Vous êtes sur la page 1sur 198

SANTALDIH

THERMAL POWER STATION


SANTALDIH THERMAL POWER STATION

TECHNICAL DIARY

P.O- Santaldih T.P, Dist- Purulia, WB723146


THE WEST BENGAL POWER
DEVELOPMENT CORPORATION
LIMITED
(A Government of West Bengal
Enterprise)

2x
250MW

UNITS

TECHNICAL DIARY-Santaldih Thermal


Power Station

PERSONAL MEMORANDA
NAME
-----------------------------------------------------------------------------------

DESIGNATION
-------------------------------------------------------------------

MIS NO.
----------------------------------------------------------------------------------

DEPARTMENT
---------------------------------------------------------------------

RESIDENTIAL ADDRESS
--------------------------------------------------------------------------------------------------------------------------------------------------------

TECHNICAL DIARY-Santaldih Thermal


Power Station

PERMANENT ADDRESS
---------------------------------------------------------------------------------------------------------------------------------------------------------

TELEPHONE NO.
------------------------------------------------------------------

MOBILE NO.
--------------------------------------------------------------------------

BLOOD

GROUP
--------------------------------------------------------------------

DATE OF

BIRTH--------------------------------------------------------------------

TECHNICAL DIARY-Santaldih Thermal


Power Station

STPS VISION
To be one of the best Thermal Power
Plant fulfilling directions of excellence
including
socioeconomic
&
environment
aspects
in
power
generation as a responsible business
entity.

OPERATION VISION

To generate reliable & economic power


by optimal utilization of resources.

TECHNICAL DIARY-Santaldih Thermal


Power Station

GENERAL INFORMATION

Name of the Project:


POWER STATION

SANTALDIH THERMAL

Phase-1
4x120=480MW
Unit -1 was de-commissioned
Unit -2 was de-commissioned
Unit -3 was de-commissioned
Unit -4 was de-commissioned

Phase-2

(Unit 1 to 4)
on 18.12.2009.
on 04.10.2009
on 20.01.2009
on 07.10.2008
(Unit 5 & 6)

2x250=500MW
Unit-5 Oil Synchronization on 01.09.2007
Coal Synchronization on 31.03.2008
COD on 01.04.2009
Unit-6 Oil Synchronization on 21.11.2010
at19:32 hrs
Coal Synchronization on 03.03.2011 at
00:37 hrs
Location: SANTALDIH THERMAL POWER STATION
is situated at SANTALDIH, Village in
Purulia District of West Bengal, Nearest
Rly. Stn.; Santaldih
Longitude: 86d2809E and
Latitude: 23d3607N
Ambient Temperature
Highest: 45 0C
Lowest: 8 0C
Relative Humidity-: 86% Max
Annual average rain fall: 1392 mm

TECHNICAL DIARY-Santaldih Thermal


Power Station

Land:

Total Land
: 1363.470 Acres
Main Plant
: 546.60 Acres
Ash Pond
: 271.180 Acres
(comprising ash pond 1 & 2).
Intake p/p house, pipelines &
Road corridor
: 146.06 Acres
Township
: 328.23 Acres
Approach Road : 42.06 Acres
Police station, Rehabilitation
area & Fire brigade barrack
etc.:29.00 Acres

Main Package: M/S Bharat Heavy


Main
Contractor: Electrical Limited
Water Package from Panchet Dam
Reservoir to STPS M/S- SPML
Coal Handling Plant: M/S- MBEL
Railway Infrastructure: M/s Rites Ltd.
COAL from:
BCCL
ECL
Main Fuel: MCL
IMPORTED COALLIERIES

TECHNICAL DIARY-Santaldih Thermal


Power Station

Auxiliary Fuel is LDO. Estimated total


annual requirement is 10000 KL. For
Auxiliary Fuel:
Phase-2 only average oil rate
considered 1 ml/KWH.
DVC:
OLD INTAKE (BHOJUDIH): 810
cu.mm/hr x 6 NO. OF PUMPS
Water:

NEW INTAKE
(PANCHET):
1500
Unloading
in Railway
Track hopper
NO. OF PUMPS
fromcu.mm/hr
Bottomx 5Discharge
Wagon
(BOBR) has been envisaged. Coal
Coal Handlingbunker storage (800 T/bunker) X 6
System:
per unit has been envisaged.
Size of incoming Coal: (-) 300mm
Size of crushed Coal: (-) 20 mm
Track Hopper Capacity: 100 T X 70
=7000T
Total Storage of Crushed Coal: 88571
Ton
Total Dead Stock
: 4834
Ton
Yard-4
Yard-5
Total stock pile length : 240m &
213.15m
Width : 35m & 35

TECHNICAL DIARY-Santaldih Thermal


Power Station

Ash Disposal:Total Ash Generation -360MU [with


100% PLF] x40 %( ash Content)
x0.65Kg/unit (Coal rate) x1000
=93600MT/month =3120MT/day
Fly ash Generation (80% of Ash)
=3120x0.80 = 2496MT/day.
Wet ash Generation (20% of ash)
=3120X0.20 = 624MT/day.
Utilization:1. Supplying of Fly ash to brick
field
owners
(approx)
500MT/month.
2. Supply of Fly ash to asbestos
sheet manufacturing company.
3.
Land filling by Wet Ash
accumulated
at
ash
pond
30000Mt/Month.
Dry Ash from ESP through ISH to silo
& wet ash in slurry form from bottom
ashing
to slurry
pump house,
220
KV:moves
ASANSOL,
DURGAPUR,
where fly BISHNUPUR
ash is converted
CHANDIL,
I & II. to slurry
Power
Evacuation: 132 KV: PURULIA I & II.
33 KV: BHOJUDIH I & II.
** PTOPOSED 220 KV FEEDERS
BISHNUPUR III & IV.

TECHNICAL DIARY-Santaldih Thermal


Power Station

Two chimney of 220M height has


Environment: been envisaged for unit-5 & 6.
High efficiency (99.98%) ElectroStatic Precipitators (ESP) capable of
meeting the environment (SPM
50mg/Nm3) is envisaged.
Water quality shall be maintained
as applicable as per IS 2490/MINAS
standard
1. Effluent Treatment Plant for
arresting oil grease & solid waste.
2. N-Pit used for maintain PH
3. Guard Pond for sedimentation of
plant solid waste
4. Decantation pond at ash pond.
5. Fly ash Disposal amenities with
erecting and commission of 4 nos.
dry ash
Silo.Pond: 2 x 2, 00,000 m3
Raw
Water
6. Maintaining
Raw
water Sump:of greeneries with
Clarified Sump for each Unit: 2 x
3
Capacity of 3500 m
Filtered
Water Sump: 3 x 200m3 +
Reservoir:
3
150 m
Guard Pond:
Two Clariflocculators each: 860

TECHNICAL DIARY-Santaldih Thermal


Power Station

Conversion of Important Units


1 MU
=
106 KWH
1 m
=
10 -3 mm
1 Ata
=
1.032 Kg/cm 2
1 Bar
=
1.019 Kg/cm 2
1 HP
=
75
Kgf/sec=746 W
1 Joule
=
0.120 Kgm
1W
=
1 Joule/sec
1 Kcal
=
4.186 KJ
1 KWH
=
860 Kcal
1S/Cm
=
1 mho/Cm
1 Microgram/lit =
1 PPb
1 PPm
=
100 PPb
1 PSI
=
0.0703
Kg/Cm2
Newton/mm2=106 pascal=106 N/m2 =10
bar
1 Mpa
=
10 Kg/cm 2
1 lb/sec/ft
=
0.0672 poise

TECHNICAL DIARY-Santaldih Thermal


Power Station

1 stroke
=
gm/(sec x cm x
density)
16 Ounces
= 1 lb =0.45359
kg
1 Cft
=
0.028 m 3
10 Mwcl
= 1 Kg/cm 2
12
tera =10 , giga=109 , Mega=106,
Micro= 10-6 Nano = 10-9 Pico=10-12
Femto=10-15 Auto= 10-18
10 Pa=1 mmwcl ;
1 Kpa= 7.6 mm
of Hg.

Definition used in Power


Generation

Utilization Factor:
The ratio of the electrical energy
produced, conveyed or absorbed,
to the capacity hours available.
The ratio of electrical energy
Plant Load Factor:
(Average load %) supplied from a generator or
group of generators during a
given period to the energy that
would have been supplied had
the generator or generators
operated at maximum continuous
rating throughout that period,
usually
expressed
as
a

TECHNICAL DIARY-Santaldih Thermal


Power Station
Load Factor:

The ratio of the electrical energy


supplied during a given period to
the energy that would have been
supplied had the maximum
demand
been
maintained
throughout that period, usually
expressed as a percentage.
Availability Factor:
The ratio, in a given period, of
the capacity hours available to
the product of the maximum
capacity and the hours in the
period.
Demand Factor: The ratio of the maximum
demand of an installation of a
system in a given period of time
to
the
aggregate
installed
capacity concerned.
The ratio of the simultaneous
maximum demand of a group of
installation or apparatus in a
given period o0f time to the sum
of their individual maximum
demands during the same period.
Diversity Factor:The reciprocal of the coincidence
factor.
Coincidence
Factor:

TECHNICAL DIARY-Santaldih Thermal


Power Station
Commercial
Operation:

Commercial
operation
shall
mean the conditions of operation
in which all the plant &
equipments including all system
& sub-system in the automatic
position
of
control
system
covered under the Contract are
officially
declared
by
the
Purchaser to be available for
continuous operation at different
loads
and
including
rated
capacity. Such declaration by the
Purchaser will normally be issued

Commercial
Commercial Operation Date
Operation Date:
shall mean the date when the
commercial operation of the unit
Test on
is officially declared.
Completion:
Test on Completion shall mean
such tests as are prescribed in
the Specifications and/or other
tests as mutually agreed upon by
the purchaser and the contractor
to be carried out by the
Contractor on erection of the
Plant to prove satisfactory
performance as per specification.

TECHNICAL DIARY-Santaldih Thermal


Power Station
Acceptance Test/
Acceptance Test / Performance
Performance
Guarantee Test:Guarantee Test shall mean such
tests
as
are
required
to
determine and demonstrate the
declared guarantee parameters
such as capacity, efficiency etc.
including
all
operating
characteristics of the Plant to the
satisfaction of the Purchaser as
stipulated
in
the
Contract

Commissioning:Commissioning shall mean the


first successful operation of the
Plant at full load with Coal by the
Reliability
or Trialall
Runinitial
shall
Contractor Run
after
mean
the all
firsttrialscontinuous
adjustments,
cleaning
operation
of the complete
Planton
&
and re-assembly
required
Equipment
all system
&
completion including
of installation
at the
sub-systems
in been
the completed
automatic
site , if any, have
position
of control
system for
as per specified
time schedule.
Reliability Run fourteen (14) days at varying
or Trial Run:
loads out of which at least
seventy two (72) hours shall be
on continuous full load to be
successfully demonstrated by the

TECHNICAL DIARY-Santaldih Thermal


Power Station

Oil Grades which are used in


different Equipments at S.T.P.S
1
2
3
4
5

Turbine Lub. Oil:


Gen. Seal oil
Vacuum
P/p gear box
Centrifuge
gearbox
BFP Lub. Oil &
Working Oil:
Actuator of
Hydro Coupling

Servo Prime 46
Servo Pride 40/sae-30
Servo System/Prime150/
ALPHAZN 150
Servo System HLP 32
Servo System 311

TECHNICAL DIARY-Santaldih Thermal


Power Station
Scoop
6
7
8
9
10
11
12
13
14
15
16

CEP Thrust Oil:


Governing
System
Control Oil:
ID Fan Lub Oil &
Working Oil:
PA Fan Lub Oil &
Control Oil:
FD Fan Lub Oil &
Control Oil:
Coal Mill Lub Oil:
Mill Roller
Journals
Feeder:
HP Bypass Oil:
LP Bypass Oil:

17

CW & ACW Lub


Oil:
CT Gear Box Oil:

18

Fire Pump Lub

Servo Prime 46
Servo Prime 46
Lub oil- Servo Prime 68
W.O- Servo System HLP
32
Servo Prime 68
Servo Prime 68
Servo mesh SP 320
Servo Mesh Sp 680
Servo mesh SP 320
Servo Conval 46
Fyrquel EHC/Castrol Anvol
PE 46 HR
Servo Prime 46
Servo Mesh SP 460 ( for
U-5)
Servo System 150 ( for U6)

TECHNICAL DIARY-Santaldih Thermal


Power Station
19
20
21
22
23
24
25
26

Oil:
HP/LP Chemical
P/p gearbox
APH
Suppot/guide
brg. Lub oil
APH GB
APH Fluid
Coupling
APH Soot
blowing GB
APH Air motor
KOBELCO Air
Comp.
Seal Air Fan lub
oil

Servo Mesh 220


Servo Cyl-C 680
Servo Mesh SP 220
Servo Prime 46
Servo mesh SP 460
Servo System 32
Mobil Rasus-462
Servo Prime 32

Coal Gradation
Grade

A
B
C
D
E
F
G

UHV (Useful Heat Value)

6200-7300
5600-6200
4940-5600
4200-4940
3360-4200
2400-3360
1300-2400

Kcal/Kg
Kcal/Kg
Kcal/Kg
Kcal/Kg
Kcal/Kg
Kcal/Kg
Kcal/Kg

TECHNICAL DIARY-Santaldih Thermal


Power Station

Local Management Instructions


1.

Trip the Turbine:


a.

b.
c.
d.

2.

Trip the Boiler in case of:


a.
b.

3.

When Shaft vibration actually exceeds


320 micron peak to peak and pedestal
vibration actually exceeds 106 micron
peak to peak.
When Normal Vibration level of TG Brg.
Increase by 35 %.
When any sparking & Fire occurs in
Turbine Gland, Generator Brg. And
Exciter area.
When uncontrolled Oil & Gas leakage
occurs.
When Drum level goes very very
Low/High & out of control.
When Furnace Pressure goes beyond the
tripping limit values & out of control.

Auxiliary Equipments:
a.

No Auxiliary equipment could be allowed


to run if vibration velocity crosses 12
mm/sec & vibration level crosses 300

TECHNICAL DIARY-Santaldih Thermal


Power Station

b.

micron peak to peak (Priority to velocity


component).
Any abnormal increase of Brg. Babbit
temp. by 150C from current value is
alarming and in no case temp. should
exceed 1200C

VIBRATION GUIDELINES

For All HT Motors

Motor bearing vibration high at >


4.5mm/sec.

Motor bearing vibration very high at > 7.1


mm/sec
For ID, FD, PA fan

Fan bearing vibration high at > 9.9 mm/sec.

Fan bearing vibration very high at > 19.8


mm/sec.
For All Mills

Vibration high at > 10 mm/sec.

Vibration very high at > 15 mm/sec.


For CW Pump

Vibration high at > 11mm/sec.

Vibration very high at > 18 mm/sec.


For BFP, CEP, ACW Pump

Vibration high at > 14 mm/sec.

Vibration very high at > 18 mm/sec.

TECHNICAL DIARY-Santaldih Thermal


Power Station
For DMCW (T)

Vibration high at > 10 mm/sec.

Vibration very high at > 15 mm/sec.


For Turbine Scale range:

Bearing vibration 0-200 microns

Shaft vibration 0-800 microns

Limit value for turbine tripping:

B
C
C

B
B

: 106 m
: 320 m

A
A
A
A

M/CClass-II
M/CClass-III
M/CClass-IV
M/CClass-V

Absolute bearing housing vibration


Absolute shaft vibration

0.64

1.00

1.58

2.54

3.96

6.37

10.00

15.80

25.40

39.60

63.70

0.45

0.71

1.12

1.80

2.80

4.50

7.10

11.20

18.00

28.00

45.00

0.40
0.28

(mm/s)Velocity
M/CClass-I
(mm/s)Velocity

on B.S. 4675 : 1976Tolerances Based

TECHNICAL DIARY-Santaldih Thermal


Power Station

CLASS I UPTO 15 KW
CLASS II 15 TO 75 KW
CLASS III> 75 KW
ACCEPTABLE
CLASS IV
TG SETS
UNACCEPTABLE

A = GOOD
B = ROUGH
C = STILL
D=

LEGENDS
CLASS
CLASS-II

CLASSIII

STANDARD
VIBRATION LEVEL
UP TO 2.8 mm/Sec
2.8 TO 7.1mm/Sec
ABOVE 7.1 mm/Sec
UP TO 4.5 mm/Sec

MACHINE
CONDITION
NORMAL
ALARMING(MARGI
NAL)
CRITICAL
NORMAL

TECHNICAL DIARY-Santaldih Thermal


Power Station
4.5 TO 11.2
mm/Sec
ABOVE 11.2
mm/Sec

ALARMING(MARGI
NAL)
CRITICAL

SPM CODE ABBREVIATIONS


CODE-A
CODE-B
CODE-C
CODE-D
CODE-E2
CODE-E3

GOOD BRG CONDITION


POORLY LUBRICATED BRG
INDICATION OF BRG DAMAGE
INDICATION OF SEVERITY OF BRG
DAMAGE
COMMUNICATION ERROR
COMMUNICATION ERROR

VALUE CHANGEOVER TABLE:

TECHNICAL DIARY-Santaldih Thermal


Power Station
MULTIPLY
NUMBER
OF
PEAK TO
PEAK

PEAK

RMS

AVERAG
E

1.000

2.000

2.828

3.142

0.500
0.354
0.318

1.000
0.707
0.636

1.414
1.000
0.900

1.571
LN
1.000

BY
TO OBTAIN
PEAK TO
PEAK
PEAK
RMS
AVERAGE

Cost of Losses
Design Boiler efficiency
BMCR)

: 87.505% (at 100%

87.504% (at 100%


TMCR)
As Run turbine heat rate : 1942.6 Kcal/kwh (at 250
MW, 0% make up & 72 mm Hg Back Pr.)
As Run turbine heat rate : 1982.1 Kcal/kwh (at
187.5 MW, 0% make up & 72 mm Hg Back Pr.)
As Run Unit heat rate
: 2220 Kcal/kwh (at 250
MW)
Overall Thermal Efficiency: 36.60 %
Turbine Efficiency
: 41.83 %
HP Cylinder Efficiency
: 89.44 %

TECHNICAL DIARY-Santaldih Thermal


Power Station
IP Cylinder Efficiency
Condenser Vacuum
Condenser inlet
Coal Rate

: 89.62 %
: 684 mm of Hg at 33 oC

Turbine heat rate loss:


1
2
3
4
5

For three years oilaging


For 18 mm of Hg
vacuum loss
For Reheat Spray
For under rated MS pr.
& temp.
Reheat Temp. being
22oC less from design

: 0.56 Kg/Kwh
1.2% or 30
Kcal/KWH
2% or 44 Kcal/KWH
1% or 22 Kcal/KWH
THR increases
Increase in THR by
33 Kcal/KWH

Approximate effect of Major Turbine


area Losses

Condenser loss [@2.25kcal/kWh per 1mm Hg


deviation from design]
MS Temp. [@2.3kcal/kWh per 5 degree lesser
than 535oC]
MS Pressure [@1.31kcal/kWh per 1 kg/cm2
deviation from design]
HRH Temp. [@2.3kcal/kWh per 5degree lesser
than 535oC]
h
Re-heater Attemperation [@3Kcal/kWh per 1% of
MS Flow]
h

TECHNICAL DIARY-Santaldih Thermal


Power Station

S/H Attem. flow [@0.25Kcal/kWh per 10 T/hr


attemperation flow]
Loss for high HPHS TTD [1.8Kcal/kWh per 1 0C
excess TTD]
Loss for high HPHS DCA [0.25Kcal/kWh per 1 0C
excess DCA]
Less HPC Efficiency [0.2% of UHR per
1%deviation]
Less IPC Efficiency [0.2% of UHR per
1%deviation]
S/H Attem. flow [@0.6Kcal/kWh per 1 T/hr
attemperation flow]
APH exit FG temp. [@1 kcal/kWh per 10C higher
than 130oC]

Heaters Design Performance Data:Load


HPH-6
HPH-5
LPH-3
LPH-2

TTD/DCA
250M
W
0.0/5.
0
0.3/5.5
0.0/5.
2
3.2
3.0
3.2
3.0

262.5M
W
0.2/5.4

(in oC)
200M
W
2.0/3.
7
1.4/4.
1
2.1
2.1

150M
W
1.7/2.
5
2.7/2.
9
1.4
1.3

125M
W
1.8/1.
9
3.0/2.
1
1.2
1.1

TECHNICAL DIARY-Santaldih Thermal


Power Station
LPH-1
DC

3.2
5.1

3.0
4.9

2.0
3.5

1.0
2.0

0.7
1.4

Cooling Tower & APH Design


Performance Data:
Cooling Tower U-6
APH
Design Cold basin
temp.
Ambient wet bulb
temp.(inlet)
CT Range(R) at
36000 m3/hr flow

R
( A+ R)

100 %
Power at each
motor

29 0C
8.53
0
C

CT Approach (A) at
design RH 70%
CT effectiveness
()=

330C

APH
Leakage
Gas Side
Efficiency
APH
Effectivene
ss

4 0C

X- Ratio

68.1
%

L.M.T.D at
A/H

1.1014
%
65.7784
%
0.9172
0.7156

51.49 0C

70.83 KW (Total 850 KW


maximum)

Properties of Steam
Pressure

Saturation

Latent heat

TECHNICAL DIARY-Santaldih Thermal


Power Station
(Kg/Cm2)
( Abs.)

Temperature
(oC)

0.10
0.20
0.30
0.40
0.50
0.60
0.70
0.80
0.90
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
12.0
14.0
16.0
Pressure
(Kg/Cm2)

45.45
59.67
68.68
75.42
80.86
85.45
89.45
93.0
96,2
99.1
119.6
132.9
142.9
151
158.1
164.2
169.6
174.4
179.0
187.1
194.1
200.4
Saturation
Temperature

of
Vaporization
(Kcal/Kg)
571.6
563.4
558.0
554.1
550.7
548.0
545.6
543.4
541.3
539.5
526.4
517.3
510.2
504.2
498.9
494.2
489.8
485.8
482.1
475.1
768.9
463.1
Latent heat
of

TECHNICAL DIARY-Santaldih Thermal


Power Station
( Abs.)

(oC)

18
20
22
24
26
28
30
35
40
45
50
55
60
65
70
75
80
85
90
95
100
104
108
112
Pressure

206.1
211.4
226.2
220.7
225.0
229.0
232.7
241.4
249.2
256.2
262.7
268.7
274.3
279.5
284.5
289.2
293.6
297.9
301.9
305.8
309.5
312.4
315.2
317.9
Saturation

Vaporization
(Kcal/Kg)
457.7
452.6
447.6
443.0
438.4
434.1
429.9
420.0
410.6
401.7
393.2
385.0
377.0
369.0
361.6
353.3
346.6
339.1
331.9
324.7
317.4
311.6
305.8
300.0
Latent heat

TECHNICAL DIARY-Santaldih Thermal


Power Station
(Kg/Cm2)
( Abs.)

Temperature
(oC)

116
120
125
130
135
140
150
160
170
180

320.6
323.2
326.0
329.3
323.0
335.1
340.6
345.7
350.7
355.4

of
Vaporization
(Kcal/Kg)
294.3
288.5
281.0
274.0
266.0
259.0
243.7
227.9
211.0
192.7

TECHNICAL INFORMATIONS:
(BOILER & AUXILLIARIES):

PLANT NAME: SANTALDIH TPP 2 X 250 MW UNITS


Proposed Fuel: COAL
VM
TM
A%
FC%
%
S%
%
40.0
32.00
20.0
0.30
8.0
0
0
Ash Fusion Temperature: 1400 oC
GCV or HHV (higher heating value) Kcal/ Kg : 3900
Grindability (HGI): 48;
Size of Coal: 25 mm

TECHNICAL DIARY-Santaldih Thermal


Power Station

BURNERSSTABILISATION MAIN BURNERS

FULL FIRING EQUIPMENT:


TYPE
Coal : Tilting Tangential (
30 0)
MAKE & NO.
BHEL : 24 Nos.
CONTROL
Air damper
CAPACITY
41.0Mkcal/h (max.
(MAX.)
allowable)
POSITION
Corners
TYPE
Oil Burner
MAKE & NO.

BHEL : 12 Nos.

CONTROL

Air damper

CAPACITY
(MAX.)
POSITION

13 Mkcal/h

MILLS

TYPE
MAKE & NO.
MOTOR KW
CAPACITY
(MAX.)
SYSTEM
Fuel Oil: -

Corners

BOWL MILL XRP 883


BHEL : 6 Nos.
425
46.0 TPH
Pressurised/Cold PA
L. D. O.

TECHNICAL DIARY-Santaldih Thermal


Power Station
Kinematics Viscosity

170 centistokes at 50

Water contents % Vol


Ash % weight
Sulpher % weight
Sediments % weight

Acidity, Inorganic
Specific Gravity

1.0 (max)
0.1 (max)
4.5 (max)
0.25 (max)
nil
0.9

Boiler:
Steam generator supplied by BHEL, Trichy is a natural
circulation, single drum, radiant reheat, direct fired,
balance draft boiler with tilting tangential corner fired
burners, top supported Type, and has provision for
firing coal as the principal fuel. The unit comprising of
Furnace, Super heaters, Reheater, LTSH and
Economizer along with Drum and Down comers are
suspended from steelworks & is free to expand in
downward direction. The boiler heating surfaces are
contained in through main compartments namely the
furnace, vestibule and cage enclosure.
Boiler Water Capacity
Economizer water capacity
:
55.0
m3

TECHNICAL DIARY-Santaldih Thermal


Power Station
Water
capacity
in
including
Water wall tube
Super heater capacity

drum
:
m3
:
m3
:
m3
:

Total boiler water capacity


Reheater capacity

145.0
110.0
310.0
55 m3

DRUM
Number
Brief
particulars
construction
Inner diameter
Overall length
Material
Hydraulic test pressure
Steam Separators
Number
Type

of

:
:

1
welded

:
1778 mm
:
14104 mm
:
15N Cu M Nb (Special
Steel)
:
263.7 kg/cm2
:
:

44 nos.
Cyclone centrifugal

:
:
:
:
:
:

Balanced Draft
Fusion welded walls
14.326 m
11.506 m
6372 m3
609 Mkcal/hr

Furnace
TYPE
Construction
Width
Depth
Volume
Fuel Heat Input

TECHNICAL DIARY-Santaldih Thermal


Power Station
Super heaterStage-I
Type
Stage II
Type
Stage III
Type

PIPE LINES:
Main
Stea
m
SA 335
Mat.
P22
Spec.
260
Diame
mm ID
ter
51.0
Thickn
mm
ess

: Low Temp. Super heater


: Heating Surface area
:7504m2
: Platen Super heater
: Heating Surface area :
1257 m2
: Spaced Final Super
heater
: Heating Surface Area :
1984m2

Hot
Rehea
t

Cold
Rehea
t

Feed
Water

SA 335
P22

SA 106
Gr. C

SA 106
Gr. C

559
mm OD

457
mm OD

368
mm OD

28 mm

12.7
mm

48 mm

Surface areas of Heat Transfer are as


follows:

TECHNICAL DIARY-Santaldih Thermal


Power Station
Water wall

3608 m2

Economizer-Type : Plain Tube

8085 m2

Reheater- Type

3667 m2

: Spaced

Air heater Type


: Rotary
Regenerative
Nos
: Two (2)
1. INDUCED DRAFT (I D)
Fan
No. of Fans per boiler
2
Make
BHEL
Type
NDZV 33 S
Medium Handle
- Flue
gases
Capacity - 265.0 m3 /
sec.
Fan Speed in rpm - 718
Total head developed
in mmwc
- 490
Temperature of medium
in 0C
- 150
Density- 0.7777 kg/m3
Control - Hyd. Coupling
+ Inlet Damper

20616m2

FAN
Motor
Type : SQ cage Induction
motor
Make : BHEL
Voltage/Hz/Phase :
6.6KV/50/3
Motor speed in rpm
746
Motor KW
1925
Rated Amps( F L Current)
-208A
NL Curreny-70A
Power Factor-0.84
: 96.6% (at F.L)
FRAME SIZE: 1LA 7904-8
DE BEARING NO: 6236M
C3 NU236

TECHNICAL DIARY-Santaldih Thermal


Power Station
NDE BEARING NO: NU232

(NDZV-Radial Double Suction simply supported


bearing,
33- Impeller Tip Dia. In decimeter, S Type of
Impeller)
2. FORCED DRAFT (F D) FAN
Fan
Motor
Make- BHEL
Type : SQ cage Induction
Type-FAF 17/9.5-1
motor
Nos. of Fan per Boiler
Make : BHEL
-2
Voltage/Hz/Phase :
Total head developed.
6.6KV/50/3
-510 mmwc
Motor drive, RPM-1487
Temperature of medium
Motor KW- 800
in - 50 0C
Rated Current ( F L
Capacity-110 m3/sec
current)-88.5A
Density- 1.0108 kg/m3
No load current 29A
Air Temperature -20-45
Power factor 0.83
deg C
: 95.4% (at F.L.)
Fan Speed -1490 RPM
Motor Grease lubricated
Method of lubrication of
(servogem3)
Fan bearings -Forced
FRAME SIZE: 1LA 7636-4P
DE BEARING NO: NU226M
6226 C3
NDE BEARING NO:

TECHNICAL DIARY-Santaldih Thermal


Power Station
NU222M
(FAF- Forced Draft Fan, 17- Tip Dia in decimeter,
9.5-Hub dia in decimeter, 1- single stage)
3. PRIMARY AIR (P.A) FAN
Fan
Motor
Make BHEL
Type : SQ cage Induction
Type-PAF17/11.8-2
motor
Number/Boiler
Make : BHEL
Two
Voltage/Hz/Phase :
Capacity -90.5 M3
6.6KV/50/3
/second
Motor Rating1575kw
Total head developed
Rated Speed-1488 RPM
1420 mmwc
Rated Amps( Full Load
Air Temperature -50 deg
Current) -165A
C
No Load Curreny-34.5A
Method of lubrication of
Power Factor-0.87
Fan bearings -Forced
: 96.0% (at F.L)
Motor Grease lubricated
Quantities per fan-315
(servogem3)
lits
FRAME SIZE: 1LA 7802Method of flow control4P
Blade Pitch
DE BEARING NO:
NU230M 6230 C3
NDE BEARING NO:
NU226M
(PAF Primary air fan, 17 Tip dia in decimeter,
11.8 Hub dia in decimeter, 2 Two stage)

TECHNICAL DIARY-Santaldih Thermal


Power Station
4. SEALING AIR FAN :
Inlet Damp
Fan
Make-BHEL
TYPE-NDV 11.8N
Nos. provided per Boiler2
Capacity- 5.0 M3/Sec
Pressure-508 mmwc
Temperature -50 0C
Air density-1.2 KG/CM
Impeller data
-1020
mm dia.
ControlInlet Damper

Motor
Type : SQ cage Induction
motor
Make : BHEL
Voltage/Hz/Phase :
415V/50/3
Motor Rating37 KW
Motor Voltage
-415
Volt
Motor RPM-1480 RPM
(Sync)
Motor Grease lubricated
(servogem3)

Quantities per fan-10lits


FRAME SIZE: ND132M
DE BEARING NO: 6308ZZ
NDE BEARING NO:
6208ZZ
(NDV-Radial single Suction simply supported bearing,
11.8 - Impeller Tip Dia. In decimeter,
N Type of Impeller)
5. BOWL MILL:
MILL
Motor
Make: BHEL
Type : SQ cage Induction
Type: BOWL MILL XRP
motor

TECHNICAL DIARY-Santaldih Thermal


Power Station
883
Maxm. Capacity for each
Mill
: 46.0
Tons/Hr.
No of Mill Provided for
each Boiler: 6
Raw Coal size : 0 to 30
mm
Ball Material: Cast alloy
steel
CONTROL: Pressurized
/Cold PA

Make : BHEL
Voltage/Hz/Phase :
6.6KV/50/3
Motor Rating : 425 KW
Rated Current (F L
current)-51.5A
Motor Speed 985 rpm
No load current 25A
Power factor 0.77
: 94.2% (at F.L)
FRAME SIZE: 1LA 76366P
DE BEARING NO:
NU228M 6228 C3
NDE BEARING NO:
NU224M
This mill is designated as XRP 883 Bowl Mill where
X3 Phase, 50 Hz Supply,
R--Raymond (Inventor of the mill)
PPressurized, 88--Nominal dia. of the Bowl (inches)
3--Number of the Grinding Rolls.
RAW COAL BUNKERS
Nos. provided per Boiler::
6
Capacity: 800 MT
6. AIR PRE-HEATER:
APH
Motor
Type- Rotary Regenerative 27.5 Type : SQ cage
VI TM 2000
Induction motor

TECHNICAL DIARY-Santaldih Thermal


Power Station
27.5

VI

MT

Make : CROMPTON
GREAVES
Voltage/Hz/Phase :
415V/50/3
Motor Rating - 11
KW
N: 1460rpm
Rated Current: 21A
FRAME SIZE:
ND160L
DE BEARING NO:
6309ZZ
NDE BEARING NO:
6209ZZ

2000
Make - BHEL
Total Nos .- TWO
Flue Gas inlet temperature
318 0C
Flue gas O/L temperature- 130
0
C
Air inlet temperature
= 20500C
Hot air outlet temperature(PA)2930C
Hot air outlet temperature(SA)2980C
Total Heating Surface in M2 20616
Flue gas at Air heater inlet
-1096.0 t/hr.
Flue gas at Air heater O/L1183.5 t/hr
Hot
inlet
heating Rotor Seals:
Elements:
Radial seals hot end
a) Element type -0.63
2.5 mm Corten A
mm-DU profile
Radial seals cold end
b) Element height2.5 mm Corten A
850 mm
Axial Seals-2.5 mm

TECHNICAL DIARY-Santaldih Thermal


Power Station
c) Material- Carbon
Steel
Cold end heating
element:
a) Element type -1.2
mm-NF6 profile
b) Element height300 MM
c) Material- Corten Steel

Corten A
By pass Seals-1.6 mm
Corten A
Rotor port seals HE & CE
- 6.0 mm Carbon steel

SAFETY VALVES:
Locatio
n
Drum

SH O/L

RH I/L

Type
1750W
B
1740W
B
1739W
D
ERV15
38 VX10W
1786W
B-RHI

Mak
e
BHE
L
BHE
L
BHE
L

Nos
.
1
2

Set Pr.
(Kg/cm2)
182.5
186.2,18
8.0

166.6

164.0

BHE
L
BHE
L

Size
3/6
3/6
2.5/6

2.5/4

47.0

6/8

TECHNICAL DIARY-Santaldih Thermal


Power Station
RH O/L

1786W
D-RHO

BHE
L

2+
2

43.8,45.9

6/8

The Boiler is fitted with three varieties of


soot blowers.

41.0

44.0
8.0

48.0

633.3

391.1
498.4
730.3

WATER

662.9
544.0
659.4

398.9

674.3
439.1
542.4
738.3

TMCR
187.5MW
100 % TMCR75 %TMCR60 % 250 MW

HP Heaters in Htrs.
Service
OutBoth HP

PREDICTED PERFORMANCE

Furnace Chamber
No. of Temperature Probs -- 2 nos
Water walls - Short retractable 56 nos.
SH, RH & Eco - Long retractable -- 18 nos.
AIR HEATERS- Rotary Swivel Arm --2 nos

FLOW

109.5

90.8

957.1

704.0 592.7

148.9

FUEL

75.0

75.0

598.5

417.7 318.9

75.0

44.3

58.4

57.2

t/h

t/h

SH spray t/h

810.0

690.4

810.0

BMCR100 %
t/h

Unit

Feed water t/h

R/H O/L

SH O/L

154.1 140.4

239.3

STEAM

Description

187.5MWTMCR75 %TMCR60 % 250 MW

Htrs. OutBoth HP

TECHNICAL DIARY-Santaldih Thermal


Power Station

348
424

344

421

FLOW

airTotal Comb.

t/h

t/h

t/h

APH I/L (SA)


Blr. Lkg. Air

t/h

t/h

Tempering

APH O/L (PA)

AIR

156.2

1003.6

75.0

640.1

83.7

204.8

142.4

915.3

75.0

561.0

88.2

191.1

BMCR100 TMCR
%
100 %

Unit
HP
Heaters in

Description

512 3900501
Kcal/kgCoal (GCV = t/h

390

1130.4

722.8

370

1046.0

647.0

TMCR60 % 250 MW

Htrs. OutBoth HP

PREDICTED PERFORMANCE

TECHNICAL DIARY-Santaldih Thermal


Power Station

FLOW

HP Heaters in Service

238

O/LSH Platen

164.6 SH Platen I/L

LTSH O/L

540
DrumSat. temp. in

C
C

505

405

405

351

506

400

406

349

1183.5 1084.8

349.1 STEAM TEMPERATURE

t/h

540
AH O/LFlue ga s at

1096.0 1000.0

508

379

417

346

848.8

769.0

BMCR100 TMCR
% 187.5MW
100 % TMCR75 %

Unit

t/h

FLUE GAS

Description

501AH I/LFlue ga s at

250 MW

Htrs. OutBoth HP

PREDICTED PERFORMANCE

TECHNICAL DIARY-Santaldih Thermal


Power Station

Eco. O/L

Eco. I/L

RH O/L

RH I/L

286

247.8

540

345.3

540

505

540

319.1

540

506

540

312.3

540

512

286

246.5

278

231.1

273

221.2

WATER TEMPERATURE

540

343.3

540

506

BMCR100 TMCR
% 187.5MW
100 % TMCR75 %TMCR60 %

HP Heaters in Service

SH Final O/L

SH Final I/L

STEAM TEMP.

Description Unit

PREDICTED PERFORMANCE

TECHNICAL DIARY-Santaldih Thermal


Power Station

HP Heaters in Service
Htrs. OutBoth HP

C
C

C 1004

1148

298

293

36

33

993

1144

296

292

36

33

968

1146

282

279

53

33

935

1144

270

267

53

33

985

1129

GAS

256

248

76

33

BMCR100 TMCR
% 187.5MW
100 % TMCR75 %TMCR60 % 250 MW

Unit

PREDICTED PERFORMANCE

TECHNICAL DIARY-Santaldih Thermal


Power Station

622
442
318

635

449

323
130

729

745

130

830

844

130

299

427

591

690

789

130

286

416

570

660

754

Ambient

AIR

130

275

448

626

RH Front I/L

SH Platen I/L

AH O/L (SA)

AH O/L (PA)

732 O/LSCAPH(sec.)

829

BMCR100 TMCR
% 187.5MW
100 % TMCR75 %TMCR60 % 250 MW

Description

HP Heaters in Htrs.
Service
OutBoth HPeTemperatur

PREDICTED PERFORMANCE

TECHNICAL DIARY-Santaldih Thermal


Power Station

156.5
158.7
161.9

162.4

166.2

170.1

35.85

26.45

27.90

154.1

158.1

37.83

151.8

154.0

21.41

22.59

158.4

155.5

154.0

152.4

150.8

36.49

O/LAir heater

Air heater I/L

167.2
38.47

Eco. I/L

LTSH I/L

SH Final I/L

RH Rear I/L

GAS

163.5

160.3

156.7

153.2

TMCR
187.5MW
100 % TMCR75 %TMCR60 % 250 MW

Description

HP Heaters in Htrs.
Service
OutBoth HPeTemperatur Unit

PREDICTED PERFORMANCE

TECHNICAL DIARY-Santaldih Thermal


Power Station

1.2
0.5

1.5

0.8

1.3

2.0

10.3

-5
799

-6

832

891

-10

PRIMARY AIR

4.7

6.9

187.5MWTMCR75 %TMCR60 % 250 MW

cm2Kg/ 155.0

(g)BMCR100 %

RH O/L

RH I/L

39.59
cm2Kg/ 37.52

cm2Kg/

cm2Kg/ 173.7

cm2Kg/ 169.5
Drum
Eco I/L

cm2Kg/ 164.9
LTSH O/L

Platen SH O/Lcm2Kg/ 159.9

SH O/L

PRESSURE

Htrs. OutBoth HP Description Unit

TECHNICAL DIARY-Santaldih Thermal


Power Station

1.8

683Only)Eco(Frictioncm2Kg/

1.5

2.0

12.2

-17
303

-5

164

PA Fan O/Lclmmw

PA Fan I/L cl mmw

900

-10

853

-9

&307
GAS) PRESSURE AND DRAFT (AIR

SECONDARY AIR

261

615

2.1

811

764

RH System cm2Kg/

874

789

14.5

%
100 %
(g)BMCR100 TMCR

SH System cm2Kg/

TMCR60 % 250 MW
DropPressure

Unit
Htrs. OutBoth HP DescriptionHP
Heaters in

PREDICTED PERFORMANCE

TECHNICAL DIARY-Santaldih Thermal


Power Station

FD Fan I/L cl mmw


FD Fan O/Lclmmw

-6

-12

-5

330

-19

320

832

Mill O/Lclmmw

Mill I/L

100

clmmw

882

702

APH O/L

141

clmmw

280

-15

296

667

793

836

205

-9

302

676

971

821

BMCR100 TMCR
% 187.5MW
100 % TMCR75 %

HP Heaters in Service

clmmw

APH I/L

262

250 MW AIRPRIMARY

Htrs. OutBoth HP Description Unit

PREDICTED PERFORMANCE

TECHNICAL DIARY-Santaldih Thermal


Power Station

-6
-12

SH Final I/Lclmmw

-5

SH Platen I/Lclmmw
clmmw

100

Wind box Pr.clmmw

RH I/L

146

clmmw

APH O/L

284

clmmw

-11

-6

-5

100

236

244

-9

-6

-5

100

120

185

-9

-6

-5

FLUE GAS

100

112

152

BMCR100 TMCR
% 187.5MW
100 % TMCR75 %TMCR60 %

HP Heaters in Service

APH I/L

AIRSECONDARY

Description Unit

PREDICTED PERFORMANCE

TECHNICAL DIARY-Santaldih Thermal


Power Station

-85
-246
-291

clmmw

clmmw

clmmw
+37

-40

clmmw

cl mmw

-20

clmmw

+33

-253

-214

-74

-35

-18

+24

-168

-142

-51

-23

-13

+21

-130

-110

-41

-19

-12

+35

-265

-224

-81

-39

-20

250 MW

HP Heaters in Service
Htrs. OutBoth HP

BMCR100 TMCR
% 187.5MW
100 % TMCR75 %TMCR60 %

Unit

PREDICTED PERFORMANCE

TECHNICAL DIARY-Santaldih Thermal


Power Station

+18
CDEF

-9

-25

CDEF CDEF

70

213

211

219

70.4

69.8

72.1

CDEF

+25

199

66.3

BMCR100 TMCR
% 187.5MW
100 % TMCR75 %TMCR60 %

CDEF

-25

66-90

215

70.9

250 MW

ID Fan O/L

ID Fan I/L

ESP I/L

APH I/L

Eco. I/L

LTSH I/L

FLUE GAS

HP Heaters in Service
Htrs. OutBoth HP Description

TEDPREDIC

TECHNICAL DIARY-Santaldih Thermal


Power Station

3.56

15.5

20

3.56

15.5

20

20

15.2

3.85

MillAir Flow per

C
C

t/h

OperationBurner in

(200 mesh)Fineness %
20
Burner Tilt
Deg.

temp.Mill O/L

15.5
mill I/LAir temp. at

3.56

operationNo. of mill in

Description Unit
HP Heaters in Service
Htrs. OutBoth HP
PerformancMill AND
e
BERNER
TMCR
187.5MW
100 % TMCR75 %TMCR60 % 250 MW

TEDPREDIC

TECHNICAL DIARY-Santaldih Thermal


Power Station

at Eco O/LCO2 in gas


4.367

4.370 4.374

1.200 1.200

0.201
gas at EcoExcess air in
1.200

1.303

1.304 1.305

0.203 0.218

4.869
Eco O/LO2 in gas at

4.921 5.269

187.5MWTMCR75 %TMCR60 % 250 MW

20

15.5

3.56

BMCR100 %

Htrs. OutBoth HP Description Unit

TECHNICAL DIARY-Santaldih Thermal


Power Station

87.196

86.609

CarbonUnburnt

0.740
comb. Of H2H2O from

0.809

13.544

14.110

H2O in air

0.500
(surface &H2O in fuel

0.500

Dry gas

0.988

1.046

1.200

0.199

4.364

1.302

4.830

1.200

0.199

4.362

1.302

4.810

BMCR100 TMCR
%
100 %

0.198
Loses0.116
(as per ASME PTC 4)

TMCR60 % 250BALANCE:
MW
HEAT

Unit
Htrs. OutBoth HP DescriptionHP
Heaters in

PREDICTED PERFORMANCE

TECHNICAL DIARY-Santaldih Thermal


Power Station

Efficiency

0.280

0.996

0.116

0.769
87.505 87.504

0.765

13.260 13.265

0.270

0.989

0.106

87.206

0.787

13.561

0.400

1.019

0.164

BMCR100 TMCR
% 187.5MW
100 % TMCR75 %

HP Heaters in Service

onsists of Sensible heat loss, Radiation

Heat credits

marginManufacture
%

Unaccounted

Total losses

Radiation

BALANCE:HEAT

Description Unit

PREDICTED PERFORMANCE

TECHNICAL DIARY-Santaldih Thermal


Power Station

TECHNICAL DIARY-Santaldih Thermal


Power Station

TECHNICAL INFORMATIONS:
(TURBINE & AUXILIARIES):

250MW capacity turbine at Santaldih Thermal Power


Station which has been supplied by BHEL is of KWU (Kraft
Werk Union-Germany) design. The turbine is a machine of:
Condensing (means turbine exhaust steam going into the
condenser)
Tandem (means one shaft will follow the other shaft)
Compounded (means it has both impulse and reaction
staging)
Horizontal (means all the shafts are rotating horizontally)
Reheat type (means high pressure turbine exhaust is going
to boiler for reheating and entering into the intermediate
pressure turbine for further expansion)
It has got separate high pressure, intermediate and lowpressure sections. The HP and IP sections are of single flow
cylinder and LP section is of double flow cylinder. The turbine
rotors are rigidly coupled with each other and with generator
rotor.
The entire turbine except first stage of HPT is provided with
reaction blading. The first stage of HP turbine is provided with
impulse blading.The moving blades of HPT, IPT and front
rows of LPT have inverted T-roots and are shrouded. The last
stages of LPT are twisted drop forged moving blades with firtree roots. Highly stressed guide blades of HPT and IPT
have inverted T-roots. The other guide blades have inverted
L-roots with riveted shrouding.

DN-250

Make:BHEL,TiruchyDN-600

Type : IV 400

Type : EV 200-1

Type : N30-2x6.3

Type : M30-25

Type : H30-40

262.5 MW

250 MW

LOAD

TECHNICAL DIARY-Santaldih Thermal


Power Station

2 Bypass Stop and Control valves

1 Swing Check valve in cold reheat line

2 Reheat Stop and Control valves

mounted)2 Main Stop and Control valves (HP casing

ow (advance blading)Double flow LP Turbine with 8 reaction stages

(advance blading)Single flow IP Turbine with 17reaction stages

and 1 Impulse stage.Single flow HP Turbine with 18 reaction stages

turbine :Three cylinder reheat condensing

conditionMaximum Load under valve wide open (VWO)

Rated Load

STEAM TURBINE TECHNICAL DATA

TECHNICAL DIARY-Santaldih Thermal


Power Station

DN 300

DN 400

DN 500

DN 600

c/s) 3000 rpm (50.0

Make:BHEL,Tiruchy

Make:BHEL,Tiruchy

Make:BHEL,Tiruchy

Make:BHEL,Tiruchy

TECHNICAL DIARY-Santaldih Thermal


Power Station

eratorAnti clock wise when viewed from Front Pedestal towards the

Rated speed

Speed

Extraction 6 : No valve

Extraction 5 : 1 Swing Check Valve with actuator and

Extraction 4 : 2 Swing Check Valves with actuator

Extraction 3 : 1 Swing Check Valve with actuator and

Extraction 2 : 1 Swing Check Valve with actuator and

Extraction 1 : No valve

TECHNICAL DIARY-Santaldih Thermal


Power Station

Extraction

179.89
159.95

157.38
159.95

Long time operation


operationShort time

STEAM PRESSURE (in Kg/cm )

Check Valve without

Direction of rotation :

1 Swing

1 Swing

c/s)700 to 2850 rpm Check(11.67


Valve without
to 47.5
3330 rpm (55.5 c/s)

1 Swing

2850 rpm (47.5 c/s)


2850 rpm (47.5 c/s)
3060 rpm (51.5 c/sCheck Valve without

3060 rpm (51.5 c/s)

TECHNICAL DIARY-Santaldih Thermal


Power Station

Max. Speed, no time limitation

load *Speed exclusion range at operation without

0.30

0.48

2.81
1.10

8.11

149.89
145.4

Initial Steam
Before HP control stage

Rated

Standard over speed trip setting

is speed range
18.66should be passed through in one
ooth operation to avoid damage of the LP blades

47.49

42.69

Min. Speed, no time limitation


below Speed Permissible for maximum 2 hours during the life
130.13
of LP blading:
47.49

operationShort time

station operation :Speed limitation in load and

TECHNICAL DIARY-Santaldih Thermal


Power Station

2.81
1.10

39.55
15.81
6.75
2.30
0.89

Extraction 6
Extraction 5
Extraction 4
Extraction 3

0.385
0.1032

Extraction 1
LP cylinder exhaust

Extraction 2

8.11

35.57

inletIP cylinder stop valve

0.30

0.48

18.66

45.47

41.27

45.45

39.55

HP cylinder exhaust

130.13

118.29

After HP control stage

RatedoperationLong time

STEAM PRESSURE (in Kg/cm2)

TECHNICAL DIARY-Santaldih Thermal


Power Station

headerPressure in seal steam(Abs.)1.068 Kg/cm2

0 .6 114 Kg/cm2

0 .3 057Kg/cm2

0 .3 057Kg/cm2

Low vacuum trip, standard setting :

These values correspond to 250 MW load with


3 % make-up and 33 C cooling water
temperature with all heaters in service and
rated steam conditions.

TECHNICAL DIARY-Santaldih Thermal


Power Station

Trip

Alarm

551

537

565

565

tripHydraulic low vacuum

1.0 mm

system :Seal steam supply

mm
trip0.5
bypass
operationHydraulic low vacuum

Axial shift : tripElectrical low vacuum

551

537

Annual Long-term max.


400 hrs.
15 minThe
80 hrs.
per
safety
valves must be
average value
per year
in
set soyear
that short time values
are not exceeded.

Steam Temperatures : (C )

TECHNICAL DIARY-Santaldih Thermal


Power Station

70.0

141.6

165.5

246.1

355.0

Main steam
at HP stop
valve inlet

537

537

Annual
Rated value
average

at IP stopHRH steam

485.0

425.6

457.4

485.0

425.6

80 hrs. per year,


In special cases
Max. 15 min. in
at no load
individual case

Steam Temperatures : (C)

TECHNICAL DIARY-Santaldih Thermal


Power Station

125.5

Extraction 3 191.1
Extraction 2 105.5

510
110

exhaustLP turbine

44.9

74.57

202.1

305.0

down atMachine must be shut Extraction 4

Extraction 1

315.0

417.4

Extraction 5

70.0

94.6

422.4

345.6

343.6

Extraction 6

345.6

343.6

exhaustHP turbine

Rated
operationLong term
value

TECHNICAL DIARY-Santaldih Thermal


Power Station

Outer casing of LP cylinder

250

225

HP turbine casing exhaust

250

90

485

Alarm at

Spray water to LP turbine must be switched


on at LP outer casing temperature of 90 oC

Wall Temperatures

Casing Metal Temperatures : (C)

Load (MW)

45

correspond to 250 MW Load


eup and 33 C cooling water
70in service and
with all heaters
d steam conditions.

Long-term operation: upper limit value


permissible without time limit.

TECHNICAL DIARY-Santaldih Thermal


Power Station

Testing of main steam stop and control valves

674.737

698.76

Main steam flow (T/hr)

Feedwater Heater out of service :

30

55

Machine
Alarm
must
at be tripped at

TECHNICAL DIARY-Santaldih Thermal


Power Station

Temperature Difference

halves

Output Limit during Testing with

Extraction A6 + A5 = 0

Extraction A6 = 0

heaters out of serviceOperation with feedwater

Motoring :

of IP turbine, front & Between upper & lower casing

halves of HP turbine,
middleBetween upper & lower casing
28

17

Casing Metal Temperature

TECHNICAL DIARY-Santaldih Thermal


Power Station

wed to continue
Motoring is the condition in which the
econds.
turbine is driven by the generator at rated
speed with the stop and control valves
closed. In this operating mode, certain
turbine components are heated up by
windage of the blading. To prevent heat-up
beyond permissible temperatures, motoring
must not be allowed to continue for longer
than one minute. If the condenser low
vacuum limit of 0.3 bar is exceeded,

am temperature In the hottest line the limitations indicated

Short time period (15 min)

No time limitation

supply lines : (C )Permissible differential temperature between parallel

TECHNICAL DIARY-Santaldih Thermal


Power Station

130
130
130
130

90
100
110
115

1932 RPM

2350 RPM

Critical Speed of Turbine :

atMachine must be shut down

Alarm at

Bearing babbit metal temperatures : (C)

TECHNICAL DIARY-Santaldih Thermal


Power Station

1500 RPM

temperature above 90Operation

320 m
temperature 85 to 90Operation

200 m
temperature 75 to 85Operation

normal level50temperature
m above
below 75Operation

vibrationAbsolute shaft

Vibration :

TECHNICAL DIARY-Santaldih Thermal


Power Station

ISO : 3733

ASTM : D892

DIN : 51599

IS :1448, P-10

IS :1448, P-69

IS :1448, P-32

IS :1012, P-58

IS :1448, P-56

IS :1448, P-25

Test Method

106 m

Limit value for tripping

The normal level is the reproducible


vibration behaviour typical for the
machine & dependent on the operating
conditions.

84 m

Maximum alarm setting

Standard alarm setting

vibrationAbsolute bearing housing

TECHNICAL DIARY-Santaldih Thermal


Power Station

Properties
at

41.4 50.6 cst

Value

Min. 2000C
- 6 0C max.

Flash point (Cleveland open cup)


Pour point

fresh/in useWater content by weight - Max.0.01% / 0.1%

Emulsion characteristics
minutes)40-40-0 (20
ng tendency - Foaming characteristics at 250C :
Max.400cm3 /
Max.450 s / 600 s600cm3
/in use

0.85

Specific gravity at 500C

Viscosity Index
Min. 98
For Neutralization No.(Total acidity)KOH/gm.
:
Max.0.2mg.of

40 CKinematic Viscosity :

Turbine Oil Specification:

TECHNICAL DIARY-Santaldih Thermal


Power Station

AOP

46.116
8.0
50

139
8.3
50

JOP

49.25

Unit
rpm
rpm

Speed
48 to 57
6 to 12

17 8

1.84

25

2.3

30

Tushako

AC :1, DC : 1 AC :1, DC :1

EOP

BHEL
PlattMather & PlattMather &

MOP

TURBINE OIL PUMPS

TECHNICAL DIARY-Santaldih Thermal


Power Station

Idling speed during

Turning gear

Hydraulic turning

Speed ( c/s )

(bar gauge}Discharge Pr.

(dm3/s )Rated Capacity

Make

Quantity

brands of Recommended

TECHNICAL DIARY-Santaldih Thermal


Power Station


of MOT during operation 900 mmNominal capacity of the MOT 25 / 40 m3

Jacking Oil Pump must be in operation at turbine speed


ings.

TECHNICAL DIARY-Santaldih Thermal


Power Station

m
m
bar
bar
No.

37
200
182
1

No.
250

2.8 dm3/s
2.8 dm3/s
0.42 dm3/s

7.37 dm3/s

4.86 dm3/s

11.53 dm3/s

0.83 dm3/s

TECHNICAL DIARY-Santaldih Thermal


Power Station

ydeck, GermanyDuplex oil filter for jacking oil , Nb 25, make

system, settingPressure limiting value in Jacking Oil

Safety valve in Jacking oil system, setting

Filtration Particle size of MOT filter element

elementFiltration Particle size of duplex filter

& kirch, GermanyDuplex oil filter for bearing oil-full flow, Nb

front brg.Estimated oil requirement for Generator


rear brg.Estimated oil requirement for Generator
brg.Estimated oil requirement for slip ring shaft

Estimated oil requirement for bearing 4

Estimated oil requirement for bearing 3

Estimated oil requirement for bearing 2

OIL REQUIREMENT IN DIFFERENT


Estimated oil requirement for bearing 1

TECHNICAL DIARY-Santaldih Thermal


Power Station

5 Kg/Cm2 (g)

7 to 10%

Welded SS TP 304

28.575x0.889 mm (top two


28.575x0.7112 mm
rows)

2
15664

5 mwc

33000 m3 / hr.

72 mm Hg(a)

8.30C

330C

SHEETCONDENSER DATA

TECHNICAL DIARY-Santaldih Thermal


Power Station

498

Two

LBTP

150

SS TP-304

16 x 0.889

210

3.9

36.4

LPH -3
Shell & Tube
28
&3.0Full vacuum

OD x

Water box design pressure

Percentage tube thinning

Tube material

No. of CW pass
No. of tubes
Tube dimensions :
Thickness

CW side pressure drop

CW flow quantity

Condenser back pressure

CW Temp. rise

Designed CW Temp

TECHNICAL DIARY-Santaldih Thermal


Power Station

498
16 x 0.889
SS TP-304

No. of U-tubes

Tube ODxTh. (mm)

(Welded)Tube material

100 150

36.4

Two

Design temp. (0C)

3.9

No. of water passes

Tube side

Test Prs. (Kg/Cm2 g)


Tube side

150

36.4

SS TP-304

16 x 0.889

498

Two

150

3.9

LPH -1
LPH -2
Type
Shell & Tube
Shell & Tube
Design Prs. (Kg/Cm2
28
28
Tube side
&3.0Full vacuum
&3.0Full vacuum
g)

Data Sheet For L.P.Heaters

TECHNICAL DIARY-Santaldih Thermal


Power Station

160.10C

304.9 0C

15.0 T/Hr.
Safety Relief
pressure
7.2 Kg/Cm2 g
valve set
0.005 cc / ltr

52
TemperatureInlet Steam

pressureInlet Steam 6.13 Kg/Cm2 g

152 Cu.Mtr

120.0 0to
C LLL)Capacity (NWL
280

160.10C

0
160.1Temperature
C
Operating

6.5 Kg/Cm2 gPressureOperating 6.31 Kg/Cm2 g

3500C TemperatureDesign

2
Kg/Cm2 gFull vacuum & 8 Pressure
8 Kg/Cm
Design
gFull vacuum &

B : Feed Water Storage Tank

Data Sheet For Deaerator

TECHNICAL DIARY-Santaldih Thermal


Power Station

100

Design Temperature

Design Pressure

No.of Trays

TemperatureCondensate

1.5 Kg/cm2

feed waterDissolved oxygen in

Spray valve capacity

3 50 SCMM a t 500 mmHg Vac. No.of spray valves


2 50 oC

6.5 Kg/cm2
33 00 Kg/hr

SS TP 3 04 TemperatureOperating

3150 mm16 x 0.889 x Operating Pressure

3 0.0

150

Temperature (0C) A : Heater Assembly

TECHNICAL DIARY-Santaldih Thermal


Power Station

Length

OD x Th x

Full vacuum & 3.0

Hydraulic test pr.

Design temp

Air removal capacity

DATA SHEET FOR STARTING


Working pr. Of steam
Quantity of Steam

Welded Aust. Tube material :

Tube size

Tube side

Shell side

Design condition Pressure (Kg/Cm2 g)

Data Sheet For Drain Cooler

TECHNICAL DIARY-Santaldih Thermal


Power Station

mmHg(abs)41 kg/hr at 2 5.4

3 6 m2

12 0 0 Kg/hr

6.5 Kg/ cm2 at 210 oC

100/2 5 0 oC

3 9/ 2.5

1 Kg/cm2(g) & Full vacuum

2 6 Kg/cm2 (g)

TECHNICAL DIARY-Santaldih Thermal


Power Station

377

61.1

Test Pr. (Tube/ Shell Side)

Design Pr. Tube side

Design Pr. Shell side

SA 688 TP 3 041100 &

TRIANGULAR20.64 /

BWG(MIN) X(5/8) X (13/14)

DrainSteam &
WaterFeed

3 Zones 2 Pass

Capacity

Cooling Surface area

Quantity of Steam

Working Pr. Of Steam

2 60 2 8 02 60 / Design temp. (Tube/ Shell side)

2 90

47

Shell Side SideTube

HPH-6

TECHNICAL DIARY-Santaldih Thermal


Power Station

Booster Pump
C

TECHNICAL SPECIFICATION OF TURBINE SIDE


EQUIPMENTS:
1. BFP:

BFP Motor

5215/ 23

DrainSteam Water
&
Feed

3 Zones 2 Pass

215

materialNo. of U tube & SA


Tube
688 TP 3 041100 &

Tube Pitch/ Type TRIANGULAR2 0.64 /

Thk. X Leg lenth)U - tube size


BWG(MIN)
(OD X X(5/8) X (13/14)

Medium

No. of pass/Zones

377

Kg/cm2(g)Hydrotest 2
Pr.6
Design temp.

290

SideShellSideTube

HPH-5

20

Design Pr. Kg/cm2(g)

DATA Sheet of HPHS

TECHNICAL DIARY-Santaldih Thermal


Power Station

TECHNICAL DIARY-Santaldih Thermal


Power Station
Pump Type: FA1B56
Direction of rotation:
Anti clockwise (view
from DE)
Q : 525 m3/hr
H : 100mwcl (10Kg/cm2)
N : 1485 rpm
P : 160.1 KW ;
:
81 %
NPSH required :
3.57mwc l
No. of Stage : 1

Feed Pump
Pump Type : FK6D30
Make : BHEL Hyderabad
( WEIR Design)
No. of Stage : 6
Direction of rotation:
Anti clockwise (view
from DE)
Q : 525 m3/hr; N :
5095 rpm
H : 1920 mwc l (192
Kg/cm2)
P : 3080 KW;
:
80.9 %
Min. R/C Flow : 100
ton/hr

Type : SQ cage
Induction motor
Make : BHEL, Bhopal
P : 4600 KW; : 97
%
Voltage/Hz/Phase :
6.6KV/50/3
Rated Current : 466A
F L Current : 466 A
N L Current : 110 A
Power Factor : 0.89
N : 1485 rpm
FRAME SIZE: 1RN77184
DE/NDE BEARING NO:
SLEEVE BRG 160 X 140

Hydraulic Coupling
Type : Gear Variable
Speed Turbo Coupling R
16 K.1
Make: Voith Turbo Pvt.
Ltd.
P : 3510KW
Gear Ratio : 128/35
Primary Speed : 5430
rpm
Full load slip : 2.3 %
Max. output speed:

TECHNICAL DIARY-Santaldih Thermal


Power Station
Suction temp. : 160.2
o
C
NPSH required : 26.5
mwc l

5300 rpm
Regulation range : 4:1
(downward)

2. CEP:

Pump

Motor

Type : EN 8 H 32
Make: BHEL HYD.
No. of Stages : 8
Direction of rotation:
Clockwise (view from
DE)
Suction Temp. : 46.1 oC
H : 200 mwcl
Q : 385 m3/hr
: 78 %
P : 266 KW
N : 1485 rpm
NPSH required : 2.2
mwcl

Type : SQ cage
Induction motor
Make : BHEL
Voltage/Hz/Phase :
6.6KV/50/3
P : 325 KW; : 93.5
%
Rated Current : 35.5 A
F L Current : 35.5 A
N L Current : 10 A
Power Factor : 0.86
N : 1482 rpm
FRAME SIZE: 1LA 75604
DE BEARING NO: 6222
C3
NDE BEARING NO: 7322
B

3. CW PUMP:

Pump

Motor

TECHNICAL DIARY-Santaldih Thermal


Power Station
Type : CW 1Q
Make: BHEL HYD.
No. of Stages : 1
Direction of rotation:
Clockwise (view from
DE)
H : 24.3 mwcl
(H) bowl : 24.3 mwc l
Q : 17500 m3/hr
: 85.5 %
P : 1389.9 KW
N : 490 rpm
NPSH required : 12 mwc
l

Type : SQ cage
Induction motor
Make : BHEL
Voltage/Hz/Phase :
6.6KV/50/3
P : 1800 KW; : 96.3
%
Rated Current : 202 A
F L Current : 202 A
N L Current : 90 A
Power Factor : 0.81
N : 498 rpm
FRAME SIZE: 1RQ19005
DE BEARING NO: 6248
MC3
NDE BEARING NO:
7348B

4. ACW PUMP:

Pump
Model : 24H-1
Make: FLOWMORE Pvt.
Ltd.
No. of Stages : 1
H : 40 mwcl
(H)shut off : 62 mwcl
(Q)max :2925m3/hr
(Q)min : 675m3/hr

Motor
Type : SQ cage
Induction motor
Make : BHEL
Voltage/Hz/Phase :
6.6KV/50/3
P : 350 KW; :
94.0% (at F.L) %
Rated Current : 38 A

TECHNICAL DIARY-Santaldih Thermal


Power Station
(Q)rated : 2250 m3/hr
: 84 %
P : 291.78 KW
N : 1485 rpm
Max Vibn(peak to
peak):75 m

F L Current : 38 A
N L Current : 10.5 A
Power Factor : 0.86
N : 1484 rpm
FRAME SIZE: 1LA75604P
DE BEARING NO: 6222
C3
NDE BEARING NO: 7322
B

5. DMCW (T) PUMP:

Pump
Model : 5822-350 X
300
Make: FLOWMORE Pvt.
Ltd.
No. of Stages : 1
H : 35 mwcl
(H)shut off : 47 mwcl
(Q)max :1235m3/hr
(Q)min : 285m3/hr
(Q)rated : 950 m3/hr
: 85 %
P : 106.52 KW
N : 1485 rpm
Max Vibn(peak to
peak):75 m

Motor
Type : SQ cage
Induction motor
Make : BHEL
Voltage/Hz/Phase :
6.6KV/50/3
P : 161 KW; : 93.1
% %
Rated Current : 18.5 A
F L Current : 18.5 A
N L Current : 6.5 A
Power Factor : 0.82
N : 1482 rpm
FRAME SIZE: 1LA 75004P
DE BEARING NO:
NU222M/ 6222 C3

TECHNICAL DIARY-Santaldih Thermal


Power Station
NDE BEARING NO:
NU219M
6. DMCW (B) PUMP:

Pump
Model : 5824-200 X
150
Make: FLOWMORE Pvt.
Ltd.
No. of Stages : 1
H : 50 mwcl
(H)shut off : 64 mwcl
(Q)max :520m3/hr
(Q)min : 120m3/hr
(Q)rated : 400 m3/hr
: 82 %
P : 66.42 KW
N : 1485 rpm
Max Vibn(peak to
peak):75 m

Motor
Type : SQ cage
Induction motor
Make : ALSTOM
Voltage/Hz/Phase :
415V/50/3
P : 90 KW; : %
Rated Current : 154 A
F L Current : 154 A
N L Current : A
Power Factor : 0.87
N : 1485 rpm
FRAME SIZE: K280M
DE/NDE BEARING NO:
6317

7. DM SERVICE WATER PUMP:

Pump
Model : 5823-80 X 65
Make: FLOWMORE Pvt.
Ltd.
No. of Stages : 1
H : 30 mwcl

Motor
Type : SQ cage
Induction motor
Make : ALSTOM
Voltage/Hz/Phase :
415V/50/3

TECHNICAL DIARY-Santaldih Thermal


Power Station
(H)shut off : 35 mwcl
(Q)max :65m3/hr
(Q)min : 15m3/hr
(Q)rated : 50 m3/hr
: 65 %
P : 6.28KW
N : 1450 rpm
Max Vibn(peak to
peak):75 m

P : 9.3 KW;
Rated Current : 17A
F L Current : 17A
Power Factor : 0.86
N : 1445 rpm
FRAME SIZE: D160M
DE BEARING NO:
6309ZZ
NDE BEARING NO:
6209ZZ

8. CTP:

Pump
Model : 5823-125 X
100
Make: FLOWMORE Pvt.
Ltd.
No. of Stages : 4
H : 110 mwcl
(H)shut off : 134 mwcl
(Q)max :169m3/hr
(Q)min : 39m3/hr
(Q)rated : 130 m3/hr
: 75 %
P : 51.92 KW
N : 1480 rpm
Max Vibn(peak to
peak):75 m

Motor
Type : SQ cage
Induction motor
Make : ALSTOM
Voltage/Hz/Phase :
415V/50/3
P : 75 KW;
Rated Current : 128A
F L Current : 128A
Power Factor : 0.87
N : 1480 rpm
FRAME SIZE: D280S
DE BEARING NO: 6317
NDE BEARING NO: 6314

TECHNICAL DIARY-Santaldih Thermal


Power Station
9. AIR COMPRESSOR:

Compressor

Motor

Type: ALE180W-5ES
SCREW AIR
COMPRESSOR.
Make:
Discharge air Vol.: 26
m3/min.
Suc. Pr.- Atmospheric pr.
Suc. Temp.- 300C
Humidity: 9.3 bar
Discharge pr. : 9.3 bar
Comp. shaft power: 180
KW
Oil p/p motor o/p : 1.5
KW
Initial charge of lub oil:
35 lit.

Type : SQ cage
Induction motor
Make : Fuji Electric
Voltage/Hz/Phase :
6.6KV/50/3
P : 198 KW; : 93 %
Rated Current : 21 A
F L Current : 21 A
N L Current : 6.1 A
Power Factor : 0.89
N : 2995 rpm
FRAME SIZE: 315L
DE BEARING NO: 6316
NU216
NDE BEARING NO:
NU216

C] OUTSIDE POWER HOUSE:


1. CW MAKE UP PUMP:

Pump
Model : MSC 590-150 X
125
Make: FLOWMORE Pvt.
Ltd.
No. of Stages : 1

Motor
Type : SQ cage
Induction motor
Make : ALSTOM
Voltage/Hz/Phase :
415V/50/3

TECHNICAL DIARY-Santaldih Thermal


Power Station
H : 16 mwcl
(H)shut off : 25 mwcl
(Q)max :975m3/hr
(Q)min : 225m3/hr
(Q)rated : 750 m3/hr
: 84 %
P : 38.90 KW
N : 1460 rpm
Max Vibn(peak to
peak):75 m
2. RAW WATER PUMP:

Pump

P : 45 KW; : 92.7
%
Rated Current : 78A
F L Current : 78 A
N : 1475 rpm
FRAME SIZE: DV225M
DE BEARING NO: 6313
NDE BEARING NO: 6313

Motor

Model : 20H-1
Type : SQ cage
Make: FLOWMORE Pvt.
Induction motor
Ltd.
Make : ALSTOM
No. of Stages : 1
Voltage/Hz/Phase :
H : 18 mwcl
415 V/50/3
(H)shut off : 31 mwcl
P : 90 KW; : %
3
(Q)max :1657.5 m /hr
Rated Current : 154 A
(Q)min : 382.5m3/hr
F L Current : 154 A
(Q)rated : 1275 m3/hr
N : 1485 rpm
: 85 %
FRAME SIZE: KV280M
P : 73.52 KW
DE/NDE BEARING NO:
N : 1485 rpm
6317
n
Max Vib (peak to
peak):75 m
3. ASH WATER MAKE UP PUMP:

TECHNICAL DIARY-Santaldih Thermal


Power Station
Pump
Model : 15H-2
Make: FLOWMORE Pvt.
Ltd.
No. of Stages : 2
H : 30 mwcl
(H)shut off : 42 mwcl
(Q)max :617.5m3/hr
(Q)min : 142.5m3/hr
(Q)rated : 475 m3/hr
: 84 %
P : 46.19 KW
N : 1470 rpm
Max Vibn(peak to
peak):75 m

Motor
Type : SQ cage
Induction motor
Make : ALSTOM
Voltage/Hz/Phase :
415V/50/3
P : 55 KW; : 93 %
Rated Current : 96A
F L Current : 96A
N L Current : A
Power Factor : 0.86
N : 1470 rpm
FRAME SIZE: DV250M
DE BEARING NO: 6314
DE BEARING NO: 6313

4. ASH SEAL WATER PUMP:

Pump
Model : 10M-6
Make : FLOWMORE Pvt.
Ltd.
No. of Stages : 6
H : 50 mwcl
(H)shut off : 72 mwcl
(Q)max :130m3/hr
(Q)min : 30m3/hr
(Q)rated : 100 m3/hr

Motor
Type : SQ cage
Induction motor
Make : ALSTOM
Voltage/Hz/Phase :
415V/50/3
P : 22 KW;
Rated Current : 39A
F L Current : 39A
N: 1460 rpm

TECHNICAL DIARY-Santaldih Thermal


Power Station
: 80 %
P : 17.08 KW
N : 1460 rpm
Max Vibn(peak to
peak):75 m

FRAME SIZE: DV180L


DE BEARING NO: 6310
ZZ
NDE BEARING NO: 6210
ZZ

5. DM WATER TRANSFER PUMP:

Pump
Model : 15H-2
Make: FLOWMORE Pvt.
Ltd.
No. of Stages : 1
H : 25 mwcl
(H)shut off : 29 mwcl
(Q)max :169 m3/hr
(Q)min : 39 m3/hr
(Q)rated : 130 m3/hr
: 76 %
P : 11.64 KW
N : 1455 rpm
Max Vibn(peak to
peak):75 m

Motor
Type : SQ cage
Induction motor
Make : ALSTOM
Voltage/Hz/Phase :
415V/50/3
P : 15 KW;
Rated Current : 27.3A
F L Current : 27.3A
N : 1482 rpm
FRAME SIZE:
DE BEARING NO:
6309ZZ
NDE BEARING NO:
6209ZZ

6. SERVICE WATER PUMP:

Pump

Motor

TECHNICAL DIARY-Santaldih Thermal


Power Station
Model : 9M-5
Make: FLOWMORE Pvt.
Ltd.
No. of Stages : 6
H : 50 mwcl
(H)shut off : 59 mwcl
(Q)max :65 m3/hr
(Q)min : 15 m3/hr
(Q)rated : 50 m3/hr
: 75 %
P : 9.06 KW
N : 1460 rpm
Max Vibn(peak to
peak):75 m

Type : SQ cage
Induction motor
Make : ALSTOM
Voltage/Hz/Phase :
415 V/50/3
P : 15 KW;
Rated Current : 27.3A
F L Current : 27.3A
N : 1445 rpm
FRAME SIZE: DV 160L
DE BEARING NO: 6309
ZZ
NDE BEARING NO: 6209
ZZ

7. HVAC M/U PUMP:

Pump
Model : 7M-3
Make: FLOWMORE Pvt.
Ltd.
No. of Stages : 3
H : 50 mwcl
(H)shut off : 59 mwcl
(Q)max :65 m3/hr
(Q)min : 15 m3/hr
(Q)rated : 50 m3/hr
: 73 %
P : 9.32 KW

Motor
Type : SQ cage
Induction motor
Make : ALSTOM
Voltage/Hz/Phase :
415V/50/3
P : 15 KW;
Rated Current : 27.6A
F L Current : 27.6A
N : 2880 rpm
FRAME SIZE: DV160M
DE BEARING NO: 6309

TECHNICAL DIARY-Santaldih Thermal


Power Station
N : 2880 rpm
Max Vibn(peak to
peak):75 m

ZZ
NDE BEARING NO: 6209
ZZ

8. POTABLE WATER P/P (Plant):

Pump
Model : 6M-6
Make: FLOWMORE Pvt.
Ltd.
No. of Stages : 6
H : 60 mwcl
(H)shut off : 93 mwcl
(Q)max :52 m3/hr
(Q)min : 12 m3/hr
(Q)rated : 40 m3/hr
: 70 %
P : 9.33 KW
N : 2900 rpm
Max Vibn(peak to
peak):75 m

Motor
Type : SQ cage
Induction motor
Make : BHEL
Voltage/Hz/Phase :
6.6KV/50/3
P : 161 KW; : %
Rated Current : 18.5 A
F L Current : 18.5 A
N L Current : 6.5 A
Power Factor : 0.82
N : 1482 rpm
FRAME SIZE:
DE BEARING NO:
NDE BEARING NO:

9. POTABLE WATER P/P (Colony):

Pump
Model : 6M-5
Make: FLOWMORE Pvt.
Ltd.
No. of Stages : 5

Motor
Type : SQ cage
Induction motor
Make : BHEL
Voltage/Hz/Phase :

TECHNICAL DIARY-Santaldih Thermal


Power Station
H : 50 mwcl
(H)shut off : 78 mwcl
(Q)max :52 m3/hr
(Q)min : 12 m3/hr
(Q)rated : 40 m3/hr
: 70 %
P : 7.78 KW
N : 2900 rpm
Max Vibn(peak to
peak):75 m
NPSH required : mwc

6.6KV/50/3
P : 161 KW; : %
Rated Current : 18.5 A
F L Current : 18.5 A
N L Current : 6.5 A
Power Factor : 0.82
N : 1482 rpm
FRAME SIZE:
DE BEARING NO:
NDE BEARING NO:

10. APH WASH P/P:

Pump
Model : 14M-4
Make: FLOWMORE Pvt.
Ltd.
No. of Stages : 4
H : 95 mwcl
(H)shut off : 120 mwcl
(Q)max :357.5 m3/hr
(Q)min : 82.5 m3/hr
(Q)rated : 275 m3/hr
: 82 %
P : 86.76 KW
N : 1485 rpm
Max Vibn(peak to
peak):75 m

Motor
Type : SQ cage
Induction motor
Make : ALSTOM
Voltage/Hz/Phase :
415V/50/3
P : 110,150HP; : 94
%
Rated Current : 192A
F L Current : 192A
N : 1484 rpm
FRAME SIZE: UV315S
DE BEARING NO: 6319
NDE BEARING NO: 6316

TECHNICAL DIARY-Santaldih Thermal


Power Station

11. CHP Dust Suppression P/P:

Pump
Model : 12M-2
Make: FLOWMORE Pvt.
Ltd.
No. of Stages : 2
H : 25 mwcl
(H)shut off : 30.5 mwcl
(Q)max :227.5 m3/hr
(Q)min : 52.5 m3/hr
(Q)rated : 175 m3/hr
: 80 %
P : 14.89 KW
N : 1460 rpm
Max Vibn(peak to
peak):75 m

Motor
Type : SQ cage
Induction motor
Make : ALSTOM
Voltage/Hz/Phase :
415V/50/3
P : 18.5KW; : 90.5
%
Rated Current : 33.5A
F L Current : 33.5A
Power Factor : 0.85
N : 1460 rpm
FRAME SIZE: DVM180M
DE BEARING NO: 6310
ZZ
NDE BEARING NO: 6210
ZZ

12. NEW INTAKE PUMP:

Pump
Type: Vertical wet pit
,Non
pullout type
Number : 5 NOS.,

Motor
Type : SQ cage
Induction motor
Make :ABB Limited
Voltage/Hz/Phase :

TECHNICAL DIARY-Santaldih Thermal


Power Station
Make: FLOWMORE Pvt.
Ltd.
No. of Stages : 4
H : 106.65 mwcl
(H)bowl : 125.82 mwcl
(H)shut off : 160 mwcl
(Q)rated : 1500 m3/hr
: 88.29%
P : 578.32 KW
N : 1489 rpm
Rotation: ccw when
view from top.

6.6KV/50/3
P : 700 KW; : %
Rated Current : A
F L Current : A
N L Current : A
Power Factor :
N : 1482 rpm
FRAME SIZE:
DE BEARING NO:
NDE BEARING NO:

13. CT Fan -1 for U-5 & U-6:


CT Fan Motor for U-5
Type : SQ cage Induction
motor
Make : ALSTOM
Voltage/Hz/Phase :
415V/50/3
P : 90KW; : 93.9 %
Rated Current : 154 A
F L Current : 154 A
Power Factor : 0.87
N : 1485 rpm
FRAME SIZE: KV 280M
DE BEARING NO: 6317

CT Fan Motor for U-6

TECHNICAL DIARY-Santaldih Thermal


Power Station
NDE BEARING NO: 6317
Descripti
on
Make
Type

Apparent
Power
Active
Power
Current
Voltage

GENERATOR & AUXILIARIES


Turbo
Main
Pilot
Generato
Excitor
Excitor
r
BHEL
THRI
ELR 70/62- ELR 50/29108/44
30/6-10
30/16
Totally
Impregnat
ed
294.1 MVA
35 KVA
250 MWA

1344 KW

35 KW

10291 A
16.5V82
5V
50 S-1
50 Hz
0.85
300 V

3200 A
420V

105 A
(22022)
V
50 S-1
400Hz
1.0
-

Speed
50 S-1
Frequency
150 Hz
PF
Rated field
voltage
Rated field current for rated output
:
Critical
1255 rpm & 3360 rpm
speed

2497 A

TECHNICAL DIARY-Santaldih Thermal


Power Station
H2 Pr.

4
kg/cm2(g)
Generator Gas Volume
:
CO2 filling quantity
:
H2 filling quantity for 4 ksc :

82 m 3
164 m 3
533 m3

Generator Excitation System


A .Rectifier Wheel
(Positive Polarity):
No. of Fuses per rectifier
wheel
Fuse resistance
No. of diode per rectifier
wheel
No. of RC network
B .Rectifier Wheel
(Negative Polarity):
No. of Fuses per rectifier
wheel
Fuse resistance
No. of diode per rectifier
wheel
No. of RC network
Stroboscope:
No. of Stroboscope
Type of Stroboscope
Voltage/Frequency

BHd L 1220 type, BHEL


EDN Make
30 (700 V, 400 A)
Approx. 300
30
6
BHd L 1320 type, BHEL
EDN Make
30 (700 V, 400 A)
Approx. 300
30
6
1
ZEN-SS-77
240V/50 Hz

Generator Transformer

TECHNICAL DIARY-Santaldih Thermal


Power Station
Make
Type of cooling
Rating HV (MVA)
Rating LV(MVA)
No load Voltage HV
(KV)
No load Voltage LV
(KV
Line Current HV
(Amps)
Line Current LV
(Amps)
Power Factor
Impedance
Temp .Rise of oil
(0C)
Temp. Rise of
Winding (0C)
Connection Symbol
NGT Power Rating
NGT Voltage Rating
NGR Rating
Oil quantity

BHEL
ONAN
189(60
%)
189
235

ONAF
252(80
%)
252

OFAF
315(100
%)
315

16.5
774.81
11035.21
0.85
14.5 %
40 Over Ambient Temp. of
500C
50 Over Ambient Temp. of
500C
YNd1
75 KVA (5 min.). AN
16.5 KV/240V
0.3359 (5 min.)
63320 Liters

Station Transformer-3 & 4 & Unit


Auxiliaries Transformer (UAT)
Description
ST-3 & 4
UAT

TECHNICAL DIARY-Santaldih Thermal


Power Station
Make

BHEL
ONA
N

Type of cooling

ONAF

Rating HV
(MVA)

40

Rating LV(MVA)

LV1:2
5
LV2:1
5

No load
Voltage HV
(KV)
No load
Voltage LV (KV)
Line Current
HV (Amps)
Line Current LV
(Amps)
Temp .Rise of
oil (0C)
Temp. Rise of
Winding (0C)
Connection
Symbol
NGR rating

BHEL
ONAF

ONAN

24

20

16

15
9

20

16

220

16.5

16.5

LV1: 6.9 ;
LV2:6.9

6.9

6.9

104.973

699.81

LV1: 2091.85
Lv2: 1255.11

1673.4
79

559.8
5
1338.7
83

40 Over Ambient Temp. of 500C


50 Over Ambient Temp. of 500C
YNyn0d1

Dyn11

9.95 , 400A (10 sec)

Station Transformer-5

TECHNICAL DIARY-Santaldih Thermal


Power Station
Description
Make
Type of cooling
Rating HV
(MVA)
Rating LV(MVA)
No load
Voltage HV
(KV)
No load
Voltage LV (KV)
Line Current
HV (Amps)
Line Current LV
(Amps)
Connection
Symbol

ST-5

ST-1 & 2

BHEL

Make- Hack
Bridge Hewille
and Easun Ltd

ONAF

ONA
N

ONAF

ONAN

40

25

16

12.5

40

25

16

12.5

220

132

6.9

6.6

104.97
3346.95
YNyn0

70

54.7

1400

1094
Yd1

New Tie & Old Tie Transformer


New Tie
Old Tie Transformer
Transformer
Make- Crompton &
Greaves
MVA(HV) -78/104/130
MVA(IV) -78/104/130

Make- Crompton & Greaves


MVA-33/100/100 ; Quantity1
MVA on ON- 50MVA

TECHNICAL DIARY-Santaldih Thermal


Power Station
MVA(LV)
-26/34.67/43.33
CoolingONAN/ONAF/OFAF
Voltage (HV)-220KV
Voltage (IV)-132KV
Voltage (IV)-34.5KV
Current
(HV)341.2Amp
Current (IV)-568.6Amp
Current (LV)-Loaded
Connection- YNa0d11
Quantity-1

Cooling- ON/OFB
Voltage (HV)-220KV
Voltage (LV)-132KV
Voltage (Tert.)-33KV
Current (HV)-262.4Amp
Current (LV)-437.4Amp
Current (Tert.)-583.1Amp
Connection- HV/LV-Yy0
HV/T-Yd11
LV/T-Yd11

Bhojudih Transformer - 1 & 2


Bhojudih Transformer - 1
Bhojudih Transformer - 2
MakeHack
Bridge
Hewille and Easun Ltd.
MVA-7.5MVA ; Quantity-1
Cooling- ON
Voltage (HV)-132KV
Voltage (LV)-33KV
Current (HV)-32.8Amp
Current (LV)-131Amp
Connection- Yd1

MakeHack
Bridge
Hewille and Easun Ltd.
MVA-12.5MVA ; Quantity1
Cooling- ON
Voltage (HV)-132KV
Voltage (LV)-33KV
Current (HV)-54.6Amp
Current (LV)-218.4Amp
Connection- Yy0

TECHNICAL DIARY-Santaldih Thermal


Power Station

Colony Transformer and Old Intake


Transformer
Colony Transformer
- 1&2

Old Intake
Transformer -1&2

Make- Brentford Electric


India Ltd.
MVA-2MVA
Cooling- ON
Voltage (HV)-11KV
Voltage (LV)-6.6KV
Current (HV)-105Amp
Current (LV)-175Amp
Connection- Yd11
Quantity-2

Make- Hindustan Brown


Bouveri Ltd.
KVA-750
Cooling- ON
Voltage (HV)-33KV
Voltage (LV)-420Volt
Current (HV)-13.12Amp
Current (LV)-1032Amp
Connection- Yd11
Quantity-2

Old Intake Lighting Transformer & Old Raw


Water Pump House Transformer
Old Intake Lighting
Transformer
Make- Hindustan Brown
Bouveri Ltd.
KVA-500
Cooling- ON
Voltage (HV)-6.6KV
Voltage (LV)-420 Volt
Current (HV)-43.7mp
Current (LV)-686Amp

Old Raw Water Pump


House Transformer
Make- Hindustan Brown
Bouveri Ltd.
KVA-500
Cooling- ON
Voltage (HV)-6.6KV
Voltage (LV)-433Volt
Current (HV)-8.77Amp
Current (LV)-6667.5Amp

TECHNICAL DIARY-Santaldih Thermal


Power Station
Connection- Dyn11
Quantity-1

Connection- Dy11
Quantity-1

Old Filter Water Pump House Transformer


& Old Additional Filter Water Pump House
Transformer
Old Filter Water Pump
Old Additional Filter
House Transformer
Water Pump House
Transformer
Make- Hindustan Brown
Bouveri Ltd.
KVA-750
Cooling- ON
Voltage (HV)-6.6KV
Voltage (LV)-420 Volt
Current (HV)-61.61Amp
Current (LV)-1031Amp
Connection- Dyn11
Quantity-1

Make- Bharat Bijli


KVA-1000
Cooling- ON
Voltage (HV)-6.6KV
Voltage (LV)-420 Volt
Current (HV)-87.5Amp
Current (LV)-1375Amp
Connection- Dyn11
Quantity-1

Vacuum Pump House #5 & ESP #5&6


Transformer #1&2
Earthing Transformer for
Vacuum Pump House
Bhojudih Transformer #1
#5 & ESP #5&6
And New Tie Transformer
Transformer #1&2
Make- BHEL Jhansi
MVA-2
Cooling- AN (Dry type)

KVA-100
Cooling- ON
Voltage (HV)-33KV

TECHNICAL DIARY-Santaldih Thermal


Power Station
Voltage (HV)-6.6KV
Voltage (LV)-433V
Current (HV)-174.95Amp
Current (LV)-2660.74Amp
Connection- Dyn11
Quantity-2+4+4

Voltage (LV)-410Volt
Current (HV)-1.75Amp
Current (LV)-144.3Amp
Connection- Znyn11
Quantity-1+1

New Intake Pump House Transformer#1&2


and New Intake Pump House LT
Transformer#1&2
New Intake Pump
New Intake Pump
House
House LT
Transformer#1&2
Transformer#1&2
Make- EMCO ltd.
MVA-3.15
Cooling- ONAN
Voltage (HV)-33KV
Voltage (LV)-6.6KV
Current (HV)-55.11Amp
Current (LV)-263.57Amp
Connection- Dyn11
Quantity-2

Make- Intra Vidyut Ltd.


KVA-250
Cooling- AN (Dry Type)
Voltage (HV)-6.6KV
Voltage (LV)-433V
Current (HV)-21.86Amp
Current (LV)-333.34Amp
Connection- Dyn11
Quantity-2

LV Transformer Details
SPACIFICATION
Name of the
Transformer
a)CW Pump House #5
Transformer#1,2&3

Make- BHEL Jhansi


MVA-1.6

Qty
3+2
+

TECHNICAL DIARY-Santaldih Thermal


Power Station
b) CW Pump House #6
Transformer#1&2
c) Raw water Pump
House (New)
Transformer#1&2
d)Clarified Pump House
#6
Transformer#1&2
e)Slurry Pump House
#5&6
Transformer#1&2
f) Vacuum Pump House
#6

Cooling- AN (Dry
type)
Voltage (HV)-6.6KV
Voltage (LV)-433V
Current
(HV)139.96A
Current
(LV)2133.40A
Connection- Dyn11

2+2
+
2+2

Make-Logic Controls
Pvt. Ltd.
KVA-100
Cooling- ANAN (Dry
Type)
Voltage
(HV)415Volt
Voltage (LV)-433Volt
Current
(LV)133Amp
Connection- Dyn11
HV TRANSFORMER DETAILS (ESP):
Description
Make

2+2
+
2+4

Lighting Transformer
a) CW Pump House #5
&6
b)
Clarified
Pump
House #5 &6
c) Slurry Pump House #
5 &6
d) ESP Control Room #
5&6

TECHNICAL DIARY-Santaldih Thermal


Power Station
Type
Frequency
Type of cooling
Power Rating (KVA)
Output Voltage(DC)
Output Current
No load Voltage HV
(KV)
No load Voltage LV
(KV)
Line Current HV
(Amps)
Line Current LV (Amps)
Temp. Rise (0C)

Drive
FD Fan
ID Fan
PA Fan
BFP
CEP

Single Phase Oil immersed


50 Hz
ONAN
100
95 KV (peak)
1000 mA (mean)
74030 V
373.5 V
1.35
267.7
For Oil=500C, For
Winding=550C

HT MOTOR RATING
RPM
NLC(
FLC(A)
A)
800
1487
29.0
88.5
1926
746
70.0
208.0
1575
1488
34.5
165.0
4600
1493
110.0 466.0
325
1482
10.0
35.5
KW

Trip(A)
89
210
166
468
35.5

TECHNICAL DIARY-Santaldih Thermal


Power Station
CW
ACW
Mill
DMCW(
T)
Air
Comp.
HP W
Slurry
p/p
Air
comp.
(AHP)

1800
350
425
161

498
1481
985
1482

90.0
10.5
25.0
6.5

202.0
38.0
51.5
18.5

202.5
40
54.75
18.5

198

2995

6.1

21.0

21

300
210

1483
1481

9.8
7.5

32.6
24.0

280

1480

10.8

31.3

Drive

KW

DMC
W
(B)

90

CTP

75

DMS
W p/p
SAF

9.3
37

LT MOTOR RATING
FL
C
DE/
or
Frame
NDE
RP
M
Tri
size
Brg.
p
No
(A)
148
5

15
4

K280M

148
0
144
5
148

12
8

D280S

17
63

ND250M

6317
6317
6317
6314
6309ZZ
6209ZZ
6314

Make

ALSTOM
ALSTOM
ALSTOM
Crompto

TECHNICAL DIARY-Santaldih Thermal


Power Station
0
Coal
Feede
r
ID
LOP
UNIT
#6
ID
LOP
UNIT
#5
PA &
FD
LOP
UNIT
#6
PA &
FD
LOP
UNIT
#5
MILL
LOP
UNIT
#6
MILL
LOP
UNIT
#5

6314

n
Greaves

7.5

146
0

14.
6

MA16L4
75
/160L

6309ZZ
6209ZZ

BHARAT
BIJLEE

1.1

278
0

2.5

HX80C2

6204ZZ
6203ZZ

ABB

1.1

284
0

2.3
5

MA0802
33
/ 080

6004ZZ
C3
6004ZZ
C3

BHARAT
BIJLEE

2.2

140
0

4.7

BPM
100L

6206
6206

KIRLOSK
AR
ELEC.

2.2

144
0

4.6

ND100L

6206ZZ
6205ZZ

Crompto
n
Greaves

5.5

145
0

10.
1

ND132S

6308ZZ
6308ZZ

Crompto
n
Greaves

5.5

144
0

11.
2

FCPA
132SB-4

6308ZZ
C3
6308ZZ
C3

AC
MOTORE
N GmbH

TECHNICAL DIARY-Santaldih Thermal


Power Station
APH
LOP
MOTO
R
AOP
OF
BFP
U#5
Scann
er
FanAC
Scann
er
FanDC
Scann
er
FanDC
Motor
Unit#
6
APH
GB
MOTO
R
UNIT
#5
APH
GB
MOTO

0.7
5

138
0

1.8
0

FBPM
90S

5.5

145
0

10.
5

132S

5.5

292
0

10.
1

132S

5.5

286
5

31

AFS
180M

5.6

290
0

29.
5

KSDC
132 MX
BS 5000

11

146
0

21

ND160L

11

145
0

20.
7

PM160L

KIRLOSK
AR
ELEC.
Type:
1LA01304YA8
6308ZZ
C3
6208ZZ
C3
6309
2RS
6309
2RS

SIEMENS

BHARAT
BIJLEE
Crompto
n
Greaves

KIRLOSK
AR
ELEC.

6309ZZ
6209ZZ

Crompto
n
Greaves
KIRLOSK
AR
ELEC.

TECHNICAL DIARY-Santaldih Thermal


Power Station
R
UNIT
#5
Crompto
n
Greaves

AOP

75

297
0

12
4

ND280S

EOPAC

15

147
5

27

ND180M

EOPDC

13

142
5

97

AUS
225X

JOPAC

60

295
5

95

ND250M

JOPDC

60

290
0

31
5

AUS
280M

SOP

7.5

144
0

14.
5

ND132M

6308ZZ
6208ZZ

Crompto
n
Greaves

3.7

283
0

7.2

HX +
100L B2

6306ZZ
C3
6306ZZ
C3

ABB

6314
6314
6310
2RS
6210
2RS
6213
2RS
6311
2RS
6314
C3
6314
C3
6316
2RS C3
6316
2RS C3

Crompto
n
Greaves
Crompto
n
Greaves
Crompto
n
Greaves
Crompto
n
Greaves

SOPDC
GSC
FAN

TECHNICAL DIARY-Santaldih Thermal


Power Station
HP BP
PUMP

144
0

7.5

14.
4

BPM
132M

6308
6208

KIRLOSK
AR
ELEC.

R & I INTERLOCK & PROTECTION


Equipment: Generator
Group-1 & 2: Numerical Relay 7 UM 62 of
Siemens
Location/Relay

Trippin
g
Class-A

Back up impedance relay


21G1 , 21G2

GRP-1,3/GR1,2

Negative phase sequence


relay 46 G1, 46G2

GRP-1,3/GR1,2

Class-C

Dead machine relay


50GDM1, 50GDM

GRP-1,3/GR1,2

Class-A

Over voltage relay 59 G1,


59G2
: 19.8KV(instant)
:18.75KV(2 secs)
:17.65KV(2 secs)

GRP-1,3/GR1,2

VT fuse failure
Out of step pole slipping

ClassA/B
ClassA/B
AVR C/O from auto to
manual channel
GRP-1,3/GRAlarm
1,2
GRP-1,3/GRClass-C

TECHNICAL DIARY-Santaldih Thermal


Power Station
relay 78G1, 78G2

1,2

Differential relay 87 G1,


87G2
GT Over fluxing relay( 24
G1, 24G2) & Generator
Over flux Protection 99GT
Field failure relay 40 G1,
40G2
Under voltage relay 27G1,
27G2
Low forward power relay
(1.25 MW) :with TLR (2
secs)
:without TLR(10 secs)
37 G1, 37G2
100% stator earth fault
relay 64G1, 64G2

GRP-1,3/GR1,2
GRP-1,3/GR1,2

Class-A

GRP-1,3/GR1,2
GRP-1,3/GR1,2
GRP-1,3/GR1,2

Class-B

GRP-1,3/GR1,2

Class-A

Rotor earth fault relay


64F1
95% stator earth fault relay
59 NG1, 59 NG2
Under frequency relay
:48.5hz(3 secs)
:47.5 hz(0.5 sec) 81G1,
81G2

GRP-1,3/GR1,2
GRP-1,3/GR1,2
GRP-1,3/GR1,2

Class-A

Class-A

Class-A
Class-B
Class-A

Class-A
Alarm
Class-C

TECHNICAL DIARY-Santaldih Thermal


Power Station
Over frequency relay
:51 hz(1 sec)
:53 hz (0.5 sec) 81G1,
81G2
Reverse power protection(1.25 MW ) :with TLR (4
secs)
:without TLR (5
secs)
32 G1, 32G2
Earth fault protection relay
51NG 1, 51NG2

GRP-1,3/GR1,2

Alarm
Class-C

GRP-1,3/GR1,2

Class-B

GRP-1,3

Class-A

Class-A

Numerical Relay 7 SJ 62 of Siemens


Inter turn protection relay
87GI 1, 87GI 2

GRP-2,4

Class-A

Equipment: Generator Transformer


Location/Relay
Fire protection trip
Overall differential
Restricted earth fault
HV/LV winding temperature
Oil temperature

GRP-2,
870A/64HG
T

Trippi
ng
ClassA
ClassA
ClassA
ClassA
Class-

TECHNICAL DIARY-Santaldih Thermal


Power Station
Off circuit tap changer (GCB
closed)
Earth fault relay

GRP-4,
51GT/51NG
T

Over current relay


PRV operated

GRP3/51NG2

Sudden pressure relay


operated
Buchholz relay operated

A
ClassA
ClassC
ClassA
ClassA
ClassA
ClassA

Equipment: Unit Transformer


Location/Relay
Oil temperature
Winding
temperature
Differential relay
Buchholz relay
OLTC oil surge
relay
PRV operated

GRP-1,GRP2;
87/64UTA,
87/64UTB

Tripping
Change over from
unit bus to station
bus
Change over from
unit bus to station
bus
Class-A
Class-A
Class-A
Class-A

TECHNICAL DIARY-Santaldih Thermal


Power Station
REF protection
Fire protection

GRP-4;
UATAR/UAT
BR

HV over current
relay
LV earth fault
relay

Class-A
Class-A
Class-A
Class-A

Equipment: 6.6 KV Motor


Location/Relay
Tripping
Thermal Overload
Switchgear
Trip
(3.5 mtr) /
Short circuit
Trip
Micom P243
Sensitive earth fault
Trip
(Areva)
Negative phase over
Trip
current
Derived earth fault
Trip
Stall detection
Trip
Limit number starts
Alarm
(cold/hot)
only
Differential relay- for
Switchgear(3
Trip(>1M
BFP,CW pump,ID fan
.5 mtr)
W)
and PA fan only.
/IRXm(ABB)
DG SPECIFICATION
Suppliers name
JAKSONS LIMITED
Manufactures name &
type of Equipment:Diesel Engine:
M/S Cummins India Ltd.

TECHNICAL DIARY-Santaldih Thermal


Power Station
Alternator:
Battery:
Battery Charger:
Day tank capacity:
Engine Model:
Engine Prime Power
Rating
No. & arrangement of
cylinder
Max. cylinder pr.
Bore/Stroke
Operating Speed
Mean piston Speed
(m)/sec.
Compression ratio
Rated Engine power at
operating site condition
in
BHP/KW
Fuel consumption in
Ltrs./hr
(The fuel consumption is
with + 5% tolerance)

M/S Newage Electrical


India Ltd.
M/S Standard Furukawa
M/S Chhabi Electrical Pvt
Ltd.
990 Ltrs.
KTA38G2-1(radiator
cooled))
890BHP/664 KWm
(mechanical)
12 cylinder, VCE
configuration
13460 KPa
159 X 159 mm
1500 rpm
7.9
15.5 : 1
890 BHP

1
4

Load-50.6,

TECHNICAL DIARY-Santaldih Thermal


Power Station

1
2
3
4
Mechanical efficiency
Specification of lub oil
AC motor driven gear
lub oil pump capacity
Lub Oil Pr.(rated speed)
No. of electric stater
motor provided for
Engine start & KW rating
Time required for cold to
full load

Alternator
Type: Salient pole, self
excited/PMG excited &
self regulated AC
generator.
Frame :HC634Y2
AVR: MX 321
AVR No: 52205/0002

Load-83.6,
Load-121.4,

Full load 159.3,


110% Load-175.3
95.5 %
15W-40 Valvoline
Commins make
3 phase, 1 HP, 415 V
50 PSI
2 nos., 9 KW
30 Sec max
Battery Charger
Type of rectifier: Full
Wave type constant
voltage with float cum
boost charger.
Rated o/p current = 45A
for engine.

TECHNICAL DIARY-Santaldih Thermal


Power Station
Enclosure: IP 23
Rated KVA: 750
Rated Volts: 415 V
Rated Amps: 1043 A
Rated frequency: 50 Hz
Phase: 3
Power factor: 0.80
Rating: Continuous
Exc. Volt: 5.2V
Exc. Amps: 2.50A

Rated power
supply=240V 10% ,
50Hz 5%, 1 phase AC.
Float charging voltage:
26.4 V
Boost charging voltage:
31.8 V
O/P voltage
range( volts):24DC
Time required for
recharging the battery: 8
hrs.

PROTECTION OF DG SET:
These following protections are used to trip diesel
engine as well as DG PCC Incomer Breakers.
Through Protective Relays
1) VDG14: Earth Fault Relay: Setting: V=20V,
TMS=0.3 (No trip, only Annunciation)
2) CAG34: Differential Relay: Setting: 0.2A
3) CDV62: Voltage controlled over current Relay
(Voltage Transient Relay): Setting: PS=75%, TMS=0.6
4) MFVUM12: Under Frequency Relay: Setting: f=
49.5Hz, T=5.0 Sec
5) CTNM12: Negative Sequence Relay: Setting:
I2s=0.3A, Time setting=6.0 Sec

TECHNICAL DIARY-Santaldih Thermal


Power Station
6) VAGM22: Under Voltage Relay: Setting=70% i.e.
77 V.
7) VTIGM13: Instantaneous Overvoltage relay:
Setting: Vn (inst) =110%
8) CCUM21: Reverse Power Relay: Setting: MTA=30
Deg lead, Time delay=3.0 Sec
Through Scanner (Temperature Protection):
a) Bearing Temperature: Alarm=70 Deg C, Trip=90
Deg C
b) Winding Temperature: Alarm=130 Deg C,
Trip=140Deg C (Class B Insulation)
Through Electrical control panel:
a) Low lub oil pressure (less than122 PSI )
b) High Water temperature (Higher than 950 C)
c) Engine over speed (1650rpm for 10 Sec)
.Only applicable for Engine, not for DG PCC
I/C Breaker.

Recommended Chemicals & Reason


Actions

Recommended
Chemicals

Reason

Boiler hydro test

N2H4 & NH3

Protection of boiler
drum & boiler tube

Boiler lit up

TSP (Na3PO4)

Protection of boiler

Steam Rolling

N2H4 & NH3

Protection of SH &
other tubes

TECHNICAL DIARY-Santaldih Thermal


Power Station
Wet Storage

NH3 / N2H4 & PH


10 10.5

Protection of steel
for long period.

WATER TREATMENT PLANT


Ionic Load:
The dissolved salts in water exist in ionic form - cation
carrying positive charge and anions carrying negative charge.
Thus the influent water to demineralising plant carries cation
load and anion load.
Cation load is generally the sum of calcium, magnesium and
sodium. Anion load is generally the sum of chloride, sulphate,
nitrate, phosphate, flouride, free carbon dioxide and silica.
Cooling Tower Cycles of Concentration

TECHNICAL DIARY-Santaldih Thermal


Power Station
COC=

Concentration of solids of therecirculating coo


Concentration of solids of the original raw mak
Technical Data of DM Plant:

Quantity
ACF

2 nos.

SAC

2 nos

Degasse
r Tank

2 nos

WBA

2 nos

SBA

2 nos

MB

2 nos

Nominal
Capacity

50
m3/hr
50
m3/hr
50
m3/hr
50
m3/hr
50
m3/hr
50
m3/hr

Working
Pr.

4
kg/cm2
4
kg/cm2
Atmosp
h.
4.2
kg/cm2
4.2
kg/cm2
4.2
kg/cm2

Liquid
handele
d
Filtered
Water
Filtered
Water
Degss.
Water
Anion
Water
Anion
Water
DM
Water

3
2
4
2
2
4
2

WPIL

TurboSAM

TurboSAM

TurboSAM

CombinENGg.

TurboSAM

MoreFlow

130

20

16

10

52.5

20

55

25

19.2

10

17

42

26

40

1455

1450

1450

1500

1450

1455

1455

11.64

3.7

2.2

16

5.5

8.23

Make No (m3/hr}Q(mwclH rpmN (KW)P

415

415

415

415

415

415

415

4.8

4.8

11

TECHNICAL DIARY-Santaldih Thermal


Power Station

Recommended DM Water limit


TECHNIC

02 0 3 010 2
-

p/pDM feed

<2 0

< 0.3

20

0.3

< 10 < 10

<10

< 10

< 0.0
5<<0.2
0.0< 0.2
5 05
5 0 0.2 0.0

<2 0 <2 0

< 0.2 < 0.3

<2 0

< 0.3

< 10

< 10

< 0.2 5 < 0.2 5

< 50 0

<2.0

2-6

< 50

Deg. p/p

< 10 TransferDM

transferEffluent

<2 0

unloadingAcid

- transferAlkali

< 0.3 p/pDM Reg.

7.16.9 - 0.19 0.19 0.19 9 - 9.5 0.19 9 0.1

O / LCSTschCEPD/A
DrumBoiler
SteamBoiler SteamSH
Di O/LF W ECO I/L

TECHNICAL DIARY-Santaldih Thermal


Power Station

+Ni Fe + Cu < 10

<2 0

( p p m )N H3 / O2

( p p b )Si O2

( p p m )Cl

CHEMICAL DOSING

SOURCE: RAW WATER


1.ALUM
Treatme
nt By
2.HYPO(NaOCl)
1

N a O HFr e e

(p p m )P O4

( m h oC on d. < 0.2

7.16.9 pH

( p p b )N2 H4

O / LM B

TECHNICAL DIARY-Santaldih Thermal


Power Station

REASON
To
coagulate
colloidal particle.
To restrict growth of
algae initially.
REMARKS: 1.To separate mud by deposition in
Clariflocculator. 2. Upper part (Clariflocculator) is
divided into two parts A) For D.M plant after
filtration, B) For C.W make-up
SOURCE:
PLANT

D.M
1.HCl

REASON

To Regenerated Exhausted
Cation Bed
2.NaOH
To Regenerated Exhausted
Anion Bed
REMARKS: 1)To get D.M water exchange Cation
(Metal ion) by H+ & anion (acid radicals) by OHand formed H2O.
Treatme
nt By

TECHNICAL DIARY-Santaldih Thermal


Power Station

2)To remove CO2 from H2CO3 (Obtained after


Cation Bed), Degassifier is used by application of
Daltons law of partial pressure.
SOURCE: BOILER WATER
REASON
1.TRI SODIUM To maintain pH (9.0
Treatme
PHOSPHATE(T -9.5) & Phosphate
nt By
SP)
(2ppm 4ppm).
REMARKS: To form Phosphate sludge if any
contamination.
SOURCE: C.P; BFS; ECO;
REASON
B.D.S & M.S
1.HYDRAZINE
To
scavenge
(N2H4 )
Oxygen from water
by N2H4 & to
2.AMMONIA
Treatme
maintain higher pH
(NH3)
nt By
(8.8 9.1) by NH3;
(both
for
min.
corrosion).
REMARKS: Iron always has a tendency to
corrode in presence of water and O 2 at any
condition. Magnetic Oxide (Fe3O4) layer is formed
and stable in presence of N2H4
SOURCE: C.W WATER
Treatme
1.H2SO4
nt By

REASON
Formation
of
sulphate
from
bicarbonate salt.

TECHNICAL DIARY-Santaldih Thermal


Power Station
2.ClO2
No growth of algae
3.BIODISPERSIO
Dispersion of any
N
growth
4.BIOCIDES
To kill the Bactria
REMARKS:
1) To restrict deposition of Calcium Carbonate on
heat exchange.
2) Distribution of water in cooling tower will be
restricted by algae and minimize the cooling
effect .That means problem of vacuum of
condenser generation.
3) Due to some Bio growth in C.W. system.
4) Some Bactria grows immunity against ClO2.
SOURCE: N.PIT
1.HCl
Treatme
nt By
6

2.Na2CO3

REASON
To neutralize pH
when high pH in
N.Pit
To neutralize pH
when low pH in
N.Pit

REMARKS:
1) During regeneration excess NaOH increased
the pH. (5.5-8.5)
2) During regeneration excess Hcl decreased the
pH .
(5.5-8.5)
SOURCE: CT Water COC
REASON

TECHNICAL DIARY-Santaldih Thermal


Power Station
High Bicarbonate salt
concentration easily
Treatme
converted
to
nt By
carbonate on heat
exchanger,
e.g.
condenser.
REMARKS: COC is the ratio between the
concentration of a particular ion/species in
Cooling water to the make-up water, e.g.
Chloride, Silica or total hardness (Ca +2 + Mg+2 ).
Blow down
(COC need to
be
maintained
5 )

Recommended chemical feeding & other action to be taken:


Chemical to be
Trouble
Other action to be taken
fed
High O2 is
Hydrazine
Proper mechanical
high
(N2H4)
deaeration
High
TSP
Drum pr. to be restricted
Chlorine
High SiO2
Blow down & low drum pr.

TECHNICAL DIARY-Santaldih Thermal


Power Station

General Standards as Per Guideline of


State Pollution Board
1.

Suspended Particulate Matter (Stack Emission):


150 mg/ Nm3 (for Unit no.5) & 100 mg/ Nm3 (for
Unit no.6).
2. Effluent Discharge (max limit)
a. (a) pH
: 6.58.5.
b. (b) Oil & Grease
: 10 mg/lit.
c. (c) Biochemical Oxygen Demand (BOD)
:
30 mg/lit.
d. (d) Chemical Oxygen Demand (COD)
:
250 mg/lit.
e. (e) Total Chromium (as Cr)
:
2.0 mg/lit.
f.
(f) Copper (as Cu)
: 3.0 mg/lit.
g. (g) Iron (as Fe)
: 3.0 mg/lit.
h. (h) Dissolved Phosphates (as PO4)
:
5.0 mg/lit.
i.
(i) Zinc (as Zn)
: 5.0 mg/lit.
j.
(k) Total Suspended Solid
:
100 mg/lit.
k. (l) Total Residual Chlorine
:
1.0 mg/lit.
l.
(m) Lead as Pb
: 0.1 mg/lit.

TECHNICAL DIARY-Santaldih Thermal


Power Station
3.

Fly ash disposal as dry basis from SILO


:
100% of total Fly ash generation (as per guideline
of MoEF).

Important Interlock &


Protection
A] BOILER SIDE:
PURGE PERMISSIVE:
1. No Boiler Trip.
2. LOTV Closed.
3. All LONV Closed.
4. All PA Fans off.
5. All Feeders off.
6. All Hot Air Gates Closed.
7. All Aux. Dampers modulating.
8. Air flow >30 %( 275TPH) & <40% (380TPH).
9. All Scanners show no flame.
10. MFT O/P Module not Freezed.
MFT:
1. All ID Fans Off.
2. All FD Fans off.
3. Emergency Trip.
4. Flame Failure Trip.
5. Loss of Fuel Trip.
6. < Fireball & Loss of AC.
7. Reheat Protection Trip.

TECHNICAL DIARY-Santaldih Thermal


Power Station
8.

Furnace Pr. Very high (>150mmwcl) & very low


(<150mmwcl).
9. Loss of 220V DC.
10. Loss of 24V DC.
11. Low air flow < 30% (275TPH).
12. MFT Network failure.
13. Drum level very high (>225mmwcl) & very low (<225mmwcl).
ID FAN PERMISSIVE:
1. Control damper minimum (<5%).
2. Control damper manual.
3. Flue gas path available.
4. ID Fan off feedback.
5. Inlet gate closed.
6. Outlet gate closed.
7. Hydro coupling minimum (<5%).
8. Hydro coupling manual.
9. Switchgear not disturbed.
10. Switch gear available.
11. Motor/Fan brg. Temp. not high (<90oC).
12. Motor winding temp. not high<120oC.
13. LOPA or LOPB ON & lub oil pr. OK (>0.8 bar).
ID FAN PROTECTION:
1. Post Purge Trip.
2. Motor/ Fan Brg. Temp. very high (>105oC) [1 out of
4 logic].
3. Motor Winding temp. very high (>130oC) [1 out of 6
logic].

TECHNICAL DIARY-Santaldih Thermal


Power Station
4.

Trip from Fan brg. Vibration (New logic, high alarm


>9.9mm/sec & very high trip >19.8mm/sec with
10sec time delay).
5. Trip from motor brg. Vibration (New logic, high
alarm >4.5mm/sec & very high trip >7.1mm/sec
with 10sec time delay).
6. Scoop oil pr. Very low (<0.6bar) with 20sec time
delay.
7. Electrical protection operated.
8. Scoop working oil temp. very high >110oC.
9. Scoop working oil temp.after cooler very
high>90oC.
10. ID Fan ON & Inlet gate Closed.
11. ID Fan ON & Outlet gate Closed.
12. Lub oil pr. Very low (<0.4bar) with 30sec time delay.
13. Slow BTS transfer.
ID FAN AUTO LOGIC FOR L.O.PUMPS
FOR L.O.P-A TAKE AUTO START, IF
i)
ID Fan ON & L.O.P-B OFF
ii) ID Fan ON & L.O PRESSURE LOW/NOT
ADEQUEAT/VERY LOW (2 OUT OF 3 LOGICS
OF ABOVE)
(1 MIN DELAY AT THE TIME OF ID FAN START)
FOR L.O.PUMP-B TAKE AUTO START,IF
i)
ID Fan ON & L.O.P-A OFF
ii) ID FAN ON & L.O PRESSURE LOW/ NOT
ADQT./ VERY LOW (2 OUT OF 3 LOGICS OF
ABOVE)

TECHNICAL DIARY-Santaldih Thermal


Power Station
[1 MIN DELAY AT THE TIME OF ID FAN START]
FD FAN PERMISSIVE:
1. Both ID fans ON or One ID Fan ON & other FD Fan
OFF.
2. Outlet damper closed.
3. Inlet blade pitch minimum (<5%).
4. Inlet blade pitch manual.
5. Switchgear not disturbed.
6. Switch gear available.
7. FD Fan off feedback.
8. Motor winding temp. not high<90oC.
9. Motor/Fan brg. Temp. not high (<90oC).
10. Lub oil pr. OK (>3 bar).
11. Control oil pr. OK (>13 bar).
12. FD fan not tripped.
FD FAN PROTECTION:
1. Motor brg. Temp.very high (>105oC) [1 out of 2
logic].
2. Fan brg. Temp. very high(>105oC) [1 out of 3 logic].
3. Winding temp. very high(>130oC) [1 out of 6 logic].
4. Trip from Fan brg. Vibration (New logic, high alarm
>9.9mm/sec & very high trip >19.8mm/sec peak to
peak with 10sec time delay).
5. Trip from motor brg. Vibration (New logic, high
alarm >4.5mm/sec & very high trip >7.1mm/sec
with 10sec time delay).
6. Both ID Fans off.

TECHNICAL DIARY-Santaldih Thermal


Power Station
7.
8.

Both FD Fan ON & same side ID Fan off.


FD Fan ON for 2 mins. & Outlet gate open f/b not
coming.
9. Post purge trip.
10. Electrical motor protection acted.
11. Lub oil pr. Very low (< 1.5bar) with 60sec time
delay.
12. Slow BTS transfer.
FD FAN AUTO LOGIC FOR L.O.PUMPS
AUTO ON LOGIC FOR L.O. PUMP-A
i)
FD FAN ON & L.O.P-B ON & L.O
PRESSURE NOT ADEQUEAT (< 3KSC)
ii) FD FAN ON & CONTROL OIL PRESSUER LOW
(<13KSC)
iii) FD FAN ON & L.O.P-B OFF
AUTO ON LOGIC FOR L.O.PUMP-B
i)
FD FAN ON & L.O.P-A ON & L.O
PRESSURE NOT ADEQUEAT (< 3KSC)
ii) FD FAN ON & CONTROL OIL PRESSUER LOW
(<13KSC)
iii) FD FAN ON & L.O.P-A OFF
PA FAN PERMISSIVE:
1. FD & PA interlock.
2. Lub oil pr. OK (>3 bar).
3. Control oil pr. OK (>13 bar).
4. Inlet blade pitch minimum (<2%).
5. Motor winding temp. not high<95oC.

TECHNICAL DIARY-Santaldih Thermal


Power Station
6. Motor/Fan brg. Temp. not high (<90oC).
7. Inlet blade pitch manual.
8. Outlet gate closed.
9. LOPA or LOPB ON.
10. CAD permits from FSSS. CAD minimum (<5%).
11. PA & Air path interlock.
12. Switchgear not disturbed.
13. Switch gear available.
14. Lub oil tank level not minimum.
15. MFT Reset.
PA FAN PROTECTION:
1. MFT operated.
2. Fan & Motor brg. Temp. very high>105 oC TD=2 sec
[1 out of 6 logic].
3. Motor winding temp. very high >120oC [ 1 out of 6
logic].
4. Both FD fans off.
5. PA Fan ON for 1 min 10 sec & outlet gate closed.
6. PA Fan ON & both lub oil pump trip.
7. Trip from Fan brg. Vibration (New logic, high alarm
>9.9mm/sec & very high trip >19.8mm/sec with
10sec time delay).
8. Trip from motor brg. Vibration (New logic, high
alarm >4.5mm/sec & very high trip >7.1mm/sec
with 10sec time delay).
9. Slow BTS transfer.
PA FAN AUTO LOGIC FOR L.O.PUMPS
FOR L.O.P-A TAKE AUTO START, IF

TECHNICAL DIARY-Santaldih Thermal


Power Station
1.
2.

PA Fan ON & LOP-B TRIPPED


PA Fan ON & LOP-B ON (DELAY 60 SEC) AND
CNTL. OIL PR. AFTER FILTER V.LOW<9KSC
3. PA Fan ON AND LOP-B ON DELAY 60 SEC
L.O PR LOW <3KSC (PS 214)
FOR L.O.P-B TAKE AUTO START, IF
1. PAF-B ON & LOP-A TRIPPED
2. PAF-B ON & LOP-A ON (DELAY 60 SEC) AND
CNTL. OIL PR. AFT FILTER V.LOW<9KSC (PS
213)
3. PAF-B ON AND LOP-A ON DELAY 60 SEC
L.O PR LOW <3KSC (PS 214)
Mill PERMISSIVE:
1. Seal air header DP adequate (>200mmwcl).
2. Pulveriser off feedback.
3. Ignition permit available.[3 out of 4 LONV open or
(MS flow >30% & adjacent feeder proven.)].
4. Pulveriser Ready.

Pulveriser / Feeder start permit i.e. Purge over


and all feeders not off or (air flow <40% &
burner tilt horizontal).

Start permit from PLOS.

Discharge valve open.

Outlet temp. not high (<110oC).

Cold air gate open.

No auto unsuccessful start.

TECHNICAL DIARY-Santaldih Thermal


Power Station

Tramp Iron Gate open.

PA permits available.

Bunker outlet & feeder inlet gate open.

Feeder switch in remote.

Bunker isolation gate gate open.

Pulvariser not tripped.


Mill PROTECTION:
1. Both PA/FD off or PA header pr. Low (<500mmwcl)
with 15sec time delay or PA header pr. very low
(<350mmwcl) 2/3 logic.
2. MFT operated.
3. Trip from PLOS.
4. Pulveriser discharge gate not open [not in service].
5. Ignition permit required not available.
6. Electrical protection trip.
7. SA header to Pulveriser DP low (< 125mmwcl) with
60 sec time delay.
8. Burner Isolation gate not open [not in service].
9. Pulveriser fails to start with 10sec time delay.
10. Preferential tripping (for Mill-D,E,F).
11. Motor winding temp. very high (>130oC) & Thrust
pad temp.very high (>75oC) & Motor brg. Temp.
very high (>90oC) & Input shaft brg. Temp. very
high (>75oC).
12. Slow BTS transfer.
Mill PLOS INTERLOCK
FOR L.O.P-A TAKE AUTO START, IF
1. LOP-B FAIL TO START (2 SEC DELAY)

TECHNICAL DIARY-Santaldih Thermal


Power Station
2.

LOP-B ON (1MIN DELAY) & OILPR. AFT


COOLER <0.8KSC
3. LOP-B TRIPPED. (2SEC DELAY)
4. MILL-B ON & OIL FLOW V.LOW OR PR AFT
COOLER <0.8KSC
FOR L.O.P-A TAKE AUTO OFF, IF
1. LOP-A FAIL TO START (8SEC DELAY) & LOP-B
ON (2SEC DELAY)
2. BOTH LOP FAIL TO START (2SEC DELAY)
PROTECTION
1. TANK OIL TEMP V. LOW < 10 C
2. LUB OIL LVL V.LOW.
FOR L.O.P-B TAKE AUTO START, IF
1. LOP-A FAIL TO START (2 SEC DELAY)
2. LOP-A ON (1MIN DELAY) & OILPR. AFT
COOLER <0.8KSC
3. LOP-A TRIPPED. (2SEC DELAY)
4. MILL-B ON & OIL FLOW V.LOW OR PR AFT
COOLER <0.8KSC
FOR L.O.P-A TAKE AUTO OFF, IF
1. LOP-B FAIL TO START (8SEC DELAY) & LOP-A
ON (2SEC DELAY)
2. BOTH LOP FAIL TO START (2SEC DELAY)
PROTECTION
1. TANK OIL TEMP V. LOW < 10 C
2. LUB OIL LVL V.LOW.
FEEDER PERMISSIVE:
1. Ignition support available.

TECHNICAL DIARY-Santaldih Thermal


Power Station
2. Feeder speed to minimum (federate <20%).
3. No MFT.
4. Feeder in remote.
5. Pulveriser ON.
6. Seal air valve open.
7. Feeder outlet gate open.
8. Pulveriser ready.
FEEDER PROTECTION:
1. Pulvariser OFF.
2. No coal on belt.
3. MFT operated.
4. No ignition energy available.
5. Feeder not in remote.
6. Seal air valve not open.
7. Feeder outlet gate closed.
8. Trip from Microprocessor Unit.
BFP PERMISSIVE:
1. Motor winding temp. not high (<120oC).
2. Motor brg. Temp. not high (<75oC) & BP journal brg.
Temp. not high (<100oC) & BFP-BP DE-NDE brg.
Temp not high (<90OC) & scoop journal brg. Temp.
not high (<90OC).
3. Suction valve open.
4. Lub oil header pr. OK (>0.8Kg/cm2).
5. BFP not tripped.
6. Switch gear available.
7. BFP OFF feedback.

TECHNICAL DIARY-Santaldih Thermal


Power Station
8.

(Recirculation valve open & outlet valve closed &


outlet IBV closed) or Condition standby.
9. Deaerator level normal (>0mmwcl).
10. Scoop <5% or Standby condition.
11. Switchgear not disturbed.
BFP PROTECTION:
1. Electrical Protection operated.
2. Motor winding temp. very high (>125oC).
3. Brg. Temp very high [BFP-BP DE-NDE thrust brg.
Temp >90oC & BP journal brg. Temp. >100 oC &
Scoop journal brg. Temp. >100oC with time delay
2sec.
4.
Motor brg. Temp. >90oC TD=2sec.
5. Differential temp. very high >15oC & suction flow
low<100TPH with time delay 2sec.
6. Working oil header temp (inlet to W.O. Cooler) very
high >130oC.
7. Pump ON & Suction pr. Very low <10 Kg/cm2
TD=10sec.
8. Lub oil pr. Very low <0.5 Kg/cm2 with time delay
2sec.
9. Suction valve not open.
10. Deaerator level very low (switch <-1976mmwcl).
11. Trip from brg vibration (New logics).
12. Slow BTS transfer.
CEP PERMISSIVE:
1. Hotwell level adequate (>-100mmwcl for U-6 and
>1000mmwcl for U-5).

TECHNICAL DIARY-Santaldih Thermal


Power Station
2. Suction valve open.
3. Vent valve open.
4. Discharge valve Closed or condition Standby.
5. Minimum reciculation valve open.
6. MCC not disturbed.
CEP PROTECTION:
1. Hotwrell level very low
2. Discharge pr. Low (<15Kg/cm2) TD=5sec.
3. Journal brg. Temp. very high>90oC.
4. Thrust brg. Temp very high >90oC.
5. Winding temp. very high>130oC [1 out 6 logic].
6. Motor brg. Temp. very high>90oC.
7. Electrical Protection operated.
8. Slow BTS transfer.
DMCW (T) PERMISSIVE:
1. Motor winding temp. not high<125oC.
2. Motor brg. Temp. not high <90oC.
3. Suction pr. Normal >2.4Kg/cm2.
4. Suction valve open.
5. DMCW off feedback.
6. Switch gear available.
7. Switch gear not disturbed.
DMCW (T) PROTECTION:
1. Trip from vibration (New logic).
2. Motor brg. Temp very high >82oC with TD= 2sec.
3. Pump brg. Temp very high >100oC with TD= 2sec.
4. Motor winding temp. very high >130oC with TD= 3
sec.

TECHNICAL DIARY-Santaldih Thermal


Power Station
Discharge header pr. High >8Kg/cm2 with TD 8sec.
Pump ON & Inlet valve closed with 2sec time delay.
Suction pr. Low <1.5 Kg/cm2.
Overhead tank level low <300mmwcl with 3sec
time delay.
9. Electrical protection acted.
10. Slow BTS transfer.
5.
6.
7.
8.

AIR COMPRESSOR PROTECTION:


1. Motor electrical protection acted.
2. Motor Winding temp v.hi 110oc
3. Bearing temp very high 110oC
4. EPB PRESSED
5. 1ST STAGE (LP CYLINDER) TEMPERATURE
HIGH > 205 DEG C
6. 2ND STAGE (HP CYLINDER)TEMPERATURE
HIGH >205 DEG C
7. LUB OIL PRESSURE LOW (TD: 15 SEC.) TRIP>
1.5 bar
8. LUB OIL TEMP. VERY HIGH > 65oC
9. CIRCULATING WATER FLOW LOW (TD:
10SEC.) TRIP
CW PUMPS PERMISSIVE:
1. CW P/p not tripped.
2. CW off feedback.
3. Switch gear available.
4. MCC not disturbed.

TECHNICAL DIARY-Santaldih Thermal


Power Station
5. Motor winding temp. not high<110oC.
6. Motor/Pump brg. Temp. not high <100oC.
7. CW/ACW sump level adequate (>6500 mm).
8. Discharge valve closed.
9. Reverse rotation switch acted.
CW PUMP PROTECTION:
1. Discharge valve not open after pump ON for 40sec
with 5sec time delay.
2. Motor winding temp. very high >120 oC with
TD=2sec.
3. Pump thrust brg. Temp very high >85oC with TD=
5sec.
4. Motor brg. Temp very high >85oC with TD= 5sec.
5. Trip from vibration (New logic).
6. CW sump level very low (<5500mm) TD=5sec.
7. Discharge pr. High >4.4Kg/cm2 with TD= 15sec.
8. Discharge pr. High from switch >4.4Kg/cm2 with
time delay 15sec.
9. Electrical Protection operated.
10. Slow BTS transfer.
ACW PUMP PERMISSIVE:
1. CW P/p not tripped.
2. CW off feedback.
3. Switch gear available.
4. MCC not disturbed.
5. Motor winding temp. not high<110oC.
6. Motor/Pump brg. Temp. not high <90oC.

TECHNICAL DIARY-Santaldih Thermal


Power Station
7. CW/ACW sump level adequate (> 6500mm).
8. Discharge valve closed.
ACW PUMP PROTECTION:
1. Discharge valve not open after pump ON for 45sec
with 5sec time delay.
2. Motor winding temp. very high >120oC with 2sec
time delay.
3. Motor/Pump brg. Temp very high >100oC with
5sectime delay.
4. Trip from vibration (New logic).
5. CW sump level very low (<5500mm) with time
delay 5sec.
6. Discharge pr. High >4.5Kg/cm2 with time delay
15sec.
7. Discharge pr. High switch >4.5Kg/cm2 with time
delay 15sec.
8. Electrical Protection operated.
9. Slow BTS transfer.

B] TURBINE SIDE:
TURBINE PROTECTION:
1.
2.
3.
4.
5.

Lub oil Pr. low < 1.2 Kg/cm2.(2/3 Logic).


Axial Shift very high > 1 or < -1 (2/3 Logic).
HP Exhaust temp. Very high > 510 0C.(2/3 Logic)
Condenser back pr very high > 0.3 Kg/cm2.2/3
Logic( Cond. Vacuum very Low <540mm of Hg ) &
turbine Speed > 540 rpm.
Bearing temperature protection:

TECHNICAL DIARY-Santaldih Thermal


Power Station

6.
7.
8.
9.
10.

11.

12.
13.

For 1, 2 > 110 0C.(1/4 Logic)

For 3,4,5,6,7 > 110 0C (2/4 Logic)

For Thrust bearing > 85 0C.(1/2 or 1/2 Logic)


MFT Soft & Hard trip.
ATRS Trip.
Emergency Push Button trip (Control desk/UCP).
Fire Protection Trip.
Turbine Mechanical Trip.

Manual Trip lever 1or 2 operated.

Mechanical Over speed trip device 1 or 2


operated.

Mechanical Low Vacuum trip device operated.


Generator Mechanical trip operated if
a. Liquid level in main lead top high (2/3 logic).
b. Cold gas temp. after cooler AB high > 550C
(2/3 logic).
c. Cold gas temp. after cooler CD high > 550C
(2/3 logic).
d. Seal oil temp. after cooler high > 550C (2/3
logic).
e. Hot air temp. after Exciter high > 800C.
Generator Electrical Protection operated or turbine
speed > 3300 rpm.
Emergency trip from HMI.

Interlock For Turbine Lub Oil Pumps

TECHNICAL DIARY-Santaldih Thermal


Power Station
1.

AOP-1(AC):
Auto ON Command will be issued if following
conditions are satisfied
a. SLC AOP-1 ON & Oil Pr. < 4.8 Kg/Cm2. Or
b. SLC AOP-1 ON & (AOP-2 OFF & AOP-2 MCC
disturbance).
Auto OFF command will be issued if Fire
Protection-2 operated then SLC AOP-1 & AOP-1
turned OFF.

2.

AOP-2(AC):
Auto ON Command will be issued if following
conditions are satisfied
a. SLC AOP-2 ON & Oil Pr. < 4.5 Kg/Cm2. Or
b. SLC AOP-2 ON & (AOP-1 OFF & AOP-2 MCC
disturbance).
Auto OFF command will be issued if Fire
Protection-2 operated then SLC AOP-2 & AOP-2
will be turned OFF.

3.

EOP-(AC):
Auto ON Command will be issued if following
conditions are satisfied
a. EOP-DC ON. Or
b. SLC EOP-AC ON & Oil Pr. < 1.2 Kg/Cm2

TECHNICAL DIARY-Santaldih Thermal


Power Station
Auto OFF command will be issued if Fire
Protection-2 operated then SLC EOP-AC &
EOP-AC will be turned OFF.
4.

EOP-(DC):

5.

Auto ON Command will be issued if following


conditions are satisfied
a. SLC EOP-DC ON & Oil Pr. < 1.1 Kg/Cm2. Or
b. Emergency starts through direct pressure
switch < 1.1 Kg/Cm2. Or
c. If Fire Protection-2 operated then SLC
EOP-DC & EOP-DC will be turned ON.
JOP-(AC):
Auto ON Command will be issued if following
conditions are satisfied
a. SLC JOP-AC ON & Turbine Speed < 510 rpm.
Auto OFF command will be issued if
a. SLC JOP-AC ON & Turbine Speed > 540 rpm.
Or
b.
Fire Protection-2 operated then SLC JOP-AC
& JOP-AC will be turned OFF.

6.

JOP-(DC):

TECHNICAL DIARY-Santaldih Thermal


Power Station
Auto ON Command to JOP-DC/OFF to JOP-AC/
OFF to SLC JOP-AC will be issued if following
conditions are satisfied
a. SLC JOP-DC ON & Jacking Oil Pr. < 100
Kg/Cm2 & turbine speed < 510 rpm.
Or
b. SLC JOP-DC ON & (JOP-AC OFF & JOP-AC
discrepancy) & Turbine speed < 510 rpm.
Or
c. SLC JOP-DC ON & turbine Speed < 510 rpm
with 5 sec delay.
Or
d. If Fire Protection-2 operated then SLC
JOP-DC & JOP-DC will be turned ON.

Interlock For Generator Seal Oil Pumps


1. AC SEAL OIL PUMP-1 LOGIC:
AUTO ON COMMAND WILL BE ISSUED IF THE
FOLLOWING CONDITION SATISFIED
a. CASE-I : SLC ON & SEAL OIL STORAGE
TANK LVL NORMAL (>MIN) & S.O.P-2 OFF
b. CASE II
: SLC ON & S.O.P-2 OFF &
S.O.TANK OIL NORMAL (>MIN) & S.O.P-2
DISCREPENCY

TECHNICAL DIARY-Santaldih Thermal


Power Station
c.

CASE III : SLC ON & S. O STORAGE TANK


LVL NORMAL(>MIN) & S.O.P-2 ON AND S.O
PRESSURE AFTER S.O.P-2 <7.5KSC (02 SEC
DELAY)

2. AC SEAL OIL PUMP-2 LOGIC:


AUTO ON COMMAND WILL BE ISSUED IF THE
FOLLOWING CONDITION SATISFIED
a. CASE-I: SLC ON & SEAL OIL STORAGE TANK
LVL NORMAL (>MIN) & S.O.P-1 OFF.
b. CASE II: SLC ON & S.O.P-1 OFF &
S.O.TANK OIL NORMAL (>MIN) & S.O.P-1
DISCREPENCY.
c. CASE II : SLC ON & S. O STORAGE TANK LVL
NORMAL(>MIN) & S.O.P-1 ON AND S.O
PRESSURE AFTER S.O.P-1 <7.5KSC (02 SEC
DELAY)

3. DC SEAL OIL PUMP LOGIC:


a.
b.
c.
d.
e.

CASE I : DC S.O.P SLC ON & S.O.P-1 OFF


& S.O.P-2 OFF
CASE II : DC S.O.P SLC ON & S.O.P-1 OFF
& S.O PRESSURE AFTER S.O.P-2 <7.5KSC
CASE III : DC S.O.P SLC ON & S.O.P-2 OFF
& S.O PRESSURE AFTER S.O.P-1 <7.5KSC
CASE IV
: DC S.O.P SLC ON & S.O
PRESSURE AFTER S.O.P-1 & S.O.P-2 <7.5KSC
CASE
V : DC S.O.P SLC ON & S.O/H2
DIFFARENTIAL PRESSURE AT
TE/EE
<0.9KSC

TECHNICAL DIARY-Santaldih Thermal


Power Station

FIRE PROTECTION LOGICS


FIRE PROTECTION -1
1.
2.
3.
4.
5.

OPERATED IF

FIRE PROT.-1 PB OPERATED AT HMI (DCS


SCREEN).
FIRE PROT-1 PB OPERATED AT MBLD -1 SV1 [AT MOT ROOM]
FIRE PROT-1 PB OPERATED AT MBLD-2 SV-2
(AT TG FLOOR)
OIL TANK LVL LOW < -100 MM & TURBINE
SPEED > 150 RPM.
FIRE PROT.-1 PB OPERATED AT LPB NEAR HPT.

IF FIRE PORT.-1 OPERATED THEN


1.
2.

TURBINE TRIPPED (MTV OPERATED).


SV-1 & SV-2 OF EMERGENCY SHUT OFF V/V
ENERGISED i.e. SHUT OFF V/V CLOSED.

FIRE PROTECTION -2
1.
2.
3.
4.

OPERATED IF

FIRE PROT.-2 PB OPERATED AT HMI (DCS


SCREEN).
FIRE PROT-2 PB OPERATED AT MBLD -1 SV1 [AT MOR ROOM]
FIRE PROT-2 PB OPERATED AT MBLD-2 SV-2
(AT TG FLOOR).
FIRE PROT.-2 PB OPERATED AT LPB NEAR HPT.

IF FIRE PROT-2 OPERATED THEN

TECHNICAL DIARY-Santaldih Thermal


Power Station
1.
2.
3.
4.
5.
6.
7.
8.
9.

SGC OIL SUPPLY OFF.


SLC AOP-1 OFF & AOP-1 OFF
SLC AOP-2 OFF &
AOP-2 OFF
SLC EOP-AC OFF & EOP-AC OFF
SLC EOP-DC ON & EOP-DC ON
SLC JOP-AC OFF& JOP-AC OFF
SLC JOP-DC ON & JOP-DC ON
SLC JOP-DC ON &
TURNING GEAR
SOLINOID V/V OPEN.
FIRE PROT-1 OPERATED.

HP BYPASS

CONDITIONS REQUIRED FOR FAST OPEN:


LOAD >75 MW AND MS PR. >130KSC AND NO
MFT THEN
BP-1 & 2 FAST OPEN:
1.
GEN BKR OPEN
2. TURBINE TRIPPED
3. TURBINE LOAD SHEDDING REALY OPERATED.
BP-1&2 PRIORITY CLOSE
1. CONDENSER BACK PR.>0.6 BAR
2. BPE-1&2 DOWN STREM TEMP V.HIGH (>380
o
C)

LP BYPASS
PERMISSIVE FOR VALVE OPENING
1. LPBP HPSU PR. >150 BAR
2. COND. WALL TEMP <90 C
3. COND.BACK PR. <0.6 KSC

TECHNICAL DIARY-Santaldih Thermal


Power Station
4. HPSU EMERGENCY ON
5. LPBP EMERG PB NORMAL
6. LPBP CH-2 NOT OPERATED.
7. LPBP NOT TRIPPED FROM UCP
8. WTR INJECTION FLOW PROT. NOT OPERATED
TRIPPING
1. HPSU -1 &2 BOTH OFF AND OIL PR. <150
BAR AND PR. CONTROLLER < 10%
2. COND. WALL TEMP > 90 oC (1/4 LOGIC)
3. COND. BACK PR. >0.6kg/cm2 (2/3 LOGIC)
4. HPSU EMERG OFF (LCP) OR FIRE PROT PB
OPERATED
5. HPSU EMERG OFF
6. LPBP TRIPPED FROM HMI.
7. LPBP TRIPPED FROM UCP.
8. WTR. INJECTION FLOW..

LP BYPASS-HPSU

A. CONTROL FLUID P/P-1


AUTO ON
1. SLC CFPS ON & (CFP-2 OFF & MCC DISTB).
2. SLC CFPS ON & CFP-1 SELECTED AS
STAND BY & HPSU HDR PR<210 BAR.
3. SLC CFPS ON WITH 10 SEC DELAY.
AUTO OFF
1. SLC CFPS ON & CFP-1 SELECTED AS
STAND BY & HPSU HDR PR>210 BAR.
2. SLC CFPS ON & CFP-1 MCC DISTB.

TECHNICAL DIARY-Santaldih Thermal


Power Station
3.

SLC CFPS ON & BOTH CFPS ON & HPSU


HDR. PR <120 BAR FOR 2 MIN.
PROTECTION OFF CONDITION
1. TANK LVL V.LOW <170 MM (5 SEC DELAY)
2. CONTROL FLUID TEMP. IN HPSU >65 oC
(5SEC DELAY)
3. CF HDR PR. > 250 BAR.
4. EMERG. PB OPERATED.
B. CONTROL FLUID P/P-2
AUTO ON
1. SLC CFPS ON & (CFP-1 OFF & MCC DISTB).
2. SLC CFPS ON & CFP-2 SELECTED AS
STAND BY & HPSU HDR PR<210 BAR.
3. SLC CFPS ON WITH 10 SEC DELAY.
AUTO OFF
1. SLC CFPS ON & CFP-2 SELECTED AS
STAND BY & HPSU HDR PR>210 BAR.
2. SLC CFPS ON & CFP-2 MCC DISTB.
3. SLC CFPS ON & BOTH CFPS ON & HPSU
HDR. PR <120 BAR FOR 2 MIN.
PROTECTION OFF CONDITION
1. TANK LVL V.LOW <170 MM (5 SEC DELAY)
2. CONTROL FLUID TEMP. IN HPSU >65 C (5SEC
DELAY)
3. CF HDR PR. > 250 BAR.
4. EMERG. PB OPERATED.
C. ACCMULATOR CHARGING V/V-1
AUTO ON

TECHNICAL DIARY-Santaldih Thermal


Power Station
1. CFP-1 ON
PROTECTION OFF
1.
HPSU HDR. PR >240 BAR (PROT. OFF
PERSIST TILL HPSU HDR. PR <216 BAR)
D. ACCMULATOR CHARGING V/V-2
AUTO ON
1. CFP-1 ON
PROTECTION OFF
1.
HPSU HDR. PR >240 BAR (PROT. OFF
PERSIST TILL HPSU HDR. PR <216 BAR)
E.
CIRCULATION P/P-1
AUTO ON
1. SLC CFPS ON & HPSU HDR. PR >210 BAR
2. CIRCULATION P/P-2 ON FOR 3 SEC AND
FLOW AFTER P/P-2 <MIN.
AUTO OFF
1. TANK LVL V.LOW <170 MM
2. SLC CFPS OFF
F. CIRCULATION P/P-2
AUTO ON
1. SLC CFPS ON & HPSU HDR. PR >210 BAR
2. CIRCULATION P/P-1 ON FOR 3 SEC AND
FLOW AFTER P/P-1 <MIN.
AUTO OFF
1. TANK LVL V.LOW <170 MM
2. SLC CFPS OFF
G. FAN IN COOLING CKT-1
AUTO ON

TECHNICAL DIARY-Santaldih Thermal


Power Station
1.

CIRCULATION P/P-1 ON & CONTROL FLUID


TEMP. > 55 C.
AUTO OFF
1. CIRCULATION P/P-1 OFF.
2. C.F TEMP IN HPSU <50 C.
H. FAN IN COOLING CKT-2
AUTO ON
1. CIRCULATION P/P-2 ON & CONTROL FLUID
TEMP. > 55 C.
AUTO OFF
1. CIRCULATION P/P-2 OFF.
2. C.F TEMP IN HPSU <50 C.
I.
REGENERATION CKT. P/P
AUTO ON
1. ANY ONE CFP ON & HPSU HDR. PR >240
BAR
AUTO OFF
1. SLC CFP OFF
PROTECTION OFF
1. CF TEMP IN HPSU > 65 C.

Alarm & Tripping Set Points

TECHNICAL DIARY-Santaldih Thermal


Power Station
Equi
p.
Mill
Gr

Description
Winding temp.

Alarm
SP
>900C

Tripping
SP
> 1300C

Motor DE/NDE
brg.temp

>750C

> 900C

Thrust brg. Temp.

>750C

>850C

I/P Shaft brg. Temp.

>650C

>750C

Motor DE/NDE brg.


Vib.
Lub oil pr. adeq.
Lub oil pr. low
Lub oil temp. high

>10mm/s
ec
>0.8KSC
>600C

<0.5KSC
>650C

LO flow adequate

>120LPM

<105LPM

PA Hdr. Pr. low

Seal air-Pulv. DP

<600mm
wcl
-

<500
mmwc
TD 15sec
or
<350mm
wc
<125mm
wcl

TECHNICAL DIARY-Santaldih Thermal


Power Station
LO filter dirty
Pa fan brg. Vib.
PA fan Mtr. Brg. Vib.

PA
Fan

Fan & motor brg.


Temp.
Motor winding
temp.
LO pr. OK
LO pr. low
LO pr. after filter V.
Low
Control oil pr. OK
Control Oil pr. low
DP across LO filter
high

>2KSC
>9.9mm/
s
>4.5mm/
s
>900C
>950C

19.8mm/
s
7.1mm/s
>1050C
>1000C

>3bar
<3bar
<9bar

>13bar
<10bar

>5bar

Alarm & Tripping Set Points


Equi
p.
FD
Fan

Description
LO pr OK
LO Pr. Very low
Control Pr. OK
Control Oil pr. low
Control Oil pr. very

Alarm
SP
>3KSC
>20 KSC
<14KSC
<13KSC

Tripping
SP
<1.5KSC
-

TECHNICAL DIARY-Santaldih Thermal


Power Station
low
DP across LO filter
high
FD fan brg. Vib.

ID
Fan

FD fan motor brg.


Vib.
LO filter dirty
LO pr OK
LO Pr. low/ Very low
HCWO Pr OK
HCWO Pr. very low
HCWO filter DP high
HCWO temp.after
cooler high/very
High
HCWO temp. very
high
Fan brg/motor brg
Temp.
Winding temp
Fan brg. Vibration
Motor brg. Vibration

>5KSC
>9.9mm/
s
>4.5mm/
s
>2KSC
>0.8KSC
<0.6KSC
>0.8KSC
>0.6KSC
>800C
>1100C

>19.8m
m/s
>7.1mm/
s
<0.4KSC
<0.6KSC
>900C
-

>900C

>1050C

>1200C

>1300C

>9.9mm/
s
>4.5mm/
s

>19.8m
m/s
>7.1mm/
s

TECHNICAL DIARY-Santaldih Thermal


Power Station

Alarm & Tripping Set Points


Equi
p.

CEP

BFP

CW

Description
Motor winding temp.
Motor brg. Temp.
Jrnl brg/thrust brg.
Temp.
CEP Motor Vibration
Motor winding temp.
BFP p/p & BP Th brg
temp
BFP p/p & BP Jrnl brg
temp
Motor brg. Temp.
HC Jrnl brg. Temp.
WO temp. at cooler
I/L
LO hdr. Pr. very low
BFP p/p brg. Vibration
BFP motor brg.
Vibration
Brg. Temp
Winding temp.

Alarm
SP
>1100C
>750C
>750C

Tripping
SP
>1300C
>900C
>950C

>14mm/
s
>1000C
>800C

>18mm/
s
>1250C
>1000C

>750C

>900C

>750C
>800C
-

>900C
>1000C
>1300C

>14mm/
s
>4.5mm/
s
>600C
>1100C

<0.5KSC
>18mm/
s
>7.1mm/
s
>850C
>1200C

TECHNICAL DIARY-Santaldih Thermal


Power Station
Motor brg. Vibration
Thrust brg. Vibration
CW disch. Hdr. Pr.
Very Hi
CW Sump Lvl. Adeq.
(3000-8000mm)
CW sump Lvl low/
V.low

>4.5mm/
s
>11mm/
s

>7.1mm/
s
>18mm/
s
>4.4KSC

>6500m
m
<6300m
m

<5500m
m

Alarm & Tripping Set Points


Equi
p.
ACW

Description
Motor DE/NDE Brg.
Temp
Winding temp.
Motor DE/NDE brg.
Vib.
Thrust brg. Vibration
ACW disch Hdr. Pr.
Very Hi
ACW Sump Lvl. Adeq.
(3000-8000mm)
ACW sump Lvl low/

Alarm
SP
>800C

Tripping
SP
>1000C

>1200C
>4.5mm/
s
>14mm/
s
-

>1300C
>7.1mm
/s
>18mm/
s
>5.6KSC

>6500m
m
<6300m

<5500m

TECHNICAL DIARY-Santaldih Thermal


Power Station
V.low

Alarm & Tripping Set Points


Process
Furnace
Pr.

Drum Lvl.

D/A Lvl.

Hotwell
Lvl.
PA Hdr.
Pr.
Atom. Air

Description

Alarm SP

High / Very
High
Low / Very
Low
High / Very
High
Low / Very
Low
Low / Very
Low
(-2476mm to
1224mm
range)
Low / Very
Low
High

>75mmwc
l
<100mmwcl
>125
<- 125

Low / Very
Low

<600
mmwc

Low / Very
Low

Tripping
SP
>150mm
wc
<175mmwc
>225
<- 225

<- 695mm

<1976mm

<500mmw
c
>1250

<350mm
wc
<500
mmwc TD
15sec or
<350mm
wc
<4.5 KSC

<5 KSC

TECHNICAL DIARY-Santaldih Thermal


Power Station
DMCW
MU tank
CST
CW
Sump

Low / Very
Low
Low
High
Low / Very
Low

<1500
mmwc
<5.5
meter
> 8 meter
<6300 mm

<300
mmwc
<5500
mm

Alarm & Tripping Set Points


Proce
ss

Turbin
e

Description
LO Pr. V. Low
Axial shift
HP Exhaust temp
Turbine/Gen./Exciter
Brg. Temp.
Turbine brg. Vib.
High
Turbine Shaft Vib.
High
Differential
Expasion high
Condensor Back Pr.
(Vacuum) High

Alarm
SP
<1.1KS
C
>
0.5mm
>900C
>84
micron
>200
micron
>30
micron
>0.2
KSC

Trippin
g SP
<1.2KSC
>
1.0mm
>5100C
>1100C
>0.3
KSC

TECHNICAL DIARY-Santaldih Thermal


Power Station
DP across LO filter
Hi
DP across Jacking
Oil filter High
Overspeed
Protection
Seal oil DP High

Gen.

>0.9KS
C
>4.2
KSC

3290
rpm

Seal oil temp after


cooler
Cold gas temp after
cooler
H2 gas purity low
Hot air temp after
Exciter

>1.2KS
C
>500C

>550C

>500C

>550C

<95%
>700C

>800C

Different Tank Capacity


TANK NAME
MOT
CST
DMCW MU
DMST
LDO Storage
Service Wtr. O/H Tank TG
Hall

Capacity
40 KL
500 KL
20 KL
1000 KL
3700 KL
60 KL

Nos.
1
2
1
2
2
1

TECHNICAL DIARY-Santaldih Thermal


Power Station
Service Wtr. O/H Tank
Clarified
Potable Wtr. O/H Tank TG
Hall
Potable Wtr. O/H Tank
Clarified
Deaerator Storage Tank

10 KL

50 KL

10 KL

152 KL

ABT (Availability Based Tariff)


The Indian version of Availability
comprises of three components:
a)
b)
c)

Based Tariff

Capacity Charge, towards reimbursement of the


Fixed Cost of the Plant, linked to the Plants
Availability (Declared Capacity)
Energy Charge, to reimburse the Fuel Cost for
Scheduled Generation (not for actual generation)
Unscheduled Interchange Charge, a payment for
deviation of actual generation from Scheduled
Generation, at a rate dependent on system
frequency.

TECHNICAL DIARY-Santaldih Thermal


Power Station
The last component would be negative (indicating a payment
by the Generating Station) in case of less delivering of power
than scheduled.
Terminology:
Block: 00.00 hrs to 24.00 hrs of a day is divided into 96
Blocks each of 15 minutes.
Declared Capacity (DC): Average Ex-bus generation in a
period of time declared by the Generating Station in advance
(considering shortage in coal stock, if any)
Notional Declared Capacity: Declared Capacity considering
no shortage notionally in coal stock.
Scheduled Generation (SG): Average Ex-bus generation
schedule given by SLDC for a period of time.
Unscheduled Interchange (UI): Actual injection by the
Generating Station minus Scheduled injection.
Some salient points:
1)

At frequency bellow 50 Hz, if there is failure to inject by


the Generating Station at least to the level of 95% of the
schedule of injection for any 15 minutes time block, the
actual Availability as well as Notional Availability will be

TECHNICAL DIARY-Santaldih Thermal


Power Station
reduced to the actual injection for the concerned time
block in order to determine the amount for recovery as
Capacity Charge. If during that time block the generation
is under Back Down condition as per direction of SLDC,
the Actual / Notional Availability will be reduced by the
extent equal to the difference of revised schedule due to
back down and the actual injection.
2)

The UI charges for the injection by a Generating Station


in excess of 105% of the DC of the station in a time
block or in excess of 101% of the average DC over a
day shall not exceed the charges for the UI
corresponding to grid frequency interval of bellow 50.02
Hz to not bellow 50.00Hz.

3)

The availability affected only for the reason of shortage


in coal availability shall be separately determined
annually and may be compensated. For this purpose,
Generating Stations have to declare both actual DC and
Notional DC.

4)

Generating Station may be required to demonstrate the


DC / Notional DC as and when asked by the SLDC. In
case of failure to demonstrate DC / Notional DC, the
Capacity charges due to the Generating station shall be
reduced as a measure of penalty. The quantum of
penalty for 1st miss-declaration for any duration in a day
shall be the charges corresponding to two days capacity

TECHNICAL DIARY-Santaldih Thermal


Power Station
charges. For the 2nd miss-declaration the penalty shall
be equivalent to capacity charges for four days and for
subsequent miss-declaration the penalty shall be
multiplied in the geometrical progression till the
recoverable monthly capacity charge becomes zero in
that month.
5)

In case of revision of DC by Generating Station, revised


DC shall become effective from the 6th time block,
counting the time block in which the request for the
revision has been received in the SLDC to be the 1 st
one.
If, at any point of time, the SLDC observes that there is
need for revision of the schedules in the interest of
better system operation, it may do so on its own, and the
revised schedules shall become effective from the 4th
time block, counting the time block in which the revised
schedule is issued by the SLDC to be the 1st one.
While making or revising its DC, the Generating Station
shall ensure that the DC during peak hours is not less
than that during other hours. However, exception to this
may be allowed in case of tripping / re-synchronization
of units.

6)

7)

8)

Normative values for accounting of Capacity Charge:


a
.

Installed Capacity (IC)

: 500MW

TECHNICAL DIARY-Santaldih Thermal


Power Station
b
.
c
.
d
.

Normative
Auxiliary
Energy
Consumption : (AUX) as per Terms
and Conditions of Tariff Regulations,
2011 (in %)
Ex - Bus Normative Capacity at
100% availability (MW)
Normative annual plant availability
factor in percentage (NAPAF) for
2012-13
as per
Terms
and
Conditions of Tariff Regulations, 2011

: 9

: 455 MW
: 85

SAFETY GUIDE LINE


Follow the followings if any accident happens:
a. After accident, Concerned HOD will report to Medical/
Hospital for treatment purpose.
b. After treatment, Medical Officer / Hospital will report to
concerned HOD, Manager(HR & A) & Manager (Fire &
Safety) trough proper form( [Annexure-IV, form-IIa for
WBPDCL Staff] & [Annexure-III, form-II for Contractor
Worker]).
c.
Then Concerned HOD will fill up proper form [Annexure-V,
form-III ] and copies of which is to be submitted to Manager
(HR & A) & Manager (Fire & Safety).
Note: All forms are available to HR & A department.

Fire and Rescue Team

TECHNICAL DIARY-Santaldih Thermal


Power Station
Sl.
No
.
1

3
4
5

Name &
Designation
Mr Nur Ali
Gazi (Officer
in-charge
Mr
Debandranat
h Mondal
(Sub Officer)
Mr
R.K.Hemrem
(Leader)
Mr P N Kundu
(Leader)
Mr.P.C Nandi
(Leader)

Interco
m

Telephone No.
Office
Mobile
9475113335

9434883305
3255

0325126023
8

9609553976
9475209504
9475233509

Important Phone Number


a.
b.
c.
d.
e.

District Fire Brigade Office: Purulia, Ph. No.-(03252)-222201


Sub-Divisional Fire brigade Office: Raghunathpur, Ph.No.(03251)-201453.
Area Fire Brigade Office: Santaldih, Ph.No.-(03251)-260238
Fire Brigade Office:Durgapur Ph No-03432546061
Fire Brigade Office: Asansol Ph No.-03412304506

TECHNICAL DIARY-Santaldih Thermal


Power Station
Fire Classes
Type
Class-A Type
Class-B Type
Class-C Type
Class-D Type
Class-E Type

Area of Extinguisher
Fire of solid, Combustible organic materials
e.g. wood, paper, Tyres, straw, textiles, coal,
plastics.
Fire of flammable liquid e.g. petroleum,
alcohol, oil, tars.
Fire of Gases e.g. propane, Hydrogen,
acetylene, coal gas.
Fire of combustible metal and their alloys
e.g. lithium, sodium, magnesium, potassium,
aluminum, cerium.
Fire in electrical insulation including live
electrical contact, frequency in conjunction
with glowing fire (e.g. cable, conduits)

Selection of portable fire extinguisher


Class of
Type of fire
Suitable to
Fire
Extinguisher
quench fire in
A

SODA ACID /
WATER

Paper, Rubbish,
wood, coal, jute.

B
C
D

Foam/DCP
DCP/ CO2
DCP/ CO2

Oil, sprit.
Gases
Chemical, blanket

TECHNICAL DIARY-Santaldih Thermal


Power Station
E

DCP/ CO2

Fire in electrical
cable, motor.

Suitability on different Classes of Fire

Extinguishin
g effect

Soda
Acid /
Water
Coolin
g

A-Class fire
B-Class fire
C-Class fire
D-Class fire
E-Class fire

Yes
No
No
No
No

Blanketin
g

Dry
chemical
power
Blanketin
g

Blanketin
g

No
Yes
No
No
No

No
Yes
Yes
Yes
Yes

No
Yes
Yes
No
Yes

Chemical
Foam

CO2

STEP BY STEP PROCEDURE AFTER TOTAL


POWER FAILURE
STEP 1: Ensure DC illumination.
STEP 2: Ensure DC JOP, DC SOP, DC EOP & DC
Scanner air fan are ON automatically, if not then they
should be started manually.

TECHNICAL DIARY-Santaldih Thermal


Power Station
STEP 3: Check healthiness of charger (They should
be at Float mode) and Monitor the operating DC
drives and DC bus voltages.
STEP 4: DG# 1 & 2 should ON automatically (if not
then DG should be started manually from DCS or from
Local).
DG PCC I/C -1 and 2 should be ON automatically (if
not then Close the circuit breakers manually from DCS
or from Local)
Power
available
at
both
Emergency
buses
automatically (if not then Close the circuit breakers
manually from DCS or from Local)
STEP 5: Start AC AOP-2 & AC SOP-2 and START AC
SCANNER AIR fan and Stop corresponding DC drives.
STEP 6: Check current rating of DG (it should not be
above 950 A) and If no seal oil pump in service,
To avoid
arrange for H2 purging.

rupture

STEP 7: Open the vacuum breaker immediately after


of
LP
turbine trip.
STEP 8: Close turbine side drains toTurbine
flash box
manually if any are open.
diaphra
STEP 9: Close all extraction block valves manually.

gm

TECHNICAL DIARY-Santaldih Thermal


Power Station
STEP 10: Keep HP and LP bypass in closed condition.
STEP 11: Close the Gland steam and ejector Supply
valve manually from PRDS.
STEP 12: Close Aux PRDS MS line Isolating valve.
STEP 13: If necessary close MS v/vs. (boiler side)
manually.
STEP14: Close soot blower steam isolation v/v if
blowing is in
progress before power failure
STEP 15: Start diesel fire water pumps, sprinkler
pump.
STEP16: Hand barring of turbines is to be ensured at
every 30min. interval if barring gear is not coming
into service
STEP 17: Removes all standby drive.
STEP 18: Closing of LFO Trip / nozzle isolation valves
manually.
STEP 19:
Ascertain cause of Power and Open
Generator Breaker Isolator.
STEP 20: During normalization ST#3, 4 & 5 should be
ON after checking the Bus voltage;
STEP 21: Give trip command to all the HT & LT drives
from DCS.
STEP 22: Station and Unit board should be
normalised. (Ensure BTS is OUT at Unit #5 otherwise
Tie CB will not be closed from DCS)

TECHNICAL DIARY-Santaldih Thermal


Power Station
STEP 23: Reset all the BUS PT at Unit and Station
board.
STEP 24: Ensure power is available at Unit PCC.
STEP
25:
Normalize
Emergency
MCC
(synchronization at Unit # 6, manually at Unit
#5), DG should be kept OFF and put DG PCC at
Auto at DCS Page.
STEP 26: Check the status of Battery charger and all
the emergency drives and converted them from DC to
AC.
STEP 27: Normalize CW area PMCC & Chlorination
Plant MCC so that ACW & CW p/p are put into service
as early as possible.
STEP 28: Normalize other out going 6.6 kV and
415 V breakers and respective downstream
Buses.

Do the followings
Restoration:
1.
2.
3.
4.
5.

immediately

after

Power

Start APH electric motor.


Start ACW p/p A or B.
Start one CW p/p after proper venting.
Start DMCW (T) P/p and DMCW (B) P/ps
Start IAC and PAC as per requirement to maintain
header pressure.

TECHNICAL DIARY-Santaldih Thermal


Power Station
6.
7.
8.

Start service water p/p and maintain hot well normal


level.
Ensure BFPs lub oil p/ps and APHs are running.
Start normal light up process of Boiler & Turbine taking
clearance with ECR.
IMPORTANT NOTES ON OPERATION

1.
2.
3.
4.

5.
6.
7.
8.

Gas temp. at APH outlet below 1300C tender dew point


corrosion.
During cold start up fuel firing rate <12 15 % of rated
value to prevent burning of tubes.
Start up vent need to be kept open till HP/LP bypass put
in service.
Wind box differential pressure:
a) Boiler load up to 30% = WB DP 40mmwcl
b) Boiler load 30% - 45% = WB DP increase linearly
from 40mmwc to 60mmwc.
c) Boiler load 45% - 60% = WB DP increase linearly
from 60mmwc to 100mmwc.
d) Boiler load 60% - 100% = WB DP 100mmwc.
Turbine gland sealing steam supply is prohibited without
turning gear.
Steam consumption at full speed & no load condition
50TPH.
Blade speed/steam speed= 0.55 for best efficiency.

Motoring must not be allowed to continue


for longer than one minute. If the condenser

TECHNICAL DIARY-Santaldih Thermal


Power Station
low vacuum limit of 0.3 bars is exceeded,
motoring must not be allowed to continue
for more than 4 seconds.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.

Critical Speed of Turbine :


1500 RPM
1932 RPM
2350 RPM
Maximum (highest) oil level from top of MOT during
operation 900 mm
Minimum (lowest) oil level from top of MOT during
operation 950 mm
Maximum temperature of oil during operation 47 oC
Minimum temperature of oil during operation 38 oC
Normal temperature of oil during operation 45 oC
Oil temperature at cooler outlet maximum 75 oC, then
unit should be shut down.
Temperature rise of oil in bearings is 20 oC (Normal)
and 25 oC (Maximum).
The MOT is so dimensioned that the total oil in the tank
is re-circulated not more than 8-10 times per hour.
Spray water to LP turbine must be switched on at LP
outer casing temperature of 90 oC.
Jacking Oil Pump must be in operation at turbine
speed below 510 rpm to avoid damage to bearings.
Jacking Oil Pump should be cut out at speed above 540
rpm.
Machine must be shut down at 510 0C HP turbine casing
exhaust.
Machine must be shut down at 110 0C outer casing of LP
cylinder.

TECHNICAL DIARY-Santaldih Thermal


Power Station
23. Main Steam temp. at HP stop valve inlet 565 oC for
maximum 15 min in any individual case.
24. HRH temp. at IP stop valve inlet 565 0C for maximum
15 min in any individual case.
25. Limit value for turbine tripping;
Absolute bearing housing vibration : 106 m
Absolute shaft vibration
: 320 m
26. Do not run turbine if:

Protection system is out of order.

Turbine oil temp. is out of order.


27. During hot start up machine loading rate 5MW/min.
28. Turning gear should be run upto metal temp. 120oC.
29. Rate of change of temp. of boiler 1.5oC/min.
30. CEP should be run upto LP outer casing temp. 50oC.
31. Turbine lub. Oil pump should be run upto 80oC Metal
temp.
32. During boiler attemperation spray water flow need to be
adjusted in such ways that after attemperation temp.
must be greater than saturation temp. of the
corresponding pressure.
33. During run-up to rated speed, the bearing oil inlet
temperature should not be less than 38 C but not higher
than 45 C .
34. The oil inlet temperature at the shaft seals should not be
less than 38 C

TECHNICAL DIARY-Santaldih Thermal


Power Station
35. Open control valves in cooling water outlet lines as soon
as the cold air temperature has risen to >= 40C.
36. Open control valves only to the extent required to adjust
cold air temperature of <= 40C in the exciter.
37. Mode of operation:

Turbine follow mode: a) EHG auto b) Boiler master


MAN & c) Turbine I/L pr. MAN. (Load has been
increased by giving manual command in the coal
feeders keeping pre determined turbine I/L pr by
operator). In this mode Run back could not active.

Boiler follow mode: a) EHG MAN b) Boiler master


AUTO & c) Turbine I/L pr. AUTO. (Load has been
increased by giving load set point in EHG DCS
screen). In this mode Run back could not active.

CMC mode: a) EHG AUTO b) Boiler master AUTO


& c) Turbine I/L pr. AUTO (Load has been
increased by giving load set point in CMC DCS
screen). In this mode Run back active.

TECHNICAL INFORMATIONS OF
HANDLING PLANT

ASH

Sam Turbo

Make

150
8

4000mmWC
1360
900 m3/hr

Stroke

Disch.Pr

Speed

Capacity

650

160

HP Bore

635

150

160

255

Flow more Kirlosk-ar Kirlosk-ar

255

Root type

Sam Turbo

LP Bore

Type

Nos.

ratingEquipt.P/PVacuumBlowerFluidizing
BlowerConveying
Comp.Inst.
Comp.
Air RejectMill

TECHNICAL DIARY-Santaldih Thermal


Power Station

1480

1LA7502-4P

NU219M
DVM180M

1460

1485

10.8A

K280M

14A

62A

31.5A

6210ZZ

33.5A

153A

6.6 /50/3

6317

415/50/3

415/50/3

280

6310ZZ 6222C3NU222M

18.5

90

BHEL

6317

Alstom

Alstom
55

Alstom

D250M

6313

6314

1470

32A

96A

D 250 M

6313

6314

1470

32A

96A

415/50/ 3 415/50/ 3

55

Alstom

Vacuum P/P BlowerFluidizing


BlowerConveying
Comp.Inst.
Comp.
Air RejectMill

TECHNICAL DIARY-Santaldih Thermal


Power Station

moreFlow
HES

Sam Turbo

510AR150/

65
2900

50

975

6309ZZ
6209ZZ

6535

6580

10

21

620

200X150

Slurry P/P P/PSeal Wtr.

1480

140

510

HES

moreFlow

HP P/P

10

10

300

moreFlow

Frame size

NDE Brg

DE Brg

RPM

( I )NL

( I )FL

V/ Hz/

P (KW)

Make

LP P/P ratingMotor

TECHNICAL DIARY-Santaldih Thermal


Power Station

32.6 A
9.8 A

16.9 A

6314

NU219M
LA7560-4P

6209ZZ

DV180L

D 280 S

6317

1478

415/50/3

60

6309ZZ 6222C3NU222M ,

1483

34 A

6.6/50/3

415/50/3

2910

103 A

300

6.7

Alstom

BHEL

Marathon Motor

LP P/P

HP P/P

Seal Wtr. P/P

NDE Brg No.

DE Brg. No.

Test Pr. (KSC)

rpm

Total H (mmwcl)

(m3 / hr)Disch.Capacity

P/P Size

Type

Make

Nos.

Equipments rating

TECHNICAL DIARY-Santaldih Thermal


Power Station

24 A

7.5 A

1481

NU 222M 6222C3

NU219M

1 LA 7500-4F

( I )FL

( I )NL

RPM

DE Brg

NDE Brg

Frame size

210
P (KW)

6.6/50/3

BHEL
Make

V/ Hz/

Slurry P/P
ratingMotor

TECHNICAL DIARY-Santaldih Thermal


Power Station

ESP DETAILS
Design Condition: Firing condition & BMCR Worst Coal
Gas flow rate
41.4 m3/sec.
Temperature
1300C
Inlet dust concentration, Dry
83.2 gm/Nm3
Outlet dust concentration (n-1 fields), Dry
50 mg/Nm3
ESP efficiency (n-1 fields), Dry
99.939 %
FAA-9X37.5mType of precipitator
116150-2
Number of precipitator offered per unit
4
Number of gas path per ESP
1
Number of fields 1n series in each gas
9
path
Pressure drop across the precipitator
25 mmWC

TECHNICAL DIARY-Santaldih Thermal


Power Station
Velocity of gas inside ESP
Treatment time

0.65 m/sec.
45.8 sec.

Collecting Electrodes
No. of rows of collecting electrodes per
field
No. of collecting electrodes per fields
No. of collecting electrodes arranged in
each row per field
Total no. of collecting plates per boiler
Nominal height of collecting plate
Nominal length of collecting plate

30
150
5
5400
15.0 meters
750 mm

Emitting Electrodes
Type
Size
No. of electrodes in the frame forming
one row
No. of electrodes in each fields
Total No. of electrodes per boiler
Total length of electrodes per field
Plate / wire spacing

Spiral with
hooks
2.7 mm dia.
45
1305
46980
8182 meters
200mm
(400 mm pitch)

TECHNICAL DIARY-Santaldih Thermal


Power Station

Turbine HBD

TECHNICAL DIARY-Santaldih Thermal


Power Station
P
(AT)

T
(0C)

M
(T/H)

245.
9

150

537

39.56

343.
6

35.60

537

6.76

305

762.51
6
745.16
1
658.69
2
658.69
2
578.42
8

H
(Kcal/Kg
)
254.9
816.4
735.7
844.4
733.5

L
Ex-6

39.56

Ex-5

15.83

Ex-4

6.76

Ex-3

2.303

Ex-2

0.897

Ex-1

0.386
0.097
3
0.198

I
K

343.
6
417.
4
305
191.
1
105.
5
0.98
44.9
59.4

81.212

735.7

40.93

786.6

40.699

733.5

30.404

681.1

22.123

642.2

21.022
605.87
5
99.506

617.6
44.9
59.4

Q
(Kcal/H)
1.94 X
108
6.08 X
108

TECHNICAL DIARY-Santaldih Thermal


Power Station