1. SIPAT SUPER THERMAL POWER PROJECT
SIPAT STAGE # I BOILER

2. SIPAT STAGE # 1 BOILER

3. ECONOMISER TO 1 ST PASS TOP HEADERS :
ECO. O/L LINKS
ECONOMISER TO 1 ST PASS TOP HEADERS :
OUTLET HEADERS
ECO O/L HDR
VERTICAL WALL
INTERMITTENT HEADERS
ECO. JUNTION
HEADERS
ECO. MIXING PIECE
SPIRAL WALL
ECONOMISER
BOTTOM RING HEADER
ECO I/L HDR

4. SPIRAL AND VERTICAL WALLS :
ECONOMISER :
COUNTER FLOW 4 BANKS 163 ASSEMBLIES 4 JUNCTION HEADERS 224 HANGER TUBES ECO OUTLET HEADER SA 106 C ; SA 210 C
SPIRAL AND VERTICAL WALLS :
TOTAL SPIRAL TUBES : 440 (102X2 FRONT & REAR; 108X LEFT & RIGHT) SPIRAL TO VERTICAL RATIO = 1:3 FRONT VERTICAL TUBES: 336 SIDE WALL TUBES: 648 REAR SCREEN TUBES : 280 REAR HANGER TUBES : 56 TUBES : T22 HEADERS : P12

5. 1ST PASS ROOF O/L HEADERS
START UP SYSTEM :
SEPERATORS I/L LINKS
1ST PASS ROOF O/L HEADERS
SEPERATOR TANKS
STORAGE TANK
STORAGE TANK WR WR ZR ZR
BCP
BCP
TO ECONOMISER
TO ECONOMISER
MIXING PIECE
MIXING PIECE
FLASH TANK
FLASH TANK UG UG
CONDENSER
CONDENSER
FEED WATER LINE
FEED WATER LINE
BOILER FILL LINE
BOILER FILL LINE

6. BACK PASS BOTTOM RING HDR
2ND PASS STEAM FLOW :
EXTENDED WALL :
1ST PASS ROOF I/L HDR
BACK PASS ROOF I/L HDR
BACK PASS TOP LHS HDR
BACK PASS TOP RHS HDR
EXTENDED WALL
EXTENDED WALL HDR
BACK PASS BOTTOM RING HDR

7. BACK PASS WALLS & HEADERS : BACK PASS WALLS & HEADERS :
EXTENDED WALL :
FURNACE FRONT ROOF : 168
BACK PASS ROOF : 111
BACK PASS REAR WALL : 111
BACK PASS SIDE WALL : 328
BACK PASS FRONT WALL : 167
BACK PASS SCREEN : 167
TUBES : T12
HEADERS : P12
EXTENDED WALL FLOOR : 142
EXTENDED SIDE WALL : 142
TUBES : T12
HEADERS : P12
FLUID COOLED SPACER TUBES: 3
BACK PASS WALLS & HEADERS :
START UP SYSTEM :
LINK PIPES : P12
SEPERATORS &
STORAGE TANK : SA 302C
LINK PIPES : P12
SEPERATORS &
STORAGE TANK : SA 302C

8. DIVISIONAL PANEL : SH DIV. PANEL TUBES : 480 TUBES : T23; T91
II ND PASS TOP RHS HDR
DIV. PANEL I/L HDR
FROM II nd PASS BOTTOM RING RHS HDR
DIV. PANEL O/L HDR
DIV. PANEL O/L HDR
DIV. PANEL I/L HDR
II ND PASS TOP LHS HDR
FROM II nd PASS BOTTOM RING LHS HDR
SH DIV. PANEL TUBES : 480
TUBES : T23; T91
HEADERS : P12; P23
FLUID COOLED SPACER TUBES : 6
DIV. PANEL
DIV. PANEL

9. PLATEN AND FINAL SH : PLATEN ASSEMBLIES : 20 NO OF TUBES : 480
PLATEN TO FINAL SH LINK
DIV. PANEL TO PLATEN LINK
TO HP TURBINE
PLATEN I/L HDR
PLATEN O/L HDR
FINAL SH O/L HEADERS
DIV. PANEL I/L HDR
FINAL SH I/L HDR
DIV. PANEL O/L HDR
DIV. PANEL O/L HDR
DIV. PANEL I/L HDR
PLATEN ASSEMBLIES : 20
NO OF TUBES : 480
TUBES : T12; T23; T91
HEADERS : P12; P23
PLATEN COILS
FINAL SH COILS
COUNTER FLOW DIRECTION
NO OF STAGES : 2
ASSMBLIES : 2X55
NO OF TUBES : 935
TUBES : T23; T91
HEADERS : P23; P91

10. REHEATERS : FINAL RH TO IPT NO OF BANKS : 3 NO OF TUBES : 111
LTRH O/L TO FINAL RH I/L LINKS
LTRH O/L HDR
FINAL RH I/L HDR
FINAL RH O/L HDRS
NO OF BANKS : 3
NO OF TUBES : 111
TUBES : SA 210C; T12; T23
HEADERS : SA 106C; P12
TO IPT
LTRH BANKS
FINAL RH
FROM CRH
NO OF ASSEMBLIES : 41
NO OF TUBES : 615
TUBES : T23; T91; SUPER 304H
HEADERS : P12; P91
LTRH I/L HDR
FROM CRH

11. G SEPARATOR 540°C, 255 Ksc 568°C, 47 Ksc 492°C, 260 Ksc 457°C, 49 Ksc
FUR ROOF I/L HDR
ECO HGR O/L HDR
HRH LINE
MS LINE
411°C, 277Ksc
411°C, 275 Ksc
SEPARATOR
STORAGE TANK
FINAL SH
FINAL RH
LTRH
DIV PANELS SH
PLATEN SH
VERTICAL WW G
ECO JUNCTION HDR
LPT
LPT
IPT
305°C, 49 Ksc
CONDENSER
HPT
ECONOMISER
ECO I/L
Spiral water walls
BWRP
FEED WATER
290°C, 302 KSC
FUR LOWER HDR
FRS

12. WATER WALL/ EVAPORATOR
FEATURES OF SUPER CRITICAL BOILER :
1. ONCE THROUGH OPERATION :
FEED WATER
PUMP
ECONOMISER
WATER WALL/ EVAPORATOR
SEPERATOR
SUPERHEATER
STORAGE
TANK
RECIRCULATION
CONSTANT WATER WALL FLOW (below 30% load)
FEED WATER
PUMP
ECONOMISER
WATER WALL/ EVAPORATOR
SEPERATOR
SUPERHEATER
ONCE THROUGH FLOW OPERATION (above 30% load)

13. 2. CONSTANT PRESSURE OPERATION :
Above 90% & below 30%
3. SLIDING PRESSURE OPERATION :
B/W 30% & 90%

14. ADVANTAGES OF SLIDING PRESSURE OPERATION
1. No additional pressure loss between boiler and turbine
2. Low Boiler Pr. at low loads
- Less fatigue of Pr. part components
- Longer life of all components, Less wear of components
- Less Maintenance
3. Lower thermal stresses in the turbine during load changes
4. Control range of RH temp is extended
5. Overall reduction in power consumption and improved heat rate

15. 660MW PARAMETERS : DESCRIPTION UNIT 660 MW AT BMCR S/H STEAM FLOW T/HR
2225
SH STEAM PR
KG/CM2
256
SH STEAM TEMP 0C
540
RH STEAM FLOW
1742
RH STEAM TEMP INLET
299
RH STEAM TEMP OUTLET
568
RH STEAM PRESS OUTLET
46.61
FEED WATER TEMP
289.64
SECONDARY AIR FLOW
1732
PRIMARY AIR FLOW
946
TOTAL COAL FLOW
472

16. FEATURES OF 660 MW- STEAM QUALITY PARAMETERS
S.NO.
PARAMETER
STEAM QUALITY AT SG OUTLET
DURING START UP
DURING NORMAL OPERATION 1
TDS 20 2
SILICA 3
SODIUM 10 4
CHLORIDES 5
COPPER 6
IRON 7
CATION CONDUCTIVITY
<0.2 to 0.25 micro siemens /cm
<-0.2 micro siemens / cm 8 PH
6~8

17. COMMISSIONING NETWORK

18. Boiler Light Up & Steam Blowing
MS Line HT
CRH Line HT
HRH Line HT
SG ECW SYSTEM
MS Line Welding Completion
CRH Line Welding Completion
HRH Line Welding Completion
ID FAN # 1A TRIAL RUN
FD FAN # 1A TRIAL RUN
MS Line Hanger Erection Cold Setting
CRH Line hangers Cold Setting
HRH Line Hangers Cold Setting
SAPH # 1A TRIAL RUN
BRP TRIAL RUN
MS Line Insulation
CRH Line Insulation
HRH Line Insulation
SACNNER AIR SYSTEM READINESS
Temporary Piping Completion
FURNACE READINESS
FUEL OIL SYSTEM READINESS
Boiler Light Up & Steam Blowing
CHEMICAL CLEANING OF BOILER
AUX PRDS READINESS
ACW System
COMPRESSED AIR SYSTEM READINESS
MDBFP Trial
CW SYSTEM READINESS
GATES, DAMPERS / VALVES
TG :
SG :
CEP Trial
MFT CHECKING
TG ECW System
HOT Well Readiness
DDCMIS
FSSS READINESS

19. LIST OF APPROVED PROCEDURES
Boiler Commissioning is carried out based on the guide lines of Corporate commissionin groups. OS) These are the list of approved commissioning procedures which are followed in sipat commissioning activities
1. BOILER HYDRO TEST
2. OIL FLUSHING OF ROTARY MACHINES
3. BOILER & DUCTS AIR TIGHTNESS TEST (ATT)
4. ESP AIR IN LEAK TEST
5. ESP GAS DISTRIBUTION (GD) TEST
6. BOILER CHEMICAL CLEANING
7. BOILER COLD AIR VELOCITY TEST
8. CLEAN AIR FLOW TEST
9. LDO & HFO SYSTEMS COMMISSIONING
10. BOILER & AUX LINES STEAM BLOWING

20. COMMISSIONING MILE STONES
BOILER HYDRO TEST :
HP SYSTEM : Hydro test done on
HP system hydro test is done at 410 KSC. HP system consists of Economiser, boiler 1st & 2nd pass, divisional panel, platen & final super heater upto boiler stop valves.
MP SYSTEM : Hydro test done on
MP system hydro test is done at 80.1 KSC. MP system consists of CRH isolator to LTRH, Final Reheater upto HRH isolators.
2. BURNER TILT, OIL GUNS & IGNITOR CHECKING :
Checking is completed on
Burner tilt checking is done from inside the boiler in which burner limits +300 & angles adjusted. Oil guns & ignitors clearances are checked inside the boiler.
3. FD, ID & PA FANS COMMISSIONING :
FD Fan # 1A trial run taken on ID Fan # 1A trial run taken PA Fan # 1A trial run taken

21. COMMISSIONING MILE STONES
3. FD, ID & PA FANS COMMISSIONING :
FD Fan # 1B trial run taken on ID Fan # 1B trial run taken PA Fan # 1B trial run taken
Fans commissioning involves following steps:
Lube oil flushing of lube oil skid, lube oil lines with flushing oil (32 grade) (bearings bypassed) (Completion criterion is Moisture & Mechanical impurities should be below 100 ppm)
Lube oil flushing through bearings (32 grade)
Lube oil flushing through bearings (68 grade oil)
Blade pitch commissioning & discharge gate commng.
Cooling water lines flushing & charging
Fan trial
4. AIR PREHEATERS COMMISSIONING :
SAPH # 1A trial run taken on
SAPH # 1B trial run taken on

22. 4. AIR PREHEATERS COMMISSIONING :
PAPH # 1A trial run taken on
PAPH # 1B trial run taken on
Air Preheaters commissioning involves following steps:
Lube oil motors & main motor no load trial
Lube oil flushing of Support & Guide bearings with 32 oil (Completion criterion is Moisture & Mechanical impurities should be below 100 ppm)
Lube oil flushing through bearings (32 grade)
Lube oil flushing through bearings (680 grade oil)
Air motor service air line blowing
Cooling water lines flushing & charging
Air preheater trial with air motor & electrical motor

23. 4. BOILER & DUCT ATT :
Secondary air duct ATT is completed on Primary air duct ATT is completed on Flue gas air duct ATT is completed on Furnace ATT completed on
ATT of boiler & ducts is done at 150 mm of water column.
Secondary air duct & boiler pressurisation is done by FD Fan.
Primary air duct pressurisation is done by PA fan.
Flue gas duct pressurisation is done by using temporary blowers
5. ESP COMMISSIONING :
ESP Air In Leak test: All passes air in leak test completed on
The test is done to prove that air in leak into ESP is with in guaranteed value of 1% of design gas flow rate.
ESP Rapping system commng. : All passes rapping systems commng. completed on
Each Pass has 18 nos. collecting electrodes rapping system, 18 nos emitting electrode rapping system & 2 nos. gas distribution plates rapping system.

24. 5. ESP COMMISSIONING :
ESP Fields charging
ESP GD test completed on
This is done to verify uniform flow distribution inside the ESP Chambers.
6. BOILER CAVT :
CAVT (Cold Air Velocity Test) is completed on
This test is done to check flue gas flow patterns inside the boiler.
7. AIR BALANCE TEST (ABT):
8. BOILER CHEMICAL CLEANING :
Boiler Chemical cleaning is completed on Chemical cleaning involves following steps:
Flushing
Acid Cleaning
Rinsing
Pre Neutralization
Neutralization
Passivation

25. 9. BRP (Boiler Recirculation Pump) COMMISSIONING :
Main chemicals used are formic acid (10%), sorbic acid, coronil 200S
Boiler chemical cleaning is completed in 7 days.
9. BRP (Boiler Recirculation Pump) COMMISSIONING :
BRP trial completed on
BRP commissioning involves following steps:
Cavity filling line flushing (until Conductivity & Turbidity reaches required parameters)
Flushing through motor cavity & through cooler
ECW lines water flushing
Pump trial
10. BOILER LIGHT UP :
Boiler is Lighted Up on
Boiler is lighted up with LDO and all 4 corner oil guns were proven.
11. STEAM BLOWING : It has following steps
PRE STEP1:
Separator Superheater Main Steam Line Main Stop Valve
Temporary Piping Temporary MOV Tailpipe to atmosphere
Blowing is done from 40 KSC to 20 KSC

26. 11. STEAM BLOWING :
Steam blowing consists of following steps:
PRE STEP 2:
Separator Superheater Main Steam Line HP Bypass Valve
Cold RH line backward flush through drain pot near RH inlet
header Temporary Piping tailpipe to atmosphere
Blowing is done from 40 KSC to 20 KSC
MAIN STEP 1:
Separator Superheater Main Steam Line Main Stop Valve
Temporary Piping Temporary MOV Non-return Valve Cold
Reheat Line Reheater Hot Reheat Line IPT Stop Valve
Tailpipe to atmosphere
Blowing is done from 80 KSC to 40 KSC
MAIN STEP 2:
Separator Superheater Main Steam Line Main Stop Valve
Temporary Piping Temporary MOV Non-return Valve Cold
Reheat Line Reheater Hot Reheat Line LP Bypass Valve

27. PF SYSTEM COMMISSIONING:
(a) Seal air fan & its dampers
(b) Mills commissioning:
Lube oil pumps load trial
Lube oil flushing of oil line with 32 oil bypassing gear box & bearings (Completion criterion is Moisture & Mechanical impurities should be below 100 ppm)
Lube oil flushing through bearings & gear box(32 grade)
Lube oil flushing through bearings (320 grade oil)
Cooling water lines flushing & charging
Roller & Bowl gap adjustment
Spring tension adjustment
P&I checks & Mill solo run.

28. PF SYSTEM COMMISSIONING:
(C) RC Feeders
Motor checks
P&I checking
Feeder belt trial with clean out conveyor.
Commissioning of gates & dampers
Commng of HAD, CAD, HAG, CAG, BIG, MDV from remote
(E) Clean air flow test of mills as per approved procedure

29. PROBLEMS & MODIFICATIONS

30. Provision of manholes in ducts & hoppers
Oil gun cleaning system
BRP fill line from boiler fill pump
FD, ID & PA fans blade pitch local indication
Black Start Up line in unit # 1
Additional vents are provided in SGECW system
Boiler headers & links replacement

31. BOILER HEADERS REPLACEMENTS
Some of the super heater headers were replaced with higher grade materials.
5 nos. of headers & link pipes of Gr P23 were replaced with Gr P91.
This material replacement is done to avoid probable material failure in the pipes and fittings of the boiler subjected to very high temperature and pressures.