and frequency of operation

and the rapping intensity from the control cabinets,
b)
Provide rapper diagnostic system including miniature indicating lights,

digital indicators, etc.
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Motors
1.56.19 Drive motors of the rapping mechanism for collecting and discharge
electrodes and fans shall comprise 415V, 3 phase, 50 Hz, rated direct-online induction motors with IP-55 enclosure.
In general, motors shall conform to Specification as specified.
1.56.20 Each motor shall be connected to its supply by means of a full voltage
combination magnetic starter which shall include a moulded case circuit
breaker or switch & HRC cartridge link type fuses for the over-current and
short circuit protection. All motor starters, heater contactors, etc. shall be
mounted in their respective control cabinets. Location of motors shall be
such that they are easily accessible for any repair or maintenance.
1.57
All components, features and design parameters of the ESP specified

herein shall be considered as the minimum requirements. If the
MANUFACTURERS design dictates that these minimum requirements be
exceeded to meet specified performance guarantee and to provide a safe,
reliable operating unit, he shall include in his Bid price of all necessary
equipment and features beyond these minimum requirements.
All accessories and appurtenances required for a complete and operable
precipitator installation whether or not they are specified herein shall be
provided.
1.58
The CONTRACTOR shall optimise gas flow pattern and distribution in the
precipitator sections.
1.59
The storm water drain piping shall be provided up to the grade levels for
ESP.
Start-up/Warm-up Oil System
1.60
The start-up/warm-up oil system shall be as per the enclosed scheme no.
TCE.4857A-SK-510-0004
1.61
Warm up oil system shall be designed for burning light diesel oil (LDO) as
specified in Section C-2. This system design capacity should be sufficient to
raise steam parameters of the steam generator to meet auxiliary steam for
fuel oil heating and atomising in the shortest possible time to enable quick
changeover to HFO firing. However, this system shall have minimum
capacity of 10% of MCR rating of one steam generator. LDO will also be
utilised as flushing medium for flushing out fuel oil pipelines and headers
during long unit outages.
1.62
This system shall consist of two (2) 100% capacity LDO (1 working + 1
standby) pressurising pumps, suction strainers, compressed air atomised
burners, LDO and air piping valves and fittings, instrumentation, safety and
control systems in line with the sketch enclosed.
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Support Oil System

1.63
The support oil system shall be as per the enclosed scheme no.
TCE.4857A-510-SK-0005
1.64
This system shall use heavy fuel oil (HFO) as specified for start up/flame
stabilisation.
1.65 The fuel oil burning system shall consist of filtration and pressurising unit
having 2 x 100% capacity (one working one standby) pumps with matching
suction strainers, heating and filtration units consisting of (2 x 100%
capacity steam oil heaters) and two (2) matching pressure filters, fuel oil
safety and burner shut off valves, fuel oil pressure and temperature control
valves, fuel oil metering units, fuel oil atomising and blow-off steam headers
at burners, atomising steam pressure control valves, piping and valving
necessary for bypass and isolation, fuel oil burner header recirculation
control valve, recirculation piping with valves fuel oil atomizing burners, as
identified in the enclosed sketch.
1.66
The oil burning system shall be designed for 30 % SG MCR rating. The fuel
oil burners shall be positioned to provide support to any of the coal burners
at low loads for flame stabilisation as and when required.
1.67
All pumps, strainers and/or pump strainer assembly units shall be provided
with drip pans.
1.68
Drain oil connection and pumping system shall be provided in steam

generator area. An oil drain header of size not less than 150 NB shall be
provided to collect drain oil from pans, strainers, pumps, pipes, etc. and
return the same to the drain oil tank. The drain header shall be laid just
above the ground and shall be generously pitched towards the drain tank.
All oil drain lines shall have a size not less than 25 NB and shall be
electrically traced. The drain oil pumps suction and delivery lines shall have
a size not less than 25 NB and shall be electrically traced. The drain oil
tank shall be provided with heating coil and accessories/instruments.
1.69
The suction and discharge filters, the fuel oil pumps and the fuel oil pipes
shall be equipped with electric heat tracing. The atomising / blow off steam
system and steam oil heaters will be supplied with auxiliary steam from
auxiliary steam system.
1.70
The screw/gear type pressurising pumps shall be provided with a springloaded relief valve and it shall be built-in with the pump, the discharge end
of the valve being connected to the pumps suction side. The relief valve
shall be capable of allowing the full discharge of the pump through it. The
relief valve set pressure shall be adjustable.
Coal Pulverising and Firing System
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1.71
The coal firing system shall be designed to meet the requirement of steam
generator at 100% SG MCR condition, with worst coal as indicated in the
specification.
1.72
The coal pulverising and firing system shall consists of medium speed coal
mills with drives, coal feeders with drives, coal isolation gates at bunker
outlet, feeder inlet, coal piping with flexible couplings from mill outlets to
coal burners, coal burners with shut-off gates and drives, air registers with
drives, coal mill hot air and coal / air discharge isolation gates and drives,
two (2) x 100% seal air (SA) fans complete with air ducting to all coal
mills/feeders, isolation, interconnecting and control dampers on seal air
ducting as required, insulation, supports and hangers etc.
1.73
Forced oil lubrication system for the coal mills and motors shall consist of 2
x 100% oil pumps each with motor, 2 x 100% oil coolers and filters etc. with
necessary piping and valves.
1.74
The number and capacity of coal mills and feeders shall be

based on the following :
(a)
(b)
(c)
selected
With one mill as standby and other mills running at 85% of their MCR,
the system shall be able to meet 100% coal firing rate using worst
coal. Also, with two mills as standby, 100%SGMCR shall be met using
design coal.
Minimum three mills shall be in operation for load range of 60%
TGMCR to 100% SGMCR.
Each coal mill shall be provided with a separate gravimetric coal
feeder and its capacity shall not be less than the capacity of the coal
mill
1.75
Dampers shall be provided on coal pipes at mill outlet, on cold air and seal
air ducts and gates on hot air to coal mills. These gates / dampers shall be
of manually operated type.
1.76
The CONTRACTOR shall quantify the operating hours between major

overhauls of the coal mill and the coal throughput in tonnes, when handling
worst coal. The coal mills shall be designed for direct firing and to pulverise
raw crushed coal available from the coal crusher.
1.77
Sealing Air (SA) fans shall deliver air into a common seal air header from
where each coal mill and feeder set shall be supplied with the seal air.
1.78
For drawing coal samples (iso kinetic sampling of coal) for testing the
fineness of the ground coal, a minimum of four tapping points at right
angles to each other shall be provided on the straight length of pipe at each
coal mill outlet. Compressed air purging connections shall be provided at
the tapping points to clear the opening prior to sample collection.
1.79
Coal isolation gates shall be provided at each bunker outlet. The gates
shall be of dust-proof, rack and self-cleaning type pinion with all parts in ISSUE
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SHEET 14 OF 25
contact with coal of minimum type 410 weldable stainless steel. The gates
shall be provided with chains for hand operation.
1.78
Manual isolation gates shall also be furnished in each coal burner pipe at
the wind-box for facilitating on-line maintenance work of coal piping/coal
mill.
1.79
The coal feed pipe from the coal mills to the coal burners shall be of wear
resistant, weldable steel and of minimum thickness not less than 12 mm on
straight length and 20 mm (but not less than one and a half times the
straight pipe thickness) at outer radius of bends. The bends shall be basalt
lined or ceramic lined to prevent erosion.
1.80
Each pipe between bunker outlet and feeder inlet shall be provided with a
flanged filler piece for connection of an angle type divertor chute to permit
emergency dumping of coal from the bunkers. One carbon steel divertor
chute connection piece with flanged outlet shall be furnished.
1.81
A dresser or equal coupling shall be provided on each feeder inlet to permit

bunker and feeder expansion movements. The inner ring shall be of
stainless steel.
1.87
Adequate and suitably located poke holes shall be provided to clear the
feed pipes to the mills when they get choked.
1.82
The Bidder shall also quote for slow speed ball and tube mills option. The
Bidder shall furnish the details of this option in his bid.
Mill reject hopper
1.83 The Mills rejects (Pyrites) discharged by the Mills shall be collected in the
respective Mills pyrites hopper. The pyrites hopper shall be provided with
isolation valves / dampers such that the valve will open automatically after a
pre-set weight of the rejects for further conveyance. The arrangement of the
mill reject hopper gates shall be such that at all times atmospheric air shall
not be ingressed into the system.
Ignition System
1.84
High Energy Arc (HEA) ignitors shall be provided to ignite LDO and HFO.
One HEA ignitor for each fuel oil gun shall be provided. The ignitor system
offered shall be of well-proven design of reputed make.
1.85
Ignition system shall be complete with all-electrical gadgets viz.,

transformer control cabinets, ignitors, cabling, etc. to make the system
ISSUE
complete by itself and shall be integrated with BMS.
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SHEET 15 OF 25
1.86
Adequate number of flame scanners shall be provided for fuel oil and coal
firing. Two (2) 100% one AC and one DC motor driven scanner air fans
shall also be provided for the flame scanner cooling.
Blow Down System
1.87
The blow down system shall consist of continuous blowdown (CBD) tank
and intermittent blowdown (IBD) tank, all piping, headers, valves, supports
and hangers, insulation, etc. From steam drum to CBD tank, all piping,
headers, valves, supports and hangers, insulation etc., from CBD tank to
IBD tank and CBD tank level control system and instrumentation. The CBD
level control system shall be complete with drain control valve. All piping,
header, valves, supports and hangers, insulation etc., for emergency blow
down from steam drum to IBD tank shall also be included.
1.88
The CBD tank shall be designed to accept the continuous drain from the
steam drum for the purpose of controlling the dissolved solids in drum
water. The CBD tank shall have extra thickness at and around the point of
entry of drum water.
Soot Blowing System
1.89
The soot blowing system shall consist of motor operated steam soot
blowers of the rotary and retractable type, with drives, pressure reducing,
isolation and relief valves, steam traps, thermal drain valves, complete
piping, supports and hangers, insulation, motor control centers and soot
blower instrumentation and control system. The system shall be of selfdraining type. The Bidder can consider conventional type of soot blowing
system. The Bidder shall quote for alternative of Smart soot blowing
system (lower consumption of steam & less erosion, software based,
selective soot blowing) and furnish details of the same along with his bid.
1.90
The soot-blowers shall be suitable for remote automatic sequential and

local operation.
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Auxiliary Steam System

1.91
Auxiliary steam system shall consist of one (1) auxiliary pressure reducing
station (PRS) and a desuperheater on the steam line tapped off from the
main steam line (MSL) as shown in the enclosed flow diagram
no.TCE.4857A-SK-510-0001. The system shall be complete with the
pressure reducing valves, bypass valve and isolation valves; safety relief
valves, drains, steam traps; quick closing block spray valve; desuperheater;
steam temperature control valves, bypass valve and isolation valves;
complete piping, supports with hangers, insulation and instrumentation &
control. Pressure control valves shall be selected in such a way that it
would be possible to regulate the steam flow based on demand under all
operating regimes. CONTRACTOR shall furnish the basis of the same
during detailed engineering for approval.
1.92
The spray water for desuperheating station shall be supplied from boiler
feed pump discharge or inter-stage tap-off. The CONTRACTOR shall
provide pressure and temperature control valves to meet the requirements
of auxiliary steam system.
1.93
Refractory and Insulation
1.93.1
The refractory shall be selected appropriately at various locations in the

furnace (viz., bottom ash hopper, burner zone, goose neck, cage
roof, pent house etc.) considering the gas temperature, oxidising /reducing
atmosphere and erosion. The CONTRACTOR shall substantiate the basis
of selection of refractories in the bid document.
1.93.2
Thermal insulation and cladding shall be provided for the entire steam
generator, flue gas / air ducting, ESP, etc. The insulation selected shall
meet the requirement specified.
Chemical Dosing System
1.94
The phosphate dosing system shall be supplied for SG unit to maintain the
drum water chemistry. The system shall consist of one solution preparation
tank, one solution dilution tank, 2 x 100% dosing pumps complete with
suction / discharge valves, Y-type suction strainers, pressure guages, etc.,
dosing pump discharge header sectionalising valves and complete piping
with isolating and non-return valves as required.
1.95
Each tank shall be complete with motorised agitator, overflow and drain
connections, inlet / outlet isolating valves and side mounted level gauge /
level switch with connecting isolating valves.
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Auxiliary Cooling Water

1.96
An auxiliary cooling water system shall be supplied for the SG unit. The
system shall consist of complete piping to all equipment requiring cooling
water. Each cooler / bearing shall be supplied with isolating valves at the
inlet and throttling type valves at the outlet.
SG Fill Pump
1.97
One (1) SG fill pump shall be supplied. The SG fill pump shall draw water
from the condensate storage tank (CST) and fill the SG unit before start-up.
The CONTRACTOR shall provide SG fills connection to the SG unit at
economiser, and superheater drain headers. In addition, the fill pump
discharge shall be connected to deaerator feed storage tank and ACW
storage tank also. The capacity of the fill pump shall be enough to fill the
SG unit in about 11/2 hours time.
Vibration and Noise Levels
1.96
The design of steam generator and its auxiliaries shall ensure maintenance
of vibration and noise levels within the limits specified
in the following paragraphs over the entire operating range and during load
fluctuations.
1.97
The gas path design shall prevent the generation of excitation forces
conducive to resonant vibration.
1.98
FD, ID, PA and coal mills shall be provided with vibration isolation system
(spring mounted) or conventional block/frame type RCC foundation can be
provided.
1.99
Vibration at the bearings of FD, ID, PA and coal mills shall meet the
requirements of VDI-2056, Machine Group `G, quality class `Good.
1.100
The CONTRACTOR shall provide vibration isolators of proven performance

for preventing transmission of vibrations from one equipment to the other
neighboring equipment and structures.
1.101
The ducting shall be adequately stiffened to absorb pressure pulsations.

Guide vanes shall be provided at bends as required, to prevent turbulence.
Guide vanes in the gas duct shall be properly designed to minimise
erosion. Fan induced duct vibrations shall be avoided.
1.102
The measured noise level produced by any rotating equipment shall not
exceed 85 dBA at a distance of 1.0 m from its boundary in any direction
under any load condition.
1.103
The noise produced in valves and piping associated with handling

compressible and incompressible fluids shall be attenuated to 85dBA at a
distance of 1.0 m from the source by the use of low noise trims, baffle plate
silencers/line silencers, acoustic lagging (insulation), thick-walled pipe work
as and where necessary. All pipes and valves downstream of pressure ISSUE
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SHEET 18 OF 25
control valve (including pressure control valve) shall be one schedule

higher than needed by pressure considerations to attenuate the noise. For
safety relief valves the allowable noise level shall not exceed 115 dBA for
one-quarter hour or less per day. The CONTRACTOR shall outline the
methods adopted to limit the vibration and noise levels within specified
values.
Safety Provisions
1.104
Safety valves shall be provided on the drum, superheater and reheater

headers and its number and capacity shall conform to the code
requirements.
1.105
In addition to the safety valves required by the Code, electromatic relief

valve of capacity not less than 10% of 100% SG MCR rating, suitable for
remote operation shall be provided on superheater outlet header. The
valve shall also be capable of automatic operation on rise in drum pressure
to a value corresponding to a pressure setting lower than that of the
superheater safety valve. Each valve shall be complete with controller,
solenoid, and pilot valve and piping with two shut-off valves.
1.106
All steam safety valves shall be provided with adequately sized

atmospheric relief to 3.0 m above the steam generator roof. Weather
shields shall be provided at points where the relief pipes pass through the
roof. The electromatic relief valve, first spring loaded safety valve and start
up vents in super heater shall be provided with silencers.
1.107
Staircases on either side of mills, walkways and galleries shall be provided

so that all areas of the steam generator including ESP are safely and
conveniently accessible for operation and maintenance. Staircases shall
be provided at front on either side, or rear of steam generators to quickly
approach various floors. All staircases / platforms shall be provided with 2
rail safety handrails of 100 cm high and made of 32 mm GI pipe.
1.108
The minimum width of staircase shall be 1000 mm and the minimum width
of platforms shall be 750 mm. The minimum width of interconnecting
walkway between mill maintenance platform and the steam generator
gallery shall be 1200 mm. All platforms and staircases shall be provided
with gratings and only operating floor shall be provided with chequered
plates.
1.109
Actuators for remote operation of shut-off gates at the air inlets to coal mills
and cold air and hot air shut off gates at outlet of coal mills shall be
provided to allow positive shut-off in the event of fire in the mills.
Control Valves For System
1.110
All control valves shall be sized such that the valves are controllable over
entire operating regime viz. low load to full load. Those control valves which
require to be operated during cold, warm and hot start conditions shall also
be controllable during this mode of operation. To meet the above ISSUE
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SHEET 19 OF 25
requirements if the CONTRACTOR provides more than one control valve,

the controllable ranges of the control valves shall overlap to ensure bump
less transfer from one control valve to other. For other requirements of the
control valve refer relevant C & I section.
2.0
PERFORMANCE REQUIREMENTS
2.1
General
As the steam generator will operate generally base loaded, it shall be
designed to perform in the most efficient manner at 100% turbine generator
maximum continuous rating (TGMCR) condition.
2.2
Operation with Turbine Bypass System

A turbine bypass system having a capacity of 60% of SGMCR primarily to
enable suitable steam/metal temperature matching at the turbine end for a
quick restart following a turbine generator trip out as well as to prevent a
steam generator trip in case of turbine generator trip shall be installed. The
bypass system will also be used during cold start-up of the TG unit. The
turbine bypass system shall have one (1) HP bypass valves and two (2) LP
bypass valves.
2.3
Sudden Load Changes

Although basically a base loaded unit, the steam generator nevertheless
will be subjected to large load changes, often rapid, due to external system
disturbances and/or equipment malfunctions, mainly in downward direction.
Since the unit would normally operate in a turbine follow mode, the steam
generator shall be designed for safe / stable operation by the use of only
proven design concepts and within the recommendations of National Fire
Protection Association (NFPA) of USA: Section 85C and 8503. The
CONTRACTOR shall clearly specify the limitations in the design of steam
generator being supplied, the extent of automation feasible, desirable and
therefore recommended and the logic and control functions to be provided.
2.4
Fuel Change Over

Arrangement of burners for fuel oil and coal shall be such as to permit safe
and quick change over and safe operation under combination firing of the
fuels, such fuel changeovers shall not affect the load being carried by the
unit at the time prior to changeover.
2.5
Minimum Stable Load

The steam generator shall be capable of operating without stabilising fuel
oil, when operating with two or more coal mills each carrying the minimum
load specified by CONTRACTOR. The steam generator shall be capable of
operating with stabilising fuel oil when one coal mill operation and carrying
minimum load on the coal mill specified by CONTRACTOR. The steam ISSUE
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SHEET 20 OF 25
The CONTRACTOR shall indicate the minimum coal mill load (a) at which
point a coal mill must be removed from service when two other coal mills
are also in operation each sharing equal load (b) at which point stabilising
fuel oil is to be introduced before taking out the second mill (c) when one
mill is in operation and stabilising fuel oil is in use. CONTRACTOR shall
note that the minimum stable load without fuel oil support for pulverised fuel
flame stabilization shall not be more than 30% of steam generator MCR
(SGMCR) load.
2.6
Noise and Vibration

The steam generator shall perform continuously with its components and
auxiliaries not exceeding the levels of noise and vibration specified.
2.7
Rate of Loading
The steam generator shall be loaded as fast as practicable subsequent to
synchronisation after cold/warm/hot start-up with 60% capacity bypass
system in service. The CONTRACTOR shall indicate the criteria that will
govern the rate of loading of the steam generator. Specific reference shall
be made to thermocouples and their locations on the steam generator,
which will be used to establish steam generator loading schedules with
reference to the loading criteria. The thermo couple shall have minimum life
of ten (10) years.
2.8
Operation Without HP Feed Water Heaters

The steam generator shall also be designed for operating continuously
corresponding to the 100% TG MCR condition when the high pressure feed
water heaters are out of service.
2.9
All electrical devices, particularly solid state/ electronic components shall be

suitable for trouble-free satisfactory operation, if located outdoors around
the steam generator where high ambient temperature and dusty conditions
will prevail.
2.10
Oxides of Nitrogen
The steam generator unit shall incorporate provisions necessary to restrict
the emission of oxide of nitrogen. The CONTRACTOR shall furnish details
on NOx control systems.
2.11
Electrostatic Precipitator (ESP)

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TCE-4857A-C-
SHEET 21 OF 25
The electrostatic precipitator shall be designed for a dust concentration not

exceeding 75 mg/NM3 at ESP outlet with specified worst coal firing and with
all fields in service.
2.12
(a)
Suitable protective devices including over current and under voltage

relays and moulded case / miniature circuit breakers shall be
incorporated in the control equipment and shall operate to trip the
power supply contactor. All controls & instruments required for
operation of the ESP under manual or automatic control shall be
furnished by the Bidder.
(b)
All silicon rectifier cells shall be conservatively rated for compatibility

with maximum circuit load requirement. Protection for rectifier circuit
shall be provided.
(c)
Sufficient corona power shall be available in the sparking mode at all

operating conditions.
Sudden Loss of External Load

On occasions, the steam turbine generator system may experience sudden
total loss of all external loads. Under these conditions, the HP-LP bypass
system shall operate and the steam generator and the steam turbine
generator together shall continue operation without tripping to supply power
for the power plant auxiliaries (about 5-6% of capacity). The complete
instrumentation and control system and electrical system shall be
adequately designed to take care of the above operation of the power
plant.
2.13
The expected normal load range of the unit shall be from 40% TG MCR to
100% SG MCR.
2.13.1
The SG shall be guaranteed for coal firing to achieve following limits of

control and units response with suitable control system: (refer to I&C
Section)
Item
Particulars
(a)
Steady state
Superheater
Superheater
Outlet Pressure Outlet
Deviation
Temperature
Deviation
2
+ 0.2 kg/cm
+ 2.00C
Drum Level
Deviation (if
applicable)
+ 15mm
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SHEET 22 OF 25
(b)
(c)
Ramp between 60% TG MCR

and
100%
SG
MCR
condition :
(i)
Rate of 1% per minute
(ii)
(iii)
(iv)
Rate of 10% per
minute
Step load change from 100%
SG MCR in case of run back
due to loss of one FD/
PA/SA/ID fan or boiler feed
pump or any other emergency.
kg/cm2
kg/cm2
kg/cm2
kg/cm2
+ 30C
+ 50C
+ 80C
+ 100C
+ 15 mm
+ 20 mm
+ 25 mm
+ 50mm
+ 5.0 kg/cm2
+ 200C
+ 100 mm
+ 0.3
+ 0.5
+ 1.0
+ 1.5
3.0
MAINTENANCE REQUIREMENTS
3.1
The CONTRACTOR shall provide facilities for carrying out on-load and offload maintenance of the steam generators and its ancillaries. In general,
this should include adequate handling equipment, working space, platforms
and safety devices.
3.2
Access doors shall be provided to permit access to the furnace,

superheater, the area between the tube banks and drums, Economiser and
any other areas requiring access. Access doors on both sides of the last
pass shall also be furnished. All access doors provided for furnace, ESP,
ducts, etc., shall be of minimum 450 mm x 450 mm.
3.3
Staircases on either side of the steam generator shall be provided. The

angle of the staircase shall not be less than 45 0 with vertical except in very
critical areas. Staircases shall also be provided at the rear of the steam
generator in the burner zone connecting burner platforms to enable
operators to attend burner at other levels.
3.4
In order to carry out on-load maintenance, it is necessary that the

equipment supplied can be readily disassembled, repaired and assembled
in the shortest period. It should also be possible to attend to the equipment
by a minimum disassembly of parts. For RAPH it should be possible to
replace cold end elements without disturbing / dislodging other elements /
components of the RAPH. Arrangement for cooling the equipment and
quick access shall also be ensured.
3.5
The operating/maintenance platforms around the furnace and equipment

shall be very close to the furnace/ equipment casing and the clear gap shall
not exceed 150 mm between edge and furnace/equipment casings.
3.6
Maintenance/access platforms for pulverised fuel, steam, water. And oil

piping and fittings and for dampers on air and flue gas ducts shall be ISSUE
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SHEET 23 OF 25
provided. Access platforms, staircases and walkways with toe boards shall
be provided for all the critical equipment viz. soot blowers, air preheaters,
ID, FD, PA fans, valves of critical services, transmitter racks, junction boxes,
etc.
3.7
Material handling equipment consisting of monorails, hoists and trolleys

(Electric operated) with all other ancillaries including supporting structure as
required, shall be provided for ID, FD, PA fans and fan drives, RAPH, mills
and ESP maintenance.
3.8
One number approved type furnace inspection and maintenance

equipment (similar to sky climber) shall be supplied by the CONTRACTOR.
This equipment should be basically a combination of suspended platforms
complete with hoisting ropes, pneumatically operated hoisting winches,
safety rails, toe boards, stabilisers and all other items for safe and efficient
operation. The equipment offered must be capable of being introduced
through the access hole provided in the combustion chamber. Suitable
openings at appropriate locations in the furnace and pent house roofs with
pipe sleeves shall be provided for insertion of sky climber ropes without
entering the pent house. These openings shall be capped suitably to
prevent fly ash spillage on the roof. Supports for mounting the winches
shall be provided on the steam generator roof.
3.9
A pent house shall be formed above the roof of the steam generator for
attending to tubes and headers and thermocouples in this area. It shall be
of a hot design having the insulation on the outside of the casing to permit
it to expand and contact with the furnace walls. In order to avoid fly ash
infiltration, through the space around the tubes coming out from the furnace
in this area, all welded seals between furnace gas pass and pent house
shall be provided. Opening in the steam generator roof for introduction of
cables shall be extended through the pent house in the form of pipe
sleeves so that cables could be introduced without entering the pent house.
3.10
Pent house roof, enclosures at firing aisle platforms and at drum level shall
be covered with pre coated metal sheet.
3.11
Separate ventilation fans shall do the pent house cooling with air inlet
openings at opposite ends. The capacity of the fan shall be optimum for
safe and fast cooling of the pent house.
3.12
The maintenance tools required for routine maintenance of equipment shall

include but not is limited to the tools listed below. The CONTRACTOR shall
also furnish a comprehensive list of other recommended maintenance tools
recommended by him.
The maintenance tools that should be included in the offer for the steam
generator are as listed below:
-----------------------------------------------------------------------------------------Particulars
Numbers
------------------------------------------------------------------------------------------
ISSUE
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TCE-4857A-C-
SHEET 24 OF 25
FANS
(a)
Bearing pullers for each type of fan
(b)
Torque wrenches of following capacity

for each type of fan -
2 each
1
5
20
5 kg.m
35 kg.m
50 kg.m
(c) Lifting eye for each type of fan

10
-----------------------------------------------------------------------------------------Particulars
Numbers
-----------------------------------------------------------------------------------------(d) Bearing face out checking dial gauge for each
type of fan
2
COAL MILLS
(a)
Bearing pullers
(b)
Spanners and wrenches specific to the mills
2 sets
(c)
Bearing face out checking dial gauge
(d)
Bowl, bowl hub, gear box, etc., removal / hoisting 1 set

Fixtures
GRAVIMETRIC FEEDERS
(a)
Checking bar
2 Nos.
(b)
Pulley lift bar assembly
1 No.
(c)
Pulley removal tool
1 No.
(d)
Feeder calibrating instrument kit
1 No.
ISSUE
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TCE-4857A-C-
SHEET 25 OF 25
(e)
Digital tachometer
1 No.
(f)
Shims for calibration
6 Nos.
SOOT BLOWERS
(a)
Soot blower valve hand lapping tool
FUEL BURNERS
(a)
Oil burner cleaning bench with necessary

dismantling tools
(b) Bevel protractor

(c)
Coal burner cleaning bench with necessary

dismantling tools
2 sets
2 sets
2 sets
MOUNTING AND FITTINGS

(a)
Hand lapping tool set for safety valves
(b)
Hand lapping tool set for valves
(c)
Straight bars for seal setting for APH
4 nos.
(d)
Master level gauge
1 no.
(e)
Dial gauge for APH
2 nos.
SAFETY VALVES
On line testing/setting device for safety
valves
1 for each type
OTHER ITEMS
(a)
Inclined manometer
(b)
Introscope
(c)
Boiler tube thickness measuring

instruments with prints
1 no.
ISSUE
R0

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JSW ENERGY (VIJAYANAGAR) LIMITED

2 x 300MW COAL BASED THERMAL POWER STATION AT

VOLUME II Part IISECTION: D1.1

STEAM GENERATOR AND AUXILIARIES

The steam generator shall be designed for SGMCR capacity specified in

The steam generator unit shall be capable of operating either on constant

The steam generator shall be designed to meet the Indian Boiler

The steam generator structure shall be designed to support all loads

JSW ENERGY (VIJAYANAGAR) LIMITED

2 x 300MW COAL BASED THERMAL POWER STATION AT

VOLUME II Part IISECTION: D1.1

STEAM GENERATOR AND AUXILIARIES

Observation ports shall be designed to prevent infiltration of air into the

The circulation ratio shall be checked for adequacy under different

JSW ENERGY (VIJAYANAGAR) LIMITED

2 x 300MW COAL BASED THERMAL POWER STATION AT

VOLUME II Part IISECTION: D1.1

STEAM GENERATOR AND AUXILIARIES

The superheater and reheater shall be of proven design and shall be

With permissible and normally expected unbalance or stratification in

With all specified modes of fuel burning.

The superheater and reheater elements shall be arranged to ensure the

The attemperators are to be of spray type fitted with an inner removable

The superheater and reheater supports or hangers exposed to hot gases

JSW ENERGY (VIJAYANAGAR) LIMITED

2 x 300MW COAL BASED THERMAL POWER STATION AT

VOLUME II Part IISECTION: D1.1

STEAM GENERATOR AND AUXILIARIES

All headers shall be thoroughly cleaned and be free of scale by shot

Drains from steam drum, headers, gauge

glasses and integral piping of

JSW ENERGY (VIJAYANAGAR) LIMITED

2 x 300MW COAL BASED THERMAL POWER STATION AT

VOLUME II Part IISECTION: D1.1

STEAM GENERATOR AND AUXILIARIES

For nitrogen (N2) blanket and N2 preservation, suitable connections for N2

The general design requirements for the fans shall be as follows:

All fans shall be designed for under-frequency operation up to 47.5 Hz

The flow-induced pulsation should be avoided by suitable design of fan and

Suitable design of shaft sealing shall be provided to prevent ingress of

JSW ENERGY (VIJAYANAGAR) LIMITED

2 x 300MW COAL BASED THERMAL POWER STATION AT

VOLUME II Part IISECTION: D1.1

STEAM GENERATOR AND AUXILIARIES

Suitable braking arrangement shall be provided to ID fan so that with the

An adequate number of interconnecting, isolating and control dampers with

Locking devices shall be provided to dampers to permit locking in both open

JSW ENERGY (VIJAYANAGAR) LIMITED

2 x 300MW COAL BASED THERMAL POWER STATION AT

VOLUME II Part IISECTION: D1.1

STEAM GENERATOR AND AUXILIARIES

The number of direction changes of the flue gas duct shall be

However, the air preheater, economiser and duct hoppers shall

Dust Precipitation and Collection System

One electrostatic precipitator (ESP) shall be provided for the steam

Access doors and platforms and corresponding interior walkways shall be

For personnel protection, key interlocks shall be provided to prevent the

Each hopper shall be provided with a conveniently located 150 mm (6 inch)

If the MANUFACTURERs standard design is such that the roof is pierced

Penthouse/weather enclosures shall be ventilated by electric motor driven ISSUE

JSW ENERGY (VIJAYANAGAR) LIMITED

2 x 300MW COAL BASED THERMAL POWER STATION AT

VOLUME II Part IISECTION: D1.1