NationalCapital Power Station

4 x 210 MW UNIT (THERMAL)

National Thermal Power Corporation Ltd.

National Capital Power Station

210 MW UNIT

National Thermal Power Corporation Ltd.

PREFACE

Technical Diary for NTPC-Dadri, 4x210 MW Coal Unitswas first compiled by Operation Department after commissioningof first unit. Thereafter, many modification and improvementshave been done in all areas of Power Station to improve safetyof men & machine for enhancing the reliability and performanceof plant systems. This new edition of Technical Diary incorpo-rates all those changes, addition of new systems and sugges-tions from users.

Due care has been taken during compilation of this new ver-sion, however, errors & omissions if observed may please bebrought out to our notice.

(R.K. GAUR)Add. General Manager (O&M-Coal)

FOREWORD

In the competitive knowledge based enviornment, it is

essential to make available correct information in readily avail-able format for quick and correct decision making.

Technical Diary for 4 x 210 MW Coal Units, which was firstcompiled after commissioning of first unit has greatly helped inright decision making and improving station performance sig-nificantly. I highly appreciate the efforts y O & M staff to up-grade the technical diary in view of several modifications andincorporation of new systems.

(T.V. RAO)(General Manager)

ACKNOWLEDGEMENT

I am happy to learn that the a new updated version of

Technical Diary for 4x210 MW Dadri-Coal is being brought outby the Operation Department.

For efficient, reliable and safe operation of the units, we areoften required to refer to the plant data like specified param-eters, set point values of protection and interlocks and otherrelevant details. Efforts have been made to cover all the tech-nical aspects of 4x210 MW Units in this Technical Diary. I amsure that it will also serve as a reference handbook for check-ing the design data required for solving the day-to-day plantproblems.

I congratulate the Operation team for bringing out the updatedversion of Technical Diary.

(SANJEEV KISHORE)Dy. General Manager (O&M-Coal)

CONTENTSSECTION DESCRIPTION PAGE NO.

1 INTRODUCTION 1

1. BOILER AND AUXILIA RIES1.1 GENERAL SPECIFICATION 21.2 FURNACE SPECIFICATION 21.3 WATER WALLS 31.4 DRUM 41.5 SUPERHEATER 51.6 REHEATER 51.7 SUPERHEATER AND REHEATER 6

TEMPERATURE CONTROL1.8 ECONOMISER 81.9 BOILER MOUNTING AND FITTINGS 91.10 REGENERATIVE AND STEAM COIL 10

AIR PREHEATER1.11 ID FAN 121.12 FD FAN 141.13 PA FAN 151.14 GR FAN 161.15 FUEL PREPARATION AND FIRING 18

SYSTEM1.16 ELECTROSTATIC PRECIPITATOR 221.17 BOILER PREDICTED PERFORMANCE 261.18 SCANNER AIR FAN 341.19 SOOT BLOWER 341.20 FURNACE TEMPERATURE PROBE 341.21 BOILER CHEMICAL DOZING 351.22 PRESSURE REDUCING AND 35

DESUPERHEATING STATION1.23 BLOW DOWN VESSEL 351.24 PIPLE LINES - M.S., C.R.H., H.R.H., 361.25 CHIMNEY 361.26 BOILER AND AUX. COOLING 36

WATER FLOW1.27 RECOMMENDED FEED WATER AND 37

BOILER WATER IIMITS

2. TURBINE AND AUXILIARIES2.1 TECHNICAL SPECIFICATION- 38

MAIN TURBINE2.2 TURBINE LUB OIL SYSTEM 432.3 VACCUM SYSTEMS 462.4 CONDENSATE SYSTEM 482.5 FEED WATER SYSTEM 512.6 PREDICTED PERFORMANCE 57

OF TURBINE2.7 EQUIPMENT COOLING WATER 59

SYSTEM2.8 HP/LP BYPASS SYSTEM 602.9 HP AND LP FLASH TANKS 612.10 L.P. DOZING SYSTEM 612.11 TURBINE AND AUX. COOLING 62

WATER FLOW

3. GENERATOR AND AUXILIARIES31. GENERATOR TECHNICAL 64

SPECIFICATION3.2 DESIGN AND CONSTRUCTION 65

FEATURES3.3 GENEARATOR GAS SYSTEM 673.4 STATOR WATER SYSTEM 683.5 SEAL OIL SYSTEM 703.6 SPECIFICATION OF TRANSFORMER 713.7 HT MOTORS 773.8 BATTERY AND BATTERY CHARGER 77

4. OFFSITE AUXILIARIES4.1 RAW WATER SYSTEM 804.2 WATER TREATMENT PLANT 814.2.1 PRETREATMENT PLANT 814.2.2 DM PLANT 874.2.3 WATER SOFTENING PLANT 974.3 CIRCULATING WATER SYSTEM 1024.4 AIR COMPRESOR PLANT 1064.5 FUEL OIL HANDLING PLANT 1084.6 COAL TRANSPORTATION AND

HANDLING PLANT 1134.7 ASH HANDLING PLANT 1194.8 FIRE FIGHTING SYSTEM 1294.9 AIR CONDITONING SYSTEM 1354.10 DIESEL GENERATOR SETS 1424.11 CENTRAL LUB OIL STORAGE AND

PURIFICATION SYSTEM 1444.12 MISCELANEOUS WATER SYSTEM 1454.13 COAL MILL REJECT SYSTEM 1464.14 OFFSITE - II 148

5. CONTROL AND INSTRUMENTATION5.1 UNIT C& I SYSTEMS 1505.2 INTERLOCK AND PROTECTION5.2.1 BOILER AND AUXILIARIES 1565.2.2 TURBINE AND AUXILIARES 1715.2.3 GENERATOR AND AUXILIARIES 1805.2.4 OFFSITE AUXILIARIES 190

6. ANNEXUREI TURBINE ROLLING CURVES (9 Nos.) 193II GENERATOR CAPABILITY DIAGRAM 202III UNLOADING SCHEDULE DUE TO

HIGH DISTILLATE TEMPRATURE OFSTATOR WATER 203

IV LUB OIL SCHEDULE 204V STEAM TABLE 208VI ATRS START-UP PROGRAMME 211

INTRODUTION(SALIENT FEATURES)

i) Type of station Thermal

ii) Station capacity 840 MW (4 x 210 MW units)

iii) Fuel 100% coal or 100% oil

iv) Coal, Source Piparwar Block of North Karanpura coalfields in Bihar, about 1200 km.

Transportation Indian Railways by means of Bottom Discharge Wagons

Consumption 3.66 million tonnes per year assuming 6500hours of operation.

v) Cooling water, Source Upper Ganga Canal Dehra headworks,During closure of UGC through network oftube wells.

Consumption 50 cusecs

Method Close cycle with natural cooling tower

vi) Start up power Through 3 x 167 MVA, 400/220/33 kv singlephase auto transformer

vii) Ash disposal Dry Ash Disposal system.

viii) Chimney RCC multiflue chimney with steel flue-225 mhigh.

ix) Heat Rate 2600 Mcal/kwh

x) HP/LP Bypass capacity 60% of MCR

xi) Land requirement (in acres)

a. Plant area and green belt

between plant and ash area 1130 acres

b. Ash disposal 480 acres

c. Township 250 acres

d. Reailway siding 225 acres

e. Approach road, intake canal

and contracto’s township 115 acres.

Total 2200 acres

SECTION -1

BOILER & AUXILIARIES

1

1.1 GENERAL SPECIFICATION

(i) Manufacturer BHEL (C.E. design)(ii) Type Natural circulation, balanced draft,

smooth tube double pass, single drum,single reheat direct pulverised coal/oilfired,dry bottom type.

(iv) Capacity 700t/hr.FW. inlet temp -246 C Steam pr./tempSH - 154.0 kg/cm2; 5400cRH - 38.8 kg/cm; 3400cBoiler Efficience - 87.28%

13868 181 63.5(iv) Boiler designation ______ _______ _____ NCR10592 130 63.5

(v) Type of firing Tilting tangential(vi) Water volume

(a) Generating surface 116 m3(Water walls)

(b) Drum (full) 34 m3(c) Economiser 47 m3(d) Superheater

(Drum to SHO heater) 77 m3(e) Reheater 50 m3(f) Total water volume of 324 m3

boiler(vii) Minimum load at which

Steam Generator can beoperated continuosulywith complete flame stability 2 adjacent mill at 50% capacity.without oil support

(viii)Minimum load at whichSteam Generator can beoperated continuously withcomplete flame stabilitywith oil support 20% MCR

(ix) Minimum load for individualmill beyond which no oilsupport is required 50%

1.2 FURNACE SPECIFICATION

(I) Type Fusion welded walls(ii) Bottom Dry(iii) Draft Balanced(iv) Tube arrangement Membrane(v) Furnace width 13.868 m(vi) Furnace depth 10.592 m(vii) Furnace height (Ring header

to furnace roof) 43.136 m(viii)Furnace volume 5570 m3

(ix) Furnace projected are 3275 m2(x) Fuel heat input 519.3 MK Cal/hr(xii) Residence time for fuel

particles in furnace 3.14 sec.(xii) Effective volume used to

calculate the residence time 4200 m3(xiii) Combustion temperature

used to calculate theresidence time (overage)

(xiv) Explosion/Implosion withstand capacity at 67%yield point + 660 mmwc

1.3 WATER WALLS

Front Side Rear Roof Roofwall wall wall 1st 2nd

(i) Number 181 260 181 120 120(ii) O.D., mm 63.5 63.5 63.5 51.0 44.5(iii) Pitch, mm 76.2 76.2 76.2 114.3 114.3(iv) Actual thickness, mm.................................... 5.5 ..................................(v) Material SA210C.(vi) Total projected

surfaces (ERPS), m2 615.3 803.4 480.6 121.5(vii) Design pressure

of tubes .............................. 175.8 kg./cm2 ...........................(viii) Maximum pressure

of tubes .............................. 167.2 kg./cm2 ...........................(ix) Erosion allowance

provided on tubethickness, mm .................................... 0.6 .....................................

(x) Method of joining Butt welded.long tubes

WATER WALL HEADERS

Bottom Ring w/w Outlet Feed materHeader Header Pipe Line

(i) No. of headers 1 5 -(ii) Outside dia, mm 40.64 219./273.0 323.9x36(iii) Design pressure of

header, kg./cm2 (g) ............................. 175.8 ...................................

32

(iv) Max. working pressure

of headers, kg/cm2 (g) 170.4 167.4

(v) Material ............................. SA 106 Gr C...................................

1.4 DRUM

(i) Construction Fusion welded

(ii) Material specification SA-299

(iii) Design pressure,

kg/cm2 abs. 176.4

(iv) Max. operating

pressure, kg/cm2 abs. 167.2

(v) Design temperature, 0C 354.0

(vi) Actual thickness of

straight portion, mm 170/135

(vii) Actual thickness for

dished end, mm 135

(viii)Overall length of

drum mm 12200

(ix) O.D. of Drum, mm 2083

(x) Internal dia. of Drum, mm 1778

(xi) Corrosion allowance, mm 0.75

(xii) No. of distribution

headers 6

(xiii)No. of cyclon separator/

secondary drier 58/58

(xiv)No. of final driers Through out the length

(xv) Max. permissible

temperature difference

between any two points of

drum, 0C 55

(xvi)Water capactiy at MCR between

normal level and

lowest water level

permitted (upto low-

low trip, in seconds) 25

(xvii) Normal water level 250 mm below drum

in drum centreline.

1.5 SUPER HEATER

LTSH Platen FinalPendant S.H. S.H.Horizontal

(i) Type Convection Radiant Convection(ii) Direction of flow Counter Parallel Parallel(iii) Effective heating surface

area, m2 3700 1097 1543(iv) Gas flow path area, m2 73 138.9 72(v) Total no. of tubes 480 203 238(vi) O.D., mm 44.5 47.63 44.5(vii) Margin on tube thickness, mm ............ 0.6 corrosion allowance ............(viii) Effective length, mm 26466 8900 8360(ix) Gross length, m 34700 10100 9760(x) No. of elev/section 4 7 2(xi) Tube pitch

(a) Parallel of gas flow, 96 57 95/96 mm(b) Across gas flow, mm 114.3 457.2 114.3

(xii) Material SA 210GrC SA 213T11 SA 213T11SA 213T11 T22, 304H SA 213T11

(xiii) Method of joininglong tubes ....................... Butt welded ...................

(ivx) Total ND of assemblies 120 29 119

SUPERHEATER HEADERS

(i) Material SA121 A, SA 335 P-12, P22(ii) Max. operating pressure,

kg/cm2 167.4(iii) O.D., mm 219.1, 273.0 32.9, 406.4(iv) Thickness, mm 28, 32, 40, 45(v) Final outlet header

connection End outlet.(vi) Main steam ID-255.6x49.2

Pipe line

1.6 REHEATER

(I) Type Spaced, single stage(ii) Max. operating pressure,

kg/cm2 42.08(iii) Design pressure, kg/cm2 50.00(iv) Total circumferential

heating suface, m2 2858(v) Gas flow path area, m2 118

54

(vi) Space between two banksin direction of gas flow, mm 900

(vii) Mean effective lengthper one tube, mm 20.000

(viii)Gross lennngth per tube, mm 22,000(ix) Total no. of tubes 354(x) Acutal tube thickness

used, mm 3.6 4.0, 5.0(xi) O.D., mm 47.63/54.00(xii) Margin on tube

thickness, mm 0.6 Erosion allowance(xiii)Tube material SA 210 Gr A1, SA 213T11, T 22(xiv)Tube pitch

(a) Parallwt to gas flow, mm 101.6(b) Across gas flow, mm 228.6

(xv) Depth of each bank in thedirection of gas flow, mm 1400/1900

(xiv)Method of joininglong tubes Butt welded

REHEATER HEADERS(i) Material SA210 B, SA 335 P 22(ii) O.D. mm 406.4, 558.8(iii) Thickness, mm 46.0, 45.0(iv) Design pressure, kg/cm2 50.0(v) Max. operating

pressure, kg/cm2 40.08(vi) HRH Pipe line- ID-508x28(vii) CRH Pipe line- ID-457.2x127

1.7 SUPERHEATER & REHEATER TEMP. CONTROL1.7.1 SUPERHEATER & REHEATER TEMP.CONTROL FOR COAL FIRING

1.7.1.1 SUPERHEATER ATTEMPERATOR

(i) Type Spray mixing type(ii) Stages of attemperation One(iii) Position in steam circuit LTSH- Attemp.- PLTN S.H.(iv) Material specification SA 335 P12(v) Superheater steam temp.

range that can bemaintained between 54.90%

to 100% of boiler MCR, 0C 540 +_ 5(iv) Max. spray water flow

rate & correspondingsteam out put, kg/hr 28,000 at 54.43 % of MCR

(vii) Min. spray water flow rate &correspondeing steamout put, kg/hr 0 at 100% of MCR

(viii) Spray nozzle material SA 182 T 12(ix) Spray water source BFP discharge

1.7.1.2 REHEATER PRIMARY -TEMP. CONTROL ( BURNER -TILT CONTROL)

(i) Max. angle of tiltupwards/downwards + _ 30O

(ii) Tilt mechanism Power cylinder(iii) Reheat steam range

thai can be maintainedbetween 54.9% to 100%MCR, OC 540 + 5

(iv) Burner tilt used forreheat temp. controlwith(a) Cool firing yes(b) Oil firing yes

1.7.1.3 REHEATER EMERGENCY TEMP CONTROL

(i) Type Spray mixing type(ii) No. of stages One(iii) Position Cold reheat line(iv) Spray nozzle material Weldment(v) Spray water source BFP discharge

1.7.2.1. GAS RECIRCULATION CONTROL

(i) Type of Control InIet damper control of G.R fan(ii) Range of control Above 25% Ioad.

CAUTION: GR fan should not run below 25% Ioad it may Ioad tounstable furnace condition.

76

1.8 EC

ON

OM

ISE

R

(i)Typ

eP

lain, drainable, non-steaming,

in line

(ii)N

o. of blocksTw

o

(iii)Tube m

aterialS

A210 G

rA1

(iv)O

.D. of tubes, m

m44.5

(v)A

ctual thickness of

tubes, mm

4.5

(vi)E

rosion allowance,m

m1.0

(vii)Length of tubes, m

m32100

(viii)Tube pitch

(a) Parallel to gas path,m

m130

(b) Across gas path, m

m96

(ix)W

ater side effective heating

surface area, m2

3580

(x)G

as side effective heating

surface area, m2

5617m2

(xi)G

as flow path area m

262.8

(xii)G

as velocity at boiler

100% M

CR

, m/sec

8.9

(xiii)Min. tem

p of feed water

which econom

iser can

handle safely, Oc

150

(xiv)Design pressure of tubes,

kg/cm2 (g)

161.0

(xv)Type of tube joints

Bu

tt weld

ed

EC

ON

OM

ISE

R H

EA

DE

R

Inlet Header

Outlet H

eader

(i)M

aterial specification........... S

A 106 G

R C

............

(ii)O

uter diameter, m

m323.9

323.9

(iii)A

ctual thckness, mm

32.032.0

(iv)type of construction

Plate form

ed/Seam

less

(v)M

ax. header unbalance.....................2%

....................

(vi)M

ax. working pressure,

kg/cm2 (g)

....................171.5..................

98

1.9 BOILER MOUNTING AND FITTING1.9.1 SAFETY VALVES

Location

Boiler Drum

SHERV

CRHHRH

HRH

S.B. Line

S.No.

1

2

3

4

5

6

7

8

9

10

11

ValveTagNo.

SV1

SV2

SV3

SV4

SV5&SV6SV7

SV8

SV9

SV10

SV11&SV12SV13

Type ofSafetyValve

CONSOL 1750 WB

CONSOL 1750 WB

CONSOL 1740 WB

CONSOL 1740 WB

CONSOL 1538 VX

CONSOL 1786 WDCONSOL 1786 WD

CONSOL 1786 WD

CONSOL 1525 VX

CONSOL 1786 WD

CONSOL 1811 JBFlanged Flanged

Valve Size,mm/InchInlet

762/3”B Welded76 2/3”B Welded76 2/3”B Welded76 2/3”B Welded63.5/2.5”*B Welded

152.4/4”*B Welded1524/6”*B Welded1524/6”*B Welded1524/6”*B Welded1524/6”*B Welded38.1/1.5”

Outlet

152.4/6”Flanged152.4/6”Flanged152.4/6”Flanged152.4/6”Flanged101.6/4”Flanged

203.2/8”Flanged203.2/8”Flanged203.2/8”Flanged203.2/8”Flanged203.2/8”Flanged63.5/2.5”

Valve SetPressure,kscOpen

176.

179.9

181.7

163.0

161.4

49.0

46.31

46.66

48.42

45.8

40.0

Close

169.3

170.9

172.6

158.1

158.0

46.6

44.0

44.0

46.0

44.9

38.4

BlowDown%

4

5

5

3

2.17

5

5

5

5

2

4

R e l i e v -ingCapacityKg/hr

179 771

183317

220655

160836

100315

191460

153827

155127

160865

112195

14590

TotalRelievingCapacityKg/hr

583743

160836

200630

191460

469819

224390

14590

% ofEvaporation

83.39

22.98

14.33

30.28

74.30

17.74

% ofEvaporation

83.39

22.98

14.33

30.28

74.30

17.74

Total%o fEvaporation

106.37

28.66

104.53

35.48

Approx.Valveweightkg

218

218

218

218

295

356

356

356

356340

25

1.9.2 DRUM LEVEL INDICATOR

Location Type No. & Make

Drum DWLG 2,Yarway

Fireman’s floor RWL1 1,YarwayFIBRE OPTICS 1,Yarway

UCB Conductivity type 2,Solartron,(Hydrastep)Remote level indicator 1Remote level recorder 1

1.10 REGENERATIVE & STEAM COIL AIR PREHEATER1.10.1. REGENERATIVE AIR PREHEATER

Type Vertical inverted modulur trisector typeSize 27.5 VIMT-2000No. per boiler Two

1. Main and stand byMotor types Squirrel cage motor,

frame size D160LIP 55 enclosure, F class insulation

Rating 11kwMotor speed 1450 rpm

Motor power supply 415 v,3Ø, 50 HZ

Speed reducer Type- I, Japan, Nissawai

Coupling 11.50 FCU (PERMBRIL)Speed reduction ratio 110:1

2. Auxiliary Drive Assembly Air motor Chicago pneumatic

RSM 400Coupling Bibby 124 ASolenoid valve AVCON3/4” BSP 220 v,DCCL-H-INSflter lubrication Velgan or Norgreen 1” BSPAir pressure 5.3 kg/cm2 (g)Air consumption 6.37 Nm3/minute at approximate 0.5 rpm.

3. Heating ElementsTotal heating surface 2252.7m2Element type hot/ DU (22 guage) /DU (22

intermediate/cold end guage)/Enamelled NFElement height hot/intermediate/cold end 850mm/650mm/500mmMaterial hot/ Carbon steel/carten-A/Intermediate/cold end enomelled iron.

4. Rotor SealsRadial seals-hot end 2.5 mm thcik, carten-ARadial seals-cold end 2.5 mm thick, carten-AAxial seals 2.5 mm thick, carten-ABypass seal 1.6 mm thick, carten-ARotor post seal-hot end 6.0 mm thick, carbon steelRotor post seal-cold end 6.0 mm thick, carbon steel

5. BearingsGuide bearing Spherical roller bearing

SKF/FAG 23060 CCK W 33Support bearing Spherical roller thrust bearing

SKF/FAG 294 / 500being SKF/FAG 294/500

6. Oil CapacityGuide bearing housing 25 litresSupport bearing housing 150 litres

7. Oil Circulation SystemMotor-TEFC guide bearing 0.55 kw, 415v, 30, 50HZ, 920 rpm,

horizontal foot cum flange mounted.

Motor-TEFC support bearing 0.75 kw, 415v, 30, 50HZ, 920 rpm,IP 55 enclosure, insulation class B,horizontal foot cum flange mounted.

Pump Screw pump from M/s IMO, Sweden,capacity 15 lpm.

Cooler Universal heat exchanger, watercirculating rate 1 m3/hr, operatingpressure 5 kg/cm2

8. Rotor Stoppage AlarmGo switch 110v, M/s APCO, USA

9. Fire Sensing Device,Type Infra-red detection system.

10. Clearing DeviceType Power driven twin nozzle soot blowingMotor 0.18 kw, 3 phase, 415 v, 50 HZ,

1350 rpm, insulation class B, squirelcage motor

Clearing media Steam/air

1110

Steam pressure range 10.6-17.6 kg/cm2

Steam consumption 2100 kg/hr at 17.6 kg/cm2, 1500csuperheat.

Time required fornozzle to make one pass 50 minute.

11. Air Receiver TankNo. per boiler 2Internal diameter 1700 mmHeight 7654 mmCapacity 17.5 m3

1.10.2 STEAM COIL AIR PREHEATERNo. of per boiler 2Size 4030 x 4710 x 300 mmInstalled position VerticalDesign steam pr/temp 16kg/cm2/210c.Weight of each SCAPH 4600 kg.

1.11 ID FANManufacturer BHELNo. per boiler TwoType NDZV 31 SIDOR

Axial double suction radialdischargeLadisl Aischang

Medium handled Flue gasLocation Ground mountedOrientation Bottom delivery with 450

inclined suctionType of fan regulation Inlet damper control +

Hydraulic coupling1. Fan Design Rating

Capcity 222 cu.m/secTotal head developed 418 mmwcTemp. of medium 1450cSpecfic weight of medium 0.7896 kg/cu/.mSpeed 740 rpm

2. Fan ReserveFlow 32.6%Pressure 50%

3. Fan Drive CouplingMake TACKEType Gear

4. Drive Motor Unit.1 & 2 Unit-3 & 4Make BHEL, Bhopal BHEL BhopalFrame size 1 LA-7804-8FH-70-Z IDQ 3735-8BD Q4-2 Type Squirel cage Synchronous

induction motor 1325 KWRating 1400 kw 704 rpmSpeed 750 rpm (syn.) 2 x 120 V x 3 φφφφφPower supply 6600v, 30, 50 HZ continousType of duty Continuous 269 AmpFull load curreent 157.8 amp. -No. load current 57 amp.Insulation class F FWeight of motor 9800 kg 13,000 Kg.

5. Brg NDE NV234 M NU228 M6. Brg DE NV234 M NU240M

62343C.3 6240C.37. Fan

Nominal diameter 3.1 mFan weight 47,380 kgMoment of inertarefered to fan shaft 42000 kgm2

8. LubircaitonFan Forced oil lubrication.Motor Grease lubrication

9. BearingFixed bearing Sleeve bearing GLYCOExponsion bearing Sleeve bearing GLYCOBearing loss 11 kw

10. Seals Lobyrinth seals11. Lube OIl System

No. of oil pumps 2capacity 2,144 lpm, Boreman makeLube oil pump motor 415v, 30, 50HZ, 5.6 kw, (7.5hp)

103. ASpeed 2875 rpminsulation class B, induction motor

Filter flow rate &working pr 200 lpm, 10 kg/cm2

Working oil cooler VOITH turbo L1N1 071304-DDesign pr./temp. 16 bar/ 1000cOil tank capacity 800 litreOil heater 4 kw, 415v, 30, 50HZ

-For Unit 3 and 4 AC synchronous motor drive havingvariable frequency control incorporat-ing load commuted inverter controlsystem is provided.

1312

1.12 FD FAN

Manufacturer BHELNo. per boiler TwoType AP1-19/11Medium handled Clean airLocation Ground mounted on concrete floorOrintation Horizontal axisType of fan regulation Variable pitch controlFan Design Rating Coal firing Oil firingCapacity 144.7 cu.m/sec 126.8cm.m/secTotal head developed 334 mmwc. 544 mmwc.Temp. of medium 500cSpecific weight of medium 1.04 kg/cu.mSpeed 1480 rpm

2. Fan ReserveFlow 3.8%Pressre 43.9%

3. Fan Drive CouplingMake THYSSENType Rigiflex

4. Drive MotorMake BHEL/BhopalFram size 1LA-77124HF-70-ZRating 1000kwSpeed 1500 rpm (syn.)Power supply 6600v, 30, 50 HZ

Type of duty ContinuousFull load current 108 ampNo load current 30 ampPower consumption at 100%MCR per fan at fan shaft 390 kwWeight of motor 6700 kgmotor brg NDE NU 224MBrg DE NU 228M

6228 C-35. Fan

Norminal diameter 1884 mmHub diameter 1100 mmWeight of the fan withoutmotor and coupling 8500 kg (statro-rotor)Moment of inertia of fan(at shaft level) 500 kg m2

6. LubricationFan Forced oil lubricationMotor Grease lubrication

7. BearingsFixed bearing Nu 230 c3,7230 BUAExpansion bearing Nu 230 C3Bearing loss 8 kw

8. Lube OIl SystemNo. of oil pumps TwoType of oil pump & make Screw type, Borneman makeCapacity 70 lpmDischarge pressure 12 barLube oil pump motor 415v, 30, 50 HZ, 2860 rpm class of

insulation B, induction motor, 4.0 kw,(5.5 hp), 7.6. A

No. of coolers TwoOil tank capacity 450 litreControl oil quantity 56 lpm (Theoritically calculated value)Lub oil quantity 4 lpm (Theoritically calculated value)Oil heater 4 kw, 415 v, 30, 50 HZ,

1.13 P.A. Fan

Manufacturer BHELNo. per boiler TwoType NDZV 19 HERKALES

Axial double suction radial dischargesimply supported

Medium handled Clean air from FD fan dischargeLocation Ground mounted on concrete floorOrientation Top delivery with 450 inclined suction

chamber.1. Fan Design Rating

(i) Capacity 77.4 cu.m/sec.(ii) Total head developed 931 mmwc(iii) Temp. of medium 530c(iv) Specific weight of medium 1.0515 kg/cu.m(v) Speed 1480 rpm

2. Fan ReserveFlow 52.9%Pressure 37.5%

3. Fan Drive CouplingMake TACKEType Gear

4. Drive MotorMake BHEL/BhopalFrame size 1LA-7712-HF-70-ZType Sq. cage induction

1514

Rating 1050 kwSpeed 1500 rpm (syn.)Type of duty ContinuousPower supply 6600v, 30, 50HZ

Insulation class FFull load current 113.5 amp.No loac current 30 amp.Weight of motor 6700 kg.

5. FanNominal diamater ofimpeller 1.8m.

6. LubricationFan Forced oil lubricationMotor Grease lubrication

7. Type of Fan Regulation Inlet damper control+Hydraulic coupling.

8. Bearings

7”Fixed bearing Sleeve bearing 4 ----- RT

16 7”

Expansion bearing Sleeve bearing 4 ----- RT 16

Bearing Loses 8 Kw

9. Lube Oil SystemPump capacity & make 30 lpm, Bornomen pumpenDesign pressure & type 8kg/cm2, PDHU 32.-4Lube ol pump motor 1.5 Kw (2hp), 3.3.A, 1405 rpm

class B insulation, NGEF inducationmotor

Lube oil filter 2 no. basket type simplex filterLube oil cooler 2 no. Design pr. & temp 10kg/mc2 &

1000c(shell & tube side)

Oil tank capactiy 315 litre.

1.14 GR FAN

Manufacturer BHEL/RanipetNo.per boiler TwoType NDZV33 SIDOR

Radial double suction simply supportedfan

Medium handled Flue gasLocation Ground mountedOrientation Bottom delivery with 450 inclined

suctionFan regulation Inlet damper control

1. Fan Design RatingCapactiy 165.8 cu.m/secTotal head developed 246 mm wc

Temp of medium 4230cSpecific weight of medium 0.41914 kg/cu.mSpeed 580 rpm

2. Fan ReserveFlow 20%Pressure 32%

3. Fan Drive CouplingMake BHEL/BhopalFrame size 1LA-790-3KF-7903

4. Fan Drive CoplingMake BHEL/BhopalFrame size 1LA-7903-3KF-70-ZType Squirel cage indutionSpeed 600 rpm (syn.)Power supply 6600c, 30, 50 HZ

Class of insulation FWeight of motor 15000 kg

5. FanNominal diameter 3350 mmFan weight 53, 120 kgMoment of inertiarefered to fan shat 62,415 kg m2

6. LubricationFan Forced oil lubricationMotor Grease lubrication

7. BearingFixed bearing sleeve bearing GLYCOExpansion bearing sleeve bearing GLYCO

8. BarringMotor 15.kw, 415 v, 30, 50Hz, 20.5 amp.N1 / N2 1455/61 rpm

9. Lube oil systemNo. of lub oil pumps 2Make & type Bornomenn pumpen, PDHU-38-4Capacty 144 lite / min.Disch.Pressure 8 barMotor NGEF lnduction motor, 5.5 kw, (7.5

hp),10.3 A2875 rpm, class B insulation.

Lub oil filter Basket type simplex filter, 2 no.Lub oil cooler 2 no. 10 kg/ cm 2 & 100 0 c (shell side

tube side)design pr & temp.

Oil tank capacity 800 litreOil heater 4kw, 415v, 3050HZ

N.B:-GR fan should not run below 25% load as it may lead to unstablefurnace condition.

1716

1.15 FUEL PREPARATION AND FIRING SYSTEM1.15.1 OIL BURNER

HEAVY FUEL OIL BURNER

(i) Type Air cooled steam atomising non-retractabletilting tangential corner fired.

(ii) Oil gun design Paralle pipe(iii) Atomiser External mixed, constant pressure steam

atomised(iv) Air nozzle Rectangular(v) Diffuser 250 mm, 10 off. 450 vanes with leading edge

with scanner cutting and lignitor cutting.(vi) Oil gun assembly kf=k+20.5=2308 mm(vii) Atomiser designation Spray plate 90J16(vii) Atomiser spray angle 900

(ix) NO. of guns. 16 (4per elevation)(x) Location of oil guns AB, CD, DE, and EF elevation.(xi) Gun capacity 31.9x106 kcal/hr/burner(xii) Minimum allowable

oil pressure 2.1kg/cm2 at oil gun connection(xiv)Minimum allowable

steam pressure 3.5 kg/cm2 at oil gun connection

(xv) Oil viscosity at gun 15 to cst(xvi)Steam quality 10 to 150 superheat

LIGHT FUEL OIL BURNER(i) Service Initial start up purpose(ii) No. off oil guns Same 4 heavy oil fired gun in AB elevation(iii) Atomiser designation Spray plate 90 J 16(iv) Atomiser media Service air,(v) Fuel Light fuel oil IS 1460(vi) Oil gun capacity, 7.5%MCR heat input,(vii) Minimum allowable

LFO pressure 2.1 kg/cm2 (g)(viii) Minimum allwable

atomising air pressure 3.5 kg/cm2

1918D

ATA

CH

AR

T

Type

of

Bur

ner

H

.F.O

.LF

O B

urne

r

HF

OS

team

LF

OA

irP

ress

ure

Flo

wP

ress

ure

Flo

wP

ress

ure

Flo

wP

resu

reF

low

Kg/

cm2

Kg

/hr

Kg/

cm2

Kg

/hr

Kg/

cm2

Kg

/hr

Kg/

cm2

Kg

/hr

Max

imu

m

rati

ng

10.5

4550

6.0

300

4.0

1000

6.0

135

Min

imu

m

rati

ng

10.5

4550

6.0

300

4.0

1000

6.0

135

Min

imu

m

rati

ng

2.1

1140

6.0

430

2.1

600

6.0

145

Du

rin

g

Sca

vang

e.

.6.

048

0.

.6.

018

0

IGNITORS

(i) Make Simmonds USA(ii) Service Oil burner light up(iii) Type High energy arc ignitor (HEA)(iv) Location Burner mounting panel(v) Input 110 volts AC, 50hz, 5 amp rms,(vi) Output Min 4 sparks/second, 12 joules

nom./spark, duty cycle 15 minute on,30 minute off.

(vii) Spark rod constrution 5/8”s/s tube with s.s. wire braid,flexible 5/8”, 5/8”, s/s tube (rigid)5/8”s/s tube (rigid)

(viii) Ignitor tip dimension 191+ 3mm length, 15.9+0.15 mmdiameter

Operating temperature of tip 6500

(ix) Retraction assemblyAir cylinder stroke upto 300 mmAir pressure 5-7 kg/cm2

(x) Flexible spark rod B = 100 inckdimension

(xi) Flexibele guid pipe L= 69 inchdimension

FUEL OIL SPECIFICATION

HFO LSHS LFO(i) Standard IS-1593/1971 Nil LDO to IS1460

Grade HV(ii) Flash point, minimum 660c 750c 660c(iii) Viscosity, maximum 370 cst at 500c 180cst at 500c 2.5 to 1.5 cst(iv) Total sulpur, maximum 4.5%by weight 1.0%by weight 1.8%by weight(v) Gross heating value (typical) 10270kcal/kg 11000Kcal/kg 10720Kcal/kg

1.15.3 COAL BUNKER

(i) Type Cylindrical with conical cum hyper bolichopper at bottom.

(ii) Material of construction 8 mm M.S. plate(iii) Height 16m cylindrical and 8 m conical cum

hyperbolic at bottom(iv) Diameter (I.D.) of cylindrical

portion 7.6 m

1.15.3 BUNKER SHUT OFF GATE

(i) Size and type 36” motor operated coal valve2-67-272-00138

20

(i) No. per boiler 6(ii) Location Bunker outlet

1.15.4 GRAVIMETRIC COAL FEEDER

(i) Feeder size 36 inch inlet 7’CD(ii) Capacity Max. 60 t/hr

Min. 6 t/hr(iii) Gear box ratio 203:1(iv) Main drive AC motor 5.5 kw, 11A, 1440 rpm

and eddy current cluch with reducer,415v, 50HZ, 30 power supply, speedrange 100-1200 rpm

(v) Clean out conveyor drive AC motor, 0.25 kw, 950 rpm with reducer(1041:1), 415v, 3φφφφφ, 50 HZ, power supply.

(vi) Working pressure 500 mm wc.

1.15.5 PULVERISER

(i) Make BHEL(ii) No. per boiler 6(iii) Type XRP 883(iv) Capacity 49 T/hr(v) Coal size-inlet 25 mm

- outlet 70% through 200 mesh(vi) Grinding roll

material Ni -Hard Gr II(vii) Bull ring material Modified Ni-Hard/Hi-chrome(viii)Coupling Gear type flexible coupling betwen mill

and motor(viii)Cooling system Immersed in oil bath, cooling water

9.0m3/hr at 360c & 3kg/cm2 pressure.(ix) Mil bearing

(A) Vertical ShaftUpper radial brg C-8159-A TorringtonLower radial brg 220-RU-O-03-R3 TorringtonThru brg. T-11000 Timken(B) Journal AssyUpper radial brg HH 249949/10Lower radial brg EE350750/351687 Timken(C) Warm ShaftThrust brg SKF-29438Radial brg 170 RM03 Torrington

(x) Drive MotorFrame size, Type 1 LA-7716 - 3, HA74-7Rated output 425 KwPower supply 6600 v, 3φφφφφ, 50 HZ

Synchronous speed 600 rpmClass of insulation FNo load current 27.2 A

Full load current 54.7 AWeight of motor 7500 kg.Bearing DE NU 230 M and 6230 C3

NDE NU 226 M(x) Lub oil system

No. of pumps 2

Make and type ALEKTON, tripple screw pumpCapacity 50 lpmDrive motor NGEF make, 2.2 kw (3 hp), TEFC type,

955 rpm, 4.6 A, class B insulation.

1.15.6 COAL PIPE

(i) Pipe size φφφφφ 558.8 x 15.0(ii) Material AP1 5L gr B

1.15.7 COAL BURNER

(i) Type Tilting tangential(ii) No. per boiler 24(iii) Capacity 32.5 x 106 kcal/hr/burner(iv) Control Air damper(v) Position Corner

1.15.8 SEAL AIR FAN

(i) Make BHEL/Ranipet(ii) No. and capacity 2 x 100%(iii) Type Radial fan(iv) Pressure developed 508 mmwc(v) Drive motor Kirloskar Elect, Co. make, 37 kw,

2900 rpm, 415 v, 3θθθθθ , 50 HZ,class B insulation

1.16 ELECTROSTATIC PRECIPITATOR(i) Manufacturer BHEL(ii) Type FAA-6x45-69135-2(iii) Design conditions

Gas flow rate 312.7 cu.m / secTemperature 1360cDust concentration 64.4 gms/N cu.m

(iv) No. of precipitators per boiler Four(v) No. ofgas paths per boiler Four(vi) No. of fields in series Six

in each gas pass(vii) Pressure drop across the

precipitator for designconditions 20 mm wc

2221

Design pr. & temp. of ESP + 600 mm wc, temp 2000CWorking pr, & temp of ESP + 162 mm wc, 1360C

(viii) Treatment time 32.18 seconds.

(iv) Veloctiy of gas atelectrode zone ontotal area 0.839 m/sec

(x) Guarantee of collection 505 kwefficiency for designconditions 99.9%

(xi) Power consumption 505 kw

(xii) Collecting Electodesa) No. of rows of collecting electrodes per field 24b) No. of collecting electrode plates per field 144c) total no, of collecting plates per boiler 3456d) Nominal height of collecting plate 13.5 me) Nominal length of collecting plate 750 mmf) Specific collecting area (with one field out of service) 214.48 sq.m/cu.m/sec

(xii) Emitting Electodesa) Type Spiral with hooksb) Size Dia 2.7 mmc) No. of electrodes in the frame forming one row 54 fieldsd) No. of electrodes in each field 1242e) Total no. of electrodes per boiler 29808f) Total length of electrode per field 6967.62 m.g) Plate / wire spacing 150 mm

(xiv) Rappers for Collecting Electrodea) No. & type of rappers One drop hammer per row

of collecting electrodeshaving a collectingsurface of 121.5 sq. m.

b) Rapper size 4.9 kgs.c) Frequency of rap Varying from 20 raps/hr a the inlet field to

2raps/hr at the exit field. The frequencyof rapping for the intermediate fields canbe adjusted between 10 and 3 per houraccording to requirement.

d) Drive General electric motor controlled bymicroprocessor based rapper controller.

(xv) Rapper for emitting electodesa. No. & type of rappers Approximately one drop hammer for two

rows of electrodes.b. Rapper size 3.0c. Frequency of rap 10 raps/hourd. Drive General electric motor contrlled by

microprocessor based rapper controller.

(xvi) Hoppersa. Type & no. of hoppers Pyramidal, 6b. Capacity 8 hour storagec. Heating Electrical heating provided for the

bottom of hoppers.

(xvii) Gas distribution system Inlet OutletType & quantity Perforated plates, U shape thin

2 sets sheets - one setLocation Inlet of ESP Outlet of ESP

(xvii) Electrical ItemsI. Rectifiera. Rating 70 KV (peach, 800 mA (mean)b. Numbers 24c. Type Silicon, diode, full wave bridge connec-

tionII. Rectifier control panela. Type of of control Thyristorb. Number 24III. Auxilary control pannela. Number Fourb. Equipment controlled Collecting & emitting rapping motors,

hopper insulation & shaft insulatorheating.

IV. MotorsEmitting Rapper Collecting Rapper

a. Quantity 24 24b. Rating 0.33 hp 0.33 hpc. RPM 2.5 rpm 1.1 rpmd. Power supply 415v, 3φφφφφ, 50 HZ, 415v, 3φφφφφ, 52HZ

24 23

V. Heating elem

ents(a) H

op

pers

For 24 hoppers/Boiler

at the rate of 10 kw/happer

240 kw(b) S

haft Insulator For 24 Insulators at the rate of 1 K

w240 kw

(c) Support Insulator

For 96 Insulator at the rate of 1 kw

96 kw

(xix)Recom

mended current setting

Field

s1

23

45

6current in m

A150

250400

500600

700

(xx)O

peration sequence ofrapping m

echanismA

uto

2625

1.117 PREDICTED PERFORMANCE1. FLOW T/Hr

1 2 3 4 5 6 7 8 9 10 11STEAMSuperheater outlet 700.00 645.0 518.6 394.8 611.4 700.0 645.0 518.6 394.8 611.4

Reheater outlet 597.2 571.0 462.0 353.6 600.0 597.2 571.0 462.0 353.6 600.0

WATER

Feed water 700.00 659.0 529.4 401.6 622.7 700.00 659.4 529.4 401.6 624.7SH spray - 1.7 12.3 2.4 13.2 0 3.2 16.0 26.3 18.1

AIRAir heater outlet(Primary) - - - - - 183 175 154 128 221

Tempering air - - - - - 83 91 52 16 50Air heater outlet 711.0 660.4 534.3 403.1 712.2 531 483 397 314 529Total combusion

Air 753.3 702.8 516.7 445.5 754.5 845 791 645 500 842

OIL FIRING COAL FIRINGHP HEATERS IN SRVICE BOTH HP HEATER IN SERVICE BOTH

DESCRIPTION BMCR 210MW 68 MW 126 MW HP BMCR 210MW 168 MW 126 MW HPHEATERS HEATERSOUT OUT

2827

(III) TEMPERATURE, 0C1 2 3 4 5 6 7 8 9 10 11STEAM(I) Saturatd temp.in drum 350 349 346 344 348 350 349 346 344 348(ii) LTSH outlet 400 406 413 408 407 396 398 400 403 407(iii) SH platen outlet 501 498 48 506 498 506 506 509 513 502(iv) SH Finish outlet 540 540 344 337 362 352 350 344 337 362(v) RH inlet 352 350 344 337 362 352 350 344 337 362(vi) RH outlet 540 540 540 540 540 540 540 540 540 540

WATER

Economiser inlet 248 246 236 224 168 248 246 236 224 168Economiser outlet 303 306 305 295 249 294 292 284 276 243

AIR

Ambient 27 27 27 27 27 27 27 27 27 27AH outlet(Secondary) 331 333 327 310 289 326 324 307 288 284AH outlet(Primary) - - - - - 322 320 304 286 280

1 2 3 4 5 6 7 8 9 10 11FUELOil (HHV=11,000 46.1 43.3 35.5 27.4 46.5 - - - - -Kcal/kg)Coal (HHV=3500 - - - - 148 139 113 89 148Kcal/kg)

II PRESURES (STEAM & WATER) Kg/cm2 (g)PRESURESuperheater outlet 156.0 154.9 152.8 151.2 154.3 156.0 154.9 152.8 151.2 154.3LTSH outlet 164.4 162.1 157.7 154.0 160.6 164.4 162.1 157.7 154.0 160.6Drum 168.0 165.2 159.7 155.4 163.6 168.0 165.2 159.7 155.4 163.6

Economiser inlet 172.0 169.0 162.7 157.8 167.1 172.0 169.0 162.0 157.8 167.1Reheater outlet 38.8 37.2 29.9 22.7 39.6 38.8 37.2 29.9 22.7 39.6Reheater Inlet 40.4 38.7 31.1 23.7 41.3 40.4 38.7 31.1 23.7 41.3

PRESSUR DROPSuperheater system 12.0 10.3 6.9 3.9 9.3 12.0 10.3 6.9 3.9 9.3Reheater 1.6 1.5 1.3 1.0 1.6 1.6 1.5 1.3 1.0 1.6Economiser 2.0 1.7 1.1 0.6 1.3 2.0 1.7 1.1 0.6 1.5

3029

1 2 3 4 5 6 7 8 9 10 11

VIII HEAT BALANCE

Air heater inlet 319 292 229 177 312 228 207 174 149 223

Air heater oulet 145 139 125 114 145 125 121 114 109 125

Windbox pressure 100 100 100 100 100 100 100 100 100 100

Windbox to furnace diff. 105 105 105 105 105 105 105 105 105 105

GAS

Furnace -4 -4 -4 -4 -4 -4 -4 -4 -4 -4

Super heater platen inlet -4 -4 -4 -4 -4 -4 -4 -4 -4 -4

RH inlet -5 -5 -5 -5 -5 -5 -5 -5 -5 -5

LTSH inlet -22 -23 -21 -15 -20 -20 -18 -14 -10 -20

Economiser inlet -36 -38 -34 -24 -32 -32 -29 -21 -14 -32

Air heater inlet -74 -76 -68 -49 -66 -68 -62 -46 -34 -68

EP inlet -174 -160 -131 -91 -161 -192 -174 -123 -84 -186

ID fan inlet -198 -185 -144 -99 -184 -226 -203 -143 -97 -220

ID fan outlet +41 +36 +28 +22 +41 +52 +47 +35 +27 +52

1 2 3 4 5 6 7 8 9 10 11GAS

SH Platen inlet 1134 1103 1032 957 1143 1156 1165 1143 1120 1138RH Front inlet 1015 992 932 862 1014 1008 1008 973 931 993RH Rear inlet 889 874 824 759 884 869 864 824 775 859SH Finish inlet 787 777 738 681 779 761 754 717 673 754LTSH inlet 667 663 636 594 658 645 637 607 573 540Economiser inlet 561 560 514 485 523 499 493 473 451 498Air heater inlet 375 375 363 338 326 356 351 332 310 314Air heater outlet 146 139 136 132 133 136 136 123 107 116

IV PRESSURES & DRAFTS (AIR & GAS), MMWCPRIMARY AIRPA fan inlet 242 217 181 153 237PA fan outlet 764 752 748 754 777Air heater inlet ............................ Not applicable .......................... 756 744 743 751 769Air heater outlet 710 703 711 728 711Mill inlet 558 532 566 635 557Mill outlet 240 228 244 279 240

SECONDARY AIRFD fan inlet -13 -11 -7 -4 -13 -17 -15 -10 -6 -17FD fan outlet 365 334 257 194 362 258 232 191 160 253SCAPH inlet 352 321 248 189 246 245 221 183 155 240SCAPH outlet 327 299 233 180 320 232 210 176 150 227

(V) FU

EL

The Fuel data on which guarantee is given are as follow

s

ULTIM

ATE

AN

ALY

SIS

Descrip

tion

Oil

Co

al

Carbon, %

85.537.03

Hydrogen, %

10.952.26

Oxygen, %

0.56.53

Sulphur, %

2.50.33

Nitrogen, %

-0.85

Ash, %

0.0541.00

Water/M

oisture, %0.5

12.00H

HV

Kcal/kg

11,0003500

PR

OX

IMA

TE A

NA

LYS

IS O

F CO

AL

Fixed carbon, %24.00

Valatile m

atter, %23.0

Moisture, %

41.0A

sh, %41.0

Sulphur, %

0.33G

rindability index, HG

I57

Ash fusion tem

perature, 0c

1400

3231

1 2 3 4 5 6 7 8 9 10 11

(VIII) HEAT BALANCE

Dry gas,% 4.21 3.98 3.92 3.86 3.75 4.75 4.77 4.27 3.65 3.89

H20 & H2 in fuel,% 5.72 5.70 5.68 5.67 5.67 5.83 5.83 5.78 5.71 5.75

H20 in air,% 0.11 0.10 0.10 0.10 0.10 0.12 0.12 0.11 0.09 0.10

Unburnt Carbon,% 0.50 0.50 0.50 0.50 0.50 1.2 1.2 1.2 1.2 1.2

Rediation,% 0.11 0.11 0.13 0.16 0.11 0.11 0.11 0.12 0.17 0.11

Unaccounted &

Manufacturer’s margin,% 0.48 0.46 0.46 0.45 0.46 1.13 1.11 1.09 1.06 1.08

Total Losses,% 11.13 10.85 10.79 10.74 10.59 13.14 13.14 12.57 11.88 12.13

Heat Credit,% 0.43 0.44 0.43 0.44 0.43

Efficiency(with heat

credits),% 88.87 89.15 89.21 89.26 89.41 87.29 87.30 87.86 88.56 88.30

Guaranteed efficienccy,% 87.28 87.72

LOSSES

1.18 SCANNER AIR FAN

(i) No. per boiler Two, one A.C. driven, one D.C. driven(ii) Type Radial backward curved blade single suction centrifugal(iii) Duty Continuous(iv) Mounting On structural steel floor(v) Medium to be handled Dust ladden air(vi) Max. dust concentration 300 mg/cu.m(vii) Capacity 6000 cu. m/hr (1.67 m3/sec)(viii)Pressure developed 200 mmwc(ix) Suction pressure 0 to 559 mmwc(x) Efficiency of fan 81.86%(xi) Driving motor

AC motor 5.5 kw, TEFC, KEC make415v, 3θθθθθ, 50 HZ supplyClass of insulation - B.

DC motor 5.5 kw, 2 pole, TEFC, KEC make,(xix)Fan speed 2900 rpm(xii) Fan moment of inertia 1.52 kg m2

1.19 SOOT BLOWERType Fully automatic sequentially controlled

microprocessor based steam sootblowing

Source of steam LTSH outlet headerWall Blower LRSB

i) Number 56 18ii) Type WB 1E LRD1Eiii) Blow radius 1.5m 2.4 miv) Direction 900 900

v) Motor Power 0.56 kw 0.37 kw Travers motorvi) Cleaning medium Steam Steam

Pressure 20kg/cm2 20kg/cm2Temperature 3200c 3200cConsumption 2400 Kg/m 6000 Kg/m

vii) Blow duration 1.5 minute/blower 9.0 minute/blowerviii) Cycle duration 84 min. 162 min.

1.20 FURNACE TEMPERATURE PROBE

(i) Type FTP - 1E(ii) Travel 5.1 m

3433

12

34

56

78

910

11

VI

MIL

L &

BU

RN

ER

PE

RP

OR

MA

NC

E

No.

of m

ills

in o

pera

tion

44

32

4

Mill

load

ing,

%71

.166

.572

.484

.070

.8

Air

flow

per

mill

, t/h

r...

......

......

... N

ot a

pplic

able

....

......

......

......

......

......

......

......

...68

6668

7268

Air

tem

pera

ture

mill

inle

t, 0 c

235

224

237

258

235

Mill

out

let t

emp,

0 c77

7777

7777

Fine

ness

%(th

roug

h 20

0 m

esh)

7070

7070

70

Bur

ner t

ilt, D

eg.

-15

+2+1

2+2

4-2

5

(VII)

O2,

CO

2 (D

RY

VO

L.)A

ND

EX

CE

SS

AIR

(i)O

xyge

n in

gas

at

Econ

omis

er o

utle

t%2.

032.

032.

032.

033.

543.

543.

543.

543.

54

(i)C

O2 i

n ga

s at

Eco

nom

iser

out

let%

13.5

613

.56

13.5

613

.56

13.5

615

.86

15.8

615

.86

15.8

615

.86

(iii

)E

xces

s ai

r in

gas

at

Eco

nom

iser

out

let,%

10.0

10.0

10.0

10.0

10.0

2020

2020

20

(iii) Traversing speed 2.9 mpm(iv) Max. gas temp. measured 8150c(v) Max. gas temp. measured 5370c

without air cooling 1.1 m3

1.21 BOILER CHEMICAL DOZINGPHOSPHATE DOZING

(i) No. off pumps 1 working + 1 stand by(ii) Model PR-35(iii) Make VK pumps industries ltd.(iv) Capacity 120 litre/hr(v) Discharge pressure 210 kg/cm2 (g)(vi) Pump motor 1.5 kw, 1400 rpm; 3.4 A, 415v, 3θθθθθ, 50HZ supply(vii) Phosphate preparation

tank capacity 1.1 m3

(viii)Phosphate meteringtank capacity 1.1 m3

1.22 PRESSURE REDUCING & DESUPERHEATING STATION

High Capacity PRDS RightCapacityPRDS PRDS

(i) Steam source Main steam line CRH line at 41kg/cm2

at 155.4 kg/cm2 pressure & 3510c& 5400c temperature temperature

(ii) Flow capcity / hr 55 30(iii) Type of actuator Penumatic Penumatic(iv) Spray water BEP discharge BFP discharge

Low temp unit High temp. station Low temp stationaux. steam header aux. steam header aux.steamheader

Operating pressure 15.0 ksc 15.0ksc 15.0 kscOperating temperature 2100c 3250c 2100c

1.23 BLOW DOWN VESSELCBD IBD SCAPH

Drain Tank(i) No. One One One(ii) Design code 1328525 152825 15285(iii) Shell diameter θθθθθ 1500 x16 1922 θθθθθ 2082 x 16 x 19000 θθθθθ 1800 x16 1800

x thickness andheight, mm

(iv) Working pressure 10.0kg/cm2 1.5 kg/cm2 1.5 kg/cm2(v) Design temperature 2000c 2000c 2000c(vi) Capacity 900 litre 7000 litre 5800 litre

1.24 MAIN PIPE LINES

Main Steam Hot Reheat Cold Reheat Feed WaterSize ID 255.6x49.2 598.0x28.0 457.2x12.7 323.9 x36.0No of lines 2 2 2 1

1.25 CHIMNEY(i) No. of fuel 4 NO.(ii) Wind shield material Reinforced concerete(iii) flue material Steel(iv) Chimney height 220 m(v) Chimney base diameter 32.975(vi) Chimney raft diameter 43.120 m(vii) Flue diameter 4.5 m

1.26 BOILER AND AUXILIARIES COOLING WATER FLOW

S.No Equipment Decription Equipment/Unit Flow Quantity/coolerworking + standby m3 /hr

(i) ID fanWorking oil cooler 2 + 2 40.0Lube oil cooler 2 + 2 6.0

(ii) FD fanLube oil 2 + 2 12.0

(iii) PA fanWorking oil cooler 2 + 2 40.0Lube oil cooler 2 + 2 12.0

(iv) GR fanLube oil cooler 2 + 2 10.0

(v) Pulveriser cooler 4 + 8 9.0(vi) APH lube oil cooler 4 + 4 1.0(vii) Access door in furnace

hopper zone 2 1.0(viii) Sample cooler - 10(ix) Oil carry over probe 2 0.5(x) Fire detection system

for Air heater 2 1.5

3635

1.27 RECOMMENDED FEEDWATER AND BOILER WATER LIMITS

RECOMMENDED FEED WATER LIMITS

(i) Drum operating pressure, 61.00 101 & aboveKg/cm2

(ii) Hardness Nil Nil(iii) pH at 250c (copper alloy

pre-boiler system) 8.8-9.2 8.8-9.2(iv) Oxygen (max.), ppm 0.007 0.007

(Coper free pre boiler system) 9.0-9.4 9.0-9.4(v) Oxygen (max.), ppm 0.007 0.007(vi) Total iron (max.), ppm 0.01 0.0`(vii) Total coper (max.), ppm 0.01 0.005(viii)Total CO2 Nil Nil(ix) Total silica (max.), ppm 0.02 0.02(x) Specific electrical conductivity

at 250c measured aftercation exchanger in the H+form and after C02 removal(max.) µµµµµs/cm 0.5 0.3

(xi) Hydrqzine residual, ppm 0.01-0.02 0.01-0.02(xii) Permanagnate consumption, ppm Nil Nil(xiii)Oil ........... Not allowed ................

RECOMMENDED BOILER WATER LIMITS

(i) Drum operating pr. 61-15 126-165 166-180 181-205kg/cm2(g)

(ii) Total dissolved solids(max.), ppm 100 50 25 15

(iii) Specific electricalconductivity (max.) 200 100 50 30

(iv) Phosphate residual, ppm 5-20 5-10 5-10 2-6(v) PH at 250c 9.1-10.1 9.1-90.8 9.1-9.8 9.1-9.6(vi) Silica (max.), ppm To be controlled on the basis of silica in

boiler water & drum pressure relationship to be maintained less than 0.02ppm in the steam leaving the drum.

SECTION - 2

TURBINE & AUXILIARIES

37

2.0 MAIN TURBINE2.1 TECHNICAL SPECIFICATION

21.1 STEAM TURBINE

(i) Make BHEL, KRAFTWERK UNION DESIGN(ii) Type Tandem compound, regenerative, reheat,

condensing, three cylinder having singleflow HP turbine, double flow IP & LPturbine.

(iii) No of stages HP 25 no.IP 20 x 2 no.LP 8 x 2 no.

(iv) Type of HP/IP/LP turbine HPT-Reaction, barrel single flow typeLPT-Reaction, double flow axially split typeLPT-Reaction, double flow three shelldesign

(v) Nominal rating 210 MW(vi) Peak loading 229 MW(vii) Max./Min. speed 3090/2850 rpm (47.5 to 51.5 HZ)

Permissible for a maximum of 2 hoursoperation during the life of the LP bladingspeed below 47.5 HZ & speed above 51.5HZ.

(ix) Speed exclusion range 700 to 2850 rpm(x) Weight of turbine 475 tonne (approx.)(xi) Over speed set value 11%

2.1.2 DIMESNSIONS (IN MM)

HPT IPT LPT(i) Height of first stage moving blade 43 66 755(ii) Mean dia. of first stage

moving blade 643 756 1473.5(iii) Height of last stage

moving blade 95 100 668.8(iv) Mean dia. of last stage

moving blade 695 1041 2144.8(v) Overall length 16.975m(vi) Overall width (with cross 10.5 (approx.)

around pipes)(vii) Total exhaust area (LP Turbine) 2 x 5 m2

3938

2.1.3. TURBINE CLEARANCES (IN MW)

(i) Min. axial cold clearanceexcluding thrust bearing 3.4

(ii) Position of min. axial cold clearance IP glands ( - ) 2.4(iii) Axial clearance at stag - I

shroud (cold) 15.0 (LP shaft)(iv) Radial clearance of rotor 0.4 (HP)

gland 0.5 (IP)0.5 (LP)

(v) Min. radial clearance at 1.5 (LP)shroud

2.1.4 BEARINGS

No 1 Journal, φφφφφ 280 x 140 mmNo. 2 Radial cum thrust, tilting pad,

φ φ φ φ φ 290 x 240 mmNo.3 Journal, φ φ φ φ φ 450 x 320 mmNo. 4 Journal, φ φ φ φ φ 400 x 320 mmNo. 5 Journal, φ φ φ φ φ 400 x 320 mmNo. 6 Journal, φ φ φ φ φ 400 x 350 mmNo. 7 Journal, φ φ φ φ φ 200Lining material for all bearing - Babbit

2.1.5 VALVES

2 Main stop and control valves Type EV 1602 Reheat stop and control valves Type IV 3202 Swing check valves in cold reheat line DN 3202 Bypass stop & control valvesExtraction swing check valcesExtraction 1 : No valveExtraction 2 : 1 swing check valve with auxiliary

actuator, 1 swing check valve.Extraction 3 : 1 Swing check valce with auxilary actutor,

1 swing check valve.Extraction 4 : 1 Swing check valve with axiliary actutor,

1 swing check valve.

Extraction 5: 1 Swing check valve with auxiliary actutor,1 swing check valve.

Extraction 6 : No valve.

2.1.6. MATERIAL OF CONSTRUCTION

(i) Turbine cosingHP turbine shell GS-17 Cr Mov 511IP turbine cosing GS - 22 Mo 4LP turbine cosing St 37 - 2

(ii) BladesFirst stage Last stage

HP moving & stationary blades x22 Cr Mov 121 x20 Cr 13IP moving & stationary blades x22 Cr Mov 121 x20 Cr 13LP moving blades x20 Cr Mo 13 X7 Cr A 113

(iii) Shaft 28 Cr mo Niv 59HP rotor 28 Cr Mo Niv 59IP rotor 30 Cr MoNiv 511LP rotor 26 Cr Mo Ni V 115

2.1.7 WEIGHTS (TONNE)

HPT IPT LPTRotor 7.5 15.8 48.0Cylinder assembled 56.0 37.0 81.0

(With steam inserts)Moment of inertia (kgmw2)Rotor of HP cylinder 31694 kgm2

Rotor of IP cylinder 115559 kgm2

Rotor of LP cylinder 979413kgm2

2.1.8 CASING TEMPERATURE (0c)

Wall temperature Alarm at M/c must be shutHP turbine casing exhaust 480 500Outer casing of LP cylinder 90 110Spray water to LP turbine mustbe switched on at 900c

2.1.9 DIFFERENTIAL EXPANSION

Alarm Trip

HP turbine diff. expansion +4.50 - 2.50 +5.50, - 3.50

IP turbine diff. expansion +5.00 - 2.00 +600, - 3.00

LP turbine diff. expansion +25.00, - 5.00 + 30.00, - 7.00

2.1.10 TEMPERATURE DIFFERENCES (0C)(Between upper & lower Casing Section)

Alarm Trip

HP Turbine middle + 30 + 45

IP Turbine front + 30 + 45

IP Turbine rear + 30 + 45

Permissible differential temp between

Parallel

Steam supply lines : not more than 1.70c

Short time period 280c

(15 minute)

2.1.11 BEARING TEMPERATURE (0C)Normal Operating Alarm M/c must be

temperatues down at

Belwo 750c 900c 1200c

Above 750c 1000c 1200c

2.1.12 VIBRATION (ASBOLUTE)

of bearing of shaft

Nominal value for alarm 35 µµµµµm 30 µµµµµm above normalvalue

Maximum value for alarm - 120 µµµµµm

Limit value for tripping 45 µµµµµm 200 µµµµµm

4140

2.1.13 LOW VACUUM TRIP SETTING

Hydraulic low vacuum trip ≥≥≥≥≥ 0.3 ataElectric low vacuum trip ≥≥≥≥≥ 0.3 ataHydraulic low vacuum trip (Bypass operation) ≥≥≥≥≥ 0.6 ata

2.1.14 MEGAWATT OUTPUT (APPPROX)

HPT IPT LPT56.40 MW 53.73 MW 93.03 MW28% 28% 46%

2.1.15 FEED WATER HEATER OUT OF SERVICE

HP Heater 6 out of service MW rating 210 MWHP heater 5 & 6 out of service 209.1MW

2.1.16 STEAM PURITY

Continuous Start up Unit

operation

(i) Conductivity at 250c,

continuous measurement

at the sampling point

a. direct measurement

alkaline method No specified - µµµµµs/cm

Neutral method <0.15 <0.50 µµµµµs/cm

b. Following a strong acid

cation exchange method

Alkaline method <0.10 <0.10 µµµµµs/cm

Neutral method <0.10 <0.50 µµµµµs/cm

(ii) Silica (SiO2) 0.010 0.050 mg/kg

(iii) Total iron (Fe) <0.010 0.050 mg/kg

(iv) Total copper (Cu) <0.001 <0.050 mg/kg

(v) sodium (Na) <-.005 <0.020 mg/kg

2.2 TURBINE LUBE OIL SYSTEM

2.2 1 OIL SUPPLY

(i) Oil tank rated capacity 20/32m3

(ii) Highest / lowest oil level

from top of the tank 800 / 850 mm

(iii) Lube of temp. at cooler

out let (In operation) Min 380, normal 450, max 470C

(iv) Oil temp rise across bearings Normal 300, max 250C

(v) First oil filling (estimated) 30m3

(vi) Flushing oil quantity (estimated) 20m3

(vii) Pressure limiting value in

jacking oil system bar 120

(viii) Safety valve in jacking oil system max. 170 bar, - 10% min.

(ix) Jacking oil pump must be

switched on at 510 rpm

(x) Jacking oil pump must be

switched off at 540 rpm.

2.2.2 OIL PUMPS

Nos.

M.O.P A.O.P. DC J.O.P. J.O.P.

EOP (AC) (DC)

Nos. 1 2 1 2 1

Make BHEL KSB KSB All Allweiler weilerAG AG

Type ETA ETA SDF SDF150- 100- 40- 40-50VL 33VL RS4 RS4

Rated capacity 139 152.24 108 76 76m3/hr m3/hr lit/m lit /m lit /m

Rated discharge 8.2 84.7 27.66 120 120pressure ata mIc mk bar barSpeed, rpm 3000 1485 1425 2950 2950

4342

M.O.P A.O.P. DC J.O.P. J.O.P.E.O.P. (AC) (DC)

Drive Turbine A.C. D.C. A.C. D.C.motor motor motor motor

Make - GEC crompton Siemens siemensgreaves

Enclosure - - IP44 IP54 IP54Voltage, V - 415 220 415 220Frequency, HZ - 50 - 50 -Motor power, kw - 100 15 27.6 28Rated current, amp - 175 128 47.5 152

2.2.3 OIL COOLER

(i) Type & no. Shell & tube type, 2 x 100 %(ii) Cooling surface/oil flow 280 m2/ 27lit/s

per cooler(iii) Oil outlet temp. of per cooler

In operation Min 38, normal 45, max 470cIn shutdown 750c

(iv) Oil pressure drop acrosscooler 0.4 ata

(v) Tube material & no. of tubes CuZn 28 Sn F38, 1251 no.(vi) Design pr. & temp. shell &

tube side 10Kg/cm2 & 1000c (both)

2.2.4. OIL FILTER

(i) Duplex oil filtertype & no. DN 100 type, 1 no.

(ii) Filteration particle sizeduplex filter 37 µµµµµm

(iii) Filteration particle size MOTfilter 250 µµµµµm

2.2.5 ESTIMATED OIL REQUIREMENTS OF BEARING

Bearing 1 (HPT front pedestal) 0.8 dm3/s2 9.1 dm3/s3 4.0 dm3/s4 3.5 dm3/s

Front Generator bearing 3.5 dm3/sRear Generator bearing 5.0 dm3/s

2.2.6 BARRING GEAR

(i) Type of drive Hydraulic turbine(ii) Method of engagement Hydraulic(iii) Cut in/cut out speed 240/210 rpm(iv) Power to rotate turbine 45 kw(v) Barring speed 80-210 rpm

2.2.7. MAIN OIL CENTRIFUGE

(i) Manufacturer ALFA-LAVAL (India)(ii) Supplier BHEL Hardwar(iii) Capacity 6000 lph purifier(iv) Centrifuge Flame proof induction motor, Crompton

Greaves make, 7.5 kw, 1460 rpm, 15A,Class B, insulation, Frame E 160 LD,3θθθθθ, 415v, 50 Hz Power supply,Ref. IS : 325/1978

(vi) Bowl speed 8425 rpm approx.(vii) Revolution counter (RPM) 118-125(viii) Booster pump type Gear pump, type 206(ix) Booster pump motor Crompton Greaves make, 3.3 kw

1430 rpm, 7.5A, Fram E 132 M(x) Oil heater Indirect type 72 kw

Heater J/II/III 36 kw/ 18kw/ 18 kw(xi) Quantity of water for heater 450 litre approx. for first filling(xii) Sealing water for centrifuge 3 litre for first filling of Centrifuge

2.2.8 OIL CHARACTERISTICSAS per IS : 1448

(i) Kinetic viscosity at 37.80c 47.5 CS. to 49.5 C.S.Kinetic viscosity at 500c 28 C.S.

(ii) Sp. gravity at 500c 0.852(iii) Flash point Min 2000c(iv) Pour point -60c(v) Ash content 0.01 (% by weight)

4544

(vi) Water content Below the level of quantitiativedeteclibility

(vii) Mech. solid impurities -do-(viii)Viscosity index Min 97(ix) Inorganic acidity Nil

Organic acidity Max. 0.14 mg of KOH per gm of oil(x) Neutralisation no. Max. 0.02 mg of KOH per gm of oil(xi) Copper strip corrosion test

at 1000c for 3 hrs. Not worse than no1(xii) Emulsion characteristics 40-40-0

(20 minute)

2.3 VACUUM SYSTEM2.3.1 CONDENSER

(i) Type Surface type, double pass with dividedwater box construction.

(ii) Design conditions Steam side Water sideDesign pressure Full vaccum/1.08 kg/ 5 kg/cm2 (g) &

cm2 (g) full vacuumTest pressure Filling by water up to 7.5kg/cm2 (g)

(iii) Design c.w. flow 22,500 m3/hr

(iv) Design cold wate temp. 320c 600c

(v) Design back pressure 76 mm of Hg (abs)

(vi) No. of tubes 15330 nos.Tube O.D. x thickness, 25.4 x 0.7 thickFor top row thickness 1.0 mm

(vii) Tube material Stainless steel weldedASTM A 249 TP 304

(viii)Surface area 13727 M2

(ix) C.W. velocity 1.83 m/s

(x) Pressure drop C.W. side 4.18 mwc

(xi) C.W. temp rise 10.80c

(xii) T.T.D. 2.960c

(xii) Weight Dry 343 tonnes Operating 540 tones Flooded (1.0 m above tubes) 785 tonnes

2.3.2. VACUUM PUMP

(i) No. & capacity 2 x 100 %

(ii) Make NASH

(iii) Type AT 2004 NASH, two stage liquid ring airpump

(iv) Coupling drive make Wellman - BIBBY Type E - FLEX Size 290 / F8

(v) Unit weight, Empty 6639. kg

Operating 7074 kgFlooded 7619 kg

(vi) Vacuum pump motor ABB MotorType Totall enclosed, fan cooled.

squirrel cage induction motorPower supply 415v, 3φφφφφ, 50HZ

Poer rating 93 kw/125 hpFull load current 190 AFrame size MAFull load rpm 493

(vii) Seal water pumpType Single stage, centrifugal, foot

mounted type.Manufacturer Worthingaton simpsonFlow End suction typeMotor Totally enclosed, fan cooled cage

induction motor, 1.5 kw (2hp)2700 rpm, 3 A, 415v, 3φφφφφ, 50 HZ

power supply, frame size 90 DL

(viii) Heat exchanger Size 1244

4746

Type Single pass, counter flow, tube &shell typeShell side Tube side

Design pressure 10.54kg/cm2 10.54kg/cm2Design temp. ( - ) 6.6-1490c ( - ) 6.6 -1490c

2.3.3 GLAND SEALING SYSTEM

(i) Type of control Electro-hydraulic seal steampressure controller

(ii) Gland sealing temp. above 1200c cold start1500c hot start

(iii) Self sealing after 40% load.

2.4.1 CONDENSATE EXTRACTION PUMP

2.4.1. CONDENSATE EXTRACTION PUMP

(i) Manufactuer BHEL(ii) No. of pumps & capacity 2x100%(iii) Type NESJ14OD (2shaft), vertical

centrifugal connister type(iv) No. of stages 5(v) Discharge capacity 655 m3/hr(vi) Diff. head 190 mlc(vii) Input power to pump 422 kw(viii) Density of medium handled 0.9897 tone/m3(ix) Temperature of medium 46.30c(x) Liquid NPSH required at the

eye of the first impeller 2.8 mlc(xi) RPM 1485(xii) Efficiency of pump 79.5%(xiii) Direction of rotation

viewed from drive end Clockwise(xv) Suction bore dia. 400 mm(xvi) Discharge bore dia. 300 mm(xvii) Cooling water to thrust

bearing flow 10 lpm

(xvii) Sealing water to glands flow 20 lpm(xix) Thrust bearing type Michell 7 SNT(xx) Motor

Manufacturer BHEL/BhopalType Squirel cage induction motorFrame 1LA 7636 - 4 HE 7 4ZKW rating 550 kwPower supply 6600v, 3φφφφφ, 50 HZ

Class of insulation FConnection stator StarEfficiency at rated output 94.2%Rate speed 1487 rpmNo load current 21.4 AFull load current 62.2 ATotal weight of Motor 4900 kgBearing DE 6224-c3NDE 7322 - B

2.4.2. DRAIN COOLER

(i) Position Horizontal(ii) No. of One(iii) Type Tube & shell type(iv) Design code ASME Sec VII DIV I

Tube side Sheil side(v) Design pressure 30kg/cm2 (g) Full vacuum & 3.5 kg/

cm2 (g)(vi) Design temperature 1500c 1000c(vii) Max. working pressure 30 kg/cm2 0.4521 ata(viii) Hydraulic test pressure

(duration 30 minute) 45 kg/cm2 (g) 5.25 kg/cm2 (g)(ix) Hydraulic resistance at 0.8 mwc 0.3 mwc

design flow(x) No. of water path (tube side) one(xi) Tube O.D. x. thickness x length, 16 x 0.889 x 1540

mm(xii) Tube material Austenitic S.S. welded(xiii) No. of tubes 501(xiv) Discharge of main condensate

(design) 540 t / hr(xv) Drain quantity (design) 68.789 t / hr(xvi) Operating weight of drain cooler 3250 kg.(xvii) Cooling surface area 35 cm2

2.4.3. GLAND STEAM CONDENSER

(i) Position Horizontal(ii) No. One

4948

(iii) Type Tube & shell type(iv) Design code ASME Section VIII Div. I(v) Design pressure shell

& water box side Full vacuum/30kg/cm2(g) & 30 kg/cm2(g)(vi) Design temperature shell/

tube side 4000c/1500c(vii) No. of water path tube side one(viii) Surface area 20 m2

(ix) Shell side design flow 0.3 metric tonne/hr.(x) Allowable/design flow

of main condensateMinimum 108 /hrDesign 546/hr at V.W.O., 3% makeupMaximum 780 t / hr

(xi) Hydrauic resistance at minimum/design / maximum flow 0.2 mwc/1.0 mwc/2.3 mwc

(xii) Tube dimenssion θθθθθ x th x l,mm x mm x mm Material Welded S.S. tubes

ASTM 249 TP 304No. 325

(xiii) Exhauster fans 2 no., centrifugal, 1080m3/hr,2840 rpm, 3 hp

2.4.4 LOW PRESSURE HEATER

(i) Type LPH-1 LPH-2 LPH-3(ii) Position/location ............... Shell & tube type ................

condenser neck(iii) No. one one one(iv) Design code ............ ASME SEC VIII DIV I .................(v) Design pressure shell side ............ 3.5 kg/cm2 / Full vacuum ............

waterbox side ....................... 30 kg/cm2 .......................(vi) Design temperature shell 150 210

side(vii) No. of tubes 429 429

LPH-1 LPH-2 LPH-3(ix) Weight, Dry 11100 11100

Operating 13700 13700Flooded 19170 19170

(x) Test pressure kg/cm2Shell side 5.25 5.25W/B side 45 45

(xii) Shell assy IS 2002 Gr A BQ STEELWater box IS 2002 Gr A BQ STEELWater box cover IS 2002 Gr A BQ STEEL

2.5.1 DEAERATOR

(i) Manufacturer BHEL, Hyderabad

(ii) Type Spray cum tray type

(iii) Design pressure and temp. Spray cum tray type

(iv) Shell diameter and thicknessa. Dearator ID 2200 x 16 thk, mmb. Storage tank ID 3600 x 20 thk, mm

(v) Straight length and overalllength of shella. Deaerator 6632, 7882, mmb. Storage tank 21000, 22900, mm

(vi) No. of trays provided 240

(vii) No. of spray valves 48.

(viii) Storage capacitya. At normal water level with a filling capacity of 2/3 of cross- sectional area of the storage tank 141.4 m3b. Normal water level to low level 131.4 m3

(ix) Water level from centre line ofhorizontal vessel

5150

a. Normal 610 mm above

b. Low 118 mm above

c. Low-High 1300 mm above

d. High 860 mm above

e. High-High 1035 mm above

(x) Feed water outlet temperature 1610c

(xi) Deaerator operation condition 6.85 kg/cm2 abs. 163.80

(xii) Oxygen guarantee 0.005 cc/liter as measured by ASTM-D-888.

(xiii) Safety valve 2 no., spring loaded, 40 t / hr capacity

each, BHEL trichy make, 6.8 kg/cm2 (g)

set pressure.

(xiv) Total weight

Empty/operating/flooded 80/210/310 tonne

BOILER FEED BOOSTER PUMP

(i) Pump type FA 1B 56

(ii) Liquid pumped Boiler feed water

(iii) S.G. at suction temperature 0.90665

(iv) Suction tempreature 160.70c

(v) Differential head 100m

(vi) Flow rate 450 m3 / hr

(vii) Efficiency 79 %

(viii) Speed 1485 rpm

(ix) Power 141 kw

(x) NPSH, required 4.03 m.

(xi) Thrust bearing The Glacier Metal Co. Ltd.

Double thrust, CK range size

811/2KP-2KP

(xii) Mechanical seal Durametalic/sealEd type

4.250” PTO/type 503

BOILER FEED PUMP

(i) No and Capaciy 3 x 50%(ii) Make BHEL, Hyderabad(iii) Pump type FK 6 D 30(iv) No. of stages 6(v) Liquid pumped Boiler feed water(vi) S.G. at suction temperature 0.90665(vii) Differential head 2123m(viii) Design flow rate 450 m3 / hr(ix) Minimum recirculation flow 110 m3 / hr(x) Efficiency 81%(xi) Speed 5150 rpm.(xii) Power 2911 kw(xiii) Direction of rotation viewed

on drive end Anti-clock wise(xiv) NPSH required 24.0 mlc(xv) Thrust bearing The Glacier Metal Co. Ltd., Double Thrust,

CK range, Size 8159’/2KP-2KP

DRIVE MOTOR

(i) Make BHEL, Bhopal(ii) Type Squirrel cage induction motor(iii) Frame size 1 RN7 714-4HE 70-Z(iv) Rating 3500 kw(v) Degree of protection, type

of enclosure and methodof cooloing IP 54, CACW, ICW 37 A 81

(vi) Power supply 6600 volt, 3 phase, 50 HZ

(vii) Rated speed 1500 (synch.)(viii) Insulation class F(ix) No load current 80 A(x) Full load current 356.5 A(xi) Weight 12800 kg(xii) Winding temperature rise at

rated output over cooling air 700c (by resistance), 800c (by ETD)(xiii) Bearing - DE Sleeve bearing 160 x 14 Q

- NDE Sleeve bearing 125 x 115 (Insulated)

5352

TYPE OF COUPLINGS

(i) Turbo coupling / pump flexiblecoupling Manufacturer Torsi flex Ltd.Type HBS 1000-8x

(ii) Motor / turbo coupling flexiblecouplingManufacturer Torsi flex Ltd.Type HBS-3600 8

(iii) Motor / turbo coupling flexiblecouplingManufacturer Torsiflex Ltd.Type HB4-140X (Insulated)

HYDRAULIC TURBO COUPLING

(i) Manufacturer Vaith Turbo GMBH and Co.(ii) Type R16 K.1(iii) Power requirement of driven

machine 3245 kw(iv) Gear ratio, type 181/51, step up gear unit(v) Speed input / output 1485/5155 rpm.(vi) Full load slip 2.2%(vii) Regulating range 5:1 down wards(viii)Oil tank filling Approx. 700 litre(ix) Working oil flow rate 47 litre / min.

AUX. LUB OIL PUMP

(i) Type Gear pump(ii) Lube oil flow Approx. 120 litres/min.(iii) Pressure 2.5 bar,(iv) Motor 5.5 kw, 415v, 50 HZ, 1500 rpm

IP 55

OIL/WATER-HEAT EXCHANGER

(i) Type WORKING OIL LUB OIL(ii) Heat exchanger capacity L1 N1 09 17 04-D L1 N1 07 17 04-D(iii) Cooling water flow, V rated 52 m3/hr 38m3/hr

V / min 25 m3/hr 15 m3/ hr(iv) Cooling water inlet temperature 380c 380c(v) Cooling water outlet temperature 480c 400c(vi) Normal oil flow rate 31m3/hr 13.2m3/hr(vii) Oil inlet temperature 1000c 610c(viii) Oil outlet temperature 610c 450c(ix) Maximum permissible working

pressure, oil side 16 bar 16 bar water side 10 bar 10 bar

(x) Maximum permissible workingoil temperature 1200c 1200c

COOLING WATER FLOW

Cooler Quantity/ Pressure Temperaturecooler drop risem3 /hr kg/cm2 0c

(i) Booster pump stuffingbox cooler 2 x 1.8 0.4 2.0

(ii) Motor cooler 24 0.5 5.0(iii) Working oil cooler 52 0.5 10.0(iv) Lub oil cooler 38 0.5 2.0(v) Mech. seal cooler 6.0 0.2 3.0(vi) BFP stuffing box cooler 2x2.4 0.2 2.0

2.5.2 HIGH PRESSURE HEATERS

HP Heater No.5 6

(i) Manufacturer .............. BHEL Hyderabad .............(ii) Type and arrangement .............. U Tube Horizantal .............

5554

(iii) No. of shell passes 3 Zones 3 Zones

(iv) No. of tube passes 2 2

(v) TubesType of tubes provided Seamless SeamlessTotal no. of U tubes 757 757Effective length U tubes, mm 17270 20075Outer diameter, mm 15.875 15.875Design pressure, kgf/cm2 (g) 280 280Design temperature, 0cDesuper heating zone 235 285Other zones 215 265Design pressure, kgf/cm2 (g) 280 280Design temperature, 0cDesuper heating zone 235 285Other zones 215 265Tube side relief setpressure, kg/cm2 (g) 280 280

(vi) ShellOutler diameter / wallthickness, mm 1240/20 1264/32Length of despuer heating, mm 1980 2515Length of drain cooling, mm 3048 2515Design pressure, kg/cm2 (g) 19.0 and 50 and full

full vacuum vacuumDesign temperature skirt/shell,0c 440/215 370/265Shell side relief valve, set pr.,kgf/cm2(g) 19.0 50.0

(vii) Velcity through tubes at 670 t /hr flow, kg /cm2 2.22 2.29

(viii)Tube side pressure drop at670 t / hr flow, m/sec 0.9 1.1

(ix) Total heat transferrel, kcal/hr 23.73 32.31

(x) Drain level in heaters, mm(From C.L. of heater)a. Normal 410 410b. Maximum 100 100C. Minimum 495 495

(xi) Surface area, m2

Desuperheating / condensing /drain cooling zone 75/ 446 / 115 95/ 562 / 95Total effective area, m2 636 752

2.6 PREDICTED PERFORMANCE

STEM PRESSURE (BAR)Rated Long time Short time

Description value operation operation

bar bar bar

Initial steam 147.1 147.1 176.5

Before 1st HP drum stage 132.6 137.9 145.9

HP cylinder exhaust 39.23 45.11 47.08

IP cylinder stop valve inlet 34.13 39.59 40.08

Extraction 6 39.23 45.11 47.08

Extraction 5 16.75 19.84 19.84

Extraction 4 7.06 8.46 8.46

Extraction 3 2.37 2.91 2.91

Extraction 2 0.858 1.09 1.09

Extraction 1 0.216 0.374 0.374

HP cylinder exhaust 0.118 0.3 0.3

STEAM TEMPERATURE (0c)

Rated Long time 400 hr 80 hr.value value but per per

Description Annual keeping annum annum max.mean value within annual 15 minutes

mean value in individualcase

initial steam 535 543 549 563

IP cylinder stop 535 543 549 563

valve inlet

5756

Rated Long time 80 hr pr. In specialDescription value operation annum max. case at

0c 0c 15 min. in no loadindividual

case

HP cylinder exhaust 343 359 425 500*Extration 6 343 359 425 500*Extration 5 433 438 473 -Extration 4 316 326 366 -Extration 3 200 211 255 -Extration 2 107 127 167 -Extration 1 62 82 127 -LP cylinder exhaust 49 70 70 100

**CONDENSATE WATER

Description Pressure Temp. Flowkg/cm2 0c 1/hr

CEP suction 0.1033 46.1 508.83CEP discharge 19.379 46.3 508.83GSE oulet 10.54 46.6 508.83Drain cooler oulet 10.08 47.8 508.83LPH 1 oulet 9.63 56.6 508.83LPH 2 oulet 9.18 90.6 508.83LPH3 oulet 8.72 120.7 508.83

**HEATER DRAIN

Description Temp. Flow0c t/hr

GSC drain to LP Flash box 99.9 0.299LPH3 to LP2 123.5 27.589LPH2 o LPH1 93.4 57.651

LPH1 to drain cooler 60.3 63.437Drain cooler to LPFB 52.8 63.437HPH6 to HPH5 206.0 61.091HPHS to deaerator 170.0 95.807

**FLEED WATER

Pressure Temp. FlowDescription kg/cm2(g) 0c 1/hr

BFP suction 6.405 160.7 639.27BFP discharge 205.0 164.1 639.27HPH5 outlet 204.09 200.0 639.27PHP6 outlet 203.18 247.0 639.27

Long time operation Upper limit value permissible without timelimit.

Short time operation Permissible momentary value the aggregateduration of such must not exceeds 12hr/annum

Rated value These value corresponds to 210 mw load with3% make up and 0.1187 bar back pressure withall heaters in service and rated steamconditions.

* Only valid for no load period with high reheat pressure after trip out fromfull load for the individual cases approx. 15 minutes.

** Parameters are given when unit 210 mw, 0% make up water, 76 mm backpressure and constant pressure operation.

2.7 EQUIPMENT COOLING WATER PUMPS

(i) Manufacturer Mother & platt(ii) No. of/unit and type 3, 8/10 CME MK -1(iii) Design capacity 100 m3/hr(iv) Total head 60 m(v) Speed 1482 rpm(vi) Pump weight 750 kg.(vii) NPSH 6.4 mtrs.

5958

(vii) MotorManufacturer Crompton GreavesFrame HMHAC-400/6Type 3θθθθθAC induction motorMotor rating 215 kw (288 hp)Power supply 6600v, 3θθθθθ, 50 HZ

RPM 1482 rpmInsulation class FFull load currentq 23.5 ABeaing DE NU 321 - 1 NDE 6321

2.8 HP / LP BYPASS SYSTEM

Capacity 60 % MCR420 t/hr of main steam flow at the inletof HP bypass valve

HP Bypass

(i) Valves BP1/ BP2 Valves BPE 1,2 ValvesDesign pressure 170/50 ata 280 ataDesign temperature 540/4850c 1750cBody material 10Cr Mo 10 15 Mo3Nozzle material 10 Cr Mo 910 15 Mo3Medium Main steam spray water

(ii) ActuatorType HydraulicHydraulic system pressure 100 barpositioning time 10/3 sec (3 sec for fast opening device)

(iii) Oil supply unitOil pump type OV-32Supply capacity 24 l/min.Motor rating 7.5 kw, 415v, 3θθθθθ, 50 HZ, 1440 rpm,

14.2 AOil tank volume/useablevoulme 70l/50lOil pump cut in at 100 ksc

Cut out at 160 kscBack up protectioncut in/cut out 110 ksc/170 kscRelief valve setting 190 ksc

2.9 H.P. & L.P. FLASH TANK

H.P. FLASH TANK L.P. FLASH TANK1. Type Vertical cylindrical, Vertical cylindrical

leg supported, leg supported.2. Desing code ASME Sec VIII Div. I ASME SEc VIII Div I3. Design pressure Full vacuum & 3.5 Full vacuum & 3.54. Design temperature 2100c 2100c5. Fluid handled Water/steam Water/steam6. Shell material ASTM A 285 Gr.c/ ASTM A 285 Gr.c/

IS : 2002 Gr 2 IS : 2002 Gr. 27. Internal diameter 220 mm 1600 mm8. Shell thickness 12 mm 1600 mm8. Shell thickness 12 mm 12 mm9. Overall height 3300 mm 2400 mm.10. Corrosion allowance 3.2 mm 3.2 mm11. Thining allowance 1.5 mm (max.) 1.5 mm (max.)

2. 10 LP DOZING SYSTEM (HYDRAZINE & AMMONIA)

LP Dozing (Hydrazine) LP. Dozing (Ammonia)

1 Mixing tankDimension 750 mm dia. x 100mm 1400 mm dia.x 1000 mm

H.O.S. H.O.S.Capacity 340 litres (Net) 1200 litres (Net)Material Stainless steel as per Stainless steel as per

SS - 304 SS - 304Stirrer motor 0.37 kw, 1395 rpm. 0.75 kw, 1395 rpm

2. Metering tankDimension 750 mm dia x 1000 1400 mm dia x 1000

6160

mm H.O.S. mm H.O.S.Capacity 340 litres (Net) 1200 liters (Net)Material Stainless steel as per Stainless steel as per

SS - 304 SS - 3043. Dozing pumps

Type 2 x 100% positive 2 x 100% positivedispacement displacement

Capacity Max. 13 13 liters/hr 61 liters/hrDischarge pressure 30 bar 30 barMotor rating 0.25 kq 0.55 kw

4. Transfer systemTank no. and capacity - 2 x 3 m3

Transfer pump - 2 x 100% for 4units

2.11 COOLING WATER FLOW

S.No. EQUIPMENT EQUIPMENT/ TOTAL PRESSURE TEMPDESCRIPTION UNIT QTY./ DROP RISE REMARKS

WORKING+ UNIT mwc 0CSTANDBY m3/hr

1. Turbine lub oilcoolers 1+1 360 8.8 2.53

2. Hydrogen cooler 4+0 350 8.2 5.23. Seal oil cooler 1+1 72 1.8 0.64. Startor water

cooler 1+1 200 2.5 3.15. CEP brg cooling 1+1 1.2 3 3 Flow through stand by

CEP also considered6. BFP AUX6.1 Booster pump

stuffing boxcooler 2+1 10.8 4.0 2.0 Flow through stand-

by CEP also considered

6.2 BFP workingoil cooler(Duplex viz1+1per BFP 2+4 98 5.0 0.0

6.3 BFP motoroil cooler 2.1 48 5.0 5.0

6.4 BFP lub oil cooler Flow through standby(Duplex viz1+1 per BFP) 2+4 114 5.0 2.0 also considered

6.5 BFP seal water 2+1 18 2.0 3.0cooler

6.6 BFP stuffing box 2+1 14.4 2.0 2.0cooler

7.0 Vacuum pump 1+1 182 2.5 2.08.0 Water jel ejector 1+1 10 - 2.09.0 V.E. oil separate

(seal oil system) 2+1 5 4 2.0

ACW pressuresHydrogen cooler < 3.5 kscOil separator < 2 kscSeal oil cooler < 4.5 kscWater jet ejector < 2 kscStator water cooler < 4 kscCEP < 3 ksc

6362

SECCTION - 3

GENERATOR&

AUXILIARIES

3.1 GENERATOR TECHNICAL SPECIFICATION

(i) Make BHEL(ii) Type THW - 201-2

Two pole, cylindrical, steam turbinedriven

(iii) Code IS : 5422(iv) Cooling Stator winding Directly water cooled

Stator core and Rotor Directly hydrogen cooled(v) MW rating 210(vi) MVA rating 247(vii) Rated terminal voltage 16.5 kv(viii) Rated terminal voltage 8,645 A(ix) Rated power factor 0.85 log(x) Ratd speed/frequency 300 rpm/50 HZ

(xi) Negative sequence current

capability (l2 t) 8

(xii) Efficiency at MC Condition 98.55%(xiii) Short circuit ratio 0.49(xiv) Phase connection Double star(xv) No. of terminals brought out 9 (6 neutral, 3 phase)(xvi) Generator stator winding

resistance in each phast 0.00155 ohm at 200c(xvii) Generator rotor winding

resistance 0.0896 ohm at 200c

STATIC EXCITATION EQUIPMENT

Make BHELSEE Rating Voltage - 310 v DC

Current - 2600 amp DCAccuracy of excitation control + 0.5 %Range of voltage control in auto 90.110 %Range of voltage control inmanual 80.110 %No load field voltage 102 V DCNo load field current 917 ampMax. continuous rated fieldvoltage 355 V DCMax. continuous rated fieldcurrent 3000 amp

Ceiling. voltage 620 v DCCeiling current 4500 ampFrequency range ofoperation 47.5 - 52 HZ

No. of parallel bridgesincludingredundant bridge 4No. of redundantbridge 1Protection class IP 20Station battery supply 220c DCDuration of field forcing 10 secResponse time 40 m Sec

EXCITATION TRANSFORMER DETAIL

Make MAY and CHRISTERating 2500 kvaVoltage rating 16500/575 v ACVector group Dyn 5Insulation level 50KV/RMS/MINCooling AN-with two blower provided extra.

3.2 DESIGN & CONSTRUCTIONAL FEATURESMATERIAL

(i) Rotor shaft Steel forging 35 Ni 3 Cr 12 Mo 35V 12chromium nickle molybdenum andvanadium steel

(ii) Rotor winding Silver bearing copper(iii) Rotor slot wedges Duralumin.(iv) Rotor retaining ring 60 Mn Ni85 Cr W75, Non magentic steel(v) Stator frame ST-42w(vi) Stator core stampings Cold rolled silicon steel(vii) Bearing body CSW C25 Is:2856-64(viii) Shaft sealing ST-42w(ix) Bearing and seal babbit Grade 84(x) Carbon brushes

6564

a. Grade HM 6Rb. No. of brushes required 112+1

WEIGHT & OVERALL DIMENSIONS

(i) Weight of the heaviestlift (stator with gas cooler& lifting trunions) 175,000kg

(ii) Weight of the rotor 42,200 kg(iii) Weight of the gas cooler 1415 kg(iv) Weight of the end terminal 85 kg(v) Weight of the end shield 200 kg(vi) Total weight of the generator 239000 kg(vii) Overall dia. of stator 3960(viii) Length of stator (overall) 65822 mm(ix) Length of rotor (overall) 9770 mm(x) Diameter of rotor barrel 1075 mm

TORQUES, CRITICAL SPEEDS ETC

(i) Torque under normal working conditions 76.32 tonnes(ii) Rotio of short circuit torque to full load

torque 8(iii) Flywheel moment of the rotor 21.1 m2

(iv) 1st critical speed of the rotor (calculated) 1370 rpm(v) 2nd critical speed of the rotor (calculated) 3400 rpm

OIL CONSUMPTION

(i) Consumption of the oil per generaterbearing (excluding shaft seal) 300 lit/ minute

(ii) Oil pressure at the inlet of bearing 0.3 to 0.5 kg/cm2(iii) Consumption of oil in both shaft seals 77 lt/min

3.3 GENERATOR GAS SYSTEM

3.3.1 HYDROGEN IN STATOR CASING

(i) Nominal pressure of Hydrogen 3.5 kg/cm2 (g)permissible variation +0.2 kg/cm2 (g)

(ii) Maximum temperature of cold gas 440c(iii) Maximum permissible hot gas 650c

temperature(iv) Minimum required purity of hydrogen 9.7%(v) Maximum oxyen content 1.2%(vi) Relative humidity of hydrogen

casing pressre (maximum) 30%(vii) Maximum moisture content in

Generator casing 15 gm/m3 of H2

(viii) Total gas volume of the Generater 56 m3

(ix) Maximum make up hydrogen per day 15 m3

3.3.2 GENERATOR FILLING QUANTITIES

M/c at stand M/c under-still rolling

(i) Amount of carbon-di-oxide requiredto remove air expressed at NTP 90 m3 112 m3

(ii) Carbon-di-oxide for expelling hydrogen 120 m3 168 m3

(iii) Hydrogen filling qunatity 300 m3 336 m3

(iv) Compressed air required for purging ofcarbon-di-oxide from the generator 150 m3

(v) Quantity of compressed air required(at NTP) for carying out air tightness test 500 m3

(vi) Max. no. of H2/Co2 cylinder can e conectedat a time 8/8

3.3.3. HYDROGEN COOLER

At Rated Hydrogen Pressure 3.5 kg/cm2 (g)

6766

(i) No. of coolers/ Generator 4(ii) Gas flow per cooler 7.5 m3/ sec(iii) Max. water inlet temperature 370c(iv) Pressure drop through cooler 17.5 mwc(v) Design pressure water side of cooler 6 kg/cm2 (g)(vi) Max. permissible operating pressure

water side of cooler 3.0 kg/cm2 (g)(vii) No. of passes of water in gas cooler 2(viii) Material of tubes/fins Admiraly brass/copper(ix) Material of water boxer/Tube sheats Carben steel(x) Heat load 528 kw

3.3.2 HYDROGEN DRIER

(i) Working pressure and volume 5bar, 39 dm3, silica gel filled(ii) Heater rating 2.5kw, 415v,3θθθθθ,50 HZ supply(iii) Blower Siemens make, 1.1 kw,

2855 rpm, 2.3A

3.4 STATOR WATER SYSTEM

(i) Nominal gauge pressure at inlet to winding 3.3kg/cm2 (g)(ii) Flow of distillate through stator winding 27+3m3/hr(iii) Nominal temperature of distillate at

Inlet to winding 45 + 30c -10

(iv) Stator winding distillate filling quantity 0.35 m3(v) Nominal conductivity of distillate <5µµµµµmho/cm(vi) Maximum conductivity of distillate 13.3µµµµµmho/cm

STATOR WATER PUMP

(i) No & type 2x100% single stagecentrifugal with spiral casing& over hung impellerCPX-CM-50-200, KSB make

(ii) Flow 39.6 m3/hr

(iii) Speed 2930 rpm(iv) Head 45 mlc(v) Motor

Make GECRating kw/hp 9.3 kw/12.5 hpPower supply 415v, 3q, 50HZFull load current 18 AClass of insulation BRPM 2930Ambient temp. 500c

STATOR WATER COOLER

(i) No. of coolers per system & type Two, shell & tube type(ii) Permissible max. operating primary/

cooling water pressure 8.0 kg/cm2/5.0 kg/cm2

(iii) Primary water inlet/outlet temperature 72.6/450c(iv) Max cooling water inlet temperature 27 m3/hr/110 m3/hr(v) Pressure drop in primary water/

cooling water 6.5 mwc/0.8 mwc(vi) Max cooling water inlet temperature 360c(vii) Heat load 790 kw(viii) Shell/tube material Stainless steel/Admiarly

brass(ix) Tube sheets/water boxes material Brass/carbon steel(x) Heat transfer area 33 m2

(xi) Cooling water flow rate 200 m3 /hr(xii) Cooling water pressure drop 2.5 mwc

STATOR WATER FILTER

No. 2Make Ball and kirch fiher bar

GmbttType 1.53.1.220 500 DN 100Working pressure 10kg/cm2

Working temperature 600cVoulme 27 dm3

6968

EXPANSION TANK

Type Hermetically sealedcontainer, TGSC-E

Material Stainless steelVacuum 250 -300 mm of HgWeight 902 Kg.Volume (capacity) 2 m3

QUALITY OF DISTILLATE

Conductivity less than 5 µµµµµmho/cm preferobly1 µµµµµmho/cm

pH 6.5 to 8.5Dissolved O2 Minimum, preferably less than

50 ppb but not greater than 100 ppbDissolved CO2 NilAmmonia Minimum, preferably zeroChloride Minimum - preferably zeroDissolved/undissolved Cu less than 20 ppbDissolved /undissolved Fe less than 20 ppmDissolved solids The water should be free of any

chemicals from treatmentprocess such as hydrazine,morphoine, levoxine phosphate etc.

3.5 SEAL OIL SYSTEM

(i) Type of shaft seals Single flow ring type(ii) Hydrogen pressure of Generator

casing 3.5 + 0.2 kg/cm2

(iii) Seal oil - H2 diff pressure min. 1.0, normal 1.5 max 1.7 kg/cm2

(iv) Quantity of seal oil per seal 38.5l/min

(v) Qty of seal oil towardsAir side 2/3 rdHydrogen side 1/3 rdoil system press 7.5 Kg/cm2

3.5.1 SEAL OIL PUMPS

(i) Type TUSHCO pump TUSHCO pump3-52-46 IBSCS1x2 3.52-46-18SCSx2

(ii) Pump discharge flow 130 l/m 125 l/m(iii) Pump head 12 kg/cm2 12 kg/cm2

(iv) Pump speed RPM 1000 1000(v) Motor type Ac motor DC motor

Make Crompton Greave Kirloskar RPM 945 960 Kw 4.85 kw 5.6 kw Power supply 415 v, 3θθθθθ, 50 HZ 220v DC+10%20% Amp 10.6 A 42 A

SEAL OIL COOLER

Make BHEL, HaridwarSurface area 14.3 m3

Tube side/shell side designperssure 10.5 kg/cm2

Tube side/shell side test 16.0 kg/cm2

pressureType Surface type

VACCUM PUMP

Make LEYBOLD W. GermonyType S4-BFlow 4m3/hrUltimat pressure <250 m barMotor AM71 NY 71 NY4, 3θθθθθ, 415v, 1.2.A, 50 HZ

0.18 kw, 1400 rpm IP 54

7170

FILTER

Make Boll & Kirch Filter ba GmbHPressure 16 bar, 500cType 170/32F 200

OIL TANKS

Intermediate tank 75 LtSeal oil storage tank 500 LtSeal oil tank 1000 Lt

3.6 SPECIFICATIONS OF TRANSFORMERS3.6.1 GENERATOR TRANSFORMER

(i) Manufacturer BHEL, Bhopal(ii) No. One per unit(iii) Rating 270 mva(iv) No load voltage, HV 235 kv(v) No load voltage, LV 16.5 kv(vi) Rated current, HV 664.12 A(vii) Rated current, LV 9458.15 A(viii) Frequency 50 HZ

(ix) Vector group Ynd 11(x) Off load tap changer range -5% to + 5% in steps of 2.5%(xi) Impedance voltage at

Max tap 13.82%Normal tap 13.81%Minimum tap 13.91%

(xii) Type of cooling OFAF(xiii) Temperature rise above on

ambient of 500c - In oil 500c In winding 550c

3.6.2 UNIT AUXILIARY TRANSFORMER

(i) Manufacturer NGEF Ltd., Banglore(ii) Type OFTR 16000/22(iii) No. of transformers 2 per unit(iv) Rating 16 mva(v) Voltage ratio 16.5/6.9 kv(vi) winding connection HV/LV Delta/star(vii) Vector group Dyn 1(viii) Type of cooling onan/onaf WITH 2X50%

separately mounted radiators(ix) Rating available at different cooling 125/16 mva (78%/100%)(x) Temperature rise above ambient of

500c - In oil 500c In winding 550c

(xi) Tap changer type and range On load, + 10% to - 5%In steps of 1.25 % on HV windingNo. of steps 12

(xii) Percentage impedance 7% (+ 10%)(xiii) Bushings HV-oil filled

LV-oil filledLV neutral - oil filled

3.6.3 STATION TRANSFORMER

(i) Manufacturer NGEF Ltd. Banglore(ii) No. 2(iii) Maximum rating HV/LV1/LV2 55/27.5/27.5 mva(iv) Winding connection HV/LV1/LV2 Star/star/star(v) Voltage ratio 220/6.9/ 6.9 kv(vi) Vector group Yn YnOY n0(vii) Tap changer type and range On load tap changer,

+10% to - 10% in steps of 1.25%on HV Winding, total 16 steps.

(viii) Type of cooling ONAN/ONAF/OFAF

7372

steps of 1.25%(vii) Cooling Type ONAN ONAF OFAF

Rating available 40% 60% 100%

3.6.5 MISCELLANEOUS SERVICE TRANSFORMER

(i) Make Voltas Ltd. Pune(ii) Rating 10 mva(iii) Voltage ratio 11.5/6.6 kv(iv) Vector group Ynd 11(v) Winding connection HV/LV Star / delta(vi) type of cooling ONAN(vii) Tap changer type and range Gang operated off ckt. 5% in

steps of 2.5% each

(viii) Percentage impedence 8% + 10%(ix) Temperature rise over an ambient In oil 500c

of 500c In winding 550c

7574

(ix) Rating at different cooling 60% 80% 100%ONAN ONAF OFAF

(x) Temperature rise over anambient of 500c-In oil 500c In winding 550c

(xi) Bushing HV LV HV netural LV neutralType condenser oil filled condenser oil filledMin creepage dist. (mm) 5635 385 1170 385

(xii) Neutral bushing CT detailNo. of cores LV1-one, LV2-oneService ProtectionRatio 100/1Acuracy class 5P 20Rated burden VA 15

(xiv) Guaranteed positive sequenceimpedonce at 750c with 100% HV-LV1 HV-LV2 LV1-LV2rating at principal tap 23% 23% 41%

3.6.4 INTER CONNECTING TRANSFORMER

(i) Make Crompton Greaves Ltd.(ii) Rating 167 x 3 = 500 mva(iii) No. 2

3 single phase transformer ineach set with one spare for both.

400 200 33 kv(iv) Voltage Ratio ___ ___ ____

√√√√√3 √ √ √ √ √3

(v) Current HV-723.1 AmpIV-1314.8 AmpLV-Reactive- 1681.8 AmpActive-151-.5 Amp

(vi) % age of impedance HV/IV 9.55%HV/LV 6.1%

(vii) Tap changer On load type having 17 stepsfrom + 10% to - 10% in the

3.7 H.T. M

OTO

R

S.N

o.

Eq

uip

men

tQ

uan

tityR

ating

(i)ID

fan4

1400 kw unit 1 &

24

1325 kw unit 3 &

4(ii)

FD fan

81000 kw

(iii)PA

fan6

1050 kw(iv)

GR

fan6

700 kw(v)

Coal m

ill24

425 kw(vi)

CE

P8

550 kw(vii)

BF

P12

3500 kw(viii)

EC

W pum

p8

215 kw(ix)

CW

pump

8900 kw

(x)fire hydrant/sprinkler pum

p4

175 kw(xi)

Crusher m

otor4

590 kw(xii)

Conveyor 1 A

/B2

280 kw(xiii)

Conveyor 2 A

/B2

240 kw(xiv)

Conveyor 3 A

/B2

430 kw(xv)

Conveyor 4 A

/B2

200 kw(xvi)

Conveyor 5 A

/B2

250 kw(xviii)

Conveyor 7 A

/B2

320 kw(xviii)

Transport air compressor (A

HP

)8

545 kw(xix)

HP

water pum

p (AH

P)

6320 kw

3.8 BA

TTER

Y A

ND

BA

TTER

Y C

HA

RG

ER

3.8.1 220 V D

.C B

ATTE

RY

(i)M

anu

fcaturer

Exide

(ii)N

o of battery bank in eah unit2

(iii)N

o of cells109

(iv)C

ell designationA

s per IS 1651 T 8004

(v)N

ormal voltage of each ell

2.0 volts(vi)

Cap

acity800 A

H-10 hour

(vii)S

pecilic gravity1200 at 27

0c

7776

3.6.6. LT TRANSFORMERS

S.No. XFMR DESCRIPTION Nos. Capacity Voltage Vector %age CoolingRatio (KV) Group Impedence Type

01. Unit service xfmr (UST) 8 1250 kva 6.6/0.433 Dyn l 6% (+10%) ONAN02. ESP Service xfmr 8 1600 kva 6.6/0.433 Dyn 1 8% (+10%) ONAN03. Station Service xfmr (SST) 8 1250 kva 6.6/0.433 Dyn 1 6% (+10%) ONAN04. Swyd. Service xfmr 2 630 kva 6.6/0.433 dyn 1 5% (+10%) ONAN05. DM pant service xfmr 2 1600 kva 6.6/0.433 dyn 1 8% (+10%) ONAN06. Saltening plant Service xfmr 2 1600 kva 6.6/0.433 dyn 1 8% (+10%) ONAN07. F.O.P.H. Service xfmr 2 1600 kva 6.6/0.433 dyn 1 8% (+10%) ONAN08. Ash handling xfmr 4 1600 kva 6.6/0.433 dyn 1 8% (+10%) ONAN09. Air Compressor xfmr 4 1600 kva 6.6/0.433 dyn 1 8% (+10%) ONAN10. Workshop Service xfmr 2 1600 kva 6.6/0.433 dyn 1 8% (+10%) ONAN11. CHP Service xfmr 2 1250 kva 6.6/0.433 dyn 1 5.408% ONAN12. Track happer service xfmr 2 1000 kva 6.6/0.433 dyn 1 5.25% ONAN13. Stockyard service xfmr 2 630 kva 6.6/0.433 dyn 1 4.71% ONAN14. Bunker Service xfmr 2 1000 kva 6.6/0.433 dyn 1 - ONAN15. Lighting Distribution xfmr 8 100 kva .415/0.415 dyn 1 3% (+10%) ONAN16. Admn. Bldg. Service xfm 2 630 kva 6.6/0.433 dyn 1 5% (+10%) ONAN17. Wagon trippler service xfmr 2 630 kva 6.6/0.415 - ONAN18. Stacker reclaimer Service xfmr 2 400 kva 6.6/0.415 - ONAN19. VFD Transformer (ch-1) 4 900 kva 6.6 / 1.25 dyn 1 11.34 ONAN20. VFD Transformer (ch-2) 4 900 kva 6.6 / 1.25 dyn 1 10.5 ONAN

220V FLOAT CUM BOOST BATTERY CHARGER

(i) Manufacturer UPTRON POWERTRONICS LTD.Sahibabad

(ii) A.C. input 415v + 10%, 3θθθθθ, 50 HZ +5%, 69.7 A(iii) D.C output voltage Float 220 V-250 V

Boost 200-300 V Current Float 110 A

Boost 80A(iv) Ripple 1% peak to peak without battery(v) Efficiency at full load more than 85%(vi) Voltage setting range (manual) 220v to 300v(vii) Current setting range 50% to 100% of rated current(viii) Cooling AN(ix) Max. ambient temperature 500c(x) Response time Less than 750 m sec

2.3.2 + 26 D.C. BATTERY

(i) No of cells 13(ii) AH capacity 400AH(iii) Each cell voltage 2v

+26 V.D.C. BATTERY CHARGER

(i) Manufacturer Chhabi Electricals Pvt. Ltd.(ii) Type Float cum Boost(iii) A.C. input 415v + 10%, 3φφφφφ, 50+5% HZ

4 wire A.C. supply(iv) Specification CV-CC/175+56=231 A

+ 26v(v) D.C. Volts CV-30

CC-36(vi) Amperes D.C CV-175

CC-56(vii) Ambient temperature max. 500c(viii) Ripple 1%

3.8.3 - 26 V D.C. BATTERY

(i) No of cells 13(ii) Each cells voltage 2v(iii) AH Capacity 175

- 26 V BATTERY CHARGER

(i) Manufacturer Chhabi Electricals pvt. Ltd.(ii) Type Float cum bost charger(iii) A.C. input 415v + 10% HZ

4 Wire A.C. Supply(iv) Specification CV-CC/76+24 = 100A(v) Ambient temperature 500c(vi) Ripple 1%

3.8.4 BATTERY CHARGER FOR SWITCH YARD

(a) 50 v battery charger for 400 AH battery (2Nos.)Make Chhabi Electricals pvt Ltd.A.C. Voltage 415 v +10% 3 phase, 50 HZ

Specification Float cum boostVoltage DC 52/43 - 65Amp DC 105 / 40

(b) 220 V battery charger for 400 AH batteries (2No.s)Make Chhabi Electricall Pvt. Ltd.,AC Volts 415v + 10% 3q, 50 HZ + 5%Voh DC 240 / 196.295Amp DC 40 / 40

7978

SECTION - 4

OFF SITE

4.1 RAW WATER SYSTEM

AUXILIATY RESERVOIRS

Dimensions CapacityLive aux. reservoir 300m x 171m 87,000 m3

x 1.7mStorage aux. reservoir 580 m (av)x 1,65,000 m3

168 mx 1.7 mMake up water Upper Ganga canal Dehra Head

works, capacity 100 cu sec during closure of VGC through network of tubewells

RAW WATER PUMP (PTDM)

(i) Manufacturer Flowmore(ii) Pump size 12 M(iii) No. of pumps 3(2 working, 1 stand by)(iv) No of stages Two(v) Capacity 175 m3/hr(vi) Head 32.117 mwc(vii) Speed 1430 rpm(viii) Discharge size 200 Nb(ix) Motor

Make Crompton GreavesRating 30 kw/45 hpPower supply 415 +10%v, 3θθθθθ, 50HZ A.CRPM 1475Full load current 52Class of insulation B

RAW WATER PUMP (PT SOFTENING)

(i) Make Flowmore(ii) Pump size 27 H

(iii) No of pumps 3 (2 working, 1 stand by)(iv) Type Vertical Turbine pump(v) Flow 1750 m3 / hr(vi) Total bowl head 20.17 mwc(vii) No. of stage one(viii) Motor

Make Crompton GreavesKW/HP 125/167Power supply 415v + 10%, 3θθθθθ, 50 HZ

Full load curent 221 AInsulation class B

TUBEWELL WATER REPLENISHMENT SYSTEMBOREWELL PUMP

(i) No. 42(ii) Capacity 2 cu sec(iii) Borewell depth 100 m

RESERVOIR FOR TUBEWELL WATER REPLENISHMENT SYSTEM

Size 60 m x 15 m x 4.0 m

TUBWELL WATER REPLENISHMENT PUMP

(i) No. 4 (3Working, 1 stand by)(ii) Capacity 1750 cu.m / hr(iii) Discharge pressure 19.3 mwc(iv) Discharge connection 2 no 800 nb hume pipe.

4.2 WATER TREATMENT PLANT4.2.1 PRE - TREATMENT PLANT

RAW WATER QUALITY

Upper Ganga canal Tube wellTurbidity 2000 max. 40 max.

8180

PH value 7.5 to 8.5 7.41TDS, mg/l 210 1000Permagnate value 5 ppm -Iron as Fe, mg/l 1.0 1.0P - Alkalinity as CaCO3 Nil NilM - Alkalinity as CaCO3 106 530

TREATED WATER QUALITY

Clarified water Filtered waterTurbidity NTU Not to excees 20 Not to excees 2Organic matter Traces -Iron content Not traceable Not traceableManaganese content Not traceable Not traceable

STILLING CHAMBER

For Softening Plant For DM Plant(i) No of units One One(ii) Material of construction RCC RCC(iii) Size 6.5m x 3.7m x 3.8m 1.2msq x 4.5m(iv) Volume 90m3 7m3

(v) Detention time 74 sec 84 sec

FLASH MIXER

For Softening Plant For DM Plant(i) No of units 2 (One for each ccf) One(ii) Material of construction Rcc Rcc(iii) Size 3m. sq x 4.58m. swd 1.8 x 1.8 x 2 m. swd(iv) Volume 40m3 6.5m3

(v) Rated flow to each unit 2200m3/hr 350m3/hr(vi) Detention time 60 sec(approx.) 60 sec(appox.)(vii) Agitator One, 7.5 hp, 1500 One, 2 hp

rpm motor 1500 rpm motor

CLARIFLOCCULATOR

for Softening Plant for DM Plant(i) NO. of units 2 1(ii) Material of construction Rcc Rcc(iii) Flow to each ccf 2200m3/hr 350 m3 / hr(iv) Overall clarifilocculator size 49.7mφφφφφx3.55mswd 20.3mq φφφφφx3.5mswd(v) Overall volume 6887 1132.8 m3

(vi) Size of flocculator 19.75 mφφφφφ3.55mswd 8.3φφφφφm x3.5mswd(vii) Volume of flocculator zone 1087.6 m3 189.4 m3

(viii) Surface overflow rwe (for ratedflow), m3/hr/m2 1.3 1.3

(ix) Detention time(for flow)(i) flocculator zone 30 min 30 min (approx.)(ii) Clarification zone 158 min (approx.) 160min (approx.)

(x) For each flocculatorNo of agitators 4 2Drive motor rating 3 hp, 750 rpm 1 hp, 750 rpm

(xii) ClarifierRatating bridge type Peripherially driven Peripherially drivenNo. of bridges 1 1Motor rating for bridge drive 2 hp, 1500 rpm 1.5hp, 1500 rpm,

FILTER BEDS

For Softening Plant For DMPlant

(i) No. of units 12 2(ii) Material of construction RCC RCC

8382

(iii) Capacity (each) 300 m3 /hr 200 m3 /hr(vi) Size (each) 7.2 m x4.25 m 4.25m x 4.8 m(v) Filter area (each section) 30.6 m2 20 m2

(vi) Rate of filteration 5 m3/hr 5 m3/hr(vii) Filter media

1 st layer 50 mm x 37mm grave, 100mm deep2 nd layer 37 mm x12 mm gravel, 100mm deep3 rd layer 12 mm x6 mm gravel, 100mm deep4 th layer 6 mm x2.5 mm grit, 150mm deep5 th layer 0.35 mm x0.5 mm sand, 750mm deep

FILTER BACK WASH

For Softening Plant For DM Plant(i) Duration of air scouring 3 to 5 min. 3 to 5 min.(ii) No. of air blowers 2 ( 1 working + 1 2 ( 1 working +1

stand by) stand by)

(iii) Make / model SWAM RH -180 SWAM RH- 110(iv) Capacity 1540 m3/hr 1020m3 / hr(v) Motor capacity 60kw, 1500 rpm 30kw, 1500 rpm(vi) Backwashing By backwash pump Though overhead tank

No. of pumps 2 (1working+1 standby)Make/model Kirloskar, BHM25, 1stageCapacity (each) 1071 m3/ hrInstalled 60 hp, 1500 rpm

8584

CH

EM

ICA

L H

OU

SE

(i)

TAN

KS

Alu

m T

ank

Lim

e S

laki

ngLi

me

Sol

utio

nC

oag

ula

nt

Tan

kP

repa

ratio

n T

ank

Aid

Tan

k

(i)

No.

of

tank

s4

23

(1 w

orki

ng)

2 (

1 w

orki

ng)

(ii)

Mat

eria

l of

RC

CR

CC

RC

CM

SR

Lco

nst

ruct

ion

(iii)

Siz

e (e

ach)

3m x

3.4

m x

2.1

5m3m

x 3

.4 x

2.0

m3m

x 3

.4 x

2.1

m1.

3m x

0.8

m S

WD

(iv)

Eff

ecti

ve v

olum

e(e

ach

)22

m3

20m

322

m3

1 m

3

(v)

Mix

ing

agita

tor

No.

11

11

(eac

h)

Mo

tor

1.5

hp2

p2

hp0.

5 hp

1500

rpm

1500

rpm

1500

rpm

1500

rpm

.

FILTER WATER RESERVOIR

For Softening System For DM system(i) No. of units 1 (with 2 compartments) 1 (with 2 compartments)(ii) Material of Construction RCC RCC(iii) Size 30m x 12.5 x 2 m 12.5 m x 9.3 m x 2m(iv) Effective capacity 1500 m3 200 m3

FILTERED WATER STORAGE TANK

(i) No. One(ii) Material of construction RCC(iii) Location Overhead filter house top

CHLORINATION SYSTEM

For PT (Soft) For PT (DM)(i) No. of chlorinator 3 2(ii) Type Vacuum operated Vacuum operated(iii) Model/make V-711 V-701(iv) Capacity (each) 12 kg/hr 2 kg/hr(v) Booster pumps

No. 3 2Capacity 6m3/hr at 40 head 2m3/hr at 30 m headMotor rating 5.5 kw 2 hp, 2900 rpmModel CHG025 x 200 CHG 025 x 160Make Kishore horizontal

centrifugal (all)

4.2.2 D.M. PLANTCLARIFIED WATER ANALYSIS

Constituent As Analysis(i) Calcium (ca) CaCO3 90 ppm(ii) Magnesium CaCO3 42 ppm(iii) Sodium & potassium CaCO3 40 ppm

(mg)

8786

(ii)

PU

MP

S

Lim

e Tr

ansf

erA

lum

Sol

utio

n

Lim

e So

lutio

n

Cog

ulan

t Aid

Pum

pD

ozin

g Pu

mp

D

ozin

g Pu

mp

D

ozin

g Pu

mp

For

Softe

ning

For

DM

For

Softe

ning

For

DM

For

Softe

ning

For

DM

Syst

emSy

stem

Syst

emSy

stem

Syst

emSy

stem

(i)N

o. o

f pum

p pr

ovid

ed2

32

32

32

Wor

king

12

12

12

1

Stan

d by

11

11

11

1

(ii)

Mak

eK

isho

reV.

K. M

eter

ing

V.K

. Met

erin

gK

isor

eV.

K.

V.K

.V.

K.

Cen

trifu

gal

Pum

pPu

mp

Cnt

rfug

alM

eter

ing

Met

erin

gM

eter

ing

Plun

ger t

ype

Plun

ger

Pum

pPu

mp

Pum

p

(iii)

Mod

elKG

C-02

5x16

0PR

-35

PR-1

5KG

C-02

5x25

PR-1

5PR

-15

PR-1

5

(iv)

Cap

acity

6 m

3/hr

at 5

2204

2 LP

H48

8 LP

H1.

23m

3 at 5

m0.

2m3 /h

r29

4 LP

H a

t46

LPH

at

m h

ead

head

5m h

ead

0.5k

g/cm

20.

5kg/

cm2

(v)

Inst

alle

d hp

1 hp,

1500

rpm

20.

51h

p, 1

500

rpm

0.5h

p 15

000.

5 hp

rpm

1500

rpm

Total cations CaCO3 172 ppm

(iv) Bicarbonate (Hco3) CaCO3 95 ppm

(v) Carbonate (Co3) CaCO3 Nil

(vi) Nitrate (Co3) CaCO3 59 ppm

(vii) Chloride(Cl) CaCO3 8 ppm

(viii) Chloride (Cl) CaCO3 10 ppm

total Anions CaCO3 172 ppm

(ix) Iron Fe 0.2 ppm

(x) Free carbondioxide CO2 ND

(xi) Silica SiO2 10 ppm

(xii) PH value - 7.6 to 8.5

(xiii) Turbidity NTU 3-20

EFFLUENT QUALITY

(a) Activated carbon filter oultet

Free chloride & Iron Not detectable

Turbidity Not to exceed 0.5 NTU

(b) Cation exchange outlet

Sodium as CaCO3 Not to exceed 2 mg/l

(c) Degasser outlet

Free carbon dioxide as CO2 Not to exceed 5 mg/l

(d) Anion outlet

Silica as SiO2 (reactive) Not to exceed 0.2 mg/l

Total electrolyte Not to exceed 0.2 mg/l

Conductivity at 250c Not to exceed 10 micro mho/cm

(e) Mixed bed outlet

Total electrolyte Not to exceed 0.1 mg/l

Silica as Si02 (reactive) Not to exceed 0.02 mg/l

Iron as Fe - do -

Total Hardness - DO -

pH value 6. 8-7.3

Conductivity at 250c Less than 0.1 micro mho/cm

M.S

. FI

LTE

R A

ND

EX

CH

AN

GE

R D

ATA

Act

ivat

edW

eak

acid

icS

tron

g ac

idic

Wea

k ba

sic

Str

ong

basi

cM

ixed

bed

Deg

asse

rca

rbon

filt

erca

tion

exc

h.ca

tion

exc

h.an

ion

exc

h.

anio

n e

xch

.ex

ch.

tow

er

12

34

56

78

(i)

No.

of

unit

s3

33

33

32

(ii)

Nor

mal

flo

w r

ate,

m3/

hr10

010

010

010

010

010

020

0

(ii)

Max

. flo

w r

ate,

m3/

hr10

010

010

010

010

010

020

0

(iv)

Reg

ener

atio

n in

terv

al,

hour

s12

1212

1212

108

-

(v)

Net

ou

tpu

t b

etw

een

tw

o

rege

nera

tion

, m

312

0012

0012

0012

0012

0010

800

-

(vi)

Gro

ss o

utp

ut

bet

wee

n r

egen

erat

ion

.

m3

1260

1260

1260

1230

1230

1105

0-

Cat

ion

An

ion

(vii)

Filli

ng m

edia

Act

ivat

edIR

C 8

4 R

FIR

20

RF

IRA

93

RF

IRA

402

CIR

A 1

20IR

A 4

02Ra

ching

LM

BM

BR

ing

(vii)

Qua

ntity

of

med

ia,

m3

open

ing

8.5

2.6

2.96

2.6

2.96

1.35

1.35

7.8

In

ert

--

0.45

-0.4

5-

--

8988

1 2 3 4 5 6 7 8

(ix) Bed depth, mm Operating 1200 878 1002 878 150 1015 ......... 2500

Inet - - 150 - - - -

(x) Type of regerant - ...... Hcl to IS 265 ........ ...... Na OH to IS 252 ..... HCL NaOH

technical grade Rayon grade

(xi) Regenerant required -

(100%), Kg - ........ 170.9 ............... ............. 103.4 .............. 113.3 108

(xii) Diameter mm 3000 1950 1950 1950 1950 1850 2000

(xiii) Height on straight, mm 2400 1900 2400 2000 2400 2200 3800

(xiv) Lining & thickness, mm 3 coats ........................................... Rubber lining 4.5 ........................................................

EPOXY

(xv) Design pressure, K/cm2 7.3 7.3 7.3 6.1 6.1 6.1 atmosphere

STORAGE & MEASURING TANK DATA

D.M.water Hot water Acid Alkali Deg. Lime tank Alkali day Alkali Priming

storage tank storage storage sump. for neutra. tank prepn. chamber

tank tank tank pif. tank

(i) Type ..... Vertical cylin ..... ......Horiz. cylinderical ....... .......... vertical cylindrcal ..............

..... drical with dish ends ... with dish ends ........

(ii) Number 2 1 3 2 2 1 1 2 3

(iii) Diameter, mm 13000 1800 3200 3200 3200 1600 1800 1800 1100

(iv) HOS/LOS, mm 12000 2600 5900 5900 5900 1300 1300 1300 1200

(v) Effective capacity, m3 1500 8 50 50 50 2 2.5 2.5 0.7

(vi) Strength of fluid stored N/A N/A 30-33% 48% N.A. 10% 48% 48% N.A.

(vii) Design pressure, Kg/cm2g Atmospheric6.1 .................................................. Atmospheric ...........................................

(viii) Lining/thickness, mm Epoxy ...... Rubber 4.5 .................................. Chlorinated ......... Rubber 4.5 .............

Coating rubber paint

9190

ROTARY EQUIPMENT DATA

Filter Deg. Alkali Alkali Waste Acid D.M. Deg. Mixed

water water circu. unloading rec. transfer unloading regenerationg Blower bed

pumps pumps trans.pump pump pump pump pump pump blower

(i) Manufacturer Fair Bank ..................... Kishore .............. March Kishore ACCO Kay

Morse (Pulsa

feeder)

(ii) Model & type 11 M KGC KHL KHL KHL TE - 8C - KGC AW - 30 5 MK

100x400 50x200g 50x200g 125x2315g MD 50x315

................... Horizantal Centrifugal ............................................ ............ Rotary twin lobe....

(iii) Nos. furnished 3 3 2 2 3 2 2 3 2

Operating 2 2 1 1 2 1 1 2 1

(iv) Rated capcity, m3/hr 120 110 10 20 150 20 20 4500 360

(v) TDH at rated cap.mwc 55 50 10 10 15 10 35 0.11 5

Centrifugal pumps Blowers

Filter Deg. Alkali Alkali Waste Acid D.M. Deg. Mixed

water water circu. unloading rec. transfer unloading regenerationg Blower bed

pumps pumps trans.pump pump pump pump pump pump blower

(vii) Drive motor rating at

500c kw 30 30 3.7 3.7 15 3.7 7.5 3.7 11

(viii) Material of construction

Casing 2% NCI ASTM A743 ......... CIRL ............... PPN CF-8M MS IS-226C.I.

GrCF 8M

Impeller Gun ASTMA743 MSRL MSRL CIRL PPN CF-8M MS EN-9

metal GR. C8M

Shaft SS-410 SS-316 EN-8 EN-8 EN-8 Alum. EN-8 EN-8 EN-9

ceramic

(ix) Gand sealing arragnement packed Mech. seal NA Mech. seal NA NA NA NA

9392

METERING PUMP DATA

Alkali Metering Pump Acid Metering Pump

(i) Manufacturer .... M/s Pulsa Feeder, USA .............................

(ii) Model 7440 - S -E 7660 - S - E

(iii) Type .... Double diaphragm type (with hydratube) ..............

with mannual control

(iv) No.s furnished 2 2

(v) Capacity adjustable range 0-100% 0-100%

(vi) Rated capacity, m3/hr 1.0 2.2

(vii) Discharge pressure, kg/cm2g 4.0 4.0

(viii) Fluid handled 30-48% NaOH 30-33% HCL

(ix) Motor rating, kw 2.2 2.2

speed, rpm 1450 1450

9594

RELEVANT DATA FOR REGENERATION

(i) Chemicals per regen. Cation group Anion group MB cation MB cation

a. 100% HCI kg 170.9 - 113.4 -b. 30% HCI kg 569.7 - 377.7 -c. 30% HCI ltr. (approx.) 495.4 - 328.4 -d. 100%NaOH, Kg - 103.4 - 108e. 48% Na OH, ltrs, - 215.4 - 225f. 48% NaOh, ltrs, (approx.) - 143.6 - 150g. Dilution water flow rate, m3/hr 10.26 6.9 4.71 5.14h. Acid injection flow 1.74 - 0.79 -

rate m3/hr (30% HCL)

BOILER FILL PUMP

(i) No and type 2, 100/150 IPB-3CHRS TYPE-70(ii) Manufacturer Mather - platt(iii) Design capacity 150 m3/hr(iv) Total head 120 m(v) Speed 1485 rpm(vi) NPSH required 3.6 m(vii) KW absorbed 66.28 kw(viii) Motor

Manufacturer General Electric co. of India Ltd.Type 3θθθθθinduction motorRating 82 kwVoltage & frequency 415 v, 50 HZSpeed 1485 rpmInsulation class BCurrent rating 150 A.

(ix) Coupling 3’B’ pin and bush type coupling(x) Bearing Bush bearing

DM MAKE UP PUMP

(i) No.and type 3, 100/125 IPB-3 CHRS, Type-70(ii) Manufacturer Mather-platt(iii) Design capacity 75 m3/hr(iv) Total head 75 m(v) NPSH required 2.7 m(vi) Speed 1470 rpm(vii) Weight 550 kg.(viii) KW absorbed 20.99 kw(ix) Motor

Manufacturer General Electric Co. of India Ltd.

Type 3θθθθθ, induction motorRating 27 kw (36hp)Voltage & frequency 415v, 50 HZSpeed 1470 rpmInsulation class BCurrent rating 49 A

(x) Coupling ‘28’ pin and bush typ coupling(xi) Bearing Bush bearing

4.2.3 WATER SOFTENING PLANT

BASE EXCHANGE SOFTENERS

1. Mechanical DataNo. of streams 7Vessels per stream 3 No.Diameter 3600 mmHeight on straight 1900 mmBed depth 1050 mmVessel type Vertical shell type with dished ends,

lined inside the rubber of 4.5 mmthickness (min.) MSRL material

2. Chemical Design DataResin type Tulsion T-42 (Na)Qty. per vessel 10700 litresRate of flow-agerage 250 m3/hr/exchanger

750 m3/hr/stream max. 275 m3/hr/exchangerRunning time between tworegenerations, max. 20 hoursGross output 500 m3 / exchanger

15000 m3 / stream3. Filtered Water Pumps - Mechanical

DataNos. offered 7 Nos.

9796

Driver motor

KW raing 75 kwMotor rpm 1440Power supply 415 v, 3q 50 HZ

Class of insulation B4. Regeneration system

Regenerate qty. per vessel 100% NaCl1125+480 kg (fresh + spent)

Regeneration Flows

Flow Duration Qty. Type ofm3/hr min m3 water

(i) Backwash 90 15 22 Filtered(ii) Spent brine inj. 30 10 4.5 Spent(iii) Fresh brine inj. 30 20 11 Filtered(iv) Brine rinse 30 10 5.0 Filtered

(slow ringe)(v) Brine recovery 30 10 5.0 -(vi) Final rise 160 20 54 Filtered

DATA SHEET FOR RESINS

(i) Type of resign Tulsion T-42 (Na+)(ii) General description Polytyrene base nuclear Sulphonicacid

type strong acid cation echange resinSodium (Na+)

(iii) Form Sodium (Na+)(iv) Apprent desity (BD) 930-860 gm/ltr(v) Grading (wet/dry) 120 to 30 mesh ISS

(sieve size) (0.3 to 1.2 mm)(vi) Effetive size 0.45-0.55(vii) Eunformity

Coefficient Less than 1.7(viii) Fines(-30 mesh ISS) Less than 1.7(ix) Thermal stability 1400c

(x) Attrition loss per year 3%(xi) Resin life (estimated) 5-7 years(xii) Total exchange capacity 2.00 meg/ml min.(xiii) Effective PH range 0 to 14(xiv) Type of regeneration Co-current regeneration(xv) Moisture content 45% + 5%(xvi) Supplier of resin Thermax Ltd. pune

SALT HANDLING & DOZING FACILITIESSALT STORAGE LAGOON

Nos. offered 2 nos. Divided in 2 compatmentsType CirularSize 30 m3 dia x 3m deepCapacity 1000 m3 (salt solution)+ 2000 m3

salt crystals, both dissolved &undissolved.

Material of construction RCC epxoy painted

BRINE FILTERS

Nos. offered 2Type Conventional gravity filterCapactiy To filter @ 150 m3/hrMaterial of construction RCC epoxy paintedFilter media Sand/anthracite

SALT SATURATOR

Salt Saturated Stranger TanksQuantity 1 (2 compartemnts)Size 10 m x 20 m x 1.5 mCapacity 150 m3 each compartmentMaterial of construction RCCSalt Transfer PUmp (PST)No 3

9998

Capacity 150 m3/ hrHead 30 mwcType Vertical centrifugal typeDrive mtor 37.5 kw. 1450 rpm : 415v, 3θθθθθ, 50 HZ

power supply. TEFC, IP-54 B classinsulation

FRESH BRINE MEASURING TANK (MFBR)

Quantity 3nos.Size 5 m x 18.3 m x 23 m (mld)Material of construciont RCC apoxy pointedCapacity 15.500 usable

(Brine saturated solution)

FRESH BRINE INJECTION PUMPS

Quantity 3 nos.Capacity 45 m3 /hrMaterial of construction CI rubber linedHead 30 mwcType Horizontal, centrifugalMotorMotor kw 18.5Motor rpm 1450Power supply 415v, 3φφφφφ, 50 HZType & protection TEFC, IP-54Class of insulation B

SPENT BRINE TANKS (SBRT)

Quantity 3 no.Size 5 x 1.83 x 2.3 mldMaterial of construction RCC epoxy pointedCapacity 15.500

SPENT BRINE INJECTION PUMPS

Quantity 3 no.Capactiy 90 m3/ hrHead 27 mwcType Centrigufal, horizontalMotor kw 30Motor rpm 1440

FILTER BACKWASH WATER STORAGE TANK

Nos. offered 1Size 10 m x 10m 2.5 m (mld)Material of construction RCC

SODIUM SULPHITE DOZING SYSTEMSODIUM SULPHITE TANK

No. 3Size 1200 mm dia x 1600 mm highType Vertical cylindrical atmospheric,

dished bottomMaterial of construction MSRL (4.5 mm thick rubber lining)Empty weight 1000 kgs.Working weight 4000 kgs.

SODIUM SULPHITE DOZING PUMP

No. 3Type 50 litre/hourHead 30 mwcMaterial of construction SS 316

101100

4.3 CIRCULATING WATER SYSTEM

4.3.1 CIRCULATING WATER PUMP

1. Manufacturer Jyoti limited, Borada2. No. of pumps 83. Designation 110VM4. Type Vertical francis, mixed flow,

single stage,wet pit, bowl pull out

5. Liquid to be pumped Soft water6. Type of lubrication Self water lubrication.7. Impeller dia at inlet/

outlet/eye area, 828 mm/ 1070 mm/5385 cm2

8. Column asembly 1475 m x 200 m x 95 mm.9. Oulet size 1200 mm.10. Pump & alive shaft bearing Cutless rubber with flashing grooves11. coupling (between pump &

motor) Flanged type (rigid)12. Type of thrust brg Type of thrust brg Tilting pad, one at

motor tap.13. Operating floor level 2105 m.14. Min. forebay water level 208.5 m15. Max. forebay water level 209.5 m16. Centre line of discharge duct 212.017. Duty condition

(i) Capacity 12,500cu. m/hr

(ii) Total head at pump discharge. 20.5 mwc

(iii) Total head loss frombell to discharge flange 0.13 mwc

(iv) Rated speed

(v) Pump efficiency at designcapactiy 87%

(vi) Pump inut at design capacity 802.12 kw

(vii) Power loss in transmission inbrgs 0.45 kw

viii) Bowl head at rated speed &closed discharge 36.23 mwc

(ix) Max. & Min. capacities upto whichpump can be operated satisfactorycu m / hra. at max volume Min Max.

6250 14,600b. at normal volume 6250 14,400

18. Motor(i) Type Squirel cage induction(ii) Frame size CUD - 710(iii) Motor rating 900 kw(iv) Method of starting DOL(v) Power supply 6600 v, 3θθθθθ, 50 HZ

(vi) Duty Continuous(vii) Class & type of insulation F(viii) Direction of rotation (viewed

from top) Anticlock wise(ix) Full load current rated

voltage & frequency 102 A(x) No load current at rated

voltage & frequency 40 A(xi) Temp. rise at rated condition

of out putBy wdg resistance method 700cETD method 700c

19. Disch valveType Butterfly tight, shut off type,

1600 mm NbValve closure time 45-60 seconds

4.3.2 COOLING TOWER

1. Type Natural draft type2. No. 4, 1 for each unit3. Construction type Reinforce concrete, hyperbolic,

doublecurvature shell with a big beam at thebase supported on rocker columns

4. Total height 117 m

103102

5. Base diameter 78.9 m6. Throat diameter 46.7 m7. Top diameter 49.77 m8. Length of open channel

(from coling tower to 900 m long & 150 m longpump house)

9. Flow 25,000 m3/hr10. Drift Limited to max, of 0.05%

of total water in circulation11. Range of cooling 110c12. Recooled water temp. 320c13. Ambient wet bulb temp. 270c14. Design relative humidity 50%15. Approach. 50c

4.3. CW CHLORINATION

CHLORINE TON CONTAINERS

(i) No. supplied 34(ii) No installed 12(iii) Arrangement 2 sets of manifolds having 6 tonnersper mainfold

CHLORINE EVAPORATOR

(i) No. & capacity Three, 90 kg/hr(ii) Manufacturer M/s Fischer & Porter(iii) Type electically heated immersed in water

bath(iv) Heater capacity 18 kw

CHLORINE STRAINERS

(i) No. 1 working and 1 standby(ii) Location Outlet of each evaporator(iii) Manufacturer M/s Fischer & Porter

CHLORONIATORS

(i) No. Three(ii) Capacity 90kg/hr(iii) Manufacturer M/s Fischer & Porter(iv) Model Vacuum feed, 70C 5500(v) Injector for chlorine &

water mixingNo. One per chlorinatorType Adjustable throatMaterial PlasticManufacturer M/s Fischer & Porter

CHLORINATED WATER DOZING SYSTEM

BOOSTER PUMP

(i) No. 3, (2 working & one stand by)(ii) Capacity & head 50 m3/hr at 40 mwc(iii) Make & type M/s Kishore pumps

Horizontal centrifugal(iv) Motor TEFC, Squirrel cage induction

motor, 18.5 kw

CHLORINE DIFFUSER

(i) No. Six sets(ii) Location One set near each individual C.W.

pump. suction bay trash track

105104

4.4 AIR COMPRESSOR PLANT

Manufacturer K.G. Khosla compressor LimitedType Reciprocating, horizontal, balance

opposed, non-lubricatedNo. of compressor 9, (5 instrument air & 4 plant air)

CONSTRUCTION FEATURES

(i) No. of compressor Two(ii) Cylinder arrangementq Horizontally apposed(iii) Cylinder bore LP 2 x 310 mm

HP 2 x 185 mm(iv) Stroke 150 mm(v) Clearance in % of volume HP 15.76%

LP 10.71%(vi) Thickness HP 11 mm

LP 12 mm(vii) Cooling water pressure &

quatity 3 - 4 kg/cm2/4.4 m3/hr / compressor(viii) Intercooler cooling water

pressure & quantity 3 - 4 kg/cm2/8.8m3/hr/compressor(ix) Type of drive Direct throught flexible coupling(x) Main bearing type Split sleeve

Method of lubrication Forced feed by gear pumpMaximum allowable lub oiltemp. 700cCross head lubrication HPC/LPC By gear pump/splash type

PERFORMANCE DATA

(i) Nominal capacity of compressor 20Nm3/min(ii) Discharge pressure 8 kg/cm3 (g)(iii) Air temperature after first/

last stage of compressor 1530/1470c

(iv) Outlet air temperature (afteraftercoolder) 80c above cooling water inlet temp.

(v) Air pressure after LP stage 3.012kg/cm2 (a)(vi) Volumetric efficiency at design

condition 78.9%(vii) Crank shoft speed 735 rpm(viii) Total cooling water requirement 22 x 9 = 198 m3/hr

MOTOR

(i) Rated output for 500c ambient air 175 kw(ii) Manufacturer Kirloskar Electric Co. Ltd., Bangalore(iii) Frame size KD 355(iv) Type Cage motor(v) Class & type of insulation B(vi) Rated speed 743 rpm.(vii) Power supply 415v, 3 phase, 50 HZ

(viii) Full load current 320 A(ix) No load current 150 A(x) Bearing type Artificition ball & roller bearing

AIR DRYING PLANT

(i) No. Five(ii) Dessicant Silica gel as per IS 340](iii) Duty Continuous(iv) Drying cycle 8 hour(v) Nominal flow rate & working

pressure(vi) Type of dryig 20N m3 / min. 8.0 kg/cm2 (g)(vii) Type of reactivation open thro-system(viii) Type of change Automatic with provision for manual

107106

ADP BLOWER

(i) Type and capacity Centrifugal blower, 10 N m3/min.(ii) Motor rating voltage, phase

& frequency 7.5 kw,415v,3θθθθθ,50HZ,dassB insulation

(iii) Motor Manufacturer Crompton Greaves Ltd.(iv) Motor fll load current & speed 14.0 A, 2900 rpm(v) Method of connection of motor

to blower Vee belt & pulley

REGENERATION CYCLE

(i) Depressurisation 25 minute(ii) Heating 4 hrs, 25 minute(iii) Cooling 2 hrs 25 minute(iv) repressurising 25 minute

4.5 FUEL OIL HANDLING PLANT4.51 L.F.O. HANDLING PLANT

L.F. O. STORAGE TANKS

(i) Type of tank design code Vertical, cylindrical, non-pressurisedflixed roof type with atmosphericvent as per IS 803/ AP 1650/BS 2654part I & II

(ii) No. Two(iii) Type of oil stored Light diesel oil(iv) Capacity of each tank 160 m3

(v) Diameter & height of tank 6m x 6m(vi) Design tank temperature 600c(vii) Design pressure Internal 66 kg/cm2

External 63.5kg/cm2

LF.O. UNLOADING HEADER

(i) No. of header One(ii) No. of nozzle connections 5 nozzle connection of 80 nb

L.F.O. UNLOADING PUMP

No. TwoCapacity 50m3 / hr at 30 mlcPump make & model no. M/s Delta Corporation, Model-216,

105/064Motor Kirloskar make, 15 kw rating 1450

rpm, B class insulation, 415 V 3φφφφφ,50HZ power supply, 27.5 A full loadcurrent.

L.F.O PRESSURING PUMP

(i) Make Allweiller AG(ii) Pump designation 5 NH 80 ER 42 E 67 W 12(iii) Drive Motor

Make & frame size GEC KF 132 MRating & power supply 7.5 Kw, 415v, 3φφφφφ, 50 HZ

(iv) Pump construction detaila. Mounting Horizontal/foolb. Pitch & shaft material & BHN Nitrided steel-vickers 2c. Rotor shaft material & BHN Nitrided steel-vickers 2d. Idler material & BHN Nitrided steel-vickers 2e. Body & cover material Welded stellf. Bearing type & No. Ball bearing oneg. Cou;ong type & make 3 piece pi piush Flender ‘N’Eurex

make(v) Performance date

(i) Capacity at min CST of /2 max. CST to 20 120 lpm / 130 lpm(ii) Suction pressure/ discharge pressure Minus 0.5 kg/cm2(g) 15 kg/cm2(g)(iii) NPSH required 2.6 mwc at max. CST(iv) Pumping temperature 350c(v) RPM 2920

H.F.O./LS.H.S. HANDLING SYSTEMH.F.O./LS.H.S. STORAGE TANKS

(i) Type Vertical, cylindrical, non-pressurised,fixed roof type with atmospheric vent.

(ii) No. Four

109108

(iii) Tank design code As per IS-803/AP 1650/BS 5254 part I& II

(iv) Type of oil stored Heavy fuel oil/Low sulphur heavystock

(v) capacity of each tank 15,000 m3

(vi) O.D./ height of tank 40 m x 12 m(vii) Tank oil temperature 500c for HFO, 650c for LSHS, 800c for

HPS(viii) Design pressure

Internal pressure 66 kg/cm2

External pressure 63.5 kg/cm2

(ix) Tank heating coilsa. Steam coil tubes 40 mm dia seamless as per ASTM-A-

106b. Heating medium steamc. Steam parameter 16 data pressure & 2100c temp.d. Time for heating oil from initial temp to final temp. 36 hour for 15,000 m3 of oil

(x) Suction heatera. Type Shell & tube type with ‘U’ tube

(seamless steel tube)Shell side Tube side

b. Medium Oil Steamc. Design pressure 2.5kg/cm2 20kg/cm2d. Design temperature 1200c 2100c

(xi) Tank oulet oil temperature 600c for HFO, 750c for LSHS, 900c forHPS

FUEL OIL UNLOADING CUM TRANSFER PUMP

(i) No. of wagons that can beunloaded at a time 2 rack of 76 wagons.

(ii) No. of fuel oil pumps & make 10 no. M/s Delta corporation, model216.135/075

(iii) Capacity of each pump 100 m3/hr at 50 mlc(iv) Motor Kirloskar Elect Co. make 55kw, 1475

rpm, 415v 3φφφφφ, 50HZ B classinsulation, full load current 93 A

FUEL OIL UNLOADING HEADER

(i) No. & construction Two, fabricated with 8 mm steelplate, 450 Nb

(ii) No. of nozzle connections 80 per header.(iii) Size of nozzle connection 80 Nb

DRAIN OIL TANK (UNLOADING AREA)

(i) No. one(ii) Tank design reference IS-800(iii) Capacity 6m3

(iv) Size 3m x 1.5 x 1.5 m.(v) Condensate heating coil 40 mm dia, seamless tube.

DRAIN OIL PUMP (UNLOADING AREA )

(i) No. of pump One(ii) Capacity of pump 4m3/hr at 40 mlc(iii) Make M/s Delta Corporation(iv) Model 3.38/4.6(v) Motor Kirloskar Elect. Co. 5.5 KW, 415v supply.

FLASH TANK (UNLOADING AREA)

(i) No. of tank One(ii) Type Cylindrical with dished end.(iii) Diameter of tank 2.2 m(iv) Height of tank 3m(v) Capacity of tank 10 m3

(vi) Design pr. & temp. 16kg/m2, 2100c(vii) Insulation thickness 40 mm (min)

SUMP PUMP (UNLOADING AREA)

(i) Type Wet type, vertical shaft, single stagenon-clog desing

(ii) No. & make Four, Kishore PUmp Ltd.(iii) Capacity 30m3/hr at 10 mlc for 2 pumps

15m3/hr at 10 mlc for 2 pumps(iv) Type of stuffing box Mech. packing type(v) Motor 2.2 kw (2no.) & 3.7 kw (2no)

415 v supply, Crompton Geavesmake

H.F.O. / L.S.H.S. PRESSURING PUMP

(i) Type Three screw, rotory,positive displacement pump

111110

(i) No. 4 x 100% + 2 x 60%(ii) Make All weiller(iv) Pump designation 100% pump SNH 1300 ER 46 E6.7

YW1260% pump SNH 940 ER 42 E6.7 YW 12

(v) Performance data100% Pump 60% Pump

a. Capacity at 150 cst (min)/ 370 cst (max) 1250lpm/1260lpm 790lpm/760 lpmb. Suction pressure Minus0.5kg/cm2 Minus 0.5 kg/cm2

c. Delivery pressure 30kg/cm2 30kg/cm2d. NPSH required 7.0 mwc at max 5.2 mwc at

cst max cste. Delivery temperature 700c 700cf. RPM 1450 1450

(vi) Pump construction detaila. Mounting Horizontal/floor Horizontal/floorb. Pitch & rotor dia 200mm/100 mm 150mm/90mmc. Rotor shaft & idler material Nitrided steel Nitrided steeld. Body & cover material welded steel welded steele. Type & no. of bearing Ball bearing, one Ball bearing, onef. Type & make of coupling 3 piece pin, push, 3 piece, pin, push,

flender-’N’ eurex flender-’N’ eurexg. Steam jacket End cover design End cover design

(vii) Drive motora. make & frame size GEC, KF-280m GEC, KF 280mb. Power rating & power supply 90kw, 415v 3θθθθθ 90kw, 415v 3θθθθθ

HEAT EXCHANGER

(i) Type U tube, hair pin type, oil on shell side,condensing type

(ii) No. 6(iii) Heater area 40 sq. m each(iv) Oil flow rate 4000 to 34760 kg/hr(v) Oil heating range 50 to 1200c HFO

70 to 1300c LSHS

(vi) Stem parameter 14kg/cm2 (g), 2150c(vii) Relief valve set pr. 32 kg/cm2 (g)(viii) Design pressure 32kg/cm2 (g) oil side

24kg/cm2 (g), steam side

DRAIN OIL TANK (PRESSURISING AREA)

(i) Type Rectangular(ii) Size 4m x1.7m x 1.5 m(iii) Capacity 10m3

DRAIN OIL PUMP (PRESSURISING AREA)

(i) Type Cylindrical shape with dished end(ii) Capacity 10m3/hr at 25 mk

FLASH TANK (PRESURISING AREA)

(i) Type Cylindrical shape with dished end(ii) Size 2m dia x 3.5m height(iii) Capacity 10m3

4.6 COAL TRANSPORATION AND HANDLING SYSTEMCOAL TRANSPORTAION SYSTEM

Source Piparwara block of North karanpuracoal field of Eastern coal field

Means of transportation RailwayRoutl of railway Khalari - Garwa road-Seonnagar-

Mughal sarai-Allahabad- Kanpur-Alighar-Dadri- Plant unloading area

Total distance 1124 km from khalari to Dadri withelectrified track from Seonnager

Type of wagon Bottom discharge type or Box ‘N’ RCtype

No. of wagons/rake 58 wagons of 56.78 tonners capacityNo. of rakes required per day 4 to 5Total cycle time of one rake Approximately 6 days.Rolling stock required for stag-1 13/6 wagonsType of Icons WD 56 (910 hp)

113112

COAL HANDLING SYSTEMTRACK HOPPER

(i) No. of hoppers one(ii) Type of hoper RCC underground(iii) Length of track hopper 201.6 m(iv) Breadth of track hopper 6m(v) Height of track hopper 6.350m(vi) Capacity of track hopper 6000 tonnes.

TRACK HOPPER

(vii) Type of wagon unloaded BOBR(viii) Mode of Bottom relieving Pneumatic

of wagons(ix) Working pressure 5-6 KSC(x) Air receiver capacity 3000 litres

WAGON TIPPLER(i) No. 1(ii) Type of tippled BOX-N type(iii) Wagon tippler guaranteed capactiy 12 trips / hr.(iv) Capacity One no. 90 tonne 8 wheeled box wagon

OR 2 no 4 wheeled wagon handled in pairin a single trip

BEETLE CHARGER

Pulling & pushing capacity 15 nos. of 90 tonne 8 wheeled fullyloaded box wagon on straight level.

PADDLE FEEDER

(i) No. of paddle feeder 4(ii) Type of paddle feeder Rotary type(ii) Design/rated capacity 1000 tph/875 tph(iv) travel speed 2 m/ min (approx.)

VIBRATING GRIZZLY FEEDER

(i) No of vibrating grizzly feeder 4 No(ii) Capacity 875 tonner/hr(iii) Screen type BSS 11-44824(iv) Frequency 300-1000 rpm(v) Amptitude 35 mm(vi) Stroke angle & screen angle 400,0-100

(vii) Motor 45 KW, 415V, 3φφφφφ, 50HZ, 79A, 1465 rpm

CRUSHER HOUSE

(i) No. & Make of Crusher 4, Pennsylvenia, USA(ii) Type & size Ring Granulators, TKKGN-48093(iii) Main crusher capacity 875 tonne/hr each.(iv) Max. coal size before crusher 250 mm(v) Coal size after crusher 20 mm(vi) Motor rating 800 h.p (597kw)

Make Kirloskar Elect Ltd.Power supply 6.6 kv, 3φφφφφ, 50 HZ

RPM 743Full load ampere 69 AInsulation class F

(vii) No. of belt corrveyors 60

CONVEYOR

(i) No. of belt converyors 16

(ii) Design / rated capacity 1540 tph / 1400 tph

conveyor no.

1A1 1B1 1A 1B 2A 2B 3A3B 4A 4B 5A5B 6A6B 7A7B

(iii) Conceyor capacity 700 ........ ........ 1400 ......... ....... ........ .........

(iv) Belt speed (m/sec) - 3.14 3.37 3.14 3.36 3.0 3.0 3.0

(v) Belt width (mm) 1000 ......... ........ 1400 ..........................

(vi) Fabric type Nylon __ __ palamide ___ __ ___ synthetic ___

(vii) No of piles 4 3 3 4 3 4 4 3

(viii) Belt rating KN/mlc - 63 100 100 125 63 80 10

(ix) Face cover - 5 5 6 5 5 5 5

thicknss (mm)

(x) Back Cover - 2 2 2 2 2 2 2

thickness (mm)

(xii) Cover grade _________________ Fire resistant ________________

115114

(xii) No. of metal detector 4(xiii) No. of belt weigher 6(xiv) No. of sampling unit 4(xv) No. and type of magnetic 4, suspended type separators(xvi) No. of suspended magnet 2(xvii)Conveyor motor

Conveyor Motor rating Make Power supply Full load current1A/1B 280 kw Kriloskar 6.6 kv. 3φφφφφ 31.5 A2A/2B 240 kw Kriloskar 6.6 kv. 3φφφφφ 27.5 A3A/3B 430 kw Kriloskar 6.6 kv. 3φφφφφ 47 A4A/4B 200 kw NGEF 6.6 kv. 3φφφφφ 23 A5A/5B 250 kw Kriloskar 0.415 kv. 3φφφφφ6A/6B 140 kw NGEF 0.415 kv. 3φφφφφ7A/7B 320 kw Kriloskar 6.6 kv. 3φφφφφ1A/1B 110 kw Cromption

greaves 0.415 kv. 3φφφφφ 188 A

TRIPPER

(i) Type Travelling type(ii) No. 4(iii) Capacity 1400 tonnes/hr each(iv) Travel speed 12m/min(v) Motor for tripper 2no. for travel, 2.2 kw each(vi) Tripper travel 216.950 m(vii) Electrical linear actuator provided yes(viii) AC electro magnetic brake yes

STACKER/RECLAIMER

(i) No. 2(ii) Model ASK 650(iii) Stacking capacity (rated/

design) 1400/1540/1540 tph(vi) Reclaiming capacity (rated/

design) 1400/1750 tph

(v) Travel speed 4-20 nm/ minute(vi) Travel motor Continuous variable DC motor, 6 x 10 kw.(vii) Bucket motor specification A.C. squirrel cage motor, 90 kw(viii) Boom conveyor speed 3m/sec(ix) Boom conveyor motor type &

rating Squirel cage reversible type, 75 kw(x) Slew speed 17.5 to 30.48 m/ min.(xi) Slew motion motor D.C. type, 2x 14 kw

STOCKYARD

(i) Capacity 45 days coal of stagel requiremnt5,00,000 m3 of coal approx.

(ii) No. of coal piles in stockyard 4(iii0 Length/height of each plies 470/10m

COAL SAMPLING UNIT

No. 2 Nos. (one at TP-1, one at TP-4)Make Ramsey EngineeringNo. of cuts/Hr. 21 (TP-1), 50 (TP-4)Intake Material Size 40 mm nominal tap sizeOutput Sample - 3 mmPower Requirement : Hyd. Pack 7.5 KW (Each) Feeder .7 KW (Each) Crusher 12 KW (Each)

W/T VIBROFEEDERNo. 4Make TATA ROBINS-FRASWER Ltd.Model TE-9, 48” X 120”Motor Rating 11 KWCapacity 450 MT/Hr.

DUST EXTRACTION SYSTEMVentury Scrubber Cover Type : No. 2 Nos. for Crusher HouseCentrifugal Fan Capacity 66000 Cubic Metre / HrVacuum Created 400 mm WC

Slury Pump Capacity 88 Cubic metre / Hr

117116

BAG FILTER DE SYSTEM

No. 4 Nos. ( 1 each for Bunkers of One Unit)Centrifugal Fan Blower AirHandling Capacity 44000 Cubic Metre / HrVacuum created inside 350 mm WCMotor Rating 100 HPRotary Air Lock (RAL) System Associated with each DE fanMotor Rating of RAL 1 HPMotor RPM 20Drive Mechanism Chain & Sprocket

DUST SUPPRESSION SYSTEM

Supplier F-HarleyPrinciple To apply water in spray form

in order to settle coal dust

MAGNETS

Make / Type ERIEZ maek / Oil CooledMagnetic Separators(Suspended Magnets) : No. 2 Nos. (Installed over Conv. 1A/ 1B)In Line Magentic separators(Self Cleaning type) No. 4 Nos ( 2 Nos over 1A / 1B,

2 Nos. over 3A/3B)

METAL DETECTORS

No. 4 Nos. (2Nos over 1A/ 1B,2 Nos. over 4A/4b)

Type Eddy current induced imbalance in aset of mutually balanced coils

Frequency 20 KHz to 100 KHz

FIRE FIGHTING / PROTECTION SYSTEM IN CHP

Fire fighting System: MVW Spray System 45 Zones spread throughout the

Conveyors Fire Hydrants 34 Nos. (Internal), 73 Nos. (external)

spread throughtout CHPFire Extinguishers 57 locations

Fire Detection System:LHSC (Linear heat Sensing Cable) Along all Conveyors except 4A/4B &

5A/5BIRD (Infra Red Detection System) Located at 1A/1B, 2A/2B, 3A/3B, 7A/7B

Fire Alarm :Smoke Detectors CHP C/R, CHP SWGR Room, CHP Cable

gallery room, T/H MCC room

4.7 ASH HANDLING SYSTEM

Ash handling system capacity Ash pro

4.7 ASH HANDLING SYSTEM

Ash handling system capacity Ash produced by 4 x 210 MW unit boilerin 24 hour to be evacuated in 5.5 hour

Ash mound capactiy 25 year of ash producedAsh mound area and height 200 hectre, 55mAsh mound settlement allowed 700-800 mm

TRANSPORT AIR COMPRESSOR

(i) No. 8 no.,2 for each unit(ii) Make Khosla-Crephille

For unit 1 and 2 For unit 3 and 4(iii) Capacity 159 m3/min 147/min(iv) Discharge pressure 2.26Kg/cm2 1.97kg/cm2

(v) Drive motorMake BHELRating 545 kwPower supply 6.6 kv, 3φφφφφ, 50 HZ

119118

INSTRUMENT AIR COMPRESSOR

(i) No. 3 no.2 working, 1 standby

(ii) Capacity 14m3/min(ii) Pressure 8kg/cm2

(iv) Motor 125 kw, 415v supply(v) Air drying plant-capacity 1800 N cub. m /hr

VACUUM PUMP

(i) Make Roots Division Dressers IndustiresINC, USA

(ii) No. 16 No. (4 for each unit)4 for each unit (2 working, 2 standy by)

(iii) Capacity 46.8 cu.m/min at 16 inch of Hg.(iv) Type Rotary Lube vacuum blower(v) Inlet Volume 46.8 CuM /min. at 16 mm Hg.(vi) Drive motor

Make KEC, PuneRating 75 kwPower supply 415V, 3φφφφφ, 50 HZ, 75 KW; 1057 rpm

H.P. WATER PUMP

(i) No. 6(3 for unit 1 and 2, 3 for unit 3 and 4)(ii) Make Becon weir Ltd. Unit 1 and 2 Unit 3 and 4(iii) Working pump/stand by 2/1 2/1(iv) Capacity 396 cuM/hr 406 cuM/hr(v) Discharge pressure 20.8kg/cm2 17.6 Kg/cm2

(vi) No. of Stages 7(vii) Drive motor

Make BHELRating 320 kwPower supply 6.6 kv, 3φφφφφ, 50 HZ

Type Multistage, single suction centrifugal

LP. WATER PUMP

(i) No. 6 no.3 for unit 1 and 2 & 3 for unit 3 and 4

(ii) Capacity 81.7 litres/sec(iii) Make Becon weir Ltd.(iv) Type Single stage, Double suction centiri fugal

(iii) Pressure 6.3 kg/cm2

(iv) Drive motorMake KEC, PuneRating 75 kwPower Supply 440 v

SEAL WATER PUMP

(i) Make Bewn Wier Ltd.(ii) Model Fnd-9(iii) Type Multistage Centrifugal type(iv) No. of stages 7(v) Flow 8.3 litres/sec.(vi) No. 2(vii) Discharge pressure 21.6 kg/cm2

(viii)Drive motorMake KEC PuneRating 45 kwPower supply 415 v, 3φφφφφ, HZ

OVER FLOW PUMP

(i) Make Indure Ltd.(ii) No. 8,2 for each unit(iii) Capacity 245 m3/hr(iv) Pressure 2.8 kg/cm2

(v) Motor 45 kw, 415 v supply(vi) Overflow tank capacity 54 m3

MIXER SPRAY WATER PUMP

(i) NO. 3(2 operating and 1 standby)(ii) Make Becon Weir Ltd.(iii) Type Centrifugal double suction(iv) No. of stages 2(ii) Capacity 81.7 litre/sec.(iii) Pressure 6.3 /cm2

(iv) Drive motorMake KEC, PuneRating 75 kwPower supply 440v, 3φφφφφ, 50 HZ

121120

COOLING TOWER

(i) No. 2(ii) Cooling Tower Discharge Pump

No. 4 (2 for each cooling tower)Pump capacity 500 cu m/hrPump discharge pressure 0.85 kg/cm2

Motor 45 kw, 415 v supply(iii) Cooling Tower Fan

No. 2Motor 12.5 kw, 415 v supply

SURGE TANK

No. 2Capacity 1500 m3

SLUDGE PUMP

No. 8Capacity 50 cu.m/hrDischarge pressure 3.0 kg/cm2

Motor 11.0kw, 415 v supply

SILO AERATION BLOWER

(i) Make Swam Engineering(ii) Type Twin lobe compressor(iii) No. 12(iv) Capacity 770m3/hr(v) Pressure 1.41 kg/cm2

(vi) Motor 30 kw, 415 v supply

DRY ASH SILO

(i) No. 5(ii) Capacity 2949 cuM

HYDROMIX DUST CONDITIONER

(i) No. 15(ii) Capacity 200T/hr(iii) Motor 7.5, HP, 415v

ROTARY FEEDERS

No. 15 ( 3 FOR EACH SILO)Motor 2.2 kw, 4.5 vNo. of silo filter vent fans 10:18.5 kw motorNo. of telescopic chutevent fan 5 / 5.5 kw motor

DEWATERING BINS

No. 6Capacity 650 t each

CONVEYORS

Belt 1600 mmCapacity 200t/hrBelt speed 3m/sec

123122

TECHNICAL SPECIFICATIONS OF ASH HANDLING PLANTPACKAGE-2

1. CONVEYOR C-10 to C- 05 :Location - Blow Silos HMDCCapacity - 850 TPHLength - 19.65 MSpeed - 1.5 M / Sec.Motor Specification - 25 KW, 415 V, 45 Amp.

2. CONVEYOR C-10 to C -15 :Location - Blow Hydrobins VibrofeederCapacity - 750 TPHLength - 16.625 MSpeed - 1.5 M / Sec.

Motor Specification - 25 KW, 415 V, 45 Amp.3. CONVEYOR C-20 / 21 :

Location - From Silos / Hydrobins TO JH -1Capacity - 200 TPH For Fly Ash

1500 TPH For Bottom AshLength - 341.592 MSpeed - 3.0 M / Sec.Motor Specification - 220 KW, 6.6 KV, 26 Amp.

4. CONVEYOR C-24 / 25 :Location - From JH-2 TO JH-4Capacity - Same as AboveLength - 1034.868 MSpeed - 3.0M / Sec.Motor Specification - Same As Above

5. CONVEYOR C-24 / 25 :Location - From JH-2 To JH-4Capacity - Same As AboveLength - 1034.868 MSpeed - 3.0 M / Sec.Motor Specification - 320 KW, 6.6 KV, 37 Amp.

6. CONVEYOR C- 30 / 31 :Location - From JH-4 To JH-7Capacity - Same As AboveLength - 212 MSpeed - 2.6 M / Sec.Motor Specification - 90 / 100 KW, 415 V, 165 / 175 Amp.

7. CONVEYOR C- 32 :Location - Ash Mound Field (SC-1)Capacity - Same As AboveLength - 13.8 M

Speed - 2.76 M / Sec.Motor Specification - 55 KW, 415 V, 104 Amp.

8. CONVEYOR C- 33 :Location - Ash Mound FieldCapacity - Same As AboveLength - Extendable & Shiftable,

Maximum 100 MSpeed - 2.76 M / Sec.Motor Specification - 2*355 KW, 6.6KV, 41 Amp.

9. CONVEYOR C- 34 :Location - Ash Mound FieldCapacity - Same As AboveLength - 25 MSpeed - 2.7 M / Sec.Motor Specification - 2*37 KW, 415 V, 70 Amp.

10.CONVEYOR C- 35 :Location - Ash Mound Field Boom

Spreader (SP-1)Capacity - Same As AboveLength - 35 MSpeed - 2.7 M / Sec.Motor Specification - 2*55 KW, 415 V, 104 Amp.

11.CONVEYOR C- 40 :Location - From JH-4 TO JH-6 (Temporary

Stock Yard)Capacity - Same As AboveLength - 1009 MSpeed - 3.0 M / Sec.Motor Specification - 2*220 KW, 6.6 KV, 26 Amp.

12.CONVEYOR C- 41 :Location - Stacker (Temporary Stock Yard)Capacity - Same As AboveLength - 2.89 MSpeed - 3.0 M / Sec.Motor Specification - 70 KW, 415 V, 120 Amp.

13.CONVEYOR C- 42 :Location - Bucket Reclaimer BR-1

(Temporary Stock Yard)Capacity - 840 TPHLength - 10 MSpeed - 2.7 M / Sec.Motor Specification - 37 KW, 415 V, 70 Amp.

14.CONVEYOR C- 43 :Location - Bucket Reclaimer BR-1

(Temporary Stock Yard)

125124

Capacity - 840 TPHLength - 17.3 MSpeed - 2.7 M / Sec.Motor Specification - 37 KW, 415 V, 70 Amp.

15.CONVEYOR C- 44 :Location - Mobile conveyor MC-1

(Temporary Stock Yard)Capacity - 840 TPHLength - 32 MSpeed - 2.7 M / Sec.Motor Specification - 37 KW, 415 V, 70 Amp.

16.CONVEYOR C- 45 :Location - Temporary Stock Yard To Jh-5Capacity - 700 TPHLength - 1004.89 MSpeed - 3.0 M / Sec.Motor Specification - 200 KW, 6.6 KV, 35 Amp.

17.CONVEYOR C- 43 :Location - Bucket Reclaimer BR-1

(Temporary Stock Yard To Jh-5Capacity - 200 TPH For Fly Ash

1500 TPH For Bottom AshLength - 334.50 MSpeed - 2.60 M / Sec.Motor Specification - 2*90 KW, 415 V, 165 Amp.

18.CONVEYOR C- 51 :Location - Ash Mound Emergency Stock

Yard (SC-2)Capacity - Same As AboveLength - 46 MSpeed - 2.76 M / Sec.Motor Specification - 132 KW, 415 V, 232 Amp.

19.CONVEYOR CA / CB :Location - From JH-7 To JH-8Capacity - Same As AboveLength - 400 MSpeed - 3.0 M / Sec.Motor Specification - 2*235 KW, 6.6 KV, 26 Amp.

20.CONVEYOR CC :Location - From JH-8 To con. CECapacity - Same As AboveLength - Extendable & Shiftable Max. 1000 MSpeed - 3.0 M / Sec.Motor Specification - 2*200 KW, 6.6 KV, 22.5 Amp.

20.CONVEYOR CC :Location - From JH-8 To con. CECapacity - Same As AboveLength - Extendable & Shiftable Max. 1000 MSpeed - 3.0 M / Sec.Motor Specification - 2*200 KW, 6.6 KV, 22.5 Amp.

21.CONVEYOR CD :Location - From JH-8 To SC-1Capacity - Same As AboveLength - Extendable & Shiftable Max. 1000 MSpeed - 3.0 M / Sec.Motor Specification - 2*200 KW, 6.6 KV, 22.5 Amp.

22.CONVEYOR CE :Location - Ash Mound FieldCapacity - Same As AboveLength - Extendable & Shiftable Max. 1000 MSpeed - 3.0 M / Sec.Motor Specification - 2*315 KW, 6.6 KV, 34 Amp.

23.CONVEYOR CF :Location - Ash Mound FieldCapacity - Same As AboveLength - 28.705 MSpeed - 3.2 M / Sec.Motor Specification - 110 KW, 415 V, 180 Amp.

24.CONVEYOR CG :Location - Teporary Stock YardCapacity - Same As AboveUse - Ash Dumping

25.STAKER :Location - Temporary Stock YardTravel Motor - 6*5.5 KWm 415 V, 23 AmpLuff - Discharge Boom Left & RightHyd. Pump Motor - 11 KW, 415 V, 23 AmpSlew - Discharge Boom Left & RightSlew Motor - 2.2 KW, 415 V, 5.2 Amp

26.BOOM SPREADER (SP-1) :Location - Ash MoundCapacity - Same As AboveUse - Ash Dumping

FUNCTIONS : Travel - Forward & BackwardSP-1 Travel Motor - 2*23 KW, 415V, 6.5 Amp.TR-1 Travel Motor - 8*2.2 KW,415 V, 6.5 Amp.Luff - Discharge Boom Upper & LowerHyd. Pump Motor- - 30 KW,, 415 V, 53 AmpSlew - Discharge Boom Left & Right SwingSlew Motor - 2*7.0 KW, 415 V, 16.7 V, 16.7 Amp.

127126

27.BOOM SPREADER (SP-2) :Location - Ash MoundCapacity - Same As AboveUse - Ash Dumping

FUNCTIONS : Travel - Forward & BackwardSP-2 Travel Motor - 2*75 KW, 415V, 132 Amp.TR-2 Travel Motor - 16*1.5 KW, 415 V, 3.4 Amp.Luff - Discharge Boom Upper & LowerSlew - Discharge Boom Left & Right SwingSlew Motor - 2*7.0 KW, 415 V, 16.7 V, 16.7 Amp.

28.BOOM SPREADER (BR-1) :Location - Temporary Stock YardCapacity - Average 350 Cu.M/Hr. (Max. 700 TPH)Use - Reclaiming Of Ash

FUNCTIONS : Travel - Forward & BackwardTravel Motor - 2*22 KW, 415V, 43 Amp.Luff - Receive Boom Upper & Lower

Discharge Boom Uper & LowerL.Hyd. Pump Motor - 11 KW, 415 V, 20.6 AmpSlew - Receive Boom Left & Right SwingS. Hyd. Pump Motor - 30 KW, 415 V, 55 AmpB.W. Wheel Motor - 75 W, 415 V, 130 Amp

29.MOBILE CONVEYOR (MC-1) :Location - Temporary Stock YardCapacity - 840 TPH

FUNCTIONS : Travel - Forward & BackwardTravel Motor - 2*14 KW, 415V, 31 Amp.Luff - Conveyor Boom Upper & LowerHyd. Pump Motor - 11 KW, 415 V, 20.6 AmpSlew - Conveyor Boom Left & Right SwingS. Hyd. Pump Motor - 30 KW, 415 V, 55 AmpB.W. Wheel Motor - 75 W, 415 V, 130 Amp

30.LOADING HOPPER (LH-1) :Travel - Forward & BackwardTravel Motor - 6*2.2 KW,415 V, 6.5 Amp.

31.DUST SUPRESSION SYSTEM :DS - 2, 3 & 4 - For Junction House Transfer ChutesDS - 6 - For Temporary Stock YardDS - 9 - For Ash Mound

31.ASH LAGOON PUMP : No. - 4Location - Ash Lagoon Pump HouseCapacity - 3600 Cu.m / Hr.Motor Specification - 55 KW, 415 V, 115 Amp.

32.ELECTRICAL TRANSFORMERS :a. Control Room LT MCC (2No.) - 1600KVA, 6.6KV/415, 139.96/

133.39 Amp.

b. LT MCC-A (2No.) - 750KVA, 6.6KV / 415V, 1000.02/69.0 Amp.

c. LT MCC-B (2No.) - 500KVA, 6.6KV / 415V, 46.04/666.69 Amp.

d. SPREADER (SP-1) MCC - 400KVA, 6.6KV / 34.99 / 556.489Amp.

e. SPREADER (SP-2) MCC - 500KVA, 6.6KV /415, 34.99 /556.48 Amp

f. STACKER MCC - 500KVA, 6.6KV / 415v, 46.04 /666.69 Amp.

g. BUCKET RECLAIMER MCC - 315KVA, 6.6KV / 415v, 438.24Amp.

32.ASH LAGOON PUMP : No. - 4Location - Ash Lagoon Pump HouseCapacity - 375 AcressMotor Specification - 55 KW, 415 V, 115 Amp.

33.ELECTRICAL TRANSFORMERS :a. Control Room LT MCC ( 2No.) - 1600KVA, 6.6 KV/415V, 139.96/133.39 Amp.b. LT MCC A ( 2No.) - 750KVA, 6.6 KV/415V, 1000.02/69.00 Amp.c. LT MCC B ( 2No.) - 500KVA, 6.6 KV/415V, 46.01/666.69 Amp.d. SPREADER (SP-1) MCC - 400KVA, 6.6 KV/415V, 34.99/556.489 Amp.e. SPREADER (SP-2) MCC - 500KVA, 6.6 KV/415V, 46.04/666.69 Amp.f. STACKER MCC - 250KVA, 6.6 KV/415V, 21.86/333.3 Amp.g. BUCKET RECLAIMER MCC - 315KVA, 6.6 KV/415V, 27.56/438.24 Amp.

34.ASH MOUND SALIENT FEATURES -Total Land For Ash Disposal System- 500 AcresTotal Area For Mound Construction - 375 AcresFinal Height Of Ash Mound - 55 MGradient Of Slopes - 1 In 4.5 & 1 In 4.0Ash Mound Volume - 530 Lac Cu. MCapacity Of Temporary Stock Yard - 1,00,000 Cu. MThickness Of Drainage Blanket - 1.0 To 1.50 MBen At+15 M,+ 30 M &+45 M Elevation - 10 M Wide

4.8 FIRE FIGHTING SYSTEMFIRE HYDRANT PUMP

(i) No. 43 Electrical driven, 1 Diesel engine driven

(ii) Location Raw water pump house(iii) Make Kirloskar Ltd.

Electrical driven Diesel engine driven(iv) Total head 120.4 m 120.4 m(v) Size 250 mm 250 mm(vi) Rate of flow 113.89 L/s. 118.05 L/s

(410m3/hr)

129128

(vii) Speed 1482 rpm 1500 rpm(viii)Pump input 174.59 kw 180.97 kw(ix) Drive Electric motor drive Diesel engine drive

Make Crompton Make KirloskarGreaves Cummins Ltd.KW/HP 220/295 Rated BHP : 326RPM 1482 RPM :2000Power supply 6.6kv, Model:NTA-855F3θθθθθPower supply 6.6 kv, Model : NTA-855-F3θθθθθ 50 HZMax current 24.2A Luboil specification

As per IS 496Insulation Class F Fuel oil specification

As per IS 1460

FIRE SPRINKLER PUMP

No. of pumps 2 (One Electrical driven, one diesel enginedriven Rest as in case of fire hydrant pumps

JOCKEY PUMP

(i) No. of pums One(ii) Type Single stage(iii) Capacity 30 m3 / hr(iv) Head 120 mwc(v) Drive Electrical driven, 2 pole, 415v, 50HZ, 37 kw,

65A

AIR COMPRESSOR

(i) Model TC 500 FAD/DIS 500 lit/min(ii) Working pressure 12.0 kg/cm2

(iii) Drive motor 3.7 kw/5 hp, 415v, 3φφφφφ, 50 HZ, power supply,7.3. A, 1440 rpm

(iv) Tank capacity 250 litres

HYDRO PNEUMATIC TANK

(i) Internal diameter 2600 mm(ii) Capacity 18 m3

(iii) Operating pressure 12 kg/cm2

(iv) Safety valve set pressure 13.2 kg/cm2

HALON SYSTEM

(i) Area where used Control room, DDCMIS room, Controlequipment room, UPS SWAS room

(ii) Extinguishing agent Halon 1301 gas(iii) Concentration employed 5% at design temp.(iv) Gas dischange duration 30 second.

FOAM SYSTEM

(i) Area where used HFO/LDO system(ii) Type of system Fixed foam low expansion delivered on

oil surface(iii) Application rate 5 lpm/m2 liquid surface area(iv) Discharge duration 30 minute(v) Foam concentration 3% profein based(vi) Foam tank

No. 2Type Horizontal cylinder with dished endCapacity 12 KL

MVW SPRAY SYSTEM FOR COAL CONVEYORS

(a) Type of system and actuation, Deluge valve operated MVW spray systemautomatic, (electrical), remote manual &local manual (mechanical)

(b) Spray density 10.2 lpm/m2 (of floor area+return belt area)(c) Min. pressure at hydraulically

remotest/nearest nozzle 1.4 bar/3.5 bar(d) Discharge time 30 minutes

131130

(e) Type of detection system LHSE and infra red detectors(f) Type of spray nozzles

(i) For floor protection Open head up right spray with K-79(Metric) V-1

(ii) For return belt protection Open head directional sprayers with K-46(g) Water required per zone Limited to approx 410 m3/hr(h) No. of sprayed at a time Adjacent two nos.

FIRE DETECTION AND ALARM SYSTEM

Area Type of Detectors used(1) Cable trench cable gallary Themo electric quartzoid bulbs,

ionisation and photo(2) Generator seal oil unit oil

room central oil purificationunit Quartzoid bulbs

(3) Boiler burnet fonts Quartzoid bulbs(4) Generator transformer,

station transfomer, stationtransformer, UAT, Quartzoid bulbs

(5) HT/LT switchgear, batteryroom soot blower, MCCroom Ionisation type smoke detector

(6) UCR, DDCMIS, CER, UPS Ionisation type and photo electric typeand SWAS room smoke detector

(7) CHP, control room and track lonisation type smoke detectorhoper control room

(8) Coal conveyor Liner heat sensor

SWITCHYARD FIRE FIGHTING SYSTEMWATER STORAGE TANKS

No. 2Capacity 150 m3 each

132

(iii) Head 70 mwc(iv) Make KBL(v) Model No. KPD 32/26(vi) Diesel engine

Rating 183.83 hp after deduction/deratingengine

RPM 1800Make KCLModel No. N-743-TFControl supply Battery 24v

JOCKEY PUMP NO. P-04

(i) Purpose To maintain constant level of water inhydro pneumatic tank

(ii) Rated dischage 13.5 m3/hr(iii) Head 70 mwc(iv) Type Horizontal centrifugal(v) Make KBL(vi) Model No. KPD 32/26

Rating 11 kwRPM 2850Type Sq. cage inductionMake KECPower supply 415v, 3φφφφφ, 50 HZ

AIR COMPRESSOR AC-1 & AC-2

(i) No. & capacity 2 x 100%(ii) Compressor capacity 9 m3/hr(iii) Pressure 8 kg/cm2(iv) Make Ingersoll rand(v) Model NO. M 234 F2(vi) Motor

Rating 1.5 kw

134133

HIGH PRESSURE WATER SPRAY (EMULSIFIER) PUMP No. P-01

(i) Pump discharge for Emulsifier system of the shunt reactosin 400 kv switchyard

(ii) Rated discharge flow 410 m3/hr(iii) Head 70 mwc(iv) Type Horizontal centrifugal(v) Make KBL(vi) Model No. 6 UP 4F(vii) Motor rating 160 kw

RPM 1485Type Sq. cage inductionMake KECFrame size LD 315 LM KIIPower supply 415v, 3φφφφφ, 50HZ

HYDRANT PUMP P-02

(i) Pump discharge for Hydrant around switchyard control room(ii) Rated pump discharge 97.2 m3 / hr(iii) Head 70 mwc(iv) Type Horizontal centrifugal(v) Make KBL(vi) Mode no. DB 80/26(vii) Motor rating 37 kw derated

RPM 2960Type Sq. cage inductionMake KEC, PuneFrame size LD 225 S LMK IIPower supply 415v, 3φφφφφ, 50 HZ

COMMON STAND BY PUMP (DIESEL ENGINE DRIVEN) P-03

(i) Pump discharge to Common discharge header of P-01 andP-02

(ii) Rated discharge 410 m3/hr

RPM 1500Type Sq. cage inductionMake KECModel No. KH 100 LPower supply 415v, 3φφφφφ, 50 HZ

HYDRO PNEUMATIC TANK

(i) Nominal pressure 7.5 kg/cm2

(ii) Capactiy 18 m3

4.9 AIR CONDITIONING SYSTEM

Description Main Plant D.M. Plant ESP AC Softening SwitchyardA.C. System A.C.System System A.C.System A.C. System

Capactiy(tonne) 95x1+95x1 20x2+20x2 15x1+15x1 15x1+15x1 65x1+65x1Compressor

No. 2 4 2 2 2

Make Kirloskar ACCEL ACCEL accel Kirloskar

Pneumatic Pneumatic

Co. Ltd. Co. Ltd.

No. of cylinder 12 6 4 4

Cylinder bore 85 mm 65 mm 65 mm 65 mm 85 mm

Stroke 70 mm 50 mm 50 mm 50 mm

Maximum

operating pr. 21 bar 16.5kg/cm2 16.5kg/cm2 16.5kg/cm2 21kg/cm2

Port load

capacity 75%, 50%, 25%, 50%, 100% 50%, 100% 50%, 100% -

Lub Oil Servo frize Sheetal Sheetal Sheetal Servo frize-57

F-57 N-68

(IOC) (HP) (HP) (HP)

136135

4.9 MAIN PLANT AIR-CONDITIONING

AUTO SYSTEM

Compressors 2 No.S 3 per SIIU room AIIU DDCMISAITU’S 9 No.S AHU Control room

AHU SWAS/UPS

Humidistat 6 No.S, 1High and 1Low per AHU room

Modulating thermostat 9 No.’s 1 per AIIU

Anti- Freeze thermostat 2 No.’s

On/off thermostats 14 no.’s 2 for 2 heators per AHU room (total6 no.s)4 for solonoids valves percompressor (total 8 no.s)

SETTING AND INTERLOCKS

Humidistat High 60 deg F SV on chilled water side line energisesand bypasses chilled water from AHU.

Humidistat low 45 deg F humidifier pump on command

Heater thermostat 1- Heater bank 1 on2- Heater bank 2 on

Modulating thermostat 3 way valve on chillid water line opens &bypasses chilled water from AHU.0%- valve closes100%- valve opens

On/off thermostats Chilled water temp.>10 degC SV1.CV2,SV3enertises and load 100%

TH3 Chilled water temp <10 degC SV1drops,SV& SV3energises load 75%.

TH2 Chilled water temp < 9 degC SV1 energises, SV2& SV3 drops load 50%

TH1 Chilled water temp < 8degC SV1, SV2, SV3 dropsload 25%

TH4 Chilled water temp < 6 degC, LSV drops

Anti - freeze thermostat Chilled water temp < 3 degC compressor trips

NTPC NCPSOperation & Maintenance-CoalMaintenance Planning Section

Lube Oil Used In Various Auxiliaries

SI. Equipment Oil usingNo1. ID FAN LUBE OIL, SERVO PRIME 68

HYDRAULIC OIL SERVO TORQUE 102. FD FAN LUBE OIL, SERVO PRIME 68,

HYDRAULIC OIL SERVO TORQUE 103. PA FAN LUBE OIL, SERVO PRIME 68,

HYDRAULIC OIL SERVO TORQUE 104. MILLS SERVO MECH SP- 680, MILL

JOURNAL ASSY.5. MILLS TOP BEARING SERVO MECH SP- 320. MILL GEAR

BOX6. MILLS BOTTOM BEARING SERVO MECH SP- 320, FEEDER

GEAR BOX7. APH MAIN DRIVE GEAR BOX SERVO SYSTEM 2208. APH SUPPORT BEARING SERVO CYCLE C 6809. APH GUIDE BEARING SERVO CYCLE C 68010. IRDS GEAR BOX SERVO MECH SP 46011. APH SOOT BLOWER GEAR BOX SERVO MECH SP 46012. WALL BLOWER GEAR BOX SERVO MECH SP 46013. ESP CRM GEAR BOX SERVO SYSTEM 22014. ESP ERM GEAR BOX SERVO MECH SP 46015. BFP PUMP SERVO TORQUE 1016. CEP PUMP SERVO PRIME 4617. ECW PUMP SERVO GN 2623(GREASE)18. VACUUM PUMP SERVO GN 2623(GREASE)19. STATOR WATER PUMP SERVO PRIDE 30/4020. SEAL OIL, TURBINE OIL SERVO PRIME 4621. DOZING PUMPS SERVO PRIDE 4622. MOT CENTRIFUGE GEAR BOX SERVO MECH SP 32023. WTP PUMP SAE - 4024. Raw Water P/P /soft water p/p SAE - 4025. WTP agitators/blowers Servo Prime - 32026. AC Compressor Servo Freeze - 6827. Air compressor Servo Press - 10028. EOT Crane Servo Prime - 32029. Raw Water P/P Servo Prime - 57

D\Users\R Seshadri\unit 4 shutdown\Unit#4 shutdown oil use.doc

Sheetal-68 Servo frize Servo frize Servo Frize

(HP) F-57 F-57 F-57

Bharat (IOC) (ICO) (IOC)

freezed-68

(HP)

Motor

Volt 415 v 415v 415v 415v 415v

Power(kw) 85 18.5 kw 15 15 55

Curret (A) 147 33 Amp. 27 27 -

RPM 1480 1450 1460 1460 1480

Make Cromption Cromption Cromption Cromption Cromption

Greaves Greaves Greaves Greaves Greaves

Induction Induction Induction Induction Induction

motor motor motor motor motor

CHILLED WATER PUMP ........................... N.A. ...............................

No. 2 - - - -

Pump type UP 80/38 - - - -

(Kirloskar) - - - -

Total head 42 m - - - -

Rate flow 16.6I/s - - - -

Speed (rpm) 1450 - - - -

Pump input(kw) 12.15 - - - -

MOTOR

Power 18.5 kw - - - -

Current 33 A - - - -

RPM 1450 rpm - - - -

V 415 v - - - -

CONDENSER WATER PUMP

No. 2 2 2 2 2

Total head 27m 16 m 18 m 18 m 24 m

Rate of flow 22.2I/s 8.88 l/s 3.33 l/s 3.33 l/s 6.66 l/s

138137

Speed (RPM) 1450 1430 1430 1430 1450

Pump input, kw 7.75 2.68 1.73 1.73

MOTOR

Power, kw 11 3.7 3.7 3.7 9.3

Current, A 33.0 7.9 7.9 7.9 18.0

RPM 1460 1430 1430 1430 1460

Volts 415+10% 415+10% 415+10% 415+10% 415

Ambient

temp, 0c 500c 500c 500c 500c 500c

Type & Make Crompton Crompton Crompton Crompton Crompton

Greaves Greaves Greaves Greaves Greaves

induction induction induction induction induction

motor motor motor motor motor

COOLING TOWER

No. 2 2 2 2 1

Model 4201 M 1468 P 1468 P 1468 P

Clr. water qty. 80m3/hr 32m3/hr 12m3/hr 12m3/hr

In/out water

temp. 39/32.30c 39/32.30c 39/32.30c 39/32.30c

Make up water 1.44m3/hr 0.576m3/hr 0.216m3/hr 0.216m3/hr

No. of nozzles 36 16 9 9

Pr. drop in

nozzle 0.42kg/cm2 0.42kg/cm2 0.42kg/cm2 0.42kg/cm2

Speed, rpm 686 750 1000 1000

Motor rating, kw 5.5 5.5 2.2 2.2

Motor speed, kw 1440 750 1000 1000

Fan capacity,m3/hr 10600 20480 10500 10500

AH UNIT

No UPS-3 3 2 2 2

CET-3

DDCMIS-3

Power(kw) UPS 5.5 5.5 3.7 3.7 9.3

CER-3-7

DDCMIS-15

Current UPS 11A 11A 7.9A 7.9A 18.0A

CER-3-7

DDCMIS-15

RPM UPS 1410 1460 1440 1440 1440

CER-3-7

DDCMIS-1460

BLOWER

CAPACITY UPS-12325 17000 12240 12240 25500

(m3/hr) CER 10370

DDCMIS 20485

FRESH AIR

FAN MOTOR

No. 3 1 1 1

Power, kw 1.1 0.37 0.37 0.37

Current, A 2.7 1.1 1.1 1.1

RPM 1045 1460 1460 1460

FRESH AIR

FAN

Capacity, UPS 1500 100 100 100

m3/hr DDCMIS 2000

Control Room 1500

Description Main A/C PAC Unit Microwave A/C System

(7.5 x 2 + 7.5 x 1) Tonne (7.5 x5 + 7.5x2) tonne

Model No. PAW 718 oil charged PAW 718 oil charged

Make Blue Star Blue Star

Refrigerant R-22 R-22

Refr. Qty. 64 Kg 64 Kg

Cooling capacity 7.5 7.5

140139

Max. pressure 27kg/cm2 27kg/cm2

Min. pressure 18kg/cm2 18kg/cm2

Compressor type Hermatically sealed Hermatically sealed

RPM 2900 2900

Lubrication system Forced feed by oil pump Forced feed by oil pump

Lucrication oil Servo Friz F-33 Servo Friz F-33

Capella B Capella B

Compressor motor 7.09 kw 7.09kw

CONDENSER WATER PUMP

No. 2 2

Pump head 16 m 16 m

Rate of flow 8.88 l/s 8.88 l/s

Size 65x50 mm 65x50 mm

RPM 1430 1430

Power input 2.68 Kw 2.68 Kw

Motor

Power 3.5 3.5

Current 7.9 A 7.9 A

RPM 1430 1430

Voltage 415+10% 415+10%

Make Crompton Crompton

Greaves Greaves

induction Motor induction Motor

COOLING TOWER

Model 1268 P 1468 P

Circulating water qty 18 m3/hr 32 m3/hr

In/out water temp 39/32.30c 39/32.30c

Make up water 0.324 m3/hr 0.76 m3/hr

No. of nozzles 9 16

Pressure drop in nozzle 1.42 kg/cm2 1.42 kg/cm2

Fan capacity 14550 m3/hr 20480 m3/hrSpeed 100 rpm 710 rpmMotorRating 3.7 kw 5.5 kwCurrent 7.9A 12AVoltage 415+10v 415+10vMake ABB ABB

4.10 DIESEL GENERATOR SET

MAIN PLANT D.G SET

(i) ManufacturerDiesel engine with accessories Kirloskar Cummins Ltd.Alternator and exciter NGEF Ltd.

(ii) Net electrical ouptut of DG setat 500c ambient/400c ambient 590 kw/600 kw

DIESEL ENGINE

(i) Rated BHP at 330c/500c 890/870 BHP(ii) No. of arrangement of cylinder 12-VCVCEE(iii) Speed 1500 rpm(iv) Method of starting Electric battery 24 VDC(v) Time required for starting from 30 seconds, max

cold(vi) lnterval between starting 3 second

impulses(vii) No. of starting impulses 3(viii)Type of governor PSG motorised(ix) Guaranteed fuel consumption at

full load 150 gm/BHP/hr as per BS/649/ 5514(x) Thermal efficiency 38%(xi) Method of cooling of engine

and lubrication oil Radiator water cooled/forced air blast(xii) Amount of water required for

cooling system 300 litre

142141

ALTERNATOR

(i) Rated kw capacity at 40oc/50oc 621.2/584 kw(ii) Rated KVA capacity at 40oc/50oc 776.6/730 kva(iii) Rated terminal voltage and

frequency 415v,50HZ

(iv) Rated statar current 1021 A(v) Class of insulation F(vi) Type of exciter used Brush less, 3.9 kw(vii) Excitation current and voltage

at rated power output andpower factor 20 A, 45v

BATTERY AND BATTERY CHARGER

(I) Type of battery Lead acid battery, automotive type(ii) No. of batteries Each 12V-200 AH battery

comprises of 6 cells and 4 batteriesin series/parallel comvination to give400 AH-2V DC

(iii) Type of rectifier and ratedoutput current Silicon, 40A

(iv) Time required for rechargingthe battery 6-8 hour

SWITCHYARD DIESEL GENERATOR SETDIESEL ENGINE

(i) Make Ruston and Hornshy (I) Ltd.HWM AG West Germany

(ii) Type TBD-232 V12(iii) Rated BHP 357(iv) RPM 1500(v) Method of cooling Radiator water cooled/forced air

blast

ALTERNATOR

(i) Make NGEF Ltd.(ii) Rating KW 212.5

KVA 250 Ampere 348

(iii) Rated terminal output 415v, 3φφφφφ, 0.8 p.f., 50 HZ

(iv) Class of insulation F

DIESEL TANK

(i) Capacity 1000 litre

4.12 CENTRAL LUBE OIL STORAGEAND PURIFICATION SYSTEM

STORAGE TANKS CAPACITY

(i) Dirty tank 60m3

(ii) Clean oil tank 60 m3

(iii) Oil unloading vessel 1 m3

with suitable cover 1 m3

4.11 CENTRAL OIL PURIFIER

(i) Make Alfa laval(ii) Capacity 6000 lph

PUMPS

Drain oil pump Dirty oil transfer Clean oilpump transfer pump

(i) Type Rotary positive Rotary positive Rotary positivedisplacement displacement displacement

(ii) No. 4 1 1(iii) Capacity, lph 6000 6000 6000(iv) Head,kg/cm2 (g) 2.0 2.0 2.0

144143

4.12 MISCELLANEOUS WATER SYSTEMSERVICE WATER SYSTEM

Service Water Booster Pump

(i) No. 2 (1 + 1)(ii) No. of stages Four(iii) Flow 425 m3/hr(iv) Head 60 mlc(v) Motor 110kw, 415v, 3φφφφφ power supply, Crompton

Greaves motor

TANK(i) Tank Height 34 m(ii) Tank capacity 300 m3

DRINKING WATER SYSTEMDrinking Water Pump

Plant Township(i) No. 2 2(ii) Make Flowmore Flowmore(iii) Working/standby 1 + 1 1 + 1(iv) No. of stages Seven Two(v) Flow 100 m3 300 m3

(vi) Head 60.085 mlc 42 mlc(vii) Motor rating 30 kw, 1475 rpm, 55kw, 1475 rpm,

class B insulation class B insulationCromption Greaves Make Cromption Greaves Make

Tank(i) Tank height 34 m(ii) Capacity 300 m3

APH WATER WASHING PUMPS

(i) Make Mather & Platt Ltd.(ii) No. and type 2(1+1), KL-ISO 150 x 125 - 400(iii) Flow 220m3 / hr(iv) Head 50 mlc(v) NPSH required 4.2 m(vi) Motor 55 kw, 1480 rpm, GEC make

FILTER WATER PUMPS FOR AIRCONDITIONING AND AIR COMPRESSOR COOLING

(i) Location Filter water pump house(ii) Make Flowmore(iii) No. 3(iv) Pump size 14 M(v) Flow 225m3/hr(vi) Head 70 mlc(vii) Motor Crompton Greaves make, 75kw, 1480 rpm,

415v, 3φφφφφ, power supply, class B insulation,132 A

4.13 COAL MILL REJECT SYSTEM

(i) Capacity of mill pyrite 0.625 m3

hopper(ii) General composition of Hard coal, shales, pyrite metollic pieces,

mill reject stone chips and other extraneous matterpresent in coal

(iii) Lump size of mill reject 40 mm (approx)(iv) Mill reject rate 0.1% to 1.0% of coal consumption,(v) Temperature of reject 1500c(vi) Rated capacity of system 30 tph(vii) Conveyors MRC1 MRC2

a. Belt make Hilton make Hilton makeb. Belt type 500 mm wide, Nylon 500mm wide,

500/3 GD, 5mm top Nylon 500/3and 2mm bottom GD, 5 mm toprubber cover GR HR 150 and 2 mm bottom

rubber cover GRHR 150

c. Speed 30m /min 30m / mind. Rated capacity 30 tph 30 tph

146145

e. Design capacity 60 tph 60 tph

f. Gear box Warm reduction U 1000 Warm reduction

Rodicon make, U1000 60.1 radicon

440 rpm, NGEF make, Radicon make

squirrel cage, TEFC 15HP, 1440 rpm

NGEF make, squirrelcage,

(viii) Conveyor accessories Pull chord type emergency switch system

Belts sway switches

(ix) Bin zero speed switches

a. Capacity 125 tonne

b. Type Cylindrical at top, conical at bottom

c. Diameter 5 m

d. Height 3.7 m cylindrical and 4.0 m conical

e. Liner 10 mm THK Tiskacrd liner

f. Minimum valley

angle of silo 600

147

OFF SITE - 2

WATER REPLEBISHMENT SYSTEM

TUBEWELL PUMPS

(i) No. of tubewell envisaged -42

(i) No. of tubewell commisioned - 35

(iii) Pump make - Poller

(iv) Pump type - submersible

(v) Discharge capacity - 200m3/hr.

(vi) Motor rating - 14nos - 20 hp

- 20nos - 35 hp

- 01nos - 60 hp

(vii) Full lood current - 30 Amp

- 52 Amp

- 90 Amp

(viii) Speed - 2900 RPM

CONSTRUCTION DETAILS OF DEEP BORE WELL

(i) Depth of drill bore - mtr. depending on soil strata

(ii) Size of housing pipe - 350 mm φφφφφ(iii) Length of housing pipe - 40 to 50 mtr.

(iv) Size of filter pipe - 200/250 mm

(v) Length of filter pipe - 50 to 55 mtr depending on soil strate.

(vi) Size of drill bore - 675 mm

(vii) Size of pea gravel - 2 to 6 mm (Appro.)

(viii) Type of bore - graves packes.

RESERVOIR OF TUBEWELL WATER REPLENISHMENT SYSTEM

SIZE - 60m X 15m X 4m.

RESER VOIR OF TUBEWELL WATER REPLENISHMENTSYSTEM

SIZE - 60 m X 15 m X 4m.

WATER REPLENISHMENT SYSTEM

(i) No. of tubewell envisaged - 42

(i) No. of pump - 04 (3 working 1stand by)

(ii) Dischrge capacity - 1750m3/hr.

(iii) Make - Kirlosker

(iv) Model - BHM 30, Vertical turbine

(vi) Motor rating - 180 hp

(vii) Full load current - 225 Amp

(viii) Dscharge connection - 2 nos 800 nb tube pipe Sikandrabaddistributary

- 01nos. 110 nb MS pipe- water treatment plant

PLANT STORM WATER SYSTEM

(i) No. of pumps - 06 nos (Flowage/FMI make)

- 03 nos (WPIL make)

(ii) Discharge capacity - 190 m3/hr.

(iii) Motor rating - (Flowage/ FMI)-55kw Crompton

- (WPIL) - 45 kw siemans

(iv) Speed - (Flowage/FMI) - 980rpm

- (WPIL) - 982 rpm

(v) Full Load Current - (WPIL) - 80 Amp.

- Flowage/FMI-99Amp.

PLANT SEWERAGE SYSTEM

(i) Manufacturer - Iron manufacturer

(ii) No. of pump envisaged - 14 nos.

(iii) No. of pumps commissioned - 12 nos.

(iv) Dischare capacity - 30m3/hr.

(v) Speed - 1430 RPM.

(vi) Full Load current - 4 Amp.

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SECTION - 5

CONTROL&

INSTRUMENTATION

5.1 UNIT C&I SYSTEM

SG (FSSS) Procontrtol P13/42

(BBS Sweden)

TG (ATRS) Iskamatic A&B M/s BHEL

(KWU W. Germany)

Measuremets

Automation DDCMIS (Contronic 31)_______ M/S ILK

DAS (H & B, W. Germany)

DDCMIS

Make Hartman & Braun, West

Germaby.

Model Contronnic 3 & Contrnic 31

Supplier Instrumentation LTD. Kota

DDCMIS Constitues ofi. Open Loop Control System

ii. Close Loop Control System

iii. Information System

iv. Sequence of Events Recorder (Stand alone)

OLCS/CLCS

System ConfigurationNo. of groups 03

No. of function groups(OSCS) 36

No. of function groups(SLCS) 05

No. of OLCS Cubicles 09

No. of CLCS Cubicles 09

No. of Control loops 19

Processor for OLCS XU13/14 (8085 Micro processor)

Processor for CLCS XU03/04/(8085 Micro processor)

150

System Redundancy Parallel operation available throughCRT keyboard and

push buttons on the panel.

Redundant power supply of

240 VAC Through “fuji UPS”

INFORMATION SYSTEM

No. of memory nests 02(Consist of mass memory &redundant mass memory.)

Memory capacity (hard disk) 80 MBx4

No. of central operating str. 05

No. of monitoring st. (PS-U) 05

No. of coupling st. (PS-K) 06

No. of CRT & keyboard (on desk) 07 CRT & 4 keyboard

Processor for IS PCP- 04 ( 80286)

*the system is characterised by object oriented man machine interface forease of operation through CRT keyboard.

IS System Configuration

Monitoring Functions

1. Analog inputs 1050 + 64 remote inpute

2. Digital inputs 2002 +40 remote inpute + 287 common inputs

Standard Displays

1. Alarm display 01

2. Curve display 20

3. Bar display 34

4. Op. area display 10

5. Graphic display 87

6. Function group Op. display 29

Performance Calculation Comuter

(i) Model Alpha server.800

(ii) Make Comp 091/Digital USA

(iii) Operationg system OVMS

SEQUENCE OF EVENT RECORDER

(i) Make : M/s Hathaway, USA

(ii) Model : Hathaway 7.000 SER

(iii) No. of ative points : 320

(iv) No. of wired points : 305

(v) Input per card : 64

(vi) Resolution : 1 mS

(vii) Alarm debouce time : 1 mS to 65 sec, Adjustable on perpoint basis

(viii) Buffer capacity : 2000 events

(ix) Contsct Interrogation veltage : 48 v ungrounded

(x) Acceptaility of NO/NC contact : Yes

(xi) Alarm printer : Mannesman Tally’s MT-290

(xii) Archiving facility : Wyse make PC provided (20 MBmemory)

(xii) SER terminal : Monochrome CRT, Adds model 10

Interface with FSSS/ ATRS Through Relay Panel ( Only BinaryCommunication)

FSSS/SBC/SADC

Model Procontrol P13/42

Make BBC (Brown Boveri) Sweden

Supplier BHEL (EDN( Bangalore

Software Language Procontrol P10

No. of stations 11

141 142

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No, of processors 20Type of processor 70PR 03 ( Dedicated type)

Pragram memory 4096 bytes(EPROMS)

System Configufration

1. No. of Intra-plant bus 2 (max.16)2.No.of stations. / IBP 10(max.64)&09 (max.64)3. No.of stations.entire system 11 (max.1024)4.Modules per local bus Max.64

Data Communication

i. Useful addresses Max 256ii. Time cycle (set) 20msiii. Information bit rate 204.8 KBAUDiv. Type of modulation Pulse modulationv. Amplitude +10v low activevi. Data security Parity bit, clock monitoring,

data valancy on local bus, addresscycle, watchdog timer

Intra-Panel Bus (IPB)

i. No. of assresses 256xNo of stations,1684Maxii. Time reqd./one telegram 60Micro secondsiii. Information bit rate 233.7 KBAUDiv. Signal code DPDMv. Amplitude _+ 15Vvi. Data security Parity bit, counting of binary

characters, monitoring of timeand amplitude per bit

vii. Transmission means Coaxial cable

Inputs. Outputs

Analog I/P & O/P 0/4-20mA, 100 ohm I/Presistance - 10 to+ 10vBinary I/P For O signal :- 30 to +3v

for 1 signal:11.2 to 30 v

Binary O/P for 0 signal:0 to 1 v

for 1 signal:11.7 to 30 v

All Modules are protected against short circuit and over load

Contac InputsVoltage between terminals with

open contact 48V DC

Contact current for closed

contact 5 mA

*Procontrol system is powered by +26v redundant charger with batterybackup at 175A (full Load).

Interfae With ATRS/ DDCMIS: Through relay cabinet mounted insideFSSS cabinet (only binary comm,)

ELECTRONIC AUTOMATION SYSTEM FOR TURBINE (EAST)

Manufacturer BHEL (EDN), Bangalore

East package comprises of ISKAMATIC A &B

ISKAMATIC A ISKAMATIC B

1. Turbine stress evaluator 1. Logic subgroup control

2. Electro hyd. governing control 2. Limitvalue monitoring(linear, nonlinearvariables)

3. LP-Bypass, seal/leak steam 3. Drive control modules

Control (Valves/pumps/solenoids)

4. Vibration & position monitoring 4. Relay cabinets

5. Analog signal conditioning

6. Turbine protections

7. Auto synchroniser

8. load shedding relay

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COMMON FEATURES

1. Separate ref. voltages for analog (HQ)/binary (M) signal conditioning

2. Only one connection exists between M& H, at the cabinet power supplybus.

3. Decoupling of signal conditioning paths.

4. Selective fusing and use of IC’s

- Wast package is powered by +26/-26 V redun dant battery charger(Chabbi make) with load current 231/100A with 1% ripple.

- FSSS, DDCMIS & East are powered by their own dedicated powersources.

- Signal communication in between FSSS/DDCMIS/ Eastis done throughcoupling relay cabinets CRA 01 02 with complete isolation.

UNINTERRUPTED POWER SUPPLY

(i) Make Fuji,Japan

(ii) Model CVCF 5000

(iii) No. and capacity 2 no.,sharing equal load

(iv) Capacity 75 KVA

(v) Voltage rating 420 VAC _+ 2 % OUTPUT

(vi) Frequency 50 HZ _+ 5%

(vii) Battery

Rating 240 VDC common for bothUPS

Make Exide

Capacity 750AH

No of Batteries 110

Each cell viltage 2v

(viii) Bypass mode

Type : Automatic voltage regulatior

AVR power factor : 1 to 0.8 lag

AVR Input : 415 v _+ 10% single phase two wire

Eff. at rated I/P &O/P : More than 85 %

AVR output : 240 v +2%

Cooling system : Forced air cooling

5.2. INTELOCK AND PROTECTION5.2.1 BOILER AND AUX.

FURNACE SUPERVISORY SAFEGAURD SYSTEM

1. Purge Permissivea. LOTV closed.b. HOTV closed.c. All LONV closed.d. All HONV closed.e. Drum level not. high. (Drum level less than+125 mm)f. Drum level not low. (Drum level less than-125mm)g. No boiler trip condition .h. All scanners show no flame.i. Air flow less than 40%.j. Aux. air damper modulating.k. Wind box to furnace DP not. v. high (wind box to furnace DP

less than 225mm wc)l. All PA fan off.m. All Hot air gates closed.n. All pulverisers off.o. All feeders off.

2. Purge Sequencea. Purge ready (All 16 Purge permissives are satisfied)b. Purging (2 minute cycle).c. Second stage purging. (3 minute cycle )d. purge complete.

3. First Cause of Trip* Master Fuel Trip Alarm Tripa. Both ID fan off - -b. Both FD fan off - -c. Both RAPH off - -d. Furnace pressure very high +100 + 325 mmwc

(2/3logic)e. Furnace Pressure very low -100 - 225mmwc

(2/3logic)f. Drum level very high +125 + 225mm

(for more than 10 sec)g. Drum level very low -125 - 225mm

(for more than 10 sec)h. Emergency trip.i. Loss of 220 V.D.C for more than 2 sec

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j. Air flow less than 30%.

*k. Reheat protection trip.

**l. Flame failuer trip

***m. Loss of all fuel trip.

****n. Less than fireball and loss of A.C.

power at any elevation in service.

o. All BFPS Trip.

p. Loss of unit critical power+24VDC.

q. Spare trip not connected.

*Reheat Protection Trip1. Generator breaker open or

Turbine tripped or

Boiler working and turbine not working

Any HP or LP bypass valve is close

then reheat protection os armed with time delay of 5 sec. or

2. HP bypass 1 or 2 or LP bypass 1 or 2 less than 2% open and turbineworking and

Load sheddig relay opeated with 11 sec off delay than reheat protectionis armed with time delay of 10 sec.

Turbine trip is armed if first stage pressure more than 35 bar and thenany ESV or IV closes or turbine trip

Turbine working is armed if All ESV & IV open and first stage pressureis greater than 35 bar.

Boiler working is armed if

a. Main steam pressure left more than 50 bar and main steamtemperature left more than 3500c, and

b. Main steam pressure right more than 50 bar and main steamtemperature right more than 3500c, and

c. Boiler fire on, provided

HP bypass v/v 1 & 2, and LP bypass Valve 1 & 2 opened morethan 2%. once

**Flame Failure Trip

Elevation AA, AB, BC, CD, DE, EF & FF voted and

Flame failure trip armed(i.e.any feeder proven for more than 2sec)

Elevation AA voted :

Elevation A feeder off or

Loss of elevation power for more than 2 sec. or

Elevation AA 3/4 scanner show no flame Elevation AB voted :a. Elevation AB 2/4 nozzle valve not proven and elevation AB 3/4

scanner show no flame, orb. Elevation A and B feeder off or loss of power at elevation A & B for

moer than 22 sec orc. Elevation AB 2/4 nozzle valve not proven.

Elevation BC Voted :a. Feeder B off or loss of power, and feeder Coffor loss of elevation c

power; or for more than 2 sec.b. Elevation BC 3/4 scanner show no flame.

Elevation CD Voted :a. Elevation CD 3/4 scanner show no flame and elevatio CD2/4 nozzle

volve not proven, orb. Elevation CD all HONV open any elevation CD started and loss of

AC power and elevation CD 2/4 nozzle valve not proven orc. Feeder C off or loss of power for more than 2 sec and feeder D off

or loss of power for more than 2 sec.

Elevation DE voted :Some, as CD. Instead of CD use DE.

Elevation EF voted :Same, as CD. Instead of CD, use EF.

Elevation FF voted :a. Feeder F off or loss of elevation power for more than 2 sec orb. Elevation FF 3/4 scanner show no flame.***Loss of all fuel tripa. Loss of fuel trip arming (i.e. elevation AB or CD or DE or EF any

nozzle valve open and no MFR trip)and

b. A,B,C,D,E &F all feeder off or all elevation power failed, andc. HOTV not open, or elevation AB, CD, DE and EF elevtion back up

trip andd. LOTV not open, or elenation AB all LONV closed****Less than fireball and loss of AC power at any elevation in service

for more than 2 sec and all feeder off or loss of all feeder elevationDC power.

PULVERISERTypical for all pulveriser

PULVERISER PERMISSIVE

1. Pulveriser Readya. Feeder jin remoteb. Pulveriser start permit

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i. Burner tilt horizintal and air flow less than 40% or any feeder proven, and

ii. No MFR trip.

c. Pulveriser discharge valve open and all manual corner gates open.

d. Pulveriser outlet temperature less than 95°c.

e. Bunker outlet gate open.

f. Cold air gate open .

g. Lube oil start permit

Any LOP on and lub oil pressure more than 3,0 kg/cm2 and lub oiltemp. in berween 20-500c and DP across filter O.K and no lub oiltrip.

h. Elevation A.C. available.

i. Tramp iron hopper valve open.

j. Primary air permit, or any pulvesier ON.

Primary air permit :

3 or more pulvarisers not on and any PA fan on, and primary airpressure not low.(more than 635mmwc)

k. Auto pulveriser unsuccessful start.

l. No pulveriser trip.

2. Ignition Permit

Pulveriser A :

a. Elevation AB in Service or

b. Boiler load more than 30% and feeder B proven more than/equal to50%.

Pulveriser D :

a. Elevation CD in service or

b. Elevation DE in service or

c. Boiler load more than 30% and feeder C or E proven more than/equal to 50%

Pulveriser E :

a. Elevation DE in service or

b. Elevation EF in service or

c. Boiler load more than 30% and feeder D or F proven more than/equal to 50% or

d. Elevation CD in service and feeder D proven more than/equal to50%.

Pulveriser F :

a. Elevation EF in service or

b. Boiler load nore than 30% and feeder E proven more than/equal to50%, or

c. Elevation DE in service and feeder E proven more than/equal to50%.

PULVERISER TRIP

a. MFR trip

b. Loss of unit critical power 24V DC.

c. Mill sump oil level V. low for 10 sec.

d. Loss of one PA fan, second PA fan in service, trip command toeleveation D, E, F

e. Loss of primary air (Both PA fan off and any pulveriser ON)

f. Primary air pressure very low (to all pulverisers in service ot 500mmwc in sequence of F,E,D,C,B,A with time delay of 0, 15, 30, 45,

60,75,sec.)

g. Pulveriser Lub oil trip.

h. Seal air header to pulveriser DP low (less than 5” of WC) andpulveriser on for more than 60 sec

i. pulveriser ignition permit lost.

j. Overload trip CDGM-12PSM 81%TMS 0.2(119.28% of full load current)

(overcurrent alarm CTU-12, 75% 6 sec)

K. Short circuit current trip LAG-37, 1000%

l. Sensitive earth fault CTIGM 15, 100 mA

INTERLOCK

a. Seal air damper interlock

Seal air damper opens with pulveriser start. Pulveriser off, seal airdamper closes.

b. Pulveriser on, permissive to open the hot air gate.

c. Pulveriser on, permissive to start coal feeder.

160159

HOT AIR GATE

OPEN PERMISSIVE

a. Pulveriser on.

b. Hot air gate not close.

CLOSE PROTECTIONa. Pulveiser outlet temperature more than 950c for more than 30 sec.

b. Loss of elevation DC.

c. Pulveriser off

d. Auto pulveriser unsuccessful start.

e. Feeder off , HAG closes after 30 sec.

COAL FEEDER

START PERMISSIVE

1. Feeder switch in remote condition.

2. No MFR trip

3. Elev DC power available

4. Pulveriser On.

5. Motor current not low on coal belt.

6. Pulveriser ignition permit

7. Pulveriser ready and ourlet temperature less than 930c and feeder speeddemand at minimum and if in auto mode HAG open for than 5 sec.

8. No stop command for feeder for more than 3 sec or no auto stop forfeeder.

FEEDER PROTECTION

(i.) Corresponding pulveriser trip.

(ii) No coal on belt.

(iii) Discharge plugged.

(iv) Feeder overload.

(v) Feeder switch not in remote condition.

(vi) MFR trip.

(vii) Elevation D.C. power failue

(viii) Within 30 secs of tha starting of feeder no coal on belt or feeder motorcurrent low.

(ix) Within 180 secs of the starting of feeder ignition permit is lost.

OIL GUNHEAVY OIL TRIP VALVE

OPEN PERMISSIVE

OPEN PERMISSIVE VALUE

1. No MFR trip2. Heavy oil supply pressure adequate 8.0kg/m2 3.

All HONV closed4. Heavy oil temperature adequate 95°c5. Atomising steam pressure not low 2.5kg/m2

6. Heavy oil trip valve not open7. No stop command for HOTV

orHORV open and all HONV closed

CLOSE PROTECTION

1. Loss of unit 24 v DC2. Master fuel trip (MFR Trip)3. Heavy oil header pressure low (2.2kg/cm2)or heavy oil header

temperaturelow (95Oc)or atomising steam pressure very low (2.5kg/cm2)for morethan 2 sec and HORV not open open.

HEAVY OIL EVEVATION START PERMIT

1. Pulveriser start permit (No MFR trip amd nozzle tilt horizontal amd airflow less than 40% or any feeder proven).

2. Heavy oil trip valve open3. No master fuel trip

LIGHT OIL TRIP VALVE

LIGHT OIL TRIP VALVE OPEN PERMISSIVE

1. No MFR trip.2. Light oil supply pressure adequate 8.0kg/cm2

162161

3. All light oil nozzle valve closed4. Atomising air pressire not low 2.5kg/cm2

5. LOTV not open and no stop command

CLOSE PROTECTION

1. Loss of unit 24 v DC power2. MFR trip3. Any LONV open and

L.O.pressure very low (2.0kg/cm2) for more than 2 sec and LONV openor atomising air pressure very low (2.5 kg/cm2) for more than 2 sec andat any elevation no start/stop command

LIGHT OIL ELEVATION

1. Pulversier start permit2. LOTV opend3. No MFR trip

OIL GUN START SEQUENCE(Typical for AB 1&3 pair)

1. Start command given to pair 1&32. AB 1 steam/air atomising valve open3. HEA advance if atomising valve ipen feed back available4 HEA spark cimmand if HEA fully advance feed back available and HINV

1 open5. Spark for 15 sec.6. Flame scanner show flame, Gun hold7. After 5 sec of AB1 command, command to AB 3 start.

REGENERATIVE AIR PRE HEATER

PERMISSIVE

1. Any guide bearing LOP healthy or lub oil temp. less than 35°c2. Any support bearing LOP healthy or Lub oil temp less than 35°c

3. For air motor, air pressure before solenoid valve more than 2.5 kg/cm2.

INTERLOCK

1. Electric motor B trip, elect motor A start vice versa.

2. Electric motor B fail to start when start command is given electricmotor A starts with time delay of1 sec, vice versa with electric motor B.

3. lf running electric motor trip & stand by electric motor remain off formore than 2 sec and air pressure before solenoid valve more than2.5kg/cm2, air motor starts.

4. Damper interlock

RAPH start, flue gas inlet and outlet, secondart air inlet and outlet,damper open.

5. Guide bearing LOP and suport bearing LOP interlock

a. LOP A trip, LOP B starts and vice versa.

b. LOP B foil to start, LOP A starts & vic versa.

c. LOP B on and Lub oul flow low, LOP A with time delay of 10 sec. andvice - versa.

d. If any PA fan motor is on and RAPH starts, Primary air inlet & outletdamper open.

e. RAPH remains off for more than 2 min. & other RAPH is ON flue gasinlet & outlet, sec. air inlet & outlet, and premary air inlet & outletdampers close.

PROTECTION

1. RAPH giode bearing temperature more than70oc.

2. RAPH support bearing lub oil temperature more than700c.

SCANNER AIR FAN

PERMISSIVE

INTERLOCK1. A.C. scanner air fan trip, D.C. scanner air fan starts.

2. Loss of unit critical power, D.C. scanner air fan starts.

3. A.C. scanner air fan in service and scanner air dut to furnace DP is

164163

less than 6 “ of water column, DC scanner fan starts.4. Both FD fan off, emergency air damper opens.5. Scanner fan start, dischuge damper open with time delay of 5 sec.

SEAL AIR FAN

PERMISSIVE

1. Either PA fan in service

INTERLOCK

1. Either PA fan on for more than 2 sec, seal air seal air fan starts.2. Seal air header to cold air duct DP is less than 6 “ wc for more than 10

sec., seal air fan A atart. Same with seal air fan B.3. Seal air fan B fails to start in less than 2 sec. when start command is

given, seal air fan A start, vice versa for seal air fan B.4. Seat air fan start, dischrge damper open with time delay of 5 sec.

PROTECTION

1. Both PA fan not on for more than 15 sec.

ID FAN

PERMISSIVE CRITERIA NO.

1. ID fan and motor bearing temperature less than 80°c 502. Hyd. cplg. bearing temperature less than 100°c 513. RAPH A/B on 524. ID fan LOP A/B on 535. Hyd. cplg. pump AOP A/B on 546. Lub oil cooler outlet temp less than 40°c 557. Hyd. cplg. oil cooler outlet temp. less than 70°c 568. Stack path available 579. Lub oil tank level adequate 58

10. Hyd. cplg. oil tank level adequate 5911. Luh oil pressure more than 1.5kg/cm2 6012. Hyd. cplg. oil pressure more than 1.0kg/cm2 6113. ID fan inlet gate closed 6214. ID fan outlet gate slosed 6315. Vane control minimum 6416. scoop tube control minimum 65

INTERLOCK

1. Gate interlocka. Fan start, inlet &outlet gate open.b. Fam stop/trip, inlet & outlet gate closes provided other ID fan is

on.

2. LOP interlocka. LOP B trip, LOP A starts & vice versab. LOP B on and lub oilpressure less than 0.9 kg/cm2, LOP A starts

and vice versa.c. LOP B fails to start, LOP A start & vice versad. ID fan made off, LOP A trip after 30 min. Same with LOP B.

3. AOP Interlocka. ID fan trip, AOP A startsb. AOP B trip, AOP A starts and vice versac. ID fan motor on, aOP B on and hyd. cplg. oil pressire less than 1.0

kg./cm2, AOP-A starts. vice versa for AOP B.d. AOP B fail to start when command is given, AOP A start and vice

versa.e. ID fan on,oil pressure more than 2.0 kg/cm2, AOP A stops with

time delay of 30 sec.

Same with AOP-Bf. ID fan motor made off, running AOP srop after time delay of 30

minutes.

PROTECTION1. ID fan or motor bearing temperature more than 90Oc.2. Hyd. cplg. bearing temperature more than 110Oc.3. ID fan lub oil pressure less than 0.7 ksc or Hyd.cplg. oil pressure less

than 0.6 ksc.4. Fan bearing vibration, more than 9.0 mm/sec

166165

5. Inlet or outlet gate closed with time delay of 4 minute.6. Hyd. cplg. return oil temperature more than 120°c7. Post purge trip acted.8. Corresponding FD fan tripping provided other ID fan on.9. Under voltage tripping 70% of rated voltage.10. Overload tripping CDGM - 12.96% TMS 0.2 ( 121.6% of full load

current)Overload alarm CTU 12.80% 8 sec.

11. Over current instantaneous high set CAG 37 1000%12. Sensitive earth fault tripping CTIGM 15 100 mA

*Post purge trip : LOTV and HOTVclosed and all feeder off andall pulveriser off and air flow more than 30%and all scanner shows no flame satisfied formore than 300 sec and furnace pressure veryhigh or very low post Purge trip armed.

F.D. FAN

PREMISSIVE CRITERIA NO.

1. Lub oil pressure more than 0.9 kg/cm2 502. Control oil pressure more than 9.0 kg/cm2 513. Lub oil tank level adequate 524. Bearing temperature fan and motor less than 90°c 535. ID fan A/B motor on. 546. Oil cooler outlet oil temperature less than 45°c 557. Blade pitch minimum 568. Discharge damper closed 579. Lub oil pump A/B on 58

INTERLOCK

1. Discharge damper interlockFan start, discharge damper opens.Fan motor off, discharge close. Provided other FD fan is on

2. LOP interlocka. LOP B trip, LOP A starts and vice versa.b. LOP B on and lub oil pressure less than .9 kg/cm2

LOP A starts and vice versa.c. LOP B on and control oil pressure less than 8.0 kg/cm2

LOP B starts and vice versa.

d. LOP B fail to start when start command is given,LOP A starts andvice versa.

e. FD fan off, LOP A off with time delay of 30 min. same with LOP B.

PROTECTION

1. Lub oil pressure less than 0.5 kg/cm2.

2. Bearing temperature fan or motor more than 110°c

3. Bearing vibration more than 9.0 mm/ sec

4. Discharge damper closed with time delay of 60 sec

5. Both ID fan off

6. Both FD and ID fan on and corresponding ID fan trip.

7. Post purge trip acted

8. Under voltage tripping, 70% of rated voltage

9. Overload tripping CDGM-12, 79%, TMS 0.3

(109.72% of full load current)

(overload alarm CTU 75% 9 sec.)

10. Overcirrent instantaneous high set trip CAG 37, 1000%

11. Sensitive earth fault trip CTI GM 15, 100 mA.

P.A. FAN

PERMISSIVE CRITERIA

1. Fan and mptor bearing temperature less than 80°c 50

2. Hyd. cplg. bearing temperature less than 100°c 51

3. PA fan lub oil cooler outlet temperature less

than 45°c and hyd. cplg. cooler outlet

temperatute less than 70°c 52

4. Lub oil pressure more than 1.2 kg. cm2 and hyd.

cplg. oil pressure more than 1.0 kg/cm2 53

5. Lub/Hyd. cplg. oil tank level adequate 54

6. Either FD fan on 55

7. Start permit from FSSS available ( All CAG less than

5% open and No MFR trip or either PA fan on ) 56

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8. PA fan inlet and outet gate closed 579. Regulating vane and scoop tube minimum 5810. Any lub oil pump on 5911. Any hyd. cplg. oil pump (AOP) on 6012. Oil flow at cooler outlet more than 75% 61

INTERLOCK

1. Damper interlockFan starts inlet and outlet damper opensFan trip/stop. inlet and outlet damper closes.

2. LOP interlock

a. LOP B trip, LOP A starts and vice versa.b. LOP B on and lub oil pressure less than 0.9 kg/cm2

LOP A starts. vice versa for LOP Bc. LOP B fails to start when start command is given, LOP A starts with time delay of 2 sec, and vice versad. PA fan motor off, running LOP auto stop with time delay of 30 minute.

3. AOP interlock

a. AOP B trip, AOP A starts and vice versa.b. AOP B on and oil pressure less than 0.8 kg/cm2

AOP A starts. vice versa for AOP B.c. AOP B fail to start when start commnd is given, AOP A starts, and vice versad. PA fan motor on and oil pressure more than 2.0 kg/cm2 running

AOP stops, with time delay of 3 sec.e. PA fan motor off, AOP A/B take start. running AOP stop after time

delay of 30 minute.

PROTECTION

1. Fan or motor bearing temperature more than 90°c2. Hyd. cplg. bearing temperature more than 110°c.3. Hyd. cplg. return oil temperature more than 120°c.4. Fan bearing vibration more than 9.0 mm/sec5. Lub oil pressure less than 4.0 bar.6. Hyd. cplg. oil pressure less than 0.6 bar7. PA fan inlet or outlet gate closed, with delay of 2.5 minute.8. Both FD fan off9. MFR trip.

10. Under voltage tripping 70% of rated voltage.11. Overload tripping CDGM12 87%, TMS 0.6 (114.97%of full load current)

Overload alarm CTU 12 80%, 6 sec.12. Over current instantaneous high set trip CAG 37 1000%13. Sensitive earth fault trip CTIGM 15 100 mA.

GR FAN

PERMISSIVE CRITERIA NO.

1. Fan and motor bearing temperature less than 80°c 502. Atleast one ID fan on 513. Atleast one FD fan on 524. Lub oil pump A/B on 535. GR fan inlet and ourlet gate closed 546. Oil cooler ourlet oil temprature less than 40°c 557. Oil tank level adequate 568. Fan cool air damper closed 579. Fan furnance damper closed 5810. All feeders off 5911. Boiler load index more than 30% 6012. Lub oil pressure more than 1.5 kg/cm2 61

INTERLOCK

1. Damper interlock

Fan starts, inlet, outlet and furnance damper opens.Fan motor off, inlet, outlet, outlet and furnace damper closes.

2. a. LOP B trip, LOP A starts and vice versa.b. LOP B on and lub oil pressure less than 0.7 kg/cm2, LOP A starts

with time delay od 5sec and vice versa.c. LOP B fail to start when command is given, LOP A starts with time

delay of 2 sec and vice versa.d. GR fan motor off and turning gear motor off, running LOP stops

with time delay of 60 min.

3. Turning gear interlocka. GR fan motor trip and lub oil pressure more than 1.5 kg/cm2,

turning gear motor auto start

170169

b. GR fan motor off and fan discharge temprature is less than 93°c,turning gear motor stop.

PROTECTION

1. Fan/ motor bearing temperature more than 90°c2. Fan bearing vibration more than 9.0 mm/ sec3. Lub oil pressure less than 0.4 kg/ cm2

4. GR fan on and motor current low.5. Both FD fan off6. GR fan discharge flue gas temperature more than 440°c7. MFT trip8. Any feeder on9. GR fan motor on and any domper (inlet, outlet, furnace side) closed

with time delay of 2.5 minutes.10. Under voltage tripping, 70% of rated voltage.11. Overlood tripping. CDGM-1279%TMS 1.0, timer 60 sec (105% of full

load current) Overlood alaram CTU 12 50% 8 sec, timer 80 sec)12. Over current instantaneous high set trip CAG 37 1000%.13. Sensitive esrth fault trip .CTI GM 15 100 mA

5.2.2 TURBINE AND AUXILIARIES TURBINE PROTECTION

S.No. Description Alarm Value Trip Value Remarks

1. Drum level very high +125 +2252. MFT vhannel 1/2 - -3. Generator protection channel 1/2 - -4. Lub oil pressure very low - 1.88 kg/cm2 2 / 3 logic5. Condenser vacuum very low -8.0 - 0.7 kg/ cm2

6. Low vacuum mechical trip -0.8 - 532 mm / kg7. Fire protection channel1/2 -50 -100mm zero level 800mm

down from top ofMOT8. MOT level low - 50 -100mm9. Main steam temperature 500°c 480°c

very low10 Axial shift - -Mech. trip (only

annunciation from C&I)11. Local trip 1/2 - -12. Emergency push button

from unit control board - -

13. Overspeed trip - 3330 rpm Mech. trip.

Fire Protection - 1 operated -

Turbine trip gear operated

and vacuum breaker open

Fire Protection - 2 operated-

Turbine trip gear operated,

Vacuum breaker opens,

AOP-1, AOP-2, JOP- 1, JOP - 2 off,

DC EOP, DC JOP on with SLC on,

Gate valve gearing closed.

** MOT level low

same as fire protection -2

14. Fire off

TURBINE OIL PUMP

(1) Aux, oil pump-1 start on auto SLC AOP - 1 is on and

AOP-2 trip or lub oilpressure less than 5.48 kg/cm2

(ii) Aux. oil pump-2 start on auto SLC AOP-2 is on, and

AOP-1trip or lub oil pressure isless than 5.47 kg/cm2

(iii) Emergency oi pump start on auto Lub oil pressure lessthan 1.78 kg/ cm2

(iv) Jacking oil pump-1 start on auto SLC of JOP on and turbine speedless than 510 rpm

Jacking oil pump-1 stop on auto Turbine speed more than 540 rpm

(v) Jacking oil pump-2 start on auto SLC JOP on and JOP-1 trip orjackung oil

pressure less than 100kg/cm2 andturbine

speed is less than 510 rpm or onbarring with

a time delay of 5 sec commandfor command for-

Switch off JOP -1

Switch on JOP -2

Switch off SLC

172171

(vi) Emergency Jacking oil pump SLC on and JOP 1 & 2 fails tosrart on auto develop pressure nore than 100

kg/cm2

ORAny JOP running 7 Pr. less than20 kg/cm2

TURNING GEAR

(i) Permissive- Gen/seal oil DP> 0.9 .& seal oil pr.turbine & exciter end > 3.8 ksc

(ii) Turning gear valve open on auto CLC of turning gear on andturbine speed is less than 200rpm.

Turning gear valve close on auto Turbine speed more than 250 rpmFire protection ch. I & ch II SLC offProtection close Lub oil bef. Rad/ Ax. brg. < 1.88

ksc

BOILER FEED PUMP

PERMISSIVE CRITERIA NO.

(i) AOP on 50(ii) Hydraulic coupling oil pressure more than 1.0 kg/cm2 51(iii) Discharge valve closed or discharge header pressure

more than 25 kg/ cm2 for stand by pump 52(iv) Minimum flow recirculation valve open 53(v) Motor cooling water valve closed 54(vi) Scoop tube control less than 300% 55(vii) Suction valve open 56(viii) Bearing temperature less than 85oc 57(ix) Hybraulic coipling bearing temperature less than 85oc

(for bearing 3&4 temperature less than 800c) 58(x) Cooling water pressure nore than 3.0 kg/cm2 59(xi) Deaerator level normal, 2410 mm

(610 mm above c.l. of storage tank) 60(xii) BFP stand by not selected 61

INTERLOCK

(i) BFP motor on, motor cooling water valve opens(ii) BFP motor on, discharge valve opens

(iii) AOP cut in at oil pressure 0.8 kg/cm2

AOP cut out at oil pressure 2.9 kg/cm2

BFP motor off, AOP stop after 30 minute(iv) BFP suction and discharge differential temperature more than 10°c

recirculation valve opens

PROTECTION

(i) Lub oil pressure less than 0.5 kg/ cm2

(ii) Deaerator level less than 700 mm(iii) Working oil temperature at cooler inlet more than 130°c.(iv) suction valve open and BFP booster pump suction pressure less

than 1.7 kg/cm2

(v) Bearing temperature more than 95°c(vi) Hydraulic coupling hearing temperature more than 95°c

(for bearing 3 & 4 temperature more than 90°c )(vii) Recirculation flow control command is maximum &

recirculation control valve less than 10% open.(viii) Earth fault protection CTI GM 15, 125 mA(ix) Motor differntial protection CAG 34 10%, 130(x) Overload protection CDGM 12, 79%, TMS 0.2

(110.79% of full load current)Overload alarm CTU 12, 75%, 8 sec.

CONDENSATE EXTRACTION PUMP

PERMISSIVE

(i) Suction valve open(ii) Hot well level more than 500 mm

(i.e. more than - 100 mm from normal working level)(iii) Recirculation valve opens

INTERLOCK

(i) Discharge pressure more than 15.5 kg/cm2, discharge valveopenCEP motor off, discharge valve closes.

(ii) CEP motor on and discharge valve open, discharge line ventsolenoid valve closes.

(iii) Header pr. very low ( 17.5 ksc) - stand by p/p startsHeader pr. low (18.0 ksc) - hdr. Pr. low alarm

CEP motor off, discharge line vent solenoid valve opens

174173

PROTECTION

(i) Hotwell level very low (80mm water level)(-520 mm below NWL)

(ii) Earth fault protection CTIGM 15, 100 mA(iii) Overload protection CDGM 12 96%, TMS 0.2 (115.0% of full load current)

Alaram CTU 12% 90%, 5 sec(iv) Instantaneous overcurrent 1000%

VACUUM PUMPPERMISSIVE

(i) Seal water recirculation pump on(ii) Seal water flow more than 14 m3/hr

INERLOCK

(i) Vacuum pump system ON-(Release for opening the SIV manually)Motor off or differential pressure across system inlet valve morethan 0.05 kg/ cm2, system valve closes.

(ii) Vacuum p/p auto start logic.a. Auto arming scheme seleted on desk, vacuum more than 650 mm kg Autocommandb. Vacuum less than 630mm kg.

EQUIPMENT COOLING WATER PUMPPERMISSIVE CRITERIA NO.

(i) Suction header pressure adequate ( 1.5 kg/ cm2 ) - 14(ii) Suction valve open - 15(iii) discharge valve closes - 16(iv) Recirculation valve open - 17

INERLOCK

(i) ECW pump on and discharge header pressure more than 10 kg/cm2 for morethan 5 sec, recircilation valve open.ECW pump on and dischrge vaslve open and discharge header pressureless than 10 kg/cm2 for more than 90 sec then recirculation valve close.

(ii) Running ECW pump trip and discharge pressure less than 5.0kg/ cm2, standby pump starts if selected.

(iii) Discharge pressure less than 5 kg./ cm2 or corresponding pump trip, dischargeValve closes.

PROTECTION(i) Suction pressure less than 1.0 kg/cm2

(ii) Discharge pressure more than 10 kg/cm2 and recurculation valvenot open.time delay 60 sec.

(iii) Suction valve not open.(iv) Motor over load CDGM12, 87%, TMS 0.2 (111%full load current)

Alram CTU 12, 80% 5 sec(v) Instantaneus over current 1000%(vi) Earth fault protection CAG 14 10%, 200 ΩΩΩΩΩ

HP / LP BYPASS SYSTEMHP BY PASS SYSTEM

(i) HP bypass oil pump cut in at pressure 100/100 kg/cm2

oil pump cut out at header pressure 160/170 kg/cm2

(ii) HPBP valves can be open if condenser vacuum > 0.6 kg/ cm2

HPBP valves closes at condenser vacuum 0.6 kg/cm2

(iii) HPBP down stream temperature exceed 340°c, HPBP valves closes(iv) HPBP valve position less than 2%, BPE valve closes.

LP BYPASS SYSTEMPERMISSIVE

(i) Condenser vacuum more than 0.6 kg/cm2.(ii) Condenser header pressure more than 8.5kg /cm2

(iii) Condenser wall temperature at exhaust hood less than 90°c(iv) Steam pressure at down stream of LP bypass valve less than 21.2

kg/cm2

PROTECTION

(i) Condenser vacuum less than 0.6 kg/cm2

(ii) Condenser header pressure more than 8.5kg /cm2

(iii) Condenser wall temperature at exhaust hood more than 90°c LPinjection valve opens at 90°c.

(iv) LP bypass downstream steam pressure more than 21.2 kg/cm2

176175

MAIN OIL CENTRIFUGE

INTERLOCK

(i) Booster pump motor can be started if main centrifuge motor on.(ii) Centrifuge motor trip, solenoid valve in oil suvtion line di-energise.

Solenoid valve poens when centrifuge motor on.(iii) Centrifuge motor overload or booster pump motor overload, both

motors trip and heater II and III cut off. Heater - I remain on.(iv) Broken liquid seal, centrifuge, booster pump, heater II and III trip.

Heater I remain on.(v) Polishing filter choke, centrifuge, booster pump, heater II & IIII trip.

Heater I remain on.(vi) Centrifuge motor on, heater II and III can be made on.

Oil temperature more than 60°c, heater III cut off.Oil temperature more than 70°c, all heater cut offWater temperature more than 90°c, all haeter cut off.Water level low, all heater cut off.

REGENERATIVE HEATER SYSTEMLOW RESSURE HEATER - 1

INTERLOCK(i) Very high drip level Cascade drain control valve DR 24

closes and heater is by passed fromcondensate side by opeming CD 3 1and closing CD 29 and CD 30.

LOW PRESSRE HEATER - 2

(i) Very high drip level Extraction block valve (300mm abovenormail EX-9 closes water level)Extraction drain valve EX 104&EX 105opens.Normal cascade drain control valveDR19 closes.Extraction line NRV closes.Alternate drain control valve DR 27opens.

LOW PRESSURE HEATER - 3

(i) Very high drip level Extraction block valve(above normal water level) Extraction drain valve EX-103 opens

Extraction NRV closes Alternate draincontrol valve DR 22 opens

DEAERATOR

(i) Deaerator level rises to Deaerator overflow drain2760mm (350. mm above NWL) valve DR 40 opens, and closes at

Deaerator level 2585 mm(ii) Deaerator level rises to Over flow drain valve DR40 opens

2835mm (425 mm above NWL) (Repeat command)Deaerator pegging steam valve AS2and CRH-2 closes.

(iii) Deaerator pressure controla. Cold start up 1.5 ata by AS-2b. Hot and warm start up and

bypass operation 3.5 ata by AS-2c. CRH line pressure reaches 8 ata 3.5 ata by CRH-2d. Turbine load more than 55% More than 3.5ata to 6.6

when extraction steam pressure pegging pressure EX -11.

HIGH PREASSURE HEATER - 5

(i) Very high heater level Extraction block valve EX 13 closes.(310 mm above NWL) Extraction NRV closes. Repeat

command to full open alternatedrain control valve DR 16 andnormal drain control valve DR 13.Heater bypass from feed water sideby opening bypass valve FD3 andclosing FD 1 and FD 2. Normal draincontrol valve of HPH-6, DR-2 closes

(iii) Pressure falls below a Over riding command toclose DR-2preset valve

178177

HIG

H P

RE

SS

UR

E H

EA

TER

- 6

(i)V

ery high heater levelE

xtraction steam block valve E

X 14

and NR

V closes.

( 310 mm

adove NW

L)E

xtraction drain valve EX

101o

pen

s.A

lternate d

rain valve D

R-9 an

dnorm

al drain valve DR

-2 opens fully.H

eater bypass from feed w

ater sideby opening bypass valve FD

6 andclosing FD

-4 & FD

-5.R

epeat comm

and to open alternatedrain valve D

R-9 and norm

al drainvalve D

R-2 / D

R-6.

5.2.3 GENERATOR AUXULUARESGENERATOR RELAY PANEL

GENERATOR PROTECTION

S. PRTECTION DESIGNATION CTR/PTR SET OPERATING REMARKNO. VALUE TIME

01. Gen. differential protection

02. Gen. negative phasesequence protection

03. Gen. field failure protection

04. Gen.pole slipping protection

05. Gen. back up impedance protection

876

46G

40G

98G

21G

10000/5A

10000/5A----------------16500/110v

10000/5A--------------16500/110v

10000/5A--------------16500/110v

10000/5A--------------16500/110v

5%

K1=3.3K3=2.25I2S=7.5

k1=0.8k2=2.5k3=0.5k4=2.0k5=18.6k1=0.91k2=0.74k3=41=100%k1=6k2=0.63Reverse25%reach.Ø=750

Inst.

4Sec.

Inst.

50m sec.

1.5 sec

Gen. Wdg. insulation protection

Gen. unbalance current. protection.

Protection against Generator falling out of step

Backup protection against external fault.

180179

06. Gen. stator interturn fault

07. Gen. main stator earth fault protn.

08. Gen. stator standby earth fult protection

09. Gen. rotor earth fault protection ST-II Alarm

10. Gen. stator water conductivity high11. Gen. stator water flow low12. Exc. system troble (Cl.-A)

13. Gen. low forward power protection

14. Gen. over load alarm15. Gen. under frequency alarm16. Gen. over voltage alarm

95G

64GI

64G2

30P30P30S

37A&B

51G81G59G

16.5 NTG --------- Kv .240 24.2AUX PT -------- v .240 16.5 NTG --------- Kv .240 16.5Line side ---------- kv .110 16.5/.110 -------------- Kv √3/√3 .110 AUX --------- v 80

------13m3/hr------

10000/5A--------------16500/110v

10000/5A16500/110v16500/110v

5.4V

0---95%=6.9v

95---100%=0.5v

5.4v

5kΩ2.2kΩ

20µmho25

0.5%

95%48.5HZ

110%

IDMT

1Sec.

2Sec.

IDMT

2 sec.0.5 sec.

Inst.

2 sec.

20 sec.5.5 sec.0.5 sec.

S.No. PROTECTION Design. CTR/PTR Set Operating Remark value Time

Protn. against insulation failure between twowindings

Main Protection against generator winding

Earth fault

Protection for Generator before motoring takesplace.

GENERATOR TRANSFORMER

S. No. Protection

01. Gen. GT overall differentialprotection

02. 220 kv Overhead linekifferential protection

03. GT HV sice ref. protection04. GT stand by earthfault

protection05. GT bay C.B. LBB protection06. GT bay C.B. pole discrepancy

protection07. TBC LBB protection08. TBC pole discrepancy

protection09. GT over fluxing protection

10. GT bucholtz trip11. GT winding temp high trip12. GT oil temp high trip13. GT pry. protection14. GT fire protection

DESIGNATION

87GT

87L64NGTSINGT

50Z*

*50Z*

99GT

63GT

CTR/PTR

400 kv-800/1A

Gen-10000A _______ 5

UAT-10000A _______ 5

1000/1A1000/1A1000/1A

800/1A

--800/1A

--16500/110V

SETVALUE

o pcurrent=15%Bias - 15%

25%25%PMS- 20%TMS- 0.75 %

- -5 %

K1=1.15K2=1.3

OPERATINGTIME

Inst.

Inst.Inst.IDMT

0.2 sec

1 sec0.2 sec1 secInst.

Inst.Inst.

Inst.Inst.Inst.

REMARK

protection against internal faultprotection for wdg. insulationfailureprotection for oil degradation

182181

TECHNICAL SPECIFICATIONS OF 400 KV SHUNT REACTOR

TYPE ON AN

Rated Power MVArR 63

Rated voltage KV 420

Rated current ‘A’ 86.90

Phase 3Frequency “HZ” 50Connection Symbol YNImpedanceΩΩΩΩΩ/phase 2800Temp. Rise oil (OC) 50 (OverAmb of 50OC)

Temp. Rise wdg (OC) 55 (OverAmb of 55OC)

TECHNICAL SPECIFICATIONS OF 220 KV CURRENT TRANS-FORMERS ABB MAKE

Standard 15:2705

Highest System Volt 945

Frequency 50

Insulation Level 460/1050

S.T. Current 31.5/1sec.

Extended (Thermal Current Rating) 2400amp.

Rated Primary Current Amp. 1600

Total Weight of CT. 1195

UN

IT A

UX

. XFM

R

S.

PR

OT

EC

TIO

NN

o.

01.

UA

T d

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02.

UA

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LV

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04.

UA

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sid

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ch f

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05.

UA

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ip06

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DES

IGN

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N

87 U

T

64 N

UT

51 U

T

51 N

UT

63 U

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Pro

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wd

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ault

CT

R/P

TR

HV

-100

0/5A

LV-1

600/

1A

16

00

/1A

10

00

/5A

100/

1A

-

SE

TV

AL

UE

30

%

40

%

15

0%

80

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-

OPE

RATI

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IME

Inst

.

Inst

.

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c.

. 3 se

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Ins

t

Ins

t

184183

TECHNICAL SPECIFICATIONS OF 400 KV ABB MAKE AIRBLAST CIRCUIT BREAKERS

TYPE DLVE 420 nc4RATED VOLTAGE 420KV

IMPULSE 1.2/50 MICRO SEC 1425 KV

SWITCHING IMPULSE 1025 KV PEAK

RATED FREQUENCY 50 HZ

RATED NORMAL CURRENT 200 A

RATED SHORT CIRCUIT CURRENT 40 KA

RATED SHORE CIRCUIT DURATION 40KA- 3SECS

FIRST POLE TO CLEAR FACTOR 1.3

BREAKING CAPACITY ASYMMETRICAL 40 KA

BREAKING CAPACITY ASYMMETRCAL 40 KA

WEIGHT OF COMPLETE BREAKER 3850 KG

OPERATING PRESSURE OF AIR 27-31 KG/CM SQ

RATED TRIP COIL VOLTEGE 220 V DC

RATED CLOSING COIL VOLTAGE 220 V DC

CONFIRM TO IEC - 56

220 KV ELPRO MAKE ISOLATORS

SWITCHGEAR TYPE

Highest system voltage 2000

Type HCB

Voltage 220 KV

BIR 1050 LVp

STC 40/1 KA /Sec

Motor vortage 415 V.AC.

Type of Drive MOM

Frequency 50 Hz

Control voltage --------------220 VDC

Wt of Drive. 100 KG

TECHNICAL STACIFICATIONS OF 400 KV SF-6 BHEL MAKEBREAKER

TYPE 3AT2

RATED VOLTEGE 420 KV

RATED IMPULSE WITHSTAND VOLTAGE IMPULSE 1425KV LIGHTING

RATED POWER FREQUENCY VOLTAGE 520/610 KVP

RATED FREQUENCY 50 HZ

RATED SHORT CIRCUIT CURRENT 2000 A

RATED SHORT CIRCUIT SURATION 1 SEC

FIRST POLE TO CLEAR FACTOR 1.3

BREAKING CAPACITY SYMMETRICAL 40 KA

BREAKING CAPACITY EQUIVALENT 29000 KVA

BREAKING CAPACITY ASYMMETRICAL 51.4 KA

RATED MAKING CURRENT 100 KAP

RATED OPERATING DUTY 0-0.3 SEC - CO- 3 MIN- CO

RATED PRESSIRE OF HYDRAULIC 250-350 bar

OPERATING MECHANISM

RATED PRESSURE OF SF-6 GAS AT 20 DEG C 7.5 bar

WEIGHT OF COMPLETE BREAKER 8720.5 KG

WEIGHT OF SF-6 GAS 57.5 KG

RATED TRIP COIL VOLTAGE 220 V DC

RATED CLOSING COIL VOLTAGE 220 V DC

CONFIRM TO IEC - 56

186185

TECHNICAL SPECIFICATIONS OF 200 KV SF - 6 ABB BKR

CIRCUIT BREAKER CB - TYPE

CIRCUIT BREAKER TYPE ELF SL 4-1

Voltage 245 KV

Normal current 1600/2500 AMP

Lightning impulse with stand voltage 1050

Switching impulse with stand voltage -KV

Short circuit breaking current 40 KA

Short time with stand current & duration 40 LA 1 Sec.

Line charging breaking current 125 AMP

Operatubg seqyebce 0-0 3S - co - 3 mm - co

First - pole - to - clear factor 1.3

Gas pressure SF6/20.c (abs) 7.0 bar

Closing & opening device supply voltage 220 VDC

Auxiliary circuit supply voltage 240 V AC

Air pressure 20.5 bar

Frequency 50 hz

Mass (approx) for 3 poles 400 kg

220 KV CAPACITIVE VOLTAGE TRANSFORMER

C.V.T. C.V.T. TYPETYPE WP 245 NzHighest system voltage 245 KVRated insulation level 245 / 460 / 1050 KVRated frequency 50 Hz

Standard IEC 186 / IS : 3156

H.V (PRI) Cap. : C 1 4840 PF

Int V (SEC) Cap. : C 2 48400 PF

Temperature Category - 5 To 550c

Total Thermal Burden 1000 VA

Class of Insulation ‘A’

Rated voltage 220 / 53 KV

Total creepage min. nominal mm 6125

Wt of oil 150 kg / 6 + 6

Equ cap. (cn) for PLCC 4400 PF + 10% 5%

Nominal intermediate voltage 20 / 53 KV

Suitable for hot line washing YES

220 KV CGL MAKE SF-6 BREAKERS AT 220 KV SWYD

TYPE 200 SFM - 40 A

RATED LIGHTNING IMULSE WITHST AND 1050 KV

VOLTAGE

RATED SHORT CIRCUIT BREAKING 40 KA

CAPACITY

RATED OPERATING PRESSURE 15 GK/ CM SQ

FIRST POLE TO CLEAR FACTOR 1.5

RATED DURATION OF SHORT CIRCUIT 3 SECS

CURRENT

WT OF SF - 6 GAS 24 KGS

RATED VOLTAGE 245 KV

FREQUENCY 50 KZ

RATED NORMAL CURRENT AT 20 DEG C 2500 A

CLOSE COIL VOLTAGE 220 V DC

TRIP COIL VOLTAGE 220 V DC

RATED SF-6 GAS PRESSURE 6 KG/CM SQ

RATED OPERATING SEQUENCE 0-0.3 SEC- CO-3 MIN

TOTAL WEIGHT 3900 KGS

TECHNICAL SPECIFICATIONS OF 220 KV CT (ABB MAKE)

C.T C.T. TYPETYPE 1 MB 245

Highest system voltage 245 KV

Rated insulation level 245 / 460 / 1050 KV

Rated frequency 50 Hz

Standard IEC 185 / IS : 2705

Total creepage minimum 6125 MM

Class of Insulation ‘A’

Rated Pri Normal current 1600A

Rated conti. Ther. current 2400A

S.T. current (1st) 40/ 1 KA rms / Sec

1 dyn 100 KA peak

Wt of oil 270 KG

Total weight 1700 KG

Suitabll YES

188187

STATOR WATER PUMP

PERMISSIVE

(i) Expansion tank level more than 41.0 cm

INTERLOCK

(i) Header pressure less than 2.4 kg/cm2, standby pump start

PROTECTION

(i) Expansion tank level low, less than 41.0 cm

SEAL OIL SYSTEMINTERLOCK

(i) Seal oil header pressure less than 4.0 kg/cm2, D.C seal oil pumpstarts.

(ii) AC/DC seal oil pump trip, if seal oil tank level low.(iii) Vacuum pump starts if AC or DC seal oil pump on. AC and DC seal oil

pump trip. vacuum pump trips.

5.2.4 INTERLOCK AND PROTECTION- OFFSITEAIR CONDITIONING PLANT

A.C. COMPRESSORPERMISSIVE

(i) Any cooling tower fan in service.(ii) Any condenser water pump in service.(iii) Any chilled water pump in service.(iv) Any AHU in service.(v) Condenser water flow adequate(vi) Stand by compressor off.(vii) No fire.

PROTECTION

(i) Both cooling tower fan off.(ii) Both comdenser water pump off

(iv) Low suction pressure, less than 2.0 kg/cm2.(v) High discharge pressure, more than 18 kg/cm2.(vi) Differential pressure between oil and suction pressure less than

0.5kg/cm2

(vii) Fire protection.

CW PUMPPERMISSIVE

(i) Suction sump level more than 208.5 m(ii) Discharge butterfly valve closed(iii) Motor thrust and guide bearing temperature normal(iv) Condenser tower inlet valve open(v) Cooling tower inlet valve open(vi) Cooling water flow more than predetermined quantity for more than 5

minutes ( 20 lit/min )

INTERLOCK

(i) CW motor on, discharge butterfly valve opens after 30 sec(ii) CW motor off, discharge butterfly valve closes.

PROTECTION

(i) Motor bearing temperature more than 95oc(ii) Vibraton high, more than 9 mm /sec(iii) Suction pump water level less than 208.5 m.(iv) Cooling water flow to motor bearing low.(v) Discharge valve fails to open within 90 sec of pump starting(vi) Discharge valve close(vii) Discharge pressure more than 2.8 kg/cm2

(viii) Motor earth fault protection. CTIGM 15, 100mA.(ix) Motor overload protection. CDGM 12, 79%, TMS 0.2 ( 116.17% of full

load current)Alarm CTU 12, 70%, 7 sec.

(x) Instantaneous over current, 1000%.

190189

FUEL OIL PUMP HOUSEL.F.O UNLOADING PUMP

PERMISSIVE

1. Filling line valve of any L.F.O storage tank open.

PRETECTION

1. Any L.F.O storage tank level high.2. Any L.F.O starage tank level low.3. Low pressure in the suction header of L.F.O pumps

HFO UNLOADING CUM TRANSFER PUMP

PERMISSIVE

HFO filling line valve of any HFO tank open

PROTECTION

(i) Any HFO storage tank level high.(ii) Any HFO storage tank level low(iii) Low pressure in the suction header of HFO pumps.

DRAIN OIL PUMP (UNLOADING AREA)

INTERLOCK

1. srain oil tank level high, pump starts.2. Drain oil tank level low, pump stops.

SUMP PUMP (UNLOADING AREA)

INTERLOCK

1. Sump pit level high, pump starts.2. Sump pit level low, pump stop.

LFO PRESSURING PUMP

INTERLOCK

1. Pump on auto and no trip from MCC and any pump on and LFO pressureinadequate for more than 60 sec, stand by pump starts.

2. Any pump started and tripped for more than 10 sec, stand by pumpstarts.

H.F.O PRESSURISING PUMP ( FOR ABC OF UNIT 1 & 2, OR D,E, F OFUNIT 3 & 4)

INTERLOCK

1. Start command given and pump off for more than 10sec, standypumpstart.

2. Any pump on started and tripped for more than 10 sec, stondby pumpstarts,

DRAIN OIL PUMP (PRESSURISING AREA)

INTERLOCK

1. Drain oil tank level high, pump starts.2. Drain oil tank level low, pump stops.

192191

TURBINE ROLLING CURVE-1DT (HP BYP.1 - HP SHAFT ) < X 6

STEP/ CRITERIA 15/2

Main Steam temp. before HPBP,oC

HPShaftmidmetaltem-per-tureoc

0

0

100 200 300 400 500 600 700

100

200

300

400

500

600

ProhibitedZone

SECTION - 6

ANNEXURE

193

TURBINE ROLLING CURVE-2DT (LP BYP 1-HPSHAFT) <x7

STEP/ CRITERIA

ProhibitedZone

Main Steam temp. before HPBP,oC

0

0

100 200 300 400 500 600 700

100

200

300

400

500

600

Hotreheattemp.,Oc

STEP/ CRITERIA 12/712/8

DT(LPBYP1-IP CASING) > 30 K DT(LPBYP2-IPCAS) > 30K

TURBINE ROLLING CURVE-3

ProhibitedZone

IP Inner casing temp, oC

Hotreheattemp.,Oc

20/ 2

0

0

100 200 300 400 500 600 700

100

200

300

400

500

600

195194

STEP/ CRITERIA 12/412/5

TURBINE ROLLING CURVE-4DT(HP ESV1-HP SHAFT)>x5.1DT(HP ESV2-HP CASING)>x5.2

ProhibitedZone

Main Steam Temp, before SV I, 0cMain Steam Temp, Before SV II, 0c

HP Casingtemp- 50050%depth,oc

HPShaftmid400metaltemp,oc

0

0

100 200 300 400 500 600 700

100

200

300

400

500

600

STEP/ CRITERIA 12/212/3

TURBINE ROLLING CURVE-5STEAM BEF HP ESV1 S/H>x4.1STEAM BEF HP ESV2 S/H>x4.2

ProhibitedZone

Main Steam Pressure Bars (LBA 10CP 002)Before stop valve 1 (LBA 20 CP 002)

100 200

100

200

300

400

500

600

Mainsteamtemp.

197196

TURBINE ROLLING CURVE-6DT (HP BP 1- CONTROL V/V 1) < x 3

A115.1

ProhibitedZone

Main Steam tmp before HPBP (LBA 10CT 002B),oc

STEP/ CRITERIA 5/1

HPCon-trolValvetemp50%depth(MAA10CT011B)oc

0

0

100 200 300 400 500 600 700

100

200

300

400

500

600

50 200

100

200

300

400

500

600

100 150

TURBINE ROLLING CURVE-7

STM. BEF. HP BP I S/H >300KSTM. BEF. HP BP II S/H >300KSTM. BEF. LP BP I S/H >300KSTM. BEF. LP BPII S/H >300K

ProhibitedZone

Main Steam Pressure / Hot Reheat Pressure

5/2 8/25/3 8/35/4 8/45/5 8/5

Req-uiredtemp.Mainsteam&HRH0C

199198

TURBINE ROLLING CURVE-8DT (WET STM 1- CONTROL V/V1) <x2.1DT (WET STM 2- CONTROL V/V2) < 2.2

Main Steam Pressure, Barsbefore stop valve

STEP/ CRITERIA 5/95/10

HPcontrolvalvetemp50%

depth

100 200

100

200

300

400

500

600

TURBINE ROLLING CURVE-9DT (HP BYP 1 - CTRL V1) >1.1DT (HP BYP 1- CTRL V2) >1.2

ProhibitedZone

Main Steam Pressure before HPBP Valve,oc

STEP/ CRITERIA 5/65/78/78/8

HPCon-tro

valve50%

depthoc

0

0

100 200 300 400 500 600 700

100

200

300

400

500

600

201200

ANNEXURE 2

GENERATOR CAPABILITY DIAGRAM

GENERATORE TYPE THW-210-2A

RATED GENERATER OUTPUT SN 247.000 MVARATED ARMATURE VOLTAGE UN 16.50 KVRATED ARMATURE CURRENT IN 8.645 KARATED FREQUENCY FN 50.0 HZPOWER FACTOR PF 0.85RATED H2 PRESSURE 3.50 BAR

NOTE :-1. REDUCED H2 PRESSURE OPERATION NOT PERMITTED2. VALID FOR BOTH WITH AVR WITHOUT AVR

LEADING MVAR------------------ LAGGING MVAR

0.2

0.4

0.6

0.7

0.8

0.85

0.9

0.95

100 60 20 40 80 120 160 200

240

200

160

120

80

40

0

0.2

0.4

0.6

0.7

0.8

0.9

MAX OUTPUT = 228.9 MW

ANNEXURE 3

UNLOADING SCHEDULE DUE TO HIGHDISTILLATE TEMPERATURE

247 MVA, 210 MW, 16.5 KV, 0.85 PF, 3000RPM, 3.5 BAR H2 RESSURE

Temp. of distiliate at inlet of stator winding - oc

RATED STATOR CURRENT .8645

STATOR CURRENT

MVA OUTPUT

Normaltemp. ofDistillate

RATED OUTPUT- 247 MVA

8750

8700

8650

8600

8550

8500

8450

8400

8350

8300

8250

8200

43 45 46 47 48 49

248

244

240

236

232

228

224

44

STATOR

CURRENT

203202

Annexure - IVLUBE OIL SCHEDULE

TYPE OF OIL USED IN VARIOUS EQUIPMENTS

S.No Name of Equipment Type of Oil Approx.Qty.

BOILER AND AUXILIARIES

1. PA fan Servo Prime 68 650Its/BIrHC of PA fan Servo Torque 10

2. FD fan Servo Prime 68 1000 Its/BIr3. ID fan Servo Prime 68 1700 Its/BIr

Hydraulic coupling of ID fan Servo torque 104. GR fan Servo Prime 68 1700 Its/BIr5. Gravimetric feederi) Belt drive reducer NSG Servo CylC-680 10lts.ii) C.O. conveyor reducer Servo CylC-680 4lts.iii) C.O. conveyor gear head Servo CylC-680 2lts.

6. E.S.P(i) Gear motor assy. gear

box collecting electrode Servo Gear NP-90 84 lts./Blt.(ii) Gear motor assy. gear

box emitting electrode Servo Gear NP-90 264 lts./Blt.

7. A.P.H.(i) Support bearing Servo Cyl-c 680 90 lts.(ii) Guide bearing Servo Cyl c-680 25 lts.(iii) Aux. drive electric

motor cam clutch box Servo Prime 32 0.5 lts.(iv) Cleaning device 2

stage worm gearreducer Servo Mesh SP- 460 4lts.

(v) Fluid coup fluid drive Servo Prime 32 4.5 lts.

(vi) Fluid coup. twin disc Servo Prime 32 3.5 lts.(vii) Main drive gear reducer

gear box Servo system 50lts.220

(viii) Air motor compressedair line Servo sysem32 0.5 lts.

8. Bowl mill(i) Lower radial bearing Servo mesh SP-320 3900lts/mill

Thrust bearing Servo mesh SP-320 3900lts/millUpper radial brg. Servo mesh SP-680 3900lts/mill

(ii) Juornal bearing. upper Servo Mesh SP-680 130 lts/millJuornal bearing. lower Servo Mesh SP-680 130 lts/mill

9. Wall Blowers(i) Rack housing Servo Mesh SP-460 0.5 lts.(ii) Rotary gear box Servo Mesh SP-640 0.5 lts.

10. LRSB(i) Power pack rotary Servo System 68 0.9 lts.(ii) Power Pack Traverse Servo System 68 0.8 lts.11. fTP(i) Power pack Servo System 68 0.8 lts.(ii) Chain Servo System 150 0.8 lts.

TURBINE AND AUX,

1. Main oil tank (Turbine) Servo Prime 46 30,000 lts.First filling

2. Boiler feed pumphydraulic coupling Servo Tourqe 10 1,200 lts.

3. BFP electro mechanical actuator Servo Mesh SP50/for scoop control of hyd coup. 20 7 lts

4. CEP Servo prime 46 15 lts.5. LP bypass System Servo prime 466. HP bypass system Servo convol 467. Gland steam control valve

& seal steam control valve HLP-468. Stator water pump Servo prime 469. Actuators of valve and

dampers Servo Prime 68

205204

10. Centrifuge gear box SAE-40 4 lts.

11. Equipment cooling water

bearing Grease SG-3

Off- site

1. C.W pump motor NDE & DE

bearing Servo Prime 32 55 lts.

2. Raw wwater pump house

(i) PTDM pump SAE - 40 2 lts.

(ii) Softening plant water pump SAE - 40

3. Plant air and instrument

air compressor Servo Press 100

4. A.C. plant compressor Servo friz 57

5. D.G. set switchyard Hy Lub Milcy

6. Air Comp. switch yard Servo super 40

7. WTP

i) Degasser pump SAE 20/30 1 lts.

ii) DM, regeneration pump SAE -30 1 lts.

iii) Alkali unloading pump SAE -20 1.8 lts.

iv) Waste disposal pump SAE -30 2.2 lts.

v) Drinking water pump SAE -20/30

vi) Boiler fill pump SAE 30/40

vii) DM Make up pump SAE 30/40

viii) F.W. Pump Grease

ix) Slakalitransfer pump Grease shell Alvonia No.3 0.9 lts.

x) Effluent disposal cum

recirculation pump SAE -30 0.55 lts.

xi) Acid metering pump Pulsolub 1.6 lts.

7660SE

xii) Degasser blower

(centrufugal) AW 30 Burma shell multipurpose

grease No. 2 or ESSO white 18 gm/3months

bearing Gease or CATEX

MARFEX HO - 2

xiii) Rotary twin lobe type ESSO-G.P.90 3 lts.

compressor for M.B. GP - 140

Exchanger Model- SMK IOC Mobilub- GX 140

Mobilub - GX 140

Grease servo GEM

no. 2 or 3.

Shell Multipurpose

(Lithium based) Gulf

Crown no.2 3

xiv) All Motors Lithium based grease

Lithen - 2

8. Pretreatment Plant

i) Bridge drive (gear box)

PTDM Servo Mesh SP-320 3 lts.

Servo System -320

ii) Flocilator drive -12

gear box ( PTDM) Servo Mesh SQ -320

Redicon worm reducer

type -AVD 337 Servo System 320 1.4 lts.

iii) Bride drive motor(PTMD) Gease GR -3

iv) Flash mixer gear box(PTDM) Servo Mash SP-320 14lts

v) Flash mixer motor bearing Grease GR -3

vi) Central bearing of PTDM

clarifier Servo SEA 40

vii) Air blower (PTS) Servo Mesh SP -680

Servo System SP 320

viii) Air blower (PTDM) Servo Mesh SP-680

Servo System -320

ix) Drinking water pump

Motor (Plant) brg. AP 2 of

NDE 6312 Castrol

x) Filter back wash pump

thrust bearing 10C - Servo System 317.

207206

5.06.07.08.09.010.015.020.025.030.035.040.050.060.070.080.090.0100.0110.0120.0130.0140.0150.0160.0170.0180.0190.0200.0210.0220.0

151.11158.08164.17169.61174.53179.04197.36211.38222.90232.76241.42249.18262.70274.29284.48293.62301.92309.53316.58323.15329.30335.09340.56345.74350.66355.35359.82364.08368.16372.1

1.09181.10001.10711.11401.12021.12621.15241.17511.19531.21421.23201.24931.28261.311471.34661.37871.41151.44531.4811.5181.5581.6001.6441.6931.7501.8121.8891.992.132.39

0.38180.32140.27780.24480.21900.19800.13420.10161.081500.067980.058190.050780.040260.033120.027980.024050.020970.018460.016380.014620.013140.011820.010670.009630.008680.007800.006970.006180.005350.00438

152.0159.4165.7171.4176.5181.2200.7215.9228.6239.6249.5258.4274.3288.4301.0312.8323.8334.3344.2353.9363.3372.6381.9391.0400.4410.1420.2431.4444.6463.0

504.2498.9494.2489.8485.8482.1466.0452.6440.7429.9420.0410.6393.2377.0361.6346.6331.9317.4302.9288.5274.0259.0243.7227.9211.0192.7172.7149.4121.479.3

656.3658.3659.9661.2662.3663.3666.7668.5669.3669.5669.5669.0667.5665.4662.4662.6659.4655.7647.1642.4637.3631.6625.6618.9611.4602.8592.9581.1566.0542.3

0.44260.45940.47400.48680.49830.50880.55080.58220.60780.62950.64840.66540.69500.72030.74280.76320.78170.79920.81570.83160.84660.86140.87580.89010.91450.91920.93470.95150.97130.9993

1.63091.61641.60401.59301.58331.57491.54121.51621.49621.47931.46461.45151.42891.40891.39111.37471.35891.34391.32931.31541.30311.28721.27291.25831.24271.22581.20751.18641.16061.1222

Pressure Temp. Specific Volume Specific Enthalpy Specific Entropy

P Vf Vg Keal/Kg-K Keal/Kg-K

ata *C lit/kg m3/kg hf hfg hg sf sg

ANNEXURE VSTEAM TEBLE

SATURATED PROPERTIES OF WATER AND STEAM WITH PRESSURE AS PARAMETER

0.020.050.060.080.100.200.300.400.500.600.700.800.901.01.52.02.53.03.54.04.5

17.20432.5535.8241.1645.4559.6768.6875.4280.8685.4589.4592.9996.1899.09110.79119.62126.79132.88138.19142.92147.20

1.00131.00531.00641.00841.01011.01691.02211.02611.02961.03271.03551.03811.04051.04281.05211.06001.06661.07261.07801.08291.0875

68.2628.7324.1818.4514.957.7895.2344.0663.2992.7812.4092.1261.9041.7251.1800.90190.73190.61600.53380.47080.4215

17.2532.5835.8441.1745.4559.6568.6675.4180.8685.4789.4993.0596.2599.18110.99119.9127.3133.5138.9143.7148.1

587.6578.9577.2574.0571.6563.0558.0554.1550.7548.0545.6543.4541.3539.5532.1526.4521.4517.3513.5510.2507.1

604.9611.5613.0615.2617.0623.0626.0629.5631.6633.5635.1636.4637.7638.7643.1646.3648.7650.8652.4653.9655.2

0.06120.11270.12330.14020.15400.19760.22420.24380.25930.27220.28330.29310.30190.30970.34090.36400.38230.39760.41090.42260.4331

2.08492.00651.99121.96641.94801.89031.85671.83381.81491.80031.78811.77721.76751.75891.72671.70401.68601.67161.65921.64881.6394

209208

210

PROPERTIES OF SUPERHEATED SYSTEMTemperature 0C

ata t15.0 v(197.4)h s

20.0 v(211.4)h s

25.0 v(222.9)h s

30.0 v(232.2)h s

40.0 v(249.2)h s

50.0 v(262.7)h s

200

0.1235 668.41.5445

320

0.1800 735.21.6709

0.1334 732.41.6354

0.1055 729.11.6071

0.0868 726.11.5827

0.0634 719.61.5423

0.0493 712.51.5087

220

0.1436 681.11.5699

0.1043 674.41.5280

270

0.1624 708.81.6241

0.1197 704.61.5863

0.0940 700.21.5556

0.0768 695.51.5289

0.0550 685.71.4825

0.0416 674.21.4410

300

0.1731 724.71.6527

0.1281 721.31.6166

0.1010 717.81.5874

0.0829 714.21.5624

0.0602 706.61.5200

0.0465 698.41.4842

250

0.1550 698.01.6036

0.1138 693.11.5645

0.0891 687.91.5325

0.0123 682.11.5038

0.0510 669.71.4530

350

0.1901 751.21.6970

0.1412 748081.6621

0.1120 746.11.6345

0.0924 743.51.6112

0.0678 737.91.5729

0.0531 732.21.5412

370

0.1970 761.81.7137

0.1465 759.41.6791

0.1162 757.11.6518

0.0960 754.81.6290

0.0707 749.71.5914

0.0555 744.71.5609

400

0.2070 777.51.7375

0.1542 775.51.7035

0.1225 773.41.6767

0.1013 771.41.6542

0.0749767.21.6177

0.0590762.91.5885

450

0.2234 803.51.7748

0.1667 801.91.7414

0.1328 800.41.7152

0.1101 798.71.6934

0.0816 795.41.6583

0.0646 792.01.6302

500

0.2397 829.61.8098

0.1790 828.31.7767

0.1426 827.01.7509

0.1185 825.70.1295

0.0882 823.01.6953

0.0700 820.31.6681

550

0.2559 855.81.8427

0.1913 854.71.8100

0.1527 853.71.7844

0.1269 852.61.7632

0.0946 850.41.7296

0.0752 848.21.2029

600

0.2720 882.31.8739

0.2035 881.31.8415

0.1624 880.51.8116

0.1350 879.61.7950

0.1008 877.71.7617

0.0803 875.81.7356

650

0.2880 909.01.9038

0.2156 908.21.8715

0.1722 907.51.8462

0.1432 906.71.8254

0.1071 905.11.7924

0.0853 903.417666

ata t

60.0 v(273.3) h s

80.0 v(93.6) h s

100.0 v(309.5) h s

120.0 v(309.5) h s

150.0 v(340.6) h s

200.0 v(364.1) h s

300

0.0371 689.01.4512

0.0250 667.01.3875

420

0.0505 770.91.5813

0.0367 762.61.5408

0.285 754.41.5065

0.0119 745.51.4765

0.0173 731.21.4364

0.0116 702.21.3710

320

0.3998 705.11.4788

0.0276 688.01.4239

0.0199 666.01.3688

370

0.0454 739.71.5349

0.0326 728.81.4902

0.0248 716.51.4508

0.0195 703.01.4137

0.0140 678.01.3567

0.0746 610.51.2320

400

0.0485 758.71.5635

0.0351 749.51.5217

0.0271 739.81.4858

0.0217 729.51.4537

0.0161 712.21.4083

0.0103 676.01.3327

350

0.0432 726.41.5140

0.0308 713.91.4645

0.0231 669.01.4231

0.0178 681.51.3798

0.0120 647.61.3083

450

0.0533 788.51.6065

0.0390 781.51.5676

0.0305 774.41.5353

0.0247 766.91.5074

0.0189 754.81.4698

0.0131 732.71.4140

470

0.0551 800.11.6225

0.0405 793.81.5744

0.0317 787.31.5532

0.0258 780.41.5261

0.0199 769.71.4905

0.0139 750.61.4385

500

0.0579 817.51.6453

0.0427 811.81.6082

0.0335 806.11.5781

0.0274 800.11.5522

0.0213 791.01.5188

0.0151 775.01.4709

550

0.0623 845.81.6809

0.0461 841.11.6449

0.0364 836.31.6161

0.0299 831.51.5916

0.0234 824.11.5604

0.0169 811.41.5168

600

0.0666 873.81.7138

0.0494 869.81.6788

0.0392 865.81.6519

0.0323 861.81.6273

0.0254 855.61.5976

0.0185 845.31.5567

650

0.0708 901.71.7451

0.0527 898.41.7107

0.0418 895.01.6835

0.0346 891.71.6606

0.0273 886.61.6319

0.0201 878.21.5930

700

0.0749 929.91.7750

0.0559 927.11.7411

0.0444 924.31.7142

0.0368 921.51.6917

0.0291 917.1.6639

0.0215 910.11.6265

750

0.0791 958.31.8035

0.0590 956.01.7700

0.0470 953.51.7434

0.0289 951.11.7211

0.0309 947.41.6941

0.0229 941.31.6578

209

ATRS START-UP PROGRAMME

PERISSIVES FOR OPERATION RELEASE:

1. Starting device 00000%

2. Position set point of turbine control 00000%

3. Generator field breaker OFF

4. Generator breaker off

5. Drain before HPCV-1 (MAL 11) not closed

6. Drain before HPCV-2 (MAL 12) not closed

7. Limit pressure operation ON

8. Load controller ON

9. Synchroniser OFF

10. Pressure oil pressure 5.4 Kg/cm2

11. TSE influence OFF

OPERATION RELEASE AVAILABLE :

STEP-1 : WT/MT 0/0/0/0/0/2 Sec.

Command :

1. SLC drains ON

2. ALL ESVs closed.

3. HPCV-1 closed.

4. HPCV-2 closed.

5. IPCV-1 closed.

6. IPCV-2 closed.

7. CRH NRV Left closed.

8. CRH NRV Right closed.

9. Extraction valve A5 <5% open.

10. Extraction valve A4 <5% open.

11. Extraction valve A3 <5% open.

12. Extraction valve A2 <5% open.

STEP-2 WT/MT 00000/50000000000 Sec.

NO Commands

1. Trip oil pressure > 5.0 0 0 0 0 Kg./cm2

2. Turbine speed > 15 RPM

3. Condensate pressure > 22 Kg/cm2

4. Drains NO FAULT

5. DT HP Casing (top-bottom) > - 4 00000θθθθθ K

6. DT HP Casing (top-bottom) > + 4 00000θθθθθ K

7. DT IP Casing front (top-bottom) > + 4 00000θθθθθ K

8. DT IP Casing front (top-bottom) > - 4 00000θθθθθ K

9. DT IP Casing rear (top-bottom) > + 4 00000θθθθθ K

10. DT IP Casing rear (top-bottom) > - 4 00000θθθθθ K

212211

STEP-3 : WT/MT 160 Sec.

Commands :

1. Drain before HPCV-1 close

2. Drain before HPCV-2 close

3. SLC warm up control OFF

4. Waiting time 60 Sec.

STEP-4 : WT/MT 60 Sec./ Blocked

No Commands :

1. Boiler fire on

2. Steam before HPBP-1 > 30θθθθθK superheat

3. Steam before HPBP-1 > 30θθθθθK superheat

4. Steam before LPBP-1 > 30θθθθθK superheat

5. Steam before LPBP-2 > 30θθθθθK superheat

6. Temp. (HPBP1 - control valve) > x - 1

7. Temp. (HPBP2 - control valve) > x - 1

8. Total boiler steam flow > 15%

9. DT (wet steam2 - control valve) < x - 2

10. DT ( wet steam2 - control valve) < x - 2

11. DT (HPBP1 - control valve) < x - 3

OR

Boiler stm. temp before HPBP1 < 400θ θ θ θ θ C

12. Drain before HPESV-1 (MS 101) not closed

13. Drain before HPESV-1 (MS 102) not closed

14. Drain before IPESV-1 (HRH 101) not closed

15. Drain before IPESV-2 (HRH 102) not closed

16. Oil temperature before cooler > 350C

STEP-5 : WT/MT 500000 Sec.

Commands : Starting device raise

1. Starting device > 24%

OR

HPESV-1 not closed

OR

HPSEV-2 not closed

STEP- 6 : WT/MT 1600000 Sec.

No Command

1. HPESV-1 open

2. HPSV-2 open

STEP- 7 : WT/MT Blocked

1. Total steam flow > 15%

2. Steam before HPBP-1 > 300000θθθθθ K superheat

3. Steam before HPBP-2 > 300000θθθθθ K superheat

4. Steam before LPBP-1 > 300000θθθθθ K superheat

5. Steam before LPBP-2 > 300000θθθθθ K superheat

4. Boiler fire ON

7. DT/HPBP2-control valve) > X - 1, 2

8. DT(LPBP1-control valve) > X - 1, 1

9. Condenser pressure < 00000.5 Kg/cm2

STEP- 8 : WT/MT 1.2 Sec.

Command :

1. SNC warm up control ON

STEP- 9 : WT/MT -/60Sec.

Command :

1. Tracking device ON

2. IPESV-1 OPEN

3. IPESV-2 OPEN

214213

STEP-100000 : WT/MT

No Command :1. Drains NO fault2. Speeder gear < 100%3. Gland steam pressure control ON4. SLC oil temperature control ON5. Any oil vapour extractor fan ON6. Hydrogen purity > 97%7. Gen. gas pressure > 3.4 Kg/cm2

8. Gen. seal oil gas diff. pr. > θθθθθ.9 Kg/cm9. Genrator seal oil gas diff. pr. > 3.8 Kg/cm2

1θθθθθ. Genrator seal oil EE pr. > 3.8 Kg/cm2

11. Leavel in prechamber 1 & 2. < Max.12. Generator stator water flow > 21 M3

13. Generator stator water pr. > 2.4 Kg/cm2

14. Stator water inlet temp. < 4400000 C15. Hydrogen cooler CQ Pr. < 2.5 Kg/cm2

16. Liwuid in generator Not present17. Generator SW conductivity < 5 micro mho/cm.

STEP-11 : WT/MT -/ Blocked

No Command :1. Generator conditions Fulfilled2. Steam before HPESV-1 superheat > X - 4.13. Steam before HPESV-2 superheat > X - 4.24. DT (HPESV1 - HP casing) > X - 5.15. DT (HPESV2 - HP casing) > X - 5.26. Turbine speed > 15 rpm.7. DT (LPBP1 - IP casing) > 300000θθθθθK8. DT (LPBP2 - IP casing) > 300000θθθθθK9. Steam temperature before LPBP-1 > 40000000000θθθθθC1θθθθθ. Steam temperature before LPBP-2 > 40000000000θθθθθC11. Drain before HPCV-1 Not closed12. Drain before HPCV-2 Not closed13. Load setpoint > 100000%14. Condenser pressure < 00000.2% Kg/cm2

15. Diff Expn. HP casing front > +5.00000 mm15. Diff Expn. HP casing front > - 3.8 mm16. Diff Expn. HP casing front > + 8.00000 mm17. Diff Expn. HP casing front <u - 8.00000 mm18. Diff Expn. LP casing rear > - 2.00000 mm19. Diff Expn. LP casing rear < + 23.00000 mm

2θθθθθ. Diff Expn. LP casing rear > - 2.θθθθθ mm

STEP-12 : WT/MT 400000 Sec.

Command :Speed setpoint raise.1. Speed setpoint 5400000 rpm.

STEP-13 :

NO Command :1. Turbine speed 5400000 rpm.

STEP-14 : WT/MT

Command :Turine stress test programme Blocked

1. Wall temperature HP casing > 2000000θθθθθ C2. DT (HPBP - HP shaft) < I - 63. Turbine stress margin > 300000θθθθθ K4. Brg. vibration HP casing front < 35 microns5. Brg. vibration HP casing front < 35 microns6. Brg. vibration IP casing front < 35 microns7. Brg. vibration IP casing front < 35 microns8. Brg. vibration generator front < 50 microns9. Brg. vibration generator front < 500000 microns1θθθθθ. Brg. vibration generator rear < 500000 microns11. Brg. vibration generator rear < 500000 microns12. Vibration HP shaft front < Max.13. Vibration HP shaft rear < Max.14. Vibration LP shaft front < Max.15. Vibration LP shaft rear < Max.16. Differential expansion < Max.

STEP-15 : WT/MT 30000000000 sec.Command :

1. SLC warmup control OFF2. Speeder gear raise 100%

216215

STEP-16 : WT/MT 3θθθθθθθθθθ Sec.Command :

1. Turbinde speed set point raised.2. Drain before HPV-1 closed3. Drain before HPCV-2 closed4. Speed set point 303030303036 RPM

STEP-17 : WT/MT BlockedNO Command :

1. Turbinde speed > 29500000 rpm.2. Brg. vibration Gen./Casing < Max.3. Shaft vibration < Max.

STEP-18 : WT/MT / 600000 Sec.Command :

1. Drain before HPCV-1 closed.2. Drain before HPCV-2 closed.

STEP-19 : WT/MT BlockedNO Command :

1. Both AOP OFF2. DT (LPBP - IP shaft) < X - 73. Gen. conditions fulfilled4. Field flashing supply ON5. AVR control supply ON6. AVR protection supply ON

STEP-200000 : WT/MT / 155 Sec.Command :GENERATOR FIELD BREAKER ON

1. Wait time 15 Sec.2. Gen. field breaker ON3. Gen. voltage > 95%

STEP-21 : WT/MT 15 / 600000 Sec.Command :SYNCHRONISER ON

1. Gen. breaker ON

STEP-22 : WT/MT 1Sec. / 1Sec.Command :Load setpoint raise

1. Waiting time 15 Sec.

218217

End