Ch 1 : Steam Generator

Volume III
DCPL Section 1 : Scope of Work
Mechanical Works Sheet | 14 of 37

1.15. Coal Preparation and Firing System

1.15.1. Raw Coal Chutes and Bunker shut off valves, including following:

i. Motor operated (sliding gate type) Raw Coal Bunker shut off gate at
the bunker mouth and manually operated gate at RC feeder inlet
(both shall be for each coal feeder).

ii. Chain wheel & chain for manual operation of bunker shut off and RC
feeder inlet valve from the feeder floor.

iii. Coal chute between bunker shutoff gate and RC feeder inlet.

iv. Coal chute between outlet of feeder and inlet of mill along with motor
operated shut off gate at RC feeder outlet.

v. Permanent Chutes connection shall be provided from the feeder floor

to ground near each feeder for unloading of coal from bunkers on
trucks at ground level. A cover to be provided at the mouth of
permanent chute when not in use.

vi. Bunker downspout shall have arrangement for fixing a temporary

chute for diversion of coal flow to the permanent emptying chute near
each feeder. Two (2 nos.) temporary chute shall be provided for
steam generator for the above purpose.

vii. Each feeder shall be provided with arrangement for fixing a temporary
chute and diverting the coal from bunker to the permanent chute at
feeder floor by running the feeder, for emptying the bunker. Two (2
nos.) temporary chutes shall be provided for Steam Generator for the
above purpose.

viii. Necessary handling/lifting arrangement & suitable platform &

approach shall be provided for quick installations and removal of
temporary chutes as mentioned at clause no. (vi)& (vii) above.

ix. Dresser couplings with 410 stainless steel liner ring one on each chute
between RC feeder and mill and one on each chute between coal
bunker and RC feeder.

x. Devices to detect choking/flow/no flow of coal in the coal chute

between coal bunker and RC feeder.

xi. Remote operated shut off gate between RC feeder and coal mill.

xii. A continuous operating platform for maintenance/ operation of bunker

shut-off valves.

xiii. Coal bunker shall be in the scope of bidder/contractor. Storage

capacity of the bunkers shall correspond to 12 hours requirement of
the unit under BMCR condition with worst coal firing.

Obra “C” 2x 660 MW

Thermal Power Extension Project

Bidding Doc. No. : 14A22-SPC-G-0001

 Ch 1 : Steam Generator
Volume III
DCPL Section 1 : Scope of Work
Mechanical Works Sheet | 15 of 37

1.15.2. Raw Coal Feeders

Gravimetric type raw coal feeders, all metallic belt feeder VFD drive with
microprocessor based precision weighing and calibration devices, one for
each mill. The feeders shall be complete with motor, coupling, coupling
guards, base plate, foundation bolts, sliding joints, paddle type switches to
detect presence or absence of coal on feeder or choking of feeder, speed
variator, auto declutching arrangement to high/low level, speed sensors,
coal motion monitors, and strain gauge type weight measuring system with
all instrumentation. RC feeder sizing should be 1.2 times maximum capacity
of coal pulveriser. Weighing accuracy should be +/- 0.5%.

1.15.3. Coal Pulverizer

a) The coal pulverizer shall be vertical spindle type (like pressurized type
bowl mills, ball and race mills, roller mills or the approved equivalent). The
number of coal pulverizers to be provided shall conform to sizing /standby
requirement stipulated elsewhere in the specification. Minimum Eight (8)
no’s of coal pulverizers shall be provided for each steam generator.

b) Each pulverizer shall be complete with all wear parts/ grinding elements
and shall be provided with platforms around the pulverizer, lubrication
systems (comprising of 2x100% pumps, 2x100% cooler and 2x100%
filters for each pulverizer) drive motors, auxiliary gear, instrument tapping
points and any other equipment necessary for safe and efficient operation
of pulverizer. The Pulverizer shall also include static classifier with
provision for fitting of dynamic classifier, if required, in future. All wear
parts of mill like grinding ring, grinding elements, casing/shell silencers,
classifier vanes, classifier cones, pulveriser fuel pipes bends, etc. should
be of suitable abrasion resistant materials. Grinding ring shall have
minimum of 500 BHN. Minimum guaranteed wear life should be as per the
specific design criteria. Classifier vanes should be suitably lined with
ceramic. Adequate number of temperature sensors, temperature
transmitters, local indicators and signaling contacts for bearings and lube
oil systems shall be provided as per standard practice of Contractor.
Independent purge meters, air filter cum regulator sets, local pressure
indicators, instruments and sensing device for milling system including the
instrument requirements. Primary airflow measuring devices shall be
provided at air inlet of each coal pulverizer. Adequate number of
thermocouple type fire detection system with temperature transmitters as
a composite & complete unit with all required accessories with adequate
redundancy shall be provided.

c) Proven fire detection and fire extinguishing systems in line with the
standard practice of the manufacturer shall be provided. In case of CO2/N2
based system, the scope of supply shall also include the required
cylinder/piping and valves network etc. In case, the proposed type of mill
requires inerting during start-up/ shut-down of the mill to ensure safety of
operation, suitable system along with all piping, valves, instrumentation,
interlock system etc. shall also be provided.

d) For Mill Reject System refer to Chapter-22.

Obra “C” 2x 660 MW

Thermal Power Extension Project

Bidding Doc. No. : 14A22-SPC-G-0001

 Ch 1 : Steam Generator
Volume III
DCPL Section 2 : Design Basis
Mechanical Works Sheet | 32 of 96

noise/vibration

I. Design SCAPH and connected air ducts to handle flows corresponding to 60% BMCR
loads with one of the two streams working without any undue noise/vibration.

II. Condensate from SCAPH shall be led to atmospheric flash tank through SCAPH drain
collection tank(s). SCAPH condensate collection tank(s) shall be pressurized so that
drain can go to Atmospheric flash tank. Alternatively Atmospheric SCAPH drain
collection tank(s) with proper pumping arrangement (2x100%) with necessary valves
etc. shall be provided.

III. Steam Coil Air Preheater shall have:

a) Modular construction.

b) Tube spacing to avoid choking by contamination in the entering air.

IV. SCAPH shall be located at the outlets of each of FD fans in bypass ducts for Tri-Sector
type. In case of Bi-Sector type, SCAPH shall be located at the outlets of each of PA &
FD fans in bypass ducts.

V. Provide facilities for complete SCAPH isolation from the airflow path.

VI. SCAPH shall be suitable to operate during start-up, low load operation of unit and at
abnormal conditions when an increased air inlet temperature is considered desirable.

VII. The boiler design shall ensure that the SCAPH is not required to operate under normal
operation for the complete specified range of fuel.

VIII. Provide:

a) Side entry for removal of SCAPH modules by sliding out of modular frame.

b) Approach to the side entry.

c) Handling facility (runway beam/hoist, platforms/approach etc.) for removal and

placement of SCAPH modules on ground.

10.0. COAL PREPARATION AND FIRING SYSTEM

10.1. General

I. The coal preparation and firing system shall commence with the shut-off
valve at Raw Coal Bunker outlet and shall include raw coal feeders, coal
pulverizers, primary air & seal air fans, pulverized fuel pipes, coal burners,
coal valves and associated auxiliaries.

II. The coal preparation and firing system design shall ensure:

a) Complete safety of the plant, equipment and the personnel.

Obra “C” 2x660 MW

Thermal Power Extension Project

Bidding Doc. No. : 14A224-SPC-G-0001

 Ch 1 : Steam Generator
Volume III
DCPL Section 2 : Design Basis
Mechanical Works Sheet | 33 of 96

b) Complete compliance with the latest NFPA, (USA), requirements and

other requirements specified.

III. Bunker(s)

a) A set of bunker(s) of required capacity (as specified in the Vol-III, ch-1,

sec-1) for storage of coal shall be provided. Bunkers shall be circular in
plan with hopper bottom. To facilitate easy and continuous flow of
material, the angle made by the hopper wall with the horizontal (valley
angle in the case of square and rectangular hopper bottoms), shall
preferably be 15° more than the angle of internal friction of the
materials, but should not be less than 60° to the horizontal.

b) Bunker shall be provided with minimum 6mm thick 316L stainless steel
liner.

c) Density of coal for storage volume calculation shall be 800 kg/m3 and
shall be 1200 kg/m3 for weight calculation.

10.2. Bunker Shut Off Gates & RC Feeder inlet & outlet gates

I. Bunker shut off gate(s) & RC feeder inlet gate having following features
shall be provided:

a) Size of gates/valves shall be suitable for 914.4 mm (36") round bunker

opening.

b) Bunker Shut-Off Gates shall be motor operated & RC Feeder outlet gates
shall be motor/ pneumatic operated and RC Feeder inlet gates shall be
manually operated with double rack and pinion drive arrangement and
shall be designed for non-jamming.

c) Gate Design shall ensure dust tight enclosure.

d) The gates valves shall be self cleaning type.

II. The Bunker shut off gates and feeder inlet & outlet gates shall have:

a) Totally enclosed construction to prevent leakage.

b) Gate and shaft bearings, suitable for pressure lubrication.

c) Stainless steel material for following:

i. All components coming in contact with coal.

ii. Gate and shaft roller bearing.

III. Shut off and inlet gates shall be designed to operate with "bunker full of
coal" condition without its motor getting overloaded. Further, normal

Obra “C” 2x660 MW

Thermal Power Extension Project

Bidding Doc. No. : 14A224-SPC-G-0001

 Ch 1 : Steam Generator
Volume III
DCPL Section 2 : Design Basis
Mechanical Works Sheet | 34 of 96

motorized as well as inching operation of these shut off gates should be

possible from the feeder floor.

IV. The bunker shut of gate shall insure 100% closure of bunker outlet even
"bunker full of coal" condition without its motor getting over loaded & "static
column of coal in the chute between bunker & feeder" conditions.

V. Local push buttons for open/close command & chain wheel & chain for
manual from floor level shall be provided for each gate/valve.

VI. Adequate provision shall be kept for sampling of coal.

10.3. Coal Chutes

The requirements specified herein apply to the following coal chutes:

a) Chutes between outlet of raw coal bunker shut off valves and inlet to the
coal feeders.

b) Chutes between outlet of coal feeder and inlet to the pulverizers.

I. The internal diameter of coal chutes selected shall not be less than
following:

Coal Chute Minimum I.D

i. Between bunker outlet gate & feeder 914.4 mm

inlet *
ii. Between feeder outlet & pulveriser inlet 600 mm
*Note: Chute length and gate size shall be to 'Employer's' approval.

II. Chutes shall be made of minimum 12 mm thick stainless steel SS-410

material and shall be of full welded construction.

III. Provision shall be made for the insertion of poke rods in two directions at
right angles to each other at following locations on the chute.

a) Outlet of the bunker.

b) Inlet to the feeders.

IV. The chute between feeder outlet and pulverizer inlet shall have a stainless
steel lined hopper with suitable reinforcement.

V. Dresser coupling for chute connections (at inlets of the R.C. feeder and the
coal pulverisers) with SS 410 inner ring shall be provided.

VI. Permanent Chutes shall be provided at the feeder floor near each feeder
for unloading of coal from bunkers on trucks at ground level. Each bunker
outlet chute shall have arrangement for fixing a temporary chute for

Obra “C” 2x660 MW

Thermal Power Extension Project

Bidding Doc. No. : 14A224-SPC-G-0001

 Ch 1 : Steam Generator
Volume III
DCPL Section 2 : Design Basis
Mechanical Works Sheet | 35 of 96

diversion of coal flow to the permanent emptying chute near each feeder.
Two (2 no’s) temporary chute shall be provided for the above purpose.
Necessary handling/lifting arrangement & suitable platform & approach
shall be provided for quick installations and removal of temporary chutes.

VII. Approved type of suitable indicators shall be provided in the downspout

between bunker and feeder to detect presence or flow of coal to ensure
minimum seal height at inlet to R.C. feeder and trip the R.C. feeder if the
level of coal tends to be below this seal height.

10.4. Raw Coal Feeders

I. Each mill shall be fed with coal by an independent coal feeder.

II. Provide the following minimum features in the RC feeder(s), in addition to

complying with all the stipulations of NFPA (latest edition).

1. Feeder Type Gravimetric, belt type with minimum

size of 36"
Alternatively Rotary type
Gravimetric feeder
Drive- VFD
2. Raw Coal Feeder 1.2 times maximum capacity of coal
Sizing pulverizer.
3. Environment
Withstand
capability
a) Ambient 70°C (min.)
temperature
b) Explosion pressure 3.5 Kg/cm² (min.)
c) Other environmental conditions envisaged
4. Feeder Accuracy
a) In-situ weighing ± 0.5%. (minimum)
Accuracy
b) Repeatability 0.1%
c) Shall have in-built
facility for
calibration
5. System shall be capable of tolerating large supply voltage
variation
6. All site equipment shall be suitable for 70°C ambient
temperature and other environment conditions envisaged
7. "NO COAL" flow detection to be provided to stop the feeder
when no coal is detected on the conveyor and when
pluggage occur at feeder outlet. Paddle type coal alarm
switch shall be provided for this purpose at the following
location:
a) Over the feeder For indication of loss of coal flow to
conveyor chain/belt feeder
b) Near the feeder to stop the feeder in the event of
discharge coal pluggage at the feeder outlet

Obra “C” 2x660 MW

Thermal Power Extension Project

Bidding Doc. No. : 14A224-SPC-G-0001

 Ch 1 : Steam Generator
Volume III
DCPL Section 2 : Design Basis
Mechanical Works Sheet | 36 of 96

III. The feeder casing shall be designed to withstand an explosion pressure of

3.5 Kg/cm2 (g).

IV. The feeder belt shall be of multiply reinforced rubber of single piece
construction with arrangement for tracking and to prevent spillage.

V. Width of the belt shall have sufficient margin while operating in conjunction
with the feeder inlet opening provided.

VI. All R.C. feeder components coming in contact with coal (except belt), shall
be made of stainless steel.

VII. Provide suitable arrangement to adjust belt tension.

VIII. Provide following facilities for the feeders.

a) Spraying water inside the casing

b) Providing purge air to the feeder

IX. The feeder control system shall be microprocessor based. Coal weighing
shall be automatic and shall include local & remote indication of rate of flow
& totaliser counter.

X. Provide adequate nos. of manholes on the feeder for quick and easy
release of the feeder jamming.

XI. Easy access to any part of the feeder internals shall be possible without
dismantling the complete casing.

XII. The feeder cabinet shall be located in control equipment room (CER).

10.5. Coal Pulverizers

I. Pulverizer Type:

Bidder may offer any one of the types of pulverizers indicated below:

Classification Type
Vertical Spindle Bowl Mill
Roller mill
Ball and race mills
Or
Approved equivalent.

Each mill to supply coal to only one burner elevation.

II. Sizing of Coal Pulverisers

Selection, sizing and total number of Coal pulverisers to be provided for Steam
Generator shall confirm to following stipulations:

Obra “C” 2x660 MW

Thermal Power Extension Project

Bidding Doc. No. : 14A224-SPC-G-0001