PG Part 02

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Update acc NTPC-comments, dated
AB 25.07.2019 B. van de Sandt 17.07.2019 F. P. Schiffer
Update acc mutual agreement
AA 21.06.2019 B. van de Sandt dated 25.05.2019 F. P. Schiffer
REV. DATE NAME REVISION DESCRIPTION APPD.
EMPLOYER
NTPC Limited
(A Government of India Enterprise)
PROJECT
MEJA SUPER THERMAL POWER PROJECT
(2x660 MW)
STEAM GENERATOR (SG) PACKAGE
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PACKAGE
SG CONTRACTOR
BGR ENERGY SYSTEMS LIMITED
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CHENNAI – HYDERABAD – MUMBAI - NOIDA
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DOC. NO.
JV COMPANY
BGR BOILERS PRIVATE LIMITED

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CHENNAI – INDIA
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DOC. NO.
QSGM SUB CONTRACTOR
HITACHI POWER EUROPE (IF APPLICABLE)
GMBH
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Duisburg - Germany
DOC. NO. N-100141-0-092-NE01-00002 DOC. NO.
TITLE: Steam Generator Performance Test Procedure –

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Performance Guarantees acc. to Cat-III
SIZE SCALE NTPC DOCUMENT NO. REV.

A4 NTS 0360-102-PVM-X-0191A 01
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NAME SIGN DATE

PREPARED BY B. van de Sandt signed by B. van de Sandt 01.03.2019
CHECKED BY F. P. Schiffer signed by F. P. Schiffer 01.03.2019
REVIEWED BY
APPROVED BY F. P. Schiffer signed by F. P. Schiffer 01.03.2019

REVIEWED BY (QSGM) F. P. Schiffer signed by F. P. Schiffer 01.03.2019
APPROVED BY (QSGM) F. P. Schiffer signed by F. P. Schiffer 01.03.2019 SHT. NO.
THIS DOCUMENT SHALL NEITHER BE DUPLICATED; TRANSFERRED NOR REVISED OTHER THAN STIPULATED WITH THE GCC
Special Annexure to Cat III
The points mentioned underneath will supersede the points stated in the main text of this document. This
is required to take care of the fact that the proposed procedure submitted by the vendor do not comply
the contract conditions and code even after repeated comments by NTPC and subsequent revisions.
1. Pages 4-5: Mill capacity test will be conducted at desired capacity (as mentioned in the guarantee
clause; rated capacity under design coal 100 t/h) for the required duration ( about 2 hours for PF
sampling from all pipes by following the methods outlined the test code)
Functional Guarantees, Attachment 8B, the coal pulverizers are designed for mill capacities of 100 t/hr
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for design coal at rated fineness and a new set of grinding elements. At near worn out condition of the
grinding elements mill capacities of 95 t/hr for design coal are guaranteed.
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2. Page 11: The correction for Background noise as 7dB (A) NOT applicable as it is not in line with any
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code / standard. The corrected noise levels will be determined after applying suitable corrections (as
per IS: 12065 – 1987.

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Kennwort / Code Word
Performance Test Procedure Meja All Units
Dok-Nr.: N-100141-0-092-NE01-00002 Proj-Nr.:/ Job No.:
0360-102-PVM-X-0191A N-100141
Steam Generator
Performance Test Procedure
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Performance Guarantees acc. to Cat-III
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Ersteller / Prepared by Geprüft / Checked by: Datum /Date: Rev.:

B. van de Sandt / CC3 F. P. Schiffer / CC3 25.07.2019 AB
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0360-102-PVM-X-0191A N-100141
Index
1. Introduction .................................................................................................................................. 3
2. Objective of Testing...................................................................................................................... 4
2.1 Scope of Guarantees ......................................................................................................... 4
2.2 Guarantee reference condition........................................................................................... 6
3. Operation Conditions and General Measuring .............................................................................. 8
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3.1 Operation Conditions during Testing .................................................................................. 8
3.1.1 Unit Operation ................................................................................................................... 8
3.1.2 Boiler Operation ................................................................................................................. 8
3.2 Test Measurements and Measuring Methods .................................................................... 9
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3.2.1 General Convention ........................................................................................................... 9
3.2.2 Air-/Flue Gas Measurements (Grid Measurements) ........................................................... 9
4. Guarantees according to Category-III ......................................................................................... 11
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4.1. Commissioning Tests with Special Equipment/Instruments ............................................. 11
4.1.1 Noise Emission of Various Sources ................................................................................. 11
4.1.2 Coal Pulverizer Capacity at Rated Fineness .................................................................... 12
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Mill capacity test with “Worst in Adequacy Range” coal conditions .................................. 15
4.2. Commissioning Tests by Using Permanent Site Instruments (DCS) ................................ 17
4.2.1 Maximum steam temperature imbalance at superheater (SH) & reheater (RH) outlets .... 17
4.2.2 Air heater leakage............................................................................................................ 17
4.2.3 Minimum steam generator load without supplementary oil firing ...................................... 17
4.2.4 Maximum Furnace exit gas temperature .......................................................................... 17
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5. Correction Diagrams for Mill capacity test .................................................................................. 18

6. List of Appendices ...................................................................................................................... 19
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0360-102-PVM-X-0191A N-100141
1. Introduction
The steam generators of Meja Power Station are designed as hard coal fired Once-
Through Boiler in order to supply following steam parameters at 100 % BMCR and firing
of design coal:
HP-Steam Generation 2120 T/hr

HP-Steam Pressure 256 kg/cm²
HP-Steam Temperature 568 °C
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Reheated Steam Temperature 596 °C
The steam generator furnace and the heating surface bundles are arranged as tower type
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boiler.
The air-/flue gas system is designed as two pass system consisting of two FD-fans, two
PA-fans, four steam air heaters (two primary and two secondary), four flue gas air heaters
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(two primary and two secondary), an electrostatic precipitator (ESP) and two ID-Fans.
The coal firing system consists of 4 burner levels, directly operated double front firing
system with opposite burner arrangement, in total 32 burners. Four burners of each level
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are supplied by one coal mill.
The main principles of steam generator arrangement may be referred from the attached
sketches, which are demonstrating the measuring locations for steam generator
performance test (Diagram 1 and Diagram 2).
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This document has been finally revised according to NTPC/BGR/HPE meeting, dated 22.
25.05.2019 in Chennai (Meeting Report, Appendix 9). The meeting concluded with mutual
agreements regarding the finalisation of boiler correction curves and PG test procedure –
Solapur & Meja. Open CAT-III guarantee issues regarding mill capacity test, FEGT test
and noise test have been settled.
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0360-102-PVM-X-0191A N-100141
2. Objective of Testing
2.1 Scope of Guarantees

Guarantees of category I and II are described in detail by procedure N 100141 0 092
NE01 00001 / 0360 102 PVM X 0191.
In case there is any mismatch in guarantee figures and guarantee conditions indicated in
the procedure with that of the contract document, the values and conditions mentioned in
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the contract document will be considered.
This Procedure (N 100141 0 092 NE01 00002) describes the scope of guarantees
according to:
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Category III: – Appendix 9, Attachment 8B
Performance Property Guarantee

Value
Coal Pulverizer capacity at rated fineness:
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(a) Coal Pulveriser capacities in T/hr with worst coal in adequacy range
at rated fineness as per clause 8.02.00 (i), Sub-Section VI, Part-A,
1)
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1)
Section VI. At 100 % mill loading with new set of grinding elements: 100 T/hr
2)
(b) Coal Pulveriser capacities in T/hr with worst coal in adequacy range
at rated fineness as per clause 8.02.00 (i), Sub-Section VI, Part-A,
Section VI. Capacity at originally installed grinding elements in worn
out condition or at the end of guaranteed wear life (whichever is
earlier) at 100 % mill loading (with value not less than 90 % of value
2)
indicated at (a) above): 95 T/hr
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Capacity test as mentioned at (a) & (b) above shall be demonstrated at the
following conditions occurring simultaneously during testing:
(i) passing through 200 mesh for any available coal from the specified
range: ≥ 70 %
(ii) passing through 50 mesh screen for any available coal from the
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specified range: ≥ 99 %
Minimum steam generator (% of BMCR) load above which no oil support is
required as per clause 8.02.00 (ii), Sub-section-VI, Part-A, Section-VI: 30.0
Maximum Furnace exit gas temperature (degree Celsius) (MHVT Value) in
accordance with clause 8.02.00 (v), Subsection VI, Part-A, Section-VI with
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specified design coal 1040 °C

Maximum steam temperature imbalance at superheater (SH) & reheater (RH)
outlets between left and right header (degree celsius) under all loads including
transients (In accordance with clause 8.02.00 (vi), Sub-Section VI, Part-A,
Section-VI): ≤ 10 °C
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Air heater air-in leakage and max. drift in Air leakage (% of gas flow at AH
inlet), in accordance with Clause No. 8.02.00 (vii), Sub-section-VI, Part-A,
Section-VI. ≤ 10 %

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0360-102-PVM-X-0191A N-100141
Noise:
All the plant, equipment and systems covered under this specification shall
perform continuously without exceeding the noise level over the entire range of
output and operating frequency specified as per 8.01.00 of Sub-section-VI of
Part-A, Section-VI & Clause 32.00.00 of Part-C of Section-VI
in general: ≤ 85 dB(A)
Except for:
(i) Safety valves and associated vent pipes: ≤ 105 dB(A)
(ii) Regulating drain valves: ≤ 90 dB(A)
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1)
Equivalent value determined according chapter 4.1.2 for worst coal in adequacy
range, guaranteed value for design coal: 84 T/hr. Due to burner limitations it is not
recommended to demonstrate 100 T/hr at design coal conditions, but the same mill
loading may be demonstrated by the use of worst in adequacy range coal. Please refer
to page 12, mill capacity test.
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2)
Equivalent value determined according chapter 4.1.2 for worst coal in adequacy
range, guaranteed value for design coal: 95 T/hr Due to burner limitations it is not
recommended to demonstrate 80 T/hr at design coal conditions, but the same mill
loading may be demonstrated by the use of worst in adequacy range coal. Please refer
to page 12, mill capacity test.
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0360-102-PVM-X-0191A N-100141
2.2 Guarantee reference condition

Guarantee reference conditions will be mainly applied for boiler efficiency, auxiliary power,
pressure and pressure loss testing, where deviating data are subject for corrections.
Furthermore design coal should be fired during the remaining test.
 Reference temperature for boiler and efficiency calculation is 27°C (clause 9.00.00
(iv), Sub-Section VI, Part-A, Section-VI).
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 Design ambient temperature is 27°C (clause 4.03.00 (iv), Sub-Section VI, Part-A,
Section-VI).
 Ambient air relative humidity is 60 % (clause 4.03.00 (iv), Sub-Section VI, Part-A,
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Section VI).
 HP-steam pressure at superheater outlet (acc. 0360-102-PVM-Y-0002, Design Coal)
105 % TMCR (VWO) 100 % TMCR 100 % BMCR

255.5 kg/cm² (abs)
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254.4 kg/cm² (abs) 256 kg/cm² (abs)
Steam flow at superheater outlet (acc. 0360-102-PVM-Y-0002, Design Coal)

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2060.2 T/hr. 1918.6 T/hr. 2120 T/hr

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 Steam flow to reheater (acc. 0360-102-PVM-Y-0002, Design Coal)
1729.7 T/hr. 1612.6 T/hr. 1688,6 T/hr

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 Feedwater temperature at Economizer inlet (acc. 0360-102-PVM-Y-0002, Design

Coal)

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293.1 °C 290 °C 293.8 °C

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0360-102-PVM-X-0191A N-100141
 Following permissible limits regarding coal composition have to be maintained:

- GCV deviation up to ± 0,5 MJ/kg to specified guaranteed design coal
- Ash content deviation up to ± 15% to specified guaranteed design coal
- Total moisture content deviation up to ± 10% to specified guaranteed design coal
The contractual band of coal qualities for worst and best coal is listed according to
Table-1, Sub-Section V Salient design data, Part-A, Section VI as following:
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Coal Characteristics (as received)
according to Table-1, Sub-Section V Salient Design Data,
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Part-A, Section VI
Design Coal Worst Coal Best Coal
GCV 3200 kCal/kg 2800 kCal/kg 4000 kCal/kg
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Volatiles 18.00 % wgt 17.00 % wgt 22.00 % wgt
Ash 45.00 % wgt 48.00 % wgt 38.00 % wgt
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Moisture 15.00 % wgt 17.00 % wgt 12.00 % wgt
Elemental Carbon 29.80 % wgt 25.40 % wgt 39.00 % wgt
Elemental Hydrogen 3.00 % wgt 2.80 % wgt 3.20 % wgt

Elemental Oxygen 5.40 % wgt 5.10 % wgt 5.70 % wgt
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Elemental Nitrogen 0.80 % wgt 0.70 % wgt 1.00 % wgt

Elemental Sulphur 0.30 % wgt 0.50 % wgt 0.20 % wgt
Carbonates 0.50 % wgt 0.40 % wgt 0.60 % wgt
Hardgrove 55 - 50 - 60 -
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YGP Index 70 - 80 - 60 -
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0360-102-PVM-X-0191A N-100141
3. Operation Conditions and General Measuring
3.1 Operation Conditions during Testing

3.1.1 Unit Operation
Unless otherwise mentioned, 100 % TMCR is for each performance test acc. CAT-III
assumed. Prior to the start of the test run the unit should be operated at least 24 hours in
continuous coal firing operation. The contractor will be allowed to perform final settings to
load and further parameters prior to the test run in order to achieve proper and suitable
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testing conditions.
Steady load operation, allowed operation conditions, the selection of operating mills and
the start time of test run must be agreed by the responsible test engineers of the
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concerned parties.
The aforementioned agreement must become part of the test protocol, which will be
signed by the responsible test engineers immediately after completion of test run. The test
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protocol will furthermore summarise the completion time of preparatory works.
Occurring disturbances, which may, but must not affect to proper test conditions have also
to be noted down on the test protocol in order to be discussed later on.
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3.1.2 Boiler Operation
Boiler Operation has to be performed according to the required unit load requirements.
Therefore the actual boiler load may differ slightly from the design load at TMCR
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operation, which is dedicated to 1918,6 T/hr HP steam generation.
Steam soot blowers (boiler and gas air heaters) will not be used during the test run in
order not to affect the flue gas sampling and analysing. Therefore a specific blowing
procedure will be run as close as possible prior to the start of test run.
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0360-102-PVM-X-0191A N-100141
3.2 Test Measurements and Measuring Methods

3.2.1 General Convention
The planned measuring and sampling locations are shown by draft process diagrams
(Appendix, Diagram 1 and 2) for all performance tests of Cat III. The related measuring
point identification and numbering is subject of the attached measuring list (Appendix,
Table 1). The measuring list indicates additionally which tests are related to the specific
measuring points.
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Performance tests of category III may be performed separately. All operational measure-
ments listed within the measuring list and marked for the specific test have to be verified
by test measurements prior to testing. Protocols, including test values, of verification must
be available.
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The measuring list will be revised after the installation of test instruments concerning the
instruments identification and calibration certificates with validity of time period of
calibration. The revised measuring list and the calibration certificates of installed
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instruments will be handed over prior to the conjointly site inspection of test measuring
arrangement.
The aim of the inspection is the approval of selection of measuring and recording
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instruments, proper instrument installation and conformity of the related documentation
(measuring list and calibration certificates).
All measuring data obtained from test instruments, except those of air and gas grid
measurements, will be recorded by a data acquisition system consisting of local installed
A/D converters with integrated data memory. 30 seconds should be agreed as scanning
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cycle.
After completion of final test works – such as final calibration of flue gas analysers and
coal and ash sample preparation – the measuring data will be extracted from the data
loggers to data files in presence of the company's test engineer or a responsible deputy.
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The extracted data files will be immediately handed over to the employer's responsible
engineer, who will witness the data extraction and the correct hand-over.
3.2.2 Air-/Flue Gas Measurements (Grid Measurements)

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BGR will make all necessary arrangements and mountings of high accuracy instruments
for grid measurements. All used instruments and calibration certificates from reputed
NABL accredit labs will be transmitted to NTPC with validity of time period of calibration.
All air-/flue gas temperature measurements will be performed as grid measurements. The
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related grid locations and grid arrangements are shown by Appendix 1.1 to 1.3. Calibrated
type K thermocouples (IEC 584-2, class 1) will be used. As described within appendix 5
the measuring ports within the flue gas duct upstream secondary air preheater (HNA13
CT801-804 & HNA23 CT801-804, Appendix 1.2) and downstream of the air heaters /
upstream the joint flue gas duct towards ESP (HNA16/26 CA801-806, Appendix 1.3)
should be used for air heater performance test.

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0360-102-PVM-X-0191A N-100141
The fluctuation of flue gas properties is in general of varying amplitude and period.
Therefore the observation time and the value of each single reading have to be agreed by
the participating employer's observer. The aforementioned procedure can only be
performed by manual readings.
The readings will be manually recorded to reading sheets. The reading sheet will
additional document the individual reading times, the grid locations and the identification
of the used measuring equipment. After completion of a grid run the company's observer
will sign the reading sheet and the recorded trend diagram in order to witness proper
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measurement and reliable recording.
Flue gas sampling and analysing will be carried out for oxygen and carbon monoxide
upstream secondary air preheater (HNA13 CT801-804 & HNA23 CT801-804, Appendix
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1.7) and downstream of the air heaters / upstream the joint flue gas duct towards ESP
(HNA16/26 CA801-806, Appendix 1.9).
The use of following analysing devices and the measuring method is recommended but
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may be mutually agreed by the responsible test engineers of the concerned parties.
Oxygen analysers with paramagnetic susceptibility working principle will be used. Carbon
monoxide analysing will be performed by using nondispersive infrared spectrometer
(NDIR) analysers.
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The oxygen analysers will be calibrated prior and rechecked after the test run by using
pure nitrogen gas and ambient air. The range of linearity will be checked by a
manufacturer certified oxygen calibration gas with about 4 to 5 % of volume content. The
CO analysers will be calibrated by CO calibration gas, containing about 50 to 100 ppm
CO. Pure nitrogen will be used for zero point adjustment.
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Same as for temperature grid measurements, the data registration for flue gas oxygen
and CO will be performed by manual readings, which will be observed by the employer's
responsible engineer. The results of the analyser's calibration must be also noted to the
related data reading sheets. The employer's observer will be required in due time prior to
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0360-102-PVM-X-0191A N-100141
4. Guarantees according to Category-III
4.1. Commissioning Tests with Special Equipment/Instruments

4.1.1 Noise Emission of Various Sources
Noise emissions will be checked during normal plant operation by using a suitable sound
level measuring device according to Clause 8.01.00. Check of emissions should be
performed in cooperation with NTPC for the complete steam generator.
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Selection of components for testing:
Noise level will be measured for Fans (ID, FD, PA, Sealing Air) and mills.
Noise level measurement shall be carried out with a calibrated sound level meter meeting
the requirement of IEC 651 or BS:5969 or IS:9779
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Sound pressure L’pA shall be measured all around the equipment at a distance of 1.0 m
horizontally from the nearest surface of the machine and at a height of 1.5 m from the
floor level in elevation. A minimum of 6 points around each equipment shall be covered for
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measurement. Additional measurement points shall be considered based on the
applicable standards and size of the equipment.
The noise level shall be measured in “A” scale in decibels.

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Correction for background noise shall be considered in line with applicable standards.
Corrected Noise level LpA = L’pA – K1

K1 : Correction for Background noise, dB(A)
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According to ISO 3746-2010, the correction for Background noise should be taken as 7
dB(A). Hence the Corrected Noise level.
LpA = L’pA – 7
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0360-102-PVM-X-0191A N-100141
4.1.2 Coal Pulverizer Capacity at Rated Fineness

In accordance with Clause 8.02.00 (a) mill capacity tests will be performed on one coal
pulverizer of each steam generator for a new set of grinding elements and on four coal
pulverizers of each steam generator for grinding elements of near worn out condition. The
tested coal pulverizer shall be mutually agreed prior to the testing. Per contract the mills
should provide a rated fineness ≥ 70 % passing 200 mesh and ≥ 99 % passing 50 mesh
for any available coal from the specified range. The mill capacity tests will be performed
according to the attachment “Mill Selection” of the “Design Report MPS Mill” provided by
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document N-100141-M-Y01-IB07-00002 / 0360-102-PVM-U-0703. The test for mill
grinding fineness may be part of the capacity test. The mill capacity and fineness test
requires raw coal sampling simultaneously to testing and previously sampling and
analysing of raw coal to ensure that required coal is available.
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Coal Sampling and Analysing
The coal feeders of tested mills will be equipped with a provision to collect raw coal
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samples.
The coal samples will be extracted each 30 minutes from tested mill’s feeder. During the
test run the extracted coal samples will be collected using an air tight closable bin.
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After the test run the collected coal will be mixed to a bulk sample and afterwards
divided into four portions about the same size by shovel. Two portions will be removed
and the remaining two will be mixed again. This procedure will be repeated each time
until about 10 kg of coal will remain.
This coal will be divided into four air tight cans as laboratory samples:
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● one sample to be analysed at NABL accredited govt. labs, and this analysis results
will be used for final evaluation of test.
● one sample to be analysed at the HPE laboratory in Duisburg, Germany
● one spare sample on behalf of the contractor
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● one spare sample, possibly for independent laboratory, to be stored at employer

The raw coal sample has to be tested for proximate analysis according to following
standards.
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0360-102-PVM-X-0191A N-100141
Proximate Analysis International standard utilized by HPE

Gross and Net Calorific Value ISO 1928:2009
Volatile Matter (dry, asf free) ISO 562
Ash Content (as received) ISO 1171
Total Moisture (as received) ISO 589
Fixed Carbon Content 100 % less the sum of VM, IM & Ash
Wear Properties
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YGP Abrasion Index ISO 12900
Grindability acc. to Hardgrove Index ASTM D3402
Pulverized coal sampling ISO 589
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PC sampling ASME PTC 4.2
Particle size (sieve) analysis ASME PTC 4.2, Sieve analysis
(smallest mesh size 75µm)
Mill Grinding Fineness
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Mill grinding fineness will be determined by isokinetic coal dust sampling from each PF
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line according to procedure N-100141-S-HHE-NC01-00002 (Appendix 3). The extracted
dust will be subject for sieve analysis according ISO 1953:2015-11. Used equipment: Air
jet sieving.
Mill Capacity Tests

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According to mill capacity guarantee of Appendix 9, Functional Guarantees, Attachment

8B, the coal pulverizers are designed for mill capacities of 100 t/hr for design coal at rated
fineness and a new set of grinding elements. At near worn out condition of the grinding
elements mill capacities of 95 t/hr for design coal are guaranteed. Increasing the mill
capacity to guaranteed values by using design coal would cause high heat release within
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the burner belt area. High stress may be caused to the boiler.
The mill is designed for high mill capacities to provide necessary reserves to balance wear
influences, but ducting and burners design is limited to 100 % BMCR operation.
Increasing mill capacity to 100 t/hr with design coal would imply an increase up to 50 %
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heat load related to design conditions. The burners are designed to a thermal load of 60.4
MW per burner, therefore mill output above 70.3 T/hr at design coal conditions (70.3 T/hr *
Hu,design coal / 4 burners = 60.4 MW, regarding Hu, design coal of 2956.20 kcal/kg / 12377 kJ/kg)
should be avoided. Due to burner limitations it is not recommended to demonstrate 100
t/hr at design coal conditions, but the same mill loading may be demonstrated by the use
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of worst in adequacy range coal.
Since requested coal might be not available, the measures performed to achieve
guaranteed mill capacity are solely permitted during performance test under supervision of
the responsible mill performance test engineer. The testing time of operation above
specifications must be limited to a minimum. Mill fineness tests shall be performed
previously to mill capacity test at permissible load. acc standard operation manual.

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0360-102-PVM-X-0191A N-100141
Mill, boiler operation and Preconditions for capacity test:
Capacity test should be performed during boiler part load operation. To minimize negative
impact on burner belt area due to high heat impact HPE recommends to perform the test
either on mill 30 or mill 40. Lower levels (mill 10 & 20) should be at min load operation
(1 mill out, 1 mill min load). Due to negative effect on RH heating surfaces it is not
recommended to perform test at higher levels (mill 50-80). Raw coal must be of specified
fineness, since coarser raw coal requires higher retention time within mill and increases
chance of mill choking.
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During mill capacity test two raw coal samples shall be taken. First sample during
configuration phase at load above 70 TPH feeder flow. Second sample during mill
capacity test
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Following parameters must be observed to indicate critical operation at early stage:
 Static pressure remains nearly constant
 Burner temperature constant
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 Classifier temp constant
 Mill bed height constant
Testing time:
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Operation of mill at guaranteed load with GCV > 2700 kcal/kg: 10 minutes
The guaranteed mill capacity is fulfilled, if the test demonstrates for the used test coal a
mill capacity of 100 TPH with unchanged classifier settings for 70 % grinding fineness.
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0360-102-PVM-X-0191A N-100141
Mill capacity test with “Worst in Adequacy Range” coal conditions

Regarding “Worst in Adequacy Range” coal conditions (as described in referred document
N-100141-M-Y01-IB07-00002 / 0360-102-PVM-U-0703) the highest possible coal flow per
burner level would increase to a maximum of 85.0 T/hr (85.0 T/hr * Hu, “Worst in Adequacy Range
coal” / 4 burner = 60.4 MW, regarding Hu, Worst in Adequacy Range coal of 2444,6 kcal/kg / 10235
kJ/kg) and would match the corrected mill capacity for “Worst in Adequacy Range” coal
conditions.
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Mill Design Test
base acc. Meja condition
design (reference)
Design - Test Load
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Mill MPS255 Design Coal Test Coal
Info. Design Mill Corr. Design
GCV kcal/kg 3200 3200 2700
LHV kJ/kg 12377 12377 10235
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max thermal burner load MW 60,4 60,4 60,4
max coal flow per burner kg/s 4,880 4,880 5,901
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m ax allow ed coal flow
t/hr 70,3 70,3 85,0
per burner level
Moisture content % 4,0 15,0 17,0
Hard Groove Index - 80,0 55,0 45,0

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Step 1 Step 2
Grinding
% 78,55 70,0 70,0
Fineness (passing 200 mesh)
Corrected mill capacity results from calculated correction
results from calculated correction factors, Corrected mill

parameters are applied to the MPS255 Mill base Model.
Test coal deviates from design coal, guaranteed milling

Contractual guaranteed design coal and design milling
parameters are kept constant. Corrected mill capacity

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capacity is new reference for mill capacity test.
Mill base capacity

t/hr 125 125 125
(new condition)
Mill base capacity
t/hr 119,2 119,2 119,2
(near w orn out condition)
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Correction for moisture - 1,000 0,927 0,909
Correction für HGI - 1,000 0,780 0,667

Correction for Fineness - 1,000 1,104 1,104
Total Correction factor - 1,000 0,798 0,669
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Corrected m ill capacity

t/hr 125 100 84
(new condition)
factors
Corrected m ill capacity

t/hr 119,2 95 80
(near w orn out condition)
Fig. 1 provides an example calculation, structured in two steps to demonstrate mill capacity.

Page 15
0360-102-PVM-X-0191A N-100141
Step One: Definition of design parameters:
Step One describes the adoption of design coal parameters to the mill base design of a
MPS 255 mill.
The corrected (guaranteed) mill load capacity of 100 % at 100 T/hr for a new set of
grinding elements refers to design conditions of coal, moisture content at 15 % water,
grinding fineness 70 % passing 200 mesh, Hardgrove Index (HGI) of 55 and is based on
the MPS 255 mill base capacity of 125 T/hr. For worn out elements a mill base capacity of
119.2 T/hr has to be regarded and provides a corrected mill capacity of 95 T/hr at design
ed
coal conditions conditions (as described in referred document N-100141-M-Y01-IB07-
00002 / 0360-102-PVM-U-0703).
ov
Step Two: Definition of corrected mill parameters, according to test coal (“Worst in
Adequacy Range”- Coal):
Test coal should be of “Worst in Adequacy Range”- Coal quality. If design conditions of
pr
coal quality are not accomplished the correction curves of document N-100141-M-Y01-
IB07-00002 / 0360-102-PVM-U-0703 have to be applied to the mill base capacity and
results in a corrected (guaranteed) mill capacity. The milling parameters such as
guaranteed fineness will be kept constant. In consideration of the changed coal
Ap
parameters this corrected (guaranteed) mill capacity is equal to design mill capacity
regarding the mill load. The corrected (guaranteed) mill capacity will be the reference for
calculation of load point determination at test load.
As described within the example of Fig. 1 following values will be valid for corrected
(guaranteed) mill capacity:
EP
Moisture: 17 %
HGI: 45
Fineness: 70 %
PE
Corrected (guaranteed) mill capacity (new condition): 84 T/hr

Corrected (guaranteed) mill capacity (near worn out condition): 80 T/hr
This calculation procedure complies consequently with document N-100141-M-Y01-IB07-

00002 / 0360-102-PVM-U-0703, approved by NTPC.
en
The guaranteed mill capacity is fulfilled, if the test demonstrates for the used test coal a
mill capacity equal or higher the corrected mill capacity at 70 % grinding fineness.
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Page 16
0360-102-PVM-X-0191A N-100141
4.2. Commissioning Tests by Using Permanent Site Instruments (DCS)

4.2.1 Maximum steam temperature imbalance at superheater (SH) & reheater (RH)
outlets
In accordance with clause 8.02.00 (vi) maximum steam temperature imbalance at
superheater (SH) & reheater (RH) outlets will not exceed 10 °C under contractual
reference conditions. The test itself is only an observation of the temperature
measurements during operation of the unit at 50 % TMCR and 100 % TMCR. For the
ed
evaluation of the test all relevant parameters, as listed below, will be picked up from DCS-
signals and recorded in trends.
List of relevant main DCS signals:
ov
1 0HAH40 FF901 Main Steam Flow (Boiler Load)
1 0LBA10 CT901 SH3 Outlet 10 Temp
1 0LBA20 CT901 SH3 Outlet 20 Temp
1 0LBB10 CT901 Hot Reheat 2 Outlet 10 Temp
pr
1 0LBB20 CT901 Hot Reheat 2 Outlet 20 Temp
Ap
4.2.2 Air heater leakage
The procedure for demonstration of air heater leakage is subject of appendix 5.
4.2.3 Minimum steam generator load without supplementary oil firing

EP
The procedure for demonstration of minimum steam generator load without

supplementary oil firing is subject of appendix 6.
4.2.4 Maximum Furnace exit gas temperature

PE
The furnace exit is located between the heating surfaces of RH2 and SH3, due to the lack
of feasibility to install the pyrometers at furnace exit. A key constraint comes in from sling
tubes. The sling tubes leave no clear line of sight for the pyrometers to see each other.
Therefore the pyrometers had to be installed below SH1 heating surface.
HPE has furnished additionally the FEGT calculation with backward method for proof of
en
FEGT according contract as appendix within Document N-100141-S-H__-IB02-00020

“Correction of the pyrometer temperature reading in order to obtain the furnace exit gas
temperature“ (Appendix 4)
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Page 17
0360-102-PVM-X-0191A N-100141
5. Correction Diagrams for Mill capacity test

The required correction curves are listed in document 0360-102-PVM-U-0703. Corrections
will be performed in order to correct the deviations of process data from contractual
reference conditions (please refer to chapter 2.1).
Following correction curves are available for performance testing:
Correction of Test Coal for Mill Capacity Point
ed
Correction Factor Moisture related to Standard Coal
Correction Factor Grindability related to Standard Coal
Correction Factor Fineness related to Standard Fineness
ov
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Ap
EP
PE
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Page 18
0360-102-PVM-X-0191A N-100141
6. List of Appendices
Appendix 1 Measuring Grids
Appendix 1.1 Measuring Grid at Flue Gas Duct upstream of Pri Air Heater 1/2
Appendix 1.2 Measuring Grid at Flue Gas Duct upstream of Sec Air Heater 1/2
Appendix 1.3 Measuring Grid at Flue Gas Duct upstream of electrostatic precipitator (ESP)
ed
Appendix 2 Overview Functional Guarantees for Performance Test
Appendix 3 Coal Dust Measurements by means of a Multipoint Sampler,
N-100141-S-HHE-NC01-00002-
ov
Appendix 4 Correction of the pyrometer temperature reading in order to obtain the
furnace exit gas temperature, N-100141-S-H__-IB02-00020
Appendix 5 Air Heater Leackage (BGR)
Appendix 6 Minimum steam generator load without supplementary oil firing
pr
Appendix 7 Meeting Report - Boiler Correction Curve & PGT procedure –
Solapur & Meja
Ap
Table 1 Measuring Point List
Diagram 1 Measuring Locations at Steam Generator Water-/Steam Cycle

Diagram 2 Measuring Locations at Steam Generator Air-, Flue Gas-, Coal- and
Ash Discharge System
EP
PE
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Page 19
Doc-No.: N-100141-0-092-NE01-00002 Proj-Nr.: / Job No.:
0360-102-PVM-X-0191A N-100141
ed
Appendix - 1
ov
Measuring Grids for Performance Test
Kennwort / Code Word:
pr
Ap
EP
PE
en
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Appendix 1: Measuring Grids for Performance Test, Page 1

Ersteller / Prepared by: Geprüft / Checked by: Datum / Date: Rev.:
0360-102-PVM-X-0191A N-100141
Measuring Grid Arrangement at Flue Gas Duct upstream of Primary Air Heater 1 / 2
HNA12 CT801-804 & HNA24 CT801-804
1100 2000 2000 2000
ed
3900
ov
390 780
pr 8200
Ap
EP
PE
en
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Appendix 1.1: Measuring Grid Arrangement at Flue Gas Duct upstream of Primary Air Heater 1 / 2, Page 2
0360-102-PVM-X-0191A N-100141
Measuring Grid Arrangement at Flue Gas Duct upstream of Secondary Air Heater 1 / 2
HNA13 CT801-804 & HNA23 CT801-804
1800 2600 2500 2700
ed
ov
4300
430 860
pr
Ap
11400
EP
PE
en
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Appendix 1.2: Measuring Grid Arrangement at Flue Gas Duct upstream of Secondary Air Heater 1 / 2, Page 3
0360-102-PVM-X-0191A N-100141
Measuring Grid Arrangement at Common Flue Gas Duct upstream of ESP

HNA16 CT801-806 & HNA26 CT801-806
Section E-E
680 1362 1362 1362 1362 1362
ed
ov
7000
pr 700
350
Ap
8170
EP
PE
E E E E
D D
en
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Amount of measuring points per axis might be reduced after evaluation of the first measurement.
Appendix 1.3: Measuring Grid Arrangement at Common Flue Gas Duct upstream of ESP, Page 4
Functional Guarantees for Kennwort / Code Word
Performance Test, Category III Meja All Units

0360-102-PVM-X-0191A N-100141
ed
Appendix - 2
ov
Overview Functional Guarantees for Performance Test,
Category III
pr
Ap
EP
PE
en
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Appendix 2: Overview Functional Guarantees for Performance Test, Category III, Page 1
B. van de Sandt / CC3
Ersteller / Prepared by:
Functional Guarantees for Performance Test, Category III

contractual
# contract title guarantee unit
d
value
e
(a) Coal Pulveriser capacities in T/hr. with worst coal in adequacy range at
rated fineness as per clause 8.02.00 (i), Sub-Section VI, Part-A, Section T/hr. 1001)
ov
VI. At 100 % mill loading with new set of grinding elements
F. P. Schiffer / CC3
Geprüft / Checked by:
Doc-No.: N-100141-0-092-NE01-00002
(b) Coal Pulveriser capacities in T/hr. with worst coal in adequacy range at
rated fineness as per clause 8.02.00 (i), Sub-Section VI, Part-A, Section
pr
VI. Capacity at originally installed grinding elements in worn out condition T/hr. 952)
Performance Test, Category III

0360-102-PVM-X-0191A
or at the end of guaranteed wear life (whichever is earlier) at 100 % mill
Functional Guarantees for

1 8.02.00 (i) Coal Pulveriser capacity at rated fineness loading (with value not less than 90 % of value indicated at (a) above)
Ap
Capacity test as mentioned at (a) & (b) above shall be demonstrated at
the following conditions occurring simultaneously during testing:
- -
(i) not less than 70 % through 200 mesh for any available coal from the
specified range
% ≥ 70
25.07.2019
Datum / Date:
(ii) not less than 99 % through 50 mesh screen for any available coal from
% ≥ 99
2 8.02.00 (ii)
BMCR EP
No fuel oil support shall be required above 30%
the specified range
Minimum steam generator (% of BMCR) load above which no oil support

is required as per clause 8.02.00 (ii), Sub-section-VI, Part-A, Section-VI
% 30
PE
Proj-Nr.: / Job No.:

AB
Rev.:
Meja All Units

N-100141
en
1)
Equivalent value determined according procedure N-100141-0-092-NE01-00002 chapter 4.1.2 for worst coal in adequacy range, guaranteed value
for design coal: 84 T/hr
C
2)
Equivalent value determined according procedure N-100141-0-092-NE01-00002 chapter 4.1.2 for worst coal in adequacy range, guaranteed value
for design coal: 80 T/hr
Functional Guarantees for Performance Test, Category III

contractual
# contract title guarantee unit
d
value
e
Maximum Furnace exit gas temperature (degree Celsius) (MHVT Value) in
3 8.02.00 (v) Furnace Exit Gas Temperature (FEGT) °C 1040
accordance with clause 8.02.00 (v), Sub-section VI, Part-A, Section-VI
ov
Maximum steam temperature imbalance at superheater (SH) & reheater
4 8.02.00 (vi) Steam Temperature Imbalance (RH) outlets between left and right header (In accordance with clause °C ≤ 10
F. P. Schiffer / CC3
Doc-No.: N-100141-0-092-NE01-00002
8.02.00 (vi), Sub-Section VI, Part-A, Section-VI)
pr
Combined Air heater air - leakage and max. drift in Air leakage (% of gas
Performance Test, Category III

5 8.02.00 (vii) Air Preheater air in leakage flow at AH inlet), (In accordance with Clause No. 8.02.00 (vii), Sub-section- % ≤ 10
0360-102-PVM-X-0191A
Functional Guarantees for

VI, Part-A, Section-VI)
Ap
All the plant, equipment and systems covered under this specification shall
perform continuously without exceeding the noise level over the entire
- -
range of output and operating frequency specified as per 8.01.00 of Sub-
6 08.01.00 Noise section-VI of Part-A, Section-VI & Clause 32.00.00 of Part-C of Section-VI
in general, except for dB(A) ≤ 85

25.07.2019
Datum / Date:
(i) Safety valves and associated vent pipes dB(A) ≤ 105
EP (ii) Regulating drain valves dB(A) ≤ 90

PE

AB
Rev.:
Meja All Units

N-100141
en
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EMPLOYER
NTPC Limited
PROJECT
MEJA SUPER THERMAL POWER PROJECT
(2x660 MW)
PACKAGE STEAM GENERATOR (SG) PACKAGE
SG CONTRACTOR
ed
ov
DOC. NO.
pr
JV COMPANY

Ap
CHENNAI – INDIA
DOC. NO.
EP
QSGM SUB CONTRACTOR

HITACHI POWER EUROPE (IF APPLICABLE)
GMBH
Duisburg - Germany
PE
DOC. NO. N-100141-S-HHE-NC01-00002 DOC. NO.
TITLE: Coal Dust Measurements by means of a Multipoint Sampler

en
SIZE SCALE NTPC DOCUMENT NO. REV.

A4 NTS
C
NAME SIGN DATE

PREPARED BY B. van de Sandt signed by B. van de Sandt 01.03.2019
CHECKED BY F. P. Schiffer signed by F. P. Schiffer 01.03.2019
REVIEWED BY F. P. Schiffer signed by F. P. Schiffer 01.03.2019
APPROVED BY F. P. Schiffer signed by F. P. Schiffer 01.03.2019
REVIEWED BY (QSGM) F. P. Schiffer signed by F. P. Schiffer 01.03.2019
APPROVED BY (QSGM) F. P. Schiffer signed by F. P. Schiffer 01.03.2019 SHT. NO.
N-100141-S-HHE-NC01-00002--- Page 1 of 8
Kom.-Nr./Job-No.
N100141
Commissioning procedure
Kennwort/Codeword
Meja
HPE Dok.-Nr./Doc.-No. N-100141-S-HHE-NC01-00002- --
Commissioning procedure
ed
Coal Dust Measurements
by means of a Multipoint Sampler
ov
according to ISO 9931
Explanations pr
Ap
EP
PE
en
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Ersteller/prepared by Telefon/Phone Prüfer/checked by Telefon/Phone Datum/Date Rev.

B. van de Sandt 1413 F. P. Schiffer 2632 01.03.2019 --
N-100141-S-HHE-NC01-00002--- Page 2 of 8
Table of contents
1 Principle of measurement ........................................................................................................4
2 Description of the measurement system ................................................................................5

2.1 Measurement set-up of a multipoint probe ............................................................................5
2.2 Indexing disk .............................................................................................................................7
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2.3 Auxiliary equipment ..................................................................................................................8
2.4 Sampling ....................................................................................................................................8
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pr
Ap
EP
PE
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N-100141-S-HHE-NC01-00002--- Page 3 of 8
1 Principle of measurement
The principle of measurement by means of a multipoint sampler is shown in the following
figure 1.
ed
ov
pr
Ap
EP
Figure 1: Multipoint sampler measurement principle

PE
ISO 9931:1991 describes sampling of pulverized coal by multipoint sampler that extract in 4
minutes from 64 sampling points a representative sample. The sampler is designed for circular
pipes. For clean operation a dustless connection is necessary to apply the probe to the
pulverized coal pipe. By backblowing of heated air the probe is kept clean and heated before
en
and after the sampling period.
Accurate extraction of samples requires the precise knowledge about the required extraction
velocity; therefore the gas velocity has to be measured by a dirty air probe. The extraction
C
velocity will be set to 1.1 ± 0.1 times of the mean gas velocity and has to be kept constant
during the sampling period.
The extraction velocity has to be measured before applying the multipoint sampler to the PF-
line by the dirty air probe.
N-100141-S-HHE-NC01-00002--- Page 4 of 8
Alternatively the extraction gas velocity has to be determined by calculating the mean gas
velocity of the PF-line at the sampling position. The gas velocity depends on following
parameters:
- gas flow to the pulverizer
- gas temperature at sampling position
- static pressure at sampling position
ed
- mass flow of evaporated water from coal-drying process in the pulverizer
- Sealing air of the mill
ov
2 Description of the measurement system
pr
Prior mill operation a clean air test has to be performed for operational safety. The clean air
test will be done with cold air to check the PA flow measurement of each mill and the
Ap
distribution of PA flow through the single pulverized coal pipes (PF pipes) of each mill. This is
to verify that the flow distribution is within acceptable tolerances and that the coal pipes are
free from any foreign material.
2.1 Measurement set-up of a multipoint probe

EP
The great advantage of the rotating multipoint sampler is that it makes possible to scan the
entire cross section of the line with only one of the two instrumentation ports per line
(HHExxCA801/802).
PE
For measurements according to ASME PTC 4.2 code (Coal Pulverizers) two instrumentation
ports 90 degrees apart are installed per line (HHExxCA801/802) to measure the gas velocity
by a dirty air probe
en
For measurements according to ISO 9931 (Coal – Sampling of pulverized coal conveyed by
gases in direct fired coal systems) one port per line is required (HHExxCA801) for extraction of
pulverized coal
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The sampling probe is equipped with an angular gear mechanism for radial rotation of the four
exchangeable sampling tips, which allow simultaneous extraction. The gear is set to 16 radial
positions, regarding the four measuring tips, 64 equal-sized areas will provide a representative
sample of the whole cross section.
The next figure shows the set-up of the sampling equipment.
N-100141-S-HHE-NC01-00002--- Page 5 of 8
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pr
Ap
EP
PE
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Figure 2: Arrangement of sampling equipment
N-100141-S-HHE-NC01-00002--- Page 6 of 8
2.2 Indexing disk

The next figure 3 shows the indexing disk.
ed
ov
pr
Ap
EP
PE
Figure 3: Sampling network
In coal dust lines, networked measurements according to the centroid method must be
en
performed with a larger number of data points.
Positive positioning of the sampling probe in the cross section of the burner line – a
C
prerequisite for good reproducibility – can only be achieved by means of an indexing device.
The data points on the indexing disk are marked by holes.
N-100141-S-HHE-NC01-00002--- Page 7 of 8
2.3 Auxiliary equipment
Following parameters have to be assured by the auxiliary equipment:
- measuring and controlling of the flow of the extracted gas
- the extraction time has to be controlled
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- extraction of coal dust from extracted gas
- extracted coal dust has to be collected separately and must be completely dischargeable
after sampling period
ov
- condensation must be avoided during sampling within the complete system
2.4 Sampling
pr
Ap
The mill needs to operate on constant load, the flow of coal and of gas to the mill as well as
the coal quality needs to be constant prior and during sampling to establish comparable
conditions.
EP
The sampling time is the time taken to extract a sample at each position on a pipe cross
section.
The optimum of sampling time and duration of measurement is always a compromise between
PE
a number of requirements, some of them contradictory:
- The test conditions normally remain constant only for a limited time; for this reason
en
measurement should be taken twice at all lines
- A certain minimum amount of coal dust is required for determination of the grain size
distribution.
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Sampling times of 15 seconds per position is recommended by ISO 9931:1991.
After finishing the sampling the extracted coal dust sample needs to be stored in an airtight
container.
N-100141-S-HHE-NC01-00002--- Page 8 of 8
AE 07.12.2017 Hockauf Updated x factor diagram page 14 of 20 Steinmetz
AD 13.09.2017 Hockauf Additional x factor for imported coal Steinmetz
AC 01.12.2016 Denis Internal Revision Steinmetz
AB 15.11.2016 Denis Pyrometer position is corrected within the calculation sheet, thus the position dependent x factor is adjusted. Steinmetz
OWNER
MEJA URJA NIGAM PVT. LTD.
(A JOINT VENTURE COMPANY OF NTPC & UPRVUNL)
d
CONSULTANT
NTPC Limited
e
MEJA SUPER THERMAL POWER PROJECT (2x660 MW)

PROJECT
ov
PACKAGE
STEAM GENERATOR (SG) PACKAGE
SG CONTRACTOR
pr
VENDOR DOC. NO

JV COMPANY
Ap
CHENNAI – INDIA
VENDOR DOC. NO.
HITACHI POWER EUROPE GMBH SUB CONTRACTOR

QSGM
(IF APPLICABLE)
Duisburg - Germany
VENDOR DOC. NO.
EP N-100141-S-H__-IB02-00020
TITLE: Correction of the pyrometer temperature reading in order to obtain the furnace exit gas temperature
NTPC DOCUMENT NO. REV.05 SCALE
SUB CONTRACTOR DOC. NO.
SIZE
PE
NAME SIGN DATE
PREPARED BY Denis signed by Denis 18.02.2016
CHECKED BY Busekrus signed by Busekrus 18.02.2016

en
REVIEWED BY Busekrus signed by Busekrus 18.02.2016
APPROVED BY Busekrus signed by Busekrus 18.02.2016
REVIEWED BY (QSGM) Busekrus signed by Busekrus 18.02.2016

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APPROVED BY (QSGM) Busekrus signed by Busekrus 18.02.2016 SHT. NO.1 OF 20
Correction of the pyrometer temperature
reading in order to obtain the FEGT Meja
Dok-Nr. / Doc-No. Proj-Nr.:/ Job No.:
N-100141-S-H__-IB02-00020 N-100141

reading in order to obtain the furnace exit gas
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temperature
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pr
Ap
EP
PE
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Hockauf, PE3 Steinmetz, PE3 07.12.2017 AE
Seite/Page 2 von/of 20
N-100141-S-H__-IB02-00020 N-100141
Table of Contents
Preamble ............................................................................................................................................ 4
1 Pyrometer measurement at +54 m ..................................................................................... 6
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2 Boiler load (BL) .................................................................................................................... 6
3 Thermal input at SH1 and SH3 ............................................................................................ 7

3.1 Thermal Input at SH1 ............................................................................................................ 7
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3.2 Thermal Input at SH3 .......................................................................................................... 11
4 Calculation of the FEGT Temperature .............................................................................. 13
pr
5 Example Calculation of the FEGT for 100% BMCR ......................................................... 15
5.1 Measurements readings ...................................................................................................... 15
5.2 Calculation of the thermal input at SH1................................................................................ 16
5.3 Calculation of the thermal input at SH3................................................................................ 18
Ap
5.4 Calculation of the FEGT Temperature ................................................................................. 20
EP
PE
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N-100141-S-H__-IB02-00020 N-100141
Preamble
As explained in N-100130-0-050-UA03-00206_MoM it is technically not feasible to install the

pyrometers at the Furnace Exit between SH3 and RH2.
A key constraint comes in from sling tubes (6 curtains each having tubes at 960 mm pitch). The sling
tubes leave no clear line of sight for the pyrometers to see each other.
ed
Water Walls Sling Tubes
ov
FEGT RH1
RH2
(approx. +72,4 m)
SH3
Acoustic Pyrometer
pr SH1
Ap
(approx. +54 m)
EP
PE
en
HPE has prepared a concept for correction of the pyrometer temperature reading in order to obtain the
furnace exit gas temperature (FEGT) based on the following parameters:
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 Pyrometer measurement at +54 m

 Boiler load (BL)
 Thermal input at SH1, SH3, Sling Tubes segment and intervening water wall segment
 Coal quality
The FEGT equals the difference between the mean temperature as measured from the acoustic
pyrometers 1 0HBK01 CT003/004/005/006/007/008/009/010 (TPyrometer) and a flue gas temperature
drop (dT)

N-100141-S-H__-IB02-00020 N-100141
FEGT = TPyrometer - dT
The temperature drop depends on the heat absorption in the SH1, SH3, sling tubes segment and
intervening water wall segment.
The heat input in SH1 and SH3 can be calculated using temperature, pressure and mass flow
measurements.
The boiler load and coal quality dependent heat input in to the sling tubes segment and intervening
ed
water wall segment is calculated using a boiler model and compiled in the factor x.
dT = x * (qSH1 + qSH3 )
ov
where:
qSH1 stays for thermal input at SH1 in MW
pr
x = Function of (Boiler Load; Coal Quality; heat absorption in the sling tube segment; heat absorption in
Ap
the water wall segment)
EP
PE
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N-100141-S-H__-IB02-00020 N-100141
1 Pyrometer measurement at +54 m
The pyrometer measurement is installed at approximately +54 m.

The pyrometer measurement of the flue gas temperature is located approximately 18.4 m below
furnace exit.
ed
ov
2 Boiler load (BL)
The calculation of the FEGT depends on the boiler load.
pr
100 % boiler load refers to 100 % BMCR (2120 t/h Main Steam (MS)).
The boiler loads used for the calculation of the FEGT are specified in the following table:
Ap
Name of the boiler load MS mass flow Percentage of the BMCR
MS mass flow
- t/h %
100% BMCR 2120,0 100,0
100% TMCR 1918,6 90,5
EP
80% MCR 1492,3 70,4

50% MCR 924,9 43,6
35% MCR 742,0 35,0
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N-100141-S-H__-IB02-00020 N-100141
3 Thermal input at SH1 and SH3
3.1 Thermal Input at SH1
ed
The thermal input at SH1 is calculated with following equation:
qSH1 = ṁ * ( h2 – h1 ) / 1000
ov
where:
pr
ṁ stays for steam mass flow at SH1 in kg/s
Ap
h1 stays for steam enthalpy at SH1 inlet in kJ/kg
h2 stays for steam enthalpy at SH1 outlet in kJ/kg
The steam mass flow at SH1 equals the feed water mass flow 1 0LBA75 CF904.
See P&ID Feed Water from NRV to Eco (NTPC Doc. No.: 0360-102-PVM-F-0872)
EP
The enthalpy at the inlet of SH1 is a function of the steam pressure (p1) and temperature (T1) at the
SH1 inlet and can be calculated using a steam table.
PE
h1 = Function of (p1; T1)
p1 refers to the pressure at the inlet of SH1.

T1 refers to the temperature at the inlet of SH1.
en
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N-100141-S-H__-IB02-00020 N-100141
Calculation of p1:
The pressure at the inlet of SH1 (p1) equals the difference between the pressure measurements
1 0HAH11/12 CP001 (pM) and a boiler load dependent pressure drop in the Supporting Tubes (dpST).
p1 = pM – dpST
pM equals the mean value of the pressure measurements
ed
1 0HAH11/12 CP001
dpST stays for pressure drop in the Supporting Tubes
See P&ID Superheater System (NTPC Doc. No.: 0360-102-PVM-F-0086)
ov
The following polynomic function is build according the pressure drop in the supporting tubes for the
boiler loads:
100% BMCR, 100% TMCR, 80% MCR, 50% MCR, 35% MCR
pr
as stated in:
Document: N-100141-S-H__-IB07-00006 / 0360-102-PVM-Y-0012
Chapter: 1.4 Pressure drop across each section of pressure parts
Ap
dpST = 45,2812 * BL^4 - 110,9477 * BL^3 + 98,0914 * BL^2 - 31,6556 * BL + 5,3206
BL stays for Boiler Load

EP
PE
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N-100141-S-H__-IB02-00020 N-100141
Calculation of T1:
The temperature at the inlet of SH1 (T1) equals the difference between the temperature measurements
1 0HAH11/12 CT901 (TM) and a boiler load dependent temperature increase in the Supporting Tubes
(dTST).
T1 = TM + dTST
ed
TM equals the mean value of the temperature measurements
1 0HAH11/12 CT901
dTST stays for temperature increase in the Supporting Tubes
See P&ID Eco and Evaporator System (NTPC Doc. No.: 0360-102-PVM-F-0073)
ov
The following polynomic function is build according the temperature increase in the supporting tubes
for the boiler loads:
pr
as stated in:
Ap
Chapter: 1.3 Ambient Air Conditions/ Temperatures
dTST = 118,6568 * BL^4 - 433,6193 * BL^3 + 589,3872 * BL^2 - 366,9777 * BL + 96,7531

EP

PE
en
C

N-100141-S-H__-IB02-00020 N-100141
The enthalpy at the outlet of SH1 is a function of the steam pressure (p2) and temperature (T2) at the
SH1 outlet and can be calculated using a steam table.
p2 refers to the pressure at the outlet of SH1.

T2 equals the mean value of the temperature measurements 1 0HAH41/42 CT901.
ed
Calculation of p2
ov
The pressure at the outlet of SH1 (p2) equals the difference between p1 and a boiler load dependent
pressure drop in the SH1 (dpSH1).
p2 = p1 – dpSH1
pr
The following polynomic function is build according the pressure drop in the SH1 for the boiler loads:
Ap
as stated in:
EP
dpSH1 = 7,0662 * BL^3 - 13,074 * BL^2 + 10,473 * BL - 1,1154

PE
en
C

N-100141-S-H__-IB02-00020 N-100141
3.2 Thermal Input at SH3
The thermal input at SH3 is calculated with following equation:
qSH3 = ṁ * ( h2 – h1 ) / 1000
ed
where:
ov
ṁ stays for steam mass flow at SH3 in kg/s
h1 stays for steam enthalpy at SH3 inlet in kJ/kg
h2 stays for steam enthalpy at SH3 outlet in kJ/kg
pr
The steam mass flow at SH3 equals the main steam mass flow.
Ap
The enthalpy at the inlet of SH3 is a function of the steam pressure (p1) and temperature (T1) at the
SH3 inlet and can be calculated using a steam table.

EP
p1 refers to the pressure at the inlet of SH3.

T1 equals the mean value of the temperature measurements 1 0HAH61/62 CT903.
PE
Calculation of p1
The pressure at the inlet of SH3 can be calculated using the main steam pressure and a boiler load
dependent pressure drop in the SH3 and the pressure drop in the main steam line between SH3 outlet
and the pressure measurements 1 0LBA10/20 CP002.
en
See P&ID Main Steam Piping System (NTPC Doc. No.: 0360-102-PVM-F-0870)
p1 = pMS + (dpSH3 + dpMSL)

C
pMS equals the mean value of the pressure measurements

1 0LBA10/20 CP002
dpSH3 stays for pressure drop in SH3
dpMSL stays for pressure drop in the main steam line between
SH3 outlet and the pressure measurements 1
0LBA10/20 CP002

N-100141-S-H__-IB02-00020 N-100141
The following polynomic function is build according the pressure drop in the SH3 for the boiler loads:
as stated in:
Document: N-100141-S-H__-IB07-00006
dpSH3 = 58,5289 * BL^4 - 140,1506 * BL^3 + 119,346 * BL^2 - 38,6078 * BL + 5,8435
ed
ov
The following polynomic function is build according the pressure drop in the Main Steam (MS) line for
the boiler loads:
100% BMCR and 35% MCR
dpMSL = 1,3846 * BL - 0,0846
pr
Ap
The enthalpy at the outlet of SH3 is a function of the steam pressure (p2) and temperature (T2) at the
SH3 outlet and can be calculated using a steam table.

EP
p2 refers to the pressure at the outlet of SH3.

T2 equals the mean value of the temperature measurements 1 0LBA10/20 CT001/002/003.
Calculation of p2
PE
The pressure at the outlet of SH3 can be calculated using the main steam pressure and a boiler load
dependent pressure drop in the main steam line between SH3 outlet and the pressure measurements
1 0LBA10/20 CP002.
en
p2 = pMS + dpMSL
pMS equals the mean value of the pressure measurements

1 0LBA10/20 CP002
C
dpMSL stays for pressure drop in the main steam line between
SH3 outlet and the pressure measurements 1
0LBA10/20 CP002
dpMSL = 1,3846 * BL - 0,0846

N-100141-S-H__-IB02-00020 N-100141
4 Calculation of the FEGT Temperature
The furnace exit gas temperature equals the difference between the mean temperature as measured
from the acustic pyrometers 1 0HBK01 CT003/004/005/006/007/008/009/010 (T Pyrometer) and a boiler
load and coal dependent flue gas temperature drop (dT)
ed
dT = x * (qSH1 + qSH3 )
ov
x = Function of (Boiler Load; Coal Quality; heat absorption in the sling tube segment; heat absorption in
the water wall segment)
For Design Coal:
pr
Ap
5 4 3 2
x = -179,0420*BL + 611,7365*BL - 820,2572*BL + 542,4660*BL - 180,1755*BL + 26,6829
The polynomic function is build according the boiler model calculations for design coal and the
following boiler loads:
100% BMCR, 100% TMCR, 80% MCR, 50% MCR, 35% MCR.
EP
The polynomic function considers the heat absorption in the sling tube segment and heat absorption in
the water wall segment according the boiler model.
For Worst Coal:

PE
5 4 3 2
x = -181,922*BL + 624,090*BL - 840,436*BL + 558,219*BL - 185,992*BL + 27,383
The polynomic function is build according the boiler model calculations for worst coal and the following
boiler loads:
en
C
For Best Coal:
5 4 3 2
x = -251,292*BL + 889,153*BL - 1.236,705*BL + 847,693*BL - 289,392*BL + 42,046

N-100141-S-H__-IB02-00020 N-100141
The polynomic function is build according the boiler model calculations for best coal and the following
boiler loads:
For Best blended Coal (70% Design + 30 % Import Best):
ed
5 4 3 2
x = -253,889*BL + 897,784*BL - 1.248,586*BL + 855,998*BL - 292,239*BL + 42,412
boiler loads:
ov
For Worst blended Coal (70% Design + 30 % Import Worst):
pr
Ap
5 4 3 2
x = -154,632*BL + 548,87*BL - 766,061*BL + 526,874*BL - 180,774*BL + 27,194
boiler loads:
EP
x factor dependent on calorific value

4
PE
3,5
3
en X Factor
2,5
2
C
1,5
1
30% 40% 50% 60% 70% 80% 90% 100%
Boiler Load [%]
Design Coal GCV = 3300 kcal/kg Worst Coal GCV = 2800 kcal/kg
Best Coal GCV = 4200 kcal/kg 70%Design+30%ImportBest Coal GCV = 4260 kcal/kg
70%Design+30%ImportWorst Coal GCV = 4050 kcal/kg

N-100141-S-H__-IB02-00020 N-100141
Example Calculation of the FEGT for 100% BMCR
4.1 Measurements readings
ed
In order to prepare an example calculation for the FEGT temperature following measurements values
are presumed:
ov
 Main steam mass flow: 588,89 kg/s (100% BMCR)
 An acoustic pyrometers (1 0HBK01 CT003/004/005/006/007/008/009/010) temperature reading
of 1326,4°C (average value)
pr
 Steam mass flow at SH1 (1 0LBA75 CF904): 559,45 kg/s
 Pressure at ST inlet (1 0HAH11/12 CP001): 277,8 kg/cm²
 Temperature at ST inlet (1 0HAH11/12 CT901): 426,8°C
Ap
 Temperature at SH1 outlet (1 0HAH41/42 CT901): 480°C
 Pressure at the main steam line (1 0LBA10/20 CP002): 254,7 kg/cm²
 Temperature at SH3 inlet (1 0HAH61/62 CT903): 503,3°C
 Temperature at SH3 outlet (1 0LBA10/20 CT001/002/003): 568,0°C
EP
PE
en
C

N-100141-S-H__-IB02-00020 N-100141
4.2 Calculation of the thermal input at SH1
Calculation of the SH1 inlet enthalpy

p1 = pM – dpST
ed
pM = 277,8 kg/cm²
dpST = 45,2812 * BL^4 - 110,9477 * BL^3 + 98,0914 * BL^2 - 31,6556 * BL + 5,3206
ov
dpST = 45,2812 * 100%^4 - 110,9477 * 100%^3 + 98,0914 * 100%^2 - 31,6556 * 100% + 5,3206
dpST = 6,09 kg/cm²
pr
p1 = pM – dpST
p1 = 277,8 – 6,09
p1 = 271,71 kg/cm²
Ap
T1 = TM + dTST
TM = 426,8°C
EP
dTST = 118,6568 * BL^4 - 433,6193 * BL^3 + 589,3872 * BL^2 - 366,9777 * BL + 96,7531

dTST = 118,6568 * 100%^4 - 433,6193 * 100%^3 + 589,3872 * 100%^2 - 366,9777 * 100% + 96,7531
dTST = 4,2°C
PE
T1 = TM + dTST
T1 = 426,8 + 4,2
T1 = 431°C
en
According the steam table:

h1 = Function of (271,71; 431) = 2791,98 kJ/kg
C

N-100141-S-H__-IB02-00020 N-100141
Calculation of the SH1 outlet enthalpy

p2 = p1 – dpSH1
p1 = 271,71 kg/cm²
ed
dpSH1 = 7,0662 * BL^3 - 13,074 * BL^2 + 10,473 * BL - 1,1154
dpSH1 = 3,35 kg/cm²
p2 = p1 – dpSH1
ov
p2 = 271,3 – 3,35
p2 = 268,36 kg/cm²
T2 = 480°C
pr
Ap
h2 = Function of (268,36; 480) = 3062,93 kJ/kg
EP
Calculation of the SH1 thermal input

qSH1 = ṁ * ( h2 – h1 ) / 1000
qSH1 = 559,45 * (3062,93 – 2791,98) / 1000
PE
qSH1 = 151,583 MW
en
C

N-100141-S-H__-IB02-00020 N-100141
4.3 Calculation of the thermal input at SH3
Calculation of the SH3 inlet enthalpy

ed
pMS = 254,7 kg/cm²
ov
dpSH3 = 58,5289 * BL^4 - 140,1506 * BL^3 + 119,346 * BL^2 - 38,6078 * BL + 5,8435
dpSH3 = 58,5289 * 100%^4 - 140,1506 * 100%^3 + 119,346 * 100%^2 - 38,6078 * 100% + 5,8435
dpSH3 = 4,96 kg/cm²
dpMSL = 1,3846 * BL - 0,0846

dpMSL = 1,3846 * 100% - 0,0846
pr
Ap
dpMSL = 1,3 kg/cm²

p1 = 254,7 + (4,96 + 1,3)
EP
p1 = 261kg/cm²
T1 = 503,3°C
PE

h1 = Function of (261; 503,3)
h1 = 3169,12 kJ/kg
en
C

N-100141-S-H__-IB02-00020 N-100141
Calculation of the SH3 outlet enthalpy

p2 = pMS + dpMSL
pMS = 254,7 kg/cm²
ed
dpMSL = 1,3846 * BL - 0,0846
dpMSL = 1,3846 * 100% - 0,0846
dpMSL = 1,3 kg/cm²
ov
p2 = pMS + dpMSL
p2 = 254,7+ 1,3
pr
p2 = 256,0 kg/cm²
Ap
T2 = 568,0 °C

h2 = Function of (256,0; 568,0)
EP
h2 = 3395,32 kJ/kg
PE
Calculation of the SH3 thermal input
qSH3 = ṁ * ( h2 – h1 ) / 1000
qSH3 = 588,89 * (3395,32 – 3169,12) / 1000
en
qSH3 = 133,21 MW
C

N-100141-S-H__-IB02-00020 N-100141
4.4 Calculation of the FEGT Temperature
TPyrometer = 1326,4°C
dT = x * (qSH1 + qSH3 )
ed
Factor x for Design Coal:
5 4 3 2
x = -179,0420x + 611,7365x - 820,2572x + 542,4660x - 180,1755x + 26,6829
ov
5 4 3 2
x = -179,0420*100%^ + 611,7365*100%^ - 820,2572*100%^ + 542,4660*100%^ - 180,1755*100%
+ 26,6829
x = 1,4107
dT = x * (qSH1 + qSH3 )
dT = 1,4107 * (151,583 + 133,21)
pr
Ap
dT = 401,76°C
FEGT = 1326,4 – 401,76
EP
FEGT = 924,64°C
PE
en
C

Job-No.
N-100141 Compliance Sheet
Codeword for
MEJA
Correction of the pyrometer temperature reading in order to obtain the
Doc.-Title furnace exit gas temperature
HPE-Doc.-No. N-100141-S-H__-IB02-00020 Rev.: AE

NTPC-Doc.-No. -
ed
Item NTPC-Comments HPE-Comments
1. NTPC
1 document no. may also kindly be
added
We are not able to find any reference
2. 2 Pressure is corrected. (Erroneously Solapur
document from where the value of PM =277.2
ov
performance data was used.)
Kg/cm2 (taken in the example calculation)
has been taken. As per the predicted
performance document the inlet pressure for
sling tubes is 277.8kg/cm2.
Do we understand that it is an intermediate

point between separator and sling tubes from
what is indicated in the predicted
pr
Ap
performance. If so, for reference purposes
kindly attach a table here so to indicated the
predicted PM values for different load range
and coal cases (in case there is a change in
pressure values with type of coal firing).
We are not able to find any reference
3. 2 Temperature is corrected. (Erroneously Solapur
EP
document from where the value of T E

performance data was used.)
=422.1°C (taken in the example calculation)
has been taken. As per the predicted
performance document the inlet temperature
for sling tubes is 426.8°C.
PE
Do we understand that it is an intermediate

point between separator and sling tubes
different from what is indicated in the
predicted performance. If so, for reference
purposes kindly attach a table here so to
en
indicated the predicted TE values for different

load range and coal cases (in case there is a
change in pressure values with type of coal
firing).
4. BGR/HPE
2 to further note that coal quality may Noted.
C
change and it may not be possible that coal

for which equation are provided would be
firing at that instance. In view of this it is
understood that calculation of FEGT
temperature by acoustic pyrometer equation
shall have a correction factor of Calorific
value of coal. Kindly check and confirm
Ersteller/prepared by Prüfer/checked by Datum/Date

Denis Steinmetz 08.08.2016
Seite/Page 1 ÷ 2
Dok.-Nr./Doc.-No. N-100141-S-H__-IB02-00020
5. 277.8
2 as per predicted performance Please refer to item 2. Value is corrected.
document (Erroneously Solapur performance data was
used.)
6. 3.37
2 in the predicted performance document. As demonstrated within the write-up, the pressure
Kindly clarify the discrepency drop is calculated by the given polynom. fkt. in
dependence of the boiler load.
7. As
2 per predicted performance the value of T2 Value is corrected. (Erroneously Solapur
is 480°C performance data was used.)
8. Using
2 the above equation the values is Equation is corrected.
coming out to be -4.96. Kindly check
ed
9. The
2 temperature in predicted performance Temperature is corrected. (Erroneously Solapur
document is 503.3°C, kindly clarify performance data was used.)
10. The
2 flue gas temperature at RH2 inlet Calculation corrected. (Erroneously Solapur
indicated in the predicted performance performance data was used.)
ov
document is 924.7°C. Kindly clarify the
discrepancy from the above calculated value.
11. Kindly
2 add at least one or two more One calculation as example was accepted by the
calculation for different load and coal case for NTPC management within the TCM. No further
pr
verification of the equations used. calculations will be attached!
12. FEGT calculation is integral to the approval of Additional x factor correction for import coal is
the selected acoustic now attached.
Ap
pyrometer. Hence it should be a part of the With all x factor curves can be implemented into
product datasheet. Kindly note the DCS. With interpolation depending on the
calorific value a x factor correction can be done
that the same has been made a part of the
for all coals.
Solapur document based on which
approval is being sought for Meja.
EP
hence it is again requested that response to

the following query may be
arranged on priority.
"In response to Comment at sl. no. 4 of
Compliance sheet "BGR/HPE to
PE
further note that coal quality may change and

it may not be possible that coal
for which equation are provided would be
firing at that instance. In view of this
en
it is understood that calculation of FEGT

temperature by acoustic pyrometer
equation shall have a correction factor of
Calorific value of coal. Kindly check
C
and confirm" BGR/HPE has replied "noted".

The clarification regarding the same is sought
and also correction factors
regarding the same may kindly be provided
so that these can be implemented
in logics."
Seite/Page 2 ÷ 2
Solapur /Meja 17.06.2019
Proj.-Nr.: N100131 / N100141 Hockauf
Hitachi Power Europe GmbH
d
Backwards-Calculation FEGT
e
Fuel
GCV kcal/kg 3300,00
LHV MJ/kg 12,755
ov
Carbon ɣC kg/kg 0,3170
Hydrogen ɣH kg/kg 0,0330
Sulphur ɣS kg/kg 0,0028
Nitrogen ɣN kg/kg 0,0083
pr
Oxygen ɣO kg/kg 0,0854
Ash ɣAsh kg/kg 0,4135
Moisture ɣH2O kg/kg 0,1400
Total 1,0000
Ap
volatile matter of ash ν kg/kg 0,0500 BS EN12952-15
Aus Wirkungsgradberechnung
Fuel mass flow burnt mF kg/h 425276
Fuel mass flow unburnt mFu kg/h 4296
Fuel mass flow total input mFo kg/h 429572
Fuel mass flow burnt
Fuel mass flow unburnt
Fuel mass flow total input
Oxygen Content of Dry Flue Gas at air heater inlet measured

EP
mF
mFu
mFo
yO2d
kg/s
kg/s
kg/s
Vol.% tr.
118,132
1,193
119,326
3,58
PE
dry air (BS EN12952-15)
Carbon dioxide content of dry air (Mass.-Based) xCO2Ad kg/kg 0,000505
Carbon dioxide content of dry air (Vol.-Based) yCO2Ad m³/m³ 0,00033
Oxygen content of dry air (Vol.-Based) yO2Ad Vol.% tr. 20,938
Standard density of dry air ρnAD kg/m³ 1,2930
en
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Seite: 1 von 8
d
Wet Air
Ambient air pressure (measured) pA mbar 960,00
e
Ambient air pressure (messured, dry) tA °C 27,00
Relative air humidity (messured) φ % 60,00
ov
Boiling pressure at ambient air temperature p's mbar 35,68
Air humidity based on dry air xH2OAd=0,622 * (φ*p's)/(pUmg - φ*p's) kg/kg tr. 0,01419
Standard Density CO2 (BS EN12952-15) ρnCO2 kg/m³ 1,9770
pr
Combustion air/flue gas mass to fuel mass ratios & specific heat
Combustion air content µAod=11,5122*ɣC+34,2974*ɣH+4,3129*ɣS-4,3212*ɣO - 4,4242 (8.3-58) BS EN12952-15
Ap
Flue gas content µGod=12,5122*ɣC+26,3604*ɣH+5,3129*ɣS-3,3212*ɣO+1*ɣN 4,5758 (8.3-59) BS EN12952-15
Flue gas volume (STP conditions) VGod=8,8930*ɣC+20,9724*ɣH+3,3190*ɣS-2,6424*ɣO+0,7997*ɣN 3,3014 (8.3-60) BS EN12952-15
Carbon dioxide content µCO2o=3,6699*ɣC+0,0173*ɣH+0,0022*ɣS-0,0022*ɣO 1,1637 (8.3-61) BS EN12952-15
Water vapour content µH2OF=8,9370*ɣH+1,0*ɣH2O 0,4349 (8.3-62) BS EN12952-15
Standard density of carbon dioxide ρnCO2 1,9770
Carbon dioxide content in flue gas VCO2o = µCO2o/ρnCO2 0,5886
Volume of CO2 in flue gas
Maximum carbon dioxide
Dry combustion air mass to fuel mass ration

Mass of carbon dioxide in flue gas to fuel mass ratio
Mass of water in flue gas to fuel mass ratio
EP yCO2d =(((ŷCO2d - yCO2Ad)*VGod)/(VGod+VGod*yO2d/(yO2Ad-yO2d)))+yCO2Ad
ŷCO2d = VCO2o/VGod
µAd = µAod + ρnAd VGod*(ŷCO2d-yCO2d)/(yCO2d-yCO2Ad)

µCO2=µCO2o + ρnAD*VGod * (yO2d / (yO2Ad - yO2d)) * xCO2Ad
µH2O=µH2OF + µAd*xH2OAd
-0,0254
0,1783
5,30464 (8.3-47) BS EN12952-15

1,1644 (8.3-49) BS EN12952-15
0,51018 (8.3-50) BS EN12952-15
PE
Air mass to fuel mass ratio µA=µAd * (1+xH2OAd) 5,37989 (8.3-51) BS EN12952-15
Flue gas mass to fuel mass ratio µG=µA + 1 - ɣAsh*(1-ν) 5,98707 (8.3-52) BS EN12952-15
Carbon dioxide content in flue gas xCO2 = µCO2 / µG kg/kg 0,1945 (8.3-53) BS EN12952-15
Moisture content in flue gas xH2O = µH2O / µG kg/kg 0,0852 (8.3-54) BS EN12952-15
en
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Seite: 2 von 8
d
Calculation of specific heat capacity
e
Polynom coefficent for claculation of specific heat capacity
acc BS BS EN12952-15 = FDBR-Handbook
dry air H2O in air / flue gas CO2 in flue gas
ov
Duration of limit 0 - 1200°C 0 - 1200°C
(acc. FDBR) 0 - 2000°C XH2O = 0 - 0,3 XCO2 = 0 - 0,2
a 1,004173E+00 a1 8,554535E-01 a2 -1,002311E-01
b 1,919210E-05 b1 2,036005E-04 b2 7,661864E-04
c 5,883483E-07 c1 4,583082E-07 c2 -9,259622E-07
pr
d -7,011184E-10 d1 -2,798080E-10 d2 5,293496E-10
e 3,309525E-13 e1 5,634413E-14 e2 -1,093573E-13
f -5,673876E-17
Ap
upsteam air heater
Flue gas temperature upsteam air heater, measured t1 = tFG,vor Luvo °C 351,1
Intergral specific heat of dry air cpAd0t1 = a+(b/2)*t1+(c/3)*t1^2+(d/4)*t1^3+(e/5)*t1^4+(f/6)*t1^5 kJ/(kg K) 1,025087 (8.3-77) BS EN12952-15
Factor H2O P1m,t1 = a1+(b1/2)*t1+(c1/3)*t1^2+(d1/4)*t1^3+(e1/5)*t1^4 kJ/(kg K) 0,907171 (8.3-78) BS EN12952-15
Factor CO2 P2m,t1 = a2+(b2/2)*t1+(c2/3)*t1^2+(d2/4)*t1^3+(e2/5)*t1^4 kJ/(kg K) 0,001620 (8.3-79) BS EN12952-15
Intergral specific heat of wet flue gas cpG0t1 = cpAd0t1 + P1m,t1*xH2O + P2m,t1 * xCO2 kJ/(kg K) 1,102705 (8.3-75) BS EN12952-15
between SH3 and RH2 (approx. +72,4m)

FEGT, estimated
FEGT, calculated
Difference estimated - caclulated value
Intergral specific heat of dry air
EP t2
tFEGT
cpAd0t2 = a+(b/2)*t2+(c/3)*t2^2+(d/4)*t2^3+(e/5)*t2^4+(f/6)*t2^5
°C
°C
K
kJ/(kg K)
911,40
919,7
8,3
from line 254
1,082850 (8.3-77) BS EN12952-15

PE
Factor H2O P1m,t2 = a1+(b1/2)*t2+(c1/3)*t2^2+(d1/4)*t2^3+(e1/5)*t2^4 kJ/(kg K) 1,029950 (8.3-78) BS EN12952-15
Factor CO2 P2m,t2 = a2+(b2/2)*t2+(c2/3)*t2^2+(d2/4)*t2^3+(e2/5)*t2^4 kJ/(kg K) 0,077632 (8.3-79) BS EN12952-15
Intergral specific heat of wet flue gas cpG0t2 = cpAd0t2 + P1m,t2*xH2O + P2m,t2 * xCO2 kJ/(kg K) 1,185713 (8.3-75) BS EN12952-15
Average integrale specific. heat of flue gas

en
between level of FEGT and air heater inlet cpFG =(cpG0t1 * t1 - cpG0t2 * t2)/(t1 - t2) kJ/(kg K) 1,23773 (8.3-80) BS EN12952-15
0
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d
Calculation specific heat flue dust
e
upstream air heater
Flue gas temperature upsteam air heater, measured t1 = tFG,vor Luvo °C 351,1
ov
Specific heat of ash and flue dust cpAsh1 = 0,73 + 0,445 * tanh(0,001435 * t1) kJ/(kg K) 0,936980 4.9.4 FDBR 1998
between SH3 and RH2 (approx. +72,4m)

FEGT, estimated t2 °C 911,4
pr
Specific heat of ash and flue dust cpAsh2 = 0,73 + 0,445 * tanh(0,001435 * t2) kJ/(kg K) 1,114361 4.9.4 FDBR 1998
Average integrale specific heat of ash and flue dust

1,22551 (8.3-80) BS EN12952-15
Ap
between level of FEGT and air heater inlet cpAsh =(cpAsh1 * t1 - cpAsh2 * t2)/(t1 - t2) kJ/(kg K)
Calculation flue gas flow

Flue gas due burned fuel mFG1 = µG * mF kg/s 707,27
Flue gas due unburned fuel mFG2 = mFu * (ɣH2O + ɣAsh * ν) kg/s 0,19
Total flue gas mass flow
Calculation flue gas flow

Unburnt combustible contents of flue dust, messured
Primary deashing rate
EP
mFG = mFG1 + mFG2
uFA
xSL
kg/s
%
%
707,46
1
20,00
flue dust flow, messured mFA = mF0 * ɣAsh * (1-ν) * (1- xSL) / (1 - uFA)
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kg/s 37,88
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Useful heat water / steam system
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HP-Part
Mainsteam flow mFD = mFW + mAtt1, SH + mAtt2, SH kg/s 532,9
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Spray water attemperator stage 1, measured mAtt1, SH kg/s 13,322
Spray water attemperator stage 1, measured mAtt2, SH kg/s 16,253
Feed water flow, measured mFW kg/s 503,324
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Eco 1 + 2
Feed water flow mFW kg/s 503,324
Inlet pressure, measured bar 277,8
Inlet temperature, measured °C 290
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Inlet enthalpy hInlet,Eco1 kJ/kg 1279,1
Outlet pressure bar 277,300002
Outlet temperature, measured °C 332,6
Outlet enthalpy hOutlet,Eco2 kJ/kg 1507,2
Useful heat Eco QEco = (hOutlet,Eco2 - hInlet,Eco1) * mFW MW 114,79
Evaporator - spirale
Feed water flow
Inlet enthalpy
Outlet pressure
Outlet temperature, measured
Outlet enthalpy
Useful heat Spiral
EP
mFW
hInlet, Spiral = hOutlet,Eco
hOutlet, Spiral
QSpiral = (hOutlet, Spiral - hInlet, Spiral) * mFW
kg/s
kJ/kg
bar
°C
kJ/kg
MW
503,324
1507,2
270,8999813
413,7
2625,057573
562,66
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Evaporator-vertical wall < +72,4m
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Inlet enthalpy hInlet, wall1 = hOutlet, Spiral kJ/kg 2625,1
Outlet pressure bar 269,5999865
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Outlet temperature °C 422,3
Outlet enthalpy hOutlet, wall1 kJ/kg 2713,4
Useful heat vertical wall QEva1 = (hOutlet, wall1 - hInlet, wall1) * mFW MW 44,45
Evaporator vertical wall > +72,4m
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Inlet enthalpy hInlet, wall2= hOutlet, wall1 kJ/kg 2713,4
Outlet pressure, measured bar 266,2
Outlet temperature, measured °C 423,1
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Outlet enthalpy hOutlet, wall2 kJ/kg 2733,19
Useful heat vertical wall QEva2 = (hOutlet, wall2 - hInlet, wall2) * mFW MW 9,97
SH1 inlet to +72,4m

Inlet pressure, measured bar 266,2
Inlet temperature, measured °C 423,1
Inlet enthalpy
Outlet pressure
Outlet temperature
Outlet enthalpy
Useful heat SH1
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hInlet, SH1= hOutlet, wall2
hOutlet, SH1
QSH1 = (hOutlet, SH1 - hInlet, SH1) * mFW
kJ/kg
bar
°C
kJ/kg
MW
2733,19
265,6
424,6
2747,403232
7,15
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SH2
Steam flow SH2 Inlet mSH2 = mSpw + mAtt1, SH kg/s 516,646
SH2 Inlet pressure bar 255,2
SH2 Inlet temperature, measured °C 466,1
SH2 Inlet enthalpy hInlet, SH2 kJ/kg 3016,5
SH2 Outlet pressure bar 254,8
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SH2 Outlet temperature, measured °C 518,4

SH2 Outlet enthalpy hOutlet, SH3 kJ/kg 3226,2
SH3 Outlet pressure bar 249,5
Useful heat SH2 and SH3 QSH2 = mSH2*(hOutlet, SH2-hInlet,SH2) MW 108,31
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Totoal Useful heat HP Part QHD = QEco + QEva2 + QSH1 + QSH2-3 MW 240,22
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RH Section (RH1 and RH2)
CRH mass flow, calculated by measured values mCRH kg/s 447,9
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RH attemperator spray flow mAtt, RH kg/s 0
Main steam flow HRH mHRH = mCRH + mAtt, RH kg/s 447,9
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CRH pressure, measured bar 53
CRH temperature, measured °C 334,8
CRH enthalpy hInlet,RH1 kJ/kg 3019,7
HRH pressure, measured bar 51,1
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HRH temperature, measured °C 596
HRH enthalpy hOutlet,RH2 kJ/kg 3656,6
Spray water pressure, measured bar 70
Spray water temperature, measured °C 185
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Spray water enthalpy hAtt, RH kJ/kg 788,2
Totoal Useful heat RH Part QRH = mCRH * hOutlet,RH2 - mCRH * hInlet,RH1 - mAtt, RH * hAtt, RH MW 285,29
Heat transfer>72,4 m level Qconv = QHP + QRH MW 525,51
Heat transfer>72,4 m level Qconv = QHP + QRH MW 2747,40

Losses due to Radiation and Convection
Calculation acc. BS EN12952-15
Constant - C for hard coal boilers
The maximum useful heat output
Heat losses due to Radiation and Convection for total boiler
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Calculation of radiation and convective losse for convective area >
QN
QRC = C * QN^0,7
MW
MW
0,022
1554,698
3,772
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+72,4m
Split furnace and convective part
Surface of convective part > +72,4m Acon m² 2603,696
Surface of furnace part < +72,4m Afur m² 5672,732
Losses in confective part > +72,4m Qrad = AK / (AK+AFG) MW 1,187
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FG temperature cool down DT = Qconv - Qrad / (mFG * cpFG + mFA * cpAsh) K 568,64
FG temperature upstream air heater t1 = tFG,upsteam air heater °C 351,1
=>FEGT tFEGT = tFG, vor Luvo + DT °C 919,7
for cross check
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estimated FEGT for cp calculation t2 °C 911,4

Difference: Calulation Value and Estimation Value K -8,3
Seite: 7 von 8
Backwards-Calculation FEGT
Guarantee FEGT at 100% TMCR and Design Coal °C 911,4
calculated FEGT, uncorrected tFEGT = tFG, vor Luvo + DT °C 920
Correction by LHV of coal and mainsteam flow °C

LHV, measured kJ/kg 12755
main steam flow, measured °C 532,9
Correction by LHV and mainsteam flow ΔFEGT 0,4
Corrected FEGT at 100% TMCR and Design Coal °C 919,3
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Deviation to Garantee FEGT K 7,9
Design
Changes in FEGT = f(LHV and mainCoal
steamWorst
flow)Coal Best Coal
LHV (kJ/kg) 12755 10765 16506
130Boiler Load Main steam flow FEGT FEGT FEGT
110
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% kg/s °C °C °C
Deviation in FEGT [°C]
100% BMCR
90 588,9 942,7 941,3 956,5
70100% VWO 572,3 933,2 931,8 946,7
100% TMCR
50 532,9 911,4 909,9 927,9
30100% MCR 532,0 910,7 909,2 927,2
10 80% MCR 416,8 866,9 874,1 880
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60% MCR 308,6 814,9 811,9 828,4
-10
50% MCR 257,1 780,3 784,3 793,4
-30
-50
250,0 300,0 350,0 400,0 450,0 500,0 550,0
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Main steam flow [kg/s]
main steam >532,9 kg/s y = -8,71361901E-05x3 + 1,47302555E-01x2
Design Coal (12755 kJ/kg) - 8,34938943E+01x + 1,58492821E+04
main steam <532,9 kg/s y = 4,49150190E-04x2 - 8,06382866E-01x
+ 3,02575401E+02
y = -8,52278107E-05x3 + 1,44114993E-01x2
main steam >532,9 kg/s
Worst Coal (10765 kJ/kg) - 8,17225476E+01x + 1,55232399E+04
y = 5,27635779E-06x3 - 5,42534676E-03x2
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main steam <532,9 kg/s

+ 1,26293343E+00x + 7,13680656E+01
y = -1,50062209E-04x3 + 2,52220061E-01x2
main steam >532,9 kg/s - 1,41701582E+02x + 2,65797929E+04
Best Coal (16506 kJ/kg) y = -3,53857570E-06x3 + 4,74990895E-03x2
main steam <532,9 kg/s
- 2,51558871E+00x + 5,10953946E+02
LHV (kJ/kg) 12755 10765 16506
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Boiler Load Main steam flow FEGT FEGT FEGT

% kg/s °C °C °C
100% BMCR 588,9 -31,3 -29,9 -45,1
100% VWO 572,3 -21,8 -20,4 -35,3
100% TMCR 532,9 0 1,5 -16,5
100% MCR 532,0 0,7 2,2 -15,8
80% MCR 416,8 44,5 37,3 31,4
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60% MCR 308,6 96,5 99,5 83,0

ΔFEGT at measured main steam °C 0,4 2,2 -16,2
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0360-102-PVM-X-0191A N-100141
Steam Generator
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Appendix 5
Air Heater Performance Test
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Ap
EP
PE
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T.Bhavannarayana / BGRB 25.07.2019 AB
BGRB
Appendix 5, Page 1
0360-102-PVM-X-0191A N-100141
1. Introduction
The steam generators of Meja Power Station are designed as coal fired Once-Through Boiler in
order to supply following steam parameters at 100 % BMCR and firing of design coal:

ed
The steam generator furnace and the heating surface bundles are arranged as tower type boiler.
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The air-/flue gas system is designed as two pass system consisting of two FD-fans, two PA-fans,
four steam air heaters (two primary and two secondary), four flue gas air heaters (two primary
and two secondary), an electrostatic precipitator (ESP) and two ID-Fans.
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The coal firing system consists of 4 burner levels, directly operated double front firing system with
opposite burner arrangement, in total 32 burners. Four burners of each level are supplied by one
coal mill.
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2. Procedure:
Air heater performance test will be done along with Boiler Efficiency test at 100% TMCR load.
Hence all test procedures as applicable to Boiler Efficiency test are also applicable for Air heater
performance test.
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3. Data required:
Data required for air heater performance test is given in following table A.
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4. Conclusion:
The combined leakage should be less than or equal to 10 %.
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BGRB
Appendix 5, Page 2
0360-102-PVM-X-0191A N-100141
Table - A
Combined Leakage
Item Symbol Unit Data Source Value
Coal ultimate analysis (as
received)
Carbon C kg/kg Laboratory analysis
Hydrogen H kg/kg Laboratory analysis
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Oxygen O kg/kg Laboratory analysis
Nitrogen N kg/kg Laboratory analysis
Sulphur S kg/kg Laboratory analysis
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Moisture mf kg/kg Laboratory analysis
Ash a kg/kg Laboratory analysis
Moisture in Air
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Atmospheric pressure PA kPa measured
Ambient air temperature
0
(dry bulb) tw C measured
Ambient air temperature
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0
(wet bulb) td C measured
Relative humidity f % got from chart
Saturated vapour pressure pb kPa got from chart
Absolute humidity W mA' kg/kg 0.622 * f * pb / (100 * PA - f * pb)
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Carbon burned
Unburnt carbon in fly ash ucf % Laboratory analysis
Unburnt carbon in bottom
ash ucb % Laboratory analysis
Average unburned carbon
in ash uc % (90 * ucf + 10 * cub)/100
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Dry refuse per kg of as fired

coal wd'p' kg/kg a * 100 / (100 - uc)
Carbon burned per kg as
fired coal Cb kg/kg C - wd'p' * uc / 100
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Flue gas flow entering Air

Heater
Oxygen [O2]14 % measured (SAPH inlet)
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Theoretical dry air per kg [11.51 * Cb + 34.3 * (H -

as fired coal Aθ' kg/kg O/7.937)+4.335 * S
100 ([O2]14 / 100) * (31.32 * Cb +
Excess air [A'X]14 % 11.528 * S + 13.443 * N + 10.331 *
Aθ')/(Aθ' * (2.73 - 13.068 [O2]14 / 100)
Carbon dioxide [CO2]14 % got from boiler efficiency calculation
Carbon monoxide [CO]14 % measured (SAPH inlet)
BGRB
Appendix 5, Page 3
0360-102-PVM-X-0191A N-100141
Nitrogen [N2]14 % 100 - [O2]14 - [CO2]14 - [CO]14
Dry air per kg as fired coal [W'A]14 kg/kg
Dry flue gas per kg as fired

[W G']14 kg/kg
coal
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Moisture in flue gas per kg
kg/kg
as fired coal [W mG]14 8.936H+[W'A]14*W mA'+mf
Wet flue gas per kg as fired
kg/kg
coal [W G]14 [W G']14+ [W mG]14
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Flue gas flow leaving Air
Heater
Oxygen [O2]15 % measured (combined duct)
Excess air [A'X]15 %
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100 ([O2]15 / 100) * (31.32 * Cb +
11.528 * S + 13.443 * N + 10.331 *
Aθ')/(Aθ' * (2.73 - 13.068 [O2]15 / 100)
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Carbon dioxide [CO2]15 % got from boiler efficiency calculation
Carbon monoxide [CO]15 % measured (combined duct)
Nitrogen [N2]15 % 100 - [O2]15 - [CO2]15 - [CO]15
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Dry air per kg as fired coal [W'A]15 kg/kg
Dry flue gas per kg as fired

[W G']15 kg/kg
coal
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Moisture in flue gas per kg

kg/kg
as fired coal [W mG]15 8.936H+[W'A]15*W mA'+mf
Wet flue gas per kg as fired
kg/kg
coal [W G]15 [W G']15+ [W mG]15
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Air Heater leakage AL % ([W G]15-[W G]14)/[W G]14*100

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BGRB
Appendix 5, Page 4
0360-102-PVM-X-0191A N-100141
Steam Generator
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Appendix 6
Minimum steam generator load without supplementary oil firing
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EP
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Appendix 6, Page 1
0360-102-PVM-X-0191A N-100141
1. Introduction
The steam generators of Meja Power Station are designed as coal fired Once-Through
Boiler in order to supply following steam parameters at 100 % BMCR and firing of design
coal:

ed
The steam generator furnace and the heating surface bundles are arranged as tower type
ov
boiler.
The air-/flue gas system is designed as two pass system consisting of two FD-fans, two
PA-fans, four steam air heaters (two primary and two secondary), four flue gas air
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heaters (two primary and two secondary), an electrostatic precipitator (ESP) and two ID-
Fans.
The coal firing system consists of 4 burner levels, directly operated double front firing
Ap
system with opposite burner arrangement, in total 32 burners. Four burners of each level
are supplied by one coal mill.
EP
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Appendix 6, Page 2
0360-102-PVM-X-0191A N-100141
2. Minimum steam generator load without supplementary oil firing
The steam generator of Meja is designed to provide 30 % (of BMCR = MNCR) load
without using supplementary oil firing within the steady load operation for the entire range
of the specified coal properties, with any combination of mills/ adjacent mills (to
Employer’s choice) in service. The guarantee item is achieved for a HP steam mass flow
at Superheater 3 outlet of less or equal 636 T/hr (mean value) during testing phase.
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2.1 Power Block Operation
Power Block Operation is performed according to the required steam generator load
requirements. The load setpoint of power block for MNCR will be operated in a suitable
way in order to verify a test average HP steam mass flow of 636 T/hr (2120 T/hr * 30 %).
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Therefore the actual power block load may differ slightly from boiler load.
Steady load operation, allowed operation conditions and the start time of test run must be
agreed by the responsible test engineers of the concerned parties.
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The power block should be operated under full automatic control. No process factors or
logic states are simulated, except from those, who does not affect the guaranteed process
cycle. The exceptions require the amicable agreement of the responsible test engineers.
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2.2 Steam Generator Operation
The load reduction is enforced by decrease of power block load set point. Within the load
decrease, the boiler control switches automatically to three or four mill operation, through
shut down according to mill and burner operational range.
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When under-run the Benson point the boiler circulation pump is switched automatically
into operation to assure a minimum evaporator mass flow. The auxiliary boilers are not
required to be in operation even for under-run of 30 % BMCR. The auxiliary steam is
extracted from the cold reheat.
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The MNCR operation is reached, if HP steam mass flow is less or equal to 636 T/hr. That
followed a steady load at MNCR conditions is tested for one hour duration.
The coal used for the equipment test run should be of sufficient steady quality in order to
minimize fluctuations of load and further testing parameters during the test run. For
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maintenance of steady state operation no sootblowing operation is performed during the

data acquisition period.
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Appendix 6, Page 3
0360-102-PVM-X-0191A N-100141
2.3 Duration of Test run
The steady load operation within MNCR operation is proposed to duration of 1 hour
preferable during the night. The test is divided in a data acquisition phase of at least 10
minutes to check whether the MNCR load is met. The concerned parties may agree a
deviating time duration, in case of significant reasons.
3. DCS and Test Instruments
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For test evaluation the following plant instruments are used, in order to judge whether the
MNCR load is met:
LAB75 FF904 Feedwater Mass Flow to Economizer
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LAE10 FF903 HP Spray Water Mass Flow
HAG30 FF902 HP Recirculation Mass Flow
The adaption of the design calculations to the DCS settings have to be checked prior to
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testing.
4. Calculation of Test Results

Ap
Following HP steam balancing is applied for determination of HP steam mass flow at
Superheater 3 outlet:
m HPStm  m FWEco  m HPSpr  m BCP

EP
Where
mHPStm = HP Steam Mass Flow
mFWEco = Feedwater Mass Flow to Economizer (LAB75 FF904)
mHPSpr = HP Spray Water Mass Flow (LAE10 FF903)
mBCP = HP Recirculation Mass Flow (HAG30 FF902)
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Necessary mass flows for balancing are measured with primary devices according to
ISO 5167 and associated operational measuring equipment.
For calculation purposes at least 30 DCS single values (1 minute interval) for each mass
flow of HP steam balancing are used to calculate a test average mean value. The
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Minimum Load Test is successfully completed, if the mean value of HP steam mass flow
is equal or lower than 636 T/hr.
Unaccounted losses of steam generator are negligible for testing purpose and will not be
considered in the HP steam balancing.
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5. Assessment criterion
The following criterion will be assessed:
• The HP-steam mass flow (balanced) is equal or lower 636 T/hr for a time span of at
least 30 minutes with coal fire in operation only.

Appendix 6, Page 4
0360-102-PVM-X-0191A N-100141
6. Accompanying process documentation
Accompanying process documentation will be established using the DCS facilities for
archive data trends and archive data logging.
Trend diagrams will be used as overview concerning the conduct of test operation and in
order to judge permissible fluctuations. They are recommended to be restricted to the
following main data:
• Operating Parameters of active MPS-Mills including Feeders
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• Flame monitors (IR) of active burner levels
• Feedwater-, HP Spray Water and Recirculation Mass Flow
• Coal Consumption as Sum of Belt Scale Indications
• Oil consumption as Sum
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• Feedwater Pressure and Temperature
• HP Steam Pressure and Temperature
• Cold Reheat Steam Pressure and Temperature
• Hot Reheat Steam Pressure and Temperature
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DCS trend diagrams will be witnessed by the responsible test engineers (BGR).
Objections and/or comments to operation conditions may be entered as remark to the test
operation protocol, but this should not affect the witness of test documents.
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The process parameters to be recorded for the minimum load test are listed within Table 1
and should be configured in advance of the test in agreement with NTPC. The print outs
with the action of the operators will be added to the test report.
EP
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Appendix 6, Page 5
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Appendix 7
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Appendix 7
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EP
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Appendix 7
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EP
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Appendix 7
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EP
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Appendix 7
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Appendix 7
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Appendix 7
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Appendix 7
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Appendix 7
Measuring and Testing CC3
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Report Performance Test Procedure Steam Generator Meja Duisburg, 25.07.2019
Doc.-No. N-100141-0-092-NE01-00002- AB / 0360-102-PVM-X-0191A Appendix, Table 1
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Performance Test Procedure Steam Generator Seite 1 von 7
Measuring Point List of Powerplant Meja
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Editor: Mr B. van de Sandt, HPE-CC3
MP Measuring Component Measuring device Measuring range Comment
No. Designation Alphanumerical Stage Level Type Model Alm. Ch. No. Index Supply Instal. electrical physical
Measuring Points Steam Generator (Feedwater / Superheater)
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D1021 FW upstream Eco Inlet Temperature 1 0LAB75 CT901 O °C Info, Cross-Check
D1010 FW upstream Eco Inlet Pressure 1 0LAB75 CP901 O kg/cm² Info, Cross-Check
D1001 FW to Boiler Flow 1 0LAB75 CF904 O t/hr Cross-Check, J
1021 FW at Eco Inlet Temperature 1 0LAB75 CT401 TC Type K T 250 350 °C A, F, G
1010 FW to Boiler Pressure 1 0LAB75 CP001 Druck-MU T 0 400 kg/cm² A, E
Ap
1001 FW to Boiler Flow 1 0LAB75 CF001 Diff.-Gauge T 0 490 mbar A, F
1011 FW at Eco Inlet Pressure 1 0HAC10 CP001 Druck-MU T 0 400 kg/cm² E
D1011 FW at Eco Inlet Pressure 1 0HAC10 CP001 O kg/cm² Info, Cross-Check
D1008 FW at Circulation Pump Flow 1 0HAG30 FF903 O t/hr J
D1034 FW at NPSH Flow 1 0LAE05 CF001 O t/hr Info, Cross-Check
1012 HP Spray Water Pressure 1 0LAE10 CP001 Druck-MU T 0 400 kg/cm² A
D1012 HP Spray Water Pressure 1 0LAE10 CP901 Druck-MU O kg/cm² A
D1022 HP Spray Water
1002 HP Spray Water
Temperature
Flow
Flow
Flow
Flow
Flow
Flow
1 0LAE10 CT901
1 0LAE10 CF001
1 0LAE10 CF001
1 0LAE41 FF901
1 0LAE42 FF901
1 0LAE61 FF901
1 0LAE62 FF901
EP Diff.-Gauge
O
O
O
O
O
O
T 0 490
°C
mbar
t/hr
t/hr
t/hr
t/hr
t/hr
Info, Cross-Check
A, F
Cross-Check, J
Info, Cross-Check
Info, Cross-Check
Info, Cross-Check
Info, Cross-Check
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1121 Line 1 HP-Steam Temperature 1 0LBA10 CT501 TC Type K T 450 650 °C A, N
1122 Line 2 HP-Steam Temperature 1 0LBA20 CT501 TC Type K T 450 650 °C A, N
D1023 Line 1 HP-Steam Temperature 1 0LBA10 CT001 O °C M
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D1013 Line 1 HP-Steam Pressure 1 0LBA10 CP002 O kg/cm² M
D1014 Line 2 HP-Steam Pressure 1 0LBA20 CP002 O kg/cm² M
1111 HP-Steam at SH3 Outlet Pressure 1 0HAH80 CP801 Gauge T 0 400 kg/cm² Pressure Loss HP
D1009 HP-Steam Flow 1 0HAH40 FF901 calc. O t/hr E, N, K
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Remark regarding measuring device index: O = Operational Measurement; T = Test Measurement.

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Measuring Points Steam Generator (Feedwater / Superheater)
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D1015 SH1-Steam Left Inlet Pressure 1 0HAH11 CP001 O kg/cm² M
D1016 SH1-Steam Right Inlet Pressure 1 0HAH12 CP001 O kg/cm²
D1029 SH1-Steam Left Inlet Temperature 1 0HAH11 CT901 O °C
D1030 SH1-Steam Right Inlet Temperature 1 0HAH12 CT901 O °C
D1031 SH1-Steam Left Outlet Temperature 1 0HAH41 CT901 O °C
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D1032 SH1-Steam Right Outlet Temperature 1 0HAH42 CT901 O °C
D1032 SH3-Steam Left Inlet Temperature 1 0HAH61 CT903 O °C
D1033 SH3-Steam Right Inlet Temperature 1 0HAH62 CT903 O °C
Measuring Points Steam Generator (Reheater)
1221 Line 1 CRH Steam Temperature 1 0LBC40 CT501 TC Type K T 250 400 °C A, F, G
1222 Line 2 CRH Steam Temperature 1 0LBC50 CT501 TC Type K T 250 400 °C A, F, G
1213 Line 1 CRH Steam at System TP Pressure 1 0LBC40 CP004 Gauge O 0 100 kg/cm² A
D1213 Line 1 CRH Steam at System TP Pressure
1214 Line 2 CRH Steam at System TP Pressure
D1214 Line 2 CRH Steam at System TP Pressure
1211 Line 1 CRH Steam at RH Inlet
1212 Line 2 CRH Steam at RH Inlet
CRH Steam
1215 RH Spray Water
Pressure
Pressure
Flow
Pressure
1 0LBC40 CP004
1 0LBC50 CP004
1 0LBC50 CP004
1 0HAJ11 CP801
1 0HAJ12 CP801
1 calculated
1 0LAF20 CP001
EP Gauge
Gauge
Gauge
Gauge
Gauge
calc. by turbine testing
Gauge
O
O
T
T
T
T
0
0
0
0
100
100
100
100
kg/cm²
kg/cm²
kg/cm²
kg/cm²
kg/cm²
kg/cm²
Info, Cross-Check
A
Info, Cross-Check
Info, Cross-Check
Info, Cross-Check
A, F, G
A, D
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D1215 RH Spray Water Pressure 1 0LAF20 CP001 Gauge O kg/cm² A, D
1223 RH Spray Water Temperature 1 0LAF20 CT801 TC Type K T 100 250 °C A, D
D1223 RH Spray Water Temperature 1 0LAF20 CT001 O °C A
1201 RH Spray Water Flow 1 0LAF20 CF001 Diff.-Gauge T 0 490 mbar A, D, G
D1202 RH Spray Water Flow 1 0LAF20 FF901 O t/hr A
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1224 Line 1 RH-Steam at System TP Temperature 1 0LBB10 CT501 TC Type K T 550 650 °C A
1225 Line 2 RH-Steam at System TP Temperature 1 0LBB20 CT501 TC Type K T 550 650 °C A
D1224 Line 1 RH-Steam at System TP Temperature 1 0LBB10 CT901 O °C A, N
D1225 Line 2 RH-Steam at System TP Temperature 1 0LBB20 CT901 O °C A, N
1216 Line 1 RH-Steam at RH2 Outlet Pressure 1 HAJ41CP801 Gauge T 0 100 kg/cm² Info, Cross-Check
1217 Line 2 RH-Steam at RH2 Outlet Pressure
C
1 HAJ42CP801 Gauge T 0 100 kg/cm² Info, Cross-Check

1218 Line 1 RH-Steam at System TP Pressure 1 0LBB10 CP501 Gauge T 0 100 kg/cm² A
1219 Line 2 RH-Steam at System TP Pressure 1 0LBB20 CP501 Gauge T 0 100 kg/cm² A
D1218 Line 1 RH-Steam at System TP Pressure 1 0LBB10 CP001 O kg/cm² A
D1219 Line 2 RH-Steam at System TP Pressure 1 0LBB20 CP001 O kg/cm² A
d
e
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Measuring Points Steam Generator (Air System)
pr
511 Barometric Pressure Outside 1 0.0 m outside Barometer T 900 1100 mbar ref value, A, I
521 Ambient Air Outside Temperature 1 0.0 m outside Humidity-Sensor T 0 50 °C ref value, A, I
522 Ambient Air Outside Humidity 1 0.0 m outside Humidity-Sensor T 0 100 %H ref value, A, F, G, I
D611 Pri. Air to Mill 10 Flow 1 0HFE15 FF904 - O t/h Info, Cross-Check
Ap
EP
PE
en
C

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Measuring Points Steam Generator (Flue Gas System)
pr
759 FG upstr. ESP, common duct Temperature 1 0HNA16 CA801-806 TC Type K T 80 230 °C A
760 FG upstr. ESP, common duct Temperature 1 0HNA26 CA801-806 TC Type K T 80 230 °C A
D761 FG upstr. ESP, common duct Temperature 1 0HNA16 CT001-003 O Info, Cross-Check
D762 FG upstr. ESP, common duct Temperature 1 0HNA26 CT001-003 O Info, Cross-Check
771 FG upstr. PAH 1 O2,dry 1 0HNA12 CT801-804 O2 Analyser T 0 30 Vol %, dry Info, Cross-Check
Ap
772 FG upstr. PAH 2 O2,dry 1 0HNA22 CT801-804 O2 Analyser T 0 30 Vol %, dry Info, Cross-Check
773 FG upstr. SAH 1 O2,dry 1 0HNA13 CT801-804 O2 Analyser T 0 30 Vol %, dry I
774 FG upstr. SAH 2 O2,dry 1 0HNA23 CT801-804 O2 Analyser T 0 30 Vol %, dry I
D773 FG upstr. SAH 1 O2,wet 1 0HNA13 CA001-003 O Info, Cross-Check
D774 FG upstr. SAH 2 O2,wet 1 0HNA23 CA001-003 O Info, Cross-Check
779 FG upstr. ESP, common duct O2,dry 1 0HNA16 CA801-806 O2 Analyser T 0 30 Vol %, dry A, I
780 FG upstr. ESP, common duct O2,dry 1 0HNA26 CA801-806 O2 Analyser T 0 30 Vol %, dry A, I
785a FG upstr. ESP, common duct
785b FG upstr. ESP, common duct
786a FG upstr. ESP, common duct
786b FG upstr. ESP, common duct
787 FG upstr. SAH 1
788 FG upstr. SAH 2
789 FG at stack CEMS
CO
NOx,dry
CO
NOx,dry
CO
CO
NOx,dry
EP
1 0HNA16 CA801-806
1 0HNA16 CA801-806
1 0HNA26 CA801-806
1 0HNA26 CA801-806
1 0HNA13 CT801-804
1 0HNA23 CT801-804
1 0HNE10
CO-Analyser
NO-Analyser
CO-Analyser
NO-Analyser
CO-Analyser
CO-Analyser
NO-Analyser
T
T
T
T
T
T
T
0 1000 ppm, dry A, I
0
0
500 ppm, dry C
0 1000 ppm, dry A, I
500 ppm, dry C
0 1000 ppm, dry I
0 1000 ppm, dry I
0 500 ppm, dry C
PE
790 FG at stack CEMS O2,dry 1 0HNE10 O2 Analyser T 0 30 Vol %, dry C
D789 FG at stack CEMS NOx,dry 1 0HNE10 CA001 O Info, Cross-Check
D791 FG at stack CEMS SOx 1 0HNE10 CA002 O Info, Cross-Check
D792 FG at stack CEMS CO 1 0HNE10 CA004 O Info, Cross-Check
D793 FG at stack CEMS Mercury 1 0HNE10 CA005 O Info, Cross-Check
D799 Furnace Acoustic Pyrometer 1-10 Temperature 1 0HBK01 CT003-010 O M
en
C

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Measuring Points Steam Generator (Pulverized Fuel)
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871 Pulverized Fuel Mill 10 Sampling 1 0HHE11-14 CA801-802 lab analysis T H
Ap
Measuring Points Steam Generator (Raw Coal)
D801 Coal Feeder Mill 10 Flow 1 0HFB10 FF901B feeder scale O t/h H
D804 Coal Feeder Mill 40
821 Coal Feeder Mill 10
822 Coal Feeder Mill 20
Flow
Flow
Flow
Flow
Flow
Temperature
Temperature
EP
1 0HFB40 FF901B
1 0HFB50 FF901B
1 0HFB60 FF901B
1 0HFB70 FF901B
1 0HFB80 FF901B
1 0HFB10 CQ801
1 0HFB20 CQ801
feeder scale
feeder scale
feeder scale
feeder scale
feeder scale
TC Type K
TC Type K
O
O
O
O
O
T
T
0
0
60
60
t/h
t/h
t/h
t/h
t/h
°C
°C
H
H
H
H
H
A
A
PE
823 Coal Feeder Mill 30 Temperature 1 0HFB30 CQ801 TC Type K T 0 60 °C A
841 Coal Feeder Mill 10 Sampling 1 0HFB10 CQ801 lab analysis T A, B, G, H , I
en

847 Coal Feeder Mill 70 Sampling
C
1 0HFB70 CQ801 lab analysis T A, B, G, H , I


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Measuring Points Steam Generator (Oil Supply)
pr
D881 Light Diesel Oil Flow 1 0HJF01 CF901 O t/h J
D882 Heavy Fuel Oil Flow 1 0HHF01 FF901 O t/h J
Measuring Points Steam Generator (Bottom Ash and PJFF Ash)
850 Bottom Ash Extraction Sampling - lab analysis T A, I
855 ESP Ash Extraction Line Sampling - lab analysis T A, I
Ap
861 Mill Rejects Mill 10 Sampling - lab analysis T A (optional)
868 Mill Rejects Mill 80
869 Mill Reject Silo
Measuring Points Unit

D900 Generator Output Gross
Sampling
Sampling
Load Output
-
-
1 0BAA20 CE901
EP lab analysis
lab analysis
O
T
T
MW
A (optional)
A
L
PE
Measuring Points Steam Generator (Electrical Consumer)
901a-h Mills Active Power to be completed ampere meter T kW B
902a-b PA Fans Active Power to be completed ampere meter T kW B
903a-b FD Fans Active Power to be completed ampere meter T kW B
904a-b ID Fans Active Power to be completed ampere meter T kW B
905a-d Air Heaters Active Power to be completed ampere meter T kW B
906a-h Coal Feeders Active Power to be completed ampere meter T kW B
en
907a-b Seal Air Fans Active Power to be completed ampere meter T kW B

908 Scanner air fans Active Power to be completed ampere meter T kW B
909 DM cooling water pumps Active Power to be completed ampere meter T kW B
910 Scanner air fans Active Power to be completed ampere meter T kW B
911 Compressed air system Active Power to be completed ampere meter T kW B
912 Compressor Mill Reject System Active Power
C
to be completed ampere meter T kW B

913 Lube Oil / Hydaulic Oil Pumps Active Power to be completed ampere meter T kW B

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Comments
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Key-Legend for comment colum CAT classification
A SG Heat Balance CAT - I
B Aux Power Consumption CAT - I
C Max total NOx CAT - II
Ap
D RH Spray water flow CAT - I
E FW Pressure CAT - I
F Steam generating capacity CAT - I
G Reheater attemperation spray water flow CAT - I
H Mill capacity and fineness CAT - III
I Combined air heater air - leakage CAT - III
J Minimum steam generator load CAT - III
K
L
M
N
Run back capabilaties
Demonstration of boiler operation
Maximum Furnace exit gas temperature
Maximum steam temperature imbalance
CAT - III
CAT - III
CAT - III
CAT - III EP
PE
en
C
0360-102-PVM-X-0191A N-100141
Measuring Locations at Steam Generator Water-/Steam Cycle (basic configuration)
ECO2
ed
1021 1001
1011 ECO1 1010
1211
1212
ZUE1
ov
UE2
pr
ZUE2
1111 1217 1216

1121 1122
Ap
UE3
UE1.2
EP
1022
1213 1012
1221 1002
1201
1219 1214
1225 1222
PE
1218
1215 1224
1223
Feedwater
Hot IP Steam
Hot IP Steam
Hot HP Steam
Hot HP Steam
Cold IP Steam
RH Spray Water
Cold IP Steam
en
C
Left Side Wall Right Side Wall
Flow rate
Pressure
Temperature
Diagram 1: Measuring Locations at Steam Generator Water-/Steam Cycle (basic configuration)

B. van de Sandt / CC3 F.P. Schiffer / CC3 25.07.2019 AB
Measuring Locations at Steam Generator Air-, Flue Gas-, Coal- and Ash Discharge System (basic configuration)
C

651 601 M 911
en
655 851
M 913
751 771 775 755 701
848 844 843 847 781

779
Doc-No.:
828 824 823 827 PA 785 759

PE
753 773 853 777 757 703
783
846 845

842 841
F.P. Schiffer / CC3

826 822 821 825 657 653 603
SA
EP
658 854 654 604
511 521 522

754 774 778 758 704
784
0360-102-PVM-X-0191A
780
25.07.2019
Datum / Date:
786 760
SA
N-100141-0-092-NE01-00002
752 772 852 776 756 702

Ap
782 855
M 914
656
AB
PA
M M M M 652 602 M 912
Rev.:
906 902 901 905
pr
616 866 612 862 861 611 865 615
876 872 871 875
M M M
M M
801 850 832
908 904 831 903 907
ov
618 868 614 864 863 613 867 617 FD intake outside Flow rate
878 874 873 877
xxx
required measurement Pressure
perf. test boiler

N-100141
Temperature
optional measurement perf.

Meja All Units
xxx test boiler, required for air Quality

ed
heater leackage test
Diagram 2: Measuring Locations at Steam Generator Air-, Flue Gas-, Coal- and Ash Discharge System
Job-No.
N-100131 / N-100141 Compliance Sheet
Codeword for
SOLAPUR / MEJA
Performance Test Procedure - Performance Guarantees acc. to
Doc.-Title
Cat-III
HPE-Doc.-No. N-100141-0-092-NE01-00002
NTPC-Doc.-No. 0360-102-PVM-X-0191A
ed
Item NTPC-Comments HPE-Comments
Meja – Alignment Solapur/Meja Procedure – 14.06.2019
1. Implementation of issues which have been
ov
mutual agreed between NTPC/BGR/HPE
according NTPC/BGR/HPE-meeting, dated
22.-25.05.2019 in Chennai.
Meja – Transmittal comments dated 17.07.2019
Comments offered in the doc need to be Noted.
pr
2.
addressed and revised doc may be
submitted for approval at the earliest.
Meja – Marked comments dated 17.07.2019
Ap
Page 3: Correction methodology furnished in the
3.
Reference of MOM: Not required previous revision (Nil Rev) of the document is
now revised based on the discussion between
BGR, HPE & NTPC at HPE office, Chennai from
22.05.2019 to 25.05.2019.
Reference to previous discussion/document is to
be maintained to track the revisions.
EP
Page 4: Values are updated.

4.
Mill capacity test: Capacity test at rated
fineness as per clause 8.02.00 (i), Sub-Section
VI, Part-A, Section VI. At 100 % mill loading
with new set of grinding elements and 90% for
PE
mills with grinding elements in worn out

condition
According to mill capacity guarantee of

Appendix 9, Functional Guarantees,
Attachment 8B, the coal pulverizers are
en
designed for mill capacities of 100 t/hr for

design coal at rated fineness and a new set of
grinding elements. At near worn out condition
of the grinding elements mill capacities of 95
t/hr for design coal are guaranteed.
C
Correct values to be put as in Tech Specs.

This can cot be modified.
grinding elements in worn out condition
Ersteller/prepared by Telefon/Phone Prüfer/checked by Telefon/Phone Datum/Date
Seite/Page 1 ÷ 2
Dok.-Nr./Doc.-No. 0360-102-PVM-X-0191A
Page 4: Run back capability test & Rate of Removed on request of NTPC
5.
change of load test:
All C&I issues to be separately taken up with
OS C&I / PE C&I
Page 11: As per technical specification, Section VI, Part
6.
Background noise correction: what's the basis A, Sub Section-VI, Functional Guarantees,
and conditions for applicability. Provide details. clause 8.01.00, corrections for background noise
it is not being considered for other NTPC shall be considered.
Stations. It can be removed.
Based on our experience with other projects, we
have considered 7 dB(A) for Background noise
correction.
Page 14: Mill capacity test: This point has been discussed in the meeting
ed
7.
between BGR, HPE & NTPC at HPE office,
a) Full (rated load 660 MW). Chennai from 22.05.2019 to 25.05.2019 and it
was agreed (point 4) that HPE will explore the
b) Selection of Mill is as per NTPC's possibility of increase in heat input per burner
ov
choice. over and above 110% of the value specified in
c) All sampling at steady full load the technical specification.
capacity
d) Near to design coal Clause 4.1.2. Mill Capacity Test is revised to
e) The corrected mill capacity should indicate: 100 t/h Mill capacity will be
pr
achieve guarantee value to ensure demonstrated for 10 minutes.
compliance
Page 25: Coal Pulveriser capacity at rated Values are updated.
8.
fineness:
Ap
According to mill capacity guarantee of
Appendix 9, Functional Guarantees,
Attachment 8B, the coal pulverizers are
designed for mill capacities of 100 t/hr for
design coal at rated fineness and a new set of
grinding elements. At near worn out condition
of the grinding
EP
elements mill capacities of 95 t/hr for design

coal are guaranteed.
Page 32: Permanent access and safe platforms are

9.
2.1 Measurement set-up of a multipoint probe: already available.
Proper permanent access and safe platforms
PE
to be made by the vendor for sampling and

conducting the PG test and subsequent
performance tests of mills.
Page 75: Removed
10.
Run Back Capabilities: It is to be taken up with
en
PE C&I / OS - C&I
C
Seite/Page 2 ÷ 2
Special Annexure to Cat III
The points mentioned underneath will supersede the points stated in the main text of this document. This
is required to take care of the fact that the proposed procedure submitted by the vendor do not comply
the contract conditions and code even after repeated comments by NTPC and subsequent revisions.
1. Pages 4-5: Mill capacity test will be conducted at desired capacity (as mentioned in the guarantee
clause; rated capacity under design coal 100 t/h) for the required duration ( about 2 hours for PF
sampling from all pipes by following the methods outlined the test code)
Functional Guarantees, Attachment 8B, the coal pulverizers are designed for mill capacities of 100 t/hr
ed
for design coal at rated fineness and a new set of grinding elements. At near worn out condition of the
grinding elements mill capacities of 95 t/hr for design coal are guaranteed.
ov
2. Page 11: The correction for Background noise as 7dB (A) NOT applicable as it is not in line with any
pr
code / standard. The corrected noise levels will be determined after applying suitable corrections (as
per IS: 12065 – 1987.

Ap
EP
PE
en
C

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Coach Page 1 of 2

BGR BOILERS PRIVATE LIMITED

TITLE: Steam Generator Performance Test Procedure –

Performance Guarantees acc. to Cat-III

SIZE SCALE NTPC DOCUMENT NO. REV.

NAME SIGN DATE

APPROVED BY F. P. Schiffer signed by F. P. Schiffer 01.03.2019

per IS: 12065 – 1987.

Ersteller / Prepared by Geprüft / Checked by: Datum /Date: Rev.:

5. Correction Diagrams for Mill capacity test .................................................................................. 18

Ersteller / Prepared by Geprüft / Checked by: Datum /Date: Rev.:

HP-Steam Generation 2120 T/hr

Ersteller / Prepared by Geprüft / Checked by: Datum /Date: Rev.:

2.1 Scope of Guarantees

Performance Property Guarantee

specified design coal 1040 °C

Ersteller / Prepared by Geprüft / Checked by: Datum /Date: Rev.:

Ersteller / Prepared by Geprüft / Checked by: Datum /Date: Rev.:

2.2 Guarantee reference condition

Furthermore design coal should be fired during the remaining test.

105 % TMCR (VWO) 100 % TMCR 100 % BMCR

Steam flow at superheater outlet (acc. 0360-102-PVM-Y-0002, Design Coal)

2060.2 T/hr. 1918.6 T/hr. 2120 T/hr

 Steam flow to reheater (acc. 0360-102-PVM-Y-0002, Design Coal)

105 % TMCR (VWO) 100 % TMCR 100 % BMCR

1729.7 T/hr. 1612.6 T/hr. 1688,6 T/hr

 Feedwater temperature at Economizer inlet (acc. 0360-102-PVM-Y-0002, Design

105 % TMCR (VWO) 100 % TMCR 100 % BMCR

293.1 °C 290 °C 293.8 °C

Ersteller / Prepared by Geprüft / Checked by: Datum /Date: Rev.:

 Following permissible limits regarding coal composition have to be maintained:

GCV 3200 kCal/kg 2800 kCal/kg 4000 kCal/kg

Elemental Hydrogen 3.00 % wgt 2.80 % wgt 3.20 % wgt

Elemental Nitrogen 0.80 % wgt 0.70 % wgt 1.00 % wgt

Ersteller / Prepared by Geprüft / Checked by: Datum /Date: Rev.:

3. Operation Conditions and General Measuring

3.1 Operation Conditions during Testing

operation, which is dedicated to 1918,6 T/hr HP steam generation.

Ersteller / Prepared by Geprüft / Checked by: Datum /Date: Rev.:

3.2 Test Measurements and Measuring Methods

3.2.2 Air-/Flue Gas Measurements (Grid Measurements)

Ersteller / Prepared by Geprüft / Checked by: Datum /Date: Rev.:

the test run in order to witness the calibration also.

Ersteller / Prepared by Geprüft / Checked by: Datum /Date: Rev.:

4. Guarantees according to Category-III

4.1. Commissioning Tests with Special Equipment/Instruments

The noise level shall be measured in “A” scale in decibels.

Corrected Noise level LpA = L’pA – K1

Ersteller / Prepared by Geprüft / Checked by: Datum /Date: Rev.:

4.1.2 Coal Pulverizer Capacity at Rated Fineness

● one spare sample, possibly for independent laboratory, to be stored at employer

Ersteller / Prepared by Geprüft / Checked by: Datum /Date: Rev.:

Proximate Analysis International standard utilized by HPE

Mill Grinding Fineness

Mill Capacity Tests

According to mill capacity guarantee of Appendix 9, Functional Guarantees, Attachment

of worst in adequacy range coal.

Ersteller / Prepared by Geprüft / Checked by: Datum /Date: Rev.:

Mill, boiler operation and Preconditions for capacity test: