Working parameters Specifications Operation Parameters Alarms and actions Oil pumps and lines Regulators and Valves Ejectors Air compressors Pump house Steam header Feed water System Operating Parameters Fuel Gas path Ash content vs fuel efficiency Operating alarms operating instruments on panel

1. BPL
Bilt Power House

2. POWER HOUSE
 46 Kg/ cm2 pressure and 35 TPH Babcock and wilcox spreader stoker Boiler
X 1 NO
85 Kg/ cm2 pressure and 35 TPH x 03 nos (IJT)
TG Turbine 1 x 18 mw
 46 Kg/ cm2 pressure and 25 TPH Heat recovery Boiler X 1 NO (JMW)
 BTH TURBINE 6.25 MW X 1 NO (BRITISH THOMSON HOUSTEN)
 46 Kg/ cm2 pressure and 25 TPH Heat recovery Boiler X 1 NO (ABL)
Ash handling plant
Coal handling plant

3. BOILER SPECIFICATIONS BOILER PARAMETERS
Boiler No. Unit 7 1 2 3 Boiler No. Units 7
s
1 2 3
Type of Water Water Water Water
boiler Tube Tube Tube tube
Make B&W IJT IJT IJT Steam kg/cm2 46 85 85 85
pressure
Designed t/hr 35 35 35 35
Capacity
Steam ºC 404 490 490 490
Designed % 78 81 81 81
temperature
efficiency
Operating t/hr 10 to 30 to 30 to 30 to
Capacity 35 40 40 40
Blow down % 4-5 5-6 5-6 5-6
Operating % 75-77 77 to 77to 77 to
efficiency 80 80 80 %
Pollution (ESP, ESP ESP ESP ESP
Fuel used coal coal coal Coal control cyclone)
device used

4. COAL HANDLING LAY OUT
TRF/GB
Make
:
Capacity, tons /hr 80/40
1.FEEDING SCREEN
2.VIBRATOR
3.COAL CRUSHER OR GRANULATOR (HAMMER TYPE)
4.CONVEYER BELTS
5.ROLLERS
6.COAL BUNKER
Details of belt conveyor:
Belt conveyer 1 [ 800 x 34, 263 long ]
Belt conveyer 2 [ 600 x 14, 362 long ]
Belt conveyer 3 [ 600 x 126,267 long]
Belt conveyer 4 [ 600 x 21, 168 long ]
Belt conveyer 5a & 5b [ 800 x 32, 500 long ]
Vibrating feeder [ 915 wide x 1500 long ]
Coal size ¾ inches ( 15 – 20 mm )
Grade of coal B
Calorific value of coal 4500- 5000 kcal/kg

5. 1 Type: V1000
TRF COAL HANDLING LAY OUT
m
coal
Coal charge crusher
2
Type: 7 sfm
800x800x450
3
5A 4
me
1- gear ratio : 30:1
5B 2- : 30:1 ELECON
3- :20 :1
4- :20:1 crusher crusher
5a : :30:1
5b : :30:1
OPP

6. FLUE GAS PATH HP BOILER
SECONDARY AIR
BOILER 1 ST CYCLON 2 ND CYCLON 3RD CYCLON
TO GRATE
HOT AIR OUT
AIR PRE
ESP ECONOMISER
HEATER
FD AIR
SCREW CONVEYERS
TO SUBMURGED ASH BELT

7. FLUE GAS PATH MP BOILER
econ
GRN
ESP
ID 90 KW
ID 200 KW

8. WORKING OF ESP
The flue gas laden with fly ash is sent through pipes having negatively
charged plates which give the particles a negative charge. The particles
are then routed past positively charged plates, or grounded plates,
which attract the now negatively-charged ash particles. The particles
stick to the positive plates until they are collected. The air that leaves
the plates is then clean from harmful pollutants. Just as the spoon
picked the salt and pepper up from the surface they were on, the
electrostatic precipitator extracts the pollutants out of the air.

9. ASH HANDLING LAY OUT
ASH HANDLING PLANT Impact rollers
MAIN EQUIPMENTS: plain rollers
1.ASH BELT CONVEYER Scrapper
2.SUBMERGE BELTS
Skirting
3.SCREW CONVEYERS (SMALL AND LONG)
4.ASH HOPPERS
5.RIDDLING HOPPERS
6. ROLLERS
To main ash Hooper
SB1 SB3 SB3
ABC 3
ABC 1
Plain return
ABC 3 BYPASS
Carrying idler
Impact
Carrying idler
Return
Trough

10. ASH HANDLING LAY OUT
BL 7 ESP
HB
SB
RAH
FAH
ECO APH ESP ESP
APH

11. ASH HANDLING PRE CAUTIONS
If inclined belt trips, Horizontal and submerged belt will automatically stops
OPP Submerged belt bypass : Trolley is used to transfer ash when it is bypassed
.Inclined belt : Bypass ABC 3 with in 3-5 minutes
Horizontal belt : ESP Hooper bypass

NPP Submerged belt has two bypass.
ABC 3 bypass PCS
Pull cord switch
ZSS
BSS
 ( Belt 1,Belt 2, Belt 3 (ABC 3by pass) ,horizontal belt, Inclined belt, submerged belts
(3 in NPP and 1 in OPP). Only horizontal belt in OPP is having chain drive.

12. PDM
DEAERATOR
OT Suction
TO
HP
BOILERS
TO
ABL
BOILERS
DARE.
ABL
Suction
ABL EFP1 85 KG ABL
FP EFP2 STEAM STEAM
FP FP
ABL
deae. pump LAY OUT FEED WATER (HP) SYSTEM

13. FEED PUMP SPECIFICATIONS
ABL 85 KG ELECT ELECT ABL FP
STEAM SFP FP 1 FP 2
FP
MAKE KSB MATH & MATH & MATH & KSB
NEW POWER PLANT
PLATT PLATT PLATT
TYPE HAD 4/6 BFO 4/6 BFO 4/6 BFO HAD 50/15
50/15 9 CHR 9 CHR 9 CHR
FLOW 25.3 145 145 145 25.3
HEAD 747MLC 1068 M 1068 M 1068 M 747 MLC
RPM 2960 2980 2980 2980 2950
KW/HP ------- ------- 700/938 700/938 100/134

14. Cond. From plant
Over head
Prv outlet
tank
Prv outlet
Prv outlet
Deaerator
Vent
Vent
Cond
tank
ST
3 KG Exh M ST
Exh
suction
MAIN
DIRECT
46 KG
BL 7 FEED PUMP LINES

15. BL 7 FEED PUMP AREA PRE CAUTIONS
Condensate pump running indication by bulbs.
ABL feed pumps running indication by bulbs.
Inside feed pump attendants room electric feed pump running indication bulb
OT Level 10.5 feet indication bulb
OCT and NCT Level gauges (OCT-0-50-100 %=0-0.25-0.50 LEVEL),
(NCT-0-50-100 % = 0-0.20-0.4 LEVEL)
Inform DM plant if OCT level falls below 20 %)
OT level graphical indication also
Alarm will ring when any of the above condition is not satisfied.
Electric feed pump Amps above 370 Amps (OL on 380), Immediately steam
feed pump to be taken in service. Or if demand is more, inform NPP to start
supply from their end for ABL boiler in case BL 7 is running.
If any pump stops or trips immediately standby pump to be started.

16. BL 7 FEED PUMP AREA PRE CAUTIONS
Deaerator bypass system always in line
Balancing pressure should be within operating range to maintain the thrust
clearance
There are 2 supplies for ABL/Condensate / Deaerator pump viz. BTH / TG
Incase 2nd extraction pressure is more in BTH , Steam pump extraction line valve
required to be operate if instructed from BTH
Gland cooling line is to be continuously observed, There are two valves which are
of 55 & 150 hp , and if this is not available third one which comes from emergency
tank , valve to be opened
When JMW & BL 7 are in operation, ABL boiler feed water supply to be stopped
and ABL condensate pump to be started. (Valve near ABL boiler stairs entry). If only
JMW boiler is running feed water supply is from BL 7 feed pump.
JMW boiler feed water heater out temperature 130 deg. Cel. Maximum and steam
outlet temperature 405 deg. Cel. Maximum (Runs max 450 deg. Cel. )
No steam / water valve should be opened till the written memo is received and
physical check for drain, or isolation is confirmed

17. BL 7 FEED PUMP LINES
TI TO STEAM DRUM
ECO OUT
RTD
ECO IN
MAIN
Direct

18. JMW FEED WATER LINES
To Boiler Drum
Eco in
3 kg steam Direct
Feed water heater
Main
Condensate to NCT

19. Sr no Parameter OV Alarm Trip
FEED PUMP
FEED PUMP OPERATING PARAMETERS
Make: M&P 1 Condensate pump load 30-32 A
2 Deaerator water temperature 105
Type: V.G PLUROVANE
3 Deaerator pump load 15-17 A
Head : 1980 ft.
(600 m) 4 Deaerator discharge pressure 2-2.5
Size : 6” x 4” 5 Electric feed pump load 350 370 380
Discharge : 349 GPM
6 Suction pressure 1.5-2
92 M3/HR
7 Discharge pressure 58-60
Motor : 322 HP
430 KW 8 Balancing pressure 3 6
RPM : 9 Oil level
SP 1 : 3850
10 Overhead tank level ABOVE 10.5
SP 2 : 3740 10.5 FT
EFP : 2960 11 OCT LEVEL Above 30 % 30 % Below
20%
12 NCT Level Above 50 % 50 % Below
40 %

20. CONDENSATE TANKS AND PDM
 TG condensate goes to PDM tank and from PDM tank to HP deaerator
BTH turbine,PM4, SPL machine condensate to NCT, then it is pumped to DM
plant for polishing, back to PDM tank
Remaining condensate from clo2,PM1,PM2,Pulp mill, S/R plant, chemical house
comes in OCT
From OCT it is pumped to Overhead feed tank of Boiler no 7 and other pump for
ABL overhead tank
OCT & NCT are inter connected ,OCT being on height than NCT.
Level is maintained by DM plant, still if OCT level drops to 25 – 20 % verbally to
be inform to DM plant SE.
Hydrazine + Ammonia –LP Dosing & Nalcol 2518 + Caustic – HP Dosing
POLISHING: NCT Charcoal filter Iron filter DM tank
PDM PUMP
Total head:45 m
PDM Tank Secondary mixed bed
Flow : 416.7 lps
BEFORE START UP OF BL 7, DM PLANT TO BE IMFORMED

21. 85/46 STEAM HEADER
Attempt. Line
Range v/v BL2
Range v/v BL 3
85 kg st pump
Range v/v BL1
TO TG
pg
85/46
Condensate tank pump ( 1 and 3) and 2
46 KG HEADER
46 kg to TG Ejector
Raw water pump 1 and 3
To ABL st pump
Type: 4 U P3 (Double extraction)
Size : 150 x 100
Capacity : 40 lps (144 m3 / hr)
Head : 40 m
HP : 50
RPM : 1450

22. 46/3 STEAM HEADER
BTH TURBINE
ABL 46
JMW 46
OLD 46
Steam feed pump
46 KG/CM2 FROM 46/3 PRV
85/46 PRV
Location: JMW 46/17/7
BTH
When condensate flow to TG condenser is less ,46/3 PRV is
required to be charged. Control of opening of this valve is in
TG Control room.
It is assumed that steam flow from this line is 5 Tons Per
Hour.

23. SOOTING JMW
46 HEADER 650/250/100
Blade
coating Pulp mill
46/17/7 17
7
From 10/7 TG
Chem house 7/3 PRV
Not in use
BTH 7

24. PM1 , PM2 LINES
Supplim. For PM1
From BTH
7 / 3 PRV
PM 1 Supplim
PM 2 Supplim
3 kg PM1
PM2

25. OPP office
10KG STEAM HEADER rail clo2
SM PULP MILL
ABL
PRV 10/7 10 KG
TG
LIME KLIN
From 46/17/7 prv
Dorr plant JMW APH 7 KG BTH

26. PMC4 3 KG NETWORK
85 KG SFP ABL
PULP MILL
DEAERATOR
PM 4
DORR
JMW FW HEATER
CH
DEAERATOR
FP EXH LINE
BTH 7 KG
SM
10 KG
CLO2
SR EVAP
CLO2
SPL M/C

27. MP STEAM VALVE LOCATIONS
Sr. Customer Pr. Location
No Kg/cm2
.
1 PM 5 10 Back side of CT
2 STARCH MILL 10 Railway gate
3 ABL 10 Railway gate
4 PULP MILL 10 Behind TG room platform
5 CLO2 10 Behind OPP Office
6 PULP MILL 7 Wooden bridge Boiler & BTH
7 CHEMICAL HOUSE 7 BTH header chain valve
8 BLADE COATING 17 Wooden bridge Boiler & BTH
9 FEED PUMP 46 ASH plant

28. LP STEAM VALVE LOCATIONS
Sr. Customer Pr. Location
No. Kg/cm2
1 CHEMICAL HOUSE 3 Above MW section TR 18 (Toilet)
2 PM 1 3 Platform in front of PM 1
3 PM2 3 Platform in front of PM 2
4 PM1 SUPPLM.VALVE 3 BTH house
5 PM2 SUPPLM.VALVE 3 In front of BTH between 2 tanks
6 S/R EVAPORATOR 3 Near 46/3 PRV STAIRS
7 PM 5 / 6 / 7 3 Above BL 7 Control room
8 PM4 3 Near BL 1 FD fan area
9 DORR PLANT 3 Near JMW ESP Stairs
10 HP DEAERATOR 3 Hp deaerator
11 ABL DEAERATOR 3 ABL deaerator
12 BL 7 DEAERATOR 3 BL 7 feed pump area
13 PULP MILL 3 Rail gate + 46/10 PRV
14 MC NO 4 3 From BTH also
15 CLO2 3 Above BL 7 Control room

29. BOILER NO 7
FRONT AND REAR TUBES GOES TO STEAM DRUM
RIGHT & LEFT END TUBES FORM HEADER ,THEN
GOES TO STEAM DRUM
RIGHT
COAL FEEDER SIDE
FRONT
REAR
LEFT

30. BL NO 7 WATER WALLS
REAR END
LEFT END
RIGHT END
FRONT END

31. BOILER NO 7,8 MOUNTINGS AND FITTINGS
Drum safety valves
SH stop valve
SH safety valve
Drum gauge glass
Range valve
Blow down valve (04 + 02) RGG
Economizer safety valve
Steam flow meter
Water flow meter
Hi and LO Whistle
DOSING

32. COOLING TOWERS
MAKE : PAHARPUR COOLING TOWERS (Induced draft )
BTH TG
Total fans :9 nos Fans : 02 nos
Current : 36 amps Current : Fan 1 VFD 45 amps
Circulation rate: 2900 m3/hr Fan 2 65 amps
Evaporation lass : 16 m3/hr Circulation rate : 3200 m3/hr
Evaporation loss: 32 m3/hr
.
TUBE WELL SUPPLY: 3,4,8,16,20,22. 10,12,14,15,17 18,19 1,21
CHEMICALS USED:
H2SO4 - PH CONTROL 7002
2718: 7500
7000: CHLORINE

33. 150 HP PUMP HOUSE
NOT IN USE
Pump 1 current: 25 A OLD PH PULP MILL
VFD 40 HZ
PM 4 & OLD
PH
5 4 3 2 1
TANK LEVEL 12 FEET
SCALE
READING -------FEET
EMPTY
TO HYDRANT
TUBE WELL LINES: 3,4,8,16,20,22. 10,12,14,15,17 18,19 1,21

34. 150 HP PUMP HOUSE ELECTRICAL SUPPLY
 PUMP NO 1 IS HAVING VFD.
PUMP NO 2 IS HAVING COS FROM DB2 (BTH AND TG).
PUMP NO 3 IS HAVING BTH SUPPLY
PUMP NO 4 AND 5 HAS COS FROM DB2.
FROM 150 HP PUMP HOUSE COS DB2 AND COS DB1 SUPPLY IS GIVEN.
PUMP NO 1 RUNS NORMALLY IN 150 HP PUMP HOUSE
PUMP NO 4 – HYDRANT

35. 55 HP PUMP HOUSE
NOT IN USE
MC 1,4 NOT IN USE COATING PLANT NOT IN USE
Pump 5 current: 82-84 A
1 2 4 5
TANK LEVEL 5 FEET
SCALE
READING -------FEET
FULL
MC 1,4 / DM/ DORR/ SR/ PH/ CH/ NPP
TUBE WELL LINES: 3,4,8,16,20,22. 10,12,14,15,17 18,19 1,21

36. FROM SPL PUMP
55 HP PUMP HOUSE
DM PLANT
TUBE WELL NO 6 / 9 CONNECTION
55
PMC 1 , 2
EMERGENCY
FROM SPLITY PUMP HOUSE
GLAND
FILLING TANK
BTH SUMP
BFW PUMPS
GLAND
DORR / SR/NPP
BFW PUMPS
GLAND
BTH OIL / AIR COOLER
SR/NPP
BTH DRINKING/WASHING
CH

37. 55 HP PUMP HOUSE ELECTRICAL SUPPLY
 PUMP NO 5 IS HAVING VFD.
SUPPLY FROM PANEL NO 2
DB1 SUPPLY TO TUBE WELL NO 1 AND 2 ,AND TO SERVICE PUMP NO 4.
COS IS FOR ABOVE. (Main supply from 150 HP pump house)
SUPPLY FOR PUMP NO 1 FROM PANEL NO 1.
COS FOR DB2 IS FOR SERVICE PUMP NO 1 , 2 , AND 5.
PUMP NO 5 RUNS NORMALLY.

38. FIRE PUMP DETAILS
At four location Fire pump stations are available
 Main fire pump house at S/R area (4 Pumps)
At ETP (2 Pumps, One electric driven and other Diesel 12 cyl driven )
At Yard sump Electric pump
At 150 HP pump house , pump no 4.
From main fire pump house, pump no 4 runs normally
Yard fire pump some times used when sump level to be make up
All three supply available

39. FIRE PUMP DETAILS
Fire hydrant circuit 1 (cooling pond) Pump 2
Pump 1 (Pump no 3) Make Mather and greeves
Make : Mather and Platt Type: 8/8 MHL
Type : 7.2 ST MEDI Capacity: 1500 gpm
Capacity: 1000 gpm Head : 290 ft
Head : 290 ft
HP : 200 RPM: 1450
HP : 190 RPM : 1450
Pump 2B (ETP) Diesel engine driven pump :
Make : Kirloskar 8/8 MHL Mather and platt
Type: SVA 8 Capacity : 1500 gpm
Size: 8 x 8 Head : 290 ft
Capacity : 1400 gpm RPM : 1450
Head : 225 ft Diesel engine make: MWM
HP : 200 RPM : 1450 Type: TD – 237 – VIZ
Fire hydrant circuit 3 ( Chipper yard) BHP : 200
Pump no 3: RPM : 1500
Make : Mather and Platt
Capacity : 1500 gpm
Head : 290 ft
HP : 200 RPM : 1440
Reservoir capacity : 2 lacs gallon

40. FIRE PUMP HOUSE
Sometimes pump no 2 is started for CH increased consumption
1 2 4 3
66 A / 2.5 K/c2

41. SPECIALITY PUMP HOUSE DETAILS
250 M3/HR
4 K/C2
TW NO 9 / 6 85 A
COATING PLANT
NEW POWER HOUSE
AIR COMPRESSOR
M3/HR
55/ 150 LINE
2-2.5 K/C2
65-70 A
PULP MILL
SHUT 1 RUNNING 1 RUNNING
TUBE WELL LINES: 3,4,8,16,20,22. 10,12,14,15,17 18,19 1,21

42. AIR COMPRESSORS
 Air compressors in power house are situated as follows Motor load: 230-250 A
1) 2 nos at old power plant
2) 2 nos at new power plant
3) 4 nos at specialty machine area
cooler 2.5 kg/cm2
Air comp no 2,6,4,5 PROCESS
cooler
Coating plant
5 kg/cm2
AD AD
cooler
5 kg/cm2 Pulp mill , spl machines ,
RECIEVER Clo2 plant, power house
TANK
cooler

43. AIR COMPRESSORS
NPP : KG KHOSLA MAKE SPL : KG KHOSLA MAKE
Double stage Double stage
3H Y2TCER Air comp no 4,5,6
RPM : 650 RPM : 800
Pr. : 7 kg/cm2 Pr. : 7 kg/cm2
Cap : 5.89 m3/min Cap : 51.41 m3/min
Pr 1 st stage : 2 kg/cm2 Pr 1 st stage : 2 kg/cm2
pr 2 nd stage : 5.5 kg/cm2 pr 2 nd stage : 5.5 kg/cm2
oil pr. : 2.5 kg/cm2 oil pr. : 2.5 kg/cm2
SPL : KG KHOSLA MAKE
Single stage
Air comp no 2
RPM : 560
Pr. : 7 kg/cm2
Cap : 11.01 m3/min
oil pr. : 2.5 kg/cm2

44. AIR COMPRESSORS PRE CAUTIONS
 Air is distributed from new power plant air compressors to POWER HOUSE
 Air compressors in Old Power House are standby.
In case of air pressure drop or compressor trip, SPL pump house air compressor
valve can be opened which is at NPP electrical panel room.
Also one line from S/R plant air compressors is available for the same purpose
but it is rarely used.
Air compressors in Old Power Plant can be started in emergencies, can be put in
Auto mode .One will be Auto and other will be stand by.

45. TUBE WELL NETWORK
INSIDE 1,2,6,7,9,10,12,14,15,17,21
OUT SIDE 3,4,8,16,20,22
TUBE WELL LOCATION SUPPLY CHANGE OVER
NO
1 CHAIR REPAIR WORK SHOP 55 HP PUMP HOUSE
2 COATING PLANT (BEHIND 55 HP PUMP HOUSE) 55 HP PUMP HOUSE
3 TI CLUB NEAR TUBE WELL 8
4 RAMLEELA STAGE NEAR TUBE WELL 8
5 DOES NOT EXSISTS -------
6 BEHIND DM PLANT SAME LOCATION
7 DISPENSARY NO 5 NEAR TUBE WELL 8
8 TR BUILDING NEAR TEMPLE NEAR TUBE WELL 8
9 GHEE PLANT FROM BOILER
HOUSE DB
10 GATE NO 9 NEAR TUBE WELL 10
PUNJAB 18,19
11 DOES NOT EXSISTS -------
12 ETP MACHINE NO 5 / 7
13 DOES NOT EXSISTS -------
14 200 QTR NEW GATE SAME LOCATION
15 GATE NO 8 NEAR TUBE WELL 10
16 CHUNA BHATTI NEAR DR BUILDING
17 NANGAL POWER HOUSE
18 PUNJAB MILL NANGAL NO CCHANGE OVER
19 PUNJAB MILL NANGAL NO CHANGE OVER
20 TR BUILDING GROUND NEAR TUBE WELL 8
21 NEAR TRAFFIC DEPT. Location
22 DR BUILDING OLD NEAR DR BUILDING