tech diary

TECHNICAL DIARY

COMPILED BY: O&M COMMISSIONING

FOREWORDFOREWORDFOREWORDFOREWORD Efficient, safe and reliable operation of a thermal power plant mainly

depends upon the awareness of the O&M staff about the plant and its

equipments. A power plant has many inter-related systems and it is necessary on

part of all technical staff to understand the design parameters and limits of the

various systems. With this in mind, Commissioning department has made an

effort to compile technical data of different systems of stage-III in the form of a

technical diary.

I hope this diary will serve as a very useful ready reference to all O&M

personnel in executing their day to day jobs in efficient manner.

While all efforts have been taken to ensure correctness of data, the

possibilities of few errors and anomalies cannot be ruled out as the systems are

constantly under review during operation and maintenance stages also.

Any suggestion for improvement and pointing out of inaccuracies is

welcome and will be incorporated in subsequent editions.

With warm regards.

((((P. RameshP. RameshP. RameshP. Ramesh)))) E .D. (Rihand)

FOREWORDFOREWORDFOREWORDFOREWORD In the present competitive scenario with stringent tariff norms, efficient

& optimized operation of the equipments and fast decision making is most

important to stay ahead. The knowledge of equipment data is very helpful in

this regard.

It gives me immense pleasure that the commissioning team has brought

out the technical diary of Rihand stage-III in print as well as digital formats.

I congratulate the commissioning team for taking out this initiative to

assimilate all technical data related to stage-III.

I am sure that this technical diary will act as a ready reference for the

O&M team to take correct decisions in minimum possible time.

The errors which might have inadvertently crept in should be

brought to the executives concerned, so that they might be corrected quickly.

With warm regards.

(Shivendra Kumar Sinha)(Shivendra Kumar Sinha)(Shivendra Kumar Sinha)(Shivendra Kumar Sinha) GGGGeneral eneral eneral eneral MMMManageranageranageranager (O&M)(O&M)(O&M)(O&M)

INDEX

TAB 1 : BOILER & AUXILIARIES

TAB 2 : TG & AUXILIARIES

TAB 3 : ELECTRICAL SYSTEMS

TAB 4 : OFFSITE & COMMON SYSTEMS

N.B.- The schematics are available as PDF documents on

the operation webpage.

CONTENTS (BOILER & AUXILIARIES)

1.0 BOILER Page No. 1.1 GENERAL SPECIFICATION 3 1.2 DESIGNATION 3 1.3 FURNACE SPECIFICATION 3 1.4 WATER WALLS 4 1.5 DRUM 4 1.6 SUPERHEATERS 5 1.7 RE HEATERS 5 1.8 SUPERHEATERS & RE HEATERS TEMP CONTROL 6 1.9 ECONOMISER 6 1.10 PREDICTED PERFORMANCE DATA (DESIGEN COAL) 7 1.11 SAFETY VALVES 12

2.0 BOILER AUXILIARIES

2.1 BOILER WATER CIRCULATING PUMP 13 2.2 MILLING SYSTEM 14 2.3 COAL PIPING & BURNERS 18 2.4 OIL FIRING 18 2.5 INDUCED DRAFT FAN (ID FAN) 20 2.6 FORCED DRAFT FAN (FD FAN) 23 2.7 PRIMARY AIR FAN (PA FAN) 25 2.8 SCANNER AIR FAN 26 2.9 PRIMARY AIR PREHEATER (PAPH) 27 2.10 SECONDARY AIR PREHEATER (SAPH) 29 2.11 STEAM COIL AIR PREHEATER (SCAPH) 31

3.0 ELECTOSTATIC PRECIPITATOR (ESP)

3.1 DESIGN CONDITION 32 3.2 COLLECTING ELECTRODES 32 3.3 EMITTING ELECTRODES 32 3.4 GAS DISTRIBUTION SYSTEM 33 3.5 ESP ELECTRICALS 33 3.6 RAPPING SYSTEM 34 3.7 HOPPERS 35 3.8 HEATING ELEMENTS 35

4.0 SOOT BLOWER 35 5.0 HP DOSING PUMP 36

5.1 MIXING TANK 5.2 METERING TANK 5.3 DOSING PUMPS

6.0 BLOW DOWN VESSELS 37

7.0 PRESSURE REDUCING & DESUPERHEATING STATION (PRDS) 38

8.0 SG EQUIPMENT COOLING WATER SYSTEM 38 8.1 DMCW PUMPS 8.2 MOTOR 8.3 PLATE HEAT EXCHANGERS (PHEs)

9.0 SWAS PARAMETERS 40

9.1 CHEMICAL PARAMETERS LIMIT 9.2 EXPRESS LAB INSTRUMENTS

10.0 FUEL OIL PUMP HOUSE 41

10.1 HFO PUMPS 10.2 LDO PUMPS 10.3 HFO HEATER & DRAIN OIL COOLER 10.4 HFO DRAIN OIL PUMPS 10.5 HFO SUMP PUMP 10.6 LDO UNLOADING PUMP 10.7 DRAIN OIL PUMPS (FOHS) 10.8 SUMP PUMPS (FOHS)

11.0 MILL REJECT SYSTEM 44

11.1 GENERAL 11.2 SYSTEM DESIGN 11.3 DENSEVEYOR 11.4 MILL REJECT COMPRESSORS

12.0 STARTUP CURVES As Annexure

12.1 COMBINED BOILER TURBINE STARTUP CURVES A) COLD STARTUP B) WARM STATUP (36 HRS SHUTDOWN) C) HOT STARTUP (8 HRS SHUTDOWN)

12.2 TURBINE STARTUP CURVES- CONSTANT PRESSURE 12.3 TURBINE STARTUP CURVES- SLIDING PRESSURE

CONTENTS (TURBINE & AUXILIARIES)

1. MAIN TURBINE

1.1 SPECIFICATIONS 49 1.2 TURBINE LUBE OIL SYTEM 53 1.3 GENERATOR 56 1.4 TURBINE CONTROL FLUID SYSTEM 58 1.5 CONDENSER 60 1.6 LP HEATERS 61 1.7 DEAERATOR & FST 62 1.8 HP HEATERS 63 1.9 LP DOSING SYSTEM 64 1.10 CENTRAL LUBE OIL STORAGE & PURIFICATION UNIT 64 1.11 HP BYPASS SYSTEM 65 1.12 LP BYPASS SYSTEM 66

2.0 TURBINE AUXILIARIES

2.1 CONDENSATE EXTRACTION PUMP 67 2.2 BOILER FEED PUMP & AUXILIARIES 2.2.1 BOILER FEED PUMP (MAIN) 68

2.2.2 BOOSTER PUMP 69 2.2.3 HYDRAULIC COUPLING OF MDBFP 70 2.2.4 LUBE OIL SYSYTEM FOR MDBFP 70 2.2.5 BFP DRIVE MOTOR 71 2.2.6 TDBFP LUB OIL SYSTEM 71 2.2.7 OIL PURIFIER (CENTRIFUGE) 72

2.3 VACCUM PUMP 73

2.4 TG EQUIPMENT COOLING WATER SYSTEM 74

2.5 SG EQUIPMENT COOLING WATER SYSTEM 75

2.6 AUXILIARIES COOLING WATER SYSTEM (ACW) 75 2.7 CONDENSER ON LOAD TUBE CLEANING SYSTEM (COLTCS) 76 3.0 DM MAKEUP & CPU REGENERATION SYSTEM 77

4.0 COMPRESSED AIR SYSTEM 79

CONTENTS (ELECTRICAL)

1.0 Transformers 80 1.1 Generator Transformer (GT) 1.2 Station Transformer (ST) 1.3 Unit Transformer (UT) 1.4 Unit Auxiliary Transformer (UAT) 1.5 Station Auxiliary Transformer (SAT) 1.6 Ash Disposal Pump House Transformer (ADPHT) 1.7 Coal Handling Transformer (CHPT) 1.8 Station Service Transformer (SST) 1.9 Unit Service Transformer (UST) 1.10 ESP Transformer(ESPT) 1.11 Ash Extraction Transformer(AET ) 1.12 Fire water Transformer 1.13 Raw water Transformer 1.14 DM/CPU Transformer 1.15 PT Service Transformer 1.16 Fuel Oil Service Transformer 1.17 Ash Water /Ash Slurry Service Transformer 1.18 Bunker Service Transformer

2.0 Breaker 84 2.1 400 KV Switchyard breaker 2.2 11KV and 3.3KV MV Switchgear breaker 2.3 415V LT switchgear Breaker

CONTENTS (OFFSITE) 1. CW system Page No.

1.1 CW pump 88 1.2 CW motor 89 1.3 Electro hydraulic actuator 91 1.4 EOT crane 92

2. SACW system 2.1 SACW pump 93 2.2 SACW motor 94 2.3 EOT crane 95

3. Cooling tower 3.1 Thermal design calculation 95 3.2 Blades 96 3.3 Gearbox 96 3.4 Motor 97 3.5 Sludge pump 98

4. Raw water system 4.1 Pump 98 4.2 Motor 100 4.3 Lube water system 101

5. Fire water system 5.1 General 102 5.2 Diesel engine 102 5.3 Pump 104 5.4 Motor 105 5.5 Foam system 106 5.6 Sprinkler system 108

6. PTCW 6.1 PT Clarifier 108 6.2 Clarifier water system

6.2.1 Clarified water makeup system 109 6.2.2 HVAC makeup system 110 6.2.3 Potable water system 111

6.3 Pressure filter 111 6.4 Sludge disposal system 111 6.5 ETP(Effluent Treatment Plant) system

6.5.1 Waste water pump 112 6.5.2 Treated Effluent Disposable pump 113 6.5.3 ETP clarifier 113

6.6 Service water system 6.6.1 Service water pump 114 6.6.2 APH wash water pump 114

6.7 Chemical dosing system 6.7.1 Alum dosing pumps for PT-clarifier 115 6.7.2 Alum dosing pump for LET-clarifier 115 6.7.3 Lime dosing pump 115 6.7.4 Lime slurry transfer pump 116 6.7.5 Agitator 116

6.8 Chlorination system 116 6.9 Coal settling system(CHP area) 118

7. ADPH 7.1 Ash slurry pumps 119 7.2 BAHP 120 7.3 BALP 121 7.4 FAHP 122 7.5 Flushing water pump 122 7.6 HP seal water pump 123 7.7 LP seal water pump 124 7.8 Drain pump in ASPH 124 7.9 BA seal water pump 125 7.10 Vacuum pump in ESP 125 7.11 Bottom ash overflow pump 126 7.12 Sludge pump for settling tank 127 7.13 Eco booster pump 128 7.14 Clinker grinder 128 7.15 Instrument Air Compressor(IAC) 129 7.16 Instrument Air Drier 130 7.17 Transport Air Compressor(TAC) 130 7.18 Transport Air Drier 131 7.19 Fly Ash Conditioner water pump 131 7.20 Drain pump( Silo area) 132 7.21 Wash Water pump (Silo area) 132 7.22 Silo fluidizing blower 132 7.23 Buffer Hopper Aeration blower 132 7.24 Heaters of Silo & Buffer hopper 133

TECHNICAL DIARYTECHNICAL DIARYTECHNICAL DIARYTECHNICAL DIARY

BOILER AND AUXILIARIES

Prepared By Reviewed By Approved By S K VISHWAKARMA SUSHIL KUMAR M K SINGH

Asst Manager Manager AGM

STAGE-3 TECHNICAL DIARY (BOILER)

1

CONTENTS

1.0 BOILER Page No. 1.1 GENERAL SPECIFICATION 3 1.2 DESIGNATION 3 1.3 FURNACE SPECIFICATION 3 1.4 WATER WALLS 4 1.5 DRUM 4 1.6 SUPERHEATERS 5 1.7 RE HEATERS 5 1.8 SUPERHEATERS & RE HEATERS TEMP CONTROL 6 1.9 ECONOMISER 6 1.10 PREDICTED PERFORMANCE DATA (DESIGEN COAL) 7 1.11 SAFETY VALVES 12


2.1 BOILER WATER CIRCULATING PUMP 13 2.2 MILLING SYSTEM 14 2.3 COAL PIPING & BURNERS 18 2.4 OIL FIRING 18 2.5 INDUCED DRAFT FAN (ID FAN) 20 2.6 FORCED DRAFT FAN (FD FAN) 23 2.7 PRIMARY AIR FAN (PA FAN) 25 2.8 SCANNER AIR FAN 26 2.9 PRIMARY AIR PREHEATER (PAPH) 27 2.10 SECONDARY AIR PREHEATER (SAPH) 29 2.11 STEAM COIL AIR PREHEATER (SCAPH) 31

3.0 ELECTOSTATIC PRECIPITATOR (ESP)

3.1 DESIGN CONDITION 32 3.2 COLLECTING ELECTRODES 32 3.3 EMITTING ELECTRODES 32 3.4 GAS DISTRIBUTION SYSTEM 33 3.5 ESP ELECTRICALS 33 3.6 RAPPING SYSTEM 34 3.7 HOPPERS 35 3.8 HEATING ELEMENTS 35

4.0 SOOT BLOWER 35 5.0 HP DOSING PUMP 36

5.1 MIXING TANK 5.2 METERING TANK 5.3 DOSING PUMPS

6.0 BLOW DOWN VESSELS 37

7.0 PRESSURE REDUCING & DESUPERHEATING STATION (PRDS) 38


2

8.0 SG EQUIPMENT COOLING WATER SYSTEM 38 8.1 DMCW PUMPS 8.2 MOTOR 8.3 PLATE HEAT EXCHANGERS (PHEs)

9.0 SWAS PARAMETERS 40

9.1 CHEMICAL PARAMETERS LIMIT 9.2 EXPRESS LAB INSTRUMENTS

10.0 FUEL OIL PUMP HOUSE 41

10.1 HFO PUMPS 10.2 LDO PUMPS 10.3 HFO HEATER & DRAIN OIL COOLER 10.4 HFO DRAIN OIL PUMPS 10.5 HFO SUMP PUMP 10.6 LDO UNLOADING PUMP 10.7 DRAIN OIL PUMPS (FOHS) 10.8 SUMP PUMPS (FOHS)

11.0 MILL REJECT SYSTEM 44

11.1 GENERAL 11.2 SYSTEM DESIGN 11.3 DENSEVEYOR 11.4 MILL REJECT COMPRESSORS

12.0 STARTUP CURVES As Annexure

12.1 COMBINED BOILER TURBINE STARTUP CURVES A) COLD STARTUP B) WARM STATUP (36 HRS SHUTDOWN) C) HOT STARTUP (8 HRS SHUTDOWN)

12.2 TURBINE STARTUP CURVES- CONSTANT PRESSURE 12.3 TURBINE STARTUP CURVES- SLIDING PRESSURE


3

BOILER & ITS AUXILLIARIES

1.0 BOILER

1.1 GENERAL SPECIFICATION Manufacturer M/S BHEL Type Controlled Circulation with Refilled tubing ,

(CC+) ,Dry bottom ,Radiant Reheat ,Single drum ,Top supported ,Balanced Draft Furnace

Type of firing Tilting Tangential

1.2 DESIGNATION

1.3 FURNANCE SPECIFICATION

Type Balance Draft Furnace With Fusion Welded Water Walls

Wall Water steam cooled Tube arrangement Membrane Residence time for fuel particles in the furnace

1.84 Sec.

Effective volume used to calculate the residence time

16424 M3

Depth 16115 mm Width 19177 mm Furnace volume 17599 M3 Drum elevation (C.L) 74.977 M Fuel heat input 1233.6X10b Kcal/hr @ BMCR DC

19177 301-51 CC+

16115 235-51


4

1.4 WATER WALLS

Total water wall tubes 1072 Nos.

1.4.1 WATER WALL RIFLE TUBES

OD 51.0 & 63.5 mm Thickness 5.6, 6.0 , & 7.1 mm Materials SA 210 Gr. C Design Pr. Of tubes 214 & 211.3 Kg/cm2 Design temp 396 c

1.4.2 WATER WALL SMOOTH TUBES

OD 51.0 & 63.5 mm Thickness 7.1, 5.6, 6.0, 8.8 mm Materials SA 210 Gr. C Design Pr. Of tubes 211.3 & 214 Kg/cm2 (g) Design temp 396 & 368 c

1.4.3 WATER WALL HANGER RIFLE TUBES

OD 63.5 mm Thickness 12 mm Materials SA 210 Gr. C Design Pr. Of tubes 211.3 Kg/cm2 (g) Design temp 396 c

1.4.4 WATER WALL HEADERS

WW bottom ring drum WW top headers Number 1 5 Outside dia 914.0 mm 273.0 mm Thickness 85 mm 40.0 & 50.0 mm Design Pr. Of headers 214 Kg/cm2 (g) 209.0 Kg/cm2 (g) Material specification SA 299 SA-106 Gr. C Design temp 368 c 368 c

1..5 DRUM

Material specification SA-299 Design pressure 209 Kg/cm2 (g) Design material temp 368 c Operating pressure 195 Kg/cm2 (g)


5

Actual thickness 155/185 mm Internal dia 1778 mm Number of down comers 6 nos. Number of cyclone separators 92 Number of driers 124 Shroud materials CS-IS 2062 Gr. A

1.5.1 WATER LEVEL INDICATOR

Location Boiler Drum Boiler Drum Type DWLG EWLI Make Yarway BHEL Quantity 2 4 21 VISIBILITY BHEL VISION

1.6 SUPERHEATERS

Stage#1 Stage#2 Stage#3 Material SA 213 SA 213 SA 213 Type LTSH Horizontal &

pendant (Convective) SH division panellette (Tube projected ) Radiant

SH finish platen (Tube projected ) Radiant

Drainable/Non drainable Drainable Non drainable Non drainable Effective heating surface area

8661 M2 1415 M2 1485 M2

Tube OD 47.63 mm 44.5 mm 51.0 mm Total number of assembly

124 6 (x 8 panelletes) 25 No. of element 744 432 (9 elements per

panellete) 400 (16 per panel)

ASME Specification SA213 T11 SA 213 T22 & T91 SA213 T22, T91 & TP347H

1.7 RE HEATERS

Stage#1 Stage#2 Type Pendant Platen Pendant Spaced No. of assembly 74 74 No. of element 1036 888 Tube OD 54.0 mm 63.5 mm Total heating surface area 8620 m2 Control Burner tilt & excess air Design Pressure 42.37 Kg/cm2 (g)


6

1.8 SUPER HEATER & REHEATER TEMP CONTROL

1.8.1 SUPER HEATER ATTEMPERATOR

Type Spray type pressure atomized Stage One Position in steam circuit Between LTSH & division panel S/H Specification of material SA 335P 12 Control temp 540 c Control range 755.4-1590 T/Hr.

1.8.2 REHEATER EMERGENCY TEMP. CONTROL ATTEMPERATOR

Type Spray type pressure atomized Manufacturer BHEL Trichy Position in steam circuit CRH Line Control temp range 568 c Control range 656.8-1358 T/Hr. R/H Normal temp. control Burner tilting & Excess air

1.9 ECONOMISER

Type Plain tube non steaming Horizontal heating space area 19000 m2 Design Pressure tube 215.0 Kg/cm2 (g) OD of tubes 38.1 mm Minimum thickness of tubes 5.3 mm Length of tubes 296.4 m Pitch 103 mm (ST)

76.2 mm (SL) No. of blocks 3 Nos. Assembly 184 Element 552 Design temp. 336 c ASME Specification SA210 Gr A1


7

1.10 PREDICTED PERFORMANCE DATA (DESIGN COAL-constant pressure)


8

1.10.2 TEMPERATURE


9

1.10.3 PRESSURE (STEAM & WATER )


10

1.10.4 PRESSURE & DRAFT (AIR & GAS)

1.10.5 FUEL

Proximate Analysis Fixed Carbon Volatile matter Moisture Ash Grind ability Index Higher heating value Size of coal to mill

% % % % HGI Kcal/kg mm

24 22 20 34 55 3500 50 (Approx.)


11

Ultimate Analysis Carbon Hydrogen Sulphur Nitrogen Oxygen Carbonates Phosphorous Moisture Ash

% % % % % % % % %

34.20 3.00 0.30 0.92 6.90 0.65 0.03 20.00 34.00

1.10.6 MILL & BURNER PERFORMANCE

DESCRIPTION

Unit

HP Heaters in service HP Heaters Out

BMCR 500 MW

400 MW

300 MW

250 MW

MAX O/P

MILL

No. of mills in operation Mill loading Air flow mill Air temp at mill Inlet Mill Outlet Temperature Fineness % (Thro 200 mesh) Burner Tilt

% T/Hr c

c

%

Deg

Top 7 82.8 95.1 328

Top 7 76.7 92.7 324

Top 5 88.7 97.4 310

Top 4 86.6 96.8 291

Top 4 74.7 91.8 279

Top 7 83.3 95.3 285

66 to 100

70

-30 to +30

1.10.7 O2, CO2 (DRY VOLUME) AND EXCESS AIR

DESCRIPTION

Unit


BMCR 500 MW

400 MW

300 MW

250 MW MAX O/P

Oxygen in gas at Economizer Outlet

%

3.59 3.59 3.59 3.59 3.59 3.59

Carbon di-oxide in gas Economizer Outlet

% 14.78 14.78 14.78 14.78 14.78 14.78

Excess air in gas at Economizer Outlet

% 20.00 20.00 20.00 20.00 20.00 20.00


12

1.10.8 HEAT BALANCE

DESCRIPTION

Unit


BMCR 500 MW

400 MW

300 MW

250 MW MAX O/P

LOSSES Dry gas H2O on fuel, surf & inherent H2O from comb. Of H2 H2O in air Unburnt carbon Radiation Unaccounted Manufactures margin

Total losses

% % % % % % % %

%

4.229 3.502 4.695 0.109 1.500 0.216 0.784 0.150

15.185

4.165 3.496 4.687 0.107 1.500 0.234 0.784 0.150

15.123

4.157 3.490 4.679 0.107 1.500 0.283 0.791 0.150

15.157

4.237 3.489 4.678 .109 1.500 0.361 0.807 0.150

15.331

4.256 3.485 4.672 0.109 1.500 0.419 0.817 0.150

15.408

3.668 3.469 4.651 0.094 1.500 0.215 0.760 0.150

14.507 Efficiency % 84.81 84.87 84.84 84.66 84.59 85.49

1.11 SAFETY VALVES

LOCATION

SL. NO.

VALVE TAG NO.

TYPE OF SAFETY VALVE

VALVE SET PR.

KG/CM2 (G)

% O

F B

LOW

DO

WN

RELIEVING CAPACITY KG/HR.

OPEN CLOSE

BOILER DRUM

1 SV1 CONSOL 1750 WB 209 200.6 4.0 212800

2 SV2 CONSOL 1750 WB 211.1 200.5 5.0 214928

3 SV3 & SV4 CONSOL 1750 WB 213.2 202.5 5.0 217056 4 SV5 & SV6 CONSOL 1740 WB 215.3 204.5 5.0 261228

SH SV 5 SV7 & SV8 CONSOL 1740 WD 188.5 181.3 3.8 187670

SH ERV 6 SV9 & SV10 CONSOL 1538 VX-10 W 185.5 180.3 2.8 116388 7 SV11, SV12 &

SV13 CONSOL 1538 VX-10 W 186.6 180.6 3.2 86945

CRH 8 SV14 & SV15 CONSOL 1786 WB 52.40 49.8 5.0 207461 9 SV16 & SV17 CONSOL 1786 WB 54.0 51.3 5.0 214147

HRH SV 10 SV18 & SV19 CONSOL 1786 WE 48.4 46.0 5.0 157460 11 SV20 & SV21 CONSOL 1786 WE 49.9 47.4 5.0 162457

HRH ERV 12 SV22 & SV23 CONSOL 1525 VX 47.4 46.5 2.0 117191 13 SV24 & SV25 CONSOL 1525 VX 47.9 46.9 2.0 118402

SOOT BLOWER

14 SV30 CONSOL 1811 LC 6X 40.0 38.4 4.0 29970


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2.1 BOILER WATER CIRCULATING PUMP Number 3

2.1.1 CHARACTERISTICS

Make TORISHIMA PUMP MFG. CO. LTD., JAPAN Type Single suction double discharge (glandless)

2.1.2 NORMAL OPERATING DUTY

Suction Pressure 197.37 kg/cm2 Saturation temperature at suction pressure 363.4 c Quantity pumped 2987 m3/hr Total pump head 1.76 kg/cm2 Minimum NPSH required (Cold) 15 M Minimum NPSH required (Hot) 15 M Pump efficiency 81 % Power absorbed 176.7 KW

2.1.3 MOTOR CHARACTERISTICS

Type (Wet stator squirrel cage induction motor) Rating 350 KW Voltage & frequency 3300 V & 50 Hz Service factor 1.0 Class of insulation Y (90 C) Winding insulation material XLPE Rated power factor 75 % Motor case design temperature 368 c Full load speed 1470 RPM Full load current 89.7 Amps. Starting current 500 % FLC Hot Duty Cold Test Motor efficiency 88.2 % 91.00 % Motor power input (KW) 200.3 340.1 Pump efficiency (%) 81 81

2.1.4 BEARING

Number 2 Type Tilting pad Lubrication System Self (Boiler water) Life in hours 30000 hours Max. permissible temp. of bearing 90 c


14

2.1.5 CC PUMP OVER HEAD TANK

Type 2500 X 12 Make BHEL Trichy Capacity 20.0 M3 Temp 50 c Working pressure 7 kg/cm2 Test pressure 10.5 kg/cm2

2.1.6 CC BOOSTER PUMP (EMERGENCY COOLING) MOTOR

Make Marathon Electric Motors (I) Ltd. Type TEFC SC Eff-2 Frame size D132 S Degree of protection IP 55 Speed 2850 RPM Full load current 10.4 Amp. No load current 4.2 Amp. Rating 5.5 KW Rating Insulation class F PUMP Make Sam Turbo Industry Limited Quantity 02 Type/Model WP+C 32/200. Head 45 mwc/mlc (Discharge Pr.-8 Ksc min) Speed 2900 RPM Capacity 10 M3/Hr

2.2 COAL FIRING

2.2.1 MILL SYSTEM

2.2.1.1 PULVERISER

Make BHEL HYADRABAD Type of Pulveriser Bowl mill XRP 1003 with Planetary Gearbox No. of Mills/Boiler 9 Speed of Pulveriser in RPM 42 Motor rating KW 525 Mill capacities Standard condition Design coal Worst coal Max. capacity T/Hr 68 60.9 55.80 Moisture in raw coal % 12 20 22 HGI of raw coal 55 55 50 No. of mills for Design coal at 100% BMCR

7 7 9


15

2.2.1.2 MILL MOTOR

Manufacturer BHEL, BHOPAL Motor type SCIM Standard continuous rating at 40 c ambient temp. (As per IS)

525 KW

Rated voltage 3300 V Permissible variation of Voltage +/- 6.0 Frequency +3 -5 Combined Voltage & Frequency 10% Abs Minimum Permissible starting voltage (% ) 85 Rated speed at rated voltage & freq (RPM) 984 Starting time with minimum permissible Voltage

Without driven equipment 0.5 Sec With driven equipment coupled 5.7 Sec At rated Voltage & Frequency Full load current 129 Amp No load current (A) 55 Amp

2.2.1.3 MILL MOTOR BEARING

Drive-End Non- Drive-End

(A) Type NU 228M+62283 NU 224M

(B) Recommended Lubricant Grease IOC servo gem -3/Eqv

2.2.1.4 MILL EXTERNAL LUBRICTION SYSTEM

Manufacturer: TA Hydraulics Pvt. Ltd. Hyderabad

2.2.1.4.1 PUMPS

Make Type Three screw pump Quantity 2X100 % Capacity 150 LPM Speed 1450 RPM Coupling Love joy Operating Pressure 3 to 5 Bar Relief valve setting 8.5 Bar Filter 25 micron SS mesh, Test Press-22 ksc Operating fluid ISO VG 320


16

2.2.1.4.2 LUBE OIL PUMP MOTOR

Make Crompton greaves Ltd. Type , Frame & Duty SCIM, 132S & S1 Rated Output 5.5 KW Rated Speed 1450 RPM Rated Voltage 415 V Full load current 10.4 Amps DOR from NDE side CW Bearing type no.DE/NDE 6308 ZZ / 6208ZZ

2.2.2 RAW COAL FEEDER

2.2.2.1 FEEDER

Type of feeder Belt type Gravimetric Feeder Feeder Size 36 Inlet Capacity Min-16 T/Hr, Max-80 T/Hr Supplier BHEL Quantity per boiler 9 Gear Ratio (Main drive) 125 :1 (M/S Shanthi Gears Ltd.) Gear Ratio (COC drive) 1041:1 (M/S Shanthi Gears Ltd.) Bulk density of coal 0.88 t/m3 Working pressure 500 mmwc Purge air requirement 12 m3 / min / Feeder Application of Purge air To make positive purge air flow, recommended delta p

between feeder and pulveriser to be adjusted Service air requirement 1 m3 / hr at 2-3 KSC Application of Service air For bulls eye cleaning (Intermittent requirement) Water requirement 1 m3 / hr at 2-3 KSC Application of Water For fire quenching Type of weight sensor Strain gauge type load cell (2 Nos/Feeder) Location of weight sensor Suspended roller in the weigh span Type of speed sensor Tacho generator (2 Nos/Feeder) Location of speed sensor Output shaft of Eddy Current Clutch Output from speed sensor 45 V AC +/-5 % @1000 RPM Coal on belt switch type Micro switch actuated by a cam & with contact rating

5A @ 240V AC or 0.5A @ 220 DC Discharge plugged switch Micro switch actuated by a cam & with contact rating

5A @ 240V AC or 0.5A @ 220 DC

2.2.2.2 MAIN MOTOR Make Laxmi Hydraulics Pvt Ltd. (LHP) Rated output 5.5 KW Rated Torque 3.8 Kg.m Type of Enclosure & ventilation IP 55, TEFC Type of mounting Vertical flange Mounting Rated voltage 415 V, 50Hz , 3 Ph


17

Rated speed 1440 RPM Full load current 11.30 Amp Insulation class F (Temp rise limited to class B) Duty S1 Eff. At full load 86%

2.2.2.3 CLEAN OUT CONVEYOR Make Bharat Bijlee Ltd. Rated output 0.25 KW Frame size AD 80 D Type of Enclosure & ventilation IP 55 Type of mounting Horizontal flange Mounting Rated voltage 415 V, 50Hz , 3 Ph Rated speed 915 RPM Full load current 0.71 Amp Insulation class F (Temp rise limited to 70 degree) Duty S1 Eff. At full load 69 %

2.2.2.4 EDDY CURRENT CLUTCH Manufacturer M/S Dynaspede Integrated System Pvt. Ltd . Type Open ventilated , Drip proof , Round Frame Mounting Vertical downward flanged Duty S1 Rating 5.5 KW Clutch coil voltage 90 V DC (Max) Current 3 Amp at (Max) Speed 1200 RPM (Max) / 120 (Min)

2.2.3 SEAL AIR FAN

2.2.3.1 FAN Manufacturer BHEL Ranipet Fan Type NDFV 12.5 H (Overhung impeller with IGV) No. of fans per boiler 2 Medium handled Air from PA cold heater Location Outdoor Suction Orientation Right Horizontal Delivery Orientation Left Top 90 deg. Total head developed 508 mmwc Speed 1480 RPM

2.2.3.2 PARAMETER USED Air temp 50 c Density 1.027 Kg/m3 Volume/Fan 7.5 m3/Sec Head 508 mmwc


18

2.2.3.3 SEAL AIR FAN DRIVE MOTOR

Make Crompton Greaves Rating 75 KW Rated Voltage 415 (+/-) 10% Frequency 50 Hz +3%/- 5 % Speed 1480 rpm Full load current 134 Amps DOR CW as viewed from DE end

2.2.3.4 BEARING LUBRICATION Quantity 20 ltrs/fan Grade Servo prime 68,Bharat turbol 68,turbinol

68,teresso 68 Recommended interval of Lubrication Once in Six months

2.2.3.5 BEARING TYPE

Fixed Bearing NU314/C3 Free Bearing 6314

2.3 COAL PIPING & BURNERS

2.3.1 COAL PIPING Material of straight pipe Carbon steel Fuel pipe diameter 660.4 mm Fuel pipe thickness 14.2 mm

2.3.2 COAL BURNERS Type Tilting Tangential Make BHEL No. of coal burners feed by each mill 4 (Total No. of coal burners 36) No. of burners elevation 9 Temp of coal air mixture in PF Pipes 75 c

2.4 OIL FIRING SYSTEM

2.4.1 HEAVY FURNACE OIL BURNERS Burner Tilting Tangential; Corner fired Oil gun Parallel piping design, Steam atomized External mixed; Constant pressure atomizer Air nozzle Rectangular Diffuser 190 mm; 10 off 45 c vanes with leading

edge with scanner & ignitor cuttings Oil gun assembly dimension KF=2689+/-3 mm Atomizer Designation Spray plate 90 J24


19

Atomizer Spray Angle 90 c Fuel Fuel oil to IS1593; 1971 LSHS, HPS oil Capacity Maximum 7.5 % MCR heat input per elevation.

30 % MCR total in 4 elevations One elevation stand by

No. of oil guns 20 (4 per elevation ) Location of oil guns Auxiliary air nozzles, AB, CD, EF, FG & HJ

OIL GUN PERFORMANCE DATA CHART

MAXIMUM MINIMUM SCAVENGING HFO Flow per gun 2220 Kg/hr 820 Kg/hr - HFO Pressure 9.3 Kg/cm2 (g) 3.5 Kg/cm2 (g) - Atomising steam flow/gun 205/210/200

Kg/hr 260/260/260 Kg/hr

325 Kg/hr

Atomising steam pressure 5.25 Kg/cm2 (g) 5.25 Kg/cm2 (g) 5.25 Kg/cm2 (g) Minimum allowable HFO Pressure 4.0 Kg/cm2 (g) Minimum allowable steam Pressure

3.5 Kg/cm2 (g) Oil viscosity at the gun 15 to 30 CST Steam quality 10 to 15 C Superheat NOTE: Pressure are measured at the oil gun connection .Minimum firing rate is the minimum energy required for coal fuel ignition and stabilization. At no time the oil burners shall be operated below this rating.

2.4.2 LIGHT DIESEL OIL BURNERS Service Initial startup & warm up Atomiser External Mixed, Constant Pressure,

Compressed Air Atomised Fuel LDO to IS 1460/1974 Capacity (Max.) 7.5 % MCR heat input & total 7.5 % MCR No. of oil guns 4 guns in one elevation Location of oil guns In Auxiliary air nozzle AB.

OIL GUN PERFORMANCE DATA CHART MAXIMUM MINIMUM SCAVENGING LDO Flow/gun 2325 Kg/hr 850 Kg/hr LDO Pressure 9.50 Kg/cm2 (g) 3.0 Kg/cm2 (g) Atm. Air flow/gun 190 NM3/Hr 210 NM3/Hr 245 NM3/Hr Atm. air Pressure 5.25 Kg/cm2 (g) 5.25 Kg/cm2 (g) 5.25 Kg/cm2 (g)

The same HFO gun is used for LFO firing also without changing the atomizer .Data other than the ones indicated above are same as Heavy Fuel Oil burners.


20

2.4.3 IGNITERS

Make Unison Industries /USA Service Oil burner light off Type High energy arc Igniter Location Burner Mounting Panel Input 240 VAC ,50 Hz Output Min.4 sparks/second, 12 joules/spark Retractor Stroke 8 Flexible Spark Rod B=115 inches Flexible Guide Pipe L=2095mm

2.4.4 HEAVY FUEL OIL SPECIFICATION Standard IS-1593/1971 Gr HV/OIL Pumping Temp 57 c Flash point min 66 c Firing temp 120 c Kinematic Viscosity 370 CST at 50 c Total Sulpher CONTENT 4.5 % by weight Specific Gravity 0.925 @ 50 c Gross heating value 10270 Kcal/kg

2.4.5 LDO SPECIFICATIONS Standard IS-1460-1974 Pumping temp 40 c Firing temp 40 c Viscosity 2 TO 20 @ Firing temp Total Sulpher 1.8 % by weight Density @ 15 c 0.83 Kg/Liter High heating value 10000 Kcal/Kg approx.

2.5 INDUCED DRAFT FAN (ID FAN) 2.5.1 FAN Type NDZV 47 SIDOR Make BHEL Suction / Delivery Orientation 60deg top left/Horizontal right centre Medium handled Flue gas No. per boiler 2 Location Outdoor

2.5.2 FAN DESIGN RATING Capacity 626 m3/Sec Total head developed 525 mmwc Temp of medium 150 c Specific Wt. of medium 0.752 kg/m3 Speed 580 RPM Cooling water flow for the fan Brgs 8 TPH


21

2.5.3 FAN RESERVE Flow 50.95 % Pressure 88.17 % 2.5.4 FAN DRIVE COUPLING TYPE HOLSET PM 400 Flexible 2.5.5 LUBRICATION EQUIPMENT Fan 80 LPM FLOS. (OIL ISO VG 68)

2.5.6 TYPE OF FAN REGULATION Speed by VFD & Inlet damper

2.5.7 BEARINGS Fixed bearing 10 RLT (Water cooled) Free bearing 10 RLT (Water cooled

2.5.7.1 VARIABLE FREQUENCY DRIVE (VFD)

Motor Rating Data Single channel (6 Pulse) Dual channel (12 Pulse) Speed (RPM) 398 579 Current (Amp) Motor Voltage(v ) 1650 2300 Power (KW) 1580 4500 Power Factor (LEADING) .95 .95 Exciter voltage (RMS) (Stator 3 Ph. L-L) Volts

238 299

Exciter Stator line current RMS 39 56

VFD TRANAFORMERS Manufacturer Voltamp Transformers Limited Vadodara Service class /KVA Rating 3250 KVA/Rectifiers Duty, Mineral of filled,

Outdoor type Applicable standard IS 2026 Rated Voltage HV winding KV 11 KV+/- 6% LV winding KV 2.3 KV Rated frequency 50 Hz with variation of +3% to -5% Number of phases 3 Phase Type of cooling ONAN(Oil Natural & Air Natural ) Tap Changing Equipment Manufacturer Voltamp/Paragon Type Off circuit tap changer No of steps 4 steps/ 5 position Tap range % to % +5% to -5% @2.5% Connections Channel #1 Channel #2 HV winding Delta Delta LV winding KV Delta Star Connection symbol Ddo Dyn 1


22

VFD Reactors (Both Channel#1 & Channel#2) Manufacturer Sudhir Intra Vidyut Ltd. Quantity 8 Type Air Core DC Reactor, Dry type, Self cooled,

Smoothing type Type of application Indoor Rated current 1000 Amp DC Value of inductance 10 mili Henry +10%-0% System voltage 3600 V DC Cooling AN Temp rise Ambient/Winding 50 c/ 70 c DC Resistance at 70 c 20 milli ohms +/- 10%- Degree of protection IP 22 Class of insulation F Dimension in (mtrs) 2.35X2.25X1.975(LXBXH)

VFD Motor Exciter Make BHEL Type Brushless Number of poles 8 Stator/Rotor turns ratio 6.01 Exciter stator supply (Rated values ) PHASES 3 FREQUENCY 50 Hz VOLTS (Max) 415 V (L-L RMS) AMPS 80 A (MAX)(LINE) Exciter Rotor (Rated values) Poles 8 RPM 579 KW 26.1KW Volts 87.4 V DC AMPS 299 A DC

2.5.8 MOTOR Manufacturer BHEL, BHOPAL Frame size 1 DQ 4344, Type Max Synchronous Motor 2X2300 V Rating 4500 kW (Both channels together) Speed 100 to 530 RPM PF 0.95 Lead Insulation F Connection Double Star Max Stator Voltage 2 X 2300 V Max Stator Current 2 X 615 A


23

2.5.9 LUBE OIL SYSTEM

2.5.9.1 PUMP Oil Tank Capacity 600 litre Pump Type & Make Screw Pump/ Alekton Pump Model HF210-560-3S, 1.825 KW

Speed 2880 RPM Normal design Pressure 6.0 BAR Motor Rating 3.7 KW, 6.7 A, 2855 rpm Motor details ABB make, bearings-6206-2Z/C3, 6205-2Z/C3 Quantity of cooling water/Boiler 80 LPM Lube Oil Quantity ISO-VG-68

2.5.9.2 OIL FILTERS Type Basket Type Mesh material SS Rating 60 microns Working Pressure 5 Ksc Capacity 150 LPM Suction strainer 149 micron SS mesh

2.5.9.3 HEAT EXCHANGER Design Pressure Shell side 14 Ksc, Tube side 8 Ksc Capacity 80 LPM, Temp- 64 to 54 0C Heat Exchanger Capacity 21600 Kca/Hr

2.6 FORCED DRAFT FAN (FD)

2.6.1 FAN

Type FAF 24.5/11.8-1 No. Per Boiler Two

2.6.2 FAN DESIGN RATING Capacity 275 m3/Sec. Total head developed 410 mmWC Medium handled Atmospheric Air Location Out door Orientation Vertical Suction Horizontal Delivery Temp. of medium 50 c Density of medium 1.027 Kg/m3 Fan Speed 990 RPM Fan regulation Blade Pitch Control Fan Weight without motor and coupling 17700kg

2.6.3 FAN BEARINGS Fixed Bearing 7248 Free Bearing NU 248C3


24

2.6.4 MOTOR Manufacturer M/S BHEL BHOPAL Motor type SQ.IND.MOTOR Direction of rotation as viewed from driving end Clockwise Standard continuous rating at 40 c Ambient temp. as per Indian Standard

1710 KW

Derated rated for specified normal condition i.e. Ambient temp.

1600 KW

Rated Votlage (Volts) 11000 Permissible Variations of (a) Voltage (Volts) +/- 6% (b) Frequency (Hz) +3 % , -5% (c) Combined Voltage & Frequency +/- 10 % (Abs) minimum permissible starting voltage 80 % RV Rated speed at rated voltage and frequency 996 RPM At rated voltage and frequency Full load current 104 Amps. No load current 40 Amps. Starting time with minimum permissible voltage of 80 % of rated value

Without driven equipment coupled 5.8 Sec With driven equipment coupled 8.4 Sec

MOTOR BEARING Type Antifriction (Ball & Roller) Recommended Lubrications IOC Servogem-3 or equ. Grease Lubrication Self Guaranteed life in Hrs. 40000 Hrs

2.6.5 LUBE OIL SYSTEM

25 LPM at 35 Bar high pressure system supplied by Cenlub oil systems. Control oil pressure- Min. 8 Ksc (permissive), 6 ksc alarm and standby pump on Lub oil- Pressure 4 ksc for standby pump ON, Flow- < 4 lpm alarm

2.6.5.1 FOLS (Forced Oil Lubrication System) for FD & PA fans

Pump Make Alekton Motor Make ABB Pump type Screw pumps (Triple Screw) Motor Rating 3 phase, 415 v, 7.5 HP ,11.1 A, 0.78 pf Speed 1455 RPM Design Pressure Different settings for PA and FD fans Relief v/v Range 35 Bar System discharge capacity 35LPM Oil tank capacity 300 Ltrs. Fluid ISO-VG-68


25

2.6.5.2 LUBE OIL FILTER Type Double reversing type Mesh Material SS 304 Rating 25 microns Working Pressure 35 Bar Capacity 40 LPM Suction Strainer Filtration size-125 micron

2.6.5.3 LUBE OIL COOLERS Shell Side Tube Side Flow 10 LPM 80 LPM Design Pressure 8 Ksc 8 Ksc Test Pressure 10 Ksc 10 Ksc DesignTemp 100 c 100 c

2.7 PRIMARY AIR FAN (PA FAN)

2.7.1 FAN Type PAF19/10.6-2 No. per boiler 2 Orientation Vertical Suction Horizontal Delivery Medium Handled Atmospheric Air Location Out door Type of regulation Blade pitch control

2.7.2 FAN DESIGN RATING Capacity 183 m3/Sec. Total head developed 1250 mmwc Temp. of medium 50 c Specific Wt. of Medium 1.027 kg/m3 Speed 1490 RPM

2.7.3 FAN BERAING Fixed Bearing 7234 & NU 330 Free Bearing 7234 & NU 330

2.7.4 MOTOR Type SQ.IND.MOTOR Manufacturer BHEL, BHOPAL Type of duty Continuous Direction of rotation as viewed from driving end Clockwise Rated Voltage 11000 Volts Standard continuous rating at 40 c Ambient temp. as per Indian Standard

3207 KW

Derated rated for specified normal condition 3000 KW Permissible Variations of (a) Voltage (Volts) +/- 6% (b) Frequency (Hz) + 3/-5 %


26

(c) Combined Voltage & Frequency 10% Abs minimum permissible starting voltage 80% At rated voltage and frequency Full load current 183 Amps No load current 46 Amps. Starting time with minimum permissible voltage of 80 % of rated value

Without Fan 2.0 Sec. With Fan 10.5 Sec Rated speed at rated voltage & frequency 1494 RPM Motor Bearing Type Antifriction Recommended lubrication Guaranteed life in Hrs. Lubrication type

Grease IOC Servogem-3 or equi. 40000 Hrs. Self

2.7.5 PA FAN LUBE OIL SYSTEM

Same as FD fans except the pressure settings as below: Control oil pressure- Min. 25 Ksc (permissive), 17 ksc alarm and standby pump on Lub oil- Pressure 4 ksc for standby pump ON, Flow- < 6 lpm alarm

2.8 SCANNER AIR FAN

2.8.1 FAN No. 2( One is AC Driven + One is DC Driven ,

100% Standby ) Type of fan Radial/ Backward curved Blade, single

suction Make CB DOCTOR MAKE, SB 80 II M3 Pressure developed 200 mmwc Medium Handled Efficiency of the fan

Dust laden air 71 % (Static)/79.5 % (Total)

Power Consumption 6.13 BKW at operating Fan Speed 1440 RPM Capacity 8000 Cum/hr Direction of rotation CW (Seen from DE Side)

2.8.2 A.C. MOTOR Make Kirlosakar Electirc Company Ltd. Type & frame size Squirrel cage induction motor, P132M, IP55 Rated Output 7.5 KW Rated Speed 1440 RPM Rated Voltage, Frequency & Phase 415 V , 50Hz,3 Phase Full load current 14.3 Amp Starting current 600 % FLC Efficiency 86 % Duty Cycle S1


27

2.8.3 D.C. MOTOR Make Crompton Greaves Ltd, Applicable standard IS 4722, BS 5000 Type TEFC, SOLID YOKE, Shunt Frame size AFS 225 M Duty S1(continuous) Rated Output 7.5 KW Rated Speed 1450 RPM Armature rated voltage 220 VOL DC Type of excitation Shunt , Self excited Full load armature current 40.0 A DC Full load shunt field current 0.55 A DC Starting current 200 % FLC Full load efficiency 84.0 % Type of duty S1, Continuous Method of starting Reduced Voltage Starting

2.9 PRIMARY AIR REHEATER (PAPH) Make BHEL Type Lungstram Bisector (Regenerative) Air heater Size 27.5 VIM 2150 No. of air pre heater 2 per boiler

ELEMENTS

END NUMBER OF

BASKETS

HEIGHT OF ELEMENT

DESCRIPTION THICKNESS

HOT 240 925 mm DU .8mm INTER 240 925 mm DU .8mm COLD 288 300 mm NF 1.2mm

CASING MATERIAL: IS 2062 CASING THICKNESS: 6&10 mm

2.9.0 TYPE OF RADIAL SEALS HOT END Leaf type bend seals Cold End Leaf type bend seals

Type of circumferential seals : Staggered leaf type Type of axial seals: Leaf type bend seals

2.9.1 ROTOR SEALS Radial Seals-Hot End 2.5 mm Corten-A Radial Seals-Cold End 2.5 mm Corten-A Axial Seals 2.5 mm Corten-A By pass Seals 1.6 mm Corten-A Rotor post Seals HE & CE 6.0 mm IS-2062


28

2.9.2 ROTOR DRIVE ASSEMBLY Electric Motor Squirrel cage, Induction motor (415 V,3, 50Hz ) Motor Rating 11 KW Motor speed 1460 RPM Frame & class 160L& F Speed reducer Type- ID. 3 Input, up shaft, M/s Shanthi Gears

Limited Speed ratio Fluid coupling 11.5 FCU- M/S Pembril/T12/04- M/s Fluidomat Final speed

2.9.3 AUXILIARY DRIVE Air M/s IngersolRand,IR92RA014,5.51:1 Motor Coupling M/S Bibbly coupling type 124 A Solenoid valve 230 V,1 PH,AC, 50 Hz,-1 BSP Pressure Switch 1/4" NPT (F), 0-10 Kg/cm2 Filter & Lubricator 1 BSP

2.9.4 Rotor stoppage Alarm

Go switch M/s Smart Technologies/New Delhi

2.9.5 BEARINGS

Support Bearing Sph. Roller thrust bearing SKF 294/500 E Guide Bering Sph. Roller bearing (23060/CCK/C3/W33) RTD 1 BSP (M) Duplex -thermo well

2.9.6 OIL CIRCULATION SYSTEM Motor guide & support bearing 0.75 KW, 415 V, 3,50 Hz,1500 RPM Type Screw Pump Pump Tushaco Delta,model:T3S-25/46 John Type of lubrication Sump oil Filter Fowler/hp values-15 LPM Cooler M/s Patel Air Temp Ltd. Coupling Love Joy-L-095 Pr. Gauge with needle valve M20 X1.5; 0-10 Kg/cm2 Flow switch Universal flow monitors Dial thermometer with well 3/4" BSP 0-100 c

2.9.7 DELUGE AND WATER WASHING

Pressure Gauge M20 X1.5; 0-10 KG/CM2


29

2.9.8 CLEANING DEVICE ASSEMBLY 2.9.8.1 SOOT BLOWERS

Type of nozzle Twin Type of drive Sweep Location Gas inlet & outlet Quantity 2/APH Motor 0.18 KW, 3, 50 Hz, 415 v, 750 RPM, Reducer M/s Shanthi-Radicon-AOD/237/2RL ,4900:1 Coupling M/s Love Joy Coupling L-095 & L-110 Limit switch 240 V Cuttler Hammer Steam consumption 2100kg/hr/device

2.9.9 FIRE SENSING THERMOCOUPLE

Location Gas Outlet and air outlet Make M/S Pyrotech Electronic/Udaipur Quantity Thermocouple 10 Point T/C

2.9.10 SERVICE WATER CONSUPTION

HOT END COLD END Water washing 114 Cum/hr/pipe 114 Cum/hr/pipe Deluge Assembly 114 Cum/hr/pipe 114 Cum/hr/pipe

2.9.11 BEARING HOUSING OIL CAPACITY

Guide Brg. Housing 50 liters Support Brg. Housing 150 liters

2.10 SECONDARY AIR PRE HEATER (SAPH) Make BHEL Type Ljungstorm Bisector (Regenerative) Size 30.5 VIM 2150

SAPH ELEMENTS

END NUMBER OF BASKETS

HEIGHT OF ELEMENT

MATERIAL DESCRIPTION OF ELEMENTS

HOT 336 925 mm Carbon steel 0.8mm-Du profile INTER 336 925 mm Carbon steel 0.8mm -Du profile COLD 384 300 mm Carten -A 1.2mm-NF6 profile


30

2.10.1 ROTOR SEALS

Radial Seals-Hot End 2.5 mm Corten-A Radial Seals-Cold End 2.5 mm Corten-A Axial Seals 2.5 mm Corten-A By pass Seals 1.6 mm Corten-A Rotor post Seals HE & CE 6.0 mm IS-2062

2.10.2 ROTOR DRIVE ASSEMBLY

Electric Motor Squirrel cage, Induction motor (415 V, 50Hz ) Motor Rating 18.5 KW Motor speed 1460 RPM Frame & class 180 L& F Speed reducer Type- II D. 3 Input, Down shaft, M/s Shanthi Gears Limited Speed ratio Fluid coupling 12.75 FCU- M/S Pembril/T12/04 M/S Fluidomat

2.10.3 AUXILIARY DRIVE

Air Motor M/s IEC Dusterloh/Pune.8:1 Coupling M/s Bibbly coupling type 124 A Solenoid valve 230 V,1 PH,AC, 50 Hz,-1 BSP Pressure Switch 1/4" NPT (F), 0-10 Kg/cm2 Filter & Lubricator 1 BSP

2.10.4 Rotor stoppage Alarm Go switch M/S Smart Technologies/New Delhi

2.10.5 BEARINGS Support Bearing Sph. Roller thrust bearing SKF 294/500 E Guide Bering Sph. Roller bearing (23072/CCK/C3/W33) RTD 1 BSP (M) Duplex.- thermo well

2.10.6 OIL CIRCULATIO N SYSTEM

Motor guide & support bearing 0.75 KW, 415 V, 3,50 Hz,1500 RPM,fr.90S Type Screw Pump Pump Tushaco Delta,model:T3S-25/46 John Type of lubrication Sump oil Filter Fowler/hp values-15 LPM Cooler M/s United transfer (P)Ltd. Coupling Love Joy-L-095 Pr. Gauge with needle valve M20 X1.5; 0-10 KG/CM2 Flow switch Universal flow monitors Dial thermometer with well 3/4" BSP 0-100 c


31

2.10.7 DELUGE AND WATER WASHING Pressure Gauge M20 X1.5; 0-10 KG/CM2

2.10.8 CLEANING DEVICE ASSEMBLY 2.10.8.1 SOOT BLOWERS

Type of nozzle Twin Type of drive Sweep Location Gas inlet & outlet Quantity 2/APH Medium Steam at 340 c & 14 kg/cm2 Motor 0.18 KW, 3, 50 Hz, 415 v, 750 RPM, Insulation Class-F Reducer M/s Shanthi- Radicon-AOD/237/2RL Coupling Love Joy Coupling L-095 & L-110 Limit switch 240 V Cuttler Hammer Steem consumption 2100kg/hr/device

2.10.9.2 FIRE SENSING THERMOCOUPLE

Location Gas Outlet and air outlet Make M/S Pyrotech Electronic/Udaipur Quantity Thermocouple 10 Point T/C

2.10.10 SERVICE WATER CONSUPTION

HOT END COLD END Water washing 182 Cum/hr/pipe 182 Cum/hr/pipe Deluge Assembly 182 Cum/hr/pipe 182 Cum/hr/pipe

2.10.11 BEARING HOUSING OIL CAPACITY

Guide Brg. Housing 75 liters Support Brg. Housing 225 liters

2.11 STEAM COILED AIR PREHEATER (SCAPH) 2.11.1 PRIMARY SCAPH

No. of steam coil APH 2 No. per boiler Supplier M/S C Doctor & Co. Pvt. Ltd. Size of steam coil APH 3150X4700X350 mm Installed position Vertical Design pressure 20 kg/cm2(ata) Design temperature 240 c Hydraulic Test pressure 30 kg/cm2 Weight of one steam coil APH 4650 kg.


32

2.11.2 SECONDRAY STEAM COIL APH

No. of steam coil APH 2 No. per boiler Supplier M/S Patels Air Tem. Pvt. Ltd. Size of steam coil APH 6000X3700X350 mm Installed position Vertical Design pressure 20 kg/cm2(ata) Design temperature 240 c Hydraulic Test pressure 30 kg/cm2 Weight of one steam coil APH 5550 kg.

3.0 ELECTROSTATIC PRECIPATOR (ESP)

3.1 DESIGN CONDITION Gas flow rate 855.1 m3/sec Gas temperature 125 c Inlet dust concentration 46.08 gm/Nm3 Outlet dust concentration 18 mg/Nm3 Type 4xFAA-9x45M-2x92150-2 ESP Efficiency 99.961 % No. of precipitator Four No. of gas path per ESP One No. of fields in series in each gas path nine No. of bus sections Two Velocity of gas inside ESP 0.77m/sec Treatment Time 52.6 sec.

3.2 COLLECTING ELECTRODES

No. of rows of collecting electrodes per fields 47 No. of collecting electrodes per fields 282 No. of collecting electrodes arranged in each row

6

Total no. of collecting plates per boiler 10152 Nominal height of collecting plate 15 M Nominal length of collecting plate 750 mm Specific collecting Area 261.44 m2/m3/sec.

3.3 EMITTING ELECTRODES

Type Spiral with hooks Size 2.7 mm dia No. of electrodes in the frame forming one row 54 No. of electrodes in each field 2484 Total No. of electrodes per boiler 89424 Total length of electrodes per fields 15500 M Plate/Wire spacing 200 mm (across ESP )


33

3.4 GAS DISTRIBUTION SYSTEM

INLET Type & quantity Perforated-(3 screen arrangement) with GD

rapping system 1 set.. Location Inlet of Precipitator OUTLET Type & quantity Thin sheets formed to a shape of U located

with 600 mm pitch-one no. Location Outlet of Precipitator

3.5 ELECTRICAL ITEMS

HV RECTIFIER ( BY BHEL BHOPAL/JHANSI) Rating 95 KV DC (Peak) 1000 mA DC (mean) Quantity/ESP 18 Type Silicon oil, Silicon diode, Full wave bridge connection Location Mounted on the roof of ESP

ELECTRONIC CONTROLLER Type of controller Thyristor Quantity/ESP 18 Location In the control room at ground level

BAPCON Microprocessor based TR Controller BAPCON PLUS Quantity/ESP

18

RAPCON Microprocessor based rapper Controller RAPCON 24 /ESP

04

RAPPER CONTROL PANEL Quantity per boiler 8 Equipment controlled Housing RAPCONs along with relay card, data communication

card &buffer cards of all rapping motors

STATCON E Microprocessor based status controller qty per boiler

04

STATCON PANEL Quantity per Boiler 4 Equipment controlled Housing STATCONs along with data Communication card and

buffer cards.Details of Heaters on/off and Ali status are connected to the controller.


34

NT-IOS Quantity per Boiler 01 set Equipment controlled Communicates & control all BAPCONs, RAPCONs, &

STATCONs. All data on fields, rapping motor running , opacity readings as well as logging of data

AUXILIARY CONTROLL PANEL Quantity per Boiler 04 Equipment controlled Geared motor rapping mechanisms of collecting & emitting

electrodes, heating elements on hoppers, Insulator housing & shaft insulators.

Location In the ESP Controlled room

3.6.1 RAPPING OF EMITTING ELECTRODES Quantity per ESP 18 Rating Geared motor, 0.50 Hp, 2.5 RPM, 3 phase, 415 V, 50Hz,AC. Location On middle frame of emitting system frame work

3.6.2 RAPPING OF COLLECTING ELECTRODES & GAS DISTRUBUTION SCREENS Quantity per ESP 18/02 Rating Geared motor, 0.50 Hp, 1.1 RPM, 3phase, 415 V, 50Hz,AC. Location On the ESP side panel./GD Housing

3.6.3 RAPPERS FOR COLLECTING ELECTRODE No. & Type of Rappers One drop hammer per row of collecting electrodes having a

collecting surface of 135 m2 Rapper size 4.9 kgs Frequency OF Rap Varying from 12 raps. per hour at the inlet field to 0.10

rap/hour at the exit field. The frequency of rapping at intermediate fields can be adjusted between 15 & 0.10 rap per hour according to the requirement

Drive Geared Electric Motor Location At the bottom of collecting electrodes

3.6.4 RAPPERS FOR EMITTING ELECTRODES No. & Type of Rappers Approximately One drop hammer for two rows of Electrodes Rapper size 3.0 kgs Frequency OF Rapping 10 Raps per hour Drive Geared Electric Motor Location On middle frame of emitting system frame work


35

3.7 HOPPERS

3.7.1 HOPPERS SPECIFICATIONS Type Pyramidal No. of hopper/ESP 36 per pass Heating Panel type heating elements provided at the bottom of hoppers Baffling Arrangement 2 sets of deflector plates for each hopper across the gas flow

direction underneath the collecting plates to prevent the gas sneakage.

3.8 HEATING ELEMEMTS

For Hopper Quantity per ESP 36 Set Type Panel Type Rating 10 Kw, 1 phase ,415 volt,50 hz Location At the bottom of the hopper Recommended Thermostat setting for heater trip.

120 c

For shaft Insulators Quantity per ESP 18 Type Tubular heaters of breathing type Rating 0.1 kw, 1 Phase, 415 AC, 50 Hz Location In the shaft Insulator housing

For Support Insulator Quantity per ESP 72 Type Tubular heaters breathing type Rating 0.1 kw 1 Phase, 415 AC, 50 Hz Location In the support Insulator housing Recommended Thermostat setting for the heater tripping

120 to140 c

4.0 SOOT BLOWER

Source of steam for soot blowing Tap off from SH Division Outlet Header Set pressure on pr. Reducing valve 30 kg/cm2 Set pr. On safety valve 40 kg/cm2 (38.4 KSC reset) Maximum flow rate 20 T/Hr Temp after pressure reducing 368 c

*

**

***

105 R, 106 L, 109 R, 110 L, 115 R, 116L

107 R, 108L, 111 R-114L, 117R-124L, 133R-144L

125R-132L


36

S. No.

DESCRIPTION TYPE OF SOOT BLOWERS WB IE LRD IIE

1 Blower Numbers 1 to 88 * (6)

**

(26) ***

(8) 2 Travel in MM 305 9700 9700 9700 3 Dead Travel in MM - 370 370 370 4 Nozzle size in mm/No. off nozzle 26/1 32/2 25/2 25/2 5 Blowing pre. In kg/cm2 (G) 11 12.5 12.5 10.5 6 Speed of travel in MPM/ Rotary in RPM 6.1/.7 1.55/5.87 1.55/5.87 1.55/5.87 7 Blowing rate per group in kg/min 89 152 93 79 8 Blowing time per group in MIN 1.4 12.04 12.04 12.04 9 Operating time per group in MIN 1.5 12.52 12.52 12.52 10 Operating time per cycle in MIN 66 75.12 325.52 100.16 11 Steam consumption per group in Kg 125 1830 1120 951 12 Steam consumption per cycle in Kg 5500 10980 29120 7608 13 Cycles per day (Assumed) 3 3 3 3 14 Steam consumption per day in Kg 16500 32940 87360 22824 15 Blowing Angle 360 c 360 c 360 c 360 c (PER DAY ) TOTAL STEAM CONSUPTION IN Kgs =159624 NOTE: BLOWING RATE IS GIVEN FOR BLOWERS OPERATED IN A GROUP OF TWO.

LRD IIE LONG RETRACTABLE SOOT BLOER ELECTRICITY OPERATED . WB IE WALL BLOWER ELECTRICITY OPERATED .

5.0 HP DOSING SYSTEM

5.1 MIXING TANK Capacity 1700 Liters Design temp 60 c Design pre 1.5 kg/cm2 Mixing motor 1.5 hp Speed 925 RPM Manufacturer Power Piping Company Mandaiyur

5.2 METERING TANK Tank Capacity 1700 Liters Temp 60 c Motor Capacity 1.5 hp Speed 925 RPM Manufacturer Power Piping Company Madras

5.3 DOSING PUMP Make M/S V. K. Pump Industries. Pvt. Ltd. Type Reciprocating Plunger type Capacity 100 Liter/Hr. Pressure 225 kg/cm2 No. of pumps boiler 2 Fluid handled Trisodium Phosphate


37

MOTOR DETAILS Make CGL/KEC/BBL Applicable Standard IS 325 Type SCIM Frame ND 100L Duty S1 Type of Enclosure IP 155 Method of cooling TEFC (IC 141) Motor Rating 2.2 KW Motor Speed 1500 RPM Power Factor 0.82 Volt 415 V, 50 Hz, 3 PHASE Starting Current 24 Amps Full load current 4.8 Amps Class of Insulation CLASS FWITH TEMPERATURE RISE

LIMITED TO CLASS B

AGITATOR MOTOR DETAIL Make CGL/KEC/BBL Applicable Standard IS 325 Type SCIM Frame 90L Duty Type of Enclosure IP 55 Method of cooling (TEFC)IC 411 Motor Rating 1.1 KW Motor Speed 935 RPM Power Factor 0.7 Volt 415 V, 50 Hz, 3 PHASE DOR Bi-directional Starting Current 13.5 Amps Full load current 2.7 Amps Class of Insulation CLASSF WITH TEMPERATURE RISE

LIMITED TO CLASS B

AGITATOR DETAIL Make V.K.Pumps INDUSTRIES PVT. LTD VOLUME TO be Mixed 1.7 m3 Component to be Mixed Water/Tri sodium phosphate Impeller SS316 MOC Speed 140 rpm

6.0 BLOW DOWN VESSELS

IBD TANK CBD TANK No. 1 1 Type IBD TANK 25000X16 CBD TANK 20000X16 Design Pressure 7.0 Kg/cm2 (g) 10 Kg/cm2 (g) Design Temp 169 c 183 c


38

Hydraulic test press 10.5 Kg/cm2 (g) 15 Kg/cm2 (g) Shell Thickness 16 mm 16 mm Shell dia 2500 mm 2000 mm Wt. when empty 6900 Kg 4100 Kg Medium Steam & Water Steam & Water Material Specification SA 515 Gr. 170 SA 515 Gr. 170

7.0 PRESSURE REDUCING & DESUPERHEATING STATION (PRDS)

7.1 SPECIFICATIONS

MS & CRH PRDS

MS CRH Pressure 186.6 to 20.0 ata 52.4 to 20.0 ata Temperature 540 to 350 c 360 to 350 c Volume of steam 92.5 T/Hr 10 T/Hr Spray Required 10.6 T/Hr (200 bar & 185 c) 8 T/Hr (200 bar & 185 c)

7.1.2 PRDS STATION SAFETY VALVES

No. of Safety Valves

Number Set Pressure (Kg/cm2) Blown Down (%) AS 32 18.0 3 to 5 AS 33 18.5 3 to 5 AS 34 19.0 3 to 5

8.0 SG EQUIPMENT COOLING WATER SYSTEM

8.1 DMCW PUMPS

Make WPIL Ltd. Model No. 8 LN 18C No. of pumps 2 Shut off head 74.8 mwc Rated Capacity 575 m3/hr

HT PRDS LT PRDS Pressure 16 ata 16 ata Temperature 310 c 210 c Volume of steam 114.74 T/Hr 80.70 T/Hr Application TG Gland Sealing/ TDBFP Gland

sealing/ AH Soot blowing/ Mill Inerting/ AC Plant

Deareator Pegging/ HFO Automisation/ SCAPH/ Turbine

wet steam washing


39

Pump Rated Speed 1485 RPM NPSH required at Rated capacity 4.5 MWC Total dynamic head at rated capacity 65 MWC Number if stages One Coupling type Flexible Type of sealing Mechanical Seal Bearing DE/NDE Type & Make Ball/SKF/FAG or Equivalent Bearing No. Inboard/Outboard 6212/6212 Type of Lubrication Grease Design Life More than 40000 Hrs.

8.2 DMCW PUMPS MOTOR

Make MARATHON ELECTRIC MOTORS LTD. Motor type Sq. cage Induction Motor Frame 315 Type of duty S1 Continuous Degree of protection IP 55 DOR CW Pump from DE Side Standard continuous rating at 40 c 180 KW Rated voltage/Frequency 415 Volts/50 Hz Rated Speed 1485 RPM Full load current 310Amps No load current 125 Amps Power factor at Full load 0.85 Efficiency at Full load 95 % Starting current 600 % FLC

8.3 PLATE HEAT EXCHANGERS (PHEs) Make IDMC Ltd, V.U Nagar, Anand Model No./type S188 No. of PHE 2 No. of Pass Single Maximum Temperature 60 c Design Pressure 12 bar LMTD 2.827 c Total eff Heat transfer area per HE (M2) 455.648 Area of each plate (M2) 1.964 Thickness (mm) 0.6 Material AISI 316 No of plate per HE 234


40

9.0 CHEMISTRY PARAMETERS & EXPRESS LAB (SWAS) 9.1 Recommended Chemical Parameters

BOILER WATER PARAMETERS Parameters Limit Values

Boiler water Regime AVT

Boiler water conductivity(S/cm) 7.0 to 15

Boiler water pH 9.0 to 9.5

Boiler water After Cation conductivity (S/cm) Less than 2.0

Boiler water Chloride, (ppb) Less than 120

Boiler water Silica, (ppb) Less than 200

SYSTEM WATER PARAMETER Parameters Limit-Values

Feed water Regime AVT-O

pH at Eco inlet 9.0-9.6

Conductivity (us/cm) 5.0 to 10.0

Ammonia (ppb) 800 to 1250

After Cation conductivity (uS/cm) for All Less than 0.2

Dissolve-O2 (ppb) at Eco inlet Less than 5.0

Dissolve-O2 (ppb) at CEP Discharge Less than 10

Oxidation reduction potential- Eco inlet, mV Oxidizing

Main Steam & condensate Sodium (ppb) Less than 2.0

Main Steam & condensate Chloride (ppb) Less than 2.0

9.2 Instrument Schedule (ABB Make) Parameters Model Range Samples analyzed Specific Conductivity

AX41050001 + AC221/231201

0-100 s/cm DM makeup water, Cond discharge after CPU, Feed water at Eco Inlet, Drum Water, Sat Steam and Main Steam

CATION CONDUCTIVITY

AX41050001 +AC221/231201

0-1 s/cm Same As above

pH AX460/50001+ AP302/11001001

0-14 Feed Water at ECO inletl, CEP discharge, CPU outlet, Boiler drum Water, Main Steam, Condenser Cooling Water, ECW-SG & ECW-TG

DISSOLVED OXYGEN

9437/0021230 0-20 ppb CEP discharge, Deaerator Outlet, Feed Water at ECO Inlet

Phosphate Navigator 600 (AW642/54000010)

0-15 ppm Drum Water

Hydrazine 7835-00000500 0-999 ppb Feed Water at ECO Inlet Sodium 8037/000121200 .01g/kg to

10 mg/kg CEP discharge, CPU outlet, Main Steam, Saturate Steam

Chloride 8234/0020 0-1000 ppb Drum Water


41

10.0 FUEL OIL PUMP HOUSE

10.1 HFO PUMPS

Particulars 3 X 50% triple screw pumps Make & Model Alekton Model: DH 600-1600-2-SJ Suction/discharge Pressure -0.5 / 30 kg/cm2 Speed & DOR 1450 RPM, CLOCKWISE FROM MOTOR END Pumping Temperature 57 to 90 0C Viscosity 180 cst (min.)/500 cst max NPSH required 4.58 m Capacity at min/max CST 989 / 1010 lpm BHP at min/max cst 58.6 kW/ 63 kW Efficiency at min/max cst 95.3% & 84.2% Mechanical Seal Single Action John Crane make, Model: 2100 size 65 mm Safety relief valve Integral type, Spring range-15 to 45 ksc, set @ 35 ksc Coupling 3-piece PIN-PUSH type, Love joy make

10.1.1 HFO PUMP MOTOR

Make Bharat Bijlee Ltd Type & Frame Size MD28M453 / 280M /IP 55 PROTECTION Application Standard IS 325; IS 2148 (Flame Proof) Rating 90 kW at 1480 RPM Rated current 147 A ; 42 A approx. at no load Bearings SKF/FAG Ball/Ball, 6317 C3/ 6316 C3

10.2 LDO PUMPS

Particulars 2 X 100% triple screw pumps Make & Model Alekton Model: DH 375-1000-3 Suction/discharge Pressure -0.5 / 25 kg/cm2 Speed & DOR 2920 RPM, CLOCKWISE FROM MOTOR END Pumping Temperature 40 0C Viscosity 2.5 cst (min.)/ 15.7 cst max NPSH required 2.95 m Capacity at min/max CST 451 / 476 lpm BHP at min/max cst 22.9 kW/ 23.9 kW Efficiency at min/max cst 88.3% & 82% Mechanical Seal Single Action John Crane make, Model: 2100 size 45 mm Safety relief valve Integral type, Spring range-12.5 to 37.5 ksc, set @ 30 ksc Coupling 3-piece PIN-PUSH type, Love joy make


42

10.2.1 LDO PUMP MOTOR

Make Bharat Bijlee Ltd Type & Frame Size MD20L253 / 200L /IP 55 PROTECTION Application Standard IS 325; IS 2148 (Flame Proof) Rating 37 kW at 2955 RPM Rated current 62.9 A ; 20 A approx. at no load Bearings SKF/FAG Ball/Ball, 6212 C3/ 6212 C3

10.3 HFO HEATER & DRAIN OIL COOLER

HEATER COOLER Nos 03 02 Surface Area 50 sq M Type Oil in shell, Water in U-tube Oil in shell, Water in U-tube Design Press (HFO side) 32 ksc Design Press (Steam side) 24 ksc

10.4 HFO DRAIN OIL PUMPS

LOCATION: One in Pump House, one each at boiler zero meter-both units.

Nos. 3 Pump Type Internal Gear Pump to handle LDO/HFO/LSHS at temp range-57 to

1200C Make & Model Tushaco Pumps- R20-DG Rating 67 to 71 LPM at 10 ksc, Suction pr.-(-)0.5 ksc Rotation 1445 RPM, clockwise as seen from motor end. Pump Motor CGL make 5.5 kW SCIM Coupling Love Joy- RC 042

10.5 HFO SUMP PUMP (PUMP HOUSE)

Nos. 2 (1 working) Pump type Vertical submerged to handle HFO/sludge Make & Model Sam Turbo, VO 32/200+ CPC Size & Rating 50x32 (SuctionX discharge), 10 m3/hr at 53 m total head Pump Motor Marathon make 5.5 Kw @2900 RPM SCIM Coupling SAM make Pin & Bush Bushes Total-03 nos, CFT (Carbon filled Teflon) bearings Lubrication External with Clear water


43

10.6 LDO UNLOADING PUMPS

Nos 2 (1 Working +1 Standby) Pump Type Twin Screw External Bearing Pump with Mech Seal & Timing Gear Make & Model Tushaco Pumps: TDSH 105/058 Pump Speed 1460 RPM rated (500 RPM min.- 1533 rpm max) Rating Flow:50 m3/hr at 20 mlc head (1.6 ksc) Motor 11 KW rated (160L frame size) Coupling Spacer coupling Relief Valve Built on relief valve set @2.6 ksc

10.7 DIRTY(DRAIN) OIL PUMPS (LDO UNLOADING SYSTEM)

Location OWS Pit (Oil Side) Drain Oil Tank (LDO Unloading pit) Nos 2 2 Pump Type Single screw vertical pump to handle dirty fuel oil(LDO/HFO) Model/Make TISK 100.1 VT / Tushaco Pumps TIS 200.1 EWVT Pump speed 434/150/480 RPM (Rated/Minimum/

Maximum) 446/150/480 RPM (Rated/Minimum/ Maximum)

Rating Flow- 6 m3/hr @ 1.8 ksc Flow- 10.8 m3/hr @ 5.76 ksc Motor 2.2 kW, 1450 rpm CGL make 5.5 kW, 1450 rpm CGL make DOR Clockwise from Drive End Clockwise from Drive End Speed Reducer

Helical Gear reducer/ PBL make/ Model-M0620

Helical Gear reducer/ PBL make/ Model-M0620

Gear Ratio 3.25 : 1 (Input speed-1450 rpm/Output speed-434 rpm)

3.25 : 1 (Input speed-1450 rpm/Output speed-446 rpm)

Gear lubrication

ISO VG 68 ISO VG 68

10.8 SUMP PUMP (FOHS)

Location LDO unloading Pit sump Oil Water Separator Pit Type/Make Vertical Submerged / Kishore Pumps Ltd

Model NVE 65-315 VERSA EG 50-200 Capacity 30 m3/hr @ 10 mlc (1ksc) 30 m3/hr @ 10 mlc (1ksc) Speed 960 rpm 1450 RPM Motor CGL make, 3.7 kW CGL make, 2.2 kW

Coupling Flexible(Steel & Rubber) Flexible(Steel & Rubber) Min Submergence 400 mm 360 mm


44

11.0 MILL REJECT HANDLING SYSTEM

11.1 GENERAL SPECIFICATIONS

Supplier: M/s Macawber Beekay Pvt Ltd in collaboration with CLYDE BERGMANN MATERIALS HANDLING LTD., U.K.

Material Handled: Mill rejects with assumed bulk density of 1.6 T/m3. Size of particles - below 25 mm (95% of reject). Oversize particles to be removed from the grid in pyrite hopper through plate valve.

Air receivers: 02 nos of 20 m3 capacity in each unit. One no at compressor house common for both units.

Storage bunker: Capacity- 101 Tons with bag filter. One no with bag filter for each unit.

Service Water: Sourced from plant service water system. Needed for quenching spray in pyrite hopper and for dome valve top plate cooling.

Instrument Air: Sourced from plant instrument air system.

11.2 SYSTEM DESIGN (Denseveyor/ Convey Pipe/ Pyrite Hopper)

Guaranteed Conveying Rate : 0.8 TPH/Mill Bulk Density of Mill Rejects (volumetric flow and Bunker volume) :1.6 T/CuM Bulk Density of Mill Rejects considered for Load Design of Bunker : 2.4 T/CuM (Note: For PG test, actual BD would be checked but a minimum value of 1.6 has to be considered) Approximate effective length of convey pipe : 58 to 151 m Average convey Velocity : 3.5 to 5.7 m/s Dome Valve open time (material fill time) : 5-10 Sec Dome valve closing/seal inflation : 03 sec Convey Time : 13 to 34 Secs. Reset time : 05 sec Total cycle time : 33 to 52 Secs. Max particle size of mill rejects : 50 mm For lumpy material as above, pipe size provided is generally minimum of twice the lump size. Required pipe size : 80 mm Pipe size provided :125 NB (OD:139.7,ID:128.9 mm Vessel capacity (6 cft) : 0.17 cum Material volume/batch : 0.17 cum Batch weight per cycle : 0.17*1600 kg =272 KG Hence, for 800 kg/hr capacity, cycles required : 800/272 2.94 say 3 cycles / hr.


45

11.3 DENSEVEYOR DATA

Model 6/8/5 Nos. 01 per mill Total cycle capacity 6 cft (0.17 m3) effective, 7 cft gross Pressure rating 5.0 ksc Design Temperature 200 0C (Quenching spray opens at 90 degree) Material Inlet size 200 NB Air inlet size 50 NB Material of construction

Denseveyor body-MS- IS 2062 Gr. E250A Outlet bend - Alloy Cast Iron

11.4 COMPRESSORS

Nos. 02 (1 working + 1 Standby) Make Ingersoll Rand (India) Ltd Model 16 & 10 X 7 PHE7 PKG Type Reciprocating ,Horizontal, Two Stage, Double

Acting, Water Cooled & Non Lubricating Rated Capacity 27 m3/min at 4.5 kg/cm2 Unload pressure 4.5 kg/cm2 Load Pressure 4.05 kg/cm2 Volumetric efficiency 83.3 % Mechanical Efficiency 91.73% Motor Rating 160 KW Shaft Power 125.35 KW @ 4.5 kg/cm2 compressor flange Compressor Speed 725 RPM Motor Make ABB Ltd. Motor Rating 160 KW, 415 V, 1485 RPM Starting time 1.1 sec with compressor coupled. Type of Coupling V-Belt Cylinder Stroke & Bore Stroke-7 Inches, Bore: Ist stage-16 inch, 2nd stage-10 Inch Cylinder water flow 75 lpm at 5.5 ksc Air Temperature First stage discharge- 135 degrees, 2nd stage- 129 deg Air discharge temperature at aftercooler

46.33 degree C

Intercooler water flow 185 LPM (Water in shell, Air in tubes) Aftercooler water flow 250 LPM MOC of coolers Shell- SA 106 Gr. B, Tubes- Copper Lubrication CRANKPIN, PISTON PIN, CROSS HEAD SHOES

lubricated with Force feed Lubricating Pump 01 no mounted on compressor shaft Oil Pump pressure 2.0 kg/cm2 Lubricant type INGERSOLL RAND RECIP PRIME Sump capacity 26 litres

NTPC DRG. No.: 1240-101-02-TR-PVM-N-001 JOB NO : NTPC LIMITED

RIHAND STPP, STAGE-III (2 x 500 MW) STEAM GENERATOR WITH

ELECTROSTATIC PRECIPITATOR PACKAGE

STATUS: CONTRACT DISTRIBUTION

TO BHARAT HEAVY ELECTRICALS LTD.

UNIT : HIGH PRESSURE BOILER PLANT TIRUCHIRAPPALLI 620 014

Dept Code

Name Sign Date

No. of DRN SR -Sd- 16.02.10 REV. Date ALTD CHD APPD DESN JLJ/AVR -Sd- 16.02.10 CHD MA -Sd- 16.02.10 APPD MA/SCS -Sd- 16.02.10

TITLE: COMBINED BOILER TURBINE START UP CURVES

DEPT. SCALE DRAWING NO. SIGN.

DATE. SHEET 1 OF 4 REV 00 CAUTION: THIS DRAWING IS THE PROPERTY OF BHARAT HEAVY ELECTRICALS LTD., AND IS NOT TO BE REPRODUCED OR USED TO FURNISH ANY INFORMATION FOR

MAKING OF DRAWINGS OR APPARATUS EXCEPT WHERE PROVIDE FOR AGREEMENT WITH SAID COMPANY.

NTPC, 2 X 500 MW RIHAND STAGE-III

NAME SIGN. DATE DRN. NEERAJ 30.09.2009

START-UP CURVES / COLD START CONSTANT PRESSURE OPERATION 1240-110-03-HW-PVM-N-206 CHD. NEERAJ 30.09.2009 TURBINE MODULES H30-100-2, M30-63 APD. A.SHAH 30.09.2009 BHEL, RANIPUR, HARDWAR STE-TD-260-MS REV. 02 SH.1 OF 3

Based on these curves, combined start up curves will be generated during contract stage in conjunction with boiler & system engineering for demonstration.

START-UP TIME (MINUTES) HP ROTOR TEMP. : 50 0C HP CASING TEMP. : 50 0C IP ROTOR TEMP. : 50 0C

5614Text BoxCAT-IV



START-UP CURVES / 36 HRS SHUT DOWN CONSTANT PRESSURE OPERATION 1240-110-03-HW-PVM-N-206 CHD. NEERAJ 30.09.2009 TURBINE MODULES H30-100-2, M30-63 APD. A.SHAH 30.09.2009 BHEL, RANIPUR, HARDWAR STE-TD-260-MS REV. 02 SH.2 OF 3





START-UP CURVES / 8 HRS SHUT DOWN CONSTANT PRESSURE OPERATION 1240-110-03-HW-PVM-N-206 CHD. NEERAJ 30.09.2009 TURBINE MODULES H30-100-2, M30-63 APD. A.SHAH 30.09.2009 BHEL, RANIPUR, HARDWAR STE-TD-260-MS REV. 02 SH.3 OF 3





START-UP CURVES / COLD START SLIDING PRESSURE OPERATION 1240-110-03-HW-PVM-N-205 CHD. NEERAJ 30.09.2009 TURBINE MODULES H30-100-2, M30-63 APD. A.SHAH 30.09.2009 BHEL, RANIPUR, HARDWAR STE-TD-261-MS REV. 02 SH.1 OF 3



5614Text BoxCAT-IV



START-UP CURVES / 36 HRS SHUT DOWN SLIDING PRESSURE OPERATION 1240-110-03-HW-PVM-N-205 CHD. NEERAJ 30.09.2009 TURBINE MODULES H30-100-2, M30-63 APD. A.SHAH 30.09.2009 BHEL, RANIPUR, HARDWAR STE-TD-261-MS REV. 02 SH.2 OF 3





START-UP CURVES / 8 HRS SHUT DOWN SLIDING PRESSURE OPERATION 1240-110-03-HW-PVM-N-205 CHD. NEERAJ 30.09.2009 TURBINE MODULES H30-100-2, M30-63 APD. A.SHAH 30.09.2009 BHEL, RANIPUR, HARDWAR STE-TD-261-MS REV. 02 SH.3 OF 3


HP ROTOR TEMP. : 490 0C HP CASING TEMP. : 490 0C IP ROTOR TEMP. : 405 0C

START-UP TIME (MINUTES)

TECHNICAL DIARY

TURBINE & AUXILIARIES

Prepared By Reviewed By Approved By RAHUL YADAV SUSHIL KUMAR M K SINGH

Asst Manager Manager AGM

STAGE-3 TECHNICAL DIARY (TG)

48

CONTENTS

1. MAIN TURBINE

1.1 SPECIFICATIONS 49 1.2 TURBINE LUBE OIL SYTEM 53 1.3 GENERATOR 56 1.4 TURBINE CONTROL FLUID SYSTEM 58 1.5 CONDENSER 60 1.6 LP HEATERS 61 1.7 DEAERATOR & FST 62 1.8 HP HEATERS 63 1.9 LP DOSING SYSTEM 64 1.10 CENTRAL LUBE OIL STORAGE & PURIFICATION UNIT 64 1.11 HP BYPASS SYSTEM 65 1.12 LP BYPASS SYSTEM 66

2.0 TURBINE AUXILIARIES

2.1 CONDENSATE EXTRACTION PUMP 67 2.2 BOILER FEED PUMP & AUXILIARIES 2.2.1 BOILER FEED PUMP (MAIN) 68

2.2.2 BOOSTER PUMP 69 2.2.3 HYDRAULIC COUPLING OF MDBFP 70 2.2.4 LUBE OIL SYSYTEM FOR MDBFP 70 2.2.5 BFP DRIVE MOTOR 71 2.2.6 TDBFP LUB OIL SYSTEM 71 2.2.7 OIL PURIFIER (CENTRIFUGE) 72

2.3 VACCUM PUMP 73

2.4 TG EQUIPMENT COOLING WATER SYSTEM 74

2.5 SG EQUIPMENT COOLING WATER SYSTEM 75

2.6 AUXILIARIES COOLING WATER SYSTEM (ACW) 75 2.7 CONDENSER ON LOAD TUBE CLEANING SYSTEM (COLTCS) 76 3.0 DM MAKEUP & CPU REGENERATION SYSTEM 77

4.0 COMPRESSED AIR SYSTEM 79


49

1.0 MAIN TURBINE

1.1 SPECIFICATIONS

Make BHEL Design KWU, West Germany Type Three cylinder reheat condensing turbine Stages HPT 17 Reaction stages.

IPT 12X2 Reaction stages. LPT 6X2 Reaction stages.

Valves HPT- 2 main stop & control valve. IPT- 2 Reheat main stop & control valve. CRH Line-1 swing check valve 2 Bypass Stop and Control Valves with actuators & HPSU.

Direction of rotation Anti-clockwise (Viewed from front pedestal towards Generator) Load Rated load Max Load

500 MW 524.2 MW (VWO-Valve Wide Open Condition)

Speed Rated speed 50 C/Sec Max speed 51.5 C/Sec (No time limitation) Min speed 47.5 C/Sec (No time limitation) *Speed Exclusion Range (Without Load) 7 to 47.5 C/Sec Standard Over Speed trip setting 55.5 C/Sec *This speed range should be passed through in one smooth operation to avoid endangering the blades due to resonance.

1.1.1 EXTRACTION VALVES

Extraction 1 No valve Extraction 2 1 Swing check valve with actuator and 1 swing check valve without actuator Extraction 3 1 Swing check valve with actuator and 1 swing check valve without actuator Extraction 4.1 2 Swing check valves with actuator Extraction 4.2 2 Swing check valves with actuator Extraction 5 1 Swing check valve with actuator and 1 swing check valve without actuator Extraction 6 No valve

1.1.2 STEAM PRESSURE AND TEMPERATURE (RATED) Pressure (Bar) Temperature (C) Initial Steam/MS at HPSV Inlet 166.7 537 Before 1ST Stage of HPT 154.2 537 HP Cylinder exhaust 44.0 336.1 IP Cylinder stop valve Inlet 39.6 565 Extraction 6 44.0 336.1 Extraction 5 17.9 444.8 Extraction 4 6.93 309.4


50

Extraction 3 2.745 208.2 Extraction 2 1.437 147.3 Extraction 1 0.339 72.0 LP Cylinder exhaust 0.1027 46.4

1.1.3 TURBINE EXTRACTIONS

Extractions Source Going to 1 LPT 5 th Stage LPH-1 2 LPT 3rd Stage LPH-2 3 LPT 2 nd Stage LPH-3 4 IPT Exhaust Deaerator (4.1) & TDBFP-A/B (4.2) 5 IPT-7th Stage HPH-5A/5B 6 CRH HPH-6A/6B , TDBFP-A/B

1.1.4 CASING TEMPERATURE LIMITING VALUES

Wall Temperatures Alarm at Machine must be shut down at

HP Turbine casing exhaust 485 C 500 C Outer casing of LP cylinder 90 C 110 C Spray water L.P. Turbine must be switched on at 90 C Temperature Difference Alarm at Machine must be

tripped Between upper & lower casing halves of HP turbine (Middle)

+/- 90 C +/- 100 C

Between upper & lower casing halves of IP turbine,front and rear

+/- 30 C +/- 45 C

Permissible temperature difference between parallel steam supply lines

No time limitation 17 C Short term period (15 Min) 28 C

1.1.5 FEED WATER HEATER OUT OF SERVICE

Operation with feed water heater out of Service

Main Steam flow kg/s Load MW

Extraction A6,A5(Both streams out) 369 500

1.1.6 OUTPUT LIMIT WITH ATT

Output limit during the testing with Automatic Turbine Tester Testing of the main steam Stop & Control Valves


51

1.1.7 MOTORING

Motoring is the condition in which the turbine is driven by the generator at the rated speed with the stop valve & control valves closed. Motoring must not be allowed to continue beyond one minute. If the condenser low vacuum limit of 0.3 bar is exceeded, motoring must not be allowed to continue beyond 4 sec.

1.1.8 LOW VACUUM TRIP STANDARD SETTING

Hydraulic low vacuum trip 0.3 bar Electrical low vacuum trip 0.3 bar Electrical low vacuum trip Bypass operation 0.6 bar

1.1.9 TURBINE SEAL STEAM SYSTEM

Seal steam supply header pressure (Above atmospheric)

35 mbar

Condenser vacuum 0.1027 bar

1.1.10 BARRING GEAR

Speed 80 to 120 RPM Drive Turbine lube oil (Hydraulic Turbine) Cut in /Cut out Speed 210/240 RPM Location Front bearing pedestal

1.1.11 TURBOVISORY

Axil Shaft ALARM TRIP +/-0.5 mm +/- 1 mm

Differential Expansions (i) HPT

(ii) IPT

-0.5 to +3.5 mm -1.0 to +3.5 mm

Over all Expansion of IP+LP Rotor -3 to 30 mm

1.1.11.1 VIBRATION

Absolute Bearing Housing Vibration

Absolute Shaft Vibration

Standard Alarm Setting 50 m above normal level Maximum Alarm Setting 84 m 200 m Limit value of tripping 106 m 300 m Fixed Points For HP Casing Turbine bearing pedestal-2 For IP Casing Turbine bearing pedestal-2 For LP Casing Turbine bearing pedestal-3 For Turbine rotor Thrust Bearing All HP, IP & LP Turbine Bearing Pedestal are fixed.


52

1.1.11.2 BEARING TEMPERATURES

Alarm Machine must be shut down at Operating temperature below 75 c 90 c 130 c Operating temperature 75 c to 85 c 100 c 130 c Operating temperature 85 c to 90 c 110 c 130 c Operating temperature above 90 C 115 c 130 c

1.1.13 WEIGHTS (TONS) HP turbine complete assembly 95 T IP turbine, top half outer casing 26 T IP turbine, top half inner casing, complete with blading 16 T LP turbine, top half outer casing complete 43 T LP turbine, top half inner outer casing, complete with blading, guide blade carriers & diffusers

37 T

HP turbine rotor, complete with blading 16 T IP turbine rotor, complete with blading 23 T LP turbine rotor, complete with blading 100 T Main stop and control valve, complete with servo motors, without bend and pipe section

22 T

Reheat stop and control valve, complete with servo motors, without bend & pipe section

32 T

1.1.14 TURBINE LOAD SHARING CAPACITY

HP Turbine 26 % LP Turbine 34 % IP Turbine 40 %

1.1.15 HEAT BALANCE DATA

Rating 500 MW 400 MW 300 MW 250 MW Vacuum(mmHg) 77 (0.927 ksc) 77 77 77 DM Make-up (%) 0 0 0 0 Turbine Gross Output 508.489 407.608 306.076 255.734 Turbine Net Output(MW) 500 400 300 200 Heat Rate(Kcal/KW-Hr) 1932.5 1975.5 2059.5 2129.3 Losses (in MW) Mechanical 1.44 1.44 1.44 1.44 Gen 6.895 5.474 4.482 4.410 TG Auxiliary 0.15 0.15 0.15 0.15 Efficiency (%) 98.33 98.26 98.01 97.757


53

1.2 TURBINE LUBE OIL SYSTEM

1.2.1 MAIN OIL TANK

MOT Capacity 25/40 m3 1st oil filling 53 m3 Flushing oil quantity 32 m3 Filtration particle size of tank filter element 250 m

1.2.2 OIL REQUIREMENT OF BEARING (dm3/S) Bearing 1 0.8 Bearing 2 15.4 Bearing 3 4.55 Bearing 4 9.29 Generator front bearing 7.92 Generator rear bearing 7.92 Exciter Bearing 0.70 Estimated oil requirement for the hydraulic bearing gear at 4.5-5.0 bar 57.4 Min. Oil temperature at cooler outlet, unit in operation Normal Max.

38 0C 45 0C 47 0C

Oil temperature at cooler outlet, unit shut down Max. 75 0C

Temperature rise of oil in bearings Normal Maximum

20 0C 25 0C

1.2.3 DUPLEX OIL FILTER (FOR BRG. OIL SUPPLY HEADER ) Number 1 Type RFLD 4020 Make M/S HYDAC FILTER TECHNIK

GMBH Filtration particle size of duplex filter 25 m Filtration particle size of main oil tank filter element 250 mm

1.2.4 JACKING OIL SYSYTEM

safety valve setting 200 Bar Pressure Regulating valve setting 178 Bar

1.2.5 DUPLEX OIL FILTER FOR JACKING OIL

Number 1 Type DFDK 330 D40 W/Hc/-V-So212 Make M/s: HYDAC FILTER TECHNIK GMBH Filtration particle size of filter element 37 m


54

JACKING OIL PUMPS CUT IN / CUT OUT SPEEDS

Jacking oil pump must be in operation at turbine speed bellows 510 RPM.

Jacking oil pump should be cut out at speeds above 540 RPM.

1.2.6 OIL PUMPS SPECIFICATIONS

MOP AOP DC EOP JACKING OIL PUMP Number 1 2 1 AC:1 DC:1

Make BHEL M&P

M&P Tushaco Tushaco

Type Centrifugal VERTICAL

EXECUTION 5/6 EHLG

VERTICAL EXECUTION

4/5 Type12 KL Model 70

T 38/46

Capacity(m3/HR) 87.48 360.96 108 1.85 LPS Dish. Pressure (bar) 8.4 6.3 2.3 178

Speed (RPM) 3000 3000 1425 2900 Drive Turbine AC Motor DC Motor AC Motor DC Motor

Voltage (V) - 415 V 220 V 415 V 220 V Motor Power(KW) - 110 13 60 60

Rated Current (Amp) - 173 97 95 310

DOR From top - Clockwise Clockwise Clockwise Clockwise Make (motor) - CGL CGL CGL CGL

1.2.7 LUB OIL COOLERS

Number 2X100 % Type of Cooler Shell & tube type (Straight tube) Heat transfer area provided/ cooler 640 m2 Oil flow 190.8 m3/Hr Heat load on cooler 100% 1900 kw Temp. of oil at inlet of cooler 65 c Temp. of oil at outlet of cooler 45 c Tube (water ) side design pressure 10 Ksc Cooling water flow/ cooler 500 m3/hr Temp of cooling water at Inlet of cooler (Design )

38 c

Max allowable Temp of cooling water at Inlet of cooler

38 c

Temp. of cooling water at outlet of cooler 41.3 c Pressure drop across the cooler on tube side 3.5 m.w.c. Shell (oil) side design pressure 9.4 kg/cm2 Oil side pressure drop 4 m.w.c. Tube Material Admiralty Brass Tube Plate Material Carbon Steel IS:2062


55

Cooler shell & water Boxes material Carbon Steel IS:2062 Velocity of water through cooler tube 1.54 m/sec Number of tubes 956 (Low fin tubes) Length of tubes 3750 mm Tube OD X Thk. X L (Effective) 22X2.1X3597 mmX mmX mm Design code TEMA Heat transfer coefficient 260 K Cal/hr-m2- c Oil pressure at cooler Inltet 9.4 kg/cm2 g No. of tubes side passes 2

1.2.8 TURBINE OIL CENTRIFUGE SYSYTEM

No. of units One Make Alfa Laval Type MAB 206 S-24 Speed of Bowl (Max) 8423 RPM Max. hydraulic capacity 10,600 lit/hr Recommended oil flow (for best performance) 7500 lit/hr at 65 C Centrifuge drive Motor rating 11kW (AC) CENTRIFUGE FEED PUMP Type Positive displacement Capacity 8250 LPH Speed 1450 rpm Discharge pressure 1.5 kg/cm2 Max allowable pump pressure 4.0 kg/cm2 CENTRIFUGE MATERIALS Bowl body SS Alloy AL 111 2377 Bowl head SS Alloy AL 111 2377 Separating discs AISI 316 Drive shaft EN 8 Gear / Worm Tin bronze /EN 8 Oil injection nozzle AISI 316

tech diary

Documents

primary air fan pa fan

technical staff

scanner air fan

boiler auxiliaries tab

technical diarycompiled

electrical systems tab

forced draft fan fd

induced draft fan id