BHARAT HEAVY ELECTRICALS LIMITED
O.P. JINDAL SUPER THERMAL POWER PLANT PHASE-III
2400 MW (4X600 MW)
SECTION 2
TECHNICAL WRITE-UP ON
MAIN PLANT
VOLUME-2
TECHNICAL SPECIFICATIONS
SECTION 2
MAIN PLANT
Page 1
BHARAT HEAVY ELECTRICALS LIMITED
O.P. JINDAL SUPER THERMAL POWER PLANT PHASE-III
2400 MW (4X600 MW)
MAIN PLANT SYSTEM
1.0
DESCRIPTION OF REGENERATIVE FEED HEATING SYSTEM
1.1
GENERAL
The thermal cycle for the plant has been designed in accordance with the latest
trends and concepts prevailing in the field of power plant design. The cycle has been
basically designed for the operation of turbine and boiler on unit system.
The steam generator is of drum type, assisted circulation, single reheat type suitable
for outdoor installation and designed for firing pulverized coal..
The steam turbine is single reheat condensing type, tandem compound design and.
comprises of a single flow HP turbine, a double flow IP and two double flow LP
cylinders.
The condenser is of double pass construction with two independent circulating water
inlets and outlets.
The regenerative feed cycle starts from the condenser at low pressure and ends at
economiser inlet at high pressure. Feed heating cycle for each unit consists of 3x50%
condensate extraction pumps, gland steam condenser, condensate polishing unit,
drain cooler, three low pressure heaters, variable pressure deaerator, 2x50% turbine
driven boiler feed pumps and 1x50% motor driven boiler feed pumps and 3x50% high
pressure heaters along with piping connecting steam and water sides.
The condensate extraction pumps take suction from condenser hot well and pump the
condensate to deaerator through gland steam condenser, condensate polishing unit,
drain cooler and low pressure heaters. Boiler feed pumps take suction from deaerator
and pump the feed water to boiler through high pressure heaters. The condensate /
feed water gets heated up progressively by bled steam from turbine extractions
together with gland leak off steam. Vacuum pumps are provided to create or maintain
vacuum in the condenser.
VOLUME-2
TECHNICAL SPECIFICATIONS
SECTION 2
MAIN PLANT
Page 2
BHARAT HEAVY ELECTRICALS LIMITED
O.P. JINDAL SUPER THERMAL POWER PLANT PHASE-III
2400 MW (4X600 MW)
1.2
MAIN STEAM, COLD REHEAT & HOT REHEAT SYSTEM
The main steam from the boiler is taken to the HP turbine. Motorized isolating valve
is provided at the boiler end for isolation.
Steam from HP turbine exhaust is taken back to the boiler for reheating through
power assisted non-return valve. Individual spray type attemperators are provided on
CRH branches at the boiler end. The cold reheat steam is led to the boiler end.
The hot reheat steam from the boiler is taken to the IP turbine.
Isolating devices are provided on the CRH and HRH lines to facilitate isolation of
reheater section for hydro-testing.
After expansion in the IPT, exhaust steam from IPT is taken from cross-over piping to
the inlet of
LPTs .
LPT exhaust steam is condensed in respective surface
condensers.
HP bypass system branches off the main steam pipe and outlet steam from HP bypass
is fed to the cold reheat piping. LP bypass system branches off the HRH pipes at the
downstream of strainers and outlet steam from LP bypass is led to the condenser.
1.3
EXTRACTION STEAM SYSTEM
The extraction steam for the HP heaters-6A & 6B is drawn from the cold reheat pipe
upstream of the attemperators. Steam for boiler feed pump turbine ,deaerator , HP
heaters-5A & 5B are fed with steam extracted from the IP turbine. Deaerator is
designed to operate under variable pressure between 55% to 100% load on turbine
and during this range steam is drawn from turbine extraction i.e. IP exhaust. During
start-up of turbine, deaerator is provided with steam supply from cold reheat line as
well from auxiliary steam header. The boiler feed pump turbines are fed with steam
from IP-LP cross-over pipe under normal condition and during start-up steam is
supplied from cold reheat line as well from auxiliary steam header. BFP turbines
VOLUME-2
TECHNICAL SPECIFICATIONS
SECTION 2
MAIN PLANT
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BHARAT HEAVY ELECTRICALS LIMITED
O.P. JINDAL SUPER THERMAL POWER PLANT PHASE-III
2400 MW (4X600 MW)
exhaust are connected to condenser through motorized butterfly valves. Steam for the
LP heaters Nos. 1, 2 & 3 are extracted from various stages of the LP turbine.
Power assisted quick closing non-return valves are provided in extraction lines to
HPH-5A & 5B (common line), deaerator, BFP turbines, LPH-3 & LPH-2 to prevent
back flow of steam into the turbine during a trip. These valves are controlled from
ATRS. Motorized block valves are provided in extraction lines to HPH-6A & 6B, HPH5A & 5B, deaerator, BFP turbines, LPH-3 & LPH-2.
1.4
FEED WATER SYSTEM
After deaeration in the deaerator, the feed water is taken to the 3 x 50% capacity boiler
feed pumps provided with booster pump units. Two of the boiler feed pumps are
turbine driven and one is electric motor driven through variable speed hydraulic
coupling. Normally turbine driven pumps are working and motor driven pump is
standby. Each of these pumps is provided with suction strainer, booster pump,
recirculation system, non-return valve and motorised discharge valve. Individual
recirculation control loops are envisaged for the pumps to maintain required minimum
flow.
A common feed water outlet from BFPs is taken to the parallel banks of HP heaters
Nos. 5A & 6A and 5B & 6B. Each of the HP heater banks are provided with inlet and
outlet motorized isolating valves and two motorized bypass valves (one valve for both
the heater strings out of service and the other valve for one heater string out of
service) which serves both the heater banks.
VOLUME-2
TECHNICAL SPECIFICATIONS
SECTION 2
MAIN PLANT
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BHARAT HEAVY ELECTRICALS LIMITED
O.P. JINDAL SUPER THERMAL POWER PLANT PHASE-III
2400 MW (4X600 MW)
Feed water to the boiler shall be regulated during low load operation by regulating low
capacity control valve using single element control and during higher load operation,
flow shall be regulated using three element control by controlling the speed of the
BFPs.
The attemperation water for HP bypass station is drawn from the main feed water line
upstream of the HP Heaters. The attemperation water for Boiler Main Steam
temperature control shall be drawn from feedwater line downstream of the HP heaters
at higher loads (~ 80 % load) and from kicker stage of the Boiler Feed pump for loads
below ~ 80 %.
The attemperation water for the reheat system is drawn from boiler feed pump inter
stage tap off.
During normal operation HP heater No. 6A / 6B drains are cascaded to HP heater5A / 5B respectively. HPH 5A / 5B drains are cascaded to deaerator. Under high level
conditions heater drains are directly led to the condenser via HPD flash tank.
1.5
CONDENSATE SYSTEM
Steam from the LP turbine exhaust and LP bypass is condensed in a condenser with
divided cooling water circuit. From hotwell, which is divided internally, two condensate
outlet pipes take the condensate to the 3 x 50% duty condensate extraction pumps.
Normally two pumps are working and third pump is standby. Condensate extraction
pumps are motor driven.
Each condensate extraction pump is provided with suction strainer, condensate
recirculation system, motorised discharge valve and non-return valve (NRV). Individual
recirculation control loops are envisaged for each condensate extraction pump. A
common delivery pipe carries the condensate from these pumps to the on-line type
gland steam condenser. To provide adequate flow through the gland steam condenser,
VOLUME-2
TECHNICAL SPECIFICATIONS
SECTION 2
MAIN PLANT
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BHARAT HEAVY ELECTRICALS LIMITED
O.P. JINDAL SUPER THERMAL POWER PLANT PHASE-III
2400 MW (4X600 MW)
the condensate flow shall be metered and a recirculation valve envisaged at down
stream of the gland steam condenser unit shall be regulated to ensure required
minimum flow. After the gland steam condenser, the main condensate passes through
the 100% duty condensate polishing unit and then to the main condensate flow control
valve.
The condensate flow regulating valve is envisaged at the downstream of the
condensate polishing unit which is regulated by the three element deaerator level
control loop. The condensate thereafter, passes through the drain cooler, LPH-1,
LPH-2, LPH-3 and then to the deaerator.
During normal operation LPH-3 drain is cascaded to LPH-2 and LPH-2 drain is
cascaded to LPH-1. Under high level conditions LPH-3 / LPH-2 drains are directly led
to condenser via LPD flash tank. No level is maintained in LPH-1. Its drain is
connected through a syphon to condenser via drain cooler and LPD flash tank.
A high level drain system is envisaged for the
deaerator to dump the excess
condensate from the feed storage tank into the LPD flash tank automatically in case of
excessive high level.
2.0
HP/LP BYPASS SYSTEM
TG unit has been provided with HP / LP bypass system designed to handle 60% of
BMCR flow at rated turbine inlet steam conditions. The bypass station for the TG set
enables boiler operation by establishing steam flow from main steam line to
condenser without passing through turbines. This allows quick raising of steam
parameters to a level acceptable to turbine for roll-off during start-up. This also
facilitates holding of stable firing from the starting of turbine roll-off till the entire flow
from the bypass station is transferred to the turbine and spinning of the TG set on
house load following export load rejection.
The high pressure bypass system
consists of two
reducing and desuperheating control valves.
numbers combined pressure
The control
valves, when opened,
bypass the steam flow from the boiler around the high pressure turbine to the
VOLUME-2
TECHNICAL SPECIFICATIONS
SECTION 2
MAIN PLANT
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BHARAT HEAVY ELECTRICALS LIMITED
O.P. JINDAL SUPER THERMAL POWER PLANT PHASE-III
2400 MW (4X600 MW)
reheater. A pressure control system is provided to control the throttle pressure by
regulating the bypass flow through the control valves. The pressure set point is
manually adjustable and will be set at a value higher than the throttle pressure set
point value of the co-ordinated control system. A temperature control system is also
provided to automatically control the steam temperature down-stream of the valves
at the given set value. The temperature set point can be adjusted remote manually.
The control of the HP bypass station is independent of the LP bypass control.
3.0
AUXILIARY STEAM SYSTEM
Auxiliary steam system is designed to provide steam for the turbine auxiliaries, boiler
auxiliaries and fuel oil system during start-up, low loads and normal running of units.
Auxiliary steam system comprises of high capacity auxiliary steam pressure reducing
and desuperheating station (PRDS) with tap off from main steam line to meet
auxiliary steam requirements during unit start-up, low loads and for fuel oil system
and other Low Capacity PRV with tap off from Cold Reheat line to meet continuous
auxiliary steam requirements during normal running of the unit. Spray water required
for desuperheating will be tapped off from condensate extraction pump discharge.
A High Temperature Unit Header takes steam from above PRDS station and Low
Temperature Unit Header draws steam from the high temperature unit header via a
desuperheater .
During normal operation low capacity PRV will be in operation. The change over of
control from low capacity PRV to high capacity PRV shall be automatic with manual
override facility.
Auxiliary steam system line drains are provided with steam trap assembly to take care
of entrapped condensate .
4.0
CENTRAL LUBE OIL STORAGE AND PURIFICATION SYSTEM
This system is used for storing and purifying the oil from unit turbine oil tank. The
system is also used for adding new oil into the system.
VOLUME-2
TECHNICAL SPECIFICATIONS
SECTION 2
MAIN PLANT
Page 7
BHARAT HEAVY ELECTRICALS LIMITED
O.P. JINDAL SUPER THERMAL POWER PLANT PHASE-III
2400 MW (4X600 MW)
The system consists of one clean oil storage tank, one dirty oil storage tank, two
numbers of oil transfer pumps and one centralised oil purifier.
The dirty oil tank is used for storing the oil drained from the unit turbine oil tank. The
oil from dirty oil tank is passed through the central oil purifier and the clean oil is
stored in the clean oil tank. From the clean oil tank, the oil may be supplied to the
unit turbine oil tank, through transfer pumps as and when required.
The transfer pumps are interconnected on suction as well as discharge with isolation
valves, so that they can work as standby to each other, if so required.
New oil may be added into the system through the tank filling connection.
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TECHNICAL SPECIFICATIONS
SECTION 2
MAIN PLANT
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