National Capital 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.

FOREWORD
In the competitive knowledge based enviornment, it is essential to make available correct information in readily available format for quick and correct decision making. Technical Diary for 4 x 210 MW Coal Units, which was first compiled after commissioning of first unit has greatly helped in right decision making and improving station performance significantly. I highly appreciate the efforts y O & M staff to upgrade the technical diary in view of several modifications and incorporation of new systems.

PREFACE
Technical Diary for NTPC-Dadri, 4x210 MW Coal Units was first compiled by Operation Department after commissioning of first unit. Thereafter, many modification and improvements have been done in all areas of Power Station to improve safety of men & machine for enhancing the reliability and performance of plant systems. This new edition of Technical Diary incorporates all those changes, addition of new systems and suggestions from users. Due care has been taken during compilation of this new version, however, errors & omissions if observed may please be brought out to our notice.

(T.V. RAO) (General Manager)

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

ACKNOWLEDGEMENT
I am happy to learn that the a new updated version of Technical Diary for 4x210 MW Dadri-Coal is being brought out by the Operation Department. For efficient, reliable and safe operation of the units, we are often required to refer to the plant data like specified parameters, set point values of protection and interlocks and other relevant details. Efforts have been made to cover all the technical aspects of 4x210 MW Units in this Technical Diary. I am sure that it will also serve as a reference handbook for checking the design data required for solving the day-to-day plant problems. I congratulate the Operation team for bringing out the updated version of Technical Diary.

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

CONTENTS
SECTION DESCRIPTION 1 INTRODUCTION 1.
1.1 1.2 1.3 1.4 1.5 1.6 1.7

3. PAGE NO. 1
2 2 3 4 5 5 6 8 9 10 12 14 15 16 18 22 26 34 34 34 35 35 35 36 36 36 37

31. 3.2 3.3 3.4 3.5 3.6 3.7 3.8

GENERATOR AND AUXILIARIES

BOILER AND AUXILIA RIES

1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 1.16 1.17 1.18 1.19 1.20 1.21 1.22 1.23 1.24 1.25 1.26 1.27

GENERAL SPECIFICATION FURNACE SPECIFICATION WATER WALLS DRUM SUPERHEATER REHEATER SUPERHEATER AND REHEATER TEMPERATURE CONTROL ECONOMISER BOILER MOUNTING AND FITTINGS REGENERATIVE AND STEAM COIL AIR PREHEATER ID FAN FD FAN PA FAN GR FAN FUEL PREPARATION AND FIRING SYSTEM ELECTROSTATIC PRECIPITATOR BOILER PREDICTED PERFORMANCE SCANNER AIR FAN SOOT BLOWER FURNACE TEMPERATURE PROBE BOILER CHEMICAL DOZING PRESSURE REDUCING AND DESUPERHEATING STATION BLOW DOWN VESSEL PIPLE LINES - M.S., C.R.H., H.R.H., CHIMNEY BOILER AND AUX. COOLING WATER FLOW RECOMMENDED FEED WATER AND BOILER WATER IIMITS

GENERATOR TECHNICAL SPECIFICATION DESIGN AND CONSTRUCTION FEATURES GENEARATOR GAS SYSTEM STATOR WATER SYSTEM SEAL OIL SYSTEM SPECIFICATION OF TRANSFORMER HT MOTORS BATTERY AND BATTERY CHARGER

64 65 67 68 70 71 77 77 80 81 81 87 97 102 106 108 113 119 129 135 142 144 145 146 148

4.

4.1 4.2 4.2.1 4.2.2 4.2.3 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14

OFFSITE AUXILIARIES

RAW WATER SYSTEM WATER TREATMENT PLANT PRETREATMENT PLANT DM PLANT WATER SOFTENING PLANT CIRCULATING WATER SYSTEM AIR COMPRESOR PLANT FUEL OIL HANDLING PLANT COAL TRANSPORTATION AND HANDLING PLANT ASH HANDLING PLANT FIRE FIGHTING SYSTEM AIR CONDITONING SYSTEM DIESEL GENERATOR SETS CENTRAL LUB OIL STORAGE AND PURIFICATION SYSTEM MISCELANEOUS WATER SYSTEM COAL MILL REJECT SYSTEM OFFSITE - II

5.

5.1 5.2 5.2.1 5.2.2 5.2.3 5.2.4 I II III

CONTROL AND INSTRUMENTATION

UNIT C& I SYSTEMS INTERLOCK AND PROTECTION BOILER AND AUXILIARIES TURBINE AND AUXILIARES GENERATOR AND AUXILIARIES OFFSITE AUXILIARIES

150 156 171 180 190 193 202 203 204 208 211

2.

2.1 2.2 2.3 2.4 2.5 2.6 2.7

TURBINE AND AUXILIARIES

2.8 2.9 2.10 2.11

TECHNICAL SPECIFICATIONMAIN TURBINE TURBINE LUB OIL SYSTEM VACCUM SYSTEMS CONDENSATE SYSTEM FEED WATER SYSTEM PREDICTED PERFORMANCE OF TURBINE EQUIPMENT COOLING WATER SYSTEM HP/LP BYPASS SYSTEM HP AND LP FLASH TANKS L.P. DOZING SYSTEM TURBINE AND AUX. COOLING WATER FLOW

38 43 46 48 51 57 59 60 61 61 62

6.

ANNEXURE

IV V VI

TURBINE ROLLING CURVES (9 Nos.) GENERATOR CAPABILITY DIAGRAM UNLOADING SCHEDULE DUE TO HIGH DISTILLATE TEMPRATURE OF STATOR WATER LUB OIL SCHEDULE STEAM TABLE ATRS START-UP PROGRAMME

INTRODUTION (SALIENT FEATURES)

i) ii)

Type of station Station capacity Source Transportation Consumption

Thermal 840 MW (4 x 210 MW units) 100% coal or 100% oil Piparwar Block of North Karanpura coal fields in Bihar, about 1200 km. Indian Railways by means of Bottom Dis charge Wagons 3.66 million tonnes per year assuming 6500 hours of operation. Upper Ganga Canal Dehra headworks, During closure of UGC through network of tube wells. 50 cusecs Close cycle with natural cooling tower Through 3 x 167 MVA, 400/220/33 kv single phase auto transformer Dry Ash Disposal system. RCC multiflue chimney with steel flue-225 m high. 2600 Mcal/kwh 60% of MCR

iii) Fuel iv) Coal,

SECTION -1

v) Cooling water,

Source

BOILER & AUXILIARIES

Consumption Method vi) Start up power vii) Ash disposal viii) Chimney ix) Heat Rate x) HP/LP Bypass capacity xi) Land requirement (in acres) a. b. c. d. e. Plant area and green belt

between plant and ash area 1130 acres Ash disposal Township Reailway siding Approach road, intake canal and contractos township Total 115 acres. 2200 acres 480 acres 250 acres 225 acres

1.1 GENERAL SPECIFICATION

(i) Manufacturer (ii) Type BHEL (C.E. design) Natural circulation, balanced draft, smooth tube double pass, single drum, single reheat direct pulverised coal/oil fired,dry bottom type. 700t/hr. FW. inlet temp -246 C Steam pr./temp SH - 154.0 kg/cm2; 5400c RH - 38.8 kg/cm; 3400c Boiler Efficience - 87.28% 13868 ______ 10592 181 63.5 _______ _____ NCR 130 63.5

(iv) Capacity

(ix) Furnace projected are (x) Fuel heat input (xii) Residence time for fuel particles in furnace (xii) Effective volume used to calculate the residence time (xiii) Combustion temperature used to calculate the residence time (overage) (xiv) Explosion/Implosion with stand capacity at 67% yield point

3275 m2 519.3 MK Cal/hr 3.14 sec. 4200 m3

+ 660 mmwc

(iv) Boiler designation (v) Type of firing (vi) Water volume (a) Generating surface (Water walls) (b) Drum (full) (c) Economiser (d) Superheater (Drum to SHO heater) (e) Reheater (f) Total water volume of boiler (vii) Minimum load at which Steam Generator can be operated continuosuly with complete flame stability without oil support

Tilting tangential 116 m3 34 m3 47 m3 77 m3 50 m3 324 m3 (i) (ii) (iii) (iv) (v) (vi)

1.3 WATER WALLS

Front wall Side wall Rear wall Roof 1st Roof 2nd

2 adjacent mill at 50% capacity.

(viii) Minimum load at which Steam Generator can be operated continuously with complete flame stability with oil support 20% MCR (ix) Minimum load for individual mill beyond which no oil support is required 50%

Number 181 260 181 120 120 O.D., mm 63.5 63.5 63.5 51.0 44.5 Pitch, mm 76.2 76.2 76.2 114.3 114.3 Actual thickness, mm .................................... 5.5 .................................. Material SA210C. 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 tube thickness, mm .................................... 0.6 ..................................... (x) Method of joining Butt welded. long tubes

1.2 FURNACE SPECIFICATION

(I) (ii) (iii) (iv) (v) (vi) (vii) Type Bottom Draft Tube arrangement Furnace width Furnace depth Furnace height (Ring header to furnace roof) (viii) Furnace volume Fusion welded walls Dry Balanced Membrane 13.868 m 10.592 m 43.136 m 5570 m3

WATER WALL HEADERS

Bottom Ring w/w Outlet Header Header 1 5 40.64 219./273.0 Feed mater Pipe Line 323.9x36

(i) No. of headers (ii) Outside dia, mm (iii) Design pressure of header, kg./cm2 (g) ............................. 175.8 ...................................

(iv) Max. working pressure of headers, kg/cm2 (g) (v) Material 170.4 167.4 ............................. SA 106 Gr C...................................

1.5 SUPER HEATER

LTSH Pendant Horizontal Convection Counter Platen S.H. Final S.H.

1.4 DRUM
(i) Construction Fusion welded SA-299 176.4 167.2 354.0 170/135 135 12200 2083 1778 0.75 6 58/58 Through out the length

(ii) Material specification (iii) Design pressure, kg/cm2 abs. (iv) Max. operating pressure, kg/cm2 abs. (v) Design temperature, 0C (vi) Actual thickness of straight portion, mm (vii) Actual thickness for dished end, mm (viii) Overall length of drum mm (ix) O.D. of Drum, mm (x) Internal dia. of Drum, mm (xi) Corrosion allowance, mm (xii) No. of distribution headers (xiii) No. of cyclon separator/ secondary drier (xiv) No. of final driers (xv) Max. permissible temperature difference between any two points of drum, 0C (xvi) Water capactiy at MCR between normal level and lowest water level permitted (upto lowlow trip, in seconds) (xvii) Normal water level in drum

(i) Type Radiant Convection (ii) Direction of flow 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 213T11 SA 213T11 T22, 304H SA 213T11 (xiii) Method of joining long tubes ....................... Butt welded ................... (ivx) Total ND of assemblies 120 29 119

SUPERHEATER HEADERS
Material Max. operating pressure, kg/cm2 (iii) O.D., mm (iv) Thickness, mm (v) Final outlet header connection (vi) Main steam Pipe line (i) (ii) SA121 A, SA 335 P-12, P22 167.4 219.1, 273.0 32.9, 406.4 28, 32, End outlet. ID-255.6x49.2

40, 45

55 (I) (ii) 25 250 mm below drum centreline.

1.6 REHEATER
Type Max. operating pressure, kg/cm2 (iii) Design pressure, kg/cm2 (iv) Total circumferential heating suface, m2 (v) Gas flow path area, m2 Spaced, single stage 42.08 50.00 2858 118

(vi) Space between two banks in direction of gas flow, mm (vii) Mean effective length per one tube, mm (viii) Gross lennngth per tube, mm (ix) Total no. of tubes (x) Acutal tube thickness used, mm (xi) O.D., mm (xii) Margin on tube thickness, mm (xiii) Tube material (xiv) Tube pitch (a) Parallwt to gas flow, mm (b) Across gas flow, mm (xv) Depth of each bank in the direction of gas flow, mm (xiv) Method of joining long tubes

900 20.000 22,000 354 3.6 4.0, 5.0 47.63/54.00 0.6 Erosion allowance SA 210 Gr A1, SA 213T11, T 22

to 100% of boiler MCR, 0C (iv) Max. spray water flow rate & corresponding steam out put, kg/hr (vii) Min. spray water flow rate & correspondeing steam out put, kg/hr (viii) Spray nozzle material (ix) Spray water source

540 +_ 5

28,000 at 54.43 % of MCR

0 at 100% of MCR SA 182 T 12 BFP discharge

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

(i) Max. angle of tilt upwards/downwards (ii) Tilt mechanism (iii) Reheat steam range thai can be maintained between 54.9% to 100% MCR, OC (iv) Burner tilt used for reheat temp. control with (a) Cool firing (b) Oil firing _ + 30O Power cylinder

101.6 228.6 1400/1900 Butt welded

540 + 5

yes yes

REHEATER HEADERS
Material O.D. mm Thickness, mm Design pressure, kg/cm2 Max. operating pressure, kg/cm2 (vi) HRH Pipe line(vii) CRH Pipe line(i) (ii) (iii) (iv) (v) SA210 B, SA 335 P 22 406.4, 558.8 46.0, 45.0 50.0 40.08 ID-508x28 ID-457.2x127

1.7.1.3 REHEATER EMERGENCY TEMP CONTROL

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

1.7 SUPERHEATER & REHEATER TEMP. CONTROL 1.7.1 SUPERHEATER & REHEATER TEMP.CONTROL FOR COAL FIRING 1.7.1.1 SUPERHEATER ATTEMPERATOR
(i) (ii) (iii) (iv) (v) Type Stages of attemperation Position in steam circuit Material specification Superheater steam temp. range that can be maintained between 54.90% Spray mixing type One LTSH- Attemp.- PLTN S.H. SA 335 P12

1.7.2.1. GAS RECIRCULATION CONTROL

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

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

(i)

(i) Type

(viii) Tube pitch

(ii) No. of blocks

(iii) Tube material

(iv) O.D. of tubes, mm

(v) Actual thickness of

(xv) Type of tube joints

(ii) Outer diameter, mm

(vii) Length of tubes, mm

(vi) Erosion allowance,mm

(iv) type of construction

(iii) Actual thckness, mm

(xii) Gas velocity at boiler

(xi) Gas flow path area m

(v) Max. header unbalance surface area, m2 surface area, m2 handle safely, Oc 100% MCR, m/sec kg/cm2 (g) Material specification
2

(ix) Water side effective heating

(vi) Max. working pressure, which economiser can (b) Across gas path, mm (a) Parallel to gas path,mm

(xiii) Min. temp of feed water

(xiv) Design pressure of tubes,

(x) Gas side effective heating

kg/cm2 (g)

tubes, mm

1.8 ECONOMISER

ECONOMISER HEADER

8
150 323.9 323.9 161.0 32.0 32.0 Butt welded Plate formed/Seamless ........... SA 106 GR C............ .....................2%.................... S. Valve Type of No. Tag Safety No. Valve Location Boiler Drum SH ERV 1 2 3 4 SV1 SV2 SV3 SV4 Valve Size, mm/Inch Outlet Inlet 176. 179.9 181.7 163.0 ....................171.5.................. Inlet Header Outlet Header

96

1.0

4.5

130

32100

1.9 BOILER MOUNTING AND FITTING 1.9.1 SAFETY VALVES

Valve Set Pressure, ksc Close Open 169.3 170.9 172.6 158.1 Blow R e l i e v Down ing % Capacity Kg/hr 4 5 5 3 179 771 183317 220655 160836 160836 22.98 22.98 583743 83.39 83.39 106.37 Total % of Relieving Evapo Capacity ration Kg/hr % of Evapo ration Total% o f Evapo ration Approx. Valve weight kg 218 218 218 5 CRH HRH HRH S.B. Line 6 7 8 9 161.4 158.0 2.17 SV5 & SV6 SV7 SV8 SV9 SV10 10 SV11 &SV12 11 SV13 49.0 46.31 46.66 48.42 45.8 40.0 46.6 44.0 44.0 46.0 44.9 38.4 5 5 5 5 2 4 100315 191460 153827 155127 160865 112195 14590 224390 14590 17.74 17.74 35.48 469819 74.30 74.30 104.53 200630 218

8.9

62.8

44.5

Two

3580

in line

5617m2

SA210 GrA1

Plain, drainable, non-steaming,

152.4/6 Flanged 152.4/6 Flanged 152.4/6 Flanged 152.4/6 Flanged 101.6/4 Flanged

14.33 191460 30.28

14.33 30.28

28.66

295 356 356 356 356 340 25 203.2/8 Flanged 203.2/8 Flanged 203.2/8 Flanged 203.2/8 Flanged 203.2/8 Flanged 63.5/2.5

CONSOL 1750 WB 762/3 B Welded CONSOL 1750 WB 76 2/3 B Welded CONSOL 1740 WB 76 2/3 B Welded CONSOL 1740 WB 76 2/3 B Welded CONSOL 1538 VX 63.5/2.5* B Welded CONSOL1786 WD CONSOL1786 WD 152.4/4* B Welded CONSOL1786WD 1524/6* B Welded CONSOL 1525 VX 1524/6* B Welded CONSOL1786WD 1524/6* B Welded CONSOL 1811 JB 1524/6* Flanged Flanged B Welded 38.1/1.5

1.9.2 DRUM LEVEL INDICATOR

Location Drum Firemans floor Type DWLG RWL1 FIBRE OPTICS Conductivity type (Hydrastep) Remote level indicator Remote level recorder No. & Make 2,Yarway 1,Yarway 1,Yarway 2,Solartron, 1 1 4.

UCB

5.

intermediate/cold end Element height hot/ intermediate/cold end Material hot/ Intermediate/cold end Rotor Seals Radial seals-hot end Radial seals-cold end Axial seals Bypass seal Rotor post seal-hot end Rotor post seal-cold end Bearings Guide bearing Support bearing

guage)/Enamelled NF 850mm/650mm/500mm Carbon steel/carten-A/ enomelled iron. 2.5 2.5 2.5 1.6 6.0 6.0 mm mm mm mm mm mm thcik, thick, thick, thick, thick, thick, carten-A carten-A carten-A carten-A carbon steel carbon steel

1.10 REGENERATIVE & STEAM COIL AIR PREHEATER 1.10.1. REGENERATIVE AIR PREHEATER
Type Size No. per boiler 1. Main and stand by Motor types Vertical inverted modulur trisector type 27.5 VIMT-2000 Two Squirrel cage motor, frame size D160L IP 55 enclosure, F class insulation 11kw 1450 rpm 415 v,3, 50 HZ Type- I, Japan, Nissawai 11.50 FCU (PERMBRIL) 110:1 6.

Spherical roller bearing SKF/FAG 23060 CCK W 33 Spherical roller thrust bearing SKF/FAG 294 / 500 being SKF/FAG 294/500 25 litres 150 litres 0.55 kw, 415v, 30, 50HZ, 920 rpm, horizontal foot cum flange mounted.

7.

Oil Capacity Guide bearing housing Support bearing housing Oil Circulation System Motor-TEFC guide bearing

Rating Motor speed Motor power supply Speed reducer Coupling Speed reduction ratio 2.

Auxiliary Drive Assembly Air motor Chicago pneumatic RSM 400 Coupling Bibby 124 A Solenoid valve AVCON3/4 BSP 220 v,DCCL-H-INS flter lubrication Velgan or Norgreen 1 BSP Air pressure 5.3 kg/cm2 (g) Air consumption 6.37 Nm3/minute at approximate 0.5 rpm. Heating Elements Total heating surface Element type hot/

3.

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, water circulating rate 1 m3/hr, operating pressure 5 kg/cm2 8. Rotor Stoppage Alarm Go switch 110v, M/s APCO, USA 9. Fire Sensing Device, Type Infra-red detection system. 10. Clearing Device Type Power driven twin nozzle soot blowing Motor 0.18 kw, 3 phase, 415 v, 50 HZ, 1350 rpm, insulation class B, squirel cage motor Clearing media Steam/air

2252.7m2 DU (22 guage) /DU (22

10

11

4. Steam pressure range Steam consumption 10.6-17.6 kg/cm2 2100 kg/hr at 17.6 kg/ cm2, 1500c superheat. 50 minute. 2 1700 mm 7654 mm 17.5 m3

Drive Motor Make Frame size Type Rating Speed Power supply Type of duty Full load curreent No. load current Insulation class Weight of motor Brg NDE Brg DE

Time required for nozzle to make one pass 11. Air Receiver Tank No. per boiler Internal diameter Height Capacity

5. 6. 7.

1.10.2 STEAM COIL AIR PREHEATER

No. of per boiler Size Installed position Design steam pr/temp Weight of each SCAPH 2 4030 x 4710 x 300 mm Vertical 16kg/cm2/210c. 4600 kg.

Unit.1 & 2 BHEL, Bhopal 1 LA-7804-8FH-70-Z Squirel cage induction motor 1400 kw 750 rpm (syn.) 6600v, 30, 50 HZ Continuous 157.8 amp. 57 amp. F 9800 kg NV234 M NV234 M 62343C.3 3.1 m 47,380 kg 42000 kgm2 Forced oil lubrication. Grease lubrication Sleeve bearing GLYCO Sleeve bearing GLYCO 11 kw Lobyrinth seals

Unit-3 & 4 BHEL Bhopal IDQ 3735-8BD Q4-2 Synchronous 1325 KW 704 rpm 2 x 120 V x 3 continous 269 Amp F 13,000 Kg. NU228 M NU240M 6240C.3

1.11 ID FAN
Manufacturer No. per boiler Type BHEL Two NDZV 31 SIDOR Axial double suction radial discharge Ladisl Aischang Flue gas Ground mounted Bottom delivery with 450 inclined suction Inlet damper control + Hydraulic coupling 222 cu.m/sec 418 mmwc 1450c 0.7896 kg/cu/.m 740 rpm 32.6% 50% TACKE Gear

Medium handled Location Orientation Type of fan regulation 1. Fan Design Rating Capcity Total head developed Temp. of medium Specfic weight of medium Speed Fan Reserve Flow Pressure Fan Drive Coupling Make Type

Fan Nominal diameter Fan weight Moment of inerta refered to fan shaft 8. Lubircaiton Fan Motor 9. Bearing Fixed bearing Exponsion bearing Bearing loss 10. Seals 11. Lube OIl System No. of oil pumps capacity Lube oil pump motor

2 2,144 lpm, Boreman make 415v, 30, 50HZ, 5.6 kw, (7.5hp) 103. A Speed 2875 rpm insulation class B, induction motor 200 lpm, 10 kg/cm2 VOITH turbo L1N1 071304-D 16 bar/ 1000c 800 litre 4 kw, 415v, 30, 50HZ AC synchronous motor drive having variable frequency control incorporating load commuted inverter control system is provided.

Filter flow rate & working pr Working oil cooler Design pr./temp. Oil tank capacity Oil heater -For Unit 3 and 4

2.

3.

12

13

1.12 FD FAN Manufacturer No. per boiler Type Medium handled Location Orintation Type of fan regulation Fan Design Rating Capacity Total head developed Temp. of medium Specific weight of medium Speed 2. Fan Reserve Flow Pressre Fan Drive Coupling Make Type Drive Motor Make Fram size Rating Speed Power supply Type of duty Full load current 108 No load current Power consumption at 100% MCR per fan at fan shaft Weight of motor motor brg NDE Brg DE Fan Norminal diameter Hub diameter Weight of the fan without motor and coupling Moment of inertia of fan (at shaft level) Lubrication Fan Motor BHEL Two AP1-19/11 Clean air Ground mounted on concrete floor Horizontal axis Variable pitch control Coal firing Oil firing 144.7 cu.m/sec 126.8cm.m/sec 334 mmwc. 544 mmwc. 500c 1.04 kg/cu.m 1480 rpm 7. Bearings Fixed bearing Expansion bearing Bearing loss Lube OIl System No. of oil pumps Type of oil pump & make Capacity Discharge pressure Lube oil pump motor No. of coolers Oil tank capacity Control oil quantity Lub oil quantity Oil heater Nu 230 c3,7230 BUA Nu 230 C3 8 kw Two Screw type, Borneman make 70 lpm 12 bar 415v, 30, 50 HZ, 2860 rpm class of insulation B, induction motor, 4.0 kw, (5.5 hp), 7.6. A Two 450 litre 56 lpm (Theoritically calculated value) 4 lpm (Theoritically calculated value) 4 kw, 415 v, 30, 50 HZ,

8.

3.8% 43.9%

3.

THYSSEN Rigiflex Manufacturer No. per boiler Type Medium handled Location Orientation 1.

1.13 P.A. Fan

BHEL Two NDZV 19 HERKALES Axial double suction radial discharge simply supported Clean air from FD fan discharge Ground mounted on concrete floor Top delivery with 450 inclined suction chamber. 77.4 cu.m/sec. 931 mmwc 530c 1.0515 kg/cu.m 1480 rpm 52.9% 37.5% TACKE Gear BHEL/Bhopal 1LA-7712-HF-70-Z Sq. cage induction

4.

BHEL/Bhopal 1LA-77124HF-70-Z 1000kw 1500 rpm (syn.) 6600v, 30, 50 HZ Continuous amp 30 amp 390 kw 6700 kg NU 224M NU 228M 6228 C-3 1884 mm 1100 mm 8500 kg (statro-rotor) 500 kg m2

Fan Design Rating (i) Capacity (ii) Total head developed (iii) Temp. of medium (iv) Specific weight of medium (v) Speed Fan Reserve Flow Pressure Fan Drive Coupling Make Type Drive Motor Make Frame size Type

5.

2.

3.

4.

6.

Forced oil lubrication Grease lubrication

14

15

Rating Speed Type of duty Power supply Insulation class Full load current No loac current Weight of motor 5. Fan Nominal diamater of impeller Lubrication Fan Motor Type of Fan Regulation Bearings Fixed bearing Expansion bearing Bearing Loses 9. Lube Oil System Pump capacity & make Design pressure & type Lube ol pump motor Lube oil filter Lube oil cooler Oil tank capactiy

1050 kw 1500 rpm (syn.) Continuous 6600v, 30, 50HZ F 113.5 amp. 30 amp. 6700 kg.

Temp of medium Specific weight of medium Speed 2. Fan Reserve Flow Pressure Fan Drive Coupling Make Frame size Fan Drive Copling Make Frame size Type Speed Power supply Class of insulation Weight of motor Fan Nominal diameter Fan weight Moment of inertia refered to fan shat Lubrication Fan Motor Bearing Fixed bearing Expansion bearing Barring Motor N 1 / N2 Lube oil system No. of lub oil pumps Make & type Capacty Disch.Pressure Motor Lub oil filter Lub oil cooler Oil tank capacity Oil heater

4230c 0.41914 kg/cu.m 580 rpm 20% 32% BHEL/Bhopal 1LA-790-3KF-7903 BHEL/Bhopal 1LA-7903-3KF-70-Z Squirel cage indution 600 rpm (syn.) 6600c, 30, 50 HZ F 15000 kg 3350 mm 53, 120 kg 62,415 kg m2 Forced oil lubrication Grease lubrication sleeve bearing GLYCO sleeve bearing GLYCO 15.kw, 415 v, 30, 50Hz, 20.5 amp. 1455/61 rpm 2 Bornomenn pumpen, PDHU-38-4 144 lite / min. 8 bar NGEF lnduction motor, 5.5 kw, (7.5 hp),10.3 A 2875 rpm, class B insulation. Basket type simplex filter, 2 no. 2 no. 10 kg/ cm 2 & 100 0 c (shell side tube side) design pr & temp. 800 litre 4kw, 415v, 3050HZ

3.

1.8m. Forced oil lubrication Grease lubrication Inlet damper control+Hydraulic cou pling. 7 Sleeve bearing 4 ----- RT 16 7 Sleeve bearing 4 ----- RT 16 8 Kw 30 lpm, Bornomen pumpen 8kg/cm2, PDHU 32.-4 1.5 Kw (2hp), 3.3.A, 1405 rpm class B insulation, NGEF inducation motor 2 no. basket type simplex filter 2 no. Design pr. & temp 10kg/mc2 & 1000c (shell & tube side) 315 litre.

6.

4.

7. 8.

5.

6.

7.

8.

9.

1.14 GR FAN
Manufacturer No.per boiler Type Medium handled Location Orientation Fan regulation 1. Fan Design Rating Capactiy Total head developed BHEL/Ranipet Two NDZV33 SIDOR Radial double suction simply supported fan Flue gas Ground mounted Bottom delivery with 450 inclined suction Inlet damper control 165.8 cu.m/sec 246 mm wc

N.B:-GR fan should not run below 25% load as it may lead to unstable furnace condition.
17

16

1.15 FUEL PREPARATION AND FIRING SYSTEM 1.15.1 OIL BURNER HEAVY FUEL OIL BURNER Flow Kg/hr

135

135

145

(ii) Oil gun design (iii) Atomiser (iv) Air nozzle (v) Diffuser (vi) (vii) (vii) (ix) (x) (xi) (xii) Oil gun assembly Atomiser designation Atomiser spray angle NO. of guns. Location of oil guns Gun capacity Minimum allowable oil pressure (xiv) Minimum allowable steam pressure (xv) Oil viscosity at gun (xvi) Steam quality

Air Presure Kg/cm2

6.0

6.0

6.0

LFO Burner

Flow Kg/hr

1000

1000

600

DATA CHART

4.0

4.0

2.1

2.1kg/cm2 at oil gun connection 3.5 kg/cm2 at oil gun connection 15 to cst 10 to 150 superheat

LFO Pressure Kg/cm2

Flow Kg/hr

300

300

430

(i) (ii) (iii) (iv) (v) (vi) (vii)

HFO Pressure Kg/cm2

10.5

2.1

3.5 kg/cm2 Type of Burner

10.5

Service No. off oil guns Atomiser designation Atomiser media Fuel Oil gun capacity, Minimum allowable LFO pressure (viii) Minimum allwable atomising air pressure

Flow Kg/hr

4550

4550

1140

Initial start up purpose Same 4 heavy oil fired gun in AB elevation Spray plate 90 J 16 Service air, Light fuel oil IS 1460 7.5%MCR heat input, 2.1 kg/cm2 (g)

Steam Pressure Kg/cm 2

LIGHT FUEL OIL BURNER

6.0

6.0

6.0

H.F.O.

Maximum

18

19

Scavange

Minimum

Minimum

During

rating

rating

rating

6.0

480

6.0

180

(i)

Type

Air cooled steam atomising non-retractable tilting tangential corner fired. Paralle pipe External mixed, constant pressure steam atomised Rectangular 250 mm, 10 off. 450 vanes with leading edge with scanner cutting and lignitor cutting. kf=k+20.5=2308 mm Spray plate 90J16 900 16 (4per elevation) AB, CD, DE, and EF elevation. 31.9x106 kcal/hr/burner

IGNITORS
(i) (ii) (iii) (iv) (v) (vi) Simmonds USA Oil burner light up High energy arc ignitor (HEA) Burner mounting panel 110 volts AC, 50hz, 5 amp rms, Min 4 sparks/second, 12 joules nom./spark, duty cycle 15 minute on, 30 minute off. (vii) Spark rod constrution 5/8s/s tube with s.s. wire braid, flexible 5/8, 5/8, s/s tube (rigid) 5/8s/s tube (rigid) (viii) Ignitor tip dimension 191+ 3mm length, 15.9+0.15 mm diameter Operating temperature of tip 6500 (ix) Retraction assembly Air cylinder stroke upto 300 mm Air pressure 5-7 kg/cm2 (x) Flexible spark rod B = 100 inck dimension (xi) Flexibele guid pipe L= 69 inch dimension Make Service Type Location Input Output

FUEL OIL SPECIFICATION

(i) (ii) (iii) (iv) (v) Standard Flash point, minimum Viscosity, maximum Total sulpur, maximum Gross heating value (typical) HFO IS-1593/1971 Grade HV 660c 370 cst at 500c 4.5%by weight 10270kcal/kg LSHS Nil 750c 180cst at 500c 1.0%by weight 11000Kcal/kg LFO LDO to IS1460 660c 2.5 to 1.5 cst 1.8%by weight 10720Kcal/kg

1.15.3 COAL BUNKER

(i) Type Cylindrical with conical cum hyper bolic hopper at bottom. 8 mm M.S. plate 16m cylindrical and 8 m conical cum hyperbolic at bottom 7.6 m

(ii) Material of construction (iii) Height (iv) Diameter (I.D.) of cylindrical portion

1.15.3 BUNKER SHUT OFF GATE

(i) Size and type 36 motor operated coal valve 2-67-272-00138

20

(i) No. per boiler (ii) Location

6 Bunker outlet 1.15.4 GRAVIMETRIC COAL FEEDER

Full load current Weight of motor Bearing (x) Lub oil system No. of pumps Make and type Capacity Drive motor

54.7 A 7500 kg. DE NU 230 M and 6230 C3 NDE NU 226 M 2 ALEKTON, tripple screw pump 50 lpm NGEF make, 2.2 kw (3 hp), TEFC type, 955 rpm, 4.6 A, class B insulation.

(i) Feeder size (ii) Capacity (iii) Gear box ratio (iv) Main drive

(v) Clean out conveyor drive (vi) Working pressure

36 inch inlet 7CD Max. 60 t/hr Min. 6 t/hr 203:1 AC motor 5.5 kw, 11A, 1440 rpm and eddy current cluch with reducer, 415v, 50HZ, 30 power supply, speed range 100-1200 rpm AC motor, 0.25 kw, 950 rpm with reducer (1041:1), 415v, 3, 50 HZ, power supply. 500 mm wc.

1.15.6 COAL PIPE

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

1.15.5 PULVERISER
(i) (ii) (iii) (iv) (v) Make No. per boiler Type Capacity Coal size-inlet - outlet (vi) Grinding roll material (vii) Bull ring material (viii) Coupling (viii) Cooling system (ix) Mil bearing (A) Vertical Shaft Upper radial brg Lower radial brg Thru brg. (B) Journal Assy Upper radial brg Lower radial brg (C) Warm Shaft Thrust brg Radial brg (x) Drive Motor Frame size, Type Rated output Power supply Synchronous speed Class of insulation No load current BHEL 6 XRP 883 49 T/hr 25 mm 70% through 200 mesh Ni -Hard Gr II Modified Ni-Hard/Hi-chrome Gear type flexible coupling betwen mill and motor Immersed in oil bath, cooling water 9.0m3/hr at 360c & 3kg/cm2 pressure. C-8159-A Torrington 220-RU-O-03-R3 Torrington T-11000 Timken HH 249949/10 EE350750/351687 Timken SKF-29438 170 RM03 Torrington 1 LA-7716 - 3, 425 Kw 6600 v, 3, 50 HZ 600 rpm F 27.2 A HA74-7 (i) (ii) (iii) (iv) (v) Type No. per boiler Capacity Control Position

1.15.7 COAL BURNER

Tilting tangential 24 32.5 x 106 kcal/hr/burner Air damper Corner 1.15.8 SEAL AIR FAN (i) (ii) (iii) (iv) (v) Make No. and capacity Type Pressure developed Drive motor BHEL/Ranipet 2 x 100% Radial fan 508 mmwc Kirloskar Elect, Co. make, 37 kw, 2900 rpm, 415 v, 3 , 50 HZ, class B insulation

(i) Manufacturer BHEL (ii) Type FAA-6x45-69135-2 (iii) Design conditions Gas flow rate 312.7 cu.m / sec Temperature 1360c Dust 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 design conditions 20 mm wc

1.16 ELECTROSTATIC PRECIPITATOR

21

22

Design pr. & temp. of ESP Working pr, & temp of ESP (viii) Treatment time (iv) Veloctiy of gas at electrode zone on total area (x) Guarantee of collection efficiency for design conditions

+ 600 mm wc, temp 2000C + 162 mm wc, 1360C 32.18 seconds.

b) Rapper size c) Frequency of rap

d) Drive 0.839 m/sec 505 kw 99.9% 505 kw

4.9 kgs. Varying from 20 raps/hr a the inlet field to 2raps/hr at the exit field. The frequency of rapping for the intermediate fields can be adjusted between 10 and 3 per hour according to requirement. General electric motor controlled by microprocessor based rapper controller.

(xi) Power consumption (xii) Collecting Electodes a) No. of rows of collecting electrodes per field b) No. of collecting electrode plates per field c) total no, of collecting plates per boiler d) Nominal height of collecting plate e) Nominal length of collecting plate f) Specific collecting area (with one field out of service)

(xv) Rapper for emitting electodes a. No. & type of rappers Approximately one drop hammer for two rows of electrodes. b. Rapper size 3.0 c. Frequency of rap 10 raps/hour d. Drive General electric motor contrlled by microprocessor based rapper controller. (xvi) Hoppers a. Type & no. of hoppers b. Capacity c. Heating

24 144 3456 13.5 m 750 mm 214.48 sq.m/cu.m/sec

Pyramidal, 6 8 hour storage Electrical heating provided for the bottom of hoppers. Inlet Perforated plates, 2 sets Inlet of ESP Outlet U shape thin sheets - one set Outlet of ESP

(xvii) Gas distribution system Type & quantity Location (xvii) Electrical Items I. Rectifier a. Rating b. Numbers c. Type II. Rectifier control panel a. Type of of control b. Number III. Auxilary control pannel a. Number b. Equipment controlled

(xii) Emitting Electodes a) Type b) Size c) No. of electrodes in the frame forming one row d) No. of electrodes in each field e) Total no. of electrodes per boiler f) Total length of electrode per field g) Plate / wire spacing

Spiral with hooks Dia 2.7 mm 54 fields 1242 29808 6967.62 m. 150 mm

70 KV (peach, 800 mA (mean) 24 Silicon, diode, full wave bridge connection Thyristor 24 Four Collecting & emitting rapping motors, hopper insulation & shaft insulator heating. Emitting Rapper 24 0.33 hp 2.5 rpm 415v, 3, 50 HZ, Collecting Rapper 24 0.33 hp 1.1 rpm 415v, 3, 52HZ

IV. Motors a. Quantity b. Rating c. RPM d. Power supply

(xiv) Rappers for Collecting Electrode a) No. & type of rappers One drop hammer per row of collecting electrodes having a collecting surface of 121.5 sq. m.

23

24

(xx) Operation sequence of rapping mechanism

V. Heating elements (a) Hoppers For 24 hoppers/Boiler at the rate of 10 kw/happer (b) Shaft Insulator For 24 Insulators at the rate of 1 Kw (c) Support Insulator For 96 Insulator at the rate of 1 kw

(xix) Recommended current setting Fields 1 current in mA 150

Auto

25
1.117 PREDICTED PERFORMANCE 1. FLOW T/Hr DESCRIPTION BMCR OIL FIRING HP HEATERS IN SRVICE 210MW 68 MW 126 MW BMCR 1 STEAM Superheater outlet Reheater outlet WATER 700.00 597.2 645.0 571.0 518.6 462.0 394.8 353.6 611.4 600.0 700.0 597.2 2 3 4 5 BOTH HP HEA TERS OUT 6 7

96 kw

240 kw

240 kw

COAL FIRING HP HEATER IN SERVICE 210MW 168 MW 126 MW

2 250 3 400 4 500 5 600 6 700

8 645.0 571.0

9 518.6 462.0

10 394.8 353.6

BOTH HP HEA TERS OUT 11 611.4 600.0

26

Feed water SH spray AIR Air heater outlet (Primary) Tempering air Air heater outlet Total combusion Air

700.00 -

659.0 1.7

529.4 12.3

401.6 2.4

622.7 13.2

700.00 0

659.4 3.2

529.4 16.0

401.6 26.3

624.7 18.1

711.0 753.3

660.4 702.8

534.3 516.7

403.1 445.5

712.2 754.5

183 83 531 845

175 91 483 791

154 52 397 645

128 16 314 500

221 50 529 842

1 FUEL Oil (HHV=11,000 Kcal/kg) Coal (HHV=3500 Kcal/kg)

2 46.1

3 43.3 -

4 35.5 -

5 27.4 -

6 46.5 -

7 148

8 139

9 113

10 89

11 148

II PRESURES (STEAM & WATER) Kg/cm2 (g) PRESURE Superheater outlet LTSH outlet Drum Economiser inlet Reheater outlet Reheater Inlet PRESSUR DROP Superheater system Reheater Economiser 12.0 1.6 2.0 10.3 1.5 1.7 6.9 1.3 1.1 3.9 1.0 0.6 9.3 1.6 1.3 12.0 1.6 2.0 10.3 1.5 1.7 6.9 1.3 1.1 3.9 1.0 0.6 9.3 1.6 1.5 156.0 164.4 168.0 172.0 38.8 40.4 154.9 162.1 165.2 169.0 37.2 38.7 152.8 157.7 159.7 162.7 29.9 31.1 151.2 154.0 155.4 157.8 22.7 23.7 154.3 160.6 163.6 167.1 39.6 41.3 156.0 164.4 168.0 172.0 38.8 40.4 154.9 162.1 165.2 169.0 37.2 38.7 152.8 157.7 159.7 162.0 29.9 31.1 151.2 154.0 155.4 157.8 22.7 23.7 154.3 160.6 163.6 167.1 39.6 41.3

27 28

1 STEAM (I) Saturatd temp. in drum (ii) LTSH outlet (iii) SH platen outlet (iv) SH Finish outlet (v) RH inlet (vi) RH outlet WATER Economiser inlet Economiser outlet AIR Ambient AH outlet (Secondary) AH outlet (Primary)

(III) TEMPERATURE, 0C 5 6 7

10

11

350 400 501 540 352 540

349 406 498 540 350 540

346 413 48 344 344 540

344 408 506 337 337 540

348 407 498 362 362 540

350 396 506 352 352 540

349 398 506 350 350 540

346 400 509 344 344 540

344 403 513 337 337 540

348 407 502 362 362 540

248 303

246 306

236 305

224 295

168 249

248 294

246 292

236 284

224 276

168 243

27 331 -

27 333 -

27 327 -

27 310 -

27 289 -

27 326 322

27 324 320

27 307 304

27 288 286

27 284 280

1 GAS SH Platen inlet RH Front inlet RH Rear inlet SH Finish inlet LTSH inlet Economiser inlet Air heater inlet Air heater outlet

10

11

1134 1015 889 787 667 561 375 146

1103 992 874 777 663 560 375 139

1032 932 824 738 636 514 363 136

957 862 759 681 594 485 338 132

1143 1014 884 779 658 523 326 133

1156 1008 869 761 645 499 356 136

1165 1008 864 754 637 493 351 136

1143 973 824 717 607 473 332 123

1120 931 775 673 573 451 310 107

1138 993 859 754 540 498 314 116

IV PRESSURES & DRAFTS (AIR & GAS), MMWC PRIMARY AIR PA fan inlet PA fan outlet Air heater inlet Air heater outlet Mill inlet Mill outlet SECONDARY AIR FD fan inlet FD fan outlet SCAPH inlet SCAPH outlet 242 764 756 710 558 240 217 752 744 703 532 228 181 748 743 711 566 244 153 754 751 728 635 279 237 777 769 711 557 240

29 30

............................ Not applicable ..........................

-13 365 352 327

-11 334 321 299

-7 257 248 233

-4 194 189 180

-13 362 246 320

-17 258 245 232

-15 232 221 210

-10 191 183 176

-6 160 155 150

-17 253 240 227

VIII HEAT BALANCE 1 Air heater inlet Air heater oulet Windbox pressure 2 319 145 100 3 292 139 100 105 4 229 125 100 105 5 177 114 100 105 6 312 145 100 105 7 228 125 100 105 8 207 121 100 105 9 174 114 100 105 10 149 109 100 105 11 223 125 100 105

Windbox to furnace diff. 105

GAS

Furnace
Super heater platen inlet

-4 -4 -5 -22 -36 -74 -174 -198 +41

-4 -4 -5 -23 -38 -76 -160 -185 +36

-4 -4 -5 -21 -34 -68 -131 -144 +28

-4 -4 -5 -15 -24 -49 -91 -99 +22

-4 -4 -5 -20 -32 -66 -161 -184 +41

-4 -4 -5 -20 -32 -68 -192 -226 +52

-4 -4 -5 -18 -29 -62 -174 -203 +47

-4 -4 -5 -14 -21 -46 -123 -143 +35

-4 -4 -5 -10 -14 -34 -84 -97 +27

-4 -4 -5 -20 -32 -68 -186 -220 +52

RH inlet LTSH inlet Economiser inlet Air heater inlet EP inlet ID fan inlet ID fan outlet

Description

Carbon, % Hydrogen, % Oxygen, % Sulphur, % Nitrogen, % Ash, % Water/Moisture, % HHV Kcal/kg

ULTIMATE ANALYSIS

Fixed carbon, % Valatile matter, % Moisture, % Ash, % Sulphur, % Grindability index, HGI Ash fusion temperature, 0c

PROXIMATE ANALYSIS OF COAL

Oil

(V) FUEL

The Fuel data on which guarantee is given are as follows

(VIII) HEAT BALANCE 1 LOSSES Dry gas,% H20 & H2 in fuel,% H20 in air,% Unburnt Carbon,% Rediation,% Unaccounted & Manufacturers margin,% 0.48 0.46 0.46 0.45 0.46 1.13 1.11 1.09 1.06 1.08 4.21 5.72 0.11 0.50 0.11 3.98 5.70 0.10 0.50 0.11 3.92 5.68 0.10 0.50 0.13 3.86 5.67 0.10 0.50 0.16 3.75 5.67 0.10 0.50 0.11 4.75 5.83 0.12 1.2 0.11 4.77 5.83 0.12 1.2 0.11 4.27 5.78 0.11 1.2 0.12 3.65 5.71 0.09 1.2 0.17 3.89 5.75 0.10 1.2 0.11 2 3 4 5 6 7 8 9 10 11

24.00 23.0 41.0 41.0 0.33 57 1400

85.5 10.95 0.5 2.5 - 0.85 0.05 0.5 11,000

31 32
Total Losses,% 11.13 10.85 10.79 10.74 Heat Credit,% Efficiency(with heat credits),% 88.87 Guaranteed efficienccy,% 89.15 89.21 89.26

Coal

41.00 12.00 3500

37.03 2.26 6.53 0.33

10.59

13.14

13.14

12.57

11.88

12.13

0.43

0.44

0.43

0.44

0.43

89.41

87.29

87.30 87.28

87.86 87.72

88.56

88.30

1.18 SCANNER AIR FAN

15.86

(i) No. per boiler (ii) Type (iii) Duty (iv) Mounting (v) Medium to be handled (vi) Max. dust concentration (vii) Capacity (viii) Pressure developed (ix) Suction pressure (x) Efficiency of fan (xi) Driving motor AC motor

Two, one A.C. driven, one D.C. driven Radial backward curved blade single suction centrifugal Continuous On structural steel floor Dust ladden air 300 mg/cu.m 6000 cu. m/hr (1.67 m3/sec) 200 mmwc 0 to 559 mmwc 81.86% 5.5 kw, TEFC, KEC make 415v, 3, 50 HZ supply Class of insulation - B. 5.5 kw, 2 pole, TEFC, KEC make, 2900 rpm 1.52 kg m2

11

-25

15.86

70.8

68

77

70

3.54

235

10

+24

15.86

84.0

3.54

258

72

77

70

+12

15.86

72.4

70

3.54

68

237

77

+2

15.86

66.5

70

3.54

66

224

77

20

20

20

20

VI MILL & BURNER PERPORMANCE

(VII) O2, CO2 (DRY VOL.)AND EXCESS AIR

DC motor (xix) Fan speed (xii) Fan moment of inertia

13.56

71.1

-15

70

3.54

68

235

77

20

1.19 SOOT BLOWER

Type
13.56

.................. Not applicable .................................................

Source of steam i) ii) iii) iv) v) vi) Number Type Blow radius Direction Motor Power Cleaning medium Pressure Temperature Consumption vii) Blow duration viii) Cycle duration
13.56

Fully automatic sequentially controlled microprocessor based steam soot blowing LTSH outlet header Wall Blower LRSB 56 18 WB 1E LRD1E 1.5m 2.4 m 900 900 0.56 kw 0.37 kw Travers motor Steam Steam 20kg/cm2 20kg/cm2 3200c 3200c 2400 Kg/m 6000 Kg/m 1.5 minute/blower 9.0 minute/blower 84 min. 162 min.

2.03

2.03

13.56

2.03

2.03

13.56

Fineness %(through 200 mesh)

Air temperature mill inlet, 0c

Economiser outlet,% 10.0

10.0

10.0

10.0

10.0

No. of mills in operation

Economiser outlet%

( i i i ) Excess air in gas at

Oxygen in gas at

1.20 FURNACE TEMPERATURE PROBE

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

Air flow per mill, t/hr

Mill outlet temp, 0c

Economiser outlet%

Burner tilt, Deg.

Mill loading,%

33

(i)

(i)

CO2 in gas at

34

(iii) Traversing speed (iv) Max. gas temp. measured (v) Max. gas temp. measured without air cooling

2.9 mpm 8150c 5370c 1.1 m3 Size No of lines

1.24 MAIN PIPE LINES

Main Steam ID255.6x49.2 2 Hot Reheat 598.0x28.0 2 Cold Reheat Feed Water 457.2x12.7 323.9x36.0 2 1

1.21 BOILER CHEMICAL DOZING PHOSPHATE DOZING

(i) (ii) (iii) (iv) (v) (vi) (vii) No. off pumps Model Make Capacity Discharge pressure Pump motor Phosphate preparation tank capacity (viii) Phosphate metering tank capacity 1 working + 1 stand by PR-35 VK pumps industries ltd. 120 litre/hr 210 kg/cm2 (g) 1.5 kw, 1400 rpm; 3.4 A, 415v, 3, 50HZ supply 1.1 m3 1.1 m3 (i) (ii) (iii) (iv) (v) (vi) (vii)

No. of fuel Wind shield material flue material Chimney height Chimney base diameter Chimney raft diameter Flue diameter

1.25 CHIMNEY 4 NO. Reinforced concerete Steel 220 m 32.975 43.120 m 4.5 m

1.26 BOILER AND AUXILIARIES COOLING WATER FLOW

S.No EquipmentDecription Equipment/Unit working + standby FlowQuantity/cooler m3 /hr

1.22 PRESSURE REDUCING & DESUPERHEATING STATION

High Capacity PRDS RightCapacity PRDS PRDS Main steam line CRH line at 41kg/cm2 at 155.4 kg/cm2 pressure & 3510c & 5400c temperature temperature 55 30 Penumatic Penumatic BEP discharge BFP discharge Low temp unit High temp. station Low temp station aux. steam header aux. steam header aux.steamheader 15.0 ksc 15.0ksc 15.0 ksc 2100c 3250c 2100c (i) ID fan Working oil cooler Lube oil cooler FD fan Lube oil

(i)

Steam source

2+ 2 2+ 2 2+2

40.0 6.0 12.0

(ii)

(ii) Flow capcity / hr (iii) Type of actuator (iv) Spray water

Operating pressure Operating temperature

1.23 BLOW DOWN VESSEL

CBD (i) No. (ii) Design code (iii) Shell diameter x thickness and height, mm (iv) Working pressure (v) Design temperature (vi) Capacity One 1328525 1500 x16 1922 IBD One 152825 2082 x 16 x 19000 SCAPH Drain Tank One 15285 1800 x16 1800

(iii) PA fan Working oil cooler Lube oil cooler (iv) GR fan Lube oil cooler (v) Pulveriser cooler (vi) APH lube oil cooler (vii) Access door in furnace hopper zone (viii) Sample cooler (ix) Oil carry over probe (x) Fire detection system for Air heater

2+ 2 2+ 2 2+ 2 4+8 4+4 2 2 2

40.0 12.0 10.0 9.0 1.0 1.0 10 0.5 1.5

10.0kg/cm2 2000c 900 litre

1.5 kg/cm2 2000c 7000 litre

1.5 kg/cm2 2000c 5800 litre

35

36

1.27 RECOMMENDED FEEDWATER AND BOILER WATER LIMITS RECOMMENDED FEED WATER LIMITS
Drum operating pressure, 61.00 101 & above Kg/cm 2 (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 after cation exchanger in the H+ form and after C02 removal (max.) s/cm 0.5 0.3 (xi) Hydrqzine residual, ppm 0.01-0.02 0.01-0.02 Nil Nil (xii) Permanagnateconsumption,ppm (xiii) Oil ........... Not allowed ................ (i)

SECTION - 2

TURBINE & AUXILIARIES

RECOMMENDED BOILER WATER LIMITS

(i) (ii) (iii) (iv) (v) (vi) Drum operating pr. kg/cm2(g) Total dissolved solids (max.), ppm Specific electrical conductivity (max.) Phosphate residual, ppm PH at 250c Silica (max.), ppm 61-15 126-165 166-180 181-205

100

50

25

15

200 100 50 30 5-20 5-10 5-10 2-6 9.1-10.1 9.1-90.8 9.1-9.8 9.1-9.6 To be controlled on the basis of silica in boiler water & drum pressure relation ship to be maintained less than 0.02 ppm in the steam leaving the drum.

37

2.0 MAIN TURBINE 2.1 TECHNICAL SPECIFICATION 21.1 STEAM TURBINE

(i) Make (ii) Type BHEL, KRAFTWERK UNION DESIGN Tandem compound, regenerative, reheat, condensing, three cylinder having single flow HP turbine, double flow IP & LP turbine. HP 25 no. IP 20 x 2 no. LP 8 x 2 no. HPT-Reaction, barrel single flow type LPT-Reaction, double flow axially split type LPT-Reaction, double flow three shell design 210 MW 229 MW 3090/2850 rpm (47.5 to 51.5 HZ) Permissible for a maximum of 2 hours operation during the life of the LP blading speed below 47.5 HZ & speed above 51.5HZ. 700 to 2850 rpm 475 tonne (approx.) 11%

2.1.3. TURBINE CLEARANCES (IN MW)

(i) Min. axial cold clearance excluding thrust bearing (ii) Positionofmin.axialcoldclearance (iii) Axial clearance at stag - I shroud (cold) (iv) Radial clearance of rotor gland (v) Min. radial clearance at shroud

3.4 IP glands ( - ) 2.4 15.0 (LP shaft) 0.4 (HP) 0.5 (IP) 0.5 (LP) 1.5 (LP)

(iii) No of stages

(iv) Type of HP/IP/LP turbine

2.1.4 BEARINGS
No 1 No. 2 No.3 No. 4 No. 5 No. 6 No. 7 Lining Journal, 280 x 140 mm Radial cum thrust, tilting pad, 290 x 240 mm Journal, 450 x 320 mm Journal, 400 x 320 mm Journal, 400 x 320 mm Journal, 400 x 350 mm Journal, 200 material for all bearing Babbit

(v) Nominal rating (vi) Peak loading (vii) Max./Min. speed

(ix) Speed exclusion range (x) Weight of turbine (xi) Over speed set value

2.1.5 VALVES 2.1.2 DIMESNSIONS (IN MM)

HPT (i) Height of first stage moving blade 43 (ii) Mean dia. of first stage moving blade 643 (iii) Height of last stage moving blade 95 (iv) Mean dia. of last stage moving blade 695 (v) Overall length 16.975m (vi) Overall width (with cross 10.5 (approx.) around pipes) (vii) Total exhaust area (LP Turbine) IPT 66 LPT 755 2 Main stop and control valves 2 Reheat stop and control valves 2Swingcheckvalvesincoldreheatline 2 Bypass stop & control valves Extraction swing check valces Extraction 1 : No valve Extraction 2 : Extraction 3 : Extraction 4 : 2 x 5 m2 Type EV 160 Type IV 320 DN 320

756 1473.5 100 668.8 1041 2144.8

1 swing check valve with auxiliary actuator, 1 swing check valve. 1 Swing check valce with auxilary actutor, 1 swing check valve. 1 Swing check valve with axiliary actutor, 1 swing check valve.

38

39

Extraction 5: Extraction 6 :

1 Swing check valve with auxiliary actutor, 1 swing check valve. No valve.

2.1.9 DIFFERENTIAL EXPANSION

Alarm HP turbine diff. expansion +4.50 +5.00 - 2.50 - 2.00 IP turbine diff. expansion LP turbine diff. expansion Trip +5.50, +600, - 3.50 - 3.00

2.1.6. MATERIAL OF CONSTRUCTION

+25.00, - 5.00

+ 30.00, - 7.00

(i)

Turbine cosing HP turbine shell IP turbine cosing LP turbine cosing

GS-17 Cr Mov 511 GS - 22 Mo 4 St 37 - 2

2.1.10 TEMPERATURE DIFFERENCES (0C)

(Between upper & lower Casing Section)

(ii) Blades HP moving & stationary blades IP moving & stationary blades LP moving blades (iii) Shaft HP rotor IP rotor LP rotor First stage x22 Cr Mov 121 x22 Cr Mov 121 x20 Cr Mo 13 28 28 30 26 Last stage x20 Cr 13 x20 Cr 13 X7 Cr A 113 Alarm HP Turbine middle IP Turbine front IP Turbine rear + 30 + 30 + 30 Trip + 45 + 45 + 45

Cr mo Niv 59 Cr Mo Niv 59 Cr MoNiv 511 Cr Mo Ni V 115

Permissible differential temp between Parallel Steam supply lines Short time period (15 minute) LPT 48.0 81.0 : not more than 1.70c 280c

2.1.7 WEIGHTS (TONNE)

HPT IPT 7.5 15.8 56.0 37.0 (With steam inserts) 31694 kgm 115559 kgm2 979413kgm2
2

Rotor Cylinder assembled Moment of inertia (kgmw2) Rotor of HP cylinder Rotor of IP cylinder Rotor of LP cylinder

2.1.11 BEARING TEMPERATURE (0C)

Normal Operating temperatues Belwo 750c Above 750c 900c 1000c Alarm M/c must be down at 1200c 1200c

2.1.8 CASING TEMPERATURE (0c)

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

2.1.12 VIBRATION (ASBOLUTE)

of bearing Nominal value for alarm value Maximum value for alarm Limit value for tripping 35 m 45 m of shaft 30 m above normal 120 m 200 m

40

41

2.1.13 LOW VACUUM TRIP SETTING

Hydraulic low vacuum trip Electric low vacuum trip Hydraulic low vacuum trip (Bypass operation) 0.3 ata 0.3 ata 0.6 ata

2.2 TURBINE LUBE OIL SYSTEM 2.2 1 OIL SUPPLY

(i) (ii) (iii)

Oil tank rated capacity Highest / lowest oil level from top of the tank Lube of temp. at cooler out let (In operation)

20/32m3 800 / 850 mm Min 380, normal 450, max 470C Normal 300, max 250C 30m3 20m3 120 max. 170 bar, - 10% min. 510 rpm 540 rpm.

2.1.14 MEGAWATT OUTPUT (APPPROX)

(iv) HPT 56.40 MW 28% IPT 53.73 MW 28% LPT 93.03 MW 46% (v) (vi) (vii) (viii)

Oil temp rise across bearings First oil filling (estimated) Flushing oil quantity (estimated) Pressure limiting value in jacking oil system bar Safety valve in jacking oil system Jacking oil pump must be switched on at Jacking oil pump must be switched off at

2.1.15 FEED WATER HEATER OUT OF SERVICE

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

(ix) (x)

2.1.16 STEAM PURITY

Continuous operation Start up Unit Nos. M.O.P A.O.P. DC EOP Nos. No specified <0.15 <0.50 s/cm s/cm Type <0.10 <0.10 0.010 <0.010 <0.001 <-.005 <0.10 <0.50 0.050 0.050 <0.050 <0.020 s/cm s/cm mg/kg mg/kg mg/kg mg/kg Rated capacity Rated discharge pressure Speed, rpm 139 m3/hr 8.2 ata 3000 ETA 15050VL 152.24 m3/hr 84.7 mIc 1485 ETA 10033VL 108 lit/m 27.66 mk 1425 Make BHEL 1 KSB 2 KSB 1 All J.O.P. (AC) 2 All weiler AG SDF 40RS4 76 lit /m 120 bar 2950 J.O.P. (DC) 1

2.2.2 OIL PUMPS

(i)

Conductivity at 250c, continuous measurement at the sampling point a. direct measurement alkaline method Neutral method b. Following a strong acid cation exchange method Alkaline method Neutral method

(ii) Silica (SiO2) (iii) Total iron (Fe) (iv) Total copper (Cu) (v) sodium (Na)

weiler AG SDF 40RS4 76 lit /m 120 bar 2950

42

43

M.O.P

A.O.P.

DC E.O.P. D.C. motor crompton greaves IP44 220 15 128

J.O.P. J.O.P. (AC) (DC) A.C. D.C. motor motor Siemens siemens IP54 415 50 27.6 47.5 IP54 220 28 152 (i) (ii) (iii) (iv) (v)

2.2.6 BARRING GEAR

Drive Make Enclosure Voltage, V Frequency, HZ Motor power, kw Rated current, amp

Turbine A.C. motor GEC 415 50 100 175

Type of drive Method of engagement Cut in/cut out speed Power to rotate turbine Barring speed

Hydraulic turbine Hydraulic 240/210 rpm 45 kw 80-210 rpm

2.2.7. MAIN OIL CENTRIFUGE (i) (ii) (iii) (iv) Manufacturer Supplier Capacity Centrifuge ALFA-LAVAL (India) BHEL Hardwar 6000 lph purifier Flame proof induction motor, Crompton Greaves make, 7.5 kw, 1460 rpm, 15A, Class B, insulation, Frame E 160 LD, 3, 415v, 50 Hz Power supply, Ref. IS : 325/1978 8425 rpm approx. 118-125 Gear pump, type 206 Crompton Greaves make, 3.3 kw 1430 rpm, 7.5A, Fram E 132 M Indirect type 72 kw Heater J/II/III 36 kw/ 18kw/ 18 kw 450 litre approx. for first filling 3 litre for first filling of Centrifuge

2.2.3 OIL COOLER

(i) Type & no. (ii) Cooling surface/oil flow per cooler (iii) Oil outlet temp. of per cooler In operation In shutdown (iv) Oil pressure drop across cooler (v) Tube material & no. of tubes (vi) Design pr. & temp. shell & tube side Shell & tube type, 2 x 100 % 280 m2/ 27lit/s

Min 38, normal 45, max 470c 750c 0.4 ata CuZn 28 Sn F38, 1251 no. 10Kg/cm2 & 1000c (both) (vi) Bowl speed (vii) Revolution counter (RPM) (viii) Booster pump type (ix) Booster pump motor (x) Oil heater

2.2.4. OIL FILTER

(i) Duplex oil filter type & no. DN 100 type, 1 no. (ii) Filteration particle size duplex filter 37 m (iii) Filteration particle size MOT filter 250 m

(xi) Quantity of water for heater (xii) Sealing water for centrifuge

2.2.8 OIL CHARACTERISTICS AS per IS : 1448 (i) Kinetic viscosity at 37.80c Kinetic viscosity at 500c (ii) Sp. gravity at 500c (iii) Flash point (iv) Pour point (v) Ash content 47.5 CS. to 49.5 C.S. 28 C.S. 0.852 Min 2000c -60c 0.01 (% by weight)

2.2.5 ESTIMATED OIL REQUIREMENTS OF BEARING Bearing 1 (HPT front pedestal) 2 3 4 Front Generator bearing Rear Generator bearing 0.8 9.1 4.0 3.5 3.5 5.0 dm3/s dm3/s dm3/s dm3/s dm3/s dm3/s

44

45

(vi) Water content (vii) Mech. solid impurities (viii) Viscosity index (ix) Inorganic acidity Organic acidity (x) Neutralisation no. (xi) Copper strip corrosion test at 1000c for 3 hrs. (xii) Emulsion characteristics

Below the level of quantitiative deteclibility -doMin 97 Nil Max. 0.14 mg of KOH per gm of oil Max. 0.02 mg of KOH per gm of oil Not worse than no1 40-40-0 (20 minute)

(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) (ii) No. & capacity Make 2 x 100 % NASH AT 2004 NASH, two stage liquid ring air pump Wellman - BIBBY E - FLEX 290 / F8 6639. kg 7074 kg 7619 kg ABB Motor Totall enclosed, fan cooled. squirrel cage induction motor 415v, 3, 50HZ 93 kw/125 hp 190 A MA 493 Single stage, centrifugal, foot mounted type. Worthingaton simpson End suction type Totally enclosed, fan cooled cage induction motor, 1.5 kw (2hp) 2700 rpm, 3 A, 415v, 3, 50 HZ power supply, frame size 90 DL Size 1244

(iii) Type

2.3 VACUUM SYSTEM 2.3.1 CONDENSER

(i) Type Surface type, double pass with divided water box construction. Steam side Water side Full vaccum/1.08 kg/ 5 kg/cm2 (g) & cm2 (g) full vacuum Filling by water up to 7.5kg/cm2 (g) 22,500 m3/hr 32 c
0

(iv) Coupling drive make Type Size (v) Unit weight, Empty Operating Flooded (vi) Vacuum pump motor Type Power supply Poer rating Full load current Frame size Full load rpm (vii) Seal water pump Type Manufacturer Flow Motor

(ii) Design conditions Design pressure Test pressure (iii) Design c.w. flow (iv) Design cold wate temp. (v) Design back pressure (vi) No. of tubes Tube O.D. x thickness, For top row thickness (vii) Tube material

60 c
0

76 mm of Hg (abs) 15330 nos. 25.4 x 0.7 thick 1.0 mm Stainless steel welded ASTM A 249 TP 304 13727 M2 1.83 m/s 4.18 mwc 10.80c

(viii) Surface area (ix) C.W. velocity (x) Pressure drop C.W. side (xi) C.W. temp rise

(viii) Heat exchanger

46

47

Type

Design pressure Design temp.

Single pass, counter flow, tube & shell type Shell side Tube side 10.54kg/cm2 10.54kg/cm2 ( - ) 6.6-1490c ( - ) 6.6 -1490c

(xvii) (xix) (xx)

2.3.3 GLAND SEALING SYSTEM

(i) (ii) (iii)

Type of control Gland sealing temp. Self sealing after

Electro-hydraulic seal steam pressure controller above 1200c cold start 1500c hot start 40% load.

Sealing water to glands flow Thrust bearing type Motor Manufacturer Type Frame KW rating Power supply Class of insulation Connection stator Efficiency at rated output Rate speed No load current Full load current Total weight of Motor Bearing DE 6224-c3 NDE 7322 - B

20 lpm Michell 7 SNT BHEL/Bhopal Squirel cage induction motor 1LA 7636 - 4 HE 7 4Z 550 kw 6600v, 3, 50 HZ F Star 94.2% 1487 rpm 21.4 A 62.2 A 4900 kg

2.4.2. DRAIN COOLER 2.4.1 CONDENSATE EXTRACTION PUMP 2.4.1. CONDENSATE EXTRACTION PUMP
(i) (ii) (iii) (iv) (v) (i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) (x) Manufactuer No. of pumps & capacity Type BHEL 2x100% NESJ14OD (2shaft), vertical centrifugal connister type 5 655 m3/hr 190 mlc 422 kw 0.9897 tone/m3 46.30c 2.8 mlc 1485 79.5% Clockwise 400 mm 300 mm 10 lpm (i) (ii) Position No. Horizontal One Position No. of Type Design code Design pressure Horizontal One Tube & shell type ASME Sec VII DIV I Tube side Sheil side 30kg/cm2 (g) Full vacuum & 3.5 kg/ cm2 (g) 1500c 1000c 30 kg/cm2 0.4521 ata 45 kg/cm2 (g) 0.8 mwc 5.25 kg/cm2 (g) 0.3 mwc

No. of stages Discharge capacity Diff. head Input power to pump Density of medium handled Temperature of medium Liquid NPSH required at the eye of the first impeller (xi) RPM (xii) Efficiency of pump (xiii) Direction of rotation viewed from drive end (xv) Suction bore dia. (xvi) Discharge bore dia. (xvii) Cooling water to thrust bearing flow

(vi) Design temperature (vii) Max. working pressure (viii) Hydraulic test pressure (duration 30 minute) (ix) Hydraulic resistance at design flow (x) No. of water path (tube side) (xi) Tube O.D. x. thickness x length, mm (xii) Tube material (xiii) No. of tubes (xiv) Discharge of main condensate (design) (xv) Drain quantity (design) (xvi) Operating weight of drain cooler (xvii) Cooling surface area

one 16 x 0.889 x 1540 Austenitic S.S. welded 501 540 t / hr 68.789 t / hr 3250 kg. 35 cm2

2.4.3. GLAND STEAM CONDENSER

48

49

(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 condensate Minimum 108 /hr Design 546/hr at V.W.O., 3% makeup Maximum 780 t / hr (xi) Hydrauic resistance at minimum/ design / maximum flow 0.2 mwc/1.0 mwc/2.3 mwc (xii) Tube dimenssion x th x l, mm x mm x mm Material Welded S.S. tubes ASTM 249 TP 304 No. 325 (xiii) Exhauster fans 2 no., centrifugal, 1080m3/hr, 2840 rpm, 3 hp

LPH-1 (ix) Weight, Dry Operating Flooded (x) Test pressure kg/cm2 Shell side W/B side

LPH-2 11100 13700 19170

LPH-3 11100 13700 19170

5.25 45

5.25 45

(xii) Shell assy Water box Water box cover

IS 2002 Gr A BQ STEEL IS 2002 Gr A BQ STEEL IS 2002 Gr A BQ STEEL

2.5.1 DEAERATOR

(i) (ii)

Manufacturer Type

BHEL, Hyderabad Spray cum tray type Spray cum tray type

(iii) Design pressure and temp. (iv) Shell diameter and thickness a. Dearator b. Storage tank (v) Straight length and overall length of shell a. Deaerator b. Storage tank

2.4.4 LOW PRESSURE HEATER

(i) Type (ii) Position/location (iii) No. (iv) Design code (v) Design pressure shell side waterbox side (vi) Design temperature shell side (vii) No. of tubes LPH-1 LPH-2 LPH-3 ............... Shell & tube type ................ condenser neck one one one ............ ASME SEC VIII DIV I ................. ............ 3.5 kg/cm2 / Full vacuum ............ ....................... 30 kg/cm2 ....................... 150 210 429 429

ID 2200 x 16 thk, mm ID 3600 x 20 thk, mm

6632, 7882, mm 21000, 22900, mm 240 48.

(vi) No. of trays provided (vii) No. of spray valves (viii) Storage capacity a. At normal water level with a filling capacity of 2/3 of crosssectional area of the storage tank b. Normal water level to low level (ix) Water level from centre line of horizontal vessel

141.4 m3 131.4 m3

50

51

a. Normal b. Low c. Low-High d. High e. High-High (x) Feed water outlet temperature (xi) Deaerator operation condition (xii) Oxygen guarantee (xiii) Safety valve

610 mm above 118 mm above 1300 mm above 860 mm above 1035 mm above 1610c 6.85 kg/cm2 abs. 163.80 0.005 cc/liter as measured by ASTM-D-888. 2 no., spring loaded, 40 t / hr capacity each, BHEL trichy make, 6.8 kg/cm2 (g) set pressure.

BOILER FEED PUMP

(xiv) Total weight Empty/operating/flooded 80/210/310 tonne

(i) No and Capaciy (ii) Make (iii) Pump type (iv) No. of stages (v) Liquid pumped (vi) S.G. at suction temperature (vii) Differential head (viii) Design flow rate (ix) Minimum recirculation flow (x) Efficiency (xi) Speed (xii) Power (xiii) Direction of rotation viewed on drive end (xiv) NPSH required (xv) Thrust bearing

3 x 50% BHEL, Hyderabad FK 6 D 30 6 Boiler feed water 0.90665 2123m 450 m3 / hr 110 m3 / hr 81% 5150 rpm. 2911 kw Anti-clock wise 24.0 mlc The Glacier Metal Co. Ltd., Double Thrust, CK range, Size 8159/2KP-2KP

BOILER FEED BOOSTER PUMP

(i)

Pump type

FA 1B 56 Boiler feed water 0.90665 160.70c 100m 450 m3 / hr 79 % 1485 rpm 141 kw 4.03 m. The Glacier Metal Co. Ltd. Double thrust, CK range size 811/2KP-2KP (i) (ii) (iii) (iv) (v)

DRIVE MOTOR

(ii) Liquid pumped (iii) S.G. at suction temperature (iv) Suction tempreature (v) Differential head (vi) Flow rate (vii) Efficiency (viii) Speed (ix) Power (x) NPSH, required (xi) Thrust bearing

(xii) Mechanical seal

Durametalic/sealEd type 4.250 PTO/type 503

Make Type Frame size Rating Degree of protection, type of enclosure and method of cooloing (vi) Power supply (vii) Rated speed (viii) Insulation class (ix) No load current (x) Full load current (xi) Weight (xii) Winding temperature rise at rated output over cooling air (xiii) Bearing - DE - NDE

BHEL, Bhopal Squirrel cage induction motor 1 RN7 714-4HE 70-Z 3500 kw

IP 54, CACW, ICW 37 A 81 6600 volt, 3 phase, 50 HZ 1500 (synch.) F 80 A 356.5 A 12800 kg 700c (by resistance), 800c (by ETD) Sleeve bearing 160 x 14 Q Sleeve bearing 125 x 115 (Insulated)

52

53

TYPE OF COUPLINGS
Turbo coupling / pump flexible coupling Manufacturer Type (ii) Motor / turbo coupling flexible coupling Manufacturer Type (iii) Motor / turbo coupling flexible coupling Manufacturer Type (i)

OIL/WATER-HEAT EXCHANGER

Torsi flex Ltd. HBS 1000-8x

Torsi flex Ltd. HBS-3600 8

Torsiflex Ltd. HB4-140X (Insulated)

HYDRAULIC TURBO COUPLING (i) Manufacturer (ii) Type (iii) Power requirement of driven machine (iv) Gear ratio, type (v) Speed input / output (vi) Full load slip (vii) Regulating range (viii) Oil tank filling (ix) Working oil flow rate Vaith Turbo GMBH and Co. R16 K.1 3245 kw 181/51, step up gear unit 1485/5155 rpm. 2.2% 5:1 down wards Approx. 700 litre 47 litre / min.

(i) Type (ii) Heat exchanger capacity (iii) Cooling water flow, V rated V / min (iv) Cooling water inlet temperature (v) Cooling water outlet temperature (vi) Normal oil flow rate (vii) Oil inlet temperature (viii) Oil outlet temperature (ix) Maximum permissible working pressure, oil side water side (x) Maximum permissible working oil temperature

WORKING OIL L1 N1 09 17 04-D 52 m3/hr 25 m3/hr 380c 480c 31m3/hr 1000c 610c 16 bar 10 bar 1200c

LUB OIL L1 N1 07 17 04-D 38m3/hr 15 m3/ hr 380c 400c 13.2m3/hr 610c 450c 16 bar 10 bar 1200c

COOLING WATER FLOW

Cooler

Quantity/ cooler m3 /hr 2 x 1.8 24 52 38 6.0 2x2.4

Pressure drop kg/cm2 0.4 0.5 0.5 0.5 0.2 0.2

Temperature rise 0 c 2.0 5.0 10.0 2.0 3.0 2.0

AUX. LUB OIL PUMP (i) (ii) (iii) (iv) Type Lube oil flow Pressure Motor Gear pump Approx. 120 litres/min. 2.5 bar, 5.5 kw, 415v, 50 HZ, 1500 rpm IP 55

Booster pump stuffing box cooler (ii) Motor cooler (iii) Working oil cooler (iv) Lub oil cooler (v) Mech. seal cooler (vi) BFP stuffing box cooler

(i)

2.5.2 HIGH PRESSURE HEATERS

HP Heater No. 5 6 .............. BHEL Hyderabad ............. .............. U Tube Horizantal .............

(i) (ii)

Manufacturer Type and arrangement

54

55

(iii) No. of shell passes (iv) No. of tube passes (v) Tubes Type of tubes provided Total no. of U tubes Effective length U tubes, mm Outer diameter, mm Design pressure, kgf/cm2 (g) Design temperature, 0c Desuper heating zone Other zones Design pressure, kgf/cm2 (g) Design temperature, 0c Desuper heating zone Other zones Tube side relief set pressure, kg/cm2 (g) (vi) Shell Outler diameter / wall thickness, mm Length of despuer heating, mm Length of drain cooling, mm Design pressure, kg/cm2 (g) Design temperature skirt/shell,0c Shell side relief valve, set pr., kgf/cm2(g) (vii) Velcity through tubes at 670 t / hr flow, kg /cm2 (viii) Tube side pressure drop at 670 t / hr flow, m/sec (ix) Total heat transferrel, kcal/hr (x) Drain level in heaters, mm (From C.L. of heater) a. Normal b. Maximum C. Minimum (xi) Surface area, m2 Desuperheating / condensing / drain cooling zone Total effective area, m2

3 Zones 2

3 Zones 2

2.6 PREDICTED PERFORMANCE STEM PRESSURE (BAR)

Rated Long time Description value operation bar Initial steam Before 1st HP drum stage HP cylinder exhaust IP cylinder stop valve inlet Extraction 6 Extraction 5 Extraction 4 Extraction 3 Extraction 2 Extraction 1 147.1 132.6 39.23 34.13 39.23 16.75 7.06 2.37 0.858 0.216 0.118 bar 147.1 137.9 45.11 39.59 45.11 19.84 8.46 2.91 1.09 0.374 0.3 Short time operation bar 176.5 145.9 47.08 40.08 47.08 19.84 8.46 2.91 1.09 0.374 0.3

Seamless 757 17270 15.875 280 235 215 280 235 215 280

Seamless 757 20075 15.875 280 285 265 280 285 265 280

1240/20 1980 3048 19.0 and full vacuum 440/215 19.0

1264/32 2515 2515 50 and full vacuum 370/265 50.0

HP cylinder exhaust

STEAM TEMPERATURE (0c)

Rated value Annual mean value Long time value but keeping within annual mean value 400 hr per annum 80 hr. per annum max. 15 minutes in individual case 563 563

2.22

2.29

Description

0.9 23.73

1.1 32.31 initial steam IP cylinder stop valve inlet 535 535 543 543 549 549

410 100 495

410 100 495

75/ 446 / 115 636

95/ 562 / 95 752

56

57

Description

Rated Long time 80 hr pr. In special value operation annum max. case at 0 0 c c 15 min. in no load individual case 343 343 433 316 200 107 62 49 359 359 438 326 211 127 82 70 425 425 473 366 255 167 127 70 500* 500* 100

LPH1 to drain cooler Drain cooler to LPFB HPH6 to HPH5 HPHS to deaerator

60.3 52.8 206.0 170.0

63.437 63.437 61.091 95.807

**FLEED WATER Pressure kg/cm2(g) 6.405 205.0 204.09 203.18 Temp. 0 c 160.7 164.1 200.0 247.0 Flow 1/hr 639.27 639.27 639.27 639.27

HP cylinder exhaust Extration 6 Extration 5 Extration 4 Extration 3 Extration 2 Extration 1 LP cylinder exhaust

Description BFP suction BFP discharge HPH5 outlet PHP6 outlet

**CONDENSATE WATER Description Pressure kg/cm2 Temp. 0 c 46.1 46.3 46.6 47.8 56.6 90.6 120.7 Flow 1/hr 508.83 508.83 508.83 508.83 508.83 508.83 508.83

Long time operation Short time operation Rated value

CEP suction 0.1033 CEP discharge 19.379 GSE oulet 10.54 Drain cooler oulet 10.08 LPH 1 oulet 9.63 LPH 2 oulet 9.18 LPH3 oulet 8.72

Upper limit value permissible without time limit. Permissible momentary value the aggregate duration of such must not exceeds 12 hr/annum These value corresponds to 210 mw load with 3% make up and 0.1187 bar back pressure with all heaters in service and rated steam conditions.

* Only valid for no load period with high reheat pressure after trip out from full load for the individual cases approx. 15 minutes. ** Parameters are given when unit 210 mw, 0% make up water, 76 mm back pressure and constant pressure operation.

**HEATER DRAIN Description Temp. 0 c 99.9 123.5 93.4 Flow t/hr 0.299 27.589 57.651

2.7 EQUIPMENT COOLING WATER PUMPS

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

GSC drain to LP Flash box LPH3 to LP2 LPH2 o LPH1

58

59

(vii)

Motor Manufacturer Frame Type Motor rating Power supply RPM Insulation class Full load currentq Beaing DE NDE

Crompton Greaves HMHAC-400/6 3AC induction motor 215 kw (288 hp) 6600v, 3, 50 HZ 1482 rpm F 23.5 A NU 321 - 1 6321

Cut out at Back up protection cut in/cut out Relief valve setting

160 ksc 110 ksc/170 ksc 190 ksc

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

2.8 HP / LP BYPASS SYSTEM

Capacity 60 % MCR 420 t/hr of main steam flow at the inlet of HP bypass valve

HP Bypass (i) Valves Design pressure Design temperature Body material Nozzle material Medium Actuator Type Hydraulic system pressure positioning time Oil supply unit Oil pump type Supply capacity Motor rating Oil tank volume/useable voulme Oil pump cut in at BP1/ BP2 Valves 170/50 ata 540/4850c 10Cr Mo 10 10 Cr Mo 910 Main steam BPE 1,2 Valves 280 ata 1750c 15 Mo3 15 Mo3 spray water

H.P. FLASH TANK Vertical cylindrical, leg supported, 2. Desing code ASME Sec VIII Div. I 3. Design pressure Full vacuum & 3.5 4. Design temperature 2100c 5. Fluid handled Water/steam 6. Shell material ASTM A 285 Gr.c/ IS : 2002 Gr 2 7. Internal diameter 220 mm 8. Shell thickness 12 mm 8. Shell thickness 12 mm 9. Overall height 3300 mm 10. Corrosion allowance 3.2 mm 11. Thining allowance 1.5 mm (max.) 1. Type

L.P. FLASH TANK Vertical cylindrical leg supported. ASME SEc VIII Div I Full vacuum & 3.5 2100c Water/steam ASTM A 285 Gr.c/ IS : 2002 Gr. 2 1600 mm 1600 mm 12 mm 2400 mm. 3.2 mm 1.5 mm (max.)

(ii)

Hydraulic 100 bar 10/3 sec (3 sec for fast opening device) 1 OV-32 24 l/min. 7.5 kw, 415v, 3, 50 14.2 A 70l/50l 100 ksc

2. 10 LP DOZING SYSTEM (HYDRAZINE & AMMONIA)

LP Dozing (Hydrazine) LP. Dozing (Ammonia) Mixing tank Dimension Capacity Material Stirrer motor Metering tank Dimension

(iii)

HZ,

1440 rpm,

750 mm dia. x 100mm H.O.S. 340 litres (Net) Stainless steel as per SS - 304 0.37 kw, 1395 rpm. 750 mm dia x 1000

1400 mm dia.x 1000 mm H.O.S. 1200 litres (Net) Stainless steel as per SS - 304 0.75 kw, 1395 rpm 1400 mm dia x 1000

2.

60

61

Capacity Material 3. Dozing pumps Type

mm H.O.S. 340 litres (Net) Stainless steel as per SS - 304 2 x 100% positive dispacement Max. 13 13 liters/hr 30 bar 0.25 kq

mm H.O.S. 1200 liters (Net) Stainless steel as per SS - 304 2 x 100% positive displacement 61 liters/hr 30 bar 0.55 kw 2 x 3 m3 2 x 100% for 4 units

4.

Capacity Discharge pressure Motor rating Transfer system Tank no. and capacity Transfer pump -

6.3 BFP motor oil cooler 6.4 BFP lub oil cooler (Duplex viz 1+1 per BFP) 6.5 BFP seal water cooler 6.6 BFP stuffing box cooler 7.0 Vacuum pump 8.0 Water jel ejector 9.0 V.E. oil separate (seal oil system)

2.1

48

5.0

5.0 Flow through standby

2+4 2+1 2+1 1+1 1+1 2+1

114 18 14.4 182 10 5

5.0 2.0 2.0 2.5 4

2.0 3.0 2.0 2.0 2.0 2.0

also considered

ACW pressures 2.11 COOLING WATER FLOW

S.No. EQUIPMENT DESCRIPTION EQUIPMENT/ UNIT WORKING+ STANDBY 1+1 4+0 1+1 1+1 1+1 TOTAL PRESSURE TEMP QTY./ DROP RISE REMARKS 0 UNIT mwc C m3/hr 360 350 72 200 1.2 8.8 8.2 1.8 2.5 3 2.53 5.2 0.6 3.1 3 Flow through stand by CEP also considered Hydrogen cooler Oil separator Seal oil cooler Water jet ejector Stator water cooler < 4 ksc CEP < 3.5 ksc < 2 ksc < 4.5 ksc < 2 ksc < 3 ksc

1. 2. 3. 4. 5. 6. 6.1

Turbine lub oil coolers Hydrogen cooler Seal oil cooler Startor water cooler CEP brg cooling BFP AUX Booster pump stuffing box cooler

2+1

10.8

4.0

2.0 Flow through standby CEP also considered

6.2

BFP working oil cooler (Duplex viz 1+1per BFP

2+4

98

5.0

0.0

62

63

SECCTION - 3

GENERATOR AUXILIARIES
&

3.1 GENERATOR TECHNICAL SPECIFICATION

(i) (ii)

Make Type

(iii) (iv) (v) (vi) (vii) (viii) (ix) (x) (xi) (xii) (xiii) (xiv) (xv) (xvi) (xvii)

Code Cooling Stator winding Stator core and Rotor MW rating MVA rating Rated terminal voltage Rated terminal voltage Rated power factor Ratd speed/frequency Negative sequence current capability (l2 t) Efficiency at MC Condition Short circuit ratio Phase connection No. of terminals brought out Generator stator winding resistance in each phast Generator rotor winding resistance

BHEL THW - 201-2 Two pole, cylindrical, steam turbine driven IS : 5422 Directly water cooled Directly hydrogen cooled 210 247 16.5 kv 8,645 A 0.85 log 300 rpm/50 HZ 8 98.55% 0.49 Double star 9 (6 neutral, 3 phase) 0.00155 ohm at 200c 0.0896 ohm at 200c

Ceiling. voltage Ceiling current Frequency range of operation No. of parallel bridges including redundant bridge No. of redundant bridge Protection class Station battery supply Duration of field forcing Response time

620 v DC 4500 amp 47.5 - 52 HZ

4 1 IP 20 220c DC 10 sec 40 m Sec

EXCITATION TRANSFORMER DETAIL

Make Rating Voltage rating Vector group Insulation level Cooling

MAY and CHRISTE 2500 kva 16500/575 v AC Dyn 5 50KV/RMS/MIN AN-with two blower provided extra.

3.2 DESIGN & CONSTRUCTIONAL FEATURES

MATERIAL

STATIC EXCITATION EQUIPMENT

(i) Make SEE Rating Accuracy of excitation control Range of voltage control in auto Range of voltage control in manual No load field voltage No load field current Max. continuous rated field voltage Max. continuous rated field current BHEL Voltage - 310 v DC Current - 2600 amp DC + 0.5 % 90.110 % 80.110 % 102 V DC 917 amp 355 V DC 3000 amp Rotor shaft Steel forging 35 Ni 3 Cr 12 Mo 35V 12 chromium nickle molybdenum and vanadium steel Silver bearing copper Duralumin. 60 Mn Ni85 Cr W75, Non magentic steel ST-42w Cold rolled silicon steel CSW C25 Is:2856-64 ST-42w Grade 84

(ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) (x)

Rotor winding Rotor slot wedges Rotor retaining ring Stator frame Stator core stampings Bearing body Shaft sealing Bearing and seal babbit Carbon brushes

64

65

a. Grade b. No. of brushes required

HM 6R 112+1

3.3 GENERATOR GAS SYSTEM 3.3.1 HYDROGEN IN STATOR CASING

WEIGHT & OVERALL DIMENSIONS

(i) Weight of the heaviest lift (stator with gas cooler & lifting trunions) Weight of the rotor Weight of the gas cooler Weight of the end terminal Weight of the end shield Total weight of the generator Overall dia. of stator Length of stator (overall) Length of rotor (overall) Diameter of rotor barrel

(i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (ix)

(ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) (x)

175,000kg 42,200 kg 1415 kg 85 kg 200 kg 239000 kg 3960 65822 mm 9770 mm 1075 mm

Nominal pressure of Hydrogen permissible variation Maximum temperature of cold gas Maximum permissible hot gas temperature Minimum required purity of hydrogen Maximum oxyen content Relative humidity of hydrogen casing pressre (maximum) Maximum moisture content in Generator casing Total gas volume of the Generater Maximum make up hydrogen per day

3.5 kg/cm2 (g) +0.2 kg/cm2 (g) 440c 650c 9.7% 1.2% 30% 15 gm/m3 of H2 56 m3 15 m3

3.3.2 GENERATOR FILLING QUANTITIES TORQUES, CRITICAL SPEEDS ETC

(i) (ii) (iii) (iv) (v) Torque under normal working conditions Rotio of short circuit torque to full load torque Flywheel moment of the rotor 1st critical speed of the rotor (calculated) 2nd critical speed of the rotor (calculated) 76.32 tonnes 8 21.1 m2 1370 rpm 3400 rpm (i) (ii) (iii) (iv) (v) (vi) Amount of carbon-di-oxide required to remove air expressed at NTP Carbon-di-oxide for expelling hydrogen Hydrogen filling qunatity Compressed air required for purging of carbon-di-oxide from the generator Quantity of compressed air required (at NTP) for carying out air tightness test Max. no. of H2/Co2 cylinder can e conected at a time M/c at stand still 90 m3 120 m3 300 m3 150 m3 500 m3 8/8 M/c underrolling 112 m3 168 m3 336 m3

OIL CONSUMPTION
(i) (ii) (iii) Consumption of the oil per generater bearing (excluding shaft seal) Oil pressure at the inlet of bearing Consumption of oil in both shaft seals

3.3.3. HYDROGEN COOLER

300 lit/ minute 0.3 to 0.5 kg/cm2 77 lt/min

At Rated Hydrogen Pressure 3.5 kg/cm2 (g)

66

67

(i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) (x)

No. of coolers/ Generator Gas flow per cooler Max. water inlet temperature Pressure drop through cooler Design pressure water side of cooler Max. permissible operating pressure water side of cooler No. of passes of water in gas cooler Material of tubes/fins Material of water boxer/Tube sheats Heat load

4 7.5 m3/ sec 370c 17.5 mwc 6 kg/cm2 (g) 3.0 kg/cm2 (g) 2 Admiraly brass/copper Carben steel 528 kw

(iii) (iv) (v)

Speed Head Motor Make Rating kw/hp Power supply Full load current Class of insulation RPM Ambient temp.

2930 rpm 45 mlc GEC 9.3 kw/12.5 hp 415v, 3q, 50HZ 18 A B 2930 500c

3.3.2 HYDROGEN DRIER

(i) (ii) (iii) Working pressure and volume Heater rating Blower 5bar, 39 dm3, silica gel filled 2.5kw, 415v,3,50 HZ supply Siemens make, 1.1 kw, 2855 rpm, 2.3A (i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) (x) (xi) (xii)

STATOR WATER COOLER

No. of coolers per system & type Permissible max. operating primary/ cooling water pressure Primary water inlet/outlet temperature Max cooling water inlet temperature Pressure drop in primary water/ cooling water Max cooling water inlet temperature Heat load Shell/tube material Tube sheets/water boxes material Heat transfer area Cooling water flow rate Cooling water pressure drop Two, shell & tube type 8.0 kg/cm2/5.0 kg/cm2 72.6/450c 27 m3/hr/110 m3/hr 6.5 mwc/0.8 mwc 360c 790 kw Stainless steel/Admiarly brass Brass/carbon steel 33 m2 200 m3 /hr 2.5 mwc

3.4 STATOR WATER SYSTEM

(i) (ii) (iii) Nominal gauge pressure at inlet to winding 3.3kg/cm2 (g) Flow of distillate through stator winding 27+3m3/hr Nominal temperature of distillate at Inlet to winding 45 + 30c -10 Stator winding distillate filling quantity 0.35 m3 Nominal conductivity of distillate <5 mho/cm Maximum conductivity of distillate 13.3 mho/cm

(iv) (v) (vi)

STATOR WATER FILTER STATOR WATER PUMP

(i) No & type 2x100% single stage centrifugal with spiral casing & over hung impeller CPX-CM-50-200, KSB make 39.6 m3/hr No. Make Type Working pressure Working temperature Voulme 2 Ball and kirch fiher bar Gmbtt 1.53.1.220 500 DN 100 10kg/cm2 600c 27 dm3

(ii)

Flow

68

69

EXPANSION TANK

3.5.1 SEAL OIL PUMPS

Type Material Vacuum Weight Volume (capacity)

Hermetically sealed container, TGSC-E Stainless steel 250 -300 mm of Hg 902 Kg. 2 m3

(i) (ii) (iii) (iv) (v)

Type Pump discharge flow Pump head Pump speed RPM Motor type Make RPM Kw Power supply Amp

QUALITY OF DISTILLATE

Conductivity pH Dissolved O2 Dissolved CO2 Ammonia Chloride Dissolved/undissolved Cu Dissolved /undissolved Fe Dissolved solids

less than 5 mho/cm preferobly 1 mho/cm 6.5 to 8.5 Minimum, preferably less than 50 ppb but not greater than 100 ppb Nil Minimum, preferably zero Minimum - preferably zero less than 20 ppb less than 20 ppm The water should be free of any chemicals from treatment process such as hydrazine, morphoine, levoxine phosphate etc.

TUSHCO pump 3-52-46 IBSCS1x2 130 l/m 12 kg/cm2 1000 Ac motor Crompton Greave 945 4.85 kw 415 v, 3, 50 HZ 10.6 A

TUSHCO pump 3.52-46-18SCSx2 125 l/m 12 kg/cm2 1000 DC motor Kirloskar 960 5.6 kw 220v DC+10%20% 42 A

SEAL OIL COOLER

Make Surface area Tube side/shell side design perssure Tube side/shell side test pressure Type BHEL, Haridwar 14.3 m3 10.5 kg/cm2 16.0 kg/cm2 Surface type

3.5 SEAL OIL SYSTEM

(i) (ii) (iii) (iv) (v) Type of shaft seals Hydrogen pressure of Generator casing Seal oil - H2 diff pressure Quantity of seal oil per seal Qty of seal oil towards Air side Hydrogen side oil system press Single flow ring type 3.5 + 0.2 kg/cm2 min. 1.0, normal 1.5 max 1.7 kg/ cm2 38.5 l /min 2/3 rd 1/3 rd 7.5 Kg/cm2 Make Type Flow Ultimat pressure Motor

VACCUM PUMP

LEYBOLD W. Germony S4-B 4m3/hr <250 m bar AM71 NY 71 NY4, 3, 415v, 1.2.A, 50 0.18 kw, 1400 rpm IP 54

HZ

70

71

FILTER
Make Pressure Type F Boll & Kirch Filter ba GmbH 16 bar, 500c 170/32 200

3.6.2 UNIT AUXILIARY TRANSFORMER

OIL TANKS

(i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) (x)

Manufacturer Type No. of transformers Rating Voltage ratio winding connection HV/LV Vector group Type of cooling Rating available at different cooling Temperature rise above ambient of 500c In oil In winding Tap changer type and range

Intermediate tank Seal oil storage tank Seal oil tank

75 Lt 500 Lt 1000 Lt

NGEF Ltd., Banglore OFTR 16000/22 2 per unit 16 mva 16.5/6.9 kv Delta/star Dyn 1 onan/onaf WITH 2X50% separately mounted radiators 125/16 mva (78%/100%) 500c 550c On load, + 10% to - 5% In steps of 1.25 % on HV winding No. of steps 12 7% (+ 10%) HV-oil filled LV-oil filled LV neutral - oil filled

3.6 SPECIFICATIONS OF TRANSFORMERS 3.6.1 GENERATOR TRANSFORMER

(xi)

(i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) (x) (xi)

(xii) (xiii)

Manufacturer No. Rating No load voltage, HV No load voltage, LV Rated current, HV Rated current, LV Frequency Vector group Off load tap changer range Impedance voltage at Max tap Normal tap Minimum tap Type of cooling Temperature rise above on ambient of 500c - In oil In winding

BHEL, Bhopal One per unit 270 mva 235 kv 16.5 kv 664.12 A 9458.15 A 50 HZ Ynd 11 -5% to + 5% in steps of 2.5% 13.82% 13.81% 13.91% OFAF 500c 550c

(xii) (xiii)

Percentage impedance Bushings

3.6.3 STATION TRANSFORMER

(i) (ii) (iii) (iv) (v) (vi) (vii) Manufacturer No. Maximum rating HV/LV1/LV2 Winding connection HV/LV1/LV2 Voltage ratio Vector group Tap changer type and range NGEF Ltd. Banglore 2 55/27.5/27.5 mva Star/star/star 220/6.9/ 6.9 kv Yn YnOY n0 On load tap changer, +10% to - 10% in steps of 1.25% on HV Winding, total 16 steps. ONAN/ONAF/OFAF

(viii)

Type of cooling

72

73

(ix) (x)

Rating at different cooling Temperature rise over an ambient of 500c-In oil In winding Bushing Type Min creepage dist. (mm) Neutral bushing CT detail No. of cores Service Ratio Acuracy class Rated burden VA Guaranteed positive sequence impedonce at 750c with 100% rating at principal tap

60% ONAN

80% ONAF

100% OFAF

(vii)

Cooling Type Rating available

steps of 1.25% ONAN ONAF OFAF 40% 60% 100%

(xi)

500c 550c HV LV HV netural condenser oil filled condenser 5635 385 1170 LV1-one, LV2-one Protection 100/1 5P 20 15 HV-LV1 23% HV-LV2 23% LV1-LV2 41%

LV neutral oil filled 385 (i) (ii) (iii) (iv) (v) (vi) (vii) (viii)

3.6.5 MISCELLANEOUS SERVICE TRANSFORMER

(xii)

(xiv)

Make Rating Voltage ratio Vector group Winding connection HV/LV type of cooling Tap changer type and range Percentage impedence

Voltas Ltd. Pune 10 mva 11.5/6.6 kv Ynd 11 Star / delta ONAN Gang operated off ckt. 5% in steps of 2.5% each 8% + 10%

3.6.4 INTER CONNECTING TRANSFORMER

(i) (ii) (iii) Make Rating No. Crompton Greaves Ltd. 167 x 3 = 500 mva 2 3 single phase transformer in each set with one spare for both. 400 200 ___ ___ 3 3 33 kv ____

(ix)

Temperature rise over an ambient In oil 500c of 500c In winding 550c

(iv) (v)

Voltage Ratio Current

(vi)

% age of impedance

HV-723.1 Amp IV-1314.8 Amp LV-Reactive- 1681.8 Amp Active-151-.5 Amp HV/IV 9.55% HV/LV 6.1% On load type having 17 steps from + 10% to - 10% in the

(vii)

Tap changer

74

75

3.6.6. LT TRANSFORMERS S.No. XFMR DESCRIPTION Nos. Capacity Voltage Ratio (KV) Vector Group %age Impedence Cooling Type

76
(i) (ii) (iii) (iv) (v) (vi) (vii) Manufcaturer No of battery bank in eah unit No of cells Cell designation Normal voltage of each ell Capacity Specilic gravity

01. 02. 03. 04. 05. 06. 07. 08. 09. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Unit service xfmr (UST) ESP Service xfmr Station Service xfmr (SST) Swyd. Service xfmr DM pant service xfmr Saltening plant Service xfmr F.O.P.H. Service xfmr Ash handling xfmr Air Compressor xfmr Workshop Service xfmr CHP Service xfmr Track happer service xfmr Stockyard service xfmr Bunker Service xfmr Lighting Distribution xfmr Admn. Bldg. Service xfm Wagon trippler service xfmr Stacker reclaimer Service xfmr VFD Transformer (ch-1) VFD Transformer (ch-2)

8 8 8 2 2 2 2 4 4 2 2 2 2 2 8 2 2 2 4 4

1250 kva 1600 kva 1250 kva 630 kva 1600 kva 1600 kva 1600 kva 1600 kva 1600 kva 1600 kva 1250 kva 1000 kva 630 kva 1000 kva 100 kva 630 kva 630 kva 400 kva 900 kva 900 kva

6.6/0.433 6.6/0.433 6.6/0.433 6.6/0.433 6.6/0.433 6.6/0.433 6.6/0.433 6.6/0.433 6.6/0.433 6.6/0.433 6.6/0.433 6.6/0.433 6.6/0.433 6.6/0.433 .415/0.415 6.6/0.433 6.6/0.415 6.6/0.415 6.6 / 1.25 6.6 / 1.25

Dyn l Dyn 1 Dyn 1 dyn 1 dyn 1 dyn 1 dyn 1 dyn 1 dyn 1 dyn 1 dyn 1 dyn 1 dyn 1 dyn 1 dyn 1 dyn 1 dyn 1 dyn 1

6% (+10%) 8% (+10%) 6% (+10%) 5% (+10%) 8% (+10%) 8% (+10%) 8% (+10%) 8% (+10%) 8% (+10%) 8% (+10%) 5.408% 5.25% 4.71% 3% (+10%) 5% (+10%) 11.34 10.5

ONAN ONAN ONAN ONAN ONAN ONAN ONAN ONAN ONAN ONAN ONAN ONAN ONAN ONAN ONAN ONAN ONAN ONAN ONAN ONAN

S.No. (i) Equipment ID fan

(ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) (x) (xi) (xii) (xiii) (xiv) (xv) (xvi) (xviii) (xviii) (xix)

FD fan PA fan GR fan Coal mill CEP BFP ECW pump CW pump fire hydrant/sprinkler pump Crusher motor Conveyor 1 A/B Conveyor 2 A/B Conveyor 3 A/B Conveyor 4 A/B Conveyor 5 A/B Conveyor 7 A/B Transport air compressor (AHP) HP water pump (AHP)

3.7 H.T. MOTOR

3.8 BATTERY AND BATTERY CHARGER

3.8.1 220 V D.C BATTERY

77

Quantity 4 4 8 6 6 24 8 12 8 8 4 4 2 2 2 2 2 2 8 6

Exide 2 109 As per IS 1651 T 8004 2.0 volts 800 AH-10 hour 1200 at 270c

Rating 1400 kw unit 1 & 2 1325 kw unit 3 & 4 1000 kw 1050 kw 700 kw 425 kw 550 kw 3500 kw 215 kw 900 kw 175 kw 590 kw 280 kw 240 kw 430 kw 200 kw 250 kw 320 kw 545 kw 320 kw

3.8.3 - 26 V D.C. BATTERY 220V FLOAT CUM BOOST BATTERY CHARGER

(i) UPTRON POWERTRONICS LTD. Sahibabad (ii) A.C. input 415v + 10%, 3, 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 Manufacturer (i) (ii) (iii) No of cells Each cells voltage AH Capacity 13 2v 175

- 26 V BATTERY CHARGER
(i) (ii) (iii) (iv) (v) (vi) Manufacturer Type A.C. input Specification Ambient temperature Ripple Chhabi Electricals pvt. Ltd. Float cum bost charger 415v + 10% HZ 4 Wire A.C. Supply CV-CC/76+24 = 100A 500c 1%

2.3.2 + 26 D.C. BATTERY

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

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 boost Voltage DC 52/43 - 65 Amp DC 105 / 40 220 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 / 196.295 Amp DC 40 / 40

+26 V.D.C. BATTERY CHARGER

(i) (ii) (iii) (iv) (v) (vi) Manufacturer Type A.C. input Specification D.C. Volts Amperes D.C Chhabi Electricals Pvt. Ltd. Float cum Boost 415v + 10%, 3, 50+5% HZ 4 wire A.C. supply CV-CC/175+56=231 A + 26v CV-30 CC-36 CV-175 CC-56 500c 1%

(b)

(vii) Ambient temperature max. (viii) Ripple

78

79

SECTION - 4

OFF SITE

4.1 RAW WATER SYSTEM AUXILIATY RESERVOIRS

Live aux. reservoir Storage aux. reservoir Make up water

Dimensions Capacity 300m x 171m 87,000 m3 x 1.7m 580 m (av)x 1,65,000 m3 168 mx 1.7 m Upper Ganga canal Dehra Head works, capacity 100 cu sec during clo sure of VGC through network of tube wells

(iii) (iv) (v) (vi) (vii) (viii)

No of pumps Type Flow Total bowl head No. of stage Motor Make KW/HP Power supply Full load curent Insulation class

3 (2 working, 1 stand by) Vertical Turbine pump 1750 m3 / hr 20.17 mwc one Crompton Greaves 125/167 415v + 10%, 3, 50 HZ 221 A B

TUBEWELL WATER REPLENISHMENT SYSTEM BOREWELL PUMP

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

RAW WATER PUMP (PTDM)

(i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (ix)

Manufacturer Pump size No. of pumps No of stages Capacity Head Speed Discharge size Motor Make Rating Power supply RPM Full load current Class of insulation

Flowmore 12 M 3(2 working, 1 stand by) Two 175 m3/hr 32.117 mwc 1430 rpm 200 Nb Crompton Greaves 30 kw/45 hp 415 +10%v, 3, 50HZ A.C 1475 52 B

RESERVOIR FOR TUBEWELL WATER REPLENISHMENT SYSTEM

Size 60 m x 15 m x 4.0 m

TUBWELL WATER REPLENISHMENT PUMP

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

RAW WATER PUMP (PT SOFTENING)

4.2 WATER TREATMENT PLANT 4.2.1 PRE - TREATMENT PLANT RAW WATER QUALITY
Upper Ganga canal 2000 max. Tube well 40 max.

(i) (ii)

Make Pump size

Flowmore 27 H

Turbidity

80

81

PH value TDS, mg/l Permagnate value Iron as Fe, mg/l P - Alkalinity as CaCO3 M - Alkalinity as CaCO3

7.5 to 8.5 210 5 ppm 1.0 Nil 106

7.41 1000 1.0 Nil 530

(v) (vi) (vii)

Rated flow to each unit Detention time Agitator

2200m3/hr 60 sec(approx.) One, 7.5 hp, rpm motor

350m3/hr 60 sec(appox.) 1500 One, 2 hp 1500 rpm motor

CLARIFLOCCULATOR TREATED WATER QUALITY

Clarified water Filtered water Not to excees 20 Not to excees 2 Traces Not traceable Not traceable Not traceable Not traceable (i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) For DM Plant One RCC 1.2msq x 4.5m 7m3 84 sec NO. of units Material of construction Flow to each ccf Overall clarifilocculator size Overall volume Size of flocculator Volume of flocculator zone Surface overflow rwe (for rated flow), m3/hr/m2 Detention time(for flow) (i) flocculator zone (ii) Clarification zone For each flocculator No of agitators Drive motor rating Clarifier Ratating bridge type No. of bridges Motor rating for bridge drive for Softening Plant 2 Rcc 2200m3/hr 49.7mx3.55mswd 6887 19.75 m3.55mswd 1087.6 m3 1.3 30 min 158 min (approx.) 4 3 hp, 750 rpm for DM Plant 1 Rcc 350 m3 / hr 20.3mq x3.5mswd 1132.8 m3 8.3m x3.5mswd 189.4 m3 1.3 30 min (approx.) 160min (approx.) 2 1 hp, 750 rpm

Turbidity NTU Organic matter Iron content Managanese content

STILLING CHAMBER
For Softening Plant One RCC 6.5m x 3.7m x 3.8m 90m3 74 sec

(i) (ii) (iii) (iv) (v)

No of units Material of construction Size Volume Detention time

(x)

(xii)

Peripherially driven Peripherially driven 1 1 2 hp, 1500 rpm 1.5hp, 1500 rpm,

FLASH MIXER
For Softening Plant 2 (One for each ccf) Rcc 3m. sq x 4.58m. swd 40m3 For DM Plant One Rcc 1.8 x 1.8 x 2 m. swd 6.5m3

(i) (ii) (iii) (iv)

No of units Material of construction Size Volume

FILTER BEDS
For Softening Plant (i) (ii) No. of units Material of construction 12 RCC For DM Plant 2 RCC

82

83

2 ( 1 working)

1.3m x 0.8 m SWD

Coagulant Aid Tank

Lime Solution Preparation Tank

50 mm x 37mm grave, 37 mm x12 mm gravel, 12 mm x6 mm gravel, 6 mm x2.5 mm grit, 0.35 mm x0.5 mm sand,

100mm 100mm 100mm 150mm 750mm

deep deep deep deep deep

MSRL

1 m3

(i) (ii)

Duration of air scouring No. of air blowers

CHEMICAL HOUSE

For Softening Plant 3 to 5 min. 2 ( 1 working + 1 stand by)

For DM Plant 3 to 5 min. 2 ( 1 working +1 stand by)

RCC

22m3

(i) TANKS

RCC

20m3

3m x 3.4 m x 2.15m

1 1

Alum Tank

RCC

22 m3

(ii) Material of construction

84

(i)

85

(iii) Size (each)

(iv) Effective volume (each)

(v) Mixing agitator No. (each) Motor

No. of tanks

1.5 hp 1500 rpm

2p 1500 rpm

(iii) (iv) (v) (vi)

Make / model Capacity Motor capacity Backwashing No. of pumps Make/model Capacity (each) Installed

SWAM RH -180 SWAM RH- 110 1540 m3/hr 1020m3 / hr 60kw, 1500 rpm 30kw, 1500 rpm By backwash pump Though overhead tank 2 (1working+1 standby) Kirloskar, BHM25, 1stage 1071 m3/ hr 60 hp, 1500 rpm

3m x 3.4 x 2.0m

Lime Slaking Tank

2 hp 1500 rpm

FILTER BACK WASH

3m x 3.4 x 2.1m

3 (1 working)

0.5 hp 1500 rpm.

(iii) (vi) (v) (vi) (vii)

Capacity (each) Size (each) Filter area (each section) Rate of filteration Filter media 1 st layer 2 nd layer 3 rd layer 4 th layer 5 th layer

300 m3 /hr 7.2 m x4.25 m 30.6 m2 5 m3/hr

200 m3 /hr 4.25m x 4.8 m 20 m2 5 m3/hr

FILTER WATER RESERVOIR

46 LPH at 0.5kg/cm2 Metering 1500 rpm For Softening For DM For Softening System 1 (with 2 compartments) RCC 30m x 12.5 x 2 m 1500 m3 For DM system 1 (with 2 compartments) RCC 12.5 m x 9.3 m x 2m 200 m3 System Pump PR-15

Dozing Pump

Cogulant Aid

294 LPH at

Metering

0.5kg/cm2

System

PR-15

0.5 hp

(i) No. of units (ii) Material of Construction (iii) Size (iv) Effective capacity

V.K.

Pump

V.K.

rpm

FILTERED WATER STORAGE TANK

1hp, 1500 rpm 0.5hp 1500 Metering 5m head (i) (ii) (iii) No. Material of construction Location One RCC Overhead filter house top

For Softening For DM

Pump

Lime Solution

Dozing Pump

PR-15 KGC-025x25

1.23m3 at 5m

Cntrfugal

0.2m3/hr

System

V.K.

System

Kisore

head

CHLORINATION SYSTEM
(i) (ii) (iii) (iv) (v) No. of chlorinator Type Model/make Capacity (each) Booster pumps No. Capacity Motor rating Model Make For PT (Soft) 3 Vacuum operated V-711 12 kg/hr 3 6m3/hr at 40 head 5.5 kw CHG025 x 200 Kishore horizontal centrifugal (all) For PT (DM) 2 Vacuum operated V-701 2 kg/hr 2 2m3/hr at 30 m head 2 hp, 2900 rpm CHG 025 x 160

V.K. Metering

(ii) PUMPS

488 LPH 22042 LPH 6 m3/hr at 5 m head

Plunger

For DM

System

Pump

PR-15

Alum Solution

Dozing Pump

For Softening

V.K. Metering

Pump

Plunger type

System

PR-35

KGC-025x160

Lime Transfer

Kishore

1 hp, 1500 rpm

Centrifugal

0.5

Pump

4.2.2 D.M. PLANT CLARIFIED WATER ANALYSIS

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

2 No. of pump provided

(iv) Capacity

(ii)

(iii) Model

Make

86

(v)

(i)

Installed hp

Stand by

Working

87

Mixed bed Degasser

Ring MB LMB

200

10800

11050

exch.

(viii) Chloride (Cl) total Anions (ix) (x) (xi) (xii) Iron Free carbondioxide Silica PH value

100

100

Weak basic Strong basic

Fe CO2 SiO2 NTU

0.2 ppm ND 10 ppm 7.6 to 8.5 3-20

1.35 2.96 2.6 2.96 2.6 8.5 opening (vii) Quantity of media, m3

CaCO3

172 ppm

108

CaCO3

10 ppm

1.35

(vii)

Chloride(Cl)

CaCO3

8 ppm

Cation Anion

(vi)

Nitrate (Co3)

CaCO3

59 ppm

200

(v)

Carbonate (Co3)

CaCO3

Nil

tower

7.8

(iv)

Bicarbonate (Hco3)

CaCO3

95 ppm

IRA 402 C IRA 120 IRA 402 Raching

Total cations

CaCO3

172 ppm

anion exch. anion exch.

1200

1230

100

100

(xiii) Turbidity

1200

M.S. FILTER AND EXCHANGER DATA

1230

100

100

12

IRA 93 RF

Weak acidic Strong acidic

carbon filter cation exch. cation exch.

EFFLUENT QUALITY
(a) Activated carbon filter oultet Free chloride & Iron Turbidity (b) (c) (d) Cation exchange outlet Sodium as CaCO3 Degasser outlet Free carbon dioxide as CO2 Anion outlet Silica as SiO2 (reactive) Total electrolyte Conductivity at 25 c
0

100

100

Not to exceed 0.5 NTU Not to exceed 2 mg/l Not to exceed 5 mg/l Not to exceed 0.2 mg/l Not to exceed 0.2 mg/l Not to exceed 10 micro mho/cm Not to exceed 0.1 mg/l - do -

1200

12

1260

IRC 84 RF

100

100

Activated

1200

1260

100

100

12

Activated

Total electrolyte Silica as Si02 (reactive) Iron as Fe Total Hardness pH value Conductivity at 250c

(iv) Regeneration interval, hours

regeneration, m3

Less than 0.1 micro mho/cm

No. of units

(ii) Max. flow rate, m3/hr

6. 8-7.3

(ii) Normal flow rate, m3/hr

- DO -

(v) Net output between two

88

89

(vii) Filling media

(i)

m3

Inert

Not to exceed 0.02 mg/l

(vi) Gross output between regeneration.

(e)

Mixed bed outlet

0.45

12

Not detectable

IR 20 RF

1200

1260

0.45

12

(ix) Bed depth, mm (x) Type of regerant

Operating Inet

1200 -

878 -

1002 150

878 -

150 -

1015 ......... HCL Rayon grade 113.3 2200

2500 NaOH

...... Hcl to IS 265 ........

...... Na OH to IS 252 ..... technical grade

(xi) Regenerant required (100%), Kg (xii) Diameter mm 3000

........ 170.9 ............... 1950 2400 EPOXY 1950 1900 1950 2400

............. 103.4 .............. 1950 2000 4.5 1850 2400

108 2000 3800

90 91

(xiii) Height on straight, mm (xiv) Lining & thickness, mm (xv) Design pressure, K/cm2

3 coats ........................................... Rubber lining 7.3 7.3 7.3 6.1

........................................................ 6.1 6.1 atmosphere

STORAGE & MEASURING TANK DATA

D.M.water Hot water storage tank tank Acid Alkali Deg. sump. Lime tank for neutra. pif. Alkali day Alkali tank prepn. tank Priming chamber

storage storage tank tank

(i)

Type

.....

Vertical cylin .....

......Horiz. cylinderical .......

.......... vertical cylindrcal ..............

..... drical with dish ends ... (ii) Number (iii) Diameter, mm (iv) HOS/LOS, mm (v) Effective capacity, m3 (vi) Strength of fluid stored (vii) Design pressure, Kg/cm2g (viii) Lining/thickness, mm 2 13000 12000 1500 N/A Epoxy Coating 1 1800 2600 8 N/A 3 3200 5900 50

with dish ends ........ 2 3200 5900 50 2 3200 5900 50 N.A. 1 1600 1300 2 10% Chlorinated rubber paint 1 1800 1300 2.5 48% 2 1800 1300 2.5 48% 3 1100 1200 0.7 N.A.

30-33% 48%

Atmospheric6.1

.................................................. Atmospheric

........................................... ......... Rubber 4.5 .............

...... Rubber 4.5 ..................................

ROTARY EQUIPMENT DATA

Filter water Deg. water Alkali circu. Alkali Waste Acid D.M. Deg. Mixed bed blower

unloading rec. transfer unloading regenerationg Blower pump pump pump pump

pumps pumps trans.pump pump

(i)

Manufacturer

Fair Bank Morse

..................... Kishore ..............

March (Pulsa feeder)

Kishore

ACCO

Kay

92 93

(ii) Model & type

11 M

KGC

KHL

KHL

KHL 125x2315g

TE - 8C MD

KGC 50x315 ............ 2 1 20 35

AW - 30

5 MK

100x400 50x200g 50x200g .... (iii) Nos. furnished Operating (iv) Rated capcity, m /hr
3

................... Horizantal Centrifugal ............................................ 3 2 120 55 3 2 110 50 2 1 10 10 2 1 20 10 3 2 150 15 2 1 20 10

Rotary twin lobe 3 2 4500 0.11 2 1 360 5

(v) TDH at rated cap.mwc

Centrifugal pumps
Filter water Deg. water Alkali circu. Alkali Waste Acid D.M.

Blowers

Deg.

Mixed bed blower

unloading rec. transfer unloading regenerationg Blower pump pump pump pump

pumps pumps trans.pump pump

(vii) Drive motor rating at 500c kw (viii) Casing 30 30 3.7 3.7 15 3.7 7.5 3.7 11

Material of construction 2% NCI ASTM A743 GrCF 8M ......... CIRL ............... PPN CF-8M MS IS-226 C.I.

Impeller

Gun metal

ASTMA743 MSRL MSRL GR. C8M EN-8

CIRL

PPN

CF-8M

MS

EN-9

Shaft

SS-410 SS-316 EN-8

EN-8

Alum. ceramic

EN-8

EN-8

EN-9

(ix) Gand sealing arragnement

packed Mech. seal

NA

Mech. seal

NA

NA

NA

NA

METERING PUMP DATA

Alkali Metering Pump Acid Metering Pump

(i) (ii) (iii)

Manufacturer Model Type

.... M/s Pulsa Feeder, USA ............................. 7440 - S -E 7660 - S - E

.... Double diaphragm type (with hydratube) .............. with mannual control

94 95

(iv) (v) (vi) (vii)

No.s furnished Capacity adjustable range Rated capacity, m3/hr Discharge pressure, kg/cm g
2

2 0-100% 1.0 4.0 30-48% NaOH 2.2 1450

2 0-100% 2.2 4.0 30-33% HCL 2.2 1450

(viii) Fluid handled (ix) Motor rating, kw speed, rpm

RELEVANT DATA FOR REGENERATION

(i) a. b. c. d. e. f. g. h.

Chemicals per regen. 100% HCI kg 30% HCI kg 30% HCI ltr. (approx.) 100%NaOH, Kg 48% Na OH, ltrs, 48% NaOh, ltrs, (approx.) Dilution water flow rate, m3/hr Acid injection flow rate m3/hr (30% HCL)

Cation group 170.9 569.7 495.4 10.26 1.74

Anion group 103.4 215.4 143.6 6.9 -

MB cation 113.4 377.7 328.4 4.71 0.79

MB cation 108 225 150 5.14 -

BOILER FILL PUMP

(i) (ii) (iii) (iv) (v) (vi) (vii) (viii)

(ix) (x)

No and type Manufacturer Design capacity Total head Speed NPSH required KW absorbed Motor Manufacturer Type Rating Voltage & frequency Speed Insulation class Current rating Coupling Bearing

2, 100/150 IPB-3CHRS TYPE-70 Mather - platt 150 m3/hr 120 m 1485 rpm 3.6 m 66.28 kw General Electric co. of India Ltd. 3 induction motor 82 kw 415 v, 50 HZ 1485 rpm B 150 A. 3B pin and bush type coupling Bush bearing

(x) (xi)

Type Rating Voltage & frequency Speed Insulation class Current rating Coupling Bearing

3 , induction motor 27 kw (36hp) 415v, 50 HZ 1470 rpm B 49 A 28 pin and bush typ coupling Bush bearing

4.2.3 WATER SOFTENING PLANT BASE EXCHANGE SOFTENERS

1. Mechanical Data No. of streams Vessels per stream Diameter Height on straight Bed depth Vessel type Chemical Design Data Resin type Qty. per vessel Rate of flow-agerage max. Running time between two regenerations, max. Gross output 3.

2.

7 3 No. 3600 mm 1900 mm 1050 mm Vertical shell type with dished ends, lined inside the rubber of 4.5 mm thickness (min.) MSRL material Tulsion T-42 (Na) 10700 litres 250 m3/hr/exchanger 750 m3/hr/stream 275 m3/hr/exchanger

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

20 hours 500 m3 / exchanger 15000 m3 / stream Filtered Water Pumps - Mechanical Data Nos. offered 7 Nos.

96

97

Driver motor
KW raing Motor rpm Power supply Class of insulation Regeneration system Regenerate qty. per vessel 75 kw 1440 415 v, 3q 50 HZ B 100% NaCl 1125+480 kg (fresh + spent)

(x) (xi) (xii) (xiii) (xiv) (xv) (xvi)

Attrition loss per year Resin life (estimated) Total exchange capacity Effective PH range Type of regeneration Moisture content Supplier of resin

3% 5-7 years 2.00 meg/ml min. 0 to 14 Co-current regeneration 45% + 5% Thermax Ltd. pune

4.

Regeneration Flows
Flow m3/hr 90 30 30 30 30 160 Duration min 15 10 20 10 10 20 Qty. m3 22 4.5 11 5.0 5.0 54 Type of water Filtered Spent Filtered Filtered Filtered

SALT HANDLING & DOZING FACILITIES SALT STORAGE LAGOON

(i) (ii) (iii) (iv) (v) (vi)

Backwash Spent brine inj. Fresh brine inj. Brine rinse (slow ringe) Brine recovery Final rise

Nos. offered Type Size Capacity

Material of construction

2 nos. Divided in 2 compatments Cirular 30 m3 dia x 3m deep 1000 m3 (salt solution)+ 2000 m3 salt crystals, both dissolved & undissolved. RCC epxoy painted

BRINE FILTERS

DATA SHEET FOR RESINS

(i) Type of resign (ii) General description acid Tulsion T-42 (Na+) Polytyrene base nuclear Sulphonic type strong acid cation echange resin Sodium (Na+) Sodium (Na+) 930-860 gm/ltr 120 to 30 mesh ISS (0.3 to 1.2 mm) 0.45-0.55 Less than 1.7 Less than 1.7 1400c

Nos. offered Type Capactiy Material of construction Filter media

2 Conventional gravity filter To filter @ 150 m3/hr RCC epoxy painted Sand/anthracite

SALT SATURATOR
Salt Saturated Stranger Tanks Quantity Size Capacity Material of construction Salt Transfer PUmp (PST) No

(iii) (iv) (v)

Form Apprent desity (BD) Grading (wet/dry) (sieve size) (vi) Effetive size (vii) Eunformity Coefficient (viii) Fines(-30 mesh ISS) (ix) Thermal stability

1 (2 compartemnts) 10 m x 20 m x 1.5 m 150 m3 each compartment RCC 3

98

99

Capacity Head Type Drive mtor

150 m3/ hr 30 mwc Vertical centrifugal type 37.5 kw. 1450 rpm : 415v, 3, 50 power supply. TEFC, IP-54 B class insulation

SPENT BRINE INJECTION PUMPS

Quantity Capactiy Head Type Motor kw Motor rpm 3 no. 90 m3/ hr 27 mwc Centrigufal, horizontal 30 1440

HZ

FRESH BRINE MEASURING TANK (MFBR) FILTER BACKWASH WATER STORAGE TANK
Quantity Size Material of construciont Capacity 3nos. 5 m x 18.3 m x 23 m (mld) RCC apoxy pointed 15.500 usable (Brine saturated solution) Nos. offered Size Material of construction 1 10 m x 10m 2.5 m (mld) RCC

SODIUM SULPHITE DOZING SYSTEM SODIUM SULPHITE TANK FRESH BRINE INJECTION PUMPS
Quantity Capacity Material of construction Head Type Motor Motor kw Motor rpm Power supply Type & protection Class of insulation 3 nos. 45 m3 /hr CI rubber lined 30 mwc Horizontal, centrifugal 18.5 1450 415v, 3, 50 HZ TEFC, IP-54 B No. Size Type Material of construction Empty weight Working weight 3 1200 mm dia x 1600 mm high Vertical cylindrical atmospheric, dished bottom MSRL (4.5 mm thick rubber lining) 1000 kgs. 4000 kgs.

SODIUM SULPHITE DOZING PUMP

No. Type Head Material of construction 3 50 litre/hour 30 mwc SS 316

SPENT BRINE TANKS (SBRT)

Quantity Size Material of construction Capacity 3 no. 5 x 1.83 x 2.3 mld RCC epoxy pointed 15.500

100

101

4.3 CIRCULATING WATER SYSTEM 4.3.1 CIRCULATING WATER PUMP

1. 2. 3. 4.

Manufacturer No. of pumps Designation Type

5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. (i) (ii) (iii)

Liquid to be pumped Type of lubrication Impeller dia at inlet/ outlet/eye area, Column asembly Oulet size Pump & alive shaft bearing coupling (between pump & motor) Type of thrust brg Operating floor level Min. forebay water level Max. forebay water level Centre line of discharge duct Duty condition Capacity Total head at pump discharge. Total head loss from bell to discharge flange Rated speed Pump efficiency at design capactiy Pump inut at design capacity Power loss in transmission in brgs Bowl head at rated speed & closed discharge

Jyoti limited, Borada 8 110VM Vertical francis, mixed flow, single stage, wet pit, bowl pull out Soft water Self water lubrication. 828 mm/ 1070 mm/5385 cm2 1475 m x 200 m x 95 mm. 1200 mm. Cutless rubber with flashing grooves Flanged type (rigid) Type of thrust brg Tilting pad, one at motor tap. 2105 m. 208.5 m 209.5 m 212.0

12,500cu. m/hr 20.5 mwc

Max. & Min. capacities upto which pump can be operated satisfactory cu m / hr a. at max volume Min Max. 6250 14,600 b. 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, 3, 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 put By wdg resistance method 700c ETD method 700c 19. Disch valve Type Butterfly tight, shut off type, 1600 mm Nb Valve closure time 45-60 seconds

(ix)

4.3.2 COOLING TOWER

0.13 mwc 1. 2. 3. 87% 802.12 kw 4. 0.45 kw Total height Type No. Construction type Natural draft type 4, 1 for each unit Reinforce concrete, hyperbolic, double curvature shell with a big beam at the base supported on rocker columns 117 m

(iv) (v)

(vi) (vii)

viii)

36.23 mwc

102

103

5. 6. 7. 8.

9. 10. 11. 12. 13. 14. 15.

Base diameter Throat diameter Top diameter Length of open channel (from coling tower to pump house) Flow Drift Range of cooling Recooled water temp. Ambient wet bulb temp. Design relative humidity Approach.

78.9 m 46.7 m 49.77 m 900 m long & 150 m long 25,000 m3/hr Limited to max, of 0.05% of total water in circulation 110c 320c 270c 50% 50c

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

One per chlorinator Adjustable throat Plastic M/s Fischer & Porter

4.3. CW CHLORINATION CHLORINE TON CONTAINERS

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

CHLORINATED WATER DOZING SYSTEM BOOSTER PUMP

(i) (ii) (iii) (iv) No. Capacity & head Make & type Motor 3, (2 working & one stand by) 50 m3/hr at 40 mwc M/s Kishore pumps Horizontal centrifugal TEFC, Squirrel cage induction motor, 18.5 kw

CHLORINE EVAPORATOR
(i) (ii) (iii) (iv) No. & capacity Manufacturer Type Heater capacity Three, 90 kg/hr M/s Fischer & Porter electically heated immersed in water bath 18 kw

CHLORINE DIFFUSER

CHLORINE STRAINERS

(i) (ii)

No. Location

(i) (ii) (iii)

No. Location Manufacturer

1 working and 1 standby Outlet of each evaporator M/s Fischer & Porter

Six sets One set near each individual C.W. pump. suction bay trash track

104

105

4.4 AIR COMPRESSOR PLANT

Manufacturer Type No. of compressor

K.G. Khosla compressor Limited Reciprocating, horizontal, balance opposed, non-lubricated 9, (5 instrument air & 4 plant air)

(iv) Outlet air temperature (after aftercoolder) (v) Air pressure after LP stage (vi) Volumetric efficiency at design condition (vii) Crank shoft speed (viii) Total cooling water requirement

80c above cooling water inlet temp. 3.012kg/cm2 (a) 78.9% 735 rpm 22 x 9 = 198 m3/hr

CONSTRUCTION FEATURES

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

(i) No. of compressor (ii) Cylinder arrangementq (iii) Cylinder bore LP HP (iv) Stroke (v) Clearance in % of volume HP LP (vi) Thickness HP LP (vii) Cooling water pressure & quatity (viii) pressure & quantity (ix) Type of drive (x) Main bearing type Method of lubrication Maximum allowable lub oil temp. Cross head lubrication HPC/ LPC

Two Horizontally apposed 2 x 310 mm 2 x 185 mm 150 mm 15.76% 10.71% 11 mm 12 mm 3 - 4 kg/cm2/4.4 m3/hr / compressor Intercooler cooling water 3 - 4 kg/cm2/8.8m3/hr/compressor Direct throught flexible coupling Split sleeve Forced feed by gear pump 700c By gear pump/splash type

AIR DRYING PLANT

(i) (ii) (iii) (iv) (v) No. Dessicant Duty Drying cycle Nominal flow rate & working pressure (vi) Type of dryig (vii) Type of reactivation (viii) Type of change Five Silica gel as per IS 340] Continuous 8 hour

PERFORMANCE DATA

20N m3 / min. 8.0 kg/cm2 (g) open thro-system Automatic with provision for manual

(i) Nominal capacity of compressor 20Nm 3/min (ii) Discharge pressure 8 kg/cm3 (g) (iii) Air temperature after first/ last stage of compressor 1530/1470c

106

107

ADP BLOWER

L.F.O. UNLOADING PUMP

No. Capacity Pump make & model no. Motor Two 50m3 / hr at 30 mlc M/s Delta Corporation, Model-216, 105/064 Kirloskar make, 15 kw rating 1450 rpm, B class insulation, 415 V 3, 50HZ power supply, 27.5 A full load current.

(i) Type and capacity (ii) Motor rating voltage, phase & frequency (iii) Motor Manufacturer (iv) Motor fll load current & speed (v) Method of connection of motor to blower

Centrifugal blower, 10 N m3/min. 7.5 kw,415v,3,50HZ,dass B insulation Crompton Greaves Ltd. 14.0 A, 2900 rpm Vee belt & pulley

REGENERATION CYCLE

L.F.O PRESSURING PUMP

(i) Make (ii) Pump designation (iii) Drive Motor Make & frame size Rating & power supply (iv) Pump construction detail a. Mounting b. Pitch & shaft material & BHN c. Rotor shaft material & BHN d. Idler material & BHN e. Body & cover material f. Bearing type & No. g. Cou;ong type & make (v) Performance date (i) Capacity at min CST of /2 max. CST to 20 (ii) Suction pressure/ discharge pressure (iii) NPSH required (iv) Pumping temperature (v) RPM Allweiller AG 5 NH 80 ER 42 E 67 W 12 GEC KF 132 M 7.5 Kw, 415v, 3, 50 HZ Horizontal/fool Nitrided steel-vickers 2 Nitrided steel-vickers 2 Nitrided steel-vickers 2 Welded stell Ball bearing one 3 piece pi piush Flender NEurex make

(i) (ii) (iii) (iv)

Depressurisation Heating Cooling repressurising

25 minute 4 hrs, 25 minute 2 hrs 25 minute 25 minute

4.5 FUEL OIL HANDLING PLANT 4.51 L.F.O. HANDLING PLANT L.F. O. STORAGE TANKS
(i) Type of tank design code Vertical, cylindrical, non-pressurised flixed roof type with atmospheric vent as per IS 803/ AP 1650/BS 2654 part I & II Two Light diesel oil 160 m3 6m x 6m 600c 66 kg/cm2 63.5kg/cm2

(ii) No. (iii) Type of oil stored (iv) Capacity of each tank (v) Diameter & height of tank (vi) Design tank temperature (vii) Design pressure Internal External

120 lpm / 130 lpm Minus 0.5 kg/cm2(g) 15 kg/cm2(g) 2.6 mwc at max. CST 350c 2920

H.F.O./LS.H.S. HANDLING SYSTEM H.F.O./LS.H.S. STORAGE TANKS LF.O. UNLOADING HEADER

(i) No. of header (ii) No. of nozzle connections One 5 nozzle connection of 80 nb (i) Type Vertical, cylindrical, non-pressurised, fixed roof type with atmospheric vent. Four

(ii) No.

108

109

(iii) Tank design code (iv) Type of oil stored (v) capacity of each tank (vi) O.D./ height of tank (vii) Tank oil temperature (viii) Design pressure Internal pressure External pressure (ix) Tank heating coils a. Steam coil tubes b. Heating medium c. Steam parameter d. Time for heating oil from initial temp to final temp. (x) Suction heater a. Type b. Medium c. Design pressure d. Design temperature (xi) Tank oulet oil temperature

As per IS-803/AP 1650/BS 5254 part I & II Heavy fuel oil/Low sulphur heavy stock 15,000 m3 40 m x 12 m 500c for HFO, 650c for LSHS, 800c for HPS 66 kg/cm2 63.5 kg/cm2 40 mm dia seamless as per ASTM-A106 steam 16 data pressure & 2100c temp. 36 hour for 15,000 m3 of oil Shell & tube type with U tube (seamless steel tube) Shell side Tube side Oil Steam 2.5kg/cm2 20kg/cm2 1200c 2100c 0 0 60 c for HFO, 75 c for LSHS, 900c for HPS

DRAIN OIL TANK (UNLOADING AREA)

(i) (ii) (iii) (iv) (v) No. Tank design reference Capacity Size Condensate heating coil one IS-800 6m3 3m x 1.5 x 1.5 m. 40 mm dia, seamless tube.

DRAIN OIL PUMP (UNLOADING AREA )

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

FLASH TANK (UNLOADING AREA)

(i) No. of tank (ii) Type (iii) Diameter of tank (iv) Height of tank (v) Capacity of tank (vi) Design pr. & temp. (vii) Insulation thickness One Cylindrical with dished end. 2.2 m 3m 10 m3 16kg/m2, 2100c 40 mm (min)

FUEL OIL UNLOADING CUM TRANSFER PUMP

(i) No. of wagons that can be unloaded at a time (ii) No. of fuel oil pumps & make (iii) Capacity of each pump (iv) Motor

2 rack of 76 wagons. 10 no. M/s Delta corporation, model 216.135/075 100 m3/hr at 50 mlc Kirloskar Elect Co. make 55kw, 1475 rpm, 415v 3, 50HZ B class insulation, full load current 93 A

SUMP PUMP (UNLOADING AREA)

(i) Type Wet type, vertical shaft, single stage non-clog desing Four, Kishore PUmp Ltd. 30m3/hr at 10 mlc for 2 pumps 15m3/hr at 10 mlc for 2 pumps Mech. packing type 2.2 kw (2no.) & 3.7 kw (2no) 415 v supply, Crompton Geaves make

(ii) No. & make (iii) Capacity (iv) Type of stuffing box (v) Motor

FUEL OIL UNLOADING HEADER

(i) No. & construction Two, fabricated with 8 mm steel plate, 450 Nb 80 per header. 80 Nb

(ii) No. of nozzle connections (iii) Size of nozzle connection

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

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

110

111

(i) No. (ii) Make (iv) Pump designation

4 x 100% + 2 x 60% All weiller 100% pump SNH 1300 ER 46 E6.7 YW12 60% pump SNH 940 ER 42 E6.7 YW 12 100% Pump 60% Pump 790lpm/760 lpm Minus 0.5 kg/cm2 30kg/cm2 5.2 mwc at max cst 700c 1450 Horizontal/floor 150mm/90mm Nitrided steel welded steel Ball bearing, one 3 piece, pin, push, flender-N eurex End cover design GEC, KF 280m 90kw, 415v 3

(vi) Stem parameter (vii) Relief valve set pr. (viii)

14kg/cm2 (g), 2150c 32 kg/cm2 (g) Design pressure 32kg/cm2 (g) oil side 24kg/cm2 (g), steam side

(v) Performance data a. Capacity at 150 cst (min)/ 370 cst (max) b. Suction pressure c. Delivery pressure d. NPSH required e. Delivery temperature f. RPM (vi) Pump construction detail a. Mounting b. Pitch & rotor dia c. Rotor shaft & idler material d. Body & cover material e. Type & no. of bearing f. Type & make of coupling g. Steam jacket (vii) Drive motor a. make & frame size b. Power rating & power supply

DRAIN OIL TANK (PRESSURISING AREA)

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

1250lpm/1260lpm Minus0.5kg/cm2 30kg/cm2 7.0 mwc at max cst 700c 1450 Horizontal/floor 200mm/100 mm Nitrided steel welded steel Ball bearing, one 3 piece pin, push, flender-N eurex End cover design GEC, KF-280m 90kw, 415v 3

DRAIN OIL PUMP (PRESSURISING AREA)

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

FLASH TANK (PRESURISING AREA)

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

4.6 COAL TRANSPORATION AND HANDLING SYSTEM COAL TRANSPORTAION SYSTEM

HEAT EXCHANGER

Source

(i) (ii) (iii) (iv) (v)

Type No. Heater area Oil flow rate Oil heating range

U tube, hair pin type, oil on shell side, condensing type 6 40 sq. m each 4000 to 34760 kg/hr 50 to 1200c HFO 70 to 1300c LSHS

Piparwara block of North karanpura coal field of Eastern coal field Means of transportation Railway Routl of railway Khalari - Garwa road-SeonnagarMughal sarai-Allahabad- KanpurAlighar-Dadri- Plant unloading area Total distance 1124 km from khalari to Dadri with electrified track from Seonnager Type of wagon Bottom discharge type or Box N RC type No. of wagons/rake 58 wagons of 56.78 tonners capacity No. of rakes required per day 4 to 5 Total cycle time of one rake Approximately 6 days. Rolling stock required for stag-1 13/6 wagons Type of Icons WD 56 (910 hp)

112

113

COAL HANDLING SYSTEM TRACK HOPPER

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

CRUSHER HOUSE
No. & Make of Crusher Type & size Main crusher capacity Max. coal size before crusher Coal size after crusher Motor rating Make Power supply RPM Full load ampere Insulation class (vii) No. of belt corrveyors 4, Pennsylvenia, USA Ring Granulators, TKKGN-48093 875 tonne/hr each. 250 mm 20 mm 800 h.p (597kw) Kirloskar Elect Ltd. 6.6 kv, 3, 50 HZ 743 69 A F 60

TRACK HOPPER
(vii) Type of wagon unloaded (viii) Mode of Bottom relieving of wagons (ix) Working pressure (x) Air receiver capacity BOBR Pneumatic 5-6 KSC 3000 litres

(i) (ii) (iii) (iv)

No. Type of tippled Wagon tippler guaranteed capactiy Capacity

WAGON TIPPLER

1 BOX-N type 12 trips / hr. One no. 90 tonne 8 wheeled box wagon OR 2 no 4 wheeled wagon handled in pair in a single trip

CONVEYOR
(i) No. of belt converyors 16 1540 tph / 1400 tph conveyor no. 1A1 1B1 (iii) Conceyor capacity (iv) Belt speed (m/sec) (v) Belt width (mm) (vi) Fabric type (vii) No of piles (viii) Belt rating KN/mlc (ix) Face cover thicknss (mm) (x) Back Cover 2 2 2 2 2 2 2 thickness (mm) (xii) Cover grade _________________ Fire resistant ________________ 700 1000 Nylon 4 1A 1B 2A 2B 3A3B 4A 4B 5A5B 6A6B 7A7B ........ 3.14 ......... __ 3 63 5 ........ 3.37 ........ __ 3 100 5 1400 3.14 1400 4 100 6 ......... 3.36 ....... 3.0 ........ ......... 3.0 3.0 (ii) Design / rated capacity

BEETLE CHARGER
Pulling & pushing capacity 15 nos. of 90 tonne 8 wheeled fully loaded box wagon on straight level.

.......................... 3 125 5 4 63 5 4 80 5 3 10 5

palamide ___ __ ___ synthetic ___

PADDLE FEEDER
(i) (ii) (ii) (iv) No. of paddle feeder Type of paddle feeder Design/rated capacity travel speed 4 Rotary type 1000 tph/875 tph 2 m/ min (approx.)

VIBRATING GRIZZLY FEEDER

(i) No of vibrating grizzly feeder (ii) Capacity (iii) Screen type (iv) Frequency (v) Amptitude (vi) Stroke angle & screen angle (vii) Motor 4 No 875 tonner/hr BSS 11-44824 300-1000 rpm 35 mm 400,0-100 45 KW, 415V, 3, 50HZ, 79A, 1465 rpm

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(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, separators (xvi) No. of suspended magnet 2 (xvii)Conveyor motor Conveyor Motor rating Make 1A/1B 280 kw Kriloskar 2A/2B 240 kw Kriloskar 3A/3B 430 kw Kriloskar 4A/4B 200 kw NGEF 5A/5B 250 kw Kriloskar 6A/6B 140 kw NGEF 7A/7B 320 kw Kriloskar 1A/1B 110 kw Cromption greaves

suspended type

Power supply 6.6 kv. 3 6.6 kv. 3 6.6 kv. 3 6.6 kv. 3 0.415 kv. 3 0.415 kv. 3 6.6 kv. 3 0.415 kv. 3

Full load current 31.5 A 27.5 A 47 A 23 A

(v) Travel speed (vi) Travel motor (vii) Bucket motor specification (viii) Boom conveyor speed (ix) Boom conveyor motor type & rating (x) Slew speed (xi) Slew motion motor

4-20 nm/ minute Continuous variable DC motor, 6 x 10 kw. A.C. squirrel cage motor, 90 kw 3m/sec Squirel cage reversible type, 75 kw 17.5 to 30.48 m/ min. D.C. type, 2x 14 kw

STOCKYARD
(i) Capacity 45 days coal of stagel requiremnt 5,00,000 m3 of coal approx. 4 470/10m

(ii) No. of coal piles in stockyard (iii0 Length/height of each plies 188 A

COAL SAMPLING UNIT

No. Make No. of cuts/Hr. Intake Material Size Output Sample Power Requirement : Hyd. Pack Feeder Crusher 2 Nos. (one at TP-1, one at TP-4) Ramsey Engineering 21 (TP-1), 50 (TP-4) 40 mm nominal tap size - 3 mm 7.5 KW (Each) .7 KW (Each) 12 KW (Each)

TRIPPER
(i) Type (ii) No. (iii) Capacity (iv) Travel speed (v) Motor for tripper (vi) Tripper travel (vii) Electrical linear actuator provided (viii) AC electro magnetic brake Travelling type 4 1400 tonnes/hr each 12m/min 2no. for travel, 2.2 kw each 216.950 m yes yes

W/T VIBROFEEDER

STACKER/RECLAIMER
(i) No. (ii) Model (iii) Stacking capacity (rated/ design) (vi) Reclaiming capacity (rated/ design) 2 ASK 650 1400/1540/1540 tph 1400/1750 tph

No. Make Model Motor Rating Capacity

4 TATA ROBINS-FRASWER Ltd. TE-9, 48 X 120 11 KW 450 MT/Hr.

DUST EXTRACTION SYSTEM

Ventury Scrubber Cover Type : No. Centrifugal Fan Capacity Vacuum Created Slury Pump Capacity 2 Nos. for Crusher House 66000 Cubic Metre / Hr 400 mm WC 88 Cubic metre / Hr

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BAG FILTER DE SYSTEM No. Centrifugal Fan Blower Air Handling Capacity Vacuum created inside Motor Rating Rotary Air Lock (RAL) System Motor Rating of RAL Motor RPM Drive Mechanism 4 Nos. ( 1 each for Bunkers of One Unit) 44000 Cubic Metre / Hr 350 mm WC 100 HP Associated with each DE fan 1 HP 20 Chain & Sprocket Fire Extinguishers Fire Detection System: LHSC (Linear heat Sensing Cable) IRD (Infra Red Detection System) Fire Alarm : Smoke Detectors

spread throughtout CHP 57 locations Along all Conveyors except 4A/4B & 5A/5B Located at 1A/1B, 2A/2B, 3A/3B, 7A/7B

CHP C/R, CHP SWGR Room, CHP Cable gallery room, T/H MCC room

DUST SUPPRESSION SYSTEM 4.7 ASH HANDLING SYSTEM

Supplier Principle F-Harley To apply water in spray form in order to settle coal dust Ash handling system capacity Ash pro

4.7 ASH HANDLING SYSTEM MAGNETS

Ash handling system capacity Make / Type Magnetic Separators (Suspended Magnets) : No. In Line Magentic separators (Self Cleaning type) No. ERIEZ maek / Oil Cooled 2 Nos. (Installed over Conv. 1A/ 1B) 4 Nos ( 2 Nos over 1A / 1B, 2 Nos. over 3A/3B) Ash mound capactiy Ash mound area and height Ash mound settlement allowed Ash produced by 4 x 210 MW unit boiler in 24 hour to be evacuated in 5.5 hour 25 year of ash produced 200 hectre, 55m 700-800 mm

TRANSPORT AIR COMPRESSOR METAL DETECTORS

No. Type Frequency 4 Nos. (2Nos over 1A/ 1B, 2 Nos. over 4A/4b) Eddy current induced imbalance in a set of mutually balanced coils 20 KHz to 100 KHz (i) No. (ii) Make (iii) Capacity (iv) Discharge pressure (v) Drive motor Make Rating Power supply 8 no.,2 for each unit Khosla-Crephille For unit 1 and 2 For unit 3 and 4 159 m3/min 147/min 2.26Kg/cm2 1.97kg/cm2 BHEL 545 kw 6.6 kv, 3, 50 HZ

FIRE FIGHTING / PROTECTION SYSTEM IN CHP

Fire fighting System: MVW Spray System Fire Hydrants

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45 Zones spread throughout the Conveyors 34 Nos. (Internal), 73 Nos. (external)

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INSTRUMENT AIR COMPRESSOR

(i) (ii) (ii) (iv) (v) No. Capacity Pressure Motor Air drying plant-capacity 3 no. 2 working, 1 standby 14m3/min 8kg/cm2 125 kw, 415v supply 1800 N cub. m /hr

(iii) Pressure (iv) Drive motor Make Rating Power Supply

6.3 kg/cm2 KEC, Pune 75 kw 440 v

SEAL WATER PUMP

(i) Make (ii) Model (iii) Type (iv) No. of stages (v) Flow (vi) No. (vii) Discharge pressure (viii)Drive motor Make Rating Power supply Bewn Wier Ltd. Fnd-9 Multistage Centrifugal type 7 8.3 litres/sec. 2 21.6 kg/cm2 KEC Pune 45 kw 415 v, 3, HZ

VACUUM PUMP
(i) Make Roots Division Dressers Industires INC, USA 16 No. (4 for each unit) 4 for each unit (2 working, 2 standy by) 46.8 cu.m/min at 16 inch of Hg. Rotary Lube vacuum blower 46.8 CuM /min. at 16 mm Hg. KEC, Pune 75 kw 415V, 3, 50 HZ, 75 KW; 1057 rpm

(ii) No. (iii) (iv) (v) (vi) Capacity Type Inlet Volume Drive motor Make Rating Power supply

OVER FLOW PUMP

(i) (ii) (iii) (iv) (v) (vi) Make No. Capacity Pressure Motor Overflow tank capacity Indure Ltd. 8,2 for each unit 245 m3/hr 2.8 kg/cm2 45 kw, 415 v supply 54 m3

H.P. WATER PUMP

(i) No. (ii) Make Becon weir Ltd. (iii) Working pump/stand by (iv) Capacity (v) Discharge pressure (vi) No. of Stages (vii) Drive motor Make Rating Power supply Type 6(3 for unit 1 and 2, 3 for unit 3 and 4) Unit 1 and 2 Unit 3 and 4 2/1 2/1 396 cuM/hr 406 cuM/hr 20.8kg/cm 2 17.6 Kg/cm2 7 BHEL 320 kw 6.6 kv, 3, 50 HZ Multistage, single suction centrifugal

MIXER SPRAY WATER PUMP

(i) (ii) (iii) (iv) (ii) (iii) (iv) NO. Make Type No. of stages Capacity Pressure Drive motor Make Rating Power supply 3(2 operating and 1 standby) Becon Weir Ltd. Centrifugal double suction 2 81.7 litre/sec. 6.3 /cm2 KEC, Pune 75 kw 440v, 3, 50 HZ

LP. WATER PUMP

(i) No. 6 no. 3 for unit 1 and 2 & 3 for unit 3 and 4 81.7 litres/sec Becon weir Ltd. Single stage, Double suction centiri fugal

(ii) Capacity (iii) Make (iv) Type

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COOLING TOWER
(i) No. (ii) Cooling Tower Discharge Pump No. Pump capacity Pump discharge pressure Motor (iii) Cooling Tower Fan No. Motor 2 4 (2 for each cooling tower) 500 cu m/hr 0.85 kg/cm2 45 kw, 415 v supply 2 12.5 kw, 415 v supply (i) No. (ii) Capacity (iii) Motor (i) No. (ii) Capacity

DRY ASH SILO

5 2949 cuM

HYDROMIX DUST CONDITIONER

15 200T/hr 7.5, HP, 415v

SURGE TANK
No. Capacity 2 1500 m3

ROTARY FEEDERS

SLUDGE PUMP
No. Capacity Discharge pressure Motor 8 50 cu.m/hr 3.0 kg/cm2 11.0kw, 415 v supply

No. Motor No. of silo filter vent fans No. of telescopic chute vent fan

15 ( 3 FOR EACH SILO) 2.2 kw, 4.5 v 10:18.5 kw motor 5 / 5.5 kw motor

DEWATERING BINS
No. Capacity 6 650 t each

SILO AERATION BLOWER

(i) (ii) (iii) (iv) (v) (vi) Make Type No. Capacity Pressure Motor Swam Engineering Twin lobe compressor 12 770m3/hr 1.41 kg/cm2 30 kw, 415 v supply

CONVEYORS
Belt Capacity Belt speed 1600 mm 200t/hr 3m/sec

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TECHNICAL SPECIFICATIONS OF ASH HANDLING PLANT PACKAGE-2

1. CONVEYOR C-10 to C- 05 : Location Capacity Length Speed Motor Specification 2. CONVEYOR C-10 to C -15 : Location Capacity Length Speed Motor Specification 3. CONVEYOR C-20 / 21 : Location Capacity Length Speed Motor Specification 4. CONVEYOR C-24 / 25 : Location Capacity Length Speed Motor Specification 5. CONVEYOR C-24 / 25 : Location Capacity Length Speed Motor Specification 6. CONVEYOR C- 30 / 31 : Location Capacity Length Speed Motor Specification 7. CONVEYOR C- 32 : Location Capacity Length

Speed Motor Specification 8. CONVEYOR C- 33 : Location Capacity Length Speed Motor Specification 9. CONVEYOR C- 34 : Location Capacity Length Speed Motor Specification 10.CONVEYOR C- 35 : Location Capacity Length Speed Motor Specification 11.CONVEYOR C- 40 : Location Capacity Length Speed Motor Specification 12.CONVEYOR C- 41 : Location Capacity Length Speed Motor Specification 13.CONVEYOR C- 42 : Location Capacity Length Speed Motor Specification 14.CONVEYOR C- 43 : Location

2.76 M / Sec. 55 KW, 415 V, 104 Amp.

Blow Silos HMDC 850 TPH 19.65 M 1.5 M / Sec. 25 KW, 415 V, 45 Amp.

Ash Mound Field Same As Above Extendable & Shiftable, Maximum 100 M 2.76 M / Sec. 2*355 KW, 6.6KV, 41 Amp.

Blow Hydrobins Vibrofeeder 750 TPH 16.625 M 1.5 M / Sec. 25 KW, 415 V, 45 Amp. From Silos / Hydrobins TO JH -1 200 TPH For Fly Ash 1500 TPH For Bottom Ash 341.592 M 3.0 M / Sec. 220 KW, 6.6 KV, 26 Amp.

Ash Mound Field Same As Above 25 M 2.7 M / Sec. 2*37 KW, 415 V, 70 Amp.

Ash Mound Field Boom Spreader (SP-1) Same As Above 35 M 2.7 M / Sec. 2*55 KW, 415 V, 104 Amp.

From JH-2 TO JH-4 Same as Above 1034.868 M 3.0M / Sec. Same As Above

From JH-4 TO JH-6 (Temporary Stock Yard) Same As Above 1009 M 3.0 M / Sec. 2*220 KW, 6.6 KV, 26 Amp.

From JH-2 To JH-4 Same As Above 1034.868 M 3.0 M / Sec. 320 KW, 6.6 KV, 37 Amp.

Stacker (Temporary Stock Yard) Same As Above 2.89 M 3.0 M / Sec. 70 KW, 415 V, 120 Amp.

From JH-4 To JH-7 Same As Above 212 M 2.6 M / Sec. 90 / 100 KW, 415 V, 165 / 175 Amp.

Bucket Reclaimer BR-1 (Temporary Stock Yard) 840 TPH 10 M 2.7 M / Sec. 37 KW, 415 V, 70 Amp.

Ash Mound Field (SC-1) Same As Above 13.8 M

Bucket Reclaimer BR-1 (Temporary Stock Yard)

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Capacity Length Speed Motor Specification 15.CONVEYOR C- 44 : Location Capacity Length Speed Motor Specification 16.CONVEYOR C- 45 : Location Capacity Length Speed Motor Specification 17.CONVEYOR C- 43 : Location Capacity Length Speed Motor Specification 18.CONVEYOR C- 51 : Location Capacity Length Speed Motor Specification 19.CONVEYOR CA / CB : Location Capacity Length Speed Motor Specification 20.CONVEYOR CC : Location Capacity Length Speed Motor Specification

840 TPH 17.3 M 2.7 M / Sec. 37 KW, 415 V, 70 Amp.

20.CONVEYOR CC : Location Capacity Length Speed Motor Specification 21.CONVEYOR CD : Location Capacity Length Speed Motor Specification 22.CONVEYOR CE : Location Capacity Length Speed Motor Specification 23.CONVEYOR CF : Location Capacity Length Speed Motor Specification 24.CONVEYOR CG : Location Capacity Use 25.STAKER : Location Travel Motor Luff Hyd. Pump Motor Slew Slew Motor 26.BOOM SPREADER (SP-1) : Location Capacity Use FUNCTIONS : Travel SP-1 Travel Motor TR-1 Travel Motor Luff Hyd. Pump MotorSlew Slew Motor

From JH-8 To con. CE Same As Above Extendable & Shiftable Max. 1000 M 3.0 M / Sec. 2*200 KW, 6.6 KV, 22.5 Amp.

Mobile conveyor MC-1 (Temporary Stock Yard) 840 TPH 32 M 2.7 M / Sec. 37 KW, 415 V, 70 Amp.

From JH-8 To SC-1 Same As Above Extendable & Shiftable Max. 1000 M 3.0 M / Sec. 2*200 KW, 6.6 KV, 22.5 Amp.

Temporary Stock Yard To Jh-5 700 TPH 1004.89 M 3.0 M / Sec. 200 KW, 6.6 KV, 35 Amp.

Ash Mound Field Same As Above Extendable & Shiftable Max. 1000 M 3.0 M / Sec. 2*315 KW, 6.6 KV, 34 Amp.

Bucket Reclaimer BR-1 (Temporary Stock Yard To Jh-5 200 TPH For Fly Ash 1500 TPH For Bottom Ash 334.50 M 2.60 M / Sec. 2*90 KW, 415 V, 165 Amp.

Ash Mound Field Same As Above 28.705 M 3.2 M / Sec. 110 KW, 415 V, 180 Amp.

Ash Mound Emergency Stock Yard (SC-2) Same As Above 46 M 2.76 M / Sec. 132 KW, 415 V, 232 Amp.

Teporary Stock Yard Same As Above Ash Dumping

From JH-7 To JH-8 Same As Above 400 M 3.0 M / Sec. 2*235 KW, 6.6 KV, 26 Amp.

Temporary Stock Yard 6*5.5 KWm 415 V, 23 Amp Discharge Boom Left & Right 11 KW, 415 V, 23 Amp Discharge Boom Left & Right 2.2 KW, 415 V, 5.2 Amp

From JH-8 To con. CE Same As Above Extendable & Shiftable Max. 1000 M 3.0 M / Sec. 2*200 KW, 6.6 KV, 22.5 Amp.

Ash Mound Same As Above Ash Dumping Forward & Backward 2*23 KW, 415V, 6.5 Amp. 8*2.2 KW,415 V, 6.5 Amp. Discharge Boom Upper & Lower 30 KW,, 415 V, 53 Amp Discharge Boom Left & Right Swing 2*7.0 KW, 415 V, 16.7 V, 16.7 Amp.

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27.BOOM SPREADER (SP-2) : Location Capacity Use FUNCTIONS : Travel SP-2 Travel Motor TR-2 Travel Motor Luff Slew Slew Motor 28.BOOM SPREADER (BR-1) : Location Capacity Use FUNCTIONS : Travel Travel Motor Luff L.Hyd. Pump Motor Slew S. Hyd. Pump Motor B.W. Wheel Motor 29.MOBILE CONVEYOR (MC-1) : Location Capacity FUNCTIONS : Travel Travel Motor Luff Hyd. Pump Motor Slew S. Hyd. Pump Motor B.W. Wheel Motor 30.LOADING HOPPER (LH-1) : Travel Travel Motor 31.DUST SUPRESSION SYSTEM : DS - 2, 3 & 4 DS - 6 DS - 9 31.ASH LAGOON PUMP : No. Location Capacity Motor Specification 32.ELECTRICAL TRANSFORMERS : a. Control Room LT MCC (2No.)

b. LT MCC-A Ash Mound Same As Above Ash Dumping Forward & Backward 2*75 KW, 415V, 132 Amp. 16*1.5 KW, 415 V, 3.4 Amp. Discharge Boom Upper & Lower Discharge Boom Left & Right Swing 2*7.0 KW, 415 V, 16.7 V, 16.7 Amp. c. LT MCC-B d.

(2No.) (2No.)

SPREADER (SP-1) MCC

e. SPREADER (SP-2) MCC f. STACKER MCC g. BUCKET RECLAIMER MCC

750KVA, 6.6KV / 415V, 1000.02/ 69.0 Amp. 500KVA, 6.6KV / 415V, 46.04/ 666.69 Amp. 400KVA, 6.6KV / 34.99 / 556.489 Amp. 500KVA, 6.6KV /415, 34.99 / 556.48 Amp 500KVA, 6.6KV / 415v, 46.04 / 666.69 Amp. 315KVA, 6.6KV / 415v, 438.24 Amp. 4 Ash Lagoon Pump House 375 Acress 55 KW, 415 V, 115 Amp.

Temporary Stock Yard Average 350 Cu.M/Hr. (Max. 700 TPH) Reclaiming Of Ash Forward & Backward 2*22 KW, 415V, 43 Amp. Receive Boom Upper & Lower Discharge Boom Uper & Lower 11 KW, 415 V, 20.6 Amp Receive Boom Left & Right Swing 30 KW, 415 V, 55 Amp 75 W, 415 V, 130 Amp

32.ASH LAGOON PUMP : No. Location Capacity Motor Specification 33.ELECTRICAL TRANSFORMERS : a. Control Room LT MCC ( 2No.) b. LT MCC A ( 2No.) c. LT MCC B ( 2No.) d. SPREADER (SP-1) MCC e. SPREADER (SP-2) MCC f. STACKER MCC g. BUCKET RECLAIMER MCC

Temporary Stock Yard 840 TPH Forward & Backward 2*14 KW, 415V, 31 Amp. Conveyor Boom Upper & Lower 11 KW, 415 V, 20.6 Amp Conveyor Boom Left & Right Swing 30 KW, 415 V, 55 Amp 75 W, 415 V, 130 Amp

1600KVA, 6.6 KV/415V, 139.96/133.39 Amp. 750KVA, 6.6 KV/415V, 1000.02/69.00 Amp. 500KVA, 6.6 KV/415V, 46.01/666.69 Amp. 400KVA, 6.6 KV/415V, 34.99/556.489 Amp. 500KVA, 6.6 KV/415V, 46.04/666.69 Amp. 250KVA, 6.6 KV/415V, 21.86/333.3 Amp. 315KVA, 6.6 KV/415V, 27.56/438.24 Amp.

34.ASH MOUND SALIENT FEATURES Total Land For Ash Disposal SystemTotal Area For Mound Construction Final Height Of Ash Mound Gradient Of Slopes Ash Mound Volume Capacity Of Temporary Stock Yard Thickness Of Drainage Blanket Ben At+15 M,+ 30 M &+45 M Elevation -

500 Acres 375 Acres 55 M 1 In 4.5 & 1 In 4.0 530 Lac Cu. M 1,00,000 Cu. M 1.0 To 1.50 M 10 M Wide

Forward & Backward 6*2.2 KW,415 V, 6.5 Amp.

For Junction House Transfer Chutes For Temporary Stock Yard For Ash Mound 4 Ash Lagoon Pump House 3600 Cu.m / Hr. 55 KW, 415 V, 115 Amp.

4.8 FIRE FIGHTING SYSTEM FIRE HYDRANT PUMP

(i) No. 4 3 Electrical driven, 1 Diesel engine driven Raw water pump house Kirloskar Ltd. Electrical driven Diesel engine driven 120.4 m 120.4 m 250 mm 250 mm 113.89 L/s. 118.05 L/s (410m3/hr)

(ii) Location (iii) Make (iv) Total head (v) Size (vi) Rate of flow

1600KVA, 6.6KV/415, 139.96/ 133.39 Amp.

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(vii) Speed (viii)Pump input (ix) Drive

1482 rpm 174.59 kw Electric motor drive Make Crompton Greaves KW/HP 220/295 RPM 1482 Power supply 6.6kv, 3 Power supply 6.6 kv, 3 50 HZ Max current 24.2A Insulation Class F

1500 rpm 180.97 kw Diesel engine drive Make Kirloskar Cummins Ltd. Rated BHP : 326 RPM :2000 Model:NTA-855F Model : NTA-855-F Luboil specification As per IS 496 Fuel oil specification As per IS 1460

HYDRO PNEUMATIC TANK

(i) (ii) (iii) (iv)

Internal diameter Capacity Operating pressure Safety valve set pressure

2600 mm 18 m3 12 kg/cm2 13.2 kg/cm2

HALON SYSTEM

(i)

Area where used

FIRE SPRINKLER PUMP

(ii) Extinguishing agent (iii) Concentration employed (iv) Gas dischange duration

Control room, DDCMIS room, Control equipment room, UPS SWAS room Halon 1301 gas 5% at design temp. 30 second.

No. of pumps

2 (One Electrical driven, one diesel engine driven Rest as in case of fire hydrant pumps (i) Area where used (ii) Type of system

FOAM SYSTEM
HFO/LDO system Fixed foam low expansion delivered on oil surface 5 lpm/m2 liquid surface area 30 minute 3% profein based 2 Horizontal cylinder with dished end 12 KL

JOCKEY PUMP
(i) (ii) (iii) (iv) (v) No. of pums Type Capacity Head Drive One Single stage 30 m3 / hr 120 mwc Electrical driven, 2 pole, 415v, 50HZ, 37 kw, 65A

(iii) (iv) (v) (vi)

Application rate Discharge duration Foam concentration Foam tank No. Type Capacity

AIR COMPRESSOR
(i) Model (ii) Working pressure (iii) Drive motor (iv) Tank capacity TC 500 FAD/DIS 500 lit/min 12.0 kg/cm2 3.7 kw/5 hp, 415v, 3, 50 HZ, power supply, 7.3. A, 1440 rpm 250 litres

MVW SPRAY SYSTEM FOR COAL CONVEYORS

(a) Type of system and actuation,

(b) Spray density (c) Min. pressure at hydraulically remotest/nearest nozzle 1.4 bar/3.5 bar (d) Discharge time 30 minutes

Deluge valve operated MVW spray system automatic, (electrical), remote manual & local manual (mechanical) 10.2 lpm/m2 (of floor area+return belt area)

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(e) Type of detection system (f) Type of spray nozzles (i) For floor protection

LHSE and infra red detectors

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 (1) Cable trench cable gallary (2) Generator seal oil unit oil room central oil purification unit (3) Boiler burnet fonts (4) Generator transformer, station transfomer, station transformer, UAT, (5) HT/LT switchgear, battery room soot blower, MCC room (6) UCR, DDCMIS, CER, UPS and SWAS room (7) CHP, control room and track hoper control room (8) Coal conveyor Type of Detectors used Themo electric quartzoid bulbs, ionisation and photo

Quartzoid bulbs Quartzoid bulbs

Quartzoid bulbs

Ionisation type smoke detector Ionisation type and photo electric type smoke detector lonisation type smoke detector Liner heat sensor

SWITCHYARD FIRE FIGHTING SYSTEM WATER STORAGE TANKS No. Capacity 2 150 m3 each

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HIGH PRESSURE WATER SPRAY (EMULSIFIER) PUMP No. P-01

(i) Pump discharge for Emulsifier system of the shunt reactos in 400 kv switchyard 410 m3/hr 70 mwc Horizontal centrifugal KBL 6 UP 4F 160 kw 1485 Sq. cage induction KEC LD 315 LM KII 415v, 3, 50HZ

(iii) (iv) (v) (vi)

(ii) Rated discharge flow (iii) Head (iv) Type (v) Make (vi) Model No. (vii) Motor rating RPM Type Make Frame size Power supply

Head Make Model No. Diesel engine Rating RPM Make Model No. Control supply

70 mwc KBL KPD 32/26 183.83 hp after deduction/derating engine 1800 KCL N-743-TF Battery 24v

JOCKEY PUMP NO. P-04

(i) (ii) (iii) (iv) (v) (vi)

Purpose Rated dischage Head Type Make Model No. Rating RPM Type Make Power supply

HYDRANT PUMP P-02

(i) Pump discharge for (ii) Rated pump discharge (iii) Head (iv) Type (v) Make (vi) Mode no. (vii) Motor rating RPM Type Make Frame size Power supply Hydrant around switchyard control room 97.2 m3 / hr 70 mwc Horizontal centrifugal KBL DB 80/26 37 kw derated 2960 Sq. cage induction KEC, Pune LD 225 S LMK II 415v, 3, 50 HZ

To maintain constant level of water in hydro pneumatic tank 13.5 m3/hr 70 mwc Horizontal centrifugal KBL KPD 32/26 11 kw 2850 Sq. cage induction KEC 415v, 3, 50 HZ

AIR COMPRESSOR AC-1 & AC-2

COMMON STAND BY PUMP (DIESEL ENGINE DRIVEN) P-03

(i)

Pump discharge to

(ii) Rated discharge

Common discharge header of P-01 and P-02 410 m3/hr

(i) (ii) (iii) (iv) (v) (vi)

No. & capacity Compressor capacity Pressure Make Model NO. Motor Rating

2 x 100% 9 m3/hr 8 kg/cm2 Ingersoll rand M 234 F2 1.5 kw

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RPM Type Make Model No. Power supply

1500 Sq. cage induction KEC KH 100 L 415v, 3, 50 HZ

4.9 MAIN PLANT AIR-CONDITIONING AUTO SYSTEM

Compressors AITUS 2 No.S 9 No.S 3 per SIIU room AIIU DDCMIS AHU Control room AHU SWAS/UPS

HYDRO PNEUMATIC TANK

Humidistat

6 No.S, 1High and 1Low per AHU room 9 No.s 1 per AIIU

Modulating thermostat (i) Nominal pressure (ii) Capactiy 7.5 kg/cm2 18 m3

Anti- Freeze thermostat 2 No.s On/off thermostats 14 no.s 2 for 2 heators per AHU room (total 6 no.s) 4 for solonoids valves per compressor (total 8 no.s)

4.9 AIR CONDITIONING SYSTEM

SETTING AND INTERLOCKS

Description Main Plant A.C. System Capactiy(tonne) 95x1+95x1 Compressor No. Make 2 Kirloskar Pneumatic Co. Ltd. No. of cylinder 12 Cylinder bore Stroke Maximum operating pr. Port load capacity Lub Oil 75%, 50%, 25%, Servo frize F-57 (IOC) 50%, 100% Sheetal N-68 (HP) (HP) (HP) 50%, 100% Sheetal 50%, 100% Sheetal Servo frize-57 TH2 TH1 TH4 21 bar 16.5kg/cm2 16.5kg/cm 2 16.5kg/cm2 21kg/cm2 TH3 85 mm 70 mm 6 65 mm 50 mm 4 65 mm 50 mm 4 65 mm 50 mm 85 mm On/off thermostats D.M. Plant A.C.System 20x2+20x2 4 ACCEL ESP AC System 15x1+15x1 2 ACCEL Softening A.C.System 15x1+15x1 2 accel Switchyard A.C. System 65x1+65x1 2 Kirloskar Pneumatic Co. Ltd. Modulating thermostat Humidistat High Humidistat low Heater thermostat 60 deg F SV on chilled water side line energises and bypasses chilled water from AHU. 45 deg F humidifier pump on command 1- Heater bank 1 on 2- Heater bank 2 on 3 way valve on chillid water line opens & bypasses chilled water from AHU. 0%- valve closes 100%- valve opens Chilled water temp.>10 degC SV1.CV2,SV3 enertises and load 100% Chilled water temp <10 degC SV1drops,SV& SV3 energises load 75%. Chilled water temp < 9 degC SV1 energises, SV2 & SV3 drops load 50% Chilled water temp < 8degC SV1, SV2, SV3 drops load 25% Chilled water temp < 6 degC, LSV drops

Anti - freeze thermostat Chilled water temp < 3 degC compressor trips

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NTPC Operation & Maintenance-Coal Maintenance Planning Section Lube Oil Used In Various Auxiliaries SI. Equipment No
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. ID FAN

NCPS

Sheetal-68 (HP) Bharat freezed-68 (HP) Motor Volt Power(kw) Curret (A) RPM Make 415 v 85 147 1480 Cromption Greaves Induction motor

Servo frize Servo frize F-57 (IOC) F-57 (ICO)

Servo Frize F-57 (IOC)

Oil using

LUBE OIL, SERVO PRIME 68 HYDRAULIC OIL SERVO TORQUE 10 FD FAN LUBE OIL, SERVO PRIME 68, HYDRAULIC OIL SERVO TORQUE 10 PA FAN LUBE OIL, SERVO PRIME 68, HYDRAULIC OIL SERVO TORQUE 10 MILLS SERVO MECH SP- 680, MILL JOURNAL ASSY. MILLS TOP BEARING SERVO MECH SP- 320. MILL GEAR BOX MILLS BOTTOM BEARING SERVO MECH SP- 320, FEEDER GEAR BOX APH MAIN DRIVE GEAR BOX SERVO SYSTEM 220 APH SUPPORT BEARING SERVO CYCLE C 680 APH GUIDE BEARING SERVO CYCLE C 680 IRDS GEAR BOX SERVO MECH SP 460 APH SOOT BLOWER GEAR BOX SERVO MECH SP 460 WALL BLOWER GEAR BOX SERVO MECH SP 460 ESP CRM GEAR BOX SERVO SYSTEM 220 ESP ERM GEAR BOX SERVO MECH SP 460 BFP PUMP SERVO TORQUE 10 CEP PUMP SERVO PRIME 46 ECW PUMP SERVO GN 2623(GREASE) VACUUM PUMP SERVO GN 2623(GREASE) STATOR WATER PUMP SERVO PRIDE 30/40 SEAL OIL, TURBINE OIL SERVO PRIME 46 DOZING PUMPS SERVO PRIDE 46 MOT CENTRIFUGE GEAR BOX SERVO MECH SP 320 WTP PUMP SAE - 40 Raw Water P/P /soft water p/p SAE - 40 WTP agitators/blowers Servo Prime - 320 AC Compressor Servo Freeze - 68 Air compressor Servo Press - 100 EOT Crane Servo Prime - 320 Raw Water P/P Servo Prime - 57

415v 18.5 kw 33 Amp. 1450 Cromption Greaves Induction motor

415v 15 27 1460 Cromption Greaves Induction motor

415v 15 27 1460 Cromption Greaves Induction motor

415v 55 1480 Cromption Greaves Induction motor

CHILLED WATER PUMP ........................... N.A. ...............................

No. Pump type Total head Rate flow 2 UP 80/38 (Kirloskar) 42 m 16.6I/s -

Speed (rpm) 1450 Pump input(kw) 12.15 MOTOR Power Current RPM V 18.5 kw 33 A 1450 rpm 415 v

CONDENSER WATER PUMP

No. Total head 2 27m 2 16 m 8.88 l/s 2 18 m 3.33 l/s 2 18 m 3.33 l/s 2 24 m 6.66 l/s

Rate of flow 22.2I/s

D\Users\R Seshadri\unit 4 shutdown\Unit#4 shutdown oil use.doc

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Speed (RPM) 1450 Pump input, kw MOTOR Power, kw Current, A RPM Volts 11 33.0 1460 415+10% 7.75

1430 2.68 3.7 7.9 1430 415+10%

1430 1.73 3.7 7.9 1430 415+10%

1430 1.73 3.7 7.9 1430 415+10%

1450

Power(kw)

UPS 5.5 CER-3-7 DDCMIS-15

5.5

3.7

3.7

9.3

9.3 18.0 1460 415 RPM Current UPS 11A CER-3-7 DDCMIS-15 UPS 1410 CER-3-7 DDCMIS-1460 BLOWER CAPACITY (m /hr)
3

11A

7.9A

7.9A

18.0A

1460

1440

1440

1440

Ambient
temp, c
0

50 c
0

50 c
0

50 c
0

50 c
0

50 c
0

Type & Make Crompton Greaves induction motor

Crompton Greaves induction motor

Crompton Greaves induction motor

Crompton Greaves induction motor

Crompton Greaves induction motor

UPS-12325 CER 10370

17000

12240

12240

25500

DDCMIS 20485

FRESH AIR COOLING TOWER

No. Model Clr. water qty. In/out water temp. 39/32.30c 39/32.30c 36 39/32.30c 16 39/32.30c 0.216m3/hr 9 0.42kg/cm2 1000 2.2 1000 10500 Model No. Make Refrigerant No UPS-3 CET-3 DDCMIS-3 3 2 2 2 Refr. Qty. Description 9 Make up water 1.44m3/hr No. of nozzles Pr. drop in nozzle Speed, rpm 0.42kg/cm 2 686 0.42kg/cm2 0.42kg/cm 2 750 5.5 750 20480 1000 2.2 1000 10500 0.576m3/hr 0.216m3/hr 2 4201 M 80m3/hr 2 1468 P 32m3/hr 2 1468 P 12m3/hr 2 1468 P 12m3/hr 1 FAN MOTOR No. Power, kw Current, A RPM 3 1.1 2.7 1045 1 0.37 1.1 1460 1 0.37 1.1 1460 1 0.37 1.1 1460

FRESH AIR FAN

Capacity, m /hr
3

UPS 1500 DDCMIS 2000

100

100

100

Motor rating, kw 5.5 Motor speed, kw 1440 Fan capacity,m3/hr 10600

Control Room 1500 Main A/C PAC Unit (7.5 x 2 + 7.5 x 1) Tonne PAW 718 oil charged Blue Star R-22 64 Kg Microwave A/C System (7.5 x5 + 7.5x2) tonne PAW 718 oil charged Blue Star R-22 64 Kg 7.5

AH UNIT

Cooling capacity 7.5

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Max. pressure Min. pressure Compressor type RPM Lubrication system Lucrication oil Compressor motor

27kg/cm2 18kg/cm 2900 Servo Friz F-33 Capella B 7.09 kw

2

27kg/cm2 18kg/cm 2900 Servo Friz F-33 Capella B 7.09kw

2

Hermatically sealed

Hermatically sealed

Forced feed by oil pump Forced feed by oil pump

Fan capacity Speed Motor Rating Current Voltage Make

14550 m3/hr 100 rpm 3.7 kw 7.9A 415+10v ABB

20480 m3/hr 710 rpm 5.5 kw 12A 415+10v ABB

4.10 DIESEL GENERATOR SET MAIN PLANT D.G SET CONDENSER WATER PUMP
(i) No. Pump head Rate of flow Size RPM Power input Motor Power Current RPM Voltage Make 3.5 7.9 A 1430 415+10% Crompton Greaves induction Motor 3.5 7.9 A 1430 415+10% Crompton Greaves induction Motor (i) (ii) (iii) (iv) (v) Rated BHP at 330c/500c No. of arrangement of cylinder Speed Method of starting Time required for starting from cold (vi) lnterval between starting impulses (vii) No. of starting impulses (viii)Type of governor (ix) Guaranteed fuel consumption at full load (x) Thermal efficiency (xi) Method of cooling of engine and lubrication oil (xii) Amount of water required for cooling system 890/870 BHP 12-VCVCEE 1500 rpm Electric battery 24 VDC 30 seconds, max 3 second 3 PSG motorised 150 gm/BHP/hr as per BS/649/ 5514 38% Radiator water cooled/forced air blast 300 litre 2 16 m 8.88 l/s 65x50 mm 1430 2.68 Kw 2 16 m 8.88 l/s 65x50 mm 1430 2.68 Kw Manufacturer Diesel engine with accessories Alternator and exciter (ii) Net electrical ouptut of DG set at 500c ambient/400c ambient Kirloskar Cummins Ltd. NGEF Ltd. 590 kw/600 kw

DIESEL ENGINE

COOLING TOWER

Model Circulating water qty In/out water temp Make up water No. of nozzles Pressure drop in nozzle

1268 P 18 m3/hr 39/32.30c 0.324 m3/hr 9 1.42 kg/cm2

1468 P 32 m3/hr 39/32.30c 0.76 m3/hr 16 1.42 kg/cm2

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ALTERNATOR

ALTERNATOR

(i) Rated kw capacity at 40oc/50oc (ii) Rated KVA capacity at 40oc/50oc (iii) Rated terminal voltage and frequency (iv) Rated statar current (v) Class of insulation (vi) Type of exciter used (vii) Excitation current and voltage at rated power output and power factor

621.2/584 kw 776.6/730 kva 415v,50HZ 1021 A F Brush less, 3.9 kw

(i) Make (ii) Rating KW KVA Ampere (iii) Rated terminal output (iv) Class of insulation

NGEF Ltd. 212.5 250 348 415v, 3, 0.8 p.f., 50 HZ F

DIESEL TANK
20 A, 45v (i) Capacity 1000 litre 4.12 CENTRAL LUBE OIL STORAGE AND PURIFICATION SYSTEM STORAGE TANKS CAPACITY

BATTERY AND BATTERY CHARGER

(I) Type of battery (ii) No. of batteries

Lead acid battery, automotive type Each 12V-200 AH battery comprises of 6 cells and 4 batteries in series/parallel comvination to give 400 AH-2V DC Silicon, 40A 6-8 hour

(i) Dirty tank (ii) Clean oil tank (iii) Oil unloading vessel with suitable cover

60m3 60 m3 1 m3 1 m3

(iii) Type of rectifier and rated output current (iv) Time required for recharging the battery

4.11 CENTRAL OIL PURIFIER

(i) Make (ii) Capacity Alfa laval 6000 lph

SWITCHYARD DIESEL GENERATOR SET DIESEL ENGINE

PUMPS
Drain oil pump Dirty oil transfer pump Rotary positive displacement 1 6000 2.0 Clean oil transfer pump Rotary positive displacement 1 6000 2.0

(i) (ii) (iii) (iv) (v)

Make Type Rated BHP RPM Method of cooling

Ruston and Hornshy (I) Ltd. HWM AG West Germany TBD-232 V12 357 1500 Radiator water cooled/forced air blast

(i)

Rotary positive displacement (ii) No. 4 (iii) Capacity, lph 6000 (iv) Head,kg/cm2 (g) 2.0

Type

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4.12 MISCELLANEOUS WATER SYSTEM SERVICE WATER SYSTEM

FILTER WATER PUMPS FOR AIR CONDITIONING AND AIR COMPRESSOR COOLING

Service Water Booster Pump

(i) (ii) (iii) (iv) (v) No. No. of stages Flow Head Motor 2 (1 + 1) Four 425 m3/hr 60 mlc 110kw, 415v, 3 power supply, Crompton Greaves motor

(i) Location (ii) Make (iii) No. (iv) Pump size (v) Flow (vi) Head (vii) Motor

Filter water pump house Flowmore 3 14 M 225m3/hr 70 mlc Crompton Greaves make, 75kw, 1480 rpm, 415v, 3, power supply, class B insulation, 132 A

(i) Tank Height (ii) Tank capacity

TANK 34 m 300 m3

4.13 COAL MILL REJECT SYSTEM

DRINKING WATER SYSTEM

Drinking Water Pump (i) No. (ii) Make (iii) Working/standby (iv) No. of stages (v) Flow (vi) Head (vii) Motor rating Plant 2 Flowmore 1+1 Seven 100 m3 60.085 mlc 30 kw, 1475 rpm, class B insulation
CromptionGreavesMake

(i) Township 2 Flowmore 1+1 Two 300 m3 42 mlc 55kw, 1475 rpm, class B insulation
CromptionGreavesMake

Capacity of mill pyrite hopper (ii) General composition of mill reject (iii) Lump size of mill reject (iv) Mill reject rate (v) Temperature of reject (vi) Rated capacity of system (vii) Conveyors a. Belt make b. Belt type

0.625 m3 Hard coal, shales, pyrite metollic pieces, stone chips and other extraneous matter present in coal 40 mm (approx) 0.1% to 1.0% of coal consumption, 1500c 30 tph MRC1 MRC2 Hilton make Hilton make 500 mm wide, Nylon 500mm wide, 500/3 GD, 5mm top Nylon 500/3 and 2mm bottom GD, 5 mm top rubber cover GR HR 150 and 2 mm bottom rubber cover GR HR 150 30m /min 30m / min 30 tph 30 tph

(i) Tank height (ii) Capacity

Tank 34 m 300 m3 c. Speed d. Rated capacity

APH WATER WASHING PUMPS

(i) (ii) (iii) (iv) (v) (vi) Make No. and type Flow Head NPSH required Motor Mather & Platt Ltd. 2(1+1), KL-ISO 150 x 125 - 400 220m3 / hr 50 mlc 4.2 m 55 kw, 1480 rpm, GEC make

145

146

e. Design capacity f. Gear box

60 tph Rodicon make, 440 rpm, NGEF make, squirrel cage, TEFC

60 tph U1000 60.1 radicon Radicon make 15HP, 1440 rpm NGEF make, squirrel cage,

Warm reduction U 1000 Warm reduction

(viii) Conveyor accessories

Pull chord type emergency switch system Belts sway switches

(ix) Bin a. Capacity b. Type c. Diameter d. Height e. Liner f. Minimum valley angle of silo

zero speed switches 125 tonne Cylindrical at top, conical at bottom 5m 3.7 m cylindrical and 4.0 m conical 10 mm THK Tiskacrd liner 600

147

OFF SITE - 2 WATER REPLEBISHMENT SYSTEM TUBEWELL PUMPS

(i) (i) No. of tubewell envisaged No. of tubewell commisioned -42 - 35 - Poller - submersible - 200m /hr.
3

WATER REPLENISHMENT SYSTEM

(i) (i) (ii) No. of tubewell envisaged No. of pump Dischrge capacity - 42 - 04 (3 working 1stand by) - 1750m3/hr. - Kirlosker - BHM 30, Vertical turbine - 180 hp - 225 Amp - 2 nos 800 nb tube pipe Sikandrabad distributary - 01nos. 110 nb MS pipe- water treatment plant

(iii) Make (iv) Model (vi) Motor rating (vii) Full load current (viii) Dscharge connection

(iii) Pump make (iv) Pump type (v) Discharge capacity (vi) Motor rating

- 14nos - 20 hp - 20nos - 35 hp - 01nos - 60 hp

(vii) Full lood current

- 30 Amp - 52 Amp - 90 Amp

PLANT STORM WATER SYSTEM

(i) No. of pumps (ii) Discharge capacity - 06 nos (Flowage/FMI make) - 03 nos (WPIL make) - 190 m3/hr. - (Flowage/ FMI)-55kw Crompton - (WPIL) - 45 kw siemans (iv) Speed (v) Full Load Current - (Flowage/FMI) - 980rpm - (WPIL) - 982 rpm - (WPIL) - 80 Amp. - Flowage/FMI-99Amp.

(viii) Speed

- 2900 RPM

CONSTRUCTION DETAILS OF DEEP BORE WELL

(i) (ii) Depth of drill bore - mtr. depending on soil strata Size of housing pipe - 350 mm

(iii) Motor rating

(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.

PLANT SEWERAGE SYSTEM

(i) (ii) Manufacturer No. of pump envisaged - Iron manufacturer - 14 nos. - 12 nos. - 30m3/hr. - 1430 RPM. - 4 Amp.

(iii) No. of pumps commissioned R E S E RV O I R O F T U B E W E L L WAT E R RE P L E N I S H M E N T S Y S T E M SIZE - 60m X 15m X 4m. RESER VOIR OF TUBEWELL WATER REPLENISHMENT SYSTEM SIZE - 60 m X 15 m X 4m. (iv) Dischare capacity (v) Speed (vi) Full Load current

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5.1 UNIT C&I SYSTEM

SG (FSSS) TG (ATRS) Measuremets Automation DAS

Procontrtol P13/42 (BBS Sweden) Iskamatic A&B (KWU W. Germany) DDCMIS (Contronic 31)_______ M/S ILK (H & B, W. Germany) DDCMIS M/s BHEL

Make

Hartman & Braun, West Germaby. Contronnic 3 & Contrnic 31 Instrumentation LTD. Kota

SECTION - 5

Model Supplier

DDCMIS Constitues of
i. Open Loop Control System

CONTROL & INSTRUMENTATION

ii. Close Loop Control System iii. Information System iv. Sequence of Events Recorder (Stand alone)

OLCS/CLCS System Configuration

No. of groups No. of function groups(OSCS) No. of function groups(SLCS) No. of OLCS Cubicles No. of CLCS Cubicles No. of Control loops Processor for OLCS Processor for CLCS 03 36 05 09 09 19 XU13/14 (8085 Micro processor) XU03/04/(8085 Micro processor)

150

141
System Redundancy Parallel operation available through CRT keyboard and push buttons on the panel. Redundant power supply of 240 VAC Through fuji UPS (i) (ii) (iii) Model Make

142
Performance Calculation Comuter

Alpha server.800 Comp 091/Digital USA OVMS

Operationg system

INFORMATION SYSTEM SEQUENCE OF EVENT RECORDER

No. of memory nests Memory capacity (hard disk) No. of central operating str. No. of monitoring st. (PS-U) No. of coupling st. (PS-K) No. of CRT & keyboard (on desk) Processor for IS 02(Consist of mass memory & redundant mass memory.) 80 MBx4 05 05 06 07 CRT & 4 keyboard PCP- 04 ( 80286)

(i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) (x) (xi) (xii) (xii)

Make Model No. of ative points No. of wired points Input per card Resolution Alarm debouce time Buffer capacity

: M/s Hathaway, USA : Hathaway 7.000 SER : 320 : 305 : 64 : 1 mS : 1 mS to 65 sec, Adjustable on per point basis : 2000 events

*the system is characterised by object oriented man machine interface for ease of operation through CRT keyboard. IS System Configuration Monitoring Functions 1. Analog inputs 2. Digital inputs mon inputs 1050 + 64 remote inpute 2002 +40 remote inpute + 287 com

Contsct Interrogation veltage : 48 v ungrounded Acceptaility of NO/NC contact : Yes Alarm printer Archiving facility SER terminal : Mannesman Tallys MT-290 : Wyse make PC provided (20 MB memory) : Monochrome CRT, Adds model 10

Standard Displays
1. Alarm display 2. Curve display 3. Bar display 4. Op. area display 5. Graphic display 6. Function group Op. display 01 20 34 10 87 29

Interface with FSSS/ ATRS Through Relay Panel ( Only Binary Communication)

FSSS/SBC/SADC
Model Make Supplier Software Language No. of stations Procontrol P13/42 BBC (Brown Boveri) Sweden BHEL (EDN( Bangalore Procontrol P10 11

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152

No, of processors Type of processor

20 70PR 03 ( Dedicated type) Pragram memory 4096 bytes (EPROMS)

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

System Configufration
1. No. of Intra-plant bus 2.No.of stations. / IBP 3. No.of stations.entire system 4.Modules per local bus 2 (max.16) 10(max.64)&09 (max.64) 11 (max.1024) Max.64

All Modules are protected against short circuit and over load

Contac Inputs
Voltage between terminals with open contact 48V DC 5 mA Contact current for closed contact

Data Communication
i. Useful addresses ii. Time cycle (set) iii. Information bit rate iv. Type of modulation v. Amplitude vi. Data security Max 256 20ms 204.8 KBAUD Pulse modulation +10v low active Parity bit, clock monitoring, data valancy on local bus, address cycle, watchdog timer

*Procontrol system is powered by +26v redundant charger with battery backup at 175A (full Load).

Interfae With ATRS/ DDCMIS: Through relay cabinet mounted inside FSSS cabinet (only binary comm,) ELECTRONIC AUTOMATION SYSTEM FOR TURBINE (EAST)

Intra-Panel Bus (IPB)

Manufacturer i. No. of assresses ii. Time reqd./one telegram iii. Information bit rate iv. Signal code v. Amplitude vi. Data security 256xNo of stations,1684Max 60Micro seconds 233.7 KBAUD DPDM + _ 15V Parity bit, counting of binary characters, monitoring of time and amplitude per bit Coaxial cable East package comprises of ISKAMATIC A 1. Turbine stress evaluator BHEL (EDN), Bangalore ISKAMATIC A &B ISKAMATIC B 1. Logic subgroup control

vii. Transmission means

2. Electro hyd. governing control 2. Limit value monitoring (linear, nonlinear variables) 3. LP-Bypass, seal/leak steam Control 3. Drive control modules (Valves/pumps/solenoids)

4. Vibration & position monitoring 4. Relay cabinets

Inputs. Outputs
Analog I/P & O/P Presistance - 10 to+ 10v Binary I/P 0/4-20mA, 100 ohm I/ For O signal :- 30 to +3v

5. Analog signal conditioning 6. Turbine protections 7. Auto synchroniser 8. load shedding relay

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COMMON FEATURES

5.2. INTELOCK AND PROTECTION 5.2.1 BOILER AND AUX. FURNACE SUPERVISORY SAFEGAURD SYSTEM 1. Purge Permissive
a. b. c. d. e. f. g. h. i. j. k. l. m. n. o. LOTV closed. HOTV closed. All LONV closed. All HONV closed. Drum level not. high. (Drum level less than+125 mm) Drum level not low. (Drum level less than-125mm) No boiler trip condition . All scanners show no flame. Air flow less than 40%. Aux. air damper modulating. Wind box to furnace DP not. v. high (wind box to furnace DP less than 225mm wc) All PA fan off. All Hot air gates closed. All pulverisers off. All feeders off.

1. 2. 3. 4. -

Separate ref. voltages for analog (HQ)/binary (M) signal conditioning Only one connection exists between M& H, at the cabinet power supply bus. Decoupling of signal conditioning paths. Selective fusing and use of ICs 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 power sources. Signal communication in between FSSS/DDCMIS/ Eastis done through coupling relay cabinets CRA 01 02 with complete isolation.

UNINTERRUPTED POWER SUPPLY

(i) (ii) Make Model Fuji,Japan CVCF 5000 2 no.,sharing equal load 75 KVA 420 VAC + _ 2 % OUTPUT 50 HZ + _ 5% 240 VDC common for both

(iii) No. and capacity (iv) Capacity (v) Voltage rating (vi) Frequency (vii) Battery Rating UPS Make Capacity No of Batteries Each cell viltage (viii) Bypass mode Type AVR power factor AVR Input Eff. at rated I/P &O/P AVR output Cooling system

2.

Purge Sequence
a. b. c. d. Purge ready (All 16 Purge permissives are satisfied) Purging (2 minute cycle). Second stage purging. (3 minute cycle ) purge complete.

3.
Exide 750AH 110 2v : Automatic voltage regulatior : 1 to 0.8 lag : 415 v + _ 10% single phase two wire : More than 85 % : 240 v +2% : Forced air cooling

First Cause of Trip * Master Fuel Trip

a. b. c. d. e. f. g. h. i.

Alarm

Trip
+ 325 mmwc - 225mmwc + 225mm - 225mm

Both ID fan off Both FD fan off Both RAPH off Furnace pressure very high +100 (2/3logic) Furnace Pressure very low -100 (2/3logic) Drum level very high +125 (for more than 10 sec) Drum level very low -125 (for more than 10 sec) Emergency trip. Loss of 220 V.D.C for more than 2 sec

155

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j. *k. **l. ***m. ****n. o. p. q.

Air flow less than 30%. Reheat protection trip. Flame failuer trip Loss of all fuel trip. Less than fireball and loss of A.C. power at any elevation in service. All BFPS Trip. Loss of unit critical power+24VDC. Spare trip not connected.

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, or b. Elevation A and B feeder off or loss of power at elevation A & B for moer than 22 sec or c. 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, or b. Elevation CD all HONV open any elevation CD started and loss of AC power and elevation CD 2/4 nozzle valve not proven or c. 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.

*Reheat Protection Trip

1. Generator breaker open Turbine tripped or 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 turbine working and Load sheddig relay opeated with 11 sec off delay than reheat protection is armed with time delay of 10 sec. Turbine trip is armed if first stage pressure more than 35 bar and then any ESV or IV closes or turbine trip Turbine working is armed if All ESV & IV open and first stage pressure is greater than 35 bar. Boiler working is armed if a. b. c. Main steam pressure left more than 50 bar and main steam temperature left more than 3500c, and Main steam pressure right more than 50 bar and main steam temperature right more than 3500c, and Boiler fire on, provided HP bypass v/v 1 & 2, and LP bypass Valve 1 & 2 opened more than 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 2 sec) Elevation AA voted : Elevation A feeder off or Loss of elevation power for more than 2 sec. or

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 or b. Elevation FF 3/4 scanner show no flame. ***Loss of all fuel trip a. 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, and c. HOTV not open, or elevation AB, CD, DE and EF elevtion back up trip and d. 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 elevation DC power.

PULVERISER Typical for all pulveriser PULVERISER PERMISSIVE

1. Pulveriser Ready a. Feeder jin remote b. Pulveriser start permit

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158

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 95c. e. Bunker outlet gate open. f. Cold air gate open . Any LOP on and lub oil pressure more than 3,0 kg/cm and lub oil temp. in berween 20-500c and DP across filter O.K and no lub oil trip.
2

d. Elevation CD in service and feeder D proven more than/equal to 50%.

Pulveriser F :
a. Elevation EF in service or b. Boiler load nore than 30% and feeder E proven more than/equal to 50%, or c. Elevation DE in service and feeder E proven more than/equal to 50%.

g. Lube oil start permit

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 to eleveation 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 500 mmwc 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) and pulveriser on for more than 60 sec i. j. pulveriser ignition permit lost. 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

h. Elevation A.C. available. i. j. Tramp iron hopper valve open. Primary air permit, or any pulvesier ON. Primary air permit : 3 or more pulvarisers not on and any PA fan on, and primary air pressure 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 to 50%.

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%

INTERLOCK
a. Seal air damper interlock

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

Seal air damper opens with pulveriser start. Pulveriser off, seal air damper closes. b. Pulveriser on, permissive to open the hot air gate. c. Pulveriser on, permissive to start coal feeder.

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HOT AIR GATE OPEN PERMISSIVE

a. Pulveriser on. b. Hot air gate not close.

OIL GUN HEAVY OIL TRIP VALVE OPEN PERMISSIVE

OPEN PERMISSIVE
1. 2. 4. 5. 6. 7. No MFR trip Heavy oil supply pressure adequate All HONV closed Heavy oil temperature adequate Atomising steam pressure not low Heavy oil trip valve not open No stop command for HOTV or HORV open and all HONV closed

VALUE

CLOSE PROTECTION
a. 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.

8.0kg/m2 3. 95 c 2.5kg/m2

COAL FEEDER START PERMISSIVE

CLOSE PROTECTION
1. 2. 3. 4. 5. 6. 7. 8. Feeder switch in remote condition. No MFR trip Elev DC power available Pulveriser On. Motor current not low on coal belt. Pulveriser ignition permit Pulveriser ready and ourlet temperature less than 930c and feeder speed demand at minimum and if in auto mode HAG open for than 5 sec. No stop command for feeder for more than 3 sec or no auto stop for feeder. 1. 2. 3. Loss of unit 24 v DC Master fuel trip (MFR Trip) Heavy oil header pressure low (2.2kg/cm2)or heavy oil header temperature low (95Oc)or atomising steam pressure very low (2.5kg/cm2)for more than 2 sec and HORV not open open.

HEAVY OIL EVEVATION START PERMIT

1. Pulveriser start permit (No MFR trip amd nozzle tilt horizontal amd air flow less than 40% or any feeder proven). Heavy oil trip valve open No master fuel trip

FEEDER PROTECTION
(i.) (ii) (iii) (iv) (v) (vi) Corresponding pulveriser trip. No coal on belt. Discharge plugged. Feeder overload. Feeder switch not in remote condition. MFR trip. 2. 3.

LIGHT OIL TRIP VALVE LIGHT OIL TRIP VALVE OPEN PERMISSIVE
1. 2. No MFR trip. Light oil supply pressure adequate

(vii) Elevation D.C. power failue (viii) Within 30 secs of tha starting of feeder no coal on belt or feeder motor current low. (ix) Within 180 secs of the starting of feeder ignition permit is lost.

8.0kg/cm2

161

162

3. 4. 5.

All light oil nozzle valve closed Atomising air pressire not low LOTV not open and no stop command

3. 2.5kg/cm
2

For air motor, air pressure before solenoid valve more than 2.5 kg/cm2.

INTERLOCK
1. 2. 3. Electric motor B trip, elect motor A start vice versa. Electric motor B fail to start when start command is given electric motor A starts with time delay of1 sec, vice versa with electric motor B. lf running electric motor trip & stand by electric motor remain off for more than 2 sec and air pressure before solenoid valve more than 2.5kg/cm2, air motor starts. Damper interlock RAPH start, flue gas inlet and outlet, secondart air inlet and outlet, damper open.

CLOSE PROTECTION
1. 2. 3. Loss of unit 24 v DC power MFR trip Any LONV open and L.O.pressure very low (2.0kg/cm2) for more than 2 sec and LONV open or atomising air pressure very low (2.5 kg/cm2) for more than 2 sec and at any elevation no start/stop command

4.

LIGHT OIL ELEVATION

1. 2. 3. Pulversier start permit LOTV opend No MFR trip

5. a. b. c. d. e.

Guide bearing LOP and suport bearing LOP interlock LOP A trip, LOP B starts and vice versa. LOP B foil to start, LOP A starts & vic versa. LOP B on and Lub oul flow low, LOP A with time delay of 10 sec. and vice - versa. If any PA fan motor is on and RAPH starts, Primary air inlet & outlet damper open. RAPH remains off for more than 2 min. & other RAPH is ON flue gas inlet & outlet, sec. air inlet & outlet, and premary air inlet & outlet dampers close.

OIL GUN START SEQUENCE (Typical for AB 1&3 pair)

1. 2. 3. 4 5. 6. 7. Start command given to pair 1&3 AB 1 steam/air atomising valve open HEA advance if atomising valve ipen feed back available HEA spark cimmand if HEA fully advance feed back available and HINV 1 open Spark for 15 sec. Flame scanner show flame, Gun hold After 5 sec of AB1 command, command to AB 3 start.

PROTECTION
1. 2. RAPH giode bearing temperature more than70oc. RAPH support bearing lub oil temperature more than700c.

REGENERATIVE AIR PRE HEATER PERMISSIVE PERMISSIVE

1. 2. Any guide bearing LOP healthy or lub oil temp. less than 35c Any support bearing LOP healthy or Lub oil temp less than 35c

SCANNER AIR FAN

INTERLOCK
1. 2. 3. A.C. scanner air fan trip, D.C. scanner air fan starts. Loss of unit critical power, D.C. scanner air fan starts. A.C. scanner air fan in service and scanner air dut to furnace DP is

163

164

4. 5.

less than 6 of water column, DC scanner fan starts. Both FD fan off, emergency air damper opens. Scanner fan start, dischuge damper open with time delay of 5 sec.

SEAL AIR FAN PERMISSIVE

1. Either PA fan in service

10. 11. 12. 13. 14. 15. 16.

Hyd. cplg. oil tank level adequate Luh oil pressure more than 1.5kg/cm2 Hyd. cplg. oil pressure more than 1.0kg/cm2 ID fan inlet gate closed ID fan outlet gate slosed Vane control minimum scoop tube control minimum

59 60 61 62 63 64 65

INTERLOCK 1. Gate interlock

a. Fan start, inlet &outlet gate open. b. Fam stop/trip, inlet & outlet gate closes provided other ID fan is on.

INTERLOCK
1. 2. 3. 4. Either PA fan on for more than 2 sec, seal air seal air fan starts. 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. 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. Seat air fan start, dischrge damper open with time delay of 5 sec.

2.

LOP interlock
a. LOP B trip, LOP A starts & vice versa b. 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 versa d. ID fan made off, LOP A trip after 30 min. Same with LOP B.

PROTECTION
1. Both PA fan not on for more than 15 sec.

3.

AOP Interlock
a. ID fan trip, AOP A starts b. AOP B trip, AOP A starts and vice versa c. 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-B f. ID fan motor made off, running AOP srop after time delay of 30 minutes.

ID FAN PERMISSIVE
1. 2. 3. 4. 5. 6. 7. 8. 9. ID fan and motor bearing temperature less than 80c Hyd. cplg. bearing temperature less than 100c RAPH A/B on ID fan LOP A/B on Hyd. cplg. pump AOP A/B on Lub oil cooler outlet temp less than 40c Hyd. cplg. oil cooler outlet temp. less than 70c Stack path available Lub oil tank level adequate

CRITERIA NO.
50 51 52 53 54 55 56 57 58

PROTECTION
1. 2. 3. 4. ID fan or motor bearing temperature more than 90Oc. Hyd. cplg. bearing temperature more than 110Oc. ID fan lub oil pressure less than 0.7 ksc or Hyd.cplg. oil pressure less than 0.6 ksc. Fan bearing vibration, more than 9.0 mm/sec

165

166

5. 6. 7. 8. 9. 10.

11. 12.

Inlet or outlet gate closed with time delay of 4 minute. Hyd. cplg. return oil temperature more than 120c Post purge trip acted. Corresponding FD fan tripping provided other ID fan on. Under voltage tripping 70% of rated voltage. Overload tripping CDGM - 12.96% TMS 0.2 ( 121.6% of full load current) Overload alarm CTU 12.80% 8 sec. Over current instantaneous high set CAG 37 1000% Sensitive earth fault tripping CTIGM 15 100 mA LOTV and HOTVclosed and all feeder off and all pulveriser off and air flow more than 30% and all scanner shows no flame satisfied for more than 300 sec and furnace pressure very high or very low post Purge trip armed.

LOP B starts and vice versa. d. LOP B fail to start when start command is given,LOP A starts and vice versa. e. FD fan off, LOP A off with time delay of 30 min. same with LOP B.

PROTECTION
1. 2. 3. 4. 5. 6. 7. 8. 9. Lub oil pressure less than 0.5 kg/cm2. Bearing temperature fan or motor more than 110c Bearing vibration more than 9.0 mm/ sec Discharge damper closed with time delay of 60 sec Both ID fan off Both FD and ID fan on and corresponding ID fan trip. Post purge trip acted Under voltage tripping, 70% of rated voltage Overload tripping CDGM-12, 79%, TMS 0.3 (109.72% of full load current) (overload alarm CTU 75% 9 sec.) 10. 11. Overcirrent instantaneous high set trip CAG 37, 1000% Sensitive earth fault trip CTI GM 15, 100 mA.

*Post purge trip :

F.D. FAN

PREMISSIVE 1. 2. 3. 4. 5. 6. 7. 8. 9. Lub oil pressure more than 0.9 kg/cm2 Control oil pressure more than 9.0 kg/cm2 Lub oil tank level adequate Bearing temperature fan and motor less than 90c ID fan A/B motor on. Oil cooler outlet oil temperature less than 45c Blade pitch minimum Discharge damper closed Lub oil pump A/B on

CRITERIA NO. 50 51 52 53 54 55 56 57 58

P.A. FAN PERMISSIVE

1. 2. 3.

CRITERIA
50 51

Fan and mptor bearing temperature less than 80c Hyd. cplg. bearing temperature less than 100c PA fan lub oil cooler outlet temperature less than 45c and hyd. cplg. cooler outlet temperatute less than 70c

INTERLOCK 1. Discharge damper interlock Fan start, discharge damper opens. Fan motor off, discharge close. Provided other FD fan is on LOP interlock a. 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 4. 5. 6. 7.

52
2

Lub oil pressure more than 1.2 kg. cm and hyd. cplg. oil pressure more than 1.0 kg/cm2 Lub/Hyd. cplg. oil tank level adequate Either FD fan on Start permit from FSSS available ( All CAG less than 5% open and No MFR trip or either PA fan on ) 56 53 54 55

2.

167

168

8. 9. 10. 11. 12.

PA fan inlet and outet gate closed Regulating vane and scoop tube minimum Any lub oil pump on Any hyd. cplg. oil pump (AOP) on Oil flow at cooler outlet more than 75%

57 58 59 60 61

10. 11. 12. 13.

Under voltage tripping 70% of rated voltage. Overload tripping CDGM12 87%, TMS 0.6 (114.97%of full load current) Overload alarm CTU 12 80%, 6 sec. Over current instantaneous high set trip CAG 37 1000% Sensitive earth fault trip CTIGM 15 100 mA.

INTERLOCK 1. Damper interlock

Fan starts inlet and outlet damper opens Fan trip/stop. inlet and outlet damper closes.

GR FAN PERMISSIVE
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.

CRITERIA NO.
50 51 52 53 54 55 56 57 58 59 60 61

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 B c. LOP B fails to start when start command is given, LOP A starts with time delay of 2 sec, and vice versa d. 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 versa d. 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.

Fan and motor bearing temperature less than 80c Atleast one ID fan on Atleast one FD fan on Lub oil pump A/B on GR fan inlet and ourlet gate closed Oil cooler ourlet oil temprature less than 40c Oil tank level adequate Fan cool air damper closed Fan furnance damper closed All feeders off Boiler load index more than 30% Lub oil pressure more than 1.5 kg/cm2

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. Turning gear interlock a. GR fan motor trip and lub oil pressure more than 1.5 kg/cm2, turning gear motor auto start

PROTECTION
1. 2. 3. 4. 5. 6. 7. 8. 9. Fan or motor bearing temperature more than 90c Hyd. cplg. bearing temperature more than 110c. Hyd. cplg. return oil temperature more than 120c. Fan bearing vibration more than 9.0 mm/sec Lub oil pressure less than 4.0 bar. Hyd. cplg. oil pressure less than 0.6 bar PA fan inlet or outlet gate closed, with delay of 2.5 minute. Both FD fan off MFR trip.

3.

169

170

b. GR fan motor off and fan discharge temprature is less than 93c, turning gear motor stop.

13.

Overspeed trip

3330 rpm Mech. trip.

Fire Protection - 1 operated Turbine trip gear operated and vacuum breaker open Fire Protection - 2 operatedTurbine 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. ** 14. MOT level low same as fire protection -2 Fire off

PROTECTION
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Fan/ motor bearing temperature more than 90c Fan bearing vibration more than 9.0 mm/ sec Lub oil pressure less than 0.4 kg/ cm2 GR fan on and motor current low. Both FD fan off GR fan discharge flue gas temperature more than 440c MFT trip Any feeder on GR fan motor on and any domper (inlet, outlet, furnace side) closed with time delay of 2.5 minutes. Under voltage tripping, 70% of rated voltage. 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) Over current instantaneous high set trip CAG 37 1000%. Sensitive esrth fault trip .CTI GM 15 100 mA

TURBINE OIL PUMP

(1) Aux, oil pump-1 start on auto SLC AOP - 1 is on and AOP-2 trip or lub oil pressure less than 5.48 kg/cm2

5.2.2 TURBINE AND AUXILIARIES TURBINE PROTECTION

(ii)

Aux. oil pump-2 start on auto

SLC AOP-2 is on, and AOP-1trip or lub oil pressure is less than 5.47 kg/cm2

S.No. Description 1. 2. 3. 4. 5. 6. 7. MOT 8. 9. 10 11. 12.

Alarm Value

Trip Value

Remarks

(iii) (iv)

Emergency oi pump start on auto than 1.78 kg/ cm2 Jacking oil pump-1 start on auto Jacking oil pump-1 stop on auto

Lub oil pressure less SLC of JOP on and turbine speed less than 510 rpm Turbine speed more than 540 rpm SLC JOP on and JOP-1 trip or jackung oil pressure less than 100kg/cm2 and turbine speed is less than 510 rpm or on barring with a time delay of 5 sec command for command forSwitch off JOP -1 Switch on JOP -2 Switch off SLC

Drum level very high +125 MFT vhannel 1/2 Generator protection channel 1/2 Lub oil pressure very low 1.88 kg/cm2 Condenser vacuum very low -8.0 Low vacuum mechical trip -0.8 Fire protection channel1/2 -50 -100mm

+225 2 / 3 logic - 0.7 kg/ cm2 - 532 mm / kg zero level 800mm down from top of -100mm 480c -Mech. trip (only annunciation from C&I) -

(v)

Jacking oil pump-2 start on auto

MOT level low Main steam temperature very low Axial shift Local trip 1/2 Emergency push button from unit control board

- 50 500c -

171

172

(vi)

Emergency Jacking oil pump srart on auto

SLC on and JOP 1 & 2 fails to develop pressure nore than 100 kg/cm2 OR Any JOP running 7 Pr. less than 20 kg/cm2

(iii)

(iv)

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 BFP suction and discharge differential temperature more than 10c recirculation valve opens

TURNING GEAR
(i) (ii) PermissiveTurning gear valve open on auto Gen/seal oil DP> 0.9 .& seal oil pr. turbine & exciter end > 3.8 ksc CLC of turning gear on and turbine speed is less than 200 rpm. Turbine speed more than 250 rpm SLC off Lub oil bef. Rad/ Ax. brg. < 1.88 ksc

PROTECTION
(i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) (x) Lub oil pressure less than 0.5 kg/ cm2 Deaerator level less than 700 mm Working oil temperature at cooler inlet more than 130c. suction valve open and BFP booster pump suction pressure less than 1.7 kg/cm2 Bearing temperature more than 95c Hydraulic coupling hearing temperature more than 95c (for bearing 3 & 4 temperature more than 90c ) Recirculation flow control command is maximum & recirculation control valve less than 10% open. Earth fault protection CTI GM 15, 125 mA Motor differntial protection CAG 34 10%, 130 Overload protection CDGM 12, 79%, TMS 0.2 (110.79% of full load current) Overload alarm CTU 12, 75%, 8 sec.

Turning gear valve close on auto Fire protection ch. I & ch II Protection close

BOILER FEED PUMP PERMISSIVE

(i) (ii) (iii)

CRITERIA NO.
50 51 52 53 54 55 56 57 58 59 60 61

AOP on Hydraulic coupling oil pressure more than 1.0 kg/cm2 Discharge valve closed or discharge header pressure more than 25 kg/ cm2 for stand by pump (iv) Minimum flow recirculation valve open (v) Motor cooling water valve closed (vi) Scoop tube control less than 300% (vii) Suction valve open (viii) Bearing temperature less than 85oc (ix) Hybraulic coipling bearing temperature less than 85oc (for bearing 3&4 temperature less than 800c) (x) Cooling water pressure nore than 3.0 kg/cm2 (xi) Deaerator level normal, 2410 mm (610 mm above c.l. of storage tank) (xii) BFP stand by not selected

CONDENSATE EXTRACTION PUMP PERMISSIVE

(i) (ii) (iii) Suction valve open Hot well level more than 500 mm (i.e. more than - 100 mm from normal working level) Recirculation valve opens

INTERLOCK
(i) Discharge pressure more than 15.5 kg/cm2, discharge valve open CEP motor off, discharge valve closes. (ii) CEP motor on and discharge valve open, discharge line vent solenoid valve closes. (iii) Header pr. very low ( 17.5 ksc) - stand by p/p starts Header pr. low (18.0 ksc) - hdr. Pr. low alarm CEP motor off, discharge line vent solenoid valve opens

INTERLOCK
(i) (ii) BFP motor on, motor cooling water valve opens BFP motor on, discharge valve opens

173

174

PROTECTION (i) (ii) (iii) (iv) Hotwell level very low (80mm water level) (-520 mm below NWL) Earth fault protection CTIGM 15, 100 mA Overload protection CDGM 12 96%, TMS 0.2 (115.0% of full load current) Alaram CTU 12% 90%, 5 sec Instantaneous overcurrent 1000%

PROTECTION (i) Suction pressure less than 1.0 kg/cm2 (ii) Discharge pressure more than 10 kg/cm2 and recurculation valve not 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

PERMISSIVE
(i) (ii)

VACUUM PUMP HP / LP BYPASS SYSTEM HP 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 HPBP valves can be open if condenser vacuum > 0.6 kg/ cm2 HPBP valves closes at condenser vacuum 0.6 kg/cm2 HPBP down stream temperature exceed 340c, HPBP valves closes HPBP valve position less than 2%, BPE valve closes.

Seal water recirculation pump on 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 more than 0.05 kg/ cm2, system valve closes. Vacuum p/p auto start logic. a. Auto arming scheme seleted on desk, vacuum more than 650 mm kg Auto command b. Vacuum less than 630mm kg.

(ii) (iii) (iv)

(ii)

PERMISSIVE
(i) (ii) (iii) (iv)

EQUIPMENT COOLING WATER PUMP CRITERIA NO.

14 15 16 17

LP BYPASS SYSTEM PERMISSIVE

(i) (ii) (iii) (iv) Condenser vacuum more than 0.6 kg/cm2. Condenser header pressure more than 8.5kg /cm2 Condenser wall temperature at exhaust hood less than 90c Steam pressure at down stream of LP bypass valve less than 21.2 kg/cm2

Suction header pressure adequate ( 1.5 kg/ cm2 ) Suction valve open discharge valve closes Recirculation valve open

INERLOCK
(i) ECW pump on and discharge header pressure more than 10 kg/cm2 for more than 5 sec, recircilation valve open. ECW pump on and dischrge vaslve open and discharge header pressure less than 10 kg/cm2 for more than 90 sec then recirculation valve close. Running ECW pump trip and discharge pressure less than 5.0kg/ cm2, stand by pump starts if selected. Discharge pressure less than 5 kg./ cm2 or corresponding pump trip, discharge Valve closes.

PROTECTION
(i) (ii) (iii) (iv) Condenser vacuum less than 0.6 kg/cm2 Condenser header pressure more than 8.5kg /cm2 Condenser wall temperature at exhaust hood more than 90c LP injection valve opens at 90c. LP bypass downstream steam pressure more than 21.2 kg/cm2

(ii) (iii)

175

176

MAIN OIL CENTRIFUGE INTERLOCK

(i) (ii) Booster pump motor can be started if main centrifuge motor on. 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 60c, heater III cut off. Oil temperature more than 70c, all heater cut off Water temperature more than 90c, all haeter cut off. Water level low, all heater cut off.

DEAERATOR
(i) Deaerator level rises to 2760mm (350. mm above NWL) (ii) Deaerator level rises to 2835mm (425 mm above NWL) Deaerator overflow drain valve DR 40 opens, and closes at Deaerator level 2585 mm Over flow drain valve DR40 opens (Repeat command) Deaerator pegging steam valve AS2 and CRH-2 closes. 1.5 ata by AS-2 3.5 ata by AS-2 3.5 ata by CRH-2 More than 3.5ata to 6.6 EX -11.

(iii) Deaerator pressure control a. Cold start up b. Hot and warm start up and bypass operation c. CRH line pressure reaches 8 ata d. Turbine load more than 55% when extraction steam pressure pegging pressure

REGENERATIVE HEATER SYSTEM

LOW RESSURE HEATER - 1

INTERLOCK
(i) Very high drip level Cascade drain control valve DR 24 closes and heater is by passed from condensate side by opeming CD 3 1 and closing CD 29 and CD 30.

HIGH PREASSURE HEATER - 5

(i) Very high heater level (310 mm above NWL) Extraction block valve EX 13 closes. Extraction NRV closes. Repeat command to full open alternate drain control valve DR 16 and normal drain control valve DR 13. Heater bypass from feed water side by opening bypass valve FD3 and closing FD 1 and FD 2. Normal drain control valve of HPH-6, DR-2 closes Over riding command to close DR-2

LOW PRESSRE HEATER - 2

(i) Very high drip level Extraction block valve (300mm above normail EX-9 closes water level) Extraction drain valve EX 104&EX 105 opens. Normal cascade drain control valve DR19 closes. Extraction line NRV closes. Alternate drain control valve DR 27 opens.

(iii) Pressure falls below a preset valve

LOW PRESSURE HEATER - 3

(i) Very high drip level (above normal water level) Extraction block valve Extraction drain valve EX-103 opens Extraction NRV closes Alternate drain control valve DR 22 opens

177

178

(i) Very high heater level ( 310 mm adove NWL)

HIGH PRESSURE HEATER - 6

179
Extraction steam block valve EX 14 and NRV closes. Extraction drain valve EX 101 opens. Alternate drain valve DR-9 and normal drain valve DR-2 opens fully. Heater bypass from feed water side by opening bypass valve FD 6 and closing FD-4 & FD-5. Repeat command to open alternate drain valve DR-9 and normal drain valve DR-2 / DR-6.
5.2.3 GENERATOR AUXULUARES GENERATOR RELAY PANEL DESIGNATION CTR/PTR SET VALUE 01. Gen. differential protection 02. Gen. negative phase sequence protection 03. Gen. field failure protection 876 46G 10000/5A 10000/5A ---------------16500/110v 40G 10000/5A -------------16500/110v 5% K 1 =3.3 K 3=2.25 I 2 S=7.5 OPERATING TIME Inst. 4Sec. Inst. REMARK GENERATOR PROTECTION S. PRTECTION NO. Gen. Wdg. insulation protection Gen. unbalance current. protection.

180
04. Gen.pole slipping protection 98G 10000/5A -------------16500/110v 05. Gen. back up impedance protection 21G 10000/5A -------------16500/110v

50m sec.

Protection against Generator falling out of step

k 1 =0.8 k 2 =2.5 k 3 =0.5 k 4 =2.0 k 5 =18.6 k 1 =0.91 k 2 =0.74 k 3 =4 1=100% k 1 =6 k 2 =0.63 Reverse25% reach. =75 0

1.5 sec

Backup protection against external fault.

S.No. PROTECTION 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 high 11. Gen. stator water flow low 12. Exc. system troble (Cl.-A) 13. Gen. low forward power protection 14. Gen. over load alarm 15. Gen. under frequency alarm 16. Gen. over voltage alarm

Design. 95G 64GI 64G2

CTR/PTR 16.5 NTG --------- Kv .240 24.2 AUX PT -------- v .240 16.5 NTG --------- Kv .240 16.5 Line side ---------- kv .110 16.5/.110 -------------- Kv 3/3 .110 AUX --------- v 80 -----13m3/hr -----10000/5A -------------16500/110v 10000/5A 16500/110v 16500/110v

Set value 5.4V 0---95%=6.9v

Operating Time IDMT 1Sec. 2Sec. IDMT 2 sec. 0.5 sec. Inst.

Remark Protn. against insulation failure between two windings Main Protection against generator winding Earth fault

95---100%=0.5v 5.4v 5k 2.2k 20 mho 25 0.5%

181 182

30P 30P 30S 37A&B 51G 81G 59G

2 sec.

Protection for Generator before motoring takes place.

95% 48.5 HZ 110%

20 sec. 5.5 sec. 0.5 sec.

GENERATOR TRANSFORMER
S. No. Protection 01. Gen. GT overall differential protection DESIGNATION 87GT Gen-10000A _______ 5 UAT-10000A _______ 5 02. 03. 04. 05. 06. 07. 08. 09. 10. 11. 12. 13. 14. 220 kv Overhead line kifferential protection GT HV sice ref. protection GT stand by earthfault protection GT bay C.B. LBB protection GT bay C.B. pole discrepancy protection TBC LBB protection TBC pole discrepancy protection GT over fluxing protection GT GT GT GT GT bucholtz trip winding temp high trip oil temp high trip pry. protection fire protection 87L 64NGT SINGT 50Z* * 50Z* 99GT 63GT 1000/1A 1000/1A 1000/1A 800/1A -800/1A -16500/110V CTR/PTR 400 kv-800/1A SET VALUE OPERATING REMARK TIME

Inst. op current=15% Bias - 15%

25% 25% PMS- 20% TMS- 0.7 5% -5%

Inst. Inst. IDMT 0.2 sec 1 sec 0.2 sec 1 sec Inst.

K 1 =1.15 K 2 =1.3

Inst. Inst. Inst. Inst. Inst.

protection against internal fault protection for wdg. insulation failure protection for oil degradation

TECHNICAL SPECIFICATIONS OF 400 KV SHUNT REACTOR

Protn. against wdg. insulation failure protection against internal fault TYPE Rated Power MVArR Rated voltage KV Rated current A Phase Frequency HZ Connection Symbol Impedance /phase Temp. Rise oil (OC) OPERATING TIME Inst. Temp. Rise wdg (OC) 3 sec. . 3 sec Inst. Inst Inst ON AN 63 420 86.90 3 50 YN 2800 50 (OverAmb of 50OC) 55 (OverAmb of 55OC)

RENARJ

UNIT AUX. XFMR

TECHNICAL SPECIFICATIONS OF 220 KV CURRENT TRANSFORMERS ABB MAKE

SET VALUE 150% 30% 40% 80%

Standard Highest System Volt

15:2705 945 50 460/1050 31.5/1sec. 2400amp. 1600 1195

HV-1000/5A LV-1600/1A

DESIGNATION CTR/PTR

Frequency 1600/1A 1000/5A 100/1A Insulation Level S.T. Current Extended (Thermal Current Rating) 63 UT Rated Primary Current Amp. Total Weight of CT. UAT ref. protection on LV side UAT HV side back up O/C protection 03. UAT LV side back up each fault protection UAT bucholtz trip UAT fire protection 04. 05. 06.

64 NUT

S. PROTECTION No.

01.

UAT differential protection

02.

183

51 NUT

87 UT

51 UT

184

TECHNICAL SPECIFICATIONS OF 400 KV ABB MAKE AIR BLAST CIRCUIT BREAKERS

TYPE RATED VOLTAGE IMPULSE SWITCHING IMPULSE RATED FREQUENCY RATED NORMAL CURRENT RATED SHORT CIRCUIT CURRENT RATED SHORE CIRCUIT DURATION FIRST POLE TO CLEAR FACTOR BREAKING CAPACITY ASYMMETRICAL BREAKING CAPACITY ASYMMETRCAL WEIGHT OF COMPLETE BREAKER OPERATING PRESSURE OF AIR RATED TRIP COIL VOLTEGE RATED CLOSING COIL VOLTAGE CONFIRM TO DLVE 420 nc4 420KV 1.2/50 MICRO SEC 1425 KV 1025 KV PEAK 50 HZ 200 A 40 KA 40KA- 3SECS 1.3 40 KA 40 KA 3850 KG 27-31 KG/CM SQ 220 V DC 220 V DC IEC - 56

TECHNICAL STACIFICATIONS OF 400 KV SF-6 BHEL MAKE BREAKER

TYPE RATED VOLTEGE

3AT2 420 KV

RATED IMPULSE WITHSTAND VOLTAGE IMPULSE 1425KV LIGHTING RATED POWER FREQUENCY VOLTAGE 520/610 KVP RATED FREQUENCY RATED SHORT CIRCUIT CURRENT RATED SHORT CIRCUIT SURATION FIRST POLE TO CLEAR FACTOR BREAKING CAPACITY SYMMETRICAL BREAKING CAPACITY EQUIVALENT BREAKING CAPACITY ASYMMETRICAL RATED MAKING CURRENT RATED OPERATING DUTY RATED PRESSIRE OF HYDRAULIC OPERATING MECHANISM RATEDPRESSUREOFSF-6GASAT20DEGC 7.5 bar 8720.5 KG 57.5 KG 220 V DC 220 V DC IEC - 56 50 HZ 2000 A 1 SEC 1.3 40 KA 29000 KVA 51.4 KA 100 KAP 0-0.3 SEC - CO- 3 MIN- CO 250-350 bar

220 KV ELPRO MAKE ISOLATORS

SWITCHGEAR Highest system voltage Type Voltage BIR STC Motor vortage Type of Drive Frequency Control voltage Wt of Drive. TYPE 2000 HCB 220 KV 1050 LVp 40/1 KA /Sec 415 V.AC. MOM 50 Hz --------------220 VDC 100 KG

WEIGHT OF COMPLETE BREAKER WEIGHT OF SF-6 GAS RATED TRIP COIL VOLTAGE RATED CLOSING COIL VOLTAGE CONFIRM TO

185

186

TECHNICAL SPECIFICATIONS OF 200 KV SF - 6 ABB BKR 220 KV CGL MAKE SF-6 BREAKERS AT 220 KV SWYD
TYPE RATED LIGHTNING IMULSE WITHST AND VOLTAGE RATED SHORT CIRCUIT BREAKING CAPACITY RATED OPERATING PRESSURE FIRST POLE TO CLEAR FACTOR RATED DURATION OF SHORT CIRCUIT CURRENT WT OF SF - 6 GAS RATED VOLTAGE FREQUENCY RATED NORMAL CURRENT AT 20 DEG C CLOSE COIL VOLTAGE TRIP COIL VOLTAGE RATED SF-6 GAS PRESSURE RATED OPERATING SEQUENCE TOTAL WEIGHT 24 KGS 245 KV 50 KZ 2500 A 220 V DC 220 V DC 6 KG/CM SQ 0-0.3 SEC- CO-3 MIN 3900 KGS 15 GK/ CM SQ 1.5 3 SECS 40 KA 200 SFM - 40 A 1050 KV CIRCUIT BREAKER CIRCUIT BREAKER TYPE Voltage Normal current Lightning impulse with stand voltage Switching impulse with stand voltage Short circuit breaking current Short time with stand current & duration Line charging breaking current Operatubg seqyebce First - pole - to - clear factor Gas pressure SF6/20.c (abs) Auxiliary circuit supply voltage Air pressure Frequency Mass (approx) for 3 poles CB - TYPE ELF SL 4-1 245 KV 1600/2500 AMP 1050 -KV 40 KA 40 LA 1 Sec. 125 AMP 0-0 3S - co - 3 mm - co 1.3 7.0 bar 240 V AC 20.5 bar 50 hz 400 kg

Closing & opening device supply voltage 220 VDC

220 KV CAPACITIVE VOLTAGE TRANSFORMER TECHNICAL SPECIFICATIONS OF 220 KV CT (ABB MAKE)

C.T TYPE Highest system voltage Rated insulation level Rated frequency Standard Total creepage minimum Class of Insulation Rated Pri Normal current Rated conti. Ther. current S.T. current (1st) 1 dyn Wt of oil Total weight Suitabll C.T. TYPE 1 MB 245 245 KV 245 / 460 / 1050 KV 50 Hz IEC 185 / IS : 2705 6125 MM A 1600A 2400A 40/ 1 KA rms / Sec 100 KA peak 270 KG 1700 KG YES

C.V.T.
TYPE Highest system voltage Rated insulation level Rated frequency Standard H.V (PRI) Cap. : C 1 Int V (SEC) Cap. : C 2 Temperature Category Total Thermal Burden Class of Insulation Rated voltage Total creepage min. nominal mm Wt of oil Equ cap. (cn) for PLCC Nominal intermediate voltage Suitable for hot line washing 245 KV

C.V.T. TYPE
WP 245 Nz 245 / 460 / 1050 KV 50 Hz IEC 186 / IS : 3156 4840 PF 48400 PF - 5 To 550c 1000 VA A 220 / 53 KV 6125 150 kg / 6 + 6 4400 PF + 10% 5% 20 / 53 KV YES

187

188

STATOR WATER PUMP PERMISSIVE

(i) Expansion tank level more than 41.0 cm

(iv) (v) (vi)

Low suction pressure, less than 2.0 kg/cm2. High discharge pressure, more than 18 kg/cm2. Differential pressure between oil and suction pressure less than 0.5kg/cm2 (vii) Fire protection.

INTERLOCK
(i) Header pressure less than 2.4 kg/cm2, standby pump start

CW PUMP PERMISSIVE
(i) (ii) (iii) (iv) (v) (vi) Suction sump level more than 208.5 m Discharge butterfly valve closed Motor thrust and guide bearing temperature normal Condenser tower inlet valve open Cooling tower inlet valve open Cooling water flow more than predetermined quantity for more than 5 minutes ( 20 lit/min )

PROTECTION
(i) Expansion tank level low, less than 41.0 cm

SEAL OIL SYSTEM INTERLOCK

(i) Seal oil header pressure less than 4.0 kg/cm2, D.C seal oil pump starts. (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.

INTERLOCK
(i) (ii) CW motor on, discharge butterfly valve opens after 30 sec CW motor off, discharge butterfly valve closes.

5.2.4 INTERLOCK AND PROTECTION- OFFSITE AIR CONDITIONING PLANT A.C. COMPRESSOR PERMISSIVE
(i) (ii) (iii) (iv) (v) (vi) (vii) Any cooling tower fan in service. Any condenser water pump in service. Any chilled water pump in service. Any AHU in service. Condenser water flow adequate Stand by compressor off. No fire.

PROTECTION
(i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) Motor bearing temperature more than 95oc Vibraton high, more than 9 mm /sec Suction pump water level less than 208.5 m. Cooling water flow to motor bearing low. Discharge valve fails to open within 90 sec of pump starting Discharge valve close Discharge pressure more than 2.8 kg/cm2 Motor earth fault protection. CTIGM 15, 100mA. Motor overload protection. CDGM 12, 79%, TMS 0.2 ( 116.17% of full load current) Alarm CTU 12, 70%, 7 sec. Instantaneous over current, 1000%.

(x)

PROTECTION
(i) Both cooling tower fan off. (ii) Both comdenser water pump off

189

190

FUEL OIL PUMP HOUSE L.F.O UNLOADING PUMP INTERLOCK

LFO PRESSURING 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

1. Pump on auto and no trip from MCC and any pump on and LFO pressure inadequate for more than 60 sec, stand by pump starts. 2. Any pump started and tripped for more than 10 sec, stand by pump starts.

H.F.O PRESSURISING PUMP ( FOR ABC OF UNIT 1 & 2, OR D,E, F OF UNIT 3 & 4)

PERMISSIVE
HFO filling line valve of any HFO tank open

INTERLOCK
1. Start command given and pump off for more than 10sec, standypump start. 2. Any pump on started and tripped for more than 10 sec, stondby pump starts,

PROTECTION
(i) (ii) (iii) Any HFO storage tank level high. Any HFO storage tank level low Low pressure in the suction header of HFO pumps.

DRAIN OIL PUMP (PRESSURISING AREA)

DRAIN OIL PUMP (UNLOADING AREA) INTERLOCK

1. 2. srain oil tank level high, pump starts. Drain oil tank level low, pump stops.

INTERLOCK
1. Drain oil tank level high, pump starts. 2. Drain oil tank level low, pump stops.

SUMP PUMP (UNLOADING AREA) INTERLOCK

1. 2. Sump pit level high, pump starts. Sump pit level low, pump stop.

191

192

TURBINE ROLLING CURVE-1 DT (HP BYP.1 - HP SHAFT ) < X 6

600

STEP/ CRITERIA

15/2

500

SECTION - 6

ANNEXURE

HP Shaft mid metal temperture o c

400

300

200

Prohibited Zone

100

0 0 100 200 300 400 500

o

600

700

Main Steam temp. before HPBP, C

193

TURBINE ROLLING CURVE-3 TURBINE ROLLING CURVE-2 DT (LP BYP 1-HPSHAFT) <x7 STEP/ CRITERIA 12/7 12/8

600

STEP/ CRITERIA

DT(LPBYP1-IP CASING) > 30 K DT(LPBYP2-IPCAS) > 30K

20/ 2

600

500

500

400
Hot reheat temp., O c

300

Hot reheat 400 temp., O c

300

200

Prohibited Zone
100

200

Prohibited Zone

100

0 0 100 200 300 400 500 600 700

0 0 100 200 300 400 500 600 700

Main Steam temp. before HPBP,oC

IP Inner casing temp, oC

194

195

TURBINE ROLLING CURVE-4 DT(HP ESV1-HP SHAFT)>x5.1 DT(HP ESV2-HP CASING)>x5.2

600

STEP/ CRITERIA

12/4 12/5

500

HP Casing temp- 500 50% depth,oc

400 HP Shaft mid 400 metal temp,oc 300

TURBINE ROLLING CURVE-5 STEAM BEF HP ESV1 S/H>x4.1 STEAM BEF HP ESV2 S/H>x4.2

STEP/ CRITERIA

12/2 12/3

600

Prohibited Zone
500

Main steam temp.

200

400

300

100
200

Prohibited Zone

0 0 100 200 300 400 500 600 700

100

100

200

Main Steam Temp, before SV I, 0c Main Steam Temp, Before SV II, 0c

Main Steam Pressure Bars (LBA 10CP 002) Before stop valve 1 (LBA 20 CP 002)

196

197

TURBINE ROLLING CURVE-6 DT (HP BP 1- CONTROL V/V 1) < x 3 A115.1

600
STEP/ CRITERIA 5/1

TURBINE ROLLING CURVE-7

HP Control Valve temp 50% depth (MAA 10CT 011B) oc

500

600

STM. BEF. HP BP I S/H >300K STM. BEF. HP BP II S/H >300K STM. BEF. LP BP I S/H >300K STM. BEF. LP BPII S/H >300K
5/2 5/3 5/4 5/5 8/2 8/3 8/4 8/5

500
400
Required temp. Main steam & HRH 0 C

400

300

300

200

200

Prohibited Zone

100

Prohibited Zone

100

0 0 100 200 300 400 500 600 700

50

100

150

200

Main Steam Pressure / Hot Reheat Pressure

Main Steam tmp before HPBP (LBA 10CT 002B),oc

198

199

TURBINE ROLLING CURVE-9 DT (HP BYP 1 - CTRL V1) >1.1 DT (HP BYP 1- CTRL V2) >1.2

600

STEP/ CRITERIA

TURBINE ROLLING CURVE-8 DT (WET STM 1- CONTROL V/V1) <x2.1 DT (WET STM 2- CONTROL V/V2) < 2.2 STEP/ CRITERIA 5/9 5/10

5/6 5/7 8/7 8/8

500

400

HP control valve temp 50% depth

600

500

HP Contro 300 valve 50% depth o c

200

Prohibited Zone

400

300

100

200

Main Steam Pressure, Bars before stop valve

100

0 0 100 200 300 400 500 600 700

200 Main Steam100 Pressure before HPBP Valve,o c

200

201

ANNEXURE 2 GENERATOR CAPABILITY DIAGRAM

GENERATORE TYPE THW-210-2A RATED GENERATER OUTPUT RATED ARMATURE VOLTAGE RATED ARMATURE CURRENT RATED FREQUENCY POWER FACTOR RATED H2 PRESSURE SN UN IN FN PF 247.000 16.50 8.645 50.0 0.85 3.50 MVA KV KA HZ BAR

ANNEXURE 3 UNLOADING SCHEDULE DUE TO HIGH DISTILLATE TEMPERATURE 247 MVA, 210 MW, 16.5 KV, 0.85 PF, 3000 RPM, 3.5 BAR H2 RESSURE

NOTE :1. REDUCED H2 PRESSURE OPERATION NOT PERMITTED 2. VALID FOR BOTH WITH AVR WITHOUT AVR

RATED STATOR CURRENT .8645

MAX OUTPUT = 228.9 MW

0.95 240
0.9 0.8

STATOR CURRENT

0.9

200

8750
0.7

8700
0.85 160
0.6

S T A T O R C U R R E N T
248 244 240 236 232

RATED OUTPUT- 247 MVA

8650
0.8 120

Normal temp. of Distillate

8600
0.7 0.6 0.4 0.2 40
0.2

MVA OUTPUT

80

0.4

8550

8500

8450
100 60 20 0 40 80 120 160 200

8400

Temp. of distiliate at inlet of stator winding - oc

LEADING MVAR------------------ LAGGING MVAR

202

8350

8300

203

228

Annexure - IV LUBE OIL SCHEDULE

(vi) (vii)

Fluid coup. twin disc Main drive gear reducer gear box

Servo Prime 32 Servo system 220 Servo sysem32

3.5 lts. 50lts.

TYPE OF OIL USED IN VARIOUS EQUIPMENTS

(viii) Air motor compressed air line

0.5 lts.

8.
S.No Name of Equipment BOILER AND AUXILIARIES (ii) 1. 2. 3. 4. 5. i) ii) iii) 6. (i) (ii) PA fan HC of PA fan FD fan ID fan Hydraulic coupling of ID fan GR fan Gravimetric feeder Belt drive reducer NSG C.O. conveyor reducer C.O. conveyor gear head E.S.P Gear motor assy. gear box collecting electrode Gear motor assy. gear box emitting electrode A.P.H. Support bearing Guide bearing Aux. drive electric motor cam clutch box Cleaning device 2 stage worm gear reducer Fluid coup fluid drive Servo Servo Servo Servo Servo Servo Prime 68 Torque 10 Prime 68 Prime 68 torque 10 Prime 68 650Its/BIr 1000 Its/BIr 1700 Its/BIr 1700 Its/BIr 10lts. 4lts. 2lts. Type of Oil Approx.Qty. (i)

Bowl mill
Lower radial bearing Thrust bearing Upper radial brg. Juornal bearing. upper Juornal bearing. lower Servo Servo Servo Servo Servo mesh mesh mesh Mesh Mesh SP-320 SP-320 SP-680 SP-680 SP-680 3900lts/mill 3900lts/mill 3900lts/mill 130 lts/mill 130 lts/mill

9.
(i) (ii)

Wall Blowers
Rack housing Rotary gear box Servo Mesh SP-460 Servo Mesh SP-640 0.5 lts. 0.5 lts.

Servo CylC-680 Servo CylC-680 Servo CylC-680

10.
(i) (ii) 11. (i) (ii)

LRSB
Power pack rotary Power Pack Traverse fTP Power pack Chain Servo System 68 Servo System 68 Servo System 68 Servo System 150 0.9 lts. 0.8 lts. 0.8 lts. 0.8 lts.

Servo Gear NP-90 Servo Gear NP-90

84 lts./Blt. 264 lts./Blt.

TURBINE AND AUX,

1. Main oil tank (Turbine) First filling Boiler feed pump hydraulic coupling BFP electro mechanical actuator for scoop control of hyd coup. CEP LP bypass System HP bypass system Gland steam control valve & seal steam control valve Stator water pump Actuators of valve and dampers Servo Prime 46 30,000 lts.

7. (i) (ii) (iii) (iv)

Servo Cyl-c 680 Servo Cyl c-680 Servo Prime 32

90 lts. 25 lts. 0.5 lts.

2. 3. 4. 5. 6. 7. 8. 9.

(v)

Servo Mesh SP- 460 Servo Prime 32

4lts. 4.5 lts.

Servo Servo 20 Servo Servo Servo

Tourqe 10 Mesh SP50/ prime 46 prime 46 convol 46

1,200 lts. 7 lts 15 lts.

HLP-46 Servo prime 46 Servo Prime 68

204

205

10. 11.

Centrifuge gear box Equipment cooling water bearing

SAE-40 Grease SG-3

4 lts. xiii) Rotary twin lobe type compressor for M.B. Exchanger Model- SMK ESSO-G.P.90 GP - 140 IOC Mobilub- GX 140 Mobilub - GX 140 Grease servo GEM no. 2 or 3. Shell Multipurpose 3 lts.

Off- site
1. 2. (i) (ii) 3. 4. 5. 6. 7. i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) C.W pump motor NDE & DE bearing Raw wwater pump house PTDM pump Plant air and instrument air compressor A.C. plant compressor D.G. set switchyard Air Comp. switch yard WTP Degasser pump DM, regeneration pump Alkali unloading pump Waste disposal pump Drinking water pump Boiler fill pump DM Make up pump F.W. Pump Slakalitransfer pump Effluent disposal cum recirculation pump Acid metering pump 7660SE Degasser blower (centrufugal) AW 30 Burma shell multipurpose grease No. 2 or ESSO white 18 gm/3 months bearing Gease or CATEX MARFEX HO - 2 x) SAE -30 Pulsolub 0.55 lts. 1.6 lts. ix) Drinking water pump Motor (Plant) brg. NDE 6312 Filter back wash pump thrust bearing viii) Air blower (PTDM) SAE 20/30 SAE -30 SAE -20 SAE -30 SAE -20/30 SAE 30/40 SAE 30/40 Grease Grease shell Alvonia No.3 0.9 lts. vii) 1 lts. 1 lts. 1.8 lts. 2.2 lts. iv) v) vi) iii) Servo Press 100 Servo friz 57 Hy Lub Milcy Servo super 40 ii) Flocilator drive -12 gear box ( PTDM) Redicon worm reducer type -AVD 337 Bride drive motor(PTMD) SAE - 40 2 lts. SAE - 40 8. i) Pretreatment Plant Bridge drive (gear box) PTDM xiv) All Motors Softening plant water pump Servo Prime 32 55 lts.

(Lithium based) Gulf Crown no.2 Lithium based grease Lithen - 2 3

Servo Mesh SP-320 Servo System -320 Servo Mesh SQ -320 Servo System 320 Gease GR -3 14lts

3 lts.

1.4 lts.

Flash mixer gear box(PTDM) Servo Mash SP-320 Flash mixer motor bearing Central bearing of PTDM clarifier Air blower (PTS) Servo SEA 40 Servo Mesh SP -680 Servo System SP 320 Servo Mesh SP-680 Servo System -320 AP 2 of Castrol Grease GR -3

10C - Servo System 317.

206

207

SATURATED PROPERTIES OF WATER AND STEAM WITH PRESSURE AS PARAMETER

Pressure P ata 0.02 0.05 0.06 0.08 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 *C 17.204 32.55 35.82 41.16 45.45 59.67 68.68 75.42 80.86 85.45 89.45 92.99 96.18 99.09 110.79 119.62 126.79 132.88 138.19 142.92 147.20 Temp. Specific Volume Vf lit/kg 1.0013 1.0053 1.0064 1.0084 1.0101 1.0169 1.0221 1.0261 1.0296 1.0327 1.0355 1.0381 1.0405 1.0428 1.0521 1.0600 1.0666 1.0726 1.0780 1.0829 1.0875 Vg m3/kg 68.26 28.73 24.18 18.45 14.95 7.789 5.234 4.066 3.299 2.781 2.409 2.126 1.904 1.725 1.180 0.9019 0.7319 0.6160 0.5338 0.4708 0.4215 hf 17.25 32.58 35.84 41.17 45.45 59.65 68.66 75.41 80.86 85.47 89.49 93.05 96.25 99.18 110.99 119.9 127.3 133.5 138.9 143.7 148.1 Specific Enthalpy Keal/Kg-K hfg 587.6 578.9 577.2 574.0 571.6 563.0 558.0 554.1 550.7 548.0 545.6 543.4 541.3 539.5 532.1 526.4 521.4 517.3 513.5 510.2 507.1 hg 604.9 611.5 613.0 615.2 617.0 623.0 626.0 629.5 631.6 633.5 635.1 636.4 637.7 638.7 643.1 646.3 648.7 650.8 652.4 653.9 655.2 sf 0.0612 0.1127 0.1233 0.1402 0.1540 0.1976 0.2242 0.2438 0.2593 0.2722 0.2833 0.2931 0.3019 0.3097 0.3409 0.3640 0.3823 0.3976 0.4109 0.4226 0.4331 Specific Entropy Keal/Kg-K sg 2.0849 2.0065 1.9912 1.9664 1.9480 1.8903 1.8567 1.8338 1.8149 1.8003 1.7881 1.7772 1.7675 1.7589 1.7267 1.7040 1.6860 1.6716 1.6592 1.6488 1.6394

ANNEXURE V STEAM TEBLE

208 209

5.0 6.0 7.0 8.0 9.0 10.0 15.0 20.0 25.0 30.0 35.0 40.0 50.0 60.0 70.0 80.0 90.0 100.0 110.0 120.0 130.0 140.0 150.0 160.0 170.0 180.0 190.0 200.0 210.0 220.0

151.11 158.08 164.17 169.61 174.53 179.04 197.36 211.38 222.90 232.76 241.42 249.18 262.70 274.29 284.48 293.62 301.92 309.53 316.58 323.15 329.30 335.09 340.56 345.74 350.66 355.35 359.82 364.08 368.16 372.1

1.0918 1.1000 1.1071 1.1140 1.1202 1.1262 1.1524 1.1751 1.1953 1.2142 1.2320 1.2493 1.2826 1.31147 1.3466 1.3787 1.4115 1.4453 1.481 1.518 1.558 1.600 1.644 1.693 1.750 1.812 1.889 1.99 2.13 2.39

0.3818 0.3214 0.2778 0.2448 0.2190 0.1980 0.1342 0.1016 1.08150 0.06798 0.05819 0.05078 0.04026 0.03312 0.02798 0.02405 0.02097 0.01846 0.01638 0.01462 0.01314 0.01182 0.01067 0.00963 0.00868 0.00780 0.00697 0.00618 0.00535 0.00438

152.0 159.4 165.7 171.4 176.5 181.2 200.7 215.9 228.6 239.6 249.5 258.4 274.3 288.4 301.0 312.8 323.8 334.3 344.2 353.9 363.3 372.6 381.9 391.0 400.4 410.1 420.2 431.4 444.6 463.0

504.2 498.9 494.2 489.8 485.8 482.1 466.0 452.6 440.7 429.9 420.0 410.6 393.2 377.0 361.6 346.6 331.9 317.4 302.9 288.5 274.0 259.0 243.7 227.9 211.0 192.7 172.7 149.4 121.4 79.3

656.3 658.3 659.9 661.2 662.3 663.3 666.7 668.5 669.3 669.5 669.5 669.0 667.5 665.4 662.4 662.6 659.4 655.7 647.1 642.4 637.3 631.6 625.6 618.9 611.4 602.8 592.9 581.1 566.0 542.3

0.4426 0.4594 0.4740 0.4868 0.4983 0.5088 0.5508 0.5822 0.6078 0.6295 0.6484 0.6654 0.6950 0.7203 0.7428 0.7632 0.7817 0.7992 0.8157 0.8316 0.8466 0.8614 0.8758 0.8901 0.9145 0.9192 0.9347 0.9515 0.9713 0.9993

1.6309 1.6164 1.6040 1.5930 1.5833 1.5749 1.5412 1.5162 1.4962 1.4793 1.4646 1.4515 1.4289 1.4089 1.3911 1.3747 1.3589 1.3439 1.3293 1.3154 1.3031 1.2872 1.2729 1.2583 1.2427 1.2258 1.2075 1.1864 1.1606 1.1222

PROPERTIES OF SUPERHEATED SYSTEM Temperature 0C 200 ata t 15.0 v 0.1235 (197.4) 668.4 h s 1.5445 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 220 0.1436 681.1 1.5699 0.1043 674.4 1.5280 250 0.1550 698.0 1.6036 0.1138 693.1 1.5645 0.0891 687.9 1.5325 0.0123 682.1 1.5038 0.0510 669.7 1.4530 270 0.1624 708.8 1.6241 0.1197 704.6 1.5863 0.0940 700.2 1.5556 0.0768 695.5 1.5289 0.0550 685.7 1.4825 0.0416 674.2 1.4410 300 0.1731 724.7 1.6527 0.1281 721.3 1.6166 0.1010 717.8 1.5874 0.0829 714.2 1.5624 0.0602 706.6 1.5200 0.0465 698.4 1.4842 320 0.1800 735.2 1.6709 0.1334 732.4 1.6354 0.1055 729.1 1.6071 0.0868 726.1 1.5827 0.0634 719.6 1.5423 0.0493 712.5 1.5087 350 0.1901 751.2 1.6970 0.1412 74808 1.6621 0.1120 746.1 1.6345 0.0924 743.5 1.6112 0.0678 737.9 1.5729 0.0531 732.2 1.5412 370 0.1970 761.8 1.7137 0.1465 759.4 1.6791 0.1162 757.1 1.6518 0.0960 754.8 1.6290 0.0707 749.7 1.5914 0.0555 744.7 1.5609 400 0.2070 777.5 1.7375 0.1542 775.5 1.7035 0.1225 773.4 1.6767 0.1013 771.4 1.6542 0.0749 767.2 1.6177 0.0590 762.9 1.5885 450 0.2234 803.5 1.7748 0.1667 801.9 1.7414 0.1328 800.4 1.7152 0.1101 798.7 1.6934 0.0816 795.4 1.6583 0.0646 792.0 1.6302 500 0.2397 829.6 1.8098 0.1790 828.3 1.7767 0.1426 827.0 1.7509 0.1185 825.7 0.1295 0.0882 823.0 1.6953 0.0700 820.3 1.6681 550 600 650

0.2559 0.2720 0.2880 855.8 882.3 909.0 1.8427 1.8739 1.9038 0.1913 0.2035 0.2156 854.7 881.3 908.2 1.8100 1.8415 1.8715 0.1527 0.1624 0.1722 853.7 880.5 907.5 1.7844 1.8116 1.8462 0.1269 0.1350 0.1432 852.6 879.6 906.7 1.7632 1.7950 1.8254 0.0946 0.1008 0.1071 850.4 877.7 905.1 1.7296 1.7617 1.7924 0.0752 0.0803 0.0853 848.2 875.8 903.4 1.2029 1.7356 17666

209 210

ata t

300

320 0.3998 705.1 1.4788 0.0276 688.0 1.4239 0.0199 666.0 1.3688

350 0.0432 726.4 1.5140 0.0308 713.9 1.4645 0.0231 669.0 1.4231 0.0178 681.5 1.3798 0.0120 647.6 1.3083

370 0.0454 739.7 1.5349 0.0326 728.8 1.4902 0.0248 716.5 1.4508 0.0195 703.0 1.4137 0.0140 678.0 1.3567 0.0746 610.5 1.2320

400 0.0485 758.7 1.5635 0.0351 749.5 1.5217 0.0271 739.8 1.4858 0.0217 729.5 1.4537 0.0161 712.2 1.4083 0.0103 676.0 1.3327

420 0.0505 770.9 1.5813 0.0367 762.6 1.5408 0.285 754.4 1.5065 0.0119 745.5 1.4765 0.0173 731.2 1.4364 0.0116 702.2 1.3710

450 0.0533 788.5 1.6065 0.0390 781.5 1.5676 0.0305 774.4 1.5353 0.0247 766.9 1.5074 0.0189 754.8 1.4698 0.0131 732.7 1.4140

470 0.0551 800.1 1.6225 0.0405 793.8 1.5744 0.0317 787.3 1.5532 0.0258 780.4 1.5261 0.0199 769.7 1.4905 0.0139 750.6 1.4385

500 0.0579 817.5 1.6453 0.0427 811.8 1.6082 0.0335 806.1 1.5781 0.0274 800.1 1.5522 0.0213 791.0 1.5188 0.0151 775.0 1.4709

550 0.0623 845.8 1.6809 0.0461 841.1 1.6449 0.0364 836.3 1.6161 0.0299 831.5 1.5916 0.0234 824.1 1.5604 0.0169 811.4 1.5168

600

650

700

750

60.0 v 0.0371 (273.3) h 689.0 s 1.4512 80.0 v 0.0250 (93.6) h 667.0 s 1.3875 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

0.0666 0.0708 901.7 873.8 1.7138 1.7451 0.0494 0.0527 898.4 869.8 1.6788 1.7107 0.0392 0.0418 895.0 865.8 1.6519 1.6835 0.0323 0.0346 891.7 861.8 1.6273 1.6606 0.0254 0.0273 886.6 855.6 1.5976 1.6319 0.0185 0.0201 878.2 845.3 1.5567 1.5930

0.0749 0.0791 929.9 958.3 1.7750 1.8035 0.0559 0.0590 927.1 956.0 1.7411 1.7700 0.0444 0.0470 924.3 953.5 1.7142 1.7434 0.0368 0.0289 921.5 951.1 1.6917 1.7211 0.0291 0.0309 917. 947.4 1.6639 1.6941 0.0215 0.0229 910.1 941.3 1.6265 1.6578

OPERATION RELEASE AVAILABLE : ATRS START-UP PROGRAMME

STEP-1 : WT/MT 0/2 Sec. PERISSIVES FOR OPERATION RELEASE:
Command : 1. 2. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Starting device 0 % Position set point of turbine control 0 % Generator field breaker OFF Generator breaker off Drain before HPCV-1 (MAL 11) not closed Drain before HPCV-2 (MAL 12) not closed Limit pressure operation ON Load controller ON Synchroniser OFF Pressure oil pressure 5.4 Kg/cm 2 TSE influence OFF 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. SLC drains ALL ESVs HPCV-1 HPCV-2 IPCV-1 IPCV-2 CRH NRV Left CRH NRV Right Extraction valve A5 <5% Extraction valve A4 <5% Extraction valve A3 <5% Extraction valve A2 <5% ON closed. closed. closed. closed. closed. closed. closed. open. open. open. open.

STEP-2 WT/MT 0/500 Sec.

NO Commands 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Trip oil pressure > 5.0 Kg./cm2 Turbine speed > 15 RPM Condensate pressure > 22 Kg/cm2 Drains DT HP Casing (top-bottom) DT HP Casing (top-bottom) DT IP Casing front (top-bottom) DT IP Casing front (top-bottom) DT IP Casing rear (top-bottom) DT IP Casing rear (top-bottom) NO FAULT > - 4 0 K > + 4 0 K > + 4 0 K > - 4 0 K > + 4 0 K > - 4 0 K

211

212

STEP-3 : WT/MT 160 Sec.

Commands : 1. 2. 3. 4. Drain before HPCV-1 Drain before HPCV-2 SLC warm up control Waiting time close close OFF 60 Sec.

STEP-5 : WT/MT 50 Sec.

Commands : Starting device raise 1. Starting device OR HPESV-1 OR HPSEV-2 not closed not closed > 24%

STEP-4 : WT/MT 60 Sec./ Blocked

No Commands : 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Boiler fire on Steam before HPBP-1 Steam before HPBP-1 Steam before LPBP-1 Steam before LPBP-2 Temp. (HPBP1 - control valve) Temp. (HPBP2 - control valve) Total boiler steam flow DT (wet steam2 - control valve) DT ( wet steam2 - control valve) DT (HPBP1 - control valve) OR Boiler stm. temp before HPBP1 12. 13. 14. 15. 16. Drain before HPESV-1 (MS 101) Drain before HPESV-1 (MS 102) Drain before IPESV-1 (HRH 101) Drain before IPESV-2 (HRH 102) Oil temperature before cooler < 400 C not closed not closed not closed not closed > 350C > 30K superheat > 30K superheat > 30 K superheat

STEP- 6 : WT/MT 160

No Command 1. 2. HPESV-1 HPSV-2

Sec.

open open

> 30K superheat >x-1 >x-1 > 15% <x-2 <x-2 <x-3

STEP- 7 : WT/MT Blocked

1. 2. 3. 4. 5. 4. 7. 8. 9. Total steam flow Steam before HPBP-1 Steam before HPBP-2 Steam before LPBP-1 Steam before LPBP-2 Boiler fire DT/HPBP2-control valve) DT(LPBP1-control valve) Condenser pressure > 15% > 30 K superheat > 30 K superheat > 30 K superheat > 30 K superheat ON > X - 1, 2 > X - 1, 1 < 0.5 Kg/cm2

STEP- 8 : WT/MT 1.2 Sec.

Command : 1. SNC warm up control ON

STEP- 9 : WT/MT -/60Sec.

Command : 1. 2. 3. Tracking device IPESV-1 IPESV-2 ON OPEN OPEN

213

214

STEP-10 : WT/MT
No Command : 1. Drains 2. Speeder gear 3. Gland steam pressure control 4. SLC oil temperature control 5. Any oil vapour extractor fan 6. Hydrogen purity 7. Gen. gas pressure 8. Gen. seal oil gas diff. pr. 9. Genrator seal oil gas diff. pr. 1 . Genrator seal oil EE pr. 11. Leavel in prechamber 1 & 2. 12. Generator stator water flow 13. Generator stator water pr. 14. Stator water inlet temp. 15. Hydrogen cooler CQ Pr. 16. Liwuid in generator 17. Generator SW conductivity

2 .

Diff Expn. LP casing rear

> - 2. mm

NO fault < 100% ON ON ON > 97% > 3.4 Kg/cm2 > .9 Kg/cm > 3.8 Kg/cm2 > 3.8 Kg/cm2 < Max. > 21 M3 > 2.4 Kg/cm2 < 440 C < 2.5 Kg/cm2 Not present < 5 micro mho/cm.

STEP-12 : WT/MT 40 Sec.

Command : Speed setpoint raise. 1. Speed setpoint

540 rpm.

STEP-13 :
NO Command : 1. Turbine speed

540 rpm.

STEP-14 : WT/MT
Command : Turine stress test programme 1. 2. 3. 4. 5. 6. 7. 8. 9. 1 . 11. 12. 13. 14. 15. 16.

Blocked > 200 C <I-6 > 30 K < 35 microns < 35 microns < 35 microns < 35 microns < 50 microns < 50 microns < 50 microns < 50 microns < < < < < Max. Max. Max. Max. Max.

STEP-11 : WT/MT

-/ Blocked

No Command : 1. Generator conditions 2. Steam before HPESV-1 superheat 3. Steam before HPESV-2 superheat 4. DT (HPESV1 - HP casing) 5. DT (HPESV2 - HP casing) 6. Turbine speed 7. DT (LPBP1 - IP casing) 8. DT (LPBP2 - IP casing) 9. Steam temperature before LPBP-1 1 . Steam temperature before LPBP-2 11. Drain before HPCV-1 12. Drain before HPCV-2 13. Load setpoint 14. Condenser pressure 15. Diff Expn. HP casing front 15. Diff Expn. HP casing front 16. Diff Expn. HP casing front 17. Diff Expn. HP casing front 18. Diff Expn. LP casing rear 19. Diff Expn. LP casing rear

Fulfilled > X - 4.1 > X - 4.2 > X - 5.1 > X - 5.2 > 15 rpm. > 30 K > 30 K > 400C > 400C Not closed Not closed > 10% < 0 .2% Kg/cm2 > +5.0 mm > - 3.8 mm > + 8.0 mm <u - 8.0 mm > - 2.0 mm < + 23.0 mm

Wall temperature HP casing DT (HPBP - HP shaft) Turbine stress margin Brg. vibration HP casing front Brg. vibration HP casing front Brg. vibration IP casing front Brg. vibration IP casing front Brg. vibration generator front Brg. vibration generator front Brg. vibration generator rear Brg. vibration generator rear Vibration HP shaft front Vibration HP shaft rear Vibration LP shaft front Vibration LP shaft rear Differential expansion 300 sec.

STEP-15 : WT/MT
Command : 1. 2.

SLC warmup control Speeder gear raise

OFF 100%

215

216

STEP-16 : WT/MT
Command : 1. 2. 3. 4.

3 Sec.

STEP-21 : WT/MT
Command : SYNCHRONISER raised. closed closed 30 36 RPM 1. Gen. breaker

15 / 60 Sec. ON ON

Turbinde speed set point Drain before HPV-1 Drain before HPCV-2 Speed set point

STEP-22 : WT/MT STEP-17 : WT/MT

NO Command : 1. 1. 2. 3. Turbinde speed Brg. vibration Gen./Casing Shaft vibration > 2950 rpm. < Max. < Max. Waiting time Blocked Command : Load setpoint

1Sec. / 1Sec. raise 15 Sec.

STEP-18 : WT/MT
Command : 1. 2.

/ 60 Sec.

Drain before HPCV-1 Drain before HPCV-2

closed. closed.

STEP-19 : WT/MT
NO Command : 1. 2. 3. 4. 5. 6.

Blocked

Both AOP DT (LPBP - IP shaft) Gen. conditions Field flashing supply AVR control supply AVR protection supply / 155 Sec.

OFF <X-7 fulfilled ON ON ON

STEP-20 : WT/MT

Command : GENERATOR FIELD BREAKER 1. 2. 3. Wait time Gen. field breaker Gen. voltage

ON 15 Sec. ON > 95%

217

218

End