Data Thermal Units KTPS

SAMPLE HEAT RATE CALCULATIONS ABSTRACT FOR UNIT #1 to 6 FOR DEC.
07
CALCULATION FOR EFFICIENCY OF BOILER, TURBO-GENERATOR & OVERALL UNIT
S.No.
Particulars :
Unit
II
III
IV
VI
Kcal/Kg
3845.71
3875.97
3828.86
3828.86
4079.45
4085.25
Gross C.V.
Total moisture in coal.
11.15
11.12
11.46
11.46
11.48
11.54
Ash in coal
36.64
36.40
36.12
35.31
34.59
34.68
Volatile Matter in coal
20.91
21.05
20.40
21.20
21.50
21.40
Fixed Carbon
31.39
31.52
32.10
32.10
32.12
32.08
Un burnt carbon in fly ash
1.90
1.36
0.86
0.68
0.61
0.51
Un burnt carbon in bottom ash
2.73
3.21
1.90
1.44
0.89
0.69
Flue gas temp. at APH outlet
Degree C
136.36
148.97
143.81
145.60
136.00
126.14
Ambient Temperature
Degree C
24.85
25.19
27.00
27.00
27.90
27.80
10
CO2 in flue gas at APH outlet
15.67
15.12
14.47
14.87
13.89
13.89
11
Oxygen in flue gas at APH out let
3.33
3.88
4.53
4.46
5.11
5.11
12
Average Vaccuum
Kg/Sq cm
0.91
0.89
0.89
0.88
0.89
0.89
13
Average Main steam pressure before ESV.
Kg/Sq cm
129.64
126.81
146.74
147.25
146.99
149.89
14
Average Main steam temperature before ESV
Degree C
526.39
524.03
534.66
535.09
537.81
517.65
15
Average CRH Steam pressure after HPT
Kg/Sq cm
36.70
34.28
36.25
36.79
37.59
37.67
16
Average R H Steam pressure before I.V.
Kg/Sq cm
31.79
32.00
33.81
34.56
33.81
37.63
17
Average R H Steam temperature before I.V.
Degree C
527.96
523.77
532.18
525.78
525.82
532.96
18
Average Feed water temperature at ECO. Inlet
Degree C
189.25
195.35
248.97
245.81
245.75
236.68
19
D M water make-up
2.64
2.80
6.24
4.89
0.87
1.22
20
Total Generation as on day
LU
26.54
26.75
51.36
51.60
1557.50
1512.00
21
No. of hours m/c on bar.
Hours
24.00
24.00
24.00
24.00
22
Avg. load
MW
110.49
111.43
210.64
232.30
216.32
210.00
23
Total Quantity of oil used .
KL
0.00
0.00
10.20
15.00
24
a)For start- up activities
10.20
15.00
b)For flame support

25
Oxygen in flue gas at APH Inlet
2.33
2.88
3.33
3.46
3.50
3.40
SAMPLE HEAT RATE CALCULATIONS ABSTRACT FOR UNIT #1 to 6 FOR DEC. 07

contd2
S.No
1)
Particulars :
Unit
Unit-I
Unit-II
Unit-III
Unit-IV
Unit-V
Unit-VI
Kcal/Kg
3618.94
3648.47
3600.62
3597.36
3846.58
3852.53
0.39
0.39
0.39
0.40
0.40
0.40
EFFICIENCY OF BOILER
Net C.V of coal
Total moisture in fired coal (A)
Kg/Kg of coal
Heat of Moisture
(B)
Kcal/Kg
658.47
664.13
634.73
635.53
658.31
653.88
Total Carbon
(C)
Kg/Kg of coal
37.61
37.87
37.86
38.58
38.87
38.74
Nitrogen
(D)
1.85
1.85
1.86
1.85
1.84
1.84
Total oxygen required
(E)
Kg/Kg of coal
1.15
1.16
1.16
1.18
1.19
1.19
3.07
3.09
3.06
3.12
3.15
3.14
Kg mole/Kg
0.20
0.21
0.22
0.22
0.23
0.23
Kg/Kg of coal
0.01
0.01
0.00
0.00
0.00
0.00
Loss due to un-burnt carbon in ash.
1.72
1.43
0.88
0.67
0.49
0.40
Loss due to dry flue gas.
5.41
6.14
5.13
5.19
6.01
5.55
Loss due to moisture & hydrogen in

fuel.
7.05
7.08
6.88
6.99
6.81
6.75
Loss due to sensible heat in ash.
0.57
0.59
0.52
0.51
0.50
0.49
Loss due to moisture in air.
0.18
0.19
0.15
0.16
0.17
0.16
Radiation & un-accounted loss

(assumed)
5.00
5.00
4.50
4.50
1.50
1.50
Total Losses :
19.94
20.43
18.06
18.01
15.48
14.85
Boiler efficiency.(Guaranteed 86.1

% at
80.06
79.57
81.94
81.99
84.52
85.15
Hydrogen
Dry flue gas
Total Unburnt Carbon.
MCR based/ on Coal HHV 4278

Kcal/Kg)
SAMPLE HEAT RATE CALCULATIONS ABSTRACT FOR UNIT #1 to 6 FOR DEC. 07

contd3
(2) EFFICIENCY OF TURBO GENERATOR
I
09/25/89
II
8923.50
8922.00
III
6672.00
IV
6672.00
V
4998.00
VI
1585.00
(Designed heat rate of Tur.-1980.64 Kcal/KWH)

Estimated heat rate of turbine due to
aging factor (K cal/KWH) as on date :
Kcal/KWH
2272.01
2272.00
2052.89
2052.89
2034.47
1996.93
Increase in heat rate in K cal / KWH due to:Fall in vaccuum.
Kcal/KWH
0.00
2.38
2.94
3.82
2.54
1.57
Fall in M S pressure
Kcal/KWH
0.43
3.82
3.90
3.29
3.60
0.13
Fall in M S temperature
Kcal/KWH
4.81
6.13
0.19
-0.05
-1.57
9.70
Fall in R H S Pressure
Kcal/KWH
3.10
0.00
0.00
0.00
0.00
0.00
Fall in R H S Temperature
Kcal/KWH
2.73
4.36
1.09
3.58
3.57
0.79
Fall in feed water temperature
Kcal/KWH
37.87
33.22
-7.59
-5.19
-5.14
1.77
Kcal/KWH
48.94
49.92
0.53
5.46
3.00
13.96
Kcal/KWH
2320.96
2321.92
2053.42
2058.35
2037.47
2010.89
37.05
37.04
41.88
41.78
42.21
42.77
29.66
29.47
34.32
34.26
35.67
36.42
Heat rate .
Kcal/KWH
2899.1
2918.1
2506.0
2510.5
2410.7
2361.6
Increase in heat rate due to DM water make

up
Kcal/KWH
0.00
15.68
30.04
23.57
4.03
5.54
Heat Value of oil
Kcal/KWH
0.00
0.00
0.00
0.00
0.65
0.99
Kcal/KWH
5.67
5.67
5.67
5.70
5.67
5.67
Total Heat Loss
Kcal/KWH
5.67
21.34
35.70
29.27
10.35
12.20
Over all Heat rate of the Unit.
Kcal/KWH
2904.72
2939.41
2541.73
2539.80
2421.06
2373.76
29.61
29.26
33.84
33.86
35.52
36.23
Kg/KWH
0 80
0 81
0 71
0 71
0 63
0 62
Estimated heat rate of turbine

Efficiency of Turbine .( Designed 43.42 % )
(3) Over all Efficiency of the Unit

Thermal efficiency of the Unit.
Windage loss
( Constant)
Over all Thermal Efficiency of the Unit.

Theoritical Coal Consumption
UNIT WISE & STATION WEIGHTED AVERAGE GCV OF COAL

FOR THE YEAR 2000-01 to 2006-07
Unit-1
Year
GCV of Coal in
Kcal/Kg
SP.Coal
consumption
(kg/kwh)
SP.Oil consumption
(ml/kwh)
Avg GCV of Oil

(Kcal/Ltr.)
Heat Rate (Kcal/Kwh)
2000-01
4457
0.644
1.168
8972
2881
2001-02
4325
0.640
0.642
9054
2774
2002-03
4211
0.671
0.522
9071
2830
2003-04
4105
0.708
0.564
9042
2911
2004-05
3826
0.738
0.505
9092
2828
2005-06
4049
0.735
0.429
9093
2981
2006-07
3996
0.753
0.664
9945
3014
Unit-2
Year
GCV of Coal in
Kcal/Kg
SP.Coal
consumption
(kg/kwh)
SP.Oil consumption
(ml/kwh)
Avg GCV
of Oil
(Kcal/Ltr.)
Heat Rate
(Kcal/Kwh)
2000-01
4437
0.637
1.073
8995
2836
2001-02
4326
0.639
0.901
9064
2772
2002-03
4202
0.663
0.460
9139
2790
2003-04
4104
0.713
0.546
8989
2931
2004-05
3813
0.737
0.465
9044
2814
2005-06
4039
0.738
0.495
9001
2985
2006-07
3952
0.754
0.448
9937
2986

FOR THE YEAR 2000-01 to 2006-07
Unit-3
Year
GCV of Coal in
Kcal/Kg
SP.Coal
consumption
(kg/kwh)
SP.Oil consumption
(ml/kwh)
Avg GCV of Oil

(Kcal/Ltr.)
Heat Rate
(Kcal/Kwh)
2000-01
4406
0.588
0.294
8995
2593
2001-02
4328
0.583
0.584
9131
2529
2002-03
4196
0.611
0.440
9063
2568
2003-04
4047
0.645
0.440
8993
2614
2004-05
3922
0.640
0.434
9003
2514
2005-06
4013
0.642
0.304
9367
2580
2006-07
3933
0.671
0.580
9951
2644
Unit-4
Year
GCV of Coal in
Kcal/Kg
SP.Coal
consumption
(kg/kwh)
SP.Oil consumption
(ml/kwh)
Avg GCV of Oil

(Kcal/Ltr.)
Heat Rate
(Kcal/Kwh)
2000-01
4415
0.571
0.507
9061
2526
2001-02
4323
0.583
0.582
8977
2526
2002-03
4204
0.611
0.400
9148
2572
2003-04
4035
0.645
0.170
9082
2604
2004-05
3909
0.667
0.568
8983
2613
2005-06
4003
0.642
0.308
9115
2574
2006-07
3948
0.666
0.475
9904
2633

FOR THE YEAR 2000-01 to 2006-07
Unit-5
Year
GCV of Coal in
Kcal/Kg
SP.Coal
consumption
(kg/kwh)
SP.Oil consumption
(ml/kwh)
Avg GCV of Oil

(Kcal/Ltr.)
Heat Rate (Kcal/Kwh)
2000-01
4289
0.611
0.789
9009
2627
2001-02
4227
0.638
0.567
9033
2702
2002-03
3926
0.654
0.399
9010
2571
2003-04
3906
0.684
0.430
9017
2675
2004-05
3938
0.664
0.633
9016
2621
2005-06
4073
0.633
0.543
9027
2582
2006-07
3901
0.669
0.679
9929
2617
Unit-6
Year
GCV of Coal in
Kcal/Kg
SP.Coal
consumption
(kg/kwh)
SP.Oil consumption
(ml/kwh)
2004-05
4126
0.641
1.469
8967
2658
2005-06
4081
0.597
0.774
9029
2445
2006-07
3895
0.615
0.574
9927
2403
Unit No. #6 Commercial Operation w.e.f. 1st Aug. 2004.
Avg GCV of Oil

(Kcal/Ltr.)
Heat Rate
(Kcal/Kwh)

FOR THE YEAR 2000-01 to 2006-07
Station HR as
per RERC/
CERC Norms
STATION
Year
GCV of Coal
in Kcal/Kg
SP.Coal
consumption
(kg/kwh)
SP.Oil
consumption
(ml/kwh)
Avg GCV of
Oil
(Kcal/Ltr.)
2000-01
4389
0.604
0.682
9005
2657
2001-02
4300
0.611
0.628
9052
2633
2002-03
4131
0.635
0.431
9083
2627
2003-04
4022
0.670
0.394
9018
2698
2004-05
3927
0.672
0.671
9000
2645
2645
2005-06
4041
0.650
0.483
9084
2632
2621
2006-07
3932
0.675
0.572
9932
2661
2616
Design
SHR
Heat Rate
(Kcal/Kwh)
2348 Kcal/Kwh
STACK EMISSION & AMBIENT AIR QUALITY

DATA FOR 2007-08
Average Stack Emission
Average Ambient Air Quality
SPM (mg/N.cum)
Month
Permissible
limit (Max.)
Apr 2007
SPM
SO2
NOx
CO
RPM
Stg-I (2x110
MW)
Stg-II & III (3 x 210

Stg-IV
ug/C ug/C ug/C ug/C ug/C
MW)
(1x195 MW) um
um
um
um
um
UnitUnit-IV Unit-V
Unit-VI
Unit-I Unit-II
III
150
150
150
150
150
150
500
120
120
5000
120
118
126
130
120
51
85
194
17
12
640
86
May 2007
105
113
119
110
64
60
191
17
12
507
82
Jun
2007
131
125
124
68
54
61
176
14
11
554
76
Jul
2007
S/D
S/D
115
121
111
70
159
10
517
66
Aug 2007
114
S/D
122
120
112
68
180
10
509
79
Sep
2007
S/D
113
123
100
75
50
173
11
506
80
Oct
2007
123
128
110
131
45
62.12
186
10
512
82
Nov 2007
126
130
121
78
47
92.32
194
10
498
82
STACK EMISSION & AMBIENT AIR QUALITY DATA 2006-07

Average Stack Emission
Average Ambient Air Quality
SPM (mg/N.cum)
Month
Permissible limit
(Max.)
Stg-I
(2x110 MW)
Stg-II & III

(3 x 210 MW)
Stg-IV
(1x195
MW)
SPM
SO2
NOx
CO
RPM
ug/
Cum
ug/
Cum
ug/
Cum
ug/
Cum
ug/
Cum
Unit-I
UnitII
UnitIII
UnitIV
Unit-V
Unit-VI
150
150
150
150
150
150
500
120
120
5000
120
Apr
2006
60
68
98
69
61
70
200
16
13
607
91
May
2006
78
S/D
110
84
62
66
191
30
27
512
83
Jun
2006
94
105
S/D
106
89
87
191
20
17
490
84
Jul
2006
S/D
93
89
68
61
73
184
18
15
446
77
Aug
2006
65
106
107
128
71
76
168
11
455
66
Sep
2006
111
112
123
S/D
96
87
168
14
11
559
73
Oct
2006
102
123
119
88
117
92
153
15
13
567
67
Nov
2006
86
101
99
75
86
93
158
17
14
557
70
Dec
2006
103
107
107
59
81
89
159
15
18
546
66
Jan
2007
72
110
120
64
51
89
173
16
19
490
75
Feb
2007
113
129
74
93
45
89
174
12
15
528
74
Mar
2007
123
S/D
106
96
52
89
170
16
11
491
73
TRADE EFFLUENT ANALYSIS RESULT OF KSTPS

Condenser Cooling Water Stage-I
Month
Max. limit
pH
Temp.
inlet C
Temp.
outet C
6.5-8.5
Temp.
Diff. C
Condenser Cooling Water Stage-II&III

Free of
mg/lt
pH
10
0.5
6.5-8.5
Temp.
inlet C
Temp.
outet C
Temp.
Diff. C
Free of
mg/lt
10
0.5
Apr
06
7.9
33.6
42.2
8.6
Nil
7.9
33.6
40.0
6.4
Nil
May
06
8.1
35.4
44.0
8.6
Nil
8.1
35.4
43.1
7.7
Nil
Jun
06
7.9
35.4
44.0
8.6
Nil
8.0
35.4
43.0
7.6
Nil
Jul
06
7.7
33.6
42.3
8.7
Nil
7.7
33.6
41.7
8.1
Nil
Aug
06
7.7
31.2
39.5
8.3
Nil
7.8
31.2
38.7
7.5
Nil
Sep
06
7.8
30.0
38.8
8.8
Nil
7.7
30.0
38.0
8.0
Nil
Oct
06
7.6
29.8
38.3
8.5
Nil
7.7
29.8
36.5
6.7
Nil
Nov
06
7.7
28.5
37.2
8.7
Nil
7.7
28.5
36.2
7.7
Nil
Dec
06
7.7
23.0
32.0
9.0
Nil
7.8
23.0
31.0
8.0
Nil
Jan
07
7.7
23.2
32.0
8.8
Nil
7.8
23.2
31.2
8.0
Nil
Feb
07
7.7
25.5
34.4
8.9
Nil
7.7
25.5
33.5
8.0
Nil
Mar
07
7.8
26.5
35.2
8.7
Nil
7.8
26.5
34.6
8.1
Nil

Cooling Tower Stage-IV
Month
Free cl
mg/lt.
Zinc
mg/lt
Ash pond
Cromium
mg/lt
Phosphate
mg/lt
pH
TSS
mg/lt
oil& grease
mg/lt
Max. limit
0.5
1.0
0.2
5.0
6.5-8.5
100.0
20.0
Apr
06
Nil
ND
ND
0.63
7.59
69.00
4.80
May
06
Nil
ND
ND
0.60
7.65
63.00
5.20
Jun
06
Nil
ND
ND
0.61
7.52
56.00
4.10
Jul
06
Nil
ND
ND
0.62
7.43
59.00
3.90
Aug
06
Nil
ND
ND
S/D
7.41
69.20
5.00
Sep
06
Nil
ND
ND
0.68
7.35
71.00
4.40
Oct
06
Nil
ND
ND
0.68
7.47
66.0
5.40
Nov
06
Nil
ND
ND
ND
7.66
65.0
4.70
Dec
06
Nil
ND
ND
ND
7.56
68.00
5.10
Jan
07
Nil
ND
ND
ND
7.50
73.00
4.50
Feb
07
Nil
ND
ND
2.1
7.45
68.00
3.10
Mar
07
Nil
ND
ND
1.2
7.35
65.00
3.60

Boiler blow down mix drain Unit-IV
Month
Max. limit
TSS
mg/lt
Oil &
Greas
e
mg/lt
Cu.
mg/lt
Fe
mg/lt
100.0
20.0
1.0
1.0
Boiler blow down mix drain Unit-V

TSS
mg/lt
Oil &
Grease
mg/lt
Cu.
mg/lt
Fe
mg/lt
100.0
20.0
1.0
1.0
Boiler blow down mix drain Unit-VI

TSS
mg/lt
Oil &
Grease
mg/lt
Cu.
mg/lt
Fe
mg/lt
100.0
20.0
1.0
1.0
Apr
06
5.20
1.10
0.10
0.11
5.10
1.00
0.10
0.10
5.20
1.1
0.10
0.11
May
06
5.10
1.00
0.10
0.10
5.20
1.10
0.10
0.11
5.20
1.10
0.10
0.10
Jun
06
5.10
1.00
0.10
0.10
5.20
1.10
0.10
0.10
5.20
1.10
0.10
0.10
Jul
06
5.20
1.04
0.10
0.10
5.10
1.00
0.10
0.10
5.16
1.02
0.10
0.10
Aug
06
5.10
1.00
0.10
0.11
5.20
1.05
0.10
0.11
S/D
S/D
S/D
S/D
Sep
06
S/D
S/D
S/D
S/D
5.30
1.10
0.10
0.11
5.20
1.10
0.10
0.11
Oct
06
5.08
1.00
0.10
0.10
5.08
1.00
0.10
0.10
5.10
1.00
0.10
0.10
Nov
06
5.20
1.05
0.10
0.10
5.07
1.03
0.10
0.10
5.15
1.05
0.10
0.10
Dec
06
5.32
1.02
0.10
0.10
4.97
1.00
0.10
0.10
4.95
1.00
0.10
0.10
Jan
07
5.13
1.00
0.10
0.10
5.07
1.10
0.10
0.10
5.13
1.00
0.10
0.10
Feb
07
5.70
0.42
0.01
0.11
5.00
0.18
0.01
0.11
5.50
0.43
0.01
0.10
Mar
07
5.25
1.00
0.01
0.11
4.50
1.00
0.01
0.09
4.50
1.00
0.01
0.10

Boiler blow down mix drain Unit-I
Month
Max. limit
TSS
mg/lt
Oil &
Greas
e
mg/lt
Cu.
mg/lt
Fe
mg/lt
100.0
20.0
1.0
1.0
Boiler blow down mix drain Unit-II

TSS
mg/lt
Oil &
Grease
mg/lt
Cu.
mg/lt
Fe
mg/lt
100.0
20.0
1.0
1.0
Boiler blow down mix drain Unit-III

TSS
mg/lt
Oil &
Grease
mg/lt
Cu.
mg/lt
Fe
mg/lt
100.0
20.0
1.0
1.0
Apr
06
5.20
1.00
0.10
0.11
5.20
1.00
0.10
0.10
5.30
1.10
0.10
0.11
May
06
5.20
1.10
0.10
0.10
5.20
1.10
0.10
0.11
5.20
1.10
0.10
0.11
Jun
06
5.10
1.00
0.10
0.10
5.10
1.00
0.10
0.11
S/D
S/D
S/D
S/D
Jul
06
5.20
1.15
0.10
0.11
5.20
1.12
0.10
0.11
5.12
1.05
0.10
0.10
Aug
06
5.07
1.00
0.10
0.10
5.07
1.00
0.10
0.10
5.17
1.02
0.10
0.10
Sep
06
5.05
1.00
0.10
0.10
5.10
1.00
0.10
0.10
5.07
1.00
0.10
0.10
Oct
06
5.20
1.10
0.10
0.11
5.12
1.04
0.10
0.10
5.16
1.04
0.10
0.10
Nov
06
5.02
1.00
0.10
0.11
4.80
1.03
0.10
0.10
5.10
1.00
0.10
0.10
Dec
06
5.07
1.02
0.10
0.10
4.87
1.00
0.10
0.10
5.02
1.00
0.10
0.10
Jan
07
5.10
1.00
0.10
0.10
5.03
1.00
0.10
0.10
5.13
1.00
0.10
0.10
Feb
07
7.00
0.35
0.01
0.1
5.2
0.45
0.01
0.10
6.50
0.41
0.01
0.10
Mar
07
5.70
1.00
0.01
0.09
5.00
1.00
0.01
0.10
5.25
1.00
0.01
0.10
ESP DATA
Unit
No.
Rating
(MW )
No. of
existing
fields
No. of
fields
added
Efficiency of
revamped /
retrofitted ESP
Designed
emission level
after
retrofitting
Month of
commissioning
(in mg/Cu.M)
110
10
99.82%
105
Nov.93
II
110
10
99.82%
105
July, 94
III
210
24
99.84%
80
Sept. 92
IV
210
24
99.84%
80
July, 92
210
28
99.94%
30
March, 94
VI
195
28
99.94%
30
July, 03
DESIGN STACK DATA

Stage-I
(2x110 MW)
Stage-II
(2x210 MW)
Stage-III
(1x210 MW)
Stage-IV
(1x195 MW)
180 (One
stack two
flues)
180 (One stack

three flues. One
flue for Stg.III
180 (II stack)
180
(Single)
Flue gas Temp. at inlet

of ESP in C
141
136
136
136
Assumed temp. at exit

point with 5 C Temp. fall
136
131
131
131
Stack top inside dia. (M)
4.125
4.90
4.90
4.50
Stack top inside venturi

diameter (Mtr.)
3.20
4.13
4.13
4.13
13.84
18.7
18.7
18.7
25
27.4
27.4
27.4
2x2000
33.5% (ash)
2x3550
33.5% (ash)
1x3550
33.5% (ash)
1x3550
33.5% (ash)
74.8
100.1
87.6
87.6
Particulars
Stack height (Mtr.)
Flue gas exit velocity at

stack top 174 M (M/sec.)
Flue gas exit velocity at
venturi (M/sec.)
Coal consumption
(T/day) with ash content
Emission rate (Kg. hr)
(Calculated from design
gas flow & SPM)
ELECTROSTATIC PRECIPITATOR (ESPs) DESIGN DATA

S.No.
Description
Stage-I
Stage-II
Stage-III
Stage-IV
1-
Manufacturer
BHEL
BHEL
BHEL
BHEL
2-
Arrangement(Inline)
In line
In line
In line
In line
3-
Type of ESP
Rigid frame
Rigid frame
Rigid frame
Rigid frame
4-
No.of ESP Boxes
5-
Gas flow
198 m3 / Sec.
347 m3 / Sec.
348 m3 / Sec.
419 m3 / Sec.
6-
Total gas treated
400 TPH
600 TPH
600 TPH
600 TPH
7-
Gas temperature at inlet
141 Deg.C.
134 Deg.C.
129 Deg.C.
132 Deg.C.
8-
Design efficiency
99.82%
99.84%
99.94%
99.94%
9-
Number of bus sections
10-
What % of bus sections

can be de-emergized to
meet design efficiency
NA
NA
NA
NA
11-
Net specific collection area
128 m2/ m3 /Sec.
187 m2/ m3 /Sec.
331 m2/ m3 /Sec.
275 m2/ m3 /Sec.
12-
Number of fields per boiler
17
28
28
28
13-
Fields in operation at full load
17
28
28
28
14-
Any fly ash treatment used
No
No
No
No
15-
Hopper fly ash handling system
Pneumatic
Pneumatic
Pneumatic
Pneumatic
ELECTROSTATIC PRECIPITATOR (ESPs)

Contd
16-
Hopper heating system
6 KW
6 KW
6 KW
6 KW
AICE
AICE
ICE
BAPCON
design detail
17-
Type of supervisory
control for ESP
i-
Monitoring of automatic
HV controls
ii-
T-R-Sets
Manual
Manual
Manual
Manual
iii-
Rapping system
Auto run
Auto run
Auto run
Auto run
Not installed
Partly installed
Auto
Auto
Auto
Auto
Auto
Auto
No
No
No
No
150 mg/Nm3
150 mg/Nm3
150 mg/Nm3
150 mg/Nm3
No
No
No
No
715KVA
820 KVA
415 KVA
440 KVA
Not installed
Not installed
Not installed
Not installed
iv-
Ash Hopper level

indicators
v18-
Hopper Heaters
Is opacity used as a feed
back in control
19-
Are there mass emissions

or opacity regulatory
limits
20-
Any co-relation done

between mass emissions
&
opacity
21-
Estimated power needs

for
ESP Control
22-
No x control & FGD

System
EQUIPMENT DETAILS
STEAM GENERATOR (BOILER)
INCLUDING DUCTS & VALVES :
Description
Type
Make
Size /Capacity
Steam Pressure (at
boiler outlet)
Stage-I
Stage-II
Stage-IV
Natural circulation, Single drum, Radiant reheat type,

Tangentially fired, balanced draught, Make: BHEL
BHEL
375 T/HR
880 T/HR
690 T/HR
670 T/HR
138 Kg./sqm.
155 Kg./sqm.
155
Kg./sqm.
155
Kg./sqm.
Steam Temperature
(at boiler outlet)
540C
Type of air preheater
Rotary regenerative tri sector
Fuel used :
Primary
Secondary
Others
Boiler efficiency
Stage-III
Pulverised coal
HSD/FO/LSHS
Nil
86.8%
86.1%
86.1%
86.1%
STEAM GENERATOR
Description
Unit 1 & 2
Unit 3 & 4
Unit No. 5
Unit No. 6.
Manufacturer:
M/s BHEL
M/s BHEL
M/s BHEL
M/s BHEL
Type- Drum/Once Through:
Drum Type
Drum Type
Drum Type
Drum Type
Division Wall:
Fusion welded wall
Balance Draft or Forced Draft:

Operating Pressure With % Overpressure (Drum Pr. In
kg/cm)
Super Heater Pr. In kg/cm :
Super Heater & Reheater Outlet Tempr.:
Balanced Draft
148.96
164.9
164.9
164.9
138
154.35
154.16
154
540C
540C
540C
540C
Firing Configuration:
Tangential Tilting
No. of Installed Pulverizer:
4 Nos.
6 Nos.
3 Nos.
3 Nos.
No. Pulverizers To Meet Design Steam Flow:
3 Nos.
4 Nos.
2 Nos.
2 Nos.
Type of Pulverizer:
Bowl Mill
Bowl Mill
Ball Mill
Ball Mill
Manufacturer:
M/s BHEL
M/s BHEL
M/s BHEL
M/s BHEL
4 Nos.
4 Nos.
8 Nos.
8 Nos.
M/s BHEL
M/s BHEL
M/s BHEL
M/s BHEL
No. of Wall Soot Blowers:
40 Nos.
52 Nos.
56 Nos.
56 Nos.
No. of Retractable Soot Blower:
28 Nos.
24 Nos.
22 Nos.
18 Nos.
Soot Blowing Media (Air or Steam)
Steam
Steam
Steam
Steam
Rated Main Steam Flow - T/Hr.
338 TPH
630.8 TPH
630.8 TPH
627 TPH
Reheater Steam Flow - T/Hr.
316 TPH
567.8 TPH
567.8 TPH
563 TPH
Coal
Coal
Coal
Coal
Ignition Fuel
HSD/FO
HSD/FO
HSD/FO
HSD/FO
Circulation (Natural or Forced?)
Natural
Natural
Natural
Natural
No. of Burners Per Pulverizer:

Burner Manufacturer:
Primary Fuel
Secondary Fuel
FANS MANUFACTURER
Description
Unit 1 & 2
Unit 3 & 4
Unit No. 5
Unit No. 6.
FD & ID (If Balanced Draft Furnace)
M/s BHEL
M/s BHEL
M/s BHEL
M/s BHEL
Primary Fans:
M/s BHEL
M/s BHEL
M/s BHEL
M/s BHEL
Numbers Installed PA Fan
3 Nos.
3 Nos.
3 Nos.
3 Nos.
Numbers Installed FD Fan
2 Nos.
2 Nos.
2 Nos.
2 Nos.
Numbers Installed ID Fan
3 Nos.
4 Nos.
5 Nos.
6 Nos.
Capacity SCFM Each PA Fan:
45.79
70.00
66.00
66.00
Capacity SCFM Each FD Fan:
48.57
105.30
89.00
89.00
Capacity SCFM Each ID Fan:
148.3
230.00
230.00
230.00
Total Discharge Pressure - (H2O At MCR For PA):
1300
1210
1220
1220
Total Discharge Pressure - (H2O At MCR For FD):
377
520
475
475
Total Discharge Pressure - (H2O At MCR For ID):
384
398
500
500
Controls Used (Blade Pitch, Inlet Vanes) PA
IGV
Damper
Damper
Damper
Controls Used (Blade Pitch, Inlet Vanes) FD
IGV
IGV
IGV
IGV
Controls Used (Blade Pitch, Inlet Vanes) ID
Speed
Speed
Speed
Speed
300/850/820
800/1400/1250
600/1700/1250
1500/1700/1250
Type of Fans (Axial, Centrifugal?) FD Fan
Radial
Axial
Axial
Axial
Type of Fans (Axial, Centrifugal?) ID & PA Fan
Radial
Radial
Radial
Radial
Any Air Preheating of Air
SCAPH
SCAPH
SCAPH
SCAPH
M/s BHEL
M/s BHEL
M/s BHEL
M/s BHEL
Flue Gas
Flue Gas
Flue Gas
Flue Gas
Steam
Steam
Steam
Steam
Fans Manufacturer:
Total Suction Pressure- (H2O For FD/ID/PA?)
Motor Size - KW (FD/ID/PA)
Air Preheater Manufacturer :

Type (Coils In Duct Work?)
Source of Heat:
If Coils, Heating Medium In Coil:
MAIN & REHEAT STEAM TEMPEATURE

Description
Unit 1 & 2
Unit 3 & 4
Unit No. 5
Unit No. 6.
- Main Steam Temperature
540C
540C
540C
540C
- Reheat Steam Temperature
540C
540C
540C
540C
- Design Steam Temperatures
540C
540C
540C
540C
12.0 TPH
22.7 TPH
17.5 TPH
9.0 TPH
- Reheater Attemperator Flow
- Design Attemperator Temperatures
120 C
120 C
120 C
120 C
85-92
85-92
98-99
98-99
12.50%
12.50%
12.50%
12.50%
- Excess Air
3.40%
3.40%
3.40%
3.40%
- Design Excess Air
4.00%
4.00%
4.00%
4.00%
- Number of SB Out of Service & Location
Nil
Nil
Nil
Nil
- Operator Soot blower Guideline.
Yes
Yes
Yes
Yes
-Trend Over Load Range If Possible

Attemperator Requested At Full and Low Loads:
- Main Attemperator Flow
- Trend Over Load Range If Possible

Boiler Data Requested At Full and Low Loads:
- Fly ash & Bottom Ash LOI
- Exit Gas Temperature
- SO3 Dew point Temperature
- Coal Fineness Data (100 mesh) %
- Air Heater Leakage Based On Past Testing
- Design Air Heater Leakage
- Excess Air Curve Control Over Load Range

- Steam Coil Preheating Flow
EQUIPMENT DETAILS
BOILER AUXILIARIES :
Description
Stage-I
Stage-II
Stage-III
Stage-IV
(a) I.D. FANS:

Type
Radial
Radial
Radial
Radial
850 KW
143 Cum/sec.
1400 KW
230 Cum/sec.
1700 KW
230 Cum/sec.
1700 KW
230 Cum/sec.
Quantity (Nos.)
2x3
2x3
1x3
1x3
(b) F.D. FANS:

Type
Radial
Axial
Axial
Axial
300 KW
48.57 Cum/sec.
800 KW
105.3 Cum/sec.
600 KW
89 Cum/sec.
600 KW
89 Cum/sec.
Quantity (Nos.)
2x2=4
2x2=4
(c) P.A. FANS:

Type
Radial
Radial
Radial
Radial
820 KW
45.79 Cum/sec.
1250 KW
70 Cum/sec.
1250 KW
66Cum/sec.
1250 KW
66Cum/sec.
2x2
2x2
Size /Capacity
Size /Capacity
Size /Capacity
Quantity (Nos.)
EQUIPMENT DETAILS
Description
(d) COAL MILLS:

Type
Size /Capacity
Quantity (Nos.)
Stage-I
Stage-II
Stage-III
Stage-IV
Pressurised
Bowl Mills
Pressurised
Bowl Mills
Pressurised
Tube Mills
Pressurised
Tube Mills
34 T/HR
340 KW
36.9 T/HR
340 KW
78.5 T/HR
2100 KW
78.5 T/HR
2100 KW
2x4=8
2x6=12
COAL FEEDERS
Description
Coal Feeder Manufacturer:
No. of Feeders
Type (Gravimetric?):
Economizer Inlet Temperature F:
Air Heater Manufacturer
Unit 1 & 2
Unit 3 & 4
Unit No. 5
Unit No. 6.
M/s BHEL
M/s BHEL
M/s BHEL
M/s BHEL
4 Nos.
6 Nos.
6 Nos.
6 Nos.
Volumetric
Gravimetric
Gravimetric
Gravimetric
238C
244C
246C
246C
M/s BHEL
M/s BHEL
M/s BHEL
M/s BHEL
Type :
Rotay Regenrative Tri sector
Number- Primary
2 Nos.
2 Nos.
2 Nos.
2 Nos.
Excluding Air Leakage, F :
Including Air Leakage, F :
145 C
132 C
136 C
134 C
Wet
Wet
Wet
Wet
For Superheater
Feed Water
Feed Water
Feed Water
Feed Water
For Reheater:
Feed Water
Feed Water
Feed Water
Feed Water
Control System provided With Steam Generator
Yes
Yes
Yes
Yes
Combustion and Burner Controls:
Auto
Auto
Auto
Auto
Secondary
Design Gas Temperature Leaving Air Heater
Boiler Bottom - Wet or Dry:

Source of Attemperator Water
EQUIPMENT DETAILS
(B) TURBINE
Description
Stage-I
Stage-II
Stage-III
Stage-IV
Type
Three casing, condensing

steam impulse turbine
with reheating & non
regulated 8 Nos.
extractions without HP/LP
bypass.
Three casing, condensing steam

reaction turbine with reheating non
regulated 6 Nos. extractions with HP/LP
bypass.
Make
BHEL (SKODA)
BHEL (KWU)
No. of stages per

cylinder
HP 8
IP 12
LP 2x4
HP 25
IP 2x20
LP 2x8
HP 25
IP 2x19
LP 2x8
Exhaust Pressure
0.10 Kg./cm2
0.1033 Kg./cm2
0.1187 Kg./cm2
Exhaust Temp.
Critical speed
Type of governing
system
Type of governing
/control fluid
46 Deg.C
49 Deg. C
1500 to 2500 RPM
1526 to 2127 RPM
Nozzle
Throttle
Turbine Oil -46
EQUIPMENT DETAILS
Description
Stage-I
Stage-II
Stage-III
Stage-IV
200 KHI
FK 6D30
FK 6D30
FK 6D30
480 T/HR
(4000 KW)
387 Cum/HR
(3500 KW)
445 Cum/HR
(4000 KW)
445 Cum/HR
(4000 KW)
2x2=4
2x3=6
(b) C.E.P.
Type
150 CJWS
Canister
EN5J40D30A
Canister
EN5J40D30A
Canister
EN5J40D30A
Size /Capacity
180 T/HR
(225 KW)
687 Cum/HR
(500 KW)
662 Cum/HR
(500 KW)
662 Cum/HR
(500 KW)
2x3=6
2x2=4
TURBINE AUX. :
(a) Boiler Feed Pump:
Type
Size /Capacity
Quantity (Nos.)
Quantity (Nos.)
EQUIPMENT DETAILS
Description
Stage-I
Stage-II
Stage-III
Stage-IV
(c) C.T. Pump

Type
WKS
CHC
100/320
CHC
100/320
CPHM 8032
Size /Capacity
68.38
CUM/HR
(55 kw)
Quantity (Nos.)
2x4=8
100 CUM/HR 100 cum/hr

(15 KW)
(15 KW)
2X3=6
75 M/HR.
(15 kw)
PLANT COMPONENT & DESIGN INFORMATION

S.No.
Equipment
Unit #1&2
Stg.I
Unit #3&4
Stg.II
Unit #5&6
Stg. III & IV
TURBINE
(a)
Manufacturer
BHEL,Hyderabad
BHEL
BHEL
(b)
Type
3 Casing condensing
steam turbine (impulse
type with two curtis wheel
in HP Stage) with
reheating and non
regulating extraction
3 Cylinders tandum
compound / reaction,
reheat, regerative/
condensing turbine
Same as Unit # 3 & 4
(c)
Guaranteed Gross
rating MW
110 MW
210 MW
(d)
Design Exhaust
Pressure
0.10 abs
0.1033 abs
(e)
Design inlet
steam condition
Pr./Temp.
MS Pr. 130 ata 535 Deg.C

RH Pr. 31.63 ata 535
Deg.C
MS Pr. 150 Kg/CM2 535

Deg.C
RH Pr. 34.55 Kg;/cm2 535
Deg.C
(f)
Design Steam
flow
363.5 TPH
632.76 TPH
U # 5 628 TPH
U # 6 626 TPH
(g)
Provision for over

pressure
operation Yes/No
%
Over Pr. Ms 146 ata Over

Temp. 545 Deg.C
Over Pr. RH 35 ata Over
Temp. 545 Deg.C
Yes but limited to 12 hrs.

per year
Yes but limited to 12

hrs. per year
Unit # 5 -210 MW
Unit # 6 195 MW
0.1033 abs
-do-

SNo.
TURBINE
Unit #1&2
Stg.I
Unit #3&4
Stg.II
Unit #5&6
Stg. III & IV
C.E.P. : Condensate Pump

a)
Manufacturer
BHEL
BHEL
BHEL
b)
No. of pumps
installed
3 Nos.
2 Nos.
Unit # 5 : 2
Unit # 6 : 2
c)
No. required at full

load
2 Nos.
1 No.
Unit # 5 : 1 No.
Unit # 6 : 1 No.
d)
Capacity of each
lbs/hr. at Temp.
rating
350 lbs/hr. at 40 Deg.C (160

TPH)
1381 lbs/Hr. (627 TPH)
Unit # 5 : 1458 lbs/Hr.

Unit # 6 : 1458 lbs/hr.
e)
Design head at temp.

rating
270 M WCL at 40 deg.C
21 Kg/cm2
Unit # 5 : 21 Kg/cm2
Unit # 6 : 21 Kg/cm2
f)
Type of Pump
Vertical, Multistage with

electric drive
Vertical, Multistage,
centrifuge pump with
Electric drive
g)
Stages
8 Stages
5 Stages
U # 5 : 6 Stages
U # 6 : 6 Stages
h)
Type of flow control
Through pneumatic control

valve
Through pneumatic
Control Valve
Same as Unit # 3 4

S.No.
TURBINE
Unit #1&2
Stg.I
Unit #3&4
Stg.II
Unit #5&6
Stg. III & IV
Main Condenser
a)
Manufacturer
BHEL
BHEL
BHEL
b)
Type
Two pass, divided water

box type
Two pass, Surface type
Two pass surface

type
c)
Surface area
(Sq.ft)
36360 Sq.ft (3380 M2)
123668 Sq.ft
123668 Sq.ft for each

unit
d)
No. of pass
Two
Two for each unit
Two for each unit
e)
No. of shells
4 (Two shells per

condenser)
One for each unit
One for each unit
f)
Design
condensate flow
rate
259 TPH
435 TPH
435 TPH
g)
Design condenser
back pressure
0.10 abs
0.1033 abs
0.1033 ABS

S.No.
TURBINE
Unit #1&2
Stg.I
Unit #3&4
Stg.II
Unit #5&6
Stg. III & IV
h)
Design
Circulating
Water Inlet
temp.
32 deg.C
33 Deg.C for each unit
33 Deg.C for each

unit
i)
Design circulating
water flow
15400 TPH for both

condenser
27000 TPH each unit
j)
Tube length /
OD/Gauge
7500mm / 22mmm /1 mm
thk
7.5mm/ 25,4mm/ 1 mm
same for both units
7.6 M/25.4mm/ 1mm
k)
Material tube
Aluminium brass/ Cupro

Nickel 90-10
Rolled steel plate
Cupro Nickel 90-10 same

for both units
Mild steel
Cupro Nickel 90-10

same for both units
Mild steel
Tube sheet
l)
Method of tube
sheet installed
(Rolled) ?
m)
Designed water
circulation flow
rate
2m/sec.
1.81m/sec.
1.81m/sec.
n)
Design water box

pressure
3.5 Kg/cm2
3.5 Kg/cm2
U # 5 : 3.5 Kg/cm2
U # 6 : 3.5 Kg.cm2

S.No.
TURBINE
Unit #1&2
Stg.I
Unit #3&4
Stg.II
Unit #5&6
Stg. III & IV
o)
Orientation
(transerverse)
p)
Multi pressure
No Single pressure
No single pressure
No Single pressure
q)
Temp. rise
9.25 Deg.C
8.76 Deg.C for each unit
8.76 Deg.C for each

unit
r)
Type of air
removal
equipment (Mech.
Vac. Pump)
Through steam jet ejector
Through steam jet ejector
U # 5 : Through
steam jet ejector
U # 6 : Vacuum pump
with steam jet ejector
s)
Type of tube
cleaning system
NIL
NIL
NIL
t)
Type of
Expansion Joints
Rubber expansion joint
Rubber expansion joint
Rubber expansion
joint
v)
Any Aux.
condenser
No
No
No

S.No.
TURBINE
Unit #1&2
Stg.I
Unit #3&4
Stg.II
Unit #5&6
Stg. III & IV
FEED WATER HEATER

a)
Manufacturer
BHEL
BHEL
BHEL
b)
By Pass capability
Yes
Yes
Yes
c)
Low Pressure:
i) No.of stages
ii) No.of heaters
iii) Location of
heaters & Stages
(Condenser Neck)
5
7
3 Heaters are located
outside condenser and 4
heaters on LP casing
3
3
All 3 Heaters are outside
the condenser
3
3
d)
High Pressure
i) No.of Stages
ii) No.of heater
per stage
iii) Tube material
iv) Configuration
One
One
Stainless steel SS-304
LP Heater Vertical, Cross
flow, Four Pass
HP Heater Vertical ,
Cross flow, Double pass
Two
One
SS-304
LP Heater Vertical ,
Cross flow, Double pass
Two
One
SS-304

S.No.
TURBINE
Unit #1&2
Stg.I
Unit #3&4
Stg.II
Unit #5&6
Stg. III & IV
At 24 M elevation Spray
tray reboiling type
At 24 M Elevation
Spray Tray Reboiling
type
DEAERATING HEATER
a)
Heater Type
Re-boiling Spray Tray type
b)
Physical location
At 42 M Elevation
c)
Storage capacity
265000 lbs (120 tonnes)
286000 lbs (130 Tonnes)
286000 lbs (130

Tonnes)
d)
Condensate
Centering Temp.
Leaving
304 Deg. F (151 Deg.C)

350 Deg. F (176 Deg.C)
248 Deg. F (120 Deg.C)

323 Deg. F( 162 Deg.C)
248 Deg. F (120 Deg.C)

323 Deg. F (162 Deg.C)
BOILER FEED
PUMP
a)
Manufacturer
BHEL
BHEL
BHEL
b)
Numbers
Two
Three
Three
c)
Capacity Per Hr.
980000 lbs / Hr. (445 TPH)
852000 lbs/Hr. (387 TPH)
980000 lbs/Hr. (445

TPH)
d)
Design Suction
Head Pressure
7.83 atg
16 Kg/cm2
16 Kg/cm2
e)
Design Pressure
head discharge
Pr.
177.85 atg
209.1 Kg/cm2
U # 5 : 212.7 Kg/cm2
U # 6 : 212. 7 Kg/cm2

S.No.
TURBINE
Unit #1&2
Stg.I
Unit #3&4
Stg.II
Unit #5&6
Stg. III & IV
f)
Boiler feed pump

drive
(i)
Elect. Or Steam
Electric drive
Electric Drive
Electric drive
(ii)
Manufacturer
BHEL
BHEL
BHEL
(iii)
Horse Power
5362 HP (4000 KW)
4691 HP (3500 KW)
U # 5 : 4691 HP (3500KW)
U # 6 : 5362 HP (4000 KW)
EQUIPMENT DETAILS
(B) GENERATOR
Description
Stage-I
Make
234260 / 2 H
Rated capacity
137.5 MVA
Frequency
Stage-III
Stage-IV
THW-210-2A
THW-210-2A
THRI 108/44
247.0 MVA
247.0 MVA
229.4 MVA
BHEL
Type
Power factor
Stage-II
0.80 Lagging
0.85 Lagging
50 Hz.
EQUIPMENT DETAILS
GENERATOR WITH SEAL OIL SYSTEM,
HYDROGEN GAS/ STATOR COOLING
WATER SYSTEM
Description
Stage-I
Stage-II
Stage-III
Stage-IV
Type
TG
234260/2H
THW-210-2A
THW-2102A
THRI
108/44
Size /Capacity
137.5 MVA
247.0 MVA
247.0 MVA
229.4 MVA
Quantity (Nos.)
1x2=2
1x2=2
EQUIPMENT DETAILS
(C) GENERATOR
SNo.
SNo.
Particulars
Unit #1
Unit #2
Unit #3
Unit #4
Unit #5
Unit #6
1.
Manufacturer
BHEL
BHEL
BHEL
BHEL
BHEL
BHEL
2.
Type of excitation system
Static
Static
Static
Static
Static
Brushless
3.
Rotor Cooling Media
Hydrogen
Hydrogen
Hydrogen
Hydrogen
Hydrogen
Hydrogen
4.
Stator Cooling Media
Hydrogen
Hydrogen
DM water &
Hydrogen
DM water &
Hydrogen
DM water &
Hydrogen
Hydrogen
5.
Rating
137.5 MVA
137.5 MVA
247 MVA
247 MVA
247 MVA
229.41 MVA
6.
Maximum gross output

with valves wide open
(with design exhaust
pressure, makeup over
110 MW
110 MW
210 MW
210 MW
210 MW
195 MW
7.
Approx. Aux. Power
8.
Maxm.
Maxm. Net output (Gross(GrossAux.) MW
9.
VoltageVoltage- KV
11 KV
11 KV
15.75 KV
15.75 KV
15.75 KV
15.75 KV
10.
Amperes
7220 Amp.
7220 Amp.
9050 Amp.
9050 Amp.
9050 Amp.
8410 Amp.
11.
Power factor
0.8 Lag.
0.8 Lag.
0.85 Lag.
0.85 Lag.
0.85 Lag.
0.85 Lag.
12.
Short circuit ratio
0.5
0.5
0.49
0.49
0.49
0.48
13.
Normal/ Maxm.
Maxm. H2
pressure
2.00 Kg./cm
Kg./cm
2.30 Kg./cm
Kg./cm
2.00 Kg./cm
Kg./cm
2.30 Kg./cm
Kg./cm
3.50 Kg./cm
Kg./cm
3.70 Kg./cm
Kg./cm
3.50 Kg./cm
Kg./cm
3.70 Kg./cm
Kg./cm
3.50 Kg./cm
Kg./cm
3.70 Kg./cm
Kg./cm
2.00 Kg./cm
Kg./cm
2.20 Kg./cm
Kg./cm
EQUIPMENT DETAILS
Description
Stage-I
Stage-II
Stage-III
Stage-IV
11/220 KV
15.75/240
KV
15.75/240
KV
15.75/240
KV
125 MVA
250 MVA
250 MVA
250 MVA
220/7/7 KV
220/7/7 KV
220/7/7 KV
Size /Capacity
50 MVA
50 MVA
50 MVA
Quantity (Nos.)
TRANSFORMERS
(a) Generator
Transformers
Type
Size /Capacity
Quantity (Nos.)
(b) Station
Transformers
Type
EQUIPMENT DETAILS
Description
Stage-I
Stage-II
Stage-III
Stage-IV
0.5 MVA
1+1
1.0 MVA
1.6 MVA
12
3+2
2.0 MVA
(c) Service
Transformers
Type :
Total :
0.5 MVA
2 Nos. (Oil-1 No.+ Dry-1 No.)
1.0 MVA
18 Nos. (Oil 18 Nos.)
1.6 MVA
27 Nos. (Oil 25 No. + Dry - 2 Nos.)
2.0 MVA
12 Nos. (Oil 10 Nos. + Dry 2 Nos.)
EQUIPMENT DETAILS
Description
Stage-I
Stage-II
Stage-III
Stage-IV
COMMON AUXILIARIES:
(A) Clarification cum filtration Plant
Type
Clarifiocculator bridge & rapid gravity filter bed
Size /Capacity
Rated -1000
Cum/Hr
Max,. 1250
Cum/Hr
Rated -1750
Cum/Hr
Max,. 2000
Cum/Hr
Rated -500
Cum/Hr
Rated -500
Cum/Hr
Quantity (Nos.)
(B) C.W. SYSTEM :

Type
Size / Capacity
Quantity
Vertical shaft mixed flow turbine pumps
8.275
Cum/Hr.
16.000
Cum/Hr.
16.000
Cum/Hr.
16.000
Cum/Hr.
EQUIPMENT DETAILS
Description
StageStage-I
StageStage-II
StageStage-III
StageStage-IV
(C) D.M. CumCum-Softening Plant

Type
Ion exchange process
Size /Capacity
DM Plant
Rated 60 Cum/Hr
Max. 70 Cum/Hr.
Soft Plant
Rated 100 Cum/Hr.
Max. 125 Cum/Hr.
DM Plant
Rated 80 Cum/Hr
Max. 90 Cum/Hr.
Soft Plant
Rated 210
Cum/Hr.
Max. 210 Cum/Hr.
Quantity (Nos.)
DM plantplant-2
Soft plantplant-4
DM plantplant-3
Soft plantplant-3
Type
2FAA2FAA-5X325X32-11090110902
FAAFAA-6x36(36)6x36(36)2x901252x90125-2
FAAFAA-7x457x452x10921352x1092135-2
FAAFAA-7x457x452x10921352x1092135-2
Size / Capacity
128 m
m/m
/m/sec.
187 m
m/m
/m/sec.
331.7 m
m/m
/m/sec.
275.8
m/m
/m/sec.
DM Plant
Rated 80 Cum/Hr
Max. 90 Cum/Hr.
Soft Plant
Rated 210 Cum/Hr.
Max. 210 Cum/Hr.
DM plantplant-1
Soft plantplant-1
(D) Electro Static Precipitator
Quantity
EQUIPMENT DETAILS
Description
Stage-I
Stage-II
Stage-III
Stage-IV
(E) Ash Handling Plant

Type
Size /Capacity
Quantity (Nos.)
B.A.
Fly Ash
- Wet system
- Pneumatic/ Wet system
BA 80 TPH BA 2x 80
FA 85 TPH TPH
FA 180 TPH
1
BA 2x76 TPH
FA 148 TPH
1
BA 2x76 TPH
FA 148 TPH
1
(F) Bearing Cooling Water System

Type
Recirculati
on type
close cycle
Recirculation Recirculation
type close
type close
cycle
cycle
Recirculation
type close
cycle
Size / Capacity
500 CU
M/Hr.
1100 CU
M/Hr.
3000 CU M/Hr.
Quantity
1100 CU M/Hr.
EQUIPMENT DETAILS
Description
Stage-I
Stage-II
Stage-III
Stage-IV
(G) Air Compressor

Type
Reciprocating type
Size /Capacity (i)

(ii)
(iii)
600 Cfm
200 Cfm
15 Cum/Min.
Quantity (Nos.)(i)
(ii)
(iii)
2
4
4
600 Cfm
600 Cfm
19.7
Cum/Min
5
(H) Hydrogen generating Plant

Type
Electrolysis type
Size / Capacity
10 Cu M/Hr
Quantity (Nos.)
(I) Raw water

system
Type
VT type
Size / Capacity
2400 M/Hr.
Quantity (Nos.)
EQUIPMENT DETAILS
Description
Stage-I
Stage-II
Stage-III
Stage-IV
(J) B.C.W. Raw water Pump Stg.I

Type
VT type
Size /Capacity
1200 M/Hr
Quantity (Nos.)
(K) Clarified Raw Water pump Stage-I

Type
VT type
Size / Capacity
600 M/Hr
Quantity (Nos.)
CIRCULATING WATER PUMPS

S.No.
Technical Details
Stage-I
Stage-II
Stage-III
Stage-IV
1.
Manufacturer
M/s. Jyoti Ltd.
M/s. BHEL
M/s. KBL
2.
No. Installed
5 Nos.
5 Nos.
3 Nos.
3 Nos.
3.
Capacity of each
design flow
8275 M /Hr.
16000 M/Hr.
16000 M /Hr.
16000 M /Hr.
4.
No. of operational at
Designed Unit Load
4 Nos.
4 Nos.
2 Nos.
2 Nos.
5.
Design head
19.4 MWC
25.3 MWC
26.5 MWC
25.1 MWC
6.
Type of pumps
Vertical Turbine
Vertical mixed
flow
Vertical Turbine
7.
Type of Motor
3 Phase
Asynchronous
motor
M/s. Worthington
Pump India Ltd.
Vertical mixed flow
3 Phase squirrel
cage CACW
motor
3 Phase
Asynchronous
motor
3 Phase squirrel
cage motor
COOLING TOWER
1-
Manufacturer
M/s Gammon India Ltd.
2-
Type
3-
Design flow rate
4-
Heat Removed (10 K.Cal/Hr.)
5-
Circulating water flow
6-
Hot Water Temperature
7-
Temperature range
8-
Design Wet Bulb Temperature
27.8 C
9-
Approach to wet bulb
4.2 C
10-
Fill material / Depth
11-
Make up / blow down flow rate
12-
No. of Cells
13-
Chemical treatment used
14-
Design Cycle of concentration
IDCT
34000 CMH(16 Cells)
275400 to 504900
34000 CMH(16 Cells)
42 C
42C to 32 C
Pre Cast RCC Splash bar / 3 Meter

600 M /Hr. / 300 M /Hr.
16 + 2 (standby)
H2 SO4, Chlorine
4.5 COC
WATER TREATING EQUIPMENT
Raw Water Quality information :
Water treatment equipment supplier : M/s Geo- Miller , Delhi.
Treatment stems involved :

Raw water Clarification filtration- F.A.C - S.A. C. - W. B.A. - S.B.A. M.B ( DM Water)
Base Exchanger ( soft water )
Make Up water uses : Steam Cycle ( Boiler) , Stator cooling
Make Up water quality :
Make Up rate : - 50 to 60 M/hr.
Storage details for condensate make up water :- 750 M in each unit No. 3,4,5,& 6
& 300 M in each unit No. 1 & 2
Feed point for condensate make up : Hot Well
Turbidity : 350 NTU ( Mansoon Average)

pH
: 8.0
Total Hardness ( as CaCo3 ) : 100
Silica
: 3 to 5 ppm
pH
: 6.8 to 7.2
Conductivity : < 0.2 umho/ cm
Hardness
: Nil
Total silica
: < 0.01ppm
Chloride
: Nil
LIST OF PLANT EQUIPMENT

Sl.
No.
Description
AHP Stage-I
AHP Stage-II
AHP Stage-III
AHP Stage-IV
(2 x 110 MW)
(2 x 210 MW)
(1 x 210 MW)
(1 x 195 MW)
Manufactures
Bottom Ash
Handling
Design
M/s Indure Pvt. Ltd.,

New Delhi
M/s Burn Standard &

Company Ltd.,
Howrah, W.B.
M/s DCIPS Ltd., Kolkata,

W.B.
M/s BHEL (ISG),

Banglore (K.S.)
Capacity of
bottom ash
hopper
Maximum coal consumption

at MCR is 75 Ton / hours at
3728 calorific value Kcal /
Kg. with ash contents of
42%
160 Ton / hours at

3728 calorific value
Kcal / Kg. with ash
contents of 42%
160 Ton / hours at 3728

calorific value Kcal / Kg.
with ash contents of 42%
160 Ton / hours at 3728

calorific value Kcal /
Kg. with ash contents
of 42%
Maximum bottom ash

collection value 7.5 MT per
hour Total for 8 hour shift 60
Tonnes
Maximum bottom ash

collection value 16
Tonnes per hour Total
for 8 hour shift 128
Tonnes
Maximum bottom ash

collection rate 16
Tonnes per hour.
Total collection in 8
hours of shift 128
Tonnes
Maximum bottom ash

collection rate 16
Tonnes per hour. Total
collection in 8 hours of
shift 128 Tonnes
Bottom ash
disposed to
Ash dyke (ash pond)

distance about 3.0 KM.
Ash dyke (ash pond)

distance about
2.5 KM.
Ash dyke (ash pond)

distance about 2.5
KM.
Ash dyke (ash pond)

distance about 2.0 KM.
Economizer
ash handling
and storage
design
420 Kg. x 4 ECO hoppers =

1680 Kg. / Hrs. / Unit
900 Kg. x 4 ECO

hoppers = 3600 Kg. /
Hrs./Unit
900 Kg. x 4 ECO hoppers

= 3600 Kg. / Hrs./Unit
900 Kg. x 4 ECO

hoppers = 3600 Kg. /
Hrs./Unit
8 x 1680 = 13,440 Kg. in

each shift of 8 Hrs./Unit
8 x 3600 = 28,800 Kg.

in each shift of 8
Hrs./Unit
8 x 3600 = 28,800 Kg. in

each shift of 8 Hrs./Unit
8 x 3600 = 28,800 Kg.

in each shift of 8
Hrs./Unit
LIST OF PLANT EQUIPMENT

Contd..
Sl .
No.
Description
Fly ash handling

and storage
i) Both wet and dry
i) Both wet and dry
i) Both wet and dry
i) Dry
(dry /wet, ash

pond / storage
Silo)
ii) Ash ponds
ii) Ash ponds
ii) Ash ponds
ii) Storage Silo
iii) Storage Silo
iii) Storage Silo
iii) Storage Silo
a) 1 x 500 MT + 1x100
MT
a) 2 x 75 MT = 150 MT
a) 1 x 200 MT
a) 1 x 300 MT
b) 2 x 500 MT
b) 1 x 500 MT
b) 1 x 500 MT
b) 2 x 500 MT
i) Water exhauster
i) Water exhauster
i) Water exhauster
i) Dense phase
ii) Vacuum pumps (Mech.

Exhauster)
ii) Vacuum pumps

(Mech. Exhauster)
ii) Dense phase system
ii) Vacuum pumps

(Mech.
Exhauster)
Fly ash handling

equipments
design details
(vacuum pumps
or wet pumps or
screw conveyors)
AHP Stage-I
AHP Stage-II
AHP Stage-III
AHP Stage-IV
(2 x 110 MW)
(2 x 210 MW)
(1 x 210 MW)
(1 x 195 MW)
iii) Dense phase

system
C&I EQUIPMENT
STAGE - I
STAGE II
STAGE III
STAGE-IV,
UNIT # 1 & 2
UNIT # 3 & 4
UNIT # 5
UNIT # 6
Control Concept Used (Analog, digital,

distributed Microprocessor, etc.)
Analog
Analog
DCS (H&B)
Contronic-E
DCS (ABB)
Manufacturer
I .L .Kota
SIEMEN (BHEL),
PROCONTROL
MAX DNA (BHEL)
H&B (M/s ILK)
(BHEL), Hartmann
ABB, Symphony
& Braun ( IL Kota)
Melody (ILK)
CRT
CRT
Annunciator System
CRT & Audio
CRT & Audio
(M/s ILK)
Visual
Visual
S.No
1
DESCRIPTION
Operation Stations (CRTs or Panel

Mounted)
DESK
Alarm Station (CRTs or Annunciator)
Annunciation
Panel Mounted
Symphony Melody
(M/s ILK)
Engineers Stations (CRTs)
NIL
Only for DAS
CRT
CRT
Data logging features (Strip charts,
Only Records
available.
Data logging through DAS
Data Acquisition
Data Acquisition
System
System
Log sheets or Data logger)

7
Historical data storage and retrieval

capabilities.
-do-
Yes, DAS
Symphony (ABB)
Yes
Yes
8.
Are major plant systems controlled by

Central Supervisory equipment or by
Standard Contractor supplied control
system (i.e. separate, Turbine-Generator
controls, Boiler feed pump controls,
Soot blower controls, Burner controls,
ESP), If so Manufacturers of
such controls for these systems.
Nil
Turbine: EAST
Packages (BHEL)
BFP's, Burner controls,.
Fam. Drum level,
Furnance Draft etc.
Contronic e (M/s. ILK)
Soot blowers :
Relay Logics
Central Supervisory
Central Supervisory
Balance of plant controls Combustion

controls, feed water and condensate,
minor plant loops, ash handling, coal
handling, water treatment.
Combustion
Control
Feed water
control.
ombustion Control
Feed water control.
Combustion Control
Feed water control,
Minor plant loops.
C-34 Transdata
system supplied by
H&B and IL Kota.
-do-
-do-
Combustion Control
Feed water control,
Minor plant loops.
EQUIPMENT DETAILS
Description
Stage-I
Stage-II
Stage-III
COAL HANDLING PLANT

(A) Locomotive
Type
WDS-6
Size /Capacity
1400 HP
Quantity (Nos.)
2+1
(B) Locomotive
Type
WDS-45
Size /Capacity
700 HP
Quantity (Nos.)
(C ) Railway Track with associated Point &
Crossing Tack points etc.
Type
Broad gauge
Size /Capacity
52 Kg. rails C-Class
Quantity (Nos.)
35+11
Stage-IV
EQUIPMENT DETAILS
Description
Stage-I
Stage-II
Stage-III
Stage-IV
(D) Wagon Tippler Area

(1) Wagon Tippler No. 1 & 4 with Beetle
Charger & Associated equipment Stg.I & II
Type
Rotaside
Size /Capacity
95 MT 12
Tips/Hr.
Quantity (Nos.)
(2) Wagon Tippler No. 5 with associated equipment

such as Side Arm Charger Stg.III
Type
Rotaside XL
Size /Capacity
100 MT 24 Tips/Hr.
Quantity (Nos.)
(3) Apron feeder

Type
Size /Capacity
1350 TPH
Quantity (Nos.)
EQUIPMENT DETAILS
Description
Stage-I
Stage-II
Stage-III
(4) Scrapper Conveyor

Type
Size /Capacity
15 TPH
Quantity (Nos.)
(5) Rotary Breaker

Type
12 x 21
Size /Capacity
Rated 1350 TPH
Quantity (Nos.)
(6) Roll Crusher

Type
Size /Capacity
80 SA Breaker (Roll crusher)

1350 TPH
Quantity (Nos.)
(E) Crusher Area

(1) Crusher No. 2, 3
&6
Type
Ring Graulator TK-16-54B
Size /Capacity
550 TPH
Quantity (Nos.)
3 Nos.
Stage-IV
EQUIPMENT DETAILS
Description
Stage-I
Stage-II
Stage-III
(2) Crusher No. 4, 5, &

7
Type
Ring Graulator, RG-721
Size /Capacity
550 TPH
Quantity (Nos.)
3 Nos.
(3) Crusher No. 8, 9 & 10

Type
Ring Graulator
EKK 48X93
Size /Capacity
750 TPH
Quantity (Nos.)
3 Nos.
(F) FLOW FEEDER M/Cs AREA

Flow Feeder M/c. No. 1 & 2
Type
Rotary discharge machine block model
Size /Capacity
750 TPH
Quantity (Nos.)
2 Nos.
Stage-IV
EQUIPMENT DETAILS
Description
Stage-I
StageII
StageIII
Stage-IV
(G) STACKER RECLAIMER AREA

(1) Stacker Reclaimer M/c. (M/c. S.No. HM-225) & HM-313
manufactured & supplied by M/s. ELECON
Type
ASK-550
Size /Capacity
1350 TPH Stacking & reclaiming
Quantity (Nos.)
2 Nos.
(H) DOZERS AREA:

(1) Dozer
Type
BEML/Komatsu/ Cummins/D.155
Size /Capacity
320 HP
Quantity (Nos.)
5 Nos.
(2) Dozer
Type
Size /Capacity
350 HP
Quantity (Nos.)
2 Nos.
EQUIPMENT DETAILS
Description
Stage-I
Stage-II
Stage-III
(H) DOZERS AREA:

(1) Dozer
Type
Size /Capacity
320 HP
Quantity (Nos.)
5 Nos.
(2) Dozer
Type
Size /Capacity
350 HP
Quantity (Nos.)
2 Nos.
Stage-IV
EQUIPMENT DETAILS
Description
Stage-I
Stage-II
StageIII
(3) Dozer
Type
TIL/Caterpillar/ D6H
Size /Capacity
175 HP
Quantity (Nos.)
(I) (a) FUEL OIL DECANTING PUMPS AREA :

Type / Make
FO Flowmore
HSD Flowmore
FO - Roto
HSD Roto
Size /Capacity
FO - 100 KL/H FO - 210 KL/H

HSD - 30
HSD 100
KL/H
KL/H
FO -250
KL/H
Quantity (Nos.)
FO 4
HSD 2
FO 2
FO 4
HSD - 2
FO Roto
StageIV
EQUIPMENT DETAILS
Description
Stage-I
Stage-II
StageIII
Stage-IV
(I) (b) OIL TANK AREA :

Type
F.O. Tank
HSD Tank
LDO Tank
F.O.
H.S.D.
LDO Tank
(J)
3000 KL ( 2 Nos.)
700 KL (1 (No.)
700 KL (1 No.)
4120 KL (1 No.)
800 KL ( 1 No.)
800 KL (1 No.)
WORKSHOP AREA :
(1) Lathe Machine
Type : Vikram 1250 mm Bed, 390 mm dia. 1

No.
(2) Lathe Machine
Type : NH-26/1000, HMT, 575 mm dia. 1 No.
(3) Lathe Machine
Type : NH-26/3000, HMT, 575 mm - 1 No.
EQUIPMENT DETAILS
Description
(4) Milling Machine
(5) Tool Cutter Grinder

(6) Radial Drill machine
(7) E.O.T. Crane
(8) Drill Machine (WNP)

9) Power Hacksaw
machine
Stage-I
Stage-II
Stage-III
Stage-IV
Type : FN-30 `HMT make - 1 No.
Type : CTC-28/T `HMT make - 1 No.

Type : RM-63
1 No.
HMT Sr. No. 33174 (80 MM) -
5 T capacity , Universal ropeways 1 No.
Bajaj DS -40, 1 - 1 No.

1 No.
EQUIPMENT DETAILS
Description
Stage-I
(10) Shaping machine
Stage-II
StageIII
Stage-IV
ROP MODEL RPS-600 - 1 No.
(11) Power Hacksaw

(Hydraulic)
`BESTO Make, 8 1 No.
(12) Hydraulic press
100 MT 1 No.
(K) CONVEYOR SYSTEM AREA

Conveyor System ofType
Nylone belts
Nylone belts Nylone

belts
Size /Capacity
750 /1350 TPH
1350 TPH
Quantity Stage-wise
(in Mtr.)
Total Quantity
5689
5491
1595 Mtrs.
Nylone
belts
1350
TPH
1350 TPH
4415
356

Data Thermal Units KTPS

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Data Thermal Units KTPS

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SAMPLE HEAT RATE CALCULATIONS ABSTRACT FOR UNIT #1 to 6 FOR DEC.

Total moisture in coal.

Volatile Matter in coal

Un burnt carbon in fly ash

Un burnt carbon in bottom ash

Flue gas temp. at APH outlet

CO2 in flue gas at APH outlet

Oxygen in flue gas at APH out let

Average Main steam pressure before ESV.

Average Main steam temperature before ESV

Average CRH Steam pressure after HPT

Average R H Steam pressure before I.V.

Average R H Steam temperature before I.V.

Average Feed water temperature at ECO. Inlet

Total Generation as on day

No. of hours m/c on bar.

Total Quantity of oil used .

a)For start- up activities

b)For flame support

Oxygen in flue gas at APH Inlet

SAMPLE HEAT RATE CALCULATIONS ABSTRACT FOR UNIT #1 to 6 FOR DEC. 07

Total oxygen required

Loss due to un-burnt carbon in ash.

Loss due to dry flue gas.

Loss due to moisture & hydrogen in

Loss due to sensible heat in ash.

Loss due to moisture in air.

Radiation & un-accounted loss

Boiler efficiency.(Guaranteed 86.1

MCR based/ on Coal HHV 4278

SAMPLE HEAT RATE CALCULATIONS ABSTRACT FOR UNIT #1 to 6 FOR DEC. 07

(Designed heat rate of Tur.-1980.64 Kcal/KWH)

Increase in heat rate in K cal / KWH due to:Fall in vaccuum.

Fall in feed water temperature

Increase in heat rate due to DM water make

Heat Value of oil

Total Heat Loss

Over all Heat rate of the Unit.

Estimated heat rate of turbine

(3) Over all Efficiency of the Unit

Over all Thermal Efficiency of the Unit.

UNIT WISE & STATION WEIGHTED AVERAGE GCV OF COAL

Avg GCV of Oil

Heat Rate (Kcal/Kwh)

UNIT WISE & STATION WEIGHTED AVERAGE GCV OF COAL

Avg GCV of Oil

Avg GCV of Oil

UNIT WISE & STATION WEIGHTED AVERAGE GCV OF COAL

Avg GCV of Oil

Heat Rate (Kcal/Kwh)

Unit No. #6 Commercial Operation w.e.f. 1st Aug. 2004.

Avg GCV of Oil

UNIT WISE & STATION WEIGHTED AVERAGE GCV OF COAL

STACK EMISSION & AMBIENT AIR QUALITY

Average Ambient Air Quality

Stg-II & III (3 x 210

STACK EMISSION & AMBIENT AIR QUALITY DATA 2006-07

Average Ambient Air Quality

Stg-II & III

TRADE EFFLUENT ANALYSIS RESULT OF KSTPS

Condenser Cooling Water Stage-II&III

TRADE EFFLUENT ANALYSIS RESULT OF KSTPS

TRADE EFFLUENT ANALYSIS RESULT OF KSTPS

Boiler blow down mix drain Unit-V