technical diary 200mw

TECHNICAL DIARY200 MW UNIT

KORBA SUPER THERMAL POWER STATION

P. O. Jamnipali Distt. - Korba 495 450 (C.G.)

R.BOSE

General ManagerFrom GM's Desk.....

Thermal Power plant is highly capital intensive and in order to derive sustained capacity utilization, with high availability & Plant Load Factors, sound O&M principles & practices are adopted in NTPC to run the stations in most cost effective manner. For dissemination of Plant Technical Data and Schemes pertaining to various systems to all O&M Engrs and related Functionaries, Tech Diaries and Schematic Diaries were published at Station & Corporate levels.

A need is felt for review of the initially prepared Tech & Schematics Diaries, for incorporating the changes made so far and addition of Data like Interlock & Protections and schemes of new Ash handling system for Dhanras etc.

This revised Technical/Schematic Diary is aimed at providing information & Data of the plant that may be necessary for day to day working and reference of O&M Engrs and also executives of other related functions.

I appreciate the efforts made by the team of O&M Engrs in furnishing

all useful data and reviewing the information available in existing Diaries and

publishing the sume in revised form for the use of new entrants and executives

of all functions.

Jamnipali (R. Bose )

03/10/2001 General Manager (K&B)

P.K.CHAKRABORTYAddl. GM (O&M)

FOREWORD

Availability of technical information pertaining to equipments and process is of paramount importance for effective, efficient and reliable operation and maintenance of the plant.

In this revised edition of the Technical Diary, addition of new sections like protections and interlocks, Relay settings, start-up/limit curves, data regarding new Ash Handling System inside Plant and at Dhanras etc., will make these 200 MW & 500 MW Technical Diaries more informative and useful.

This will provide technical information that are necessary for day to day operation and serve as a reference documents to O&M personnel.

I appreciate the MTP Team for acting as a nodal section and bringing

out this informative diary from the available information and interaction with

various sections.

Dated : 3rd October, 2001 P. K. CHAKRABORTY

ADDL. GM (O&M)

S. R. PATIDAR Dy. GM (MTP)

PREFACE

Thermal power station Operation & Maintenance practices in NTPC are framed through extensive documentation right from the inception of the plants. In our station all relevant O&M Instruction manuals, Operation Services Guidelines, Location Management Instructions, Tech & Schematic Diaries, Overhauling Reports etc are maintained in O&M Reference Library for ready reference of personnel. Existing Technical & Schematic diaries of both 200 & 500 MW Units, prepared at the time of Units commissioning, need revision. While making the revised editions of the Tech & Scematic diaries, additional Data like Protections & Interlocks, Relay Settings, Start up/Limit Curves etc and modification/additions of Schematics is considered.

All requisite information were compiled by this section in association with respective area engineers, so as to make the revised Technical & Schematic diaries, pertaining to both 200 & 500 MW Units, quite informative.

The revised Technical & Schematic Diaries are aimed at providing all information & Data of the plant, necessary for day to day working and reference of new entrants, Executives of O&M and other functions like FES, FQA and M&CS.

Jamnipali

03/10/2001 (SR Patidar) Dy General Manager (MTP)

CONTENTSCONTENTS

Sl NO. DESCRIPTION PAGE NO.

I MAIN BOILER & AUXILIARIES 1.1 MAIN BOILER 1 - 2

1. 2 ROTARY AIR HEATER 81.3 SOOT BLOWERS 91.4 PRESSURE REDUCING AND 10

DESUPERHEATING STATION1.5 FUEL OIL / OIL FIRING SYSTEM 111.6 F.D. FAN 131.7 I.D. FAN 141.8 P.A. FAN 151.9 ELECTRO STATIC PRECIPITATOR 171.10 MILL AND BURNER PERFORMANCE 191.11 BOILER PARAMETERS 241.12 CHEMICAL CONTROL LIMITS 29(WATER/STEAM CYCLE)

II. MAIN TURBINE & AUXILIARIES 2.1 TECHNICAL SPECIFICATIONS 31 - 32 2.2 CONDENSER, EJECTOR, DRAIN COOLER 38 2.3 Low pressure heaters 39 2.4 Deaerator 40 2.5 High pressure heaters 40 2.6 BOILER FEED PUMP 41 2.7 CONDENSATE EXTRACTION PUMP 43

III. OFF SITE AUXILIARIES 3.1. FUEL OIL SYSTEM 44 - 45 3.2 WATER TREATMENT PLANT 47 3.3 M.G.R. AND COAL HANDLING PLANT 53 3. 4 COMPRESSED AIR SYSTEM 55 3.5 AIR CONDITIONING SYSTEM 56 3.6 COOLING WATER SYSTEM 64 3.7 EQUIPMENTS OF ASH HANDLING SYSTEM 71

IV. GENERATOR & AUXILIARIES 4.1 SPECIFICATIONS 76 - 77 4.2 AUTOMATIC VOLTAGE REGULATION 84

4.3 STATOR WATER COOLING SYSTEM 86

CONTENTS

Sl NO. DESCRIPTION PAGE NO.4.4 GAS SYSTEM DATA 86

4.5 SEAL OIL SYSTEM 87 4.6 Generator Transformer 88 4.7 TIE TRANSFORMER 90 4.8 UNIT TRANSFORMER 92 4.9 STATION TRANSFORMER 94

V. INTERLOCK & PROTECTION 1.1 BOILER 96 - 97 1.2 PULVERISER & FEEDERS 98 1.3 ID FAN 99 1.4 FD FAN 100 1.5 PA FAN 100 1.6 IGNITOR AIR FAN 101 1.7 SCANNER AIR FAN 101 1.8 SEAL AIR FAN 101 1.9 AIR PREHEATER 101 2.1 TURBINE 102 2.2 B F P 102 2.3 CEP 103 2.4 INTERLOCKS FOR HP - BYPASS SYSTEM 103 2.5 INTERLOCKS OF AUXILIARY PRDS 103 3.1 GENERATOR TECHNICAL DATA 104 3.2 PROTECTIONS 106 3.3 GENERATOR TRANSFORMER 109 3.4 UATS 110

3.5 GENERATOR RELAY SETTING 111

VI. GRAPHS, CURVES & TABLES 1. EQUIPEMENT - WISE OIL RESERV0IR CAPACITY 115 - 116 2. EQUIPEMENT - WISE OIL RESERV0IR CAPACITY (WTP) 117 3. TURBINE STARTUP CURVES 118 4. Steam Turbine Limit Curves 124

5. GENERATOR REACTIVE CAPABILITY CURVE 1296. STEAM PROPERTIES TABLE I, II.III.IV 1327. MOLLIER DIAGRAM 146

I

MAIN BOILER

& AUXILIARIES

1.1. MAIN BOILER

A. GENERAL

i) Manufacturer BHEL, CE DESIGNii) Design Code ISOiii) Type RAD,RH, NATURAL

CIRCULATION SINGLE DRUM, SEMI OUT DOOR, BALANCED DRAFT, DIRECT FIRED.

iv) Type of firing TILTING, TANGENTIALv) Type of super heaters PENDENT, PLATEN, HORIZONTALvi) Total Aux. power 5400 KW at 91% MCRvii) Min. load the Boiler can 40%

M.C.R.sustain without oil support(T/HR)

viii) Min. mill load with oil 50% support %

ix) Total Water content of 321.5 (Including Reheater)Boilor (T)

B. FURNACEi) Type FUSION WELDED WALLSii) Comb, chamber volume (M3) 5200iii) Furnace Height 43129 MM

(Seal to Fur. roof)iv) Furnace width 13868 MMv) Furnace depth 10592 MMvi) Water walls

a) Front wall (M2) (EPRS) 618b) Side walls (M2) (EPRS) 757c) Rear wall (M2) (EPRS) 620d) Roof (M2) (EPRS) 122e) Total Heat surface (M2) (EPRS) 211

2

vii) Furnace adjustment factors for surface.a) Front wall 1.0b) Side wall 1.0c) Rear wall 1.0d) Roof 1.0Specification of tube material.SA - 210, Gr.A1O. D. x Thickness MM x MM 63.5 x 6.3Margin of tube thickness Under normal opern.over & above the press. conditions 0.4 mmrequirement. (As per I.S.O 0.2 mm)Design metal temp. 4040CDesign Pr. of Tubes (Kg/cm2)a. 176.9 as per ISOTotal wt. tonnes (water walls) 290

viii) Residence time of fuel 2.5 secondsparticles in Furnace

ix) Water wall header.Material SPN SA - 106, Gr. 'B' & Gr. O.D. MM 406.4, 273.0, 219.1Thickness M.M. 50.0, 45.0, 36/40Design pr. kg/cm2 at 179.6Approx. total weight of 55headers

x) Max. header unbalance 2%

C. BOILER DRUMi) Spn. of material SA - 299ii) Elevation of drum mm 53340iii) Overall length mm (Approx) 15000iv) Mean O.D. mm 1913.0v) Shell thickness mm 170/135 (Bt-thickness)vi) Design pressure Kg/cm2 175.8vii) Design metal temp 0C 354

3

viii) Permissible max. temp. 0Cdiff. between any parts of druma) Normal operation 55b) Accelerated starting 55

xi) Drum wt. without Internals 107(T)

x) Drum wt. with all Internals 120(T)

xi) Water capacity with MCR 25 seconds (upto tripping)conditions (in sec) betweennormal and lowest water levelpermitted.

D. SUPER HEATERSi) Heating surface

LTSH M2 6490PLATEN SH M2 810FINAL SH M2 823

ii) No. of stages Threeiii) Spn. of material LT SH PLATEN FINAL

SA 210Gr SA 213 TII SA 213 T 22

A1SA 209 T1 SA 213 T22 SA

213 TBSA 213 T11 SA 213 TB 347

Hiv) Type of flow Counter ParalletParallet

(Counter or parallel)v) No. of coils 120 29 89vi) O.D. x thickness. mm xmm 44. 5x4.5 51.0x5.651x8.8 (Thickness varies)vii) Max. Gas side metal temp 0C 490 570 585viii) No. and type of themocouples

fitted to S.H. Tubes Chromel / AlumelA) In gas path Nil

4

b) In pent house Permnt. 63 Tempr. 83 Total wt. of S.H. tonnes 440

(ix) Super heaters headers Spn. SA - 210 Gr. B. SA-335 P12,of Materials. SA 335 P22Design Pr. (Kg/cm2) a 176.8Approx. total weight T 68Max. Header unbalance 5.7 %

E. SUPERHEATER ATTEMPERATORi) Type Spray type mixingii) Stages of attemp. Oneiii) Position in steam circuit LTSH - Attem - Platen SHiv) Specification of material SA 335 p12v) SH temp. range that can be 540 + 5

maintained between 60% and100 % MCR of boiler (0C)

vi) Spray nozzle material SA 213 T 11vii) Max. spray water flow rate 15 x 103 at 60% MCR

and corresponding steam output(kg/hr)

F. REHEATERSi) Total heating surface M2 2630ii) No. of stages Oneiii) Material SA 269 T SA 233 T T22

SA 213 TP 304 Hiv) Max. gas to metal

temp 0C 585v) Approx. wt. (Tubes) T 120vi) Reheater Headers :

a) Material SA - 106 Gr. 3 (INLET)SA - 335 P22 (OUTLET)

b) Design Pr. (Kg/cm2) at 46.0

5

c) Design metal temp. 0C Inlet 350, Outlet 550

d) Wt. Tonnes 15.0

vii) O.D. x thickness of tubes 54 x 3.5, 4.0

mm x mm

viii) No. of coils 59

G. REHEATER PRIMARY TEMP. CONTROL

i) In case of tilting burners

a) Angle of tilt (Max) + 300

b) Type of tillting Power tilting Cyl.

c) RH steam temp. 60% - 540 + 50C

100% MCR

H. R. H. EMERGENCY TEMP. CONTROL

i) Type Spray type mixing

ii) Stages One

iii) Position in steam ckt. In cold RH Line

iv) Material SA - 106 Gr. B

v) Max. flow of spray water 22

T/hr.

vi) Spray Nozzle material Body-SA-182 Gr. F11

Tip an Disc AIBI Gr. 420.

I. ECONOMISER

i) Material (Tubes) SA 210 Gr. A1

ii) O.D. x thickness mm x mm 44.5 x 4.5

iii) No. of coils 145

iv) max. Gas side metal temp 0C 295

v) Wt. (Tube and Reders) 210

vi) Headers

a) Material SA - 106, Gr. B

6

b) Design Pr. (Kg/cm2) 181.1c) Design metal temp 0C 310.0

vii) Max. Header unbalance 2%

J. BOILER MOUNTINGS & FITTINGS

1) Drum safety valvesMake M/s Dresser, USAType Spring loadedNo. ThreeSet Pr. (Kg/cm2) gauge 175.8, 179.3, 181.1Reset Pr. (Kg/cm2) gauge 168.8, 170.3, 172.0Relieving capacity T/hr 177.1, 180.6, 182.5

2) S.H. safety valvesMake M/s Consolidated, USAType & Rating Sp. loaded with relieving

capacityof 154. 7 T/hr.

No. OneSet Pr. (Kg/cm2) gauge 163.3Reset pressure kg/cm2 gauge 158.4

3) Reheater safety valvesType and ratting Sp. loaded with combined

rellevingcapacity of 494 T/hr at RH Inletand 139 T/hr at Rh outlet.

No. 3 at Inlet, 1 at outlet. HRHSet pressure (kg/cm2) gauge 45.0 45.5 46.3 42.7Reset pressure kg/cm2 gauge 43.6 44.1 45.0 41.4Flow capacity (T/Hr) 123.8 178.0 181.0

140.7Material Body - ASTM A216 Gr. WCB

ASTM - A217 WCB4) Electromatic safety valve

on S.H. outlet

Make M/s DRESSER U.S.A.Type of actuator SolenoidNumber One at S.H. outlet

Capacity of valve T/Hr 98.4 (14.7%)Set pressure (Kg/cm2) gauge 160.0

156.8

7

5) Drum level Gauges

Make Yarway or equivalent.Type and No. 1.Direct gauge (colour

portgauge) - 3 Nos.

ii. Remote manometer - 1No.iii Remote hydrastep - 2 Nos.

Location i. Two on one side, one on other

sideii Fire Man's flooriii U.C.B.

Size 475 MM (MIN) visibilityFlow meters for ST flow, FW flow, Oil flowmaterial of flow meters SS SSNozzle/ Orifice plate Nozzle Nozzle Areameter.

1. 2 ROTARY AIR HEATER

A. ROTARY TYPE AIR HEATER

i) No. per boiler/size 2 Nos. / 27Vt (T) 80'' (720)ii) Max. opn. temp 0C 365iii)Max. air leakage % 9.3iv)Bearings guide and support Radial/SPH Roller

thrustv) Rotor

a) Effective heating 19000 M2 (per heater) surfaceb) Gas flow area M2 23.9

c) Air flow area M2 21.6d) Size of electric 11.0 motor (KW)e) Speed of motor RPM 1500f) Size of Air motor (HP) 5.0

g) Speed of air heater RPM 1.42

8

vi) Elements

a) Length hot end/ 864 / 305 MM

cold end

b) Material hot end/cold Corten 'A'/Corten 'A'

end

c) Total Wt. of elements KG 130000 kg/ heater

vii) Material - shaft Carbon steel

Material - Seals Corten steel 'A'

B. STEAM COIL AIR HEATERS(NOT In Use)

Air temp inlet/outlet 0C 30/100

Air/steam flow (MM3/sec. 57/13000

kg/hr

Steam pr/temp. 13.0 kg/cm2, 2100C

Material Corten steel

1.3 SOOT BLOWERS

Type LRSB, Wall/deslagger

Steam/Pr/Temp. (Design) 42.0kg/cm2(g), 3300C

Source LTSH Outlet header

Total operation time per group LRSBs - 212.16 Min.

Wall - 84 Min.

Swivel - 45 Min.

Power supply 415 V, 3 phase,

50 cps, 2.5 KVA

a) Wall soot blowers

No. of 56

Travel MM 305

Material ASTMA A 447Blowing pressure 11.0 kg/cm2

9b) (SH and RH) / Eco soot blowers

Nos. of 22/2Travel (Total) 7200 mmTravel (Dead) 350 mmMaterial ASTM A - 447Blowing pressure 9.0 and 12.0 kg/cm2

c) AH Soot blowers

No. of Two/heatermat. of head ASTM A48/CI 3C - Cast IronBlowing press. 15 kg/cm2 - Normal

13 kg/cm2 - during starting.

1.4 PRESSURE REDUCING AND DESUPERHEATING STATION

a) Pr. PRD valves OneFlow cap. of each valve T/hr 55Type of actuator Electro hydraulicBody/trim material Alloy steel/11% Cr.

steelBody design pres/Temp. 161/540

b) Desuper heaters Direct spray typeFlow capacity T/hr 70Design Temp. 0C 490Desup. water Press 200 kg/cm2

Temp. 1660C Quantity 15.0 T.H.

E. BLOW DOWN VESSEL Unit Flash tank Blowdown vessel

Design code I.S. 2825 IS 2825Material I.S. 2062 IS 2062Shell Dia/ Height MM 1496/1980 1498 / 1980Operating press/Temp.kg/cm2/0C Vacuum/206 1.5/200

F. FUEL PREPARATION AND FIRING SYSTEM1. COAL

a) Bunker shut off gate Motor operated, 2.5 KW motor.Material IS 226/IS 2062

10b) R.C. Feeder gravimeric type

Max. Capacity (T/HR) 45.0Output control PIV

C) Pulverisers XRP 803, 6 Nos.Overall Dimensions 3600 x 5700 Height.Design Cap (T/HR) 41.3 (58HGI). M 12 %Size of coal inlet/ outlet 25 mm/70%

Through 200 MeshTotal Wt. Of Mill ( Tonnes) 75.0

d) Grinding Rings and Rolls Comb Alloy/NIHARDPyrite/ plough Manganese steel

e) Life of rolls/Grinding 3500 to 4000/7000 to 8000Rings (Hour)

f) Mill fuel piping material IS : 226pipes/Bends. IS : 4896 Gr. IIMax. Vel of Gas 25 m/sec.

g) Coal Bumers Four x 6 ElevationsTip- AISI 304 SSCoal nozzle - ASTM A 536Ductile Iron casing.

1.5 FUELOIL / OIL FIRING SYSTEMa) Fuel Oil pumps +ve displ. Screw - Type

steam jacketed.Capacity/ Discharge 23.4 m3/hr/30 kg/ cm2

Pump speed RPM 1450Min/Max. absolute visc. 21/ 1000 centipoiseof oilMin. NPSH Reg. (M) 0.5

Material

Casting Carbon steel Fab. Body.Shaft and impellers Nitrided Steel

b) Fuel oil heatersType/ No. U- tube/ one per boiler.Capacity (kg/hr) atTemp oC 24000 at 110oCHeat transfer surface area 45 m2

11

c) Filter 50 Microm Mesh, Press. drop

Basket type-two nos. 0.5 (at 75 % clear)

d) Oil Burners

Type/ No/ Elevation Steam Atomised/12/3

Capacity (kg/hr) Press. 1250/13.2

kg./cm2

Oil visc. at Burner tip 12.5 to 16.0 centipoise.

Max. turn down ratio 3:1

Burner Body/ Tip material Carbon steel / H.S.S.

e) Ignitors.

Type and Model Non- RET, H.S.D.

EDDY Plate.Heat input/ Ignitor 0.5 millions Kcl/hr.

12

1.6 F.D. FAN Type & Size Axial ReactionType API 18/11Orientation HorizontalMedium Handled Atmospheric AirLocation Ground LevelNo. per boiler 2

1. FAN DESIGN RATINGCapacity 105 m3 / sec.Total Head developed 510 mmwcTemp. of Medium 50oCSpec. wt. of medium 1.619 kg/m3

Speed 1480 RPM

2. FAN RESERVEFlow 26.5%Pressure 50%

3. FAN DRIVE COUPLINGMake Rigiflex couplingType form 11 1001

4. DRIVE MOTORMake BHEL, HardwarFrame Size AC 13240 H 41Type Squirrel cage Induction

MotorFan Weight 8570 kgs.Rating 750 KW

6600 V, 3 Phase

50 HzSpeed 1480 RPM

5. LUBRICATING EQUIPMENTFan Forced Lud. Oil System

Capacty - 70 LPMMotor Grease Lubricated

6. TYPE OF FAN REGULATION Pitch Control

7. BEARINGSMixed Bearing NU 230 C 3 & 7230 EUAExpansion Bearing N 230

131.7 I.D. FAN

Type and size Axial Impulse Type AN 28 e6Orientation HorizontalMedium Handled Flue GasLocation Ground LevelNo. per boiler 2

1. FAN DESIGN RATINGCapacity 225m3/sec.Total Head developed 358mmwcTemp. of Medium 136 Spec. Wt. of medium 0. 7966 kgSpeed 740 RPM

2. FAN RESERVEFlow 25.7 %Pressure 37.7%

3. FAN DRIVE COUPLINGMake M/S PSGType PPC 180- 200

4. DRIVE MOTORMake BHEL, HardwarFrame size AC 15196 H 8 AType squirrel cage Induction MotorFan Weight 26186 kgsRating 1100 kw

6600 V, 3 Phase50 Hz

Speed 740 RPM

5. LUBRICATING EQUIPMENTFan Grease LubricationMotor Forced Oil Lubrication

System 5 LPM - M/s Prakash6. TYPE OF FAN REGULATION Inlet Guide Vane

Control

14

7. BEARINGSFixed Bearing 22328 C/C 3Expanstion Bearing 222332 C/C 3

1.8 P.A. FAN Type and size Single Suction Radial

Fan - NDFV 22bOrientation Horizontal Bottom DeliveryMedium Handled Atmospheric AirLocation Ground LevelNo. per boiler 2

1. FAN DESIGN RATINGCapacity 75M3 /Sec.Total Head developed 1187 mmwcTemp. of Medium 500CSpec. wt. of medium 1.019 kg/M3

Speed 1480 RPM

2. FAN RESERVEFlow 70.4%Pressure 55%

3. FAN DRIVE COUPLINGMake M/s. PSGType PPC 150 - 160

4. DRIVE MOTOR

Make BHEL, HardwarFrame MC 75288 M4 AIHType Squirrel Cage Induction MotorFan Hetght 9870 Kgs Rating 1250 kw

6600 V,3 phase50 Hz

Speed 1480 R. P.M.

155. LUBRICATING EQUIPMENTS

Fan Forced Lub. Oil System-5 LPMMotor Grease LubricatedType of Fan Regulation Inlet Guide Vane Control

6. BEARINGSFixed Bearing Nu 332 C3 & 7234 BUAExpansion Bearing N 234 C 3

OIL CIRCULATION SYSTEM OF P.A. FAN1. Tank

The oil tank is 100 litres capacity,which has the followingaccessories :a) Oil level indicatorb) Oil drain valvec) Sight glassd) Air breather cum oil fillere) Cleaning door opening

2. Motora) Manufacturer Crompton Greavesb) Type and frame TEPC- AM 80 N4c) Output rating 1 HP - Continuousd) Supply 415 Volts,1.8 Amps;

50 Hz, 3 phasee) full load speed 1400 rpmf) Insulation Class `B`g) Power factor 0.80h) Efficiency 73%I) Bearing Ball bearing NDE 6204Z

DE: B/B 2 OF 002 z3. Pump

a) Manufacturer Delta Corporation , Bombayb) Type & Capacity Trochoidal pump ( 5 Ipm)c) Operating pr. 7 kg/cm2 (gauge)d) Relief valve Built ine) Speed 1400 rpmf) Ports 2 ' BSPg) Casing material C. I. Close grainh) Shaft EN- 8i) Seal Oil Sealj Hydraulic Test Pressure 10 ata

16

1.9 ELECTRO STATIC PRECIPITATORS. No. Technical Data Stage-I

1. Gas flow rate (m3/s) 358.42. APH outlet temperature 1360

3. Dust concentration (gm/Nm3) 59.024. Precipitator type 2FAA -7 x

3211190-25. No. of precipitators per boiler 26. No. of gas paths per boiler 47. No. of fields in series in each gas pass 78. Efficiency 99.49 %9. Pressure drop across the precipitator 15

(in mm wc)10. Velocity of gas at electrode zone on 0.869

total area (m/s)11. Treatment time in seconds 24.97512. No. of rows of collecting electrodes per field 3813. No. of collecting plates per field 30414. total number of collecting plates per boiler 851215. Nominal height of collecting plates in meters 916. Nominal length of the collecting plate (mm) 40017. Specific collecting area (m2/m3/s) 166.518. Type of emitting electrodes Spiral with

hook

19. Size (diameter in mm) 2.720. No. of electrodes in frame forming one row 32

21. No. of electrodes in each field 118422. Total number of electrodes per boiler 3315223. Total length of electrodes per field (m) 682024. Plate to wire spacing (mm) 15025. Rapper size (collecting) in Kg. 4.926. Rapper size (emitting) in Kg. 3.027. Rapping frequency (collecting) in 12 to 1

raps/hr

17

S. No. Technical DataStage-I

28. Rapping frequency (emitting) in raps/hr 1029. Type of hopper Pyramidal30. No. of hoppers 5631. Capacity of hopper 8 hour storage

32. No. of collecting rapping mechanisms 28per boiler (CRM)

33. No. of emitting rapping mechanisms per 28boiler (ERM)

34. No. of gas distribution rapping Nilrechanisms per boiler (GDRM)

Details of Rapping mechanisms :

Statge - I CRM and ERM

Make PBL Type 73B-32.1 KD71 K4Power 0.26 KW Output speed 1.1 rpmCurrent 0.76 A S. No. 19153

18

1.10 MILL AND BURNER PERFORMANCE--------------------------------------------------------------------------------------

Description Units MCR NCR Cont. HP Heater

Load out ofMW 210 200 120

service 200-----------------------------------------------------------------------------------------

No. of burners in 16 16 12 16

operation

Burner tilt Digree -0- +5 +20 -0

No. of mills in

operation - 4 4 3 4

Mill loading % 88 80 73 83

Air flow per Mill t/h 59.33 59.33 59.33 59.30

Air temp. at mill inlet oC 260 240 220 240

Mill outlet temp. 0C 77 77 77 77

Fineness % thru

00 mesh 70 70 70 70

19

PERFORMANCE DATA (OIL BURNERS, IGNITORS)

Haavy Fuel oil Furners

i. Service - Ignition of coal fuel;

stabilisation of coal

flame at low loads.

Turbine synchronisation.

ii Type

a. Burner - Tilting tangential

corner fired

b. Oil gun - Concentric type-auto

retractable

c. Atomiser - External mix, constant

Pressure steam atomised

d. Air nozzie - Square to round;

500 mm outlet

e. Diffuser - 321 mm; 10 off 450 vanes

with leading edge.

iii. Oil gun Assembly - k = 2287.5 mm.

Dlmension

vi. Atomiser designation - I9

v. Atomiser spray angle - 900

vi. Fuel - Fuel oil to IS1593 : 1971

Grade LV -MV- HV

vii. Capacity-Maximum - 7.5 % MCR heat input

on 4 guns 15 % MCR

heat input on 12 guns

viii. Number off - 12 ( 4 per elevation )

ix. Location - Auxiliary air Nozzles

AB, CD & EF

20DATA CHART

------------------------------------------------------------------------------ Max Rating Design Rating-----------------------------------------------------------------------------a. HFO flow per

kg/ hr 1250 600b. HFO Pressure kg/cm2 (g) 13.2 5.2c. Atomising steam

flow per gun kg/hr 162 184d. Atomising steam

pressure kg/cm2 (g) 8.75 Constant at all loads------------------------------------------------------------------------------------xi. HFO burner turn down 3 to 1 approx.xii. Minimum allowable atomising 4.5 kg/cm2 (g) at the

gunsteam pr.

xiii. Steam quality 10- 15 oc superheatedxiv. Cumbustion requirement Refer secondary air control

system

NOTE

- Pressure are measured at the oil gun connection.- Design firing rate is the minimum energy required for coal

fuel ignition and coal flame stabilisation.

- Maximum firing rate normally based on turbine synchronisation

requirements.

IGNITORS

i. service Oil burner light offii. Typea. Basic 150 mm side Eddy plate

ignitorb.. Pilot Bumer Light fuel oil, air atomisedc. Spark plug Corona type

d. Monitoring Ionic Flame Monitoring

21

iii. Assembly dimension Ignitor Horn mounting dimension = 273 mm Horn

exit to wind box casing face x=584 mm.

iv. Fuel LDO to IS 1460 /1974v. Capacity 0.5 million kcal/hr/Ign.vi. No. off 12 ( 4 per elevation)vii. Location On front & rear walls adjacent

to oil burners at elevation AB,CD & EF

viii. Data chart

-----------------------------------------------------------------------------------While While notfiring firing

-----------------------------------------------------------------------------------a. Oil flow per ignitor kg/hr 50 0b. Oil pressure kg/cm2 (g) 12.5 -14 -c. Atomising air flow

perigniter Nm3 /hr 14.5 1.6 d. Atomising air pressure

kg/cm2 (g) 5.5-7.0 5.5-7.0

e. Combustion air flowper ignitor Nm3 /hr 560 720

f. Combustion air pressure( Ignitor wind-box to furnaceDifferential ) mm wc 75 75

----------------------------------------------------------------------------------ix. Ignitor turndown Nil x. Atomising air quality Service air, water free

NOTEThe oil and atomising air pressure are measured at the ignitor

controlcabinet inletHeavy Fuel oil Specificationi. Service Oil Burnersii. Standard IS 1593 / 1971

Grades LV-MV-HViii. Flash point -

minimum ( lensky- martenssed cup ) 66 0C

22

iv. Viscosity maximum 80-120-370 CST at 500C

v. Total sulphur - maximum 3.5-4.5% by weight

vi. API gravity (Typical) 12, Specific gravity

0.986 at 15 oc

vii. Gross heating 10270 Kcal/kg

value ( typical)

Light Fuel oil (LFO) Specification

i. Service Ignitors

ii. Standard Is 1460 /1974, High Speed

Diesel oil (HSD) Grade

iii. Pourpoint - Maximum 6 0C

iv. Flashpoint Minimum ( Abel) 38 0C

v. Viscosity maximum 2.0-7 .5 at 38 0C

vi. Carbon residue

maximum (Rams bottom) 1.5 % by mass

vii. Total Sulphur-max 1.5 % by mass

viii API gravity (typical ) 35, specific gravity

0.85 at 15 oc

ix Gross heating 10720 Kcal/kg.

value ( Typical)

23

1.11 BOILER PARAMETERS (1) FLOW t/hr--------------------------------------------------------------------------------------Description MCR NCR Cont. HP Heater

Load out of 200 120 service MW MW 200 MW

--------------------------------------------------------------------------------------

1. Steam

Superhater outlet 670.0 603.7 402.0 547.0

Reheater outlet 598.2 537.7 363.7 540.6

2. Water

Feed Water 670 600.7 394.8 519.7

Spray - 3.0 7.2 27.3

3. Air

Airheater outlet 79.9 167.3 121.5 193.4

( primary) Tempering air 57.4 70.0 56.5 43.9

Airheater outlet 611.4 533.7 371.8 557.1

(Secondary)

Total combustion air 870.5 792.9 571.7

816.2

4. Fuel

Coal 144.4 131.6 90.4 135.4

24

TEMPERATURE (OC)

Description MCR NCR Cont. HP HeaterLoad out of

200 120 service MW MW 200 MW

1. STEAM

Saturated temp. 349 384 344 346

In drum

LTSH Outlet 426 421 417 435

SH platen outlet 520 520 523 518

SH outlet 540 540 540 540

RH Inlet 344 339 328 345

RH Outlet 540 540 540 540

2. WATER

Economiser inlet 243 241 223 164

Economiser Outlet 286 284 270 234

3. AIR

Ambient 50 50 50 50

Airheater Outlet 325 318 297 282

(Primary)

Airheater outlet 318 313 294 277

(secondary)

4. GAS

SH Platen inlet 1135 1132 1080 1129

RH Front inlet

(Furncace exit) 1024 1025 945 1008

RH rear inlet 922 917 837 907

finish SH inlet 758 750 682 747

Finish SH outlet 727 718 658 716

LTSH Inlet 671 661 603 660

Eco. Inlet 470 462 433 467

AH Inlet 354 343 312 307

AH outlet (corrected) 136 134 124 121

25PRESSURE & DRAFTS (AIR & GAS) mmwc



1. Primary Air

PA Fan outlet 745 713 673 738AH inlet 715 686 656 705AH outlet 665 643 632 651 Mill inlet 650 630 625 636Mill outlet 244 224 220 230

2. Secondary Air

FD fan outlet 331 285 214 300SCAH inlet 317 275 209 287SCAH outlet 292 257 200 262

Air Heater inlet 291 256 199 261Air Heater outlet 171 163 151 165Aerofoil inlet 159 154 147 156Windbox to fur. diff. 100 100 100 100

3. Gas (mmwc)SH Platen inlet -4 -4 -4 -4RH inlet -5 -5 -4.5 -5Finish SH inlet -9 -8 -6 -9LTSH inlet -14 -12 -8 -13Eco. inlet -28 .24 .15 -25AH inlet -50 -43 -24 -45E.P. inlet -179 -151 -84 -154ID Fan inlet -227 -194 -113 -185 (incl. static head)

Fan delivery head +33 +27 +14 +29

26PRESSURES ( STEAM & WATER) (kg/cm2 (g)



1. PressureSH outlet 155.00 154.00 151.00 152.7LTSH outlet 161.9 159.8 153.7 158.7Drum 166.1 163.2 155.3 161.6Eco. Intet 170.2 166.9 158.1 165RH outlet 37.19 34.85 22.54 37.36RH inlet 38.69 36.2 23.54 37.36

2. Pressure DropSH system 11.1 9.15 4.3 8.86RH system 1.5 1.35 1.0 1.3Eco. system 2.16 1.8 0.85 1.45(Friction p only)

HEAT BALANCE Unit : %

Dry gas loss 3.60 3.65 2.84 2.04H

20 & H

2 in fuel 5.53 5.50 5.45 5.44

lossH

20 in air loss 0.34 0.35 0.31 0.29

Carbon loss 2.00 2.00 2.00 2.00Radiation loss 0.20 0.20 0.22 0.20

Unaccounted and Mfg.Margin loss 0.80 0.80 0.80 0.80Total losses 12.47 12.5 11.62 11.67Efficiency 87.53 87.5 88.38 88.33

Guaranteed efficiency 87.5 %

270

2 CO

2 ( Dry Vol) AND EXCESS AIR



Oxygen in gas at % 3.87 3.87 4.69 4.3Eco. outlet (by dry Vol)Oxyen in gas at AHoutlet ( by dry vol ) % 5.56 5.58 6.88 6.01Max. leakage of airacross AH % 8.13 8.8 11.5 8.6Total air to gas 77.3 76.2 71.4 76.6

leakege T/hr 77.3 76.2 71.4 76.6Carbon-di- oxide in gas at Eco. 14. 94 14.94 14.22 14.59outlet (by dry vol.) %Excess air in gas at Eco.outlet % 22 22 28 25

FUEL

The fuel data on which the guarantees given are as follows:-----------------------------------------------------------------------------------------

Description Units Valve Remarks-----------------------------------------------------------------------------------------

Fuel - CoalFixed carbn. % 26Volatile matter % 18Moisture % 12Ash % 44Grindability Hard Groove Index 58Higher heating value Kcal/kg 3500Size of coal to mill mm 25

28

1.12 CHEMICAL CONTROL LIMITS (WATER/STEAM CYCLE)

Parameters 200 MW (StageI) 500 mW (Stage II)Cond. Feed Boiler Steam Cond. Feed Boiler Steam

pH at 250C 8.8- 8.8- 9.2- 8.8- 9.0- 9.0- 9.1- 9.0 -9.0 9.0 9.4 9.0 9.2 9.2 9.4 9.2

Sp. 30.0 20.0 Conductivity /cm

Cation Cond. <0.3 <0.3 <0.3 <0.2 <0.2 <0.2 /cm

Res. Hydrazine .010- .010- as N

2H

4 ppm .020 .020

Ammonia as 0.5 0.5 1.0 1.0 NH

3 ppm (Max) (Max) (Max) (Max)

Phosphate as 2-4 1-2 PO4 ppm

Silica as SiO2 <.02 <.02 0.3 <.02 <.01 <.01 0.1 <.01 ppm Max.

Total Iron as Fe .010 .010 .010 .010 .010 .010 ppm MaX.

Total copper as .005 .005 .005 .003 .003 .003 Cu ppm

Chloride as Cl 1.0 0.5 ppm Max.

D.O. as 02, .040 .005 .040 .005 ppm Max.

Sodium as Na, .005 .005 ppm Max

TDS (mg/1) 15 10 Ppm

29

parameters StageI StageII

W/O Alkaliser With

AlkaliserGENERATOR STATOR COOLING

WATERPH at 250C 6.8-7.0 (6.5-7.0) 6.8-7.0 8.5-

9.0

(Lab)

Cond. at 250C 5 <1.0 <2.2

us/cm

D.O. (mg/1) >1.0 <0.1 <0.1

GENERATOR SYSTEMHydrogen Purity >97.0 >97.0

(%)

Dew Point (0C) at <21.0(3.0kg/cm2) <24.0 (4.0kg/cm2)

frame pressure

ECW pH at 250C

(Controlled by 9.0-9.5

dosing Caustic

Solution)

1.13 RECOMMENDED LIMIT OF SILICA IN BOILER WATER AT pH 9.5 AT

DIFFERENT OPERATING PRESSURE TO LIMIT SILICA 0.02 PPM IN

STEAM

DRUM SiO2 ppm DRUM SiO

2 ppm

PRESSURE PRESSURE

60 8.2 150 0.40

80 3.8 155 0.37

100 1.9 160 0.30

120 0.9 165 0.27-For Stage I

130 0.7 170 0.25

140 0.52 175 0.22145 0.48 180 0.18 - For Stage II

30

II

TURBINE

& AUXILARIES

31

II. MAIN TURBINE

2.1 TECHNICAL SPECIFICATIONS1. Steam Turbine

A) Make KRAFTWERK UNION, WEST GERMANY

Type Three cylinder, reheat, condensing turbine

Stages H.P. 25 nos. I.P. 20 x 2 Nos. L.P. 8 x2 Nos.

Nominal rating 210 NW

Peak loading 229 MW

Rated speed 50.05 -1

Max. / min. speed 51.55 -1 47.55 -1 (No time limit )

Speed exclusion range 11.675-1 to 47.55 -1

This speed range should be passed through in one smooth

operation to avoid endangering the blades due to resonance

B) Steam pressures and temperatures (Rated values )

pressure (b) Temp. 0C

H.P. stop valve inlet 147.1 535

H.P. cylinder exhaust 39.23 334

I.P. stop valve inlet 34.13 535

Extraction 6 39.23 343

Extraction. 5 16.75 433

Exteaction 4 7.06 316




L.P. cylinder exhaust 0.1187 49

32

C) Casing temperatures: 0C

Wall temperatures Alarm at M/c must be-------------------------- ------------- shut down atH.P. turbine casingexhaust 480 500Outer casing of LPcylinder 90 110NOTESpray water to L.P. turbine must be switched on at 90 oC

D) Differential Expansion Alarm Trip

1. H.P. Turbine diff. +4.50 +5.50Expn. -2.50 - 3.50

2. I.P. Turbine Diff. + 5.00 +6.00-2.00 -3.00

3. L.P. Turbine diff. + 25.00 +30.00Expn. - 5.00 - 7.00

E) Temperature differences C: (Between upper and lower casing section )

Alarm at M/c must beshut down at

H.P. turbine middle + 30 + 45I.P. turbine front + 30 + 45I.P. turbine rear + 30 + 45

F) Bearing temperature Alarm at M/c must beshut down at

Normal opn. temp.below750C. 900C 120 0C

G) Vibration (absolute Of bearing Of shaftvibration) housingNominal value for alarm 35 microns 30 microns

above normal level

33

B) Megawat output (Approx)

55.40 53.73 93.03

(28%) (26%) (46%)

C) Bearings

No. 1 Journal, 280 x 140 mm

No. 2 Redial cum thrust, tilting pad,

290 x 240 mm




lining material for all bearings : Babbit

D) Turbine cloorances (MM) :

1) Min. axial cold cloorance

axcluding thrust booring 3.4

2) Position of min. oxial cold I.P. glades (-) 2.4

clearance

3) Axial Clooorance at stage - 1 15.0 (I. P.) shaft

shroud (cold)

4. Radial clearance at rotor 0.4 (I. P.)

glands 0.5 (I. P.)

0.5 (I.P.)

5.) Min. radial clearance at

shroud ................... I. S. (L.P.)

E) Materals of construction

1) Turbine casing

H. P. turbine shell GS - 17 Cr. Mo

VS 11

l. P. turbine casing GS - 22 Mo-4

L . P. turbine casing St. 37 - 2

34

N) Barring Gear

Type of drive Hydraulic turbine

Method of engagement Hydraulic

Power to rotate turbine 45 KW.

Cutin/ Cutout speed 250/200 r.p.m.

NOTE

Turbine can be put on barring only when turbine is jacked up

In the bearins.

O) Steam purity (WU recommended values)

Conductivity at 250C, alkalina o.15 s/cm.

method, and by direct mesurment

01. Sillecic Acid (Sio2) < 0.010 mg/kg

Total Iron (to) and Sodium (Na) < 0.005 mg/kg each

Total copper (Cu) < 0.0001 mg/kg

02. A) Dimensions : (In mm)

HP IP LP

Turbine Turbine Turbine

Height of 1st stage moving

vlade 43 66 75.5

Mean Dia. of 1st stage

moving blade 634 756 1473.5

Height of last stage moving

blade 95 100 558.1

Steam dia of last stage moving

blade 695 1041 2144.1

blade root T T T

(Axial IIr-troo

two stages)

Total exhaust area (L.P. turbine) 2 x 5 M2

35

Press Limiting valve in - 120 ata.

jacking oil system

Oil pumps M.O.P. A.O.P. (D.C.) J. O. P.

E. O. P.

Nos. 1 2 1 2

Make K.W.U. KSB KSB Allweller

Capacity (Rated) L/S 139 78 30 1.26

Discharge press. 8.2 6.8 2.3 120

(Rated ) atg.

Speed r.p. m. 3000 1480 1460 2980

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

motor motor motor.

Make Siemens SiemensSiemens

Enclosure I.P. 44 I. P. 44 I. P. 44

Voltage V 415 220 415

Frequency Hz 50 - 50

Motor powe kw 90 11 27.6

Rated current A 154 53 49

Oil Cooler type 280 x 20 (Design dats for one cooler)

Cooling surface/oil flow 280 m2, 27 L/s

Oil Inlet/outlet temp. 65/450c

Oil press. drop o.4 ats.

Cooling water Inlet/ 36/39 0c.

Outlet temp. Oc.

Tube material Cuzn 28 Sn F 38

Max. value for alarm - 120 microns

Limit value for 45 microns 200 microns

tripping

36

H) Moments of Inertis (Kg m2)

Rotor of H. P. cylinder - 316.94

Rotor of I. P. cylinder - 1155.59

Rotor of L. P. Cylinder - 9794.13

Weights (Tonnes) H.P. I.P. I.P.

Turbine Turbine Turbine

Rotor 7.5 15.8 48.0

Cylinder assembled 56.0 37.0 81.0

(with steam Insets)

Low vacum trip settings

Hydraulic low vacum trip >0.3 ata.

Electrical low vacum trip >0.3 ata.

Hydroulic low vaccum trip >0.6 ata.

(bypass oppration)

Oil Supply

Oil tank rated capacity :

Highest/ lowest oil level from

top of tank - 800/850 = at 3000 rpm.

Lub. oil temp at cooler

outlet - 380C (min), 450C (normal)

470C (Max.)

Oil temp. rise across - 200C (normal), 250C (Max.)

bearings

Safety valve in jacking oil - 200 ata (max.)/180 ata (min.)

system

37

2) BLADES: First stage Laststage

H.P. moving and stationaryblade. x22 Cr Mo V121 x20 Cr 13I.P. moving and stationaryblades x22 Cr Mo V121 x20 Cr 13L.P. moving blades x20 Cr 13 x20 Cr13L.P. stationary blades x20 Cr 13 20 Mn5

x20 Cr Mo 13 x7CrA1133) SHAFTS

H.P. rotor 28 Cr. Mo Ni V 59I.P rotor 30 Cr Mo Ni V 511L.P. rotor 26Cr. Mo Ni V 115

2.2 CONDENSER, EJECTOR, DRAIN COOLER

A) Condenser

Type Surface type. single passDasign c.w. inlet temp. 330CC.W. flow 28570 M3 /HrC.W. temp. rise 8.29 0CC.W. press. drop. 3.4 MWCCondenser back pressure 73.2 mm Hg at 200 Mw loadTerminal temperature 4.8 0CdifferenceOxygen at hotwell outlet 0.02 cm2/LNo. of tubes 17492 totalTube O.D. x thichiness 19 x 1 mmTube length 9900mmTube material 90/10 Cu - Ni

b) AIR ELECTORSType Priming Starting Main

Nos. 1 2 2

Working steam

press kg/ cm2 (g) 3.5 -6.5 6.5 6.5

Working Steam temp. 0C 210 210 210

Working steam quantity

38kg/hr 1100 3300 1000Air relieving in capacitykg/hr 220nm2/hr 700 60

C) Gland steam condenserMax. Min. condensate flow T/hr 108/550Tube material and Nos. SS, 313 Nos.Water velocity M/s 1.95Vent fans 2 Nos. centrifugal

D) Drain coolersDesign condition 200 MW load, 33o CW

inlet temp.Condensate inlet temp. 47.80CCondensate outlet temp. 48.5 0CTube O.D.X Thick x Length 16x 1x 15400 mm

Tube material Admiralty brass

2.3 Low pressure heaters Description LPH -1 LPH-2 LPH-3

Condensate inlet/outlet

temp. OC 48.5/55.5 55.5/88.8,88.8/118.7

Steam inlet press.ata 0.1953 0.7049 2.1283

Steam inlet temp.oc 0.83 104.5 196.1

Drip inlet temp oc 91.8 121.6

Terminal temp.oc 3.6 3.0 2.9

difference

Press. drop across tubes

MWC 8.5 7.8 -

Shell/Tube side safety valve

set press ------- 7/24kg/cm2 g----------

Extraction steam turbine stage 3 LP 5 LP 7 LP

39

No. of water passes 4 4 4Tube O.D. x Thickness mm 16x1 16x1 16x1Material of tubes ---------- Admiralty

Brass-----

2.4 Deaerator Type Horizontal spray cum Tray type

Design capacity 783.1 MT/hrSteam required at 5.44kg/cm2 (g) and

314.5oc.Condensate temp. outlet 1610C

Deaerator Feed tankOperating/Design presskg/cm2 (g) 5.44/7.5 5.44/7.5Operating/Design temp. oc 161/350 161/170Storage capacity at 2/3 - 123

Dia. M3

I.D. x Th. x length 2000/14 /9812 3340/16 20826

mm x mm x mmSpray system nozzles 50 Nos. NW 50 sizePressure drop across 0.5 kg/cm2 (g.)nozzleNo. of tray sub. assemblies 264Materials: Trays SS 304 Shell IS 2002 gr. 2A

2.5 High pressure heaters DescriptionH.P.H - 5 H.P.H - 6

Feed water inlet/outlettemp. oc 164.2 /197.8 197.8/240.9Steam inlet pressure ata. 16.1 36.56Enthalpy of extraction steam 794.1 733.6K. cal/kgQty. of extraction steam 33.4 58T/ HrFeed water inlet pressure ata 190 189.3Effective surface area M

2581.6 662

Size of tubes 15.8 mm x15 BWG

No. of U - tubes 804 804Shell O.D. x Th x 1232x 16 x

1280x40 xHeight mm 9665 10765Material of shell DIN 17155 HII Carbon steel

Material of tubes Carbon steel

SA 556 Gr. C2

402.6 BOILER FEED PUMPA. Booster pump

1. Manufacturer Wier pumps Ltd.2. Type FAI F563. Direction of rotation A.C.W. (from

D.E.)Design Duty

4. S.G. at suction temp. .904 .9065. Suction temp. oc 163 1616. Suction pressure kg/cm2 7.263 7.077. Discharge pressure kg/cm2 15.118 16.028. Differential pressure 7.118 7.95

9. Differential head m 87 8810. NPSH above impeller eye m 16.85 16.011. Flow rate m 3 /h 381.6 346.212. Leak-off flow, m3/h 95.4 -13. Efficiency % 78 75.514. Speed RPM 1485 -15. Power kw 104.5 99.416. Thrust bearing The Glacier Metal Co. Ltd.

Type - Double Thrust, CK range.

Size - 8112/2kp -2kp17. Mechanical seal Crane packing Limited

Type - T 109 B with `SC` seat

18. Motor/ pump flexible Torsifilex Limited,coupling Type - OHBS 120 x

B. FEED PUMP1. Manufacturer Weir pumps Limited2. Type FK 8D 303. No. of stages Eight4. Direction of rotation A.C.W. (From D.E.)

Design Duty5. S.G. suction temp 0.904 0.9066. Suction temp. oc 163 1617. Suction press. kg/cm2 14.42 15.328. Discharge press. kg/cm2 212.66 188.869. Differential press. kg/cm2 198.24 173.54

41

10. Differential head m 2196.81918.911. NPSH above impeller eye m 96.8 101.712. Flow rate, m3 /h 381.6 346. 213. Leak -off m3 /h 95.4 -14. Efficiency % 81.0 -15. Speed RPM 4750 -16. Power KW 2542 201817.Thrust bearing The Glacier Metal Co.Limited

Type - Double thrust CK range.Size - 8154 /2KP- 2KP.

18. Mechanical seal Crane packing Limited

Type : 003/ Vg RH / 13/ S 66981

19. Turbo coupling / pump Torsiflex Limited, flexible coupling Type: HBS 1250 - 8x20. Motor/ Turbo coupling Torsiflex Limited

Flexible coupling Type:HBS 3600 -8

C. DRIVE MOTOR FOR B.F.P.1. Manufacturer BHEL2. Type Squirrel cage induction

AC 28380 AAW3. Output 3500 KW4. Current 361 amps5. Supply 6600 V, 3 ph, 50 Hz6. Power Factor 0.8 7. Efficiency 95.5 %8. Speed 1485 r.p.m.9. Insulation Class F10. Type of cooling CACW

D. HYDRAULIC TURBO COUPLING1. Manufacturer Voith Turbo GMBH and Co.2. Type R 16 K3. Rating KW 27374. Speed r.p.M. 1485 ( Input), 4750 (output)5. Slip % 3.9

6. Step up gear unit 1:3.3

42

2.7 CONDENSATE EXTRACTION PUMPA. PUMP

1) Manufacturer KSB, West Germany2) Type WKTA 200/4, Vertical

cam type 4 stage centrifugal

pump3) No. of stages Four4) Speed 1480 r.p.m

5) No. of pumps / unit 2 x 100 %Duty Overload

6) Discharge capacitym3 /hr 610 710

7) Head m 190 1708) Power KW 402 4299) Density of medium 0.9922 0.9922

Pumped T/M 3

10) Temp.of medium OC 40 40

B. Motor1) Make BHEL2) Type 3Ph, Ind Motor AVC 12156

H43) Power 470 K W4) Supply 6600 V, 3 ph, 50 Hz.

0.87 p.f.5) Current 51 Amps.6) speed 1483 r.p. m.7) Insulation Class F.8) Lubrication Servogem 2 (Grease )9) Bearing Roller Bearing,

NU 326 (D.E.)Angular contact Ball

Bearing 1322 B (NDE).

43

III OFF SITE AUXILIARIES

44

3.1. FUEL OIL SYSTEM HEAVY FUEL OIL HANDLING

a) Unloading Header1. Nos. One, steam traced2. Length 292 M.3. Diameter (Nb) 400 mm4. Capacity 40x2 wagons can be con

nected for unloading at a time.

5. Wagon heating 2 steam headers for heating each wagon.

B) Unloading pumps1. Make M/s Borneman

W- Germany2. No. Five (3 running +2 standby )3. Type Double -screw, steam &

jacketed.4. Capacity 100 m3/hr.5. Discharge press 4 bars6. Viscosity of oil 100 to 500 cst.

handled7. Power required at 29 kw.

design point8. Motor type 37 kw, 415V, 65 amps.

1480 rpm.9. Motor rating 3 ph, flame proof,

induction motor.10. Type of strainers Duplex strainer at suction to

each pump.c) H.F.O. Storage tanks

1. No. of 32. Capacity 2500 M3 each.3. dia x height 20 m x8.6 m.4. Heating system i) Coil surface Steam at 4 ata, 190 0C, Heater Fourcoils,(two

pneumatically controlled and two manually controlled)

5. ii) Suction heater Steam at 4 ata, 190 0CPneumatically

controlled

45D) H. F. O. Pressuring pump

1. Type/make Tripple screw type,Bornemann.

2. Nos. off 33. Capacity 430 Litres / Min at 370 cst.4. Suction & Discharge (-) 0.4 kg/cm2 (g) & 29 kg /

press cm2 (g)5. Speed 14506. power required 32.0 kw at 370 cst.7. Drive motor Kirloskar make (E 250)

8. Motor rating 50 kw, 415V, 3ph, 50Hz.

HIGH SPEED DIESEL HANDLINGA) HSD Storage Tank

1. Capacity 20 m3 x3 Nos.2. Diameter /length 2.5 m x 4.5 M.3. Installation Underground

B) H.S.D.pumps1) Type/make Tripple screw type/ Borne

Mann2) Nos off 23) Capacity at min/ max viscosity 130 /168 Litres / min.4) Suction & discharge (-) 0.4 kg/cm2 (g) &

29.5 kg/ press. cm2(g)5) Speed 2920 r.p.m.6) Power required 10 kw.7) Drive motor rating 13 kw. 415 v, 3 ph.

50 Hz.8) Drive motor make Kirloskar (NE 180)

SUPPORT EQUIPMENTSA. Drain Tank

1) Size 4m3 , 2.5 L x 1.5 w x1.5 H metres

2) Heating system Condensate coil heaterB. Drain pump

1) Type Screw type, steam jacketed2) Make Aroto gear pumps, bombay3) Capacity 4 m3 /hr at 50oc oil temp. 4) Discharge press 20 M.L.C.5) Speed 1450 r.p.m.6) Motor 3 kw, 415v, 5.6 amp.

3ph. 50 Hz, 1450 r.p.m.

46

C. Flash Tank1) Size 3.5 M3 , 2.0 x 2.0

metres.2) Insulation Mineral wool wrapped3) Installation Underground.

D. Vertical sump pump1) Type Centrifugal, vertical,

submerged

2) Make Kishor pumps Pvt. Ltd, Pune

3) Rated flow 30 M3/Hr.4) Total head 7 MWC 5) Speed 1450 r.p.m6) Motor H.P. 37) No. Installed Two

3.2 A WATER TREATMENT PLANT1. RAW WATERNos. of pumps 3(2+1)Service Continuous dutyDischarge press. 23.5 MWCCapacity 3600 m3 /hr eachSuction Submerged.Sealing/ cooling/lube SelfPower supply 6.6 KV, 3 ph 50 Hz.Motor enclosure TEFC, IP -54

2. CLARIFIED WATERNos of pumps 4 (3+1)Type Centrifugal, cont serivceCapacity 1000 M3 / HrDischarge press. 76 MWCSealing / cooling / lube SelfPower supply 6.6 KV, 3 ph, 50 HzMotor power 300 KWMotor enclosure TEFC, IP - 54

3. PRETREATMENT PLANT

A. Clarifier- cum FlocculatorNos. and type. Two, Rotating bridge type,

Circular

47

Rated effluent flow 3000 M3 /hrEffluent turbidity Less than 20 NTURetention time at ratedcapacity.(i) floculation zone 30 minutes(ii) Clarifier zone 2 Hrs 30 minutesO.D. at top 58.1 MO.D. clarification zone 57.5 mDia of floculation zone 19 .34M

Agitator speed 5 r.p.m.Bridge revolving speed 0.015 RPM

B. Clarified Water storage tankCapacity 1300 M3

Size

C. Gravity filterNos. 2 R.C.C. ConstructionFlow rate per filter 300 m3 /hrSurface flow rate, 5 M3 / hr/m2 (max.)

D. Filter water Reservoir and transfer pumpsReservoir Capacity 300 M3

Nos. of pumps 4 Nos. verticalCapacity of pumps 120 M3/hr each.

E. Chemical Dosing System

(i) Alum Dosing systemNo. of tanks 6 R.C.C. constructionCapacity 4 Hrs dosing capacityStrength of solution 10%

(ii) Alum dosing pumpsType Plunger type, 4 Nos.Control 0% to 100% automatically

Pneumatic control(iii) Lime slaking tank

Capacity 3.6 M3 each with motor Driver agitator

Nos 2

48

iv) Lime slurry transfer pump

Nos. Two ( one standby )

Capacity 5 M3 / hr

v) Lime solution preparation tank

Capacity Four nos. R.C.C. construction

Strength of solution 6% W/v

vi) Lime solution dosing dosing pump

Capacity 4 Nos. 50% capacity each

plunger type, (+ve )

displacement

Control 0% to 100% automatically

by pneumatic

positioner

vii) Coagulant aid Preparation tank

Nos 2 MSRL of 1.0 M3

capacity each

vii) Coagulant aid dosing pump

Nos. 2 (1 working +1 standby)

Control 0% to 100% manually by

micrometer dial.

F. Chlorination System

Nos. 3 ( one for each clarifier 1

standby

Capacity 15 kg/hr, vacuum type

Type of injector MSRL

Water booster pump 2 Nos. ( One working )

49

3.2 B D.M. PLANT

A. GENERALNo. of streams ThreeNormal flow through 100M3 /hrone streamD.M. water storage tanks 4 Nos. of 1500 M3

eachB. ACTIVATED CARBON FILTER

No.per stream OneDesign flow rate 110 M3/hrDesign surface flow rate 15 M3 /hr m2

Filled with Activated carbonSupporting material Graded GravelShell size 310 Dia x 2500

CYL. HeightMaterial of shell Mild steelInternal painting 3 coats of epoxy

paint.C. CATION EXCHANGER

No. per stream OneDesign flow rate 100 M3 /hrSurface flow rate 20 M3 hr/m2

(max.)Filled with Resin(IR -120 Strongly Acidic)Qty. of resin. 5.85 M3

Regeneration by Hydrochloric acid - 30%Shell size 2400 Dia x 3000 Cyl HeightMaterial of shell Mild steel

D. DEGASSER SYSTEMi) Degasser

Nos 2 Nos. ( Common for 3 streams)

Type Force draft typeNormal flow rate 180 M3/hrFill material Polypropeline ( Rasching

Rings)

50

CO2 content in effluent 5 ppm (max)

Shell material Mild steelRubber lining 4.5 mm thickSize 2600 Dia x 4405 cyl. height

ii) Degassed - water sumpNo. off One per DegasserCapacity 75 M3

installation Horizontal, below the Degasser

size 3200 Dia x 10,000 Cyl.longiii) Air Blowers and pumps

Nos. 3, (2 running, 1 standbyType Centrifugal, outdoor,

continuous duty.pumps 3 Nos. centrifugal,

capacity 100 M3 /hr

E. ANION EXCHANGERNos. of One per stream

Design flow rate 100 M3 /hrSurface flow rate 25 M3 /hr M2 (Max)Shell lining 4.5 mm thick rubber linedMaterial of shell Mild steelSize 2800 Dia x 400 cyl. HeightFilled with Resin ( IRA- 900 - Strongly

basic)Qty of resin 11.40 M3

Regeneration 48% NaOH

F. MIXED BED UNIT Nos off One unit per streamDesign flow 100 m3 /hrSuface flow rate 30 M3 /hr M2 (max.)Material Mild steel, 4.5 mm thich

rubber linedRasin (Amberlite) Cation IR - 120 - 2.65

M3

M/s Rohm & Hass Anion - IRA- 402- 2.80 M3

W Germany (Strongly basic).Size 1950 Dia x 3700 cyl. Height

51G. REGENERATION SYSTEM

i. Storage tanks Acid AlkaliNos 4 4Size Dia x Length 3600x7000 3600x 7000Capacity M3 50 50Lining Rubber RubberConcentration of

Chemical 30% 48%ii) Un loading pumps: Acid Alkali

Nos. 2 2 Type 1 stage centrl. 1 stage centri.Service Intermittent

Intermittent.CapacityM3 /hr 20 20TDH MWC 10 10Fluid handled. 30% HCl 48% NaOH

iii) Transfer cum Recirculation pump ( for Alkali System )Nos. 1 + 1 (standby).Capacity And Head 10M3 /hr at 10 MWC.Suction Flooded suction

(5-50 % caustic lye or slurry)iv) Dosing pumps Acid Alkali

Nos. 2 2Capacity M3/hr 0-3.6 0-2.4TDH MWC 35 40

H. NEUTRALISTION SYSTEMi) Nos.of pits Two RCC, Acid/Alkali

proof brick lined pits.Capacity 300M3 (3.5 m Liquid depth)

ii) Recirculation cum disposal pumpsNos. 2 for each pit.Capacity 150M3/hr at 15 MWC.Duty 2-3 hrs every shifts.

1. D.M. TANKSNos. FourCapacity 1500 M3 each.Size 13000 Dia. 12000 height.Material Mild steel. lined with two

coat of epoxy paint.

52

3.3 M.G.R. AND COAL HANDLING PLANTA. M.G.R. SYSTEM:

1) Capacity of each wagon 32 tonnes.2) Two rakes of 33 wagons each make

total 17 trips per day for 2100 MW.3) Average working hour per day/ idle

time per shift. 18 hrs/ 2hrs.4) Loading time per wagon 40 seconds ( 5500Tph)5) Unloading time per wagon 20 seconds (3Tps)6) Speed at loading /unloading

station. 4 Kmph /8 kmph7) Maximum/average speed 75 Kmph/45 Kmph8) M. G. R. Circuit

B. TRACK HOPPER:1) No. of hoppers One2) Length of hoppers 200 Metres.3) Capacity 3200 tonnes.4) Maximum coal lump size 200 MM.

C. PADDLE FEEDERS:1) No. of feeders 42) Capacity 1000/Tonnes/hour each.3) Dia of paddle feeders wheel 3200 mm4) No. of vanes of feeder 55) Speed of feeder wheel 3.3 to 13 r.p.m.6) Max/min.speed of carriage. 0.06/0.04 M/s.7) Total travel of carriage 210 metres.

D. CRUSHER HOUSE1) No. of crushers Four.2) Type of crushers Ring hammer type.3) Capacity 1000 Tonnes/hour. each.4) Max.coal size at inlet/outlet 200 mm/20 mm5) Motor rating 6.6 KV, 750 KW, 750 r.p.m.6) Belt feeder Four numbers of 1000T /hr

capacity each.7) Vibrating feeders Four numbers of 1000

T/ hrcapacity each.

8) feeder size 2700 x 7200 mm.

53

E. TRIPPER1) Total number 2 ( 3x 200 MW)2) Capacity (each) 2000 T/hr.3) Travel of tri pper 165 M4) Travelling speed 0.3 M/ s.5) Belt speed 3.15 m/s.6) Motor for tripper 2 motors per tripper

5.5 kw, 1000 r.p.m.7) Electrical linear 1No. push pull force = 750

actuator kg stroke = 0 to 400 mm.

3.7 kw motors8) A.C. electro magnetic 2 Nos. drum dia= 250 mm

brake. Torque = 25 kg -m.

F. BUNKER1) Total Nos. 18 ( 6 per unit )2) Max. capacity of each 390 (Bunker+Hopper)

bunker3) Bunker dia/height 7.0 m/ 9.2 m.

G. STACKER/ RECLAIMER1. No. of coal piles in 2 for 1st stage

stock yard 2 for 2nd stage2. Length/ height of each 530m/10m.

pile3. Total stack 4,00,000 Tonnes

yard capacity ( 15days consumption for 2100 MW ).

4. Average capacity of 2000 T/hrreclaimer

5. Length of the boom 28 M6. No. of reclaim hopper 67) No. of vibrating feeder 68) Capacity of each 500 tonnes/ hour

feeder9) Feeder motor rating 11 KW, 440 V, 1500 r.p.m.

54

3. 4. COMPRESSED AIR SYSTEMInstrument air Instrument air Servicecompressor for compressor AirT.G. and S.G. for Aux.

CompressorService

Manufacturer M/s Khosla M/s khosla M/s khosla

Model No. 2 HA 4 Ter T 2 HY2 Bis T 2 HA4 Q

Type of compressor Balanced Opposed Reciprocating

Nos installed 4 2 4

Capacity NM3 /MIN 20 3 25

Discharge press kg/cm2 (g) 8 8 8

Design ambient temp 0C 50 50 50

Design ambient press kg/cm2 0.998 0.998 0.998

Design humidity 100% RH 100% RH 100% RH

Air temp From aftercooler 10oc higher than cooling

water inlet temp.

Motor rating KW 175 30 205

Crank shaft speed rmp 710 625 710

No. of stages 2 2 2

Cylinder bore mm LP 2x210 1x215 2x350

HP 2x185 1x140 2x210

Stock mm 150 115 150

Clearance in % of volume LP 9.0 11.9 11.5

HP 10.8 19.3 10.0

Thickness mm LP 12 11 20

HP 11 11 15

Method of cylinder Non-lub. Non-lub Lub.

Lubrication

Cooling method Water Water Water

Nos of air recelvers 4 1 4

Water capacity of each 7 1.84 7receiver M3

3.5 AIR CONDITIONING SYSTEM

A. VAPOUR ABSORPTION SYSTEM

1. Number One (1)

2. Capacity (TR) 350 TR

3. TypeDouble effect

4. Chilled water flow As per TR rating

5. Inlet chilled water temp. 12.77 dg. C

6. Quiet Chilled water temp. 7.0 deg. C

7. Cooling water flow As per TR rating

8. Material of construction

a) High temperature generator tubes SS430

b) Low temperature generator tubes Copper

c) Absorber/Evaporator/Condenser DLP Copper

tubes

d) High temperature heat exchanger Cupro Nickel

e. Low temperature heat exchanger Copper

f) Eliminators S.S

g) Shell M.S

Note : for the given chilled water and cooling water temperatures.

One TR is 3000 Kcal/hr.

56

1. SOLUTION PUMPS QTY. 1 NO.Type Nikkiso Non seal pumpModel 55491-5.5 H-BHead 9.5 m Cap 750 l/minMotor 5.5 KW, 3= 1500 rmp , 415 vNikkiso Co. Ltd, kyo Japan

2. REFRIGERANT PUMPType Nikkiso Non Seal pumpModel 5291 - 1.5 F - V001Head 3.5, Cap 600 Lit/Min = Motor 1.5 KW, 415 V, 3, 3000 rpm

3. E/P CONVERTORMake CG - Hart mann & Braun Ltd.Model I/p Cnventor - Te IP 11Sl. No. 4217059Supply 4 to 20 mAwpsoutput 0.2 - 1 kg/cm2

4. VACUUM PUMP (PURGE PUMP)Type Rotary Vacuum PumpMake Precise Vacuum System & Pvt. Ltd.Model VKC - 8, S l. No. 80064,Motor Cromption GreavesModel 2242 DVJ Zin Z5 74 (m)Rating 37 W, 415 v 3ph, 1350 RPM

5. PLUNGER PUMPType Controlled Volume PumpModel No. WH - 1750/33SPM Stroke per minute - 144Flow rate LH - 150Sl. No. 14043/ 00Discharge Pr. 23.0 Kg./cm2 = Motor Make Crompton GreavesRating 75 KW , 415 V + 10 % & 1400 rpm

57

B : ST I MAIN AC

1. AC COMPRESORS INSTALLED : 04Normal Running : 02Make : M/s. Kirloskar

Pneumatics Co. Ltd.Pune.Model : K 60 x 110Capacity of each Compressor : 130 TRMotor KW : 150Refrigerant : Freon 22

2. COOLING WATER PUMPS INSTALLED : 03Normal Running : 02Make : Beacon WeirModel : 4L3Capacity : 38.9 Litre per SecondMotor KW : 22

3. CHILLED WATER PUMPS INSTALLED : 03Normal Running : 02Male : Beacon WeirModel : 4 L 3Motor KW : 18.5Capacity : 38.9 Litre per Second

4. AIR HANDLING UNIT :a) Unit 1 :Numbers Installed : 02Normal Running : 02Make : AtlanticCapacity : of each AHU 38000 Cubic

Meter per Hourb) Unit 2&3 :Nos Installed : 04Normal Running : 04Make : AtlanticCapacity of each AHU : 33000 Cubic metre per Hour

5. COOLING TOWER :Nos Installed : 01No of Cells : 02No. of Cells Normally in Service : 02Make : Paharpur CoolingTowers Ltd.Model : 349-602Capacity of Each Cell : 194 Cubic Meter per Hour.

C : SW YARD AC

1. AC COMPRESORS INSTALLED : 02Normal Running : 01Make : Accel Compressors,

AhmedabadModel : SMC 6 - 100Capacity of each Compressor : 60 TRMotor KW : 52.5Refrigerant : Freon 22

2. COOLING WATER PUMPS INSTALLED : 02Normal Running : 01Make : Beacon WeirModel : 3L3Capacity : 16.7 Litre per SecondMotor KW : 15

3. AIR HANDLING UNIT :Nos Provided : 02Normal Running : 01Make : AtlanticCapacity : of each AHU 24700 Cubic

Meter per Hour

4. COOLING TOWER :Nos Installed : 01Make : AtlanticCapacity of Each Cell : 60 Cubic Meter per Hour.

59

D : ESP ST I (DATA OF ONE ESP - SAME FOR UNIT 1,2,3)

1. AC COMPRESORS INSTALLED : 02Normal Running : 01Make : Accel, AhmedabadModel : SMC 6 - 65Capacity of each Compressor : 25 TRMotor KW : 22Refrigerant : Freon 22

2. COOLING WATER PUMPS INSTALLED : 02Normal Running : 01Make : Beacon WeirModel : 21/2 R 13Capacity : 6.94 Litre per SecondsMotor KW : 5.5

3. AIR HANDLING UNIT :Nos Provided : 02Normal Running : 01Make : AtlanticCapacity : of each AHU 24000 Cubic

Meter per Hour

4. COOLING TOWER :Nos Installed : 01Make : AtlanticCapacity of Each Cell : 25 Cubic Meter per Hour.

60

E : EDP AC

1. AC COMPRESOORS INSTALLED : 04Normal Running : 02Make : M/s. Kirloskar Pneumatics

Co. Ltd., PuneModel : AC 1070Capacity of each Compressor : 82 TRMotor KW : 175Refrigerant : Freon 22

2. COOLING WATER PUMPS INSTALLED : 02Normal Running : 02Make : Kirloskar Brother Ltd.Model : DB 125/26Capacity : 164 Litre per SecondsMotor KW : 18.5

3. CHILLED WATER PUMPS INSTALLED : 02Normal Running : 01Make : Kirloskar Brother Ltd.Model : DB 100/40Motor KW : 15Capacity : 98 Liters per Second

4. AIR HANDLING UNIT :a. Main AHUNumbers Installed : 03Normal Running : 02Make : FlaktCapacity : each AHU 68000 Cubico

Meter per Hourb. UPS RoomNos Installed : 02Normal Running : 02Make : FlaktCapacity : 17000 Cubic Meter Hour

5. COOLING TOWER :Nos Installed : 01No. of Cells : 02No. of Cells Normally in service : 02Make : Paharpur CoolingTowers Ltd.Model : 348-602 Single FlowCapacity of each cell : 2 x 125 Meter per Hour.

F : SIMULATOR AC

1. a)COMPUTER ROOMNormal 0 Running : 01Make : Kirloskar Pneumatics Co Ltd.

PuneModel : AC 470Capacity of each compressor : 40 TRMotor KW : 37Refrigerant : Freon 22

b) UNIT CONTROL ROOMAC COMPRESSORS PROVIDED : 02Normal Running : 02Make : Kirloskar Pneumatics Co Ltd.

PuneModel : AC 570Motor KW : 45Capacity of each compressor : 45 TR

2. COOLING WATER PUMPS INSTALLED : 02Normal Running : 02Make : Beacon WeirCapacity : Liters per SecondModel : 2DM6Motor KW : 5.5Capacity : 9.7 Liters per Secod

3. AIR HANDLING UNIT :FOR COMPUTER ROOM :Nos Provided : 02Normal Running : 01Make : Haji Moosa Patra WalaCapacity : of each AHU 37000 Cubic

Metre per Hour

62

4. FOR CONTROL ROOMNOS PROVIDED : 02Normal Running : 01Make : Haji Moosa Patra WalaCapacity : of each Ahu : 39000 Cubic

Meter per Hour5. COOLING TOWER :

NOS Installed : 02Normal Running : 02Make : Paharpur Cooling Towers Ltd.Model : Perma Tower 5931

63

3.6 COOLING WATER SYSTEMA. SPECIFICATION OF C.W. PUMP & MOTOR

1. PUMPi) Make KSBii) Type SEZ 1200 -1020iii) No. of pumps supplted Seven (2 per unit one standby)iv) No. of stages OneV) Pump Design Pull out typevi) Type of impeller Open, Mixed flowvii) Operating speed 493 r.p.m.viii) Discharge Capacity 15,000 M3 /hr

ix) Total dynamic Head 12.2 MWCx) Shut-off head 30 NWCxi) Bowl efficiency 89%xii) COUPLING

a) Make KSBb) Type 16c) Weight 300

xiii) Foundation load 62,000 kgsxiv) Pump weight (G.P.) 2,600 kgs.xv) GD2 of pump 296 kg M2

2. MOTORi) Make BHELii) Frame size AVC 15156 H 12 Diii) KW/ Current 685/81.5A iv) Voltage 6.6 KV 3 ph. 50Hz.v) R. P. M. 493vi) Motor weight (GM) 11,000 kgs,vii) Motor GD2 1400 kgm2

viii) Efficiency 93.1 %ix) Stator Star-woundx) Power factor 0.7xi) Cooling CACWXii) Class of insulation Fxiii) Direction of rotation C.C.W. from D.E.

64

B. COOLING TOWERS AND C.T. PUMP

SPECIFICATIONS

1) C.T. PUMP

i) Number 2 For each 200 MW

ii) Discharge 15,000 M3/hr

iii) Head 18.5 M.W.C.

iv) Speed 493 rpm

v) Make KSB

MOTORS

i) Type Induction Motor

ii) Speed 493 r.p.m.

iii) K.W. 1015

iv) Current 116.4

v) Volts 6.6 KV, 3 50/s

vi) Make BHEL

2 COOLING TOWER

i) Number 1 for each 200 MW unit

ii) No. of cells/ tower 16 ( Rows of 8 cells each)

iii) Rate of flow per unit 27,000 M3 /Hr/Tower

iv) Cooling range 100C

v) Baffles Prestressed concrete

vi) Drift eliminators Asbestos, corrugated

3. COOLING TOWER FAN

(i) Fans/tower 16 (8 per row)

(ii) Fan type Axial Induced draft

a) Fan Impeller

i) Make Gammon

ii) Type Axial Flow

iii) Diameter 7315 mm

iv) No. of blades/fan 7

65

v) Blades variable pitch Yes

angle

vi) Pitch angle 130

vii) Speed 151 r.p.m.

viii) Air Quantity 9,97,200 CMH

ix) Fan B.H.P. 35 KW

b) Reduction Gear

i) Make ELECON

ii) Type Worm Gear

iii) Input Speed 1470 r.p.m

iv) Output speed 151 r.p.m.

c) Electric Motor

i) Make Siemens

ii) Type Squirrel Cage

iii) Frame size 225 M.

iv) Enclosure T.E.F.C. - IP 55

v) Rating 58 HP (43 KW)

vi) Supply 415 V - 3 Ph - 50 C/s.

vii) Speed 1470 r.p.m.

viii) Insulation Class 'B'

ix) Amperes 75

x) Ambient temp 500C

66

C. TRANSFORMER C.W. SYSTEM

1. Rating 25 MVA (2 wdg) 3 2. Voltage ratio 33/6.9 KV.3. Frequency 50 Hz.4. Impedence 10% at 75 0C (No +ve toberance)5. Service Outdoor6. Duty Continuous.7. Overload As per IS 6600 - 1972

8. Cooling ONAN/ONAF/OFAF/ with 2 x 50%separately mounted rediatorsand 2 x 50% all pumps per cooler% rating at different cooling60/80/100

9. Temp. above 50 0C In oil 40 0C.

10. Wdg. details HV LVFault level MVA 1000 350Basic IMP.level KVP. 170 60Wdg. connection Delta StarInsulation Fully FullyInsulated Insulated.Vector group DY 1.Isola- Non

Neutral ted effectively

67

11. Tap changer Tap range + 5% to - 7 1/2% In steps

of 2-1/2% on HV neutral end.

Tap control - Off ckt top change switch

HV LV Neutral

12. Bushing Rated voltage

KV 36 12 12

Rated

current Amp. 800 3150 300

Basic impu-

Ise level

KVP. 170 75 75

Total

Creepage

Distance

(mm) 666.8 222.3 222.3

mounting Tank Tank Tank

cover cover side/cover

13. Terminal details H.V. connected to33KV PILC or XLPE

L.V. connected to Segregated phase

Bus duct.

Neutral

connected to PVC Al cable.

14. Bushing C.T.S. No. of. Core 1

Service Protection

Ratio 300/1

Accuracy SP 20.

Burden 15VA

(with skids inplace of wheel)

68

Name and type of Qty. SpecificationTransformer

15. Raw water and 2 12.5 MVA, 33/6.9KV, 50 HZClarified water Imp. - % at 75 0C, ONAN, vectorTransformer group - Dy 1(Outdoor)

Tap changer - + 5% on HV side of CKT.

Neutral - Isolated.

16. Colony transformer 2 3 MVA, 33/11KV, 50 Hz., Imp - 7%(Outdoor) ONAN, vector group - Dy. 1.

Tap changer - + 5% - 7-1/2%Off Ckt.

Neutral HV - IsolatedLV - Solidty earthed

D. L.T. TRANSFORMERS

Outdoor L.T.Transformers.

1. C.T. Sevice 5 1250 KVA 6.6/. 433 KV ONAN.Transformer Imp. 6%IA, IB, 2A, 2B Tap changer + 5% Off ckt.and 2C Vector group - Dy1.

Neutral - LV solidly earthed.

2. C.W. Service 2 -do-TransformerIA, IB.

3. Clarified water 2 -do-Service Transformer

4. Ash Handling 2 -do-Service Transformer

69

5. Ash Water Service 2 Neutral - LV solidly earthedTransformer.

6. Workshop service 2 1600 KVa, 6.6/0 433 KV ONAN,Transformer IMP. 7%

Tap changer -+ 5% Off ckt.Vector group Dy. 1Neutral L.V. grounded

solidly.

7. Lighting Service 300 KVA, 6.6/0.433 KV ONANTransformer. Imp. - 5%i) Clarified water 1 Tap changer - + 5% Off Ckt.ii) CW Area 1 Vector group - Dy1iii) Fuel oil area 1 Neutral - LV solidly grounded.

8. E.S.P. Service 6 1600 KVA 6.6/0 433 KVTransformer ONAN, Imp - 7%

Tap changer - +5% Off ckt.Vector group - Dy. 1.Neutral - LV grounded.

9. Switch yard servce 1 500 KVA, 33/0.433 KVTransformer ONAN, Imp 7%

Tap changer - +5%Vector group - Dy. 1Neutral - LV solidly grounded.

10. Switch yard light 2 -do-Service Trfr.

11. Administrative Bldg. 1Service Trfr. -do-

70

3.7 EQUIPMENTS OF ASH HANDLING SYSTEMSl. Description Make Model Qty.

Type of

Suction Head Capacity SpeedMotor Rating

1 Ash Slurry Disposal Pump St. - I SAM AR 300/650 4Flooded 15 MWC 650 Cu. Mtr/Hr 572

(Max.)

522 (Rated)

286 (Min.) 75 KW

2 H.P. Ash Water SAM WP 125/320/ 2Flooded 25 Mtr. 160Cu. Mtr/Hr 145018.5 KW

Booster Pump back pull out

3 Vaccum Pump Khaitan Axial Flow 4Supply fan

Cu. Mtr/Hr 1410 0.75 KW

4 Fluid Coupling Prembril 18SCR25-B 41425 to 713

Scoop typeVariable speedRange of Speed regulation :

5 Instrument Air Compressor KG Khosla 2HY2T 28.0 Kg 107.13 Cu. Mtr/Hr 630

22KW

6 Collector Tank DCIPS Impingment 4Nos.Size :1450 MM OD typeAir per

seperation unitarrangement

7 Mechanical Exhauster Vacunair Water ring 4 Nos.300mm hg

type Size-200 /unitvaccum 4050 Cu. Mtr/H 440 90 KW

8 Air Washer 4Nos Size :914 MM ID per unitSpray Water Qty.:15 Cu. M./Hr.at Pressure : 35 MWC No. of Nozzles : 16Outlet Emission :150 mg/Cu.N.M. DCIPS

71

Sl. Description Make ModelQty. Type of HeadCapacity Speed Motor Rating

Suction

9 Wetting HeadSize : 10" NBOperating water Qty.:72 Cu.M./Hr. at

Working Pressure:55MWCNo. of Nozzels :16Capacity of Dry fly Ash : 47.5 MTPHSlurry concentration at outlet : Spray Water4Nos47 MTPH of (Ash:water)1:1.5 DCIPS typeperunitDry Fly Ash10 Semi EOT Crane

Trolly Drive Motor :CAP:5.0 T Span :4.3 Mtr.

Make :Crompton GreavesBridge Travel:12 Mtr.

Type :Spuirrel Cage415 Trolly travel : 2.7 Mtr.

V,3Ph,

Max. lift :2.3 Mtr.

Speed :1440 RPMHoisting Speed : 3.15 m/Min.CrossTraverse :10m./Min. Reva S/G Semi EOT 2

11 AirDrying Plant MVS ENGG.LTD. MVS-559-150blower reactiv-ated type) 2

60 N.C.U. Speed :1440

M/Hr. RPM

Motor of Stage - I Equipments

No. Description Make Qty. KWPH V AMP. RPM

1 Ash slurry disposal Pump Crompton Greaves 4 75 3

450 125 1480

2 H.P. Ash Water BoosterPump Crompton Greaves 2 18.5 3

415 334 1475

3 Instrument Air compressor Crompton Greaves 2 22 3

415 394 1475

4 Machenical Exhauster Crompton Greaves 4 90 3

415 149 1480

5 Air Drying Blower Kirloskar 4 0.75 3

415 1.84 2520

73

DETAIL OF EQUIPMENTS OF ASH HANDLING SYSTEM Sl. Equipment Qty. Capacity

Make

1 Sprinkler pumps 02 nos. 100 m3 ; 10 kg/c m2KSB

STAGE # I BOTTOM ASH

Sl. Equipment Nos. Installed SpecificationsMake.

1 Scraper conveyor. 06 nos. Capacity 06 tons/hr.

Mahindra spricers.

2 Clinker Grinders 06 nos. Capacity 06 tons.

Manindra spicers.

74

STAGE # I ASH SLURRY PUMPS ,SEAL WATER PUMPS HP ,

PUMPS & SERVICE WATER PUMPS

SN. Equipments make. Installed Specifications.Make

1 Ash slurry pumps 04 nos. Head - 3.3 kg/cm2power - 140 KW.Discharge 850

m3/hr. SAM2 HP Ash water pump 03 nos. Head - 94.5 MWCL

Power - 110 KWModel - BHR 30-35

KirloskarDischarge - 270

m3/hr. st # 4

3 LP Ash water pump. 03 nos. Head - 60 mwcl.Power - 130 KW Discharge - 570

m3/hr.St. # II Model BHR

30-35 Kirloskar4 Service water pump 03 nos. Head - 10.15 kg/cm2.

Discharge -330 m3/hr. Meghraj.5 Seal water pump -2 nos. Head - 11 kg/cm2

Discharge 100 m3/hr.St. # 5

6 Suction & discharge valves 10 nos. Knife Edge Gatevalve 125 PSI Vaas/ Dezuric

75

STAGE # I ASH SLURRY PUMPS ,SEAL WATER PUMPS HP ,

PUMPS & SERVICE WATER PUMPS

SN. Equipments make. Installed Specifications.Make

1 Ash slurry pumps 04 nos. Head - 3.3 kg/cm2power - 140 KW.Discharge 850

m3/hr. SAM2 HP Ash water pump 03 nos. Head - 94.5 MWCL

Power - 110 KWModel - BHR 30-35

KirloskarDischarge - 270

m3/hr. st # 4

3 LP Ash water pump. 03 nos. Head - 60 mwcl.Power - 130 KW Discharge - 570

m3/hr.St. # II Model BHR

30-35 Kirloskar4 Service water pump 03 nos. Head - 10.15 kg/cm2.

Discharge -330 m3/hr. Meghraj.5 Seal water pump -2 nos. Head - 11 kg/cm2

Discharge 100 m3/hr.St. # 5

6 Suction & discharge valves 10 nos. Knife Edge Gate valve 125 PSI Vaas/ Dezuric

75

IV

GENERATOR

AND AUXILIARIES

76

IV. GENERATOR AND AUXILARIES4.1 SPECIFICATIONS 1. GENERAL

Make BHELType 2 - Pole, Steam Turbine DrivenCooling, Stator Winding/ Direct Water Cooling/Stator Core, Rotor Direct Hydrogen Cooling

2. RATINGS :

Output 210 MWRated power factor 0.85 LAGRated Terminal Voltage 15.75 KVPermissible vartation on + 5% of Rated KVTerm VoltageRated RPM, Frequency 3000, 50 HZPermissible vartion in +2% to (-3)%FrequencyPhase connection Double StarNo. of parallet paths perphase 2Rated casing Hydrogenpressure 3.5 Kg/Cm2

Stator current at MCR 9050 Amps.Short CKT. Ratio 0.49Generator conferms to Codes IEC : 34-1 & 34-3, IS : 5422

GOST : 533Rise in Voltage with 100% LoadThrow 22.40 KV (without AVR)

3. TEMPERATURE AT RATED OUTPUTT. Max at H

2 Coolers outlet 0C 43

77

T. Max. of Water at H2 cooler 36

Inlet 0C

T. Max of D.M. Water atInlet to Stator 44T. Max of water at inletof D.M. Coolers 36T. Max of D. M. water atOutlet of Stator 70T. Max of Stator core 105 (BY R.T.D.)T. Max of Stator Winding 105 (BY R.T.D.)

4. REACTANCE (PER UNIT VALUES) Saturated Unsaturated

Direct Axis SYN. React Xd 2.05 2.22Direct Axis Trans. 0.234 0.266React X'dDirect Axis Sub-Trans.React X''d 0.179 0.214

NEG sequence React (X2) 0.252Zero SEQ. React (Xo) 0.105Zero SEQ. Resistance (Ro) 0.00193

5. TIME CONSTANTS (SECONDS)

Field TC with Open Ckt StatorSDG. - Cdo 7.00Field TC with 3 SC StatorWDG Cd3 0.84'' '' '' with 1 Cd1 1.62TC of aperiodic component of3 SC C A3 0.29

2 SC CA2 0.291 SC CA1 0.24Time constant of the periodiccomponent 0.03of the Sub Transient current of 3, 2of short Circuit '''' d

78

6. INERTIA CONSTANT H W SEC/KVA)

A. GEN 1.1

B. Complete T. G. Unit 3.42

Capacitance of Generator 0.72

stator Winding to Ground (Micro F)

Allowable Stator earth fault 7 Amps for 10 Sec.

Current & Duration

7. LOSSES AT DIFFERENT OUTPUTS WHEN RUNNING AT

RATED

SPEED VOLTAGE, POWER FACTOR AND HYDROGEN

PRESSURE

Capper losses of stator and (Stator) (Rotor)

rotor at 75OC

At 100% of rated output 1014 KW 790 KW

x80% 650 KW 571 KW

60 % 365 KW 391 KW

40 % 162 KW 256 KW

- Iron Losses of Gen. Stator 550 - (KW)

- Priction and windage

loss In Gen. 720 KW

Efficiency & According to

IEC Definitions, AT Rated PowerFactor and H

2 Pres. without any

tolerance.

AT 100% MCR 98.55

AT 80% MCR 98.53

79

Voltage Reg. under conditions

of Rated speed. voltage

and Out put (%)

AT 0.85 of LPG 42

AT 1.00 pf 36.5

AT 0.90 pf Lead 1.0

Saturation constant 1.086

7. GEN. CAPABILITY AND DURATION IN AIR AND AT DIFF. H2

PRESSURES WHEN RUNNING AT RATED SPEED. VOLTAGE

AND POWER

FACTORS

CAPACITY DURATION

In Air NIL (KW) NIL (Hr)

0.03 ATG, H2 Nil Nil

1.0 ATG H2 30000 Continuous

2.0 ATG H2 115000 Continuous

Rated H2 Press 210000 Continuous

Max. Cont. KVA Capacity

of Gen. with

-Loss of Stator Cooling

water flow Nill

One H2 Cooler out of service 185000 KW

GEN. REACTIVE ZERO LAG & ZERO (LEAD) AT RATED VOLTAGE AND H

2 PRESS

Max. Line charging capacity

(KVAR) 75000

Max. Inductive capacity

(KVAR) 172000

80

8. SHORT CKT SUB TRANSTENT CURRENTS

ON 3 SC 9.66 p.u.

ON 2SC 7.56 p.u.

ON 1 SC 10.36 p.u.

SHORT CKT. TRANSIENT CURRENT (p.u.)

ON 3 SC 3.76

ON 2 SC 3.58

ON 1 SC 5.10

SHORT CKT. STEADY STATE CURRENT (p.u.)

ON 3 SC 1.39

ON 2 SC 2.19

ON 1 SC 3.63

Permissible cont. Neg.

seq. current

COMPONENT (I2) 5% (Rated current)

Allowable (I2) 2 t valve 8

Permissible load and duratior

of ASYN. OPN. 84 MW for 15 Min.

9. Excitation Requirement at : AMPS VOLTS

Rated load 2600 310

No load 917 102

At max capacity load

(At O active Power) 340 40

Under Field Forcing condition 3900 620 (For 10 Sec)

Deviation Factor of Voltage

Wave/ Form Not more than 10%

81

Short Ckt Tarque/ Full

load Tarque 8

Fly wheel moment (GD2) of

GEN. + Exciter (If any)

KG. M2 21100

Critical speeds for Generator

First 1370

Second 2400

Third -

Capacity (In KW) of Space

Heaters 21 at 415 V

10. DESIGN AND CONSTRUCTIONAL FEATURES

STATOR CORE

(A) Type of spring Mounting Core mounted on Spring

Core BARS

(B) Grade of sheet steel 0.5 MM C.R. St. Steel

(Thickness 2 loss FIG) 1.25 x 103 at 1.0 TESLA

STATOR WINDING

(A) Class and type of insulation 'B' Thermosetting

Epoxy Mica

(B) Resistance per phase at

20 0C () 0.00155

(C) Capacitance per phase

(uF) 0.24

(D)Shipping test voltage

valve (KV) 34.5

(E) Impulse voltage strength

(KV) 49 (PEAK)

(F) Is the winding transposed

In the ends No.

82

TERMINALS

(A) No. of terminals Broughtout 9

(B) Type of cooling of terminalsand connections Directly water cooled

(C) Type of terminal Bushings Porcelain(D) Is provision made for

Mounting CTs YES(E) Dielectric Test Voltage-KV 52(F) Impulse voltage Strength - KV 78

ROTOR

(A) Material of Rotor Forging Chrome-nickel-Molybdenumand Vanadium Steel

(B) Material or Retaining Ring Non - Magnetic SteelForging

(C) Material of Rotor Wedge Duralumin(D)Type of mounting Retaining Ring Shunk Fitted only one

end of Shaft Barrel(E) Material of Damper winding Silver plated copper

segmental type(F) Over speed test value and 3600 RPM for 2 Mins.

duration

ROTOR WINDING

(A) Class and Type of Insulation 'B' Epoxy class(B) Turns per pole 63(C) Resistance at 20 0C 0.0896(D) Dielectric test voltage

valve 3.1 KV

83

BEARINGS

(A) Type of seal Ring Type

(B) Pressure of Seal oil 5.0 KG/Cm2

(C) Grade of oil DTE MED. of I.O.C.

(D)Quality of oil per seal 1.5 M3/hr

COOLERS

Material of Tubes Admiralty Brass

Fins Tinned copper wire

Soft Drawn

Tube Plate Steel ST. 42 w

Water Boxes Steel St. 42 S

Quantity of clarified water

Req./Cooler 87.5 M3/hr.

Pr. Drop across cooler on

water side 17.5 (M.W.C.)

4.2 AUTOMATIC VOLTAGE REGULATIONManufacturer of AVR BHEL

Type K 17020 M

Power supply to the

regulators 110 Volts

Range of voltage adjustment %

Auto position/Manual + 10% / +10

Frequency range of operation 40 to 70 Hertz

Temp. range of operation (OC) 55

Accuracy (%) +0.5

Dead Band Nil

84

Response time ( To apply field forcing voltage withA 5% Drop in Generator

Terminal voltage, seconds 40 Milli seconds

STATIC EXCITATION SYSTEM

Rectifler transformer May and Christe

Frequency 50 Hz

Phase 3

Capacity (KVA) 2500

Voltage High/Low 15750/575

Percentage impedance/Vector group 5.82 / Y5Mode connection betweenlow voltage Terminals andThyristor convertor By cables

Type of cooling Forced Air Cooling Transformer weight 7 tonnes.

Overall dimensions (lxBxH) 3 M x 2 M x 3 M Approx.

Recommended location Below the Bus Duct at 0.OMlevel in Machine Hall.

RECTIFIER ASSEMBLY

Rated current/Voltage 3000 Amp / 355 Voltage

Ceiling current/Voltage 4500 / 620

Ceiling duty duration (Sec) 10

Diode base temp. at ratedoutput 86.60C at 450C Ambient

Rated peak Inverse voltage 2200 VDiode used (voltage)

Frequency of supply

Voltage (HZ) 50 Hz

Voltage drop across

Rectifier (V) 1.425/Thyrister

2.85 V Bridge

Type of Connection 3 Full wave bridge

Over voltage withstading 2.5 KV, Power 3000 KW

capacity On D.C. Side

Spare capacity of Rectifler 19%

Overall dimensions of Assy.

(M x M x M) 5 Nos. 0.68x1.2 x 2.6

Field suppression Arrangement IT IS PROVIDED

Total loss in Excltation system 45 KW at Rated Output

Cooling, power requirement (KW)

for Thyristor convertor 45 KW

4.3 STATOR WATER COOLING SYSTEM DM water

required for cooling 27 M3/HR.

Max. Pr. at Inlet to winding

(KG/Cm2) 4.0 KG/CM2 Gauge

KM & Voltage rating of driving 9.3KW 415V, 3

Motor for Pumps 50 HZ, 1 Stand By

Quantity of water per cooler 110 M3 / Hr

Pressure drop of water through

coolers 0.08 KG/CM2

4.4 GAS SYSTEM DATA Volume of H2 Space in Gen.

56 M3

Cooling gas glow (M3/Min) 1800Vol. of Co

2 at N.T.P.

required for Displacing Air 90 (M3)

86

Vol. of Co2 at N.T.P. requiredto displace H

2120 M3

Volume of H2 at NTP required

for displacing Co2 and to bring

the casing to rated pressure 300 M3

Purity of H2 required 99% Normal 97% MIN.

Leakage of H2 by Vol./Day

at rated Pr. Not more than 15 m3

Volume of Air at NTP requiredto displace CO

2 in the casing(M3) 150

Requirement of compressed Air

for Gas Tightness test 500 M3

Standards to which the Cylindersconform H

2/C0

2BS - 399 BS - 401

4.5 SEAL OIL SYSTEM

Seal oil Pump Motor Set Stand-by Regulator

Type I.A.C. (Screw Type)

I.D.C. (Screw Type)

Capacity (M3/Hr), Disch. Pr. 7.8,10 7.8,10

Size of Motor (KW) 4.2 4.0

Vapour extraction Unit

(In seal oil Drain) Centrifugal

Capacity of Unit/Motor 400 M3/Hr, 1.5 KW

MAIN WEIGHTS

Heaviest Lift of Gen. Stator

with Trunions 175 Tonnes

Wt. of complete Stator/Rotor 163/42.2 Tonnes

Wt. of complete Gen. 239 Tonnes

Wt. of Lifting beam 20 Tonnes

87

4.6 Generator Transformer

1. Rating 240 MVA

2. Voltage Ratio 14 - 18 KV/400 KV

3. Frequency 50 Hz.

4. Impedance 14% at 750C

5. Service Outdoor

6. Duty Continuous

7. Overload As per IS 6600 - 1072

8. Cooling OFAF with 3 x 50%

Coolers and 3 x 50% oil pumps

9. Temp. rise above In oil 400C

500C In wdg. 500C (Resist method)

10.Winding details HV LV

Fault level -

MVA 25000 3000

Basic 1300 125

Impulse

level KVP

Wdg. connection Star Delta

Insulation Graded Fully

Insulated

Vector group YD II

Neutral Solidly Effecively

earthed earthed

88

11. Tap changer Tap change(+) 7. 5% to(-)(2.5%) insteps of 2.5% on HV neutral end.Tap control-Full capacity off CKT. tap

change switch.

12. Bushing HV LV NeutralRated Voltage 420 KV 24 36Rated current 500 Amp 10000 500Basic temp. levelKVP 1300 125 170Total creepage 8083.6 446.6 666.8distance MW mmMounting Tank Tank Tankcover cover cover

13. Terminal details HV connected to - Twin moose ACSR conductor

LV connected to - Isolated phase duct.Neutral connected Mild steelto grounding flat.

HV NEUTRAL

14. Bushing current No. of cores 2 2transformer Service Protection Protection

Rated primarycurrent 500 A 500ARatio 1000/1 1000/1Accuracy class PS PSKnee pointvoltage (Notless than) 1000 V 1000VSecondary wdg.resist (Not less than) 2.5 Ohms 2.5 Ohms

15. Other requirements Min. phase to phase a spacing of theIsolated phase bus duct is 1200 mm,LV terminal spacing shall match this.

89

4.7 TIE TRANSFORMER1. Rating 75 MVA

Voltage ratio 400/34.5 KV

3. Frequency 50 Hz.

4. Impedance 12.5% at 750C (with no +ve

tolerance)

5. Service Outdoor

6. Duty Continuous

7. Overload As per IS 6600 - 1972

8. Cooling ONAN/OFAF/with 2 x 50% separately

mounted radiator banks and 2x 50%

oil pumps/coolers % rating at different

coolings 75/100.

9. Temp. rise above 500C In oil 400C

In winding - 500C (Resistance)

10. Winding details HV LV

Fault level MVA 25000 1000

Basic impulse 1300 170 KVP

Level KVQ

Wdg. connection Star Delta

Insulation Graded Fully

Insulated

Vector group Yd 11

Netural Solidly Insulated

grounded

Tap changer Tap range (+) 5% to 7-1/2% in steps

of

2-1/2% on HV neutrel

end.

Tap control Off ckt. top change Switch

90

12. Bushing HV LV Neutral

Rated Voltage 420 3636

Rated current 500 2000 500

Basic temp. 1300 170 170

Level KVP.

Total creepage 8083.6 666.8

666.8

distance mw mm

Mounting Tank Tank Tank

cover cover cover

13. Terminal details HV connected to Twin moose ACSR conductor

LV connected to 33 KV PILC Or XLPE cable.

Neutral MS grounding flat.

connected to

14. Bushing current

transformer HV Neutral

No. of cores 2 2

Service Protection Protection

Rated primary current 200 200

Ratio 200/1 200/1

Accuracy PS PS

Knee point voltage 600 V 600 V

(Not less than)

Secondary winding 2.5 ohms 2.5 ohms

resistance.(Not less than)

91

4.8 UNIT TRANSFORMER 1. Rating 16 MVA; 2 winding 3 2. Voltage ratio 14 - 18/6.9 KV3. Frequency 50 Hz4. Impedance 7 % at 750C5. Service Outdoor6. Duty Continuous7. Overload As per I.S. 6660 - 19728. Cooling ONAN/ONAF with 2 x 50%

separatelymounted radiators. % rating atdefferent cooling 75/1000

9. Temp. above 500C In oil 400CIn winding 500C

10.Winding details HV LVFault level MVA 3000 350Basic imp level 125 KVP 60

KVPWdg. connection Delta StarInsulation Fully Fully

Insulated InsulatedVector grouping DY 1Neutral Noneffec- Noneffec

tively tively

11.Tap changer Tap range +5% to 7-1/2% in stepsof 1-1/2% on HVneutral end.

Tap control Full capacity on loadtop changer suitablefor local/remote,Independant elect./manual operation.

92

12. Bushing HV LV LV neutral

Rated voltage 24 12 12

Rated current

amps. 1000 1000 300

Basic impulse

level KVP. 125 75 75

Total creepage

Distance mm 444.6 222.3 222.3

Mounting Tank Tank Tank

cover cover cover

13. Terminal HV connected to - Isolated phase duct.

details LV connected to -- Segregated phase duct.

Netural connected to PVC Insulated Al cable.

14. Bushing CTSNo. of core 1 (LV Neutra)

Service Protection

Ratio 300/1

Accuracy SP20

Rated 15 VA

15. Other HV terminal arrangement :-

requirement

(Minimum phase to phase spacing of the

isolated phase duct is 1000 mm HV

terminal will match this vactor group)

93

4.9 STATION TRANSFORMER

1. Rating 31.5 MVA 2 wdg.3 2. Voltage ratio 33/6. 9 KV.

3. Frequency 50 Hz.

4. Impedence 11% at 75 0C

5. Service Outdoor

6. Duty Continuous

7. Ovarload As per IS 6600 - 1972

8. Cooling ONAN/ONAF/OFAF with 2 x

50%

separately mounted rediator and

2 x 50% oil pumps per cooler. % rating

at different cooling 60/80/100.

9. Temp. above 500C In oil 40 0C

In Wdg. 55 0C. (Resistance)

10.Winding details HV LV

Fault level MVA 1000 350

Basic impulse 170 KVP 60 KVP

level

Wdg. connectionDelta Star

Insulation Fully Fully

Insula Insula

ted ted

Vector grouping DY 1

Neutral Isolated . Non

effectivaly grounded.

94

11. Tap changer Tap range +10% to - 10% in stepson HV neutral end.

Tap controlFull capacity 0n load tapchange suitable forremot/local, Independentelect/manual operation.

12. Bushing HV LV Neutral

Rated voltageKV 36 12 12Rated 800 3150 300currentBasic 170 75 75ImpulseLevel KVP.Total creepage 66.8 22.3 222.3distanceMountings Tank Tank Tank

cover cover cover

13. Terminal HV connected to 33 KV PILC or XLPcable.details

L.V. connected to Segregated phase duct.Neutral PVC Insulatedconnected to Al cable.

14. Bushing C.T.s.No. of cores : 1 (L.V. Netural)Service : ProtectionRatio : 300/1Accuracy : 5P20Rated : 15 VA

95

V

INTERLOCK

& PROTECTIONS

96

V - INTERLOCK & PROTECTIONS 1 BOILER & AUXILIARIES1.1BOILER

a. PURGE PERMISSIVES :-

1. Elevation AB, CD & EF all ignitor valves closed.2. Elevation AB, CD & EF warm-up fuel nozzle valves closed.3. Ignitor & warm-up fuel trip valve closed.4. Elevation A,B,C,D,E & F pulverisers off.5. No Boiler trip command from MFR- A&B6. Elevation AB,CD & EF Discriminating scanner sense no flame.7. Elevation A,B,C,D,E, & F Feeders off8. Elevation AB, BC,DE & EF Fireball scanners sense No Flame9. Elevation AB, CD, EF, AA, BC, DE, FF, Aux.Air Damper

Modulating wind box to furnace differential pressure satisfactory (50 mm WC)

10. Both PA Fans off.11. Elevation A,B,C,D,E & F hot air gates closed.12. Burner tilt horizontal & Air flow less than 40 %

After all above conditions are fulfilled.(Purge ready) will appear.

b. BOILER TRIP (FOR MFR A&B) :1. Both FD fans off2. Both ID fans off3. Simulation trip4. UTR & Load > HP Bypass A5. UTR & Load > HP Bypass B6. Loss of ACS power > 2 seconds7. Drum level low-low for 15 seconds (-250 MMWCL)8. Drum level high-high for 15 seconds (+250 MMWCL)9. Loss of reheat protection with a time delay of 10 seconds.10. Emergency push button trip 2/2 logic.11. All BFPs trip.12. Furnace pressure high-high (+250MM) 1/1 logic13. Furnace pressure low-low (-150 MM) 1/1 logic14. Loss of unit critical power for > 2 seconds.15. Unit Flame failure.16. Loss of 220 V DC for more than 2 seconds.17. Loss of all fuel trip.18. Less than fireball & loss of power at elevation in service.

Air flow less than 30% for load > 30%

97

c. LOSS OF ALL FUEL TRIP :

1. All ignitor valves closed or ignitor trip valve closed. (Not Open)2. All feeders off.3. All nozzle valves closed or trip valve closed. (Not Open)4. Out of 4 Ignitor proven in any oil elevation (Arming)

d. UNIT FLAME FAILURE :

Flame failure will activate if the elevations AB, BC, DE, & EF aresensing no flame, 2/4 scanners not sensing & any feeder is

proven (Feeder on in remote for more than 50 secs.) after 2 seconds unit flame failure will occur.

ELEVATION SENSING, NO FLAME WILL VOTE :

1. If feeder is not proven for > 2 sec or2. Elevation 3 out of 4 fire ball scanner sense no flame and3. Elevation 2 out of 4 HFO nozzle valves not proven.

(Elevation power available) or4. Elevation supply is not available.

1.2 PULVERISER & FEEDERS a. PERMISSIVES :1. Seal air to bowl diff. pressure of > 8'' wcl.2. Pulveriser ready.3. Pulveriser off.4. Pulveriser Ignition permit.5. Pulveriser start command from memory.

b. PULVERISER READY WILL APPEAR WHEN FOLLOWING ARE FUL FILLED-

1. Pulveriser start permit from FSSS.2. Discharge valve open (All four corners)3. Outlet temp. < 200 degree F4. Feeder control switch is in remote5. Cold air gate open.6. No auto pulveriser unsuccesful start.7. Tramp Iron Hopper valve open.8. No. pulveriser trip.9. Primary air permit or pulveriser ON

98

c. PULVERISER TRIP CONDITIONS :1. Auto pulveriser stop.2. Stop push button pressed in manual mode3. MFT4. Discharge valve not open5. Loss of primary air (both PA fans off)6. Mill Running and seal air header/pulveriser under bowl diff.

Pressure lessthan 5 Inches with time delay of one minute.7. Elevation power failure for more than 2 secs.8. Loss of PA fan trip for elevation F,E,D.9. Support Ignitor elevation lost (elevation warm-up nozzle

valves not proven) and ignition permit reqd. and Ignition permit lost.

d. FEEDER START PERMISSIVES -1. No Master Fuel Trip.2. Elevation Power Available .3. pulverizer on.4. pulverizer ignition permit available.5. Coal on Belt.6. Feeder circuit ready includes the following permissives.

a. Coal in feeder inlet.b. SCR ready.c. Silo gate open.d. Drag chain ready.

7. No. feeder trio signal/command persists.8. Feeder speed signal set at minimum.9. Coal air temperature set at 120 deg. ferhenhit.

e. FEEDER TRIP LOGIC1. No. coal on belt.2. Feeder Discharge chute plugged.3. Lower down spout empty.4. MFT operated.5. Pulverizer not on.6. Pulverizer ignition permit is lost within three minuts of feeder

on.7. Pulverizer power not available (time delay 2 second).

1.3 ID FAN a. START PERMISSIVES :1. Flue gas path clear2. Motor/fan bearing temp. not high (< 75 deg C. for motor &

fan)3. Lube oil pressure adequte>1.50 Kg/Cm24. Any APH running for 1 st fan5. IGV minimum position6. Emergency push button released

7. Inlet and outlet damper closed.99

b. TRIPS 1. Motor (DE/NDE) Brg Temp High-High (> 85oC )

2. Fan Brg (DE/NDE) Temp High-High (> 85 oC)3. Lub Oil Pr Low-Low<1.25 Ksc

4. Air Pre heater Trip (cross & Parallel)5. Post purge trip6. EPB pressed7. Control switch8. Running FD trips

1.4 FD FAN a. PERMISSIVES -1. Motor/fan bearing remp. not high < 75 deg C.2. Blade pitch min. and discharge damper closed.3. Control oil pr. adequate > 8 KSC4. One ID fan is in service5. Lube oil temp. not high6. Emergency push button release.

b. TRIP1. Motor bearing (DE/NDE) temp. High-High [> 85 Deg. C].2. Fan bearing [DE/NDE] Temp. High-High [>85 Deg. C]3. Lube oil pressure low < 0.8 KSC4. ID fan trip [ cross/parallel ]5. Post purge trip6. E.P.B. pressed.7. Control switch

1.5 PA FAN a. PERMISSIVES -1. Motor & fan bearing temp. not high <75 deg C.2. Lube oil pr. adequate > 1.2 Ksc3. FSSS permit (no MFT & all CAD < 5% open)4. Discharge damper closed & IGV minimum5. Any FD fan running.

b. TRIPS1. Motor bearing [DE/NDE] temp. high-high >85 deg. C.2. Fan D.E. [ one thrust, two journal] bearing temp high

-high > 85 deg. C.3. Both FD fan trip.4. Lube oil pressure low-low <0.6 KCS5. Boiler trip6. Emergency push button pressed.7. control switch.

100

1.6 IGNITOR AIR FAN : a. PERMISSIVES1. Any FD fan on [ both FD fans not off ]

b. AUTO START1. If running fan frips standby will come into sevice [ through

ON/OFF status ]2. If IOTV opens fan will take start.

c. TRIPS1. Both FD fan off.2. Stop command from UCB or EPB pressed.

1.7 SCANNER AIR FAN : a. AC SCANNER FAN/DC SCANNER AIR FAN AUTO START

1. Scanner air duct to furnace delta P < 6 '' for AC only.2. If AC fan is not on. DC will come into service and vice versa.3. If unit critical power is lost for > 2sec start command will go to

both AC/DC fans.

b. SUCTION DAMPER :Scanner air fan emergency damper will open if both FD fans are

offor

Unit critical power is lost for > 2 secondsIf any FD fan is on it will close.

1.8 SEAL AIR FAN : a. PERMISSIVES :Either PA fan on for more than 2 seconds. [ for seal air fan-A

only ]

b. AUTO START - [For stand by fan-B only]1. Either PA fan on for more than 2 seconds and seal air header

to cold air duct delta p < 4 '' wcl fan-B, will start after 10 seconds.

c. TRIP :1. Seal air fan will Trip after 15 seconds of Tripping of Both PA

fans.2. from UCB stop command.3. EPB pressed .

1.9 AIR PREHEATER : If electric drive trips, air motor will take start

101

2. TURBINE & AUXILIARIES2.1 TURBINE a. PROTECTIONS

1. Turbine UCB manual trip.2. Stator water conductivity high-high > 21 micromho/cm. LVM

2/23. Stator water flow low-low < 13 M3/ hour for > 60sec LVM 2/24. Boiler to turbine through UTR5. Generator to Turbine through UTR.6. Either ESV or IV closed & generator on line, through UTR7. condenser vaccum lo-lo (220 MM / Hg

Elect.) - 0.7 ksc, hyd

vaccum trip - 0.3 ksc 8. Boilor fire- off.

9. Lube oil pressure low 2/3 logic < 1.2 KG/ Cm210. Fire protection ch. 1 MOT level <- 100MM 2 out of 3

sonar probe enable with MOT level > 50 mm11. M.S. Temperature low-low < 480 Deg. Celsius (arming

at) 510 Deg. celsius.)12. Fire protection ch-2 MOT level <-100 mm 2 out of 3

sonar probe- enabling with MOT level> - 50 mm13. UTR manual trip14. Fire protection push button - 1/215. Remote trip test relay (ATT)16. ATRS shutdown programme

b. MECHANICAL PROTECTION DEVICE :a. Axial shift high 1 out of 1 (Thrust bearing trip device)b. Condenser vaccum lo-lo (Hyd. low vaccum device) 1 out of 1c. TG over speed trip device - 1 3300 RPM 1 out of 1d. TG over speed trip device- 2 3330 RPM 1 out of 1e. Main trip valve handle - 1 --------------- local/ governing rackf. Main trip valve handle- 2 ---------------- local/governing rack

2.2 B F P a. START PERMISSIVES :-1. Deareator level not low2. Lube oil pressure adequate > 1.5 ksc3. Motor bearing temp. not high (<75 deg. C.)4. Suction valve full open5. Suction pressure of booster pump adequate > 2.0 KSC6. Cooling water pressure adequate > 2.0 KSC7. Emergency push button released8. Discharge valve closed or header pressure > 90 Kg/cm2

102

b. TRIPS1. Motor [DE/NDE] bearing temp. high > 85 deg. C2. Main pump bearing temp. high > 85 deg. C3. Lube oil pressure low <0.8 KSC.4. Working oil temp high-high > 130 0 C.5. BFP running & main pump suction pressure low < 8 KSC6. Main pump casing diff. temp. high > 30 deg. C.7. Pump flow high > 430 T/HR.8. Deaerator level low-low9. Motor vibration high-high. (not in service)10. feed water differential temp. high > 13o C. (not in

service)11. Emergency push button.

2.3 CEP a. PERMISSIVES :1. Suction valve full open2. Hotwell level adequate3. CEP released

b. TRIPS1. Hot well level low-low2. Suction valve not open3. CEP running & descharge pressure low < 14.5 Ksc (at present

not in service)

2.4 INTERLOCKS FOR HP - BYPASS SYSTEM 1. HP. bypass BP-1 or BP-2 opening less than 2% automaticaly closes

bd valve.2. If openings of either of the bypass valves BP-1 or BP-2 are

above 2% the control of spray water valves- BD, BPE-1 & BPE-2 shall be canged to ' auto' mode not withstanding their initial conditions.

3. If BP valve position drops to 2% open it will receive a close command to ensure positive shut off.

4. If the steam temperature downstream of the BP valve becomes > 380o C the closing signal for these valves are initiated, accom panied with an alarm, in this case, the BP controller will transfer itself from auto to manual.

2.5 INTERLOCKS OF AUXILIARY PRDS 01. When press cont. low range in service, the valve position 0-100

% corresponds to 0-27. Kg/cm2 of spray water pressure.

2. Steam pressure controller position 0 to 40% corresponds to 0 to 100% of pressure controller low range.

3. When pressure controller low range opens by 5% the BD2 and temperature controller are automatically switched over

to auto.4. When pressure controller. high range is in service the valve

posi tion 0-100% corresponds to 27 to 40 kg/cm2 of spray water

pressure.5. Steam pressure controller position 40 to 100% corresponds to

0-100% of pressure controller high range valve.

there is no set point for spray water pressure. It is automatically set. (as per 01 & 04 the set point is fixed for low range valve / high range valve open condition.)

3 GENERATOR & AUXILIARIES

3.1 TECHNICAL DATAa. GeneratorRated MW Capacity : 200 MWRated MVA Capacity : 247 MVARated Terminal Voltage : 15.75 KVFull Load Current : 9054 AConnection : Double StarSynchronous reactance x

d'

unsat.) : 205 % ; 2.06/900 pri

: 28.77 /900 sec (sat.) : 22.5%Transient reactance x

d "(unsat.) : 23.4%;0.235/900 prim;

: 3.28 /900 sec (sat.) : 26.6 %Sub Transient reactance xd (unsat.) : 17.9% (sat.) : 21.4 %Neg. Seq. reactance (Unsat.) : 25.2 % (sat.) : 21.7 %Zero Seq. reactance (Unsat.) : 10.5 % (sat.) : 8.4 %Gen. prim load impedance : 1.004 /900 prime

: 14.04 /900 secShort Circuit Ratio : 0.49Rated Power Factor : 0.85NGT Details

Make : B.H.E.L.

: 15.75/240V, 50 KVA

: Secondary mid pt. eathed

: Secondary earthing resist.

0.42, 330A 240V

b. Generator Transformer -

Rated MVA Capacity : 240 MVA

Voltage Ratio : 420 / 15.75 KV

Vector Group : Yd5

Cooling : OFAF

% Impedance : 12.868

Grounding : Solid

c. Unit Aux. Transformer

Rated MVA Capacity : 12 / 16 MVA

Voltage Rario : 15.75 / 6.9 KV

Vector Group : Dy 7

Cooling : OFAF

% Impedance : 7% at 16 MVA

Taps : OLTC; + 5% to-10% 0n

HV

Grounding Resistance : 12.712

105

3.2 PROTECTIONS1. Generator differential 87G2. Generator & generator (transformer or overall differential)

differential 87 GT3. Generator loss of excitation 40G

Generator loss of excitation 2A/ 40G timer 2 secGenerator loss of excitation 2B/40G TimerGenerator loss of excitation 40/27G under voltage relayGenerator loss of excitation 40GZ tripping relayGenerator loss of excitation 40GY auxiliary to 2B/40G

4. GT over fluxing 99 GT5. Low forward power 32 G1

Low forward power 2.32 G1 timer 2 Sec6. Reverse power 32 G2

Reverse power 2B/32 G2 50 Sec7. Back up impedance 21G R,Y,B

Back up Impedance 2A/21G timer 1.2 secBack up Impedance 2B/21G timer 1.5 sec

8. Stator earth fault St 1 64 G1 NGRStator earth fault St 2 64 G2 Open Delta

9. Inter turn fault 50 GI10. Rotor earth fault IWX - 161 (excitation system) Stg-I+Stg-II11. GT restricted E/F 64 GT12. GT standby E/F 51 NGT,IDMT13. Generator over voltage 59 G

Generator over voltage 2/59 G timer14. O/H line differential 87 L15. Negative phase seq. 46G16. Generator overload 51 O/L alarm17. Local breaker backup 50Z timer swyd .2 sec

Local breaker backup 2/50Z timer swyd 0.2 sec18. Pole slipping 95 G

Pole slipping 98 G19. UAT differential 87 UTA

UAT differential 87 UTB20. UAT backup 0/C 51 UTA

UAT backup 0/C 51 UTB

106

a. GENERATOR PROTECTION 86G OPERATES UNDER THE FOLOWING CONDITIONS -

1. GT fire protection (disconnected) 30 A2. GT pressure release valve. 30 B3. GT BucholTZ 30C4. Busbar protection zone ''C'' 30D5. LBB protection. 30E6. Exitation system fault (Class - A) 30Z7. Generator differential protection. 87G8. Generator overhead line differential protection 87L9. UTA diferential protection 87 UT10. UTB differential protection 87UTB11. Generator over voltage 59GC12. Generator inter-turn fault 50 GI13. Generator earth fault main one 64 GI14. GT restricted earth fault 64GT15. Generator pole slipping protection 98G16. Low forward power protection 2/32G1

this operates UTR-A / UTR- B

OPERATION OF 86G TRIP RELAY LEADS TO THE FOLLOWING :-

1. Trip unit bus 'A' 6.6 KV (intiate fast change over from UAT to station)

2. Trip unit bus 'B' 6.6 KV (Intiate fast change over from UAT to

station)

3. Trip generator breaker / transfer coupler breaker

4. Trip field breaker

5. Trip UTR - A

6. Trip UTR - B

7. Trip 286G

8. Trip 386 G / GX

9. Trip 486 G

107

b. GENERATOR PROTECTION 286G OPERATERS UNDER THE

FOLOWING CONDITINS -1. Generator transformer block overall differential protection

87GT2. Generator stator standby earth fault protection 64G23. UAT A BuchholTz trip 30K4. UAT B BucholTz trip 30 N5. UAT A fire protection 30L6. UAT B fire protection 30P7. Generator negative sequence protection 46GT8. L.B.B. protection 2/50/Z9. From relay 86G 86G10. UAT A Backup overcurrent protection 51 UTA11. UAT B backup overcurrent protection 51UTB12. GT over fluxing timer 99 GTT13. Generator backup impedence protection through 2B/21G2B/21G14. generator reverse power protection 2/32G215. Low forward power protection 32G116. Field failure with machine under voltage 40GZ+40/27G

OPERATION OF 286G TRIP RELAY LEADS TO THE FOLLOWING -

1. Trip generator breaker / transfer bus coupler breaker2. Trip field breaker3. UTR A trip4. UTR B trip5. Trip unit bus 'A' 6.6 KV6. Trip Unit bus 'B' 6.6 KV7. Trip 386G8. Trip 286G

c. GENERATOR PROTECTION 386G OPERATES UNDER THE FOLOWING CONDITIONS -1. Generator backup impedence protection

through 2A/21G 30RY,RB,BR2. Trip relay 86G 86G3. Trip relay 286G 286G4. Generator transformer backup earth

fault protection 51NGT

OPERATION OF 386G TRIP RELAY LEADS TO THE FOLLOWING -

1. Generator Breaker Trip / Transfer bus coupler breaker trip

108

UTR-A OPERATES UNDER THE FOLLOWINGS -1. Trip relay 86G 86G2. Trip relay 286G 286 G3. Faulty excitation system 30F

Regulation cubicle supply failureThyrister fan supply failExcitation transformer over temp stage 2Supply to auto channel failRotor earth fault stage-II (2.2 K OHM)

4. G.T. winding temperature 2 nd stage 30G5. 6.6 KV bus under voltage 30.H6. VAT-A winding temperature 3rd stage 30R7. VAT-B winding temperature 3rd stage 30V8. Generator loss of excitation9. Stator water flow low low (>60 sec)10. Stator water conductivity hi-hi (21micro S/cm)11. Boiler fire off.12. Turbine trip.13. All boiler feed pumps tripped.

UTR-B OPERATES UNDER THE FOLLOWINGS -1. UAT- A winding temeprature 3rd stage 30U2. UAT- B oil temeprature 3rd stage 30V3. G.T. oil temperature 3rd stage 30J4. Trip relay 86 G.5. Trip relay 286G.6. Generator loss of excitation. 40 GZ7. Faulty excitation system. 30F as above8. 6.6 KV bus, A/B under voltage. 30H9. Stator water flow low-low (>60 sec).10. Stator water conductivity Hi-Hi (21 micro s/cm.)11. Boiler fire off.12. Turbine trip.13. All boiler feed pums tripped.

3.3 GENERATOR TRANSFORMER a. TRIP1. Buchzhol tz trip2. Pressure release device at a pressure of 0.35 kg/cm2.3. winding temperature high Alarm at 90 deg.C

Trip at 100 deg. C4. Oil temperature high Alarm at 80 deg. C

Trip at 90 Deg. C

109

b. GENERATOR TRANSFORMER COOLING FANS & PUMPS

FAN AUTO START ( 4 FANS IN EACH GROUP)1. 3 Fan groups. two are normally kept on auto one is kept as

stand by. fan group selected on auto takes start at 65 deg. C winding

temperature & stops at 55.deg.C.

PUMP AUTO STARTINGOut of three pumps two are normally selected for auto

operation and third is kept as standby pump selected for auto operation takes start with closing of field breaker and stops only when winding tem

perature is below 50 deg. C & field breaker is off.

Pump - 1 Takes start instantaneously with closing of field breaker.Pump-2 Takes start after time delay of 30 seconds after field

breaker is on.Pump- 3 Start after time delay of one minute after field breaker is

on.

3.4 UATS a. TRIP1. Bucholotz relay2. On load tap changer bucholotz3. Winding temperature high Alarm at 90 deg.C

Trip at 100 deg. C4. Oil temperature high Alarm at 80 deg.C

Trip at 90 deg. C

b. FAN AUTO STARTING

TWO GROUPS OF FANS

Each group consists of three main fans and one reserve fan.Both the fan groups take start at 65 deg. winding temperature and stop at 55 deg.C winding temperature.

If one of the main fan in any of the group trips due to any reason reserve fan of corresponding group takes start automatically.

110

3.5 GENERATOR RELAY SETTINGSl. Relay Desgn Relay

type CTR / CT Core PTR, PT Core Relay

settings Remarks

No.

1. Gen Differential CAG 34 10,000 / 5A 0.5 A

87 G Rstab =

18.52. Gen & Gen. Trafo DTH 32 15.75 KV side 0.75 A

(fixed)

Overall Diff. 10.000 / 5 A Blas =

30 %

87 GT 400 KV side High Set

= 1000 %

1000 / 1 A

ICT 0.323/2.488 A

3. Gen. Loss of Excitation YCGF 11 10,000/5 A 15.75

KV/110 V Dia = 14.38 Dia = 1/2 Syn. react

40 G K1 = 0.77;

K5 = 18.6 Offset = K2 = K3 + K4 Offset = 3/4 trans rear

=

2.46 Primary values

K2= 2.5;

K3=o.5; K4=2.0 Dia = 1.03

Offset = 0.1762A/ 40 G VTT 11 t

trip = 2.0

sec.2B / 40G VTT 11 t

treset = 10

sec.

40 / 27G VTIG 12 P/u volts

= 80 Vac = 72.72%

111

40 GZ VAA 51

40 GY VAA 11 180 -

200 ms (fixed) delay

4. GT Over fluxing GTT 11 15.75 kv/110 V

1.2; trip = 12 sec

99 GT Alarm

0.5-1.0 sec (fixed)

5. Low forward Power WCD 13 10,000 / 5A 15.75 KV/110 V

0.5 % = 1.0 MW at UPF (Fixed)

32 G1

2/ 32G1 VTT 11 2.0 sec

6. Reverse Power WCD 11 10,000/5 A 15.75 KV/110 V

p.u.<0.5%= 1.0 MW at UPF (Fixed)

32 G2

2A/32G1 VTT 11 Alarm-

5.0 sec

2B/ 32G2 VTT 11 Trip =

50 sec.

7. Back up impedanceYCG 15 10,000/5 A 15.75 KV/110 V

12;K2 = 0.71 Secondary = 9.0 21 G K1 * K2

= 8.52 Primary = 0.644

setting

% Load impedar

2A/21G VTT 11 St1 :

1.5 sec

2B 21G VTT 11 St II :

2.0 sec

8. Stator Earth Fault VDG 14 NGT Ratio :

PS :1.5V 5.4V on open covers

ST-I 64 G1 15.75 KV/240 V

0.2 about 96% of stator wdg

ST - II 64 G2 VDG 14 15.75KV/110VPS : 5.4

V

open- TMS :

0.2

9. Inter Turn Fault CAG 14 3000/5A 15 %

(0.75 A) Stab. resist not used

50 GI

10. Rotor Earth Fault IWX, B.B.C.

voltage St-I:5.5K, 1.5 secs

= 300 V at St-II

2.2K, 2.0 secs

rated output

11. GT Restricted E/F CAG 14

1000/1A 0.1 A ; Rstab = 30 64 GT

12. GT Standby E/F 51 NGT CDG 11

1000/1A PS : 0.1 A ; TMS : 0.2

13. Gen. Over voltage VTIG 12

KV/110 V 110 % (121 V)

59 G

2/59 G VTT 11 3.0

secs.

14. O/H Line Diff. 87 L CAG 34 1000/1

A PS : 0.5 : Rstab = 30

15. Neg. Phase Seq. CTNM 3110,000/5A I

I25=5% ; K1 = 6.7

46 G K3 =

1.0 : Alarm = 70 %

16. Gen. Overload 51 O/L CTU 12

10,000/5 A 5 A ; 15 secs Alarm only

17. Local BKr. Backup CTIG 39 1000/1

A 0.1 A

50 Z

2 / 50 Z VTT 11 0.2

sces

18. Pole Slipping ZTO 11

10,000/5 A 15. 75 KV/110 V 1set = 5 x 1.1 A

98 G

Reverse offset = 2.27

k1 =

0.93 K2 = 0.61

t =

52.5 ms

99 GY YTGM 14 10,000/5 A 15, 75 KV/110 V

4 H1 =H 2 = 750

Forward reach = 2.0

Reverse reach = 2.9

K1 =

1.1 K2 = 0.91

K3 =

2.0 K4 = 1

K5 =

1.5 = 750

19. Gen. Under Freq. FIG 11

5KV/110 V 48.0 HZ Alarm only Presently

81 G p.u. /

d.o. diff ; 0.2 removed

20. UAT Differetial DTH 31 (LT) :

1600/ 1 A op. curr : 0.15 A (fixed)

87 UTA ICT : 1.0/0.54 A

30 %

87 UTB (HT) : 750/1 A

set : 1000 %

21. UAT Backup O/C CDG 31 750/ 1

A PS : 1.0 ; TMS : 0.3 UAT HV

side Full Lc.

Current is 78% of CT

primary rating.

114

VI

GRAPHS, CURVES

& TABLES

115

1. EQUIPEMENT - WISE OIL RESERV0IR CAPACITY Name of the Equipement Oil Brand Tank/ Reservair

Capacity.1. Coal Mill SMSP 320 1200 2. Coal Mill -Roller sembly SMSP 680 90 (3 Rollers)3. Coal Feeder- Gear Box SMSP 320 034. Mill Reject conveyor ( MR) G/ Box SM SP 320 055. Mill Reject conveyor2 (MR2) G/Box SMCP 320 056. P.A. Fan S. Prime 68 807. F.D. Fan S. Prime 68 4008. I.D. Fan S. Prime 68 3009. APH Guide Brg. S. Cyl-C-800 3010. APH Support Brg. S-cyl-C-800 10011. APH M/D G/Box SS 220 5012. Soot Blowers SMSP 320 0113 HP Dosing Pump G/Box SMSP 320 1014. Clinker Grinder B/Box SMSP 320 0515. Clinker Grinder Fluid copling S. Prime 46 0516. Scrapper Conveyor G/Box SMSP 320 6017. Scrapper Conveyor Fluid copling S. Prime 46 0518. HP Ash water pump S.S. 68 0519. LP Ash water pump SS 68 0520. Ash slurry pump SS 68 4021. Service water pump SS 68 1022. Boiler feed pump (BFP) S. Torque-10120023. Condensor extiaction p/p (CEP) S. film- 16 1524. Plant air Compressor (PAC) Lubrication SS150 0525. Plant Air Compressor (PAC) Cromkare SS150 4426. Instrument An Compressor (IAC) SS 150 4427. ARCW Pump SS 68 0228. Stator Water Pump SS 68 0129. GDT vaccume pump S. Prime 46 0130. LP Dossing pump G/Box SMSP 320 0531. LP Dozing Pump Hydraulic Chamber S. Spin 0532. MOT S. Prime 46 25,00033. CT Fan G/Box SS 220 3534. CT Pumps Thrust Brg. S Pride 20 5035. CT Pump Motors Brg. (Top/Bottom) S Prime 46

120/6036. CW Pump Thrust Brg. S. Prime 30 5037. CW Pump Motors Brg. (Top/Bottom) S. Prime 46

120/60

116

2. EQUIPEMENT - WISE OIL RESERV0IR CAPACITY ST - 1 (WTP)S. No.Brand of Oil Name of Equipments Quantity

(Ltr.)

1. S. S. 68 Compressor of sprinkler 2 Ltr.Dewatering pump near foa 2 Ltr.Alum Metering pump 25Ltr.Effluent Disposal P/P 2 Ltr.Acid Metering pump 25 Ltr.Degasser water pump 2 lTR.Compressor for Mulsifier 2 Ltr.

2. S. S. - 68 Clarified water pump 5 Ltr.Drinking Water pump 2 ltr.Fire water pump 3 ltr.DM water make up pump 2 Ltr.Boiler Fill pump 2 Ltr.Lime transfer pump 1 Ltr.DM water regeneration pum 1 Ltr.Alkali Transfer Pump 1 Ltr.Alkali Metering Pump 3 Ltr.Acid Metering P/P (Ind.) 5 Ltr.

3. S.M.S.P. - 320 Gravity filter air blowe 5 Ltr.Diesel fire water pump 5 Ltr.Mixed bed blower 5 Ltr.G/Box of lime prep. tank 5 Ltr.G/ B of alum soln. tank 5 Ltr.G/B of hoist of cl2 ton. 5 Ltr.

4. S. P. - 46

5. S. Cyl. C-800 G/Box of Agitatior of Clf 5 Ltr.G/ Box of Bridge Drive 5 Ltr.

6. SAE - 10 Mulsifier Jockey Pump 2 Ltr.7. S. S. - 1508. Grease Sump Pump

Servogem -3 Raw water pumpHorticultire PumpFilter water pumpFilter Drinking waterChlorine booster pumpDegassar water pump

117

TURBINE STARTUP CURVES

118

4. Steam Turbine Limit Curves

124

Steam Turbine Limit Curves

125


126


127

6. a GENERATOR UNLOADING SCHEDULE DUE .TO HIGH STATOR WATER

TAMPERATURE

130

6. b GENERATOR UNLOADING SCHEDULE DUE TO HIGH TAMPERATURE OF COLD GAS OR INLET

WATER TO GAS COOLER

131

TABLE - IProperties of dry saturated steam

132

TABLE - IProperties of dry saturated steam

133

TABLE - IITotal heat or enthalpy of superheated steam

Kcal/kg

134


Kcal/kg

135


Kcal/kg

136


Kcal/kg

137

TABLE - IIISpecific volume of superheated steam

cu metre/kg

138


cu metre/kg

139


cu metre/kg

140


cu metre/kg

141

technical diary 200mw

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