technical diary
TRANSCRIPT
ORISSA POWER GENERATION CORPORATION
Technical Diary 2×210 MW
IB THERMAL POWER STATION
BANHARPALI, JHARSUGUDA ORISSA, INDIA
TECHNICAL DIARY
ORISSA POWER GENERATION CORPORATION LIMITED.
IB THERMAL POWER STATION (2×210 MW)
BANHARPALI, JHARSUGUDA. 768234
First Publication 2003
All rights reserved. No part of this publication may be reproduced, stored in a retrievalsystem, copied or transmitted in any form by any other means, electronic, mechanical,photocopying or otherwise without the prior permission of the copyright owner.
For private circulation only.
FOREWORD
"OPGC’s vision is to become a leading profitable power utility by ensuring safe, environmentally responsible, commercially prudent, reliable and efficient power generation. To achieve this vision, it is essential to excel in the Operation and Maintenance of IB Thermal Power station. Our O&M team has brought out a Technical Diary compiling the technical details of the plant like design data, interlocks and protections, permissives covering all functions of the plant. It has been seen that a handy technical diary can serve as a valuable reference for use of plant personnel. I appreciate the efforts of the O&M team, in particular Shri P.K.Dora, for bringing out this edition of the Technical Diary in the shortest possible time. " Sankaran Subramaniam DIRECTOR (OPERATION)
MESSAGE
"I'm happy and proud once more that OPGC is ready with a technical document, which is going to serve the long felt need of people to have a handy technical reference on the Ib Thermal Power Station.
My sincere thanks to Mr.P.K Dora and his team for the hard work they have put in to make this possible.”
Anil K. Gupta,
Advisor, AES
MESSAGE
“It is my pleasure to know that a technical diary of ITPS being brought out by the in house effort of our own staffs. This technical diary contains plant data, equipment design specifications, interlocks and protections. I hope this will be of great help as a reference hand book to all the employees.”
A.Gochait,
DGM (PSM)
INTRODUCTION
1. Name & Location Orissa Power Generation Corporation. Ib Thermal Power Station.
Banharpali, Dist-Jharsuguda (Orissa), India.
Latitude-210 42’ North Longitude- 830 52’ East.
2. Station Capacity 420 MW(2x210 MW Units) 3. Climatic condition Max. Temp- 490C Min Temp- 70C Max relative humidity-95 % 4. Land utilization Main Plant 797.51 Acres Ash Pond (A+B) 493.16 Acres Ash Pipe Complex 13.01 Acres Merry Go Round System 85.96 Acres Town ship, Roads & Market 476.12 Acres
5. Fuel 100% Coal, oil support for initial starting & stabilization. i) Transportation from Lakhanpur mines 15 km distance by merry go round system in bottom discharge wagons. Loading point is approx.10 km from plant ii) Consumption–8016 MT/day for design coal.
6. Start up Power Through 2x55 MVA, 220/6.9 K.V.3-Ø
station transformer.
7. Cooling Water System Closed Loop with forced draft cooling tower.
8. HP/LP By pass Capacity 60% of MCR. 9. Heat Rate 2500 Kcal/ Kwh.
10.Ash disposal Disposed to ash pond in form of ash slurry with 100% ash water recycling system.
11.Chimney RCC multi flue, 220 m. High.
SECTION – 1
BOILER & AUXILIARIES
1.1 GENERAL SPECIFICATION
i) Manufacture BHEL (C.E. design). ii)Type Single reheat, natural circulation type, single drum, balanced draft, dry bottom type designed for firing coal as main fuel. iii) Boiler designation 13868 181 63.5 1778 NCRR, 10592 130 63.5 Design code: ISO-R 831 iv) Type of firing Tilting tangential. v) Design pressure, Ksc Drum 177 SH O/L 164 vi) Water volume, m3 Generating surface 125.00 Drum 40.00 Economiser 20.00 Super heater 95.00 Reheater 50.00_ Total water volume 330.00 vii)Heating surface, m2 Economiser 8087.00 Super heater 7416.00 Reheater 2656.00 Water wall 3493.00 Total heating surface 21652.00 viii) Minimum load at which steam generator can be
operated continuously with complete flame stability without oil support. 2 Mills at 50% capacity.
1.2 FURNACE SPECIFICATION i) Type Fusion welded wall. ii) Dimension 10,592 x 13,868 x 43,130 mm (D×W×H) iii)Total volume 5240m3 iv) Combustion chamber volume 4100m3
iv)Bottom Dry v)Draft Balanced vi)Effective projected radiant surface 2100m3 vii)Design pressure ±400mm wc @67% yield strength viii)Heat liberated by fuel 1,01,300 (Kcal/hr/m2) at 100% Per unit furnace vol. 65,550 (Kcal/hr/m2) at 60% ix)Fuel heat input 534.0 x 10 6 Kcal/hr.
1.3 WATER WALLS Front wall Sidewall Rear wall Furnace roof 2nd pass
i)No.of Tubes 181 130 181 120 120 ii)Dia(mm) 63.5 63.5 63.5 51.0 44.5 iii)Material --- -----------SA210 Gr.C--------------SA209T1 SA210Gr.A1 iv)Thickness -------------------5.5 mm-------------- 4.5 mm 4.5 m v)Design pr.(Ksc) --------- --------- 179.8 ---------------- 176.8 174.8 vi)Down comers. a)Nos 6 b)Dia(mm) 406.4 c)Pressure 179.5 Ksc. d)Material SA 105 Gr.C vii)Water wall headers Bottom Ring header Water wall header a)Nos. 04 07 b)Dia (mm) 273.0 219.1 c)Material SA 106 Gr.C SA 106 Gr.C d)Design pr.(Ksc) 175.4 177.0
1.4 DRUM i) Material SA-299 ii) Design Pressure, Ksc 177.00 iii) Drum operating pr. Ksc 166.00 iv) Design temp 3540C v) Overall length, mm 15,000 vi) Shell length from weld to weld, mm 10,620 vii) I.D/O.D, mm 1778/2079 viii) Thickness, in mm (straight portion/dished portion) 170/135 ix) No of distribution headers 6 x) No of cyclone separator/ secondary drier 58/58 xi) Permissible temp difference between Top& Bottom 500C
xii) Drum level indicator Location Type No & make a) MCR Conductivity 2,BHEL b) Drum DWLG 2,Yarway c) Fireman’s floor Conductivity 2,BHEL
1.5 SUPER HEATER
LTSH PSH FSH i) Type convection Radiant Radiant ii) Direction of flow counter parallel parallel iii) Heating surface (m2) 3035 1097 1543 iv) No of Tubes 480 232 357 v) O.D.(mm) 44.5 47.63 44.5 vi) No of elements/assembly 4 8 3 vii)Tube pitch, mm 114/96 457.2/57 114.3/96 (across gas path/along gas path) viii) Material SA210 Gr C SA213 TP347H SA213T22 SA 213T11 SA 213T22 SA 213T22 SH HEADER i) Max operative pressure, Ksc 155.00 ii)O.D, mm 406.4 iii)Thickness, mm 44.5 iv) Max SH steam temp. 540 + 50C
1.6 REHEATER
i)Type a)Front RH-Pendent b)Rear RH –spaced. ii)Design pressure, Ksc 44.45. iii)Max operating pressure, Ksc 38.5 iv)Total heating surface, m2 2656 v)Control Burner tilt. vi) Gross length per tube 10,000 mm (approx.)
vii) Total No of tube 59 assemblies viii) O.D, mm 54.00 ix) Tube thickness, mm 3.6 x) Tube material SA 213 T22,T11, T91, SA209 T1 xi) Tube pitch, mm a) across gas path-228.60 b) along gas path- 100.00
xii) Reheater Header a) Material SA-213 P22 b) O.D, mm Inlet-406.4, outlet-558.8 c) Thickness, mm Inlet-46.0, outlet-45.0
1.7 SUPER HEATER & REHEATER TEMP. CONTROL
1.7.1 SH ATTEMPERATOR
i)Type Spray mixing type. ii)Location Between LTSH & Platen SH. iii)No of stages One iv)Material SA 335 P 12 v)SH temp range that can be maintained between 60% to 100% of boiler MCR 5400C+5 vi) Spray water flow, T/hr max-34, normal-17, min-1.7 vii)Spray water source BFP discharge.
1.7.2 RH PRIMARY TEMP. CONTROL (BURNER TILT CONTROL)
i)Max. angle of tilt + 300
ii)Tilt mechanism Power cylinder. iii)RH temp range that can be maintained between 60% to 100% boiler MCR 5400C +5
1.7.3 RH EMERGENCY TEMP.CONTROL i)Type Spray mixing type. ii)No. of stages One iii)Location Cold RH Line. iv)Material SA 106 Gr. B v)Spray water source BFP discharge.
1.8 ECONOMISER i)Type Plain tube, seamless, continuous loop in line ii)No. of blocks 2 iii)Material SA 210 Gr. A iv) OD/thickness(mm) 44.5 / 4.5 v) Tube pitch (mm) a) across gas path-96
b) along gas path-130 vi ) Heating surface 8070 m2
vii) Gas velocity at 2nd pass of boiler at100% MCR 8.0 m/sec viii) Design pressure 181.9 Ksc. x) Economiser Header I/L Header O/L Header a)Material SA-106 Gr. C SA- 106 Gr. C b)Outer diameter, mm 323.9 323.9 c)Max. operating pr. Ksc 171.5 171.5
1.9 REGENERATIVE AIR PREHEATER
i) Type Bisector, Regenerative ii) Size 27 VIM 2000 (Bisector) iii) No. per boiler Two iv) Arrangement Vertical v) Element Height 2000 mm vi )Heating elements. a) Hot end/hot intermediate Element type DU (24 gauge) Height 850 mm Material carbon steel b)Cold end /cold intermediate Element type DU (22 gauge) Height 300 mm Material corten A vii)Rotor Seals. a)Radial seals hot end 2.5 mm thick corten A Radial seals cold end 2.5 mm thick corten A b)Axial seals 2.5 mm thick corten A c)By pass seals 1.6 mm thick corten A d)Rotor post seal hot end 6 mm BM-C20 Rotor post seal cold end 6 mm BM-C20 viii)Bearings a)Support bearings Spherical roller thrust SKF/FAG- 294/500 b)Guide bearings Spherical roller SKF/FAG-23060 CCK/W 33 ix)Oil capacity. a)Support bearing 150 litres. b)Guide bearings 25 litres. x)Oil circulation system Guide bearing a)Pump Hypo screw pump
No. per boiler 4 Model No. HSTR 3 Type 976 Size 1” x 1” Capacity 15 LMP b)Drive motor 0.55 Kw, 3∅, 50 HZ, 415V, 910 rpm, Insulation class F Support Bearing. a)Pump Hypo screw pump No. per boiler 4 Model No. HSTF 3 Type 976 Size 1” x 1 “ Capacity 15 LMP b)Drive motor TEFC rating 0.55 Kw, 3-∅,50 HZ, 415V, 910 rpm, insulation class F Heat exchanger Horizontal & shell & tubular type, capacity 7500 KL/hr. xi)Cleaning device Power driven soot blowing
a)Motor detail 0.18 kw,3∅,50 HZ,415 V,1380 rpm, insulation class F b)Reducer Allroyd gear, reduction ratio 4000:1 c)Steam consumption 2000 Kg/hr/service, at 18 Ksc,150oC x)Rotor stoppage Alarm Go switch APCO Input power 105-135 V, 50HZ Alarm power 120 or 230 V AC 10 Amps 10-150 V DC 2 Amps
1.10 ID FAN i)Manufacturer BHEL ii)No.per boiler. 02 iii)Type NDZV 31 SIDOR, Orientation Top horizontal Delivery Radial, double suction,
central discharge. iv) Medium handled Flue gas v) Fan drive & type Hydraulic coupling SVNL 1150, Voith
vi)Fan regulation Hydraulic coupling vii)Fan design rating Capacity 224.15 m3/sec. Total head developed 445 mmwc viii)Temp. & specific wt. of medium 1500C & 0.7918 Kg/m3
ix)Fan reserve over MCR
Flow 26.3% Pressure 32.0% x) Fan Diameter of impeller 3255 mm No. of blades 11 Weight 51,000 kg. Moment of inertia referred to fan shaft. 48,870 kg/m2
xi)Bearings Sleeve bearing. Fixed bearing Thrust collar 2 nos. 8”x c Expansion bearing 8” x c x)Drive motor Make BHEL, Hardwar. Type Squirrel cage induction motor Rating 1500 KW, 6600V, 3-∅, 50 HZ, 750 rpm Duty type Continuous duty, 167.4A Efficiency at 100% load 95.6 % Weight of motor 11,600 kg.
1.11 FD FAN i) Manufacturer BHEL, Ranipet ii) No. per boiler 02 iii) Type AP 1-20/11, axial reaction. iv) Medium handled Ambient air v) Location Ground level vi) Orientation Horizontal delivery vii) Type of fan regulation Blade pitch type viii)Fan Design Rating Capacity, m3/sec 150 Total head developed, mmwc 465 Temp. of medium 550C Specific wt. Of medium 1.0535 kg/m3
Speed 1480 rpm ix)Fan Reserve. Flow 30.7% Pressure 56.0% x)Fan Impeller diameter 1990 mm No. of blades 23 Aerofoil type Material of blade Al Mg Si lF 2
Hub diameter 1100 mm Wt. Of fan 8500 kg.
Fan drive coupling Regiflex type xi)Bearings
Fixed Bearings NU 230C3, 7230 BVA Expansion bearing NU 230 C3
xii)Drive motor. Make BHEL, Hardwar. Frame size LC 00710 H 04 AIH Type Squirrel cage induction motor Rating 920 KW, 6.6K V, 50 HZ, 1500 rpm, Continuous duty, 100.2A Weight of motor 7730 kg. xiii)Lubrication
Fan Forced oil lubrication Motor Grease lubrication
xiv)Lube Oil System No. of oil pumps Two Make Hypo gear pump Capacity 70 rpm Discharge pressure 12 bar Max. operating pressure 16 Ksc.
Alternative pump make IMO screw pump Lube oil pump motor 3.7 Kw,415 V,50HZ,1450 rpm, class of insulation B
No. of coolers Two Oil tank capacity 450 litres Oil heater Oil immersion type, 4 KW, 415V, 3-∅, 50HZ.
1.12 P.A. FAN
i) Manufacturer BHEL ii)No. per boiler 03 iii)Type NDZV 20 HERAKLES. iv)Medium handled Hot Air. v)Orientation Bottom delivery with 450 inclined suction chamber. vi)Location Ground mounted on concrete floor vii) Type Of Regulation Inlet damper control viii)Fan Design Rating Capacity, m3/sec 71.50 Total head developed, mmwc 808 Temp. of medium 3120C Specific wt. of medium 0.5817 Ksc. Speed 1480 rpm
ix)Fan Reserve Flow 24.3% Pressure 30.7% x)Fan Driving Coupling BHEL make pin type flexible xi)Fan Impeller dia 2113 mm Wt. Of fan(without motor & coupling) 8500 kg. xii) Drive motor Make BHEL, Hardwar. Frame size LC 00710 H 04 A-2H Type Squirrel cage induction motor Rating 800 KW, 6.6KV, 50 HZ, 15500 rpm Continuous duty, 85A Weight of motor 9540 kg.
xiii)Lubrication Fan Forced oil lubrication Motor Grease lubrication
xiv)Bearings Fixed Bearings Dodge sleeve 5 .7/16” RT Expansion bearing Sleeve bearing 5.7/16” RT
xv)Lube Oil System Pump type Screw pump. Design pressure, Ksc 8.0 LOP Motor. 1.5 KW, 415V, 3-∅, 1440 rpm, class of insulation B, Squirrel cage motor. Lub oil filter 2 nos. basket type, SS mesh, 60 microns. Lub oil cooler 2 nos. horizontal tubular type Oil tank capacity 315 litres
1.13 FUEL PREPARATION AND FIRING SYSTEM
1.13.1 OIL BURNER L.F.O BURNER
i)Service Initial start up purpose. ii)No. of oil guns 4 nos. oil guns in each AB, CD, EF
elevation. . iii)Burner Tilting tangential, corner fired. iv)Atomiser media External mixed ,constant pressure service air. v)Atomiser designation Spray plate 90 J16, 90 J14 vi)Max. capacity 7.5% MCR heat input per elevation & total 22.5% MCR. vii)Min. allowable LFO pressure 2.1 Ksc viii)Min. allowable air 5.25 Ksc.
IGNITORS
Make Simmonds, USA Service Oil burner light off Type High energy arc ignitor (HEA) Location Burner mounting panel Input 110V AC, 50HZ, 5A rms Output Min. 4 sparks/sec, 12 joules/spark. Duty cycle 15 min. ON, 30 min. OFF. Spark rod 5/8” SS tube with flexible SS wire braid, 18ft long. Igniter tip, mm Length-191, Diameter-15.9 + 0.15 Operating temp. 650C max.
Retractor Assembly Air cycle stroke 300 mm Air pressure 5 to 7 Ksc. Flexible cable Length 7.6 mtr. Max. Bend radius 100 mm
FUEL OIL SPEFICATION LFO i)Standard LDO to IS-1460/1994 . ii)Flash point min (PMCC) 560C iii)Viscosity max. 2.5 to 15.7 CST at 380C iv)Total sulpher, max. 1.8% by weight v)Gross heating value(Typical) 10720 Kcl/kg FUEL OIL PRESSURISING UNIT i)Light diesel oil pump 2 nos per both units. Make Tushaco, Delta corp. Capacity 110 LPM at min cst. Drive motor 7.5 KW, 415V, 50HZ, 3-∅, 910 rpm, Insulation class B,15.4A ii) Heavy fuel oil pump† 4 nos.for both units. Make Tushaco, Delta corp. Pressure 20 Ksc. Drive motor 22 KW, 415 V, 50HZ, 3-∅
Insulation class B, 1460 rpm.
FUEL OIL STORAGE TANK Type Vertical cylindrical Vertical cylindrical Capacity 5000m3 1000m3 Numbers 02 02 Size, m 20.0 ∅ x 18.0 10.0∅ x 15.0
DATA CHART.
LFO BURNER LFO AIR
BURNER TYPE
Pressure (Ksc) Flow (Kg/hr) Pressure (Ksc) Flow (Kg/hr) Max Rating 4.00 1000.00 5.25 135.00 Min Rating 2.1 600.00 5.25 145.00 During Scavenge 0 0 5.25 180.00 † At present LFO is burned in all the elevations.
1.13.2 GRAVIMETRIC COAL FEEDER
i) Make BHEL, U/L Stock Equipment Company, USA ii)Type 36” GF 76’CD, iii)Capacity 70 T/hr per feeder. vi)RPM 959 vii)Main drive 5.5 Kw,415V,3∅,50HZ. vii)Cleanout conveyor drive 0.25kw,415v,3∅, 50HZ,910rpm.
1.13.3 PULVERISER i)Make BHEL ii)No. per Boiler 03 iii)Type BBD11-4760 iv)Capacity 105 T/hr./mill. v)Fineness 70% through 200 mesh. vi)Max. feed size to mill 25 mm. vii)Size of grinding roll 1/3-50mm 1/3-40 mm 1/3-30 mm viii)Min. mill capacity without chattering 30 T/hr.
ix)Mill operating temp. 80-900 C x)Design. Air flow 70 T/hr xi)Design pressure 1500 mmwc xii)Drive motor Make BHEL Rating 2250 KW, 6.6KV, 50 Hz, 3-∅, 266.5A, 993rpm, squirrel cage
induction motor, Insulation class-F Bearings DE NV 240 EM & 6240 MC3 NDE NV 240 EM. xii)Lub Oil System a) L.P. Pump Make / Type Allweiler Tushaco/ Screw Pump Number 02 per mill. Flow 135 lpm at 10 bar LP side 2×44 lpm Operating Pressure 6 Ksc. Drive details 7.5 kw,415V,50 HZ, 3-∅,
715rpm, Insulation class-F Electrical heaters in tank 1 W/cm2, 2×3 KW, 415V,One heater heats 1700 litres From 100 to 350C in 5 hours. b)H.P. Pump Number 2 Per Mill. Flow 4 x 10 Lpm. Max pressure 100 bar. Drive details 11 KW, 415 V, 50 Hz 3-∅, 960rpm, 22.7A c) B & S Pump Number 01 Per Mill. Flow 2 x 3.5Lpm. Max pressure 60 bar. Drive details 1.5 KW, 415 V, 50 HZ, 3-∅. d)Dual basket filter Quantity 01 per Mill. Type RFL DP 661F10B3, 1/50,8062+BM Filtration nominal 20 Micron. Normal flow 660 lpm. e) Oil Cooler Qty. One per Mill Type MAL 353 K2K3C. Oil flow rate 135 lpm. Oil pump inlet/out let. 550C/450C Fresh water flow rate 250 lpm. Water pump inlet/out let 380C /40.40C Heat exchanger surface 7.40 m2
f) Rectangular Oil Reservoir. Dimension 1.8m x 1.2m x 1m Capacity 1770 litres Qty One per Mill. Nominal capacity 950 litres. g) Aux Reducer Make C.Messian Durand, France. Reduction type H3 H19 High/ Low speed 1450/14.58 rpm Oil 80 litres. Drive details 37 kw,63A,50 HZ, 3∅, 415 V, Insulation class –F. h) Fluid Coupling. Make Fluidomat ltd, Dewas Model SM 06 RPM 1500 i)Main Sped Reducer (MSR) Make Flender Macneil, India Type SZN 630 Pinion, mm 825.6 OD, 760.48 PCD. Length of teeth 560 mm Quantity One per Mill j) MSR Lube Oil Pump Type Gear pump Flow 220 lpm. Drive details 5.5 kw,12A,50 HZ.3∅, 415 V,
Insulation class F, 945rpm. Quantity One per mill. k) Girth Gear Greasing Unit. No.of spray Nozzles/valve manifold 06 Quantity One per Mill Flow 3.8 cm3/cycle Air consumption 5.0 m3/hr at 2 bar Drive 0.55 kw,50 HZ.3∅, 415 V, 1400rpm
1.13.4 COAL PIPE
i) Pipe Size, OD (mm) 558.0, thickness 12.5 ii) Material AP1 5L Gr B
1.13.5 COAL BURNER Type Tilting tangential No.per Boiler 24 Capacity 38 x10 6 Kcal/hr/burner Position Corner Control Air Damper.
1.13.6 SEAL AIR FAN No. of fan/Mill 2(One working, one stand by) Type Single stage centrifugal Orientation Horizontal suction, Developed pressure 1662 mmwc Drive motor Crompton Greaves make,
120KW, 415V, 3∅, 50HZ, 2960 rpm, Insulation Class-B
1.14 SCANNER AIR FAN
No. per boiler 1 AC driven,1 DC driven Duty Continuous Medium to be handle Dust laden air Max.dust con 300 mg/m3
Capacity 5000 m3/hr. Presure developed 200 mmwc Driving motor 415V, 3∅,50HZ, 5.5kw 10A, Insulation class-B D.C. motor 5.6 KW, KEC make,33 A, Insulation Class-F Fan speed 2850 rpm
1.15 SOOT BLOWERS Type Fully automatic sequentially
controlled micro processor . based steam soot blowing. Source of steam SHH-10 (LTSH-O/L Headers) / PRDS
Wall blower LRSB. i)Number 56 18 ii)Type WBIE LRDIE iii)Motor power 0.56 KW 0.37 KW 0.45 KW iv)Cleaning medium Steam Steam Pressure 20 Ksc 20 Ksc Temperature 3000C 3000C Consumption (per cycle) 3292.8 kg 8013.6 kg. v)Blow duration 1.5 min/blower 9 min/ blower vi)Cycle 84 minute 162minute
1.16 ELECTROSTATIC PRECIPITATOR i)Manufacture BHEL ii)Type FAA-6 x 45-2 x90135-2 iii)No.of precipitators/boiler Two iv)No. of gas path/boiler Two v)No. of fields in service in each gas path Six vi) In let design conditions Gas flow rate 351.27/m2/sec. Temp. 1430c Dust conditions 82.44 gms/Nm3
vii)Guaranteed collection efficiency for design conditions 99.82% viii)Pressure drop across the precipitator for design conditions 20 mmwc ix)Velocity of gas at electrode zone on total area 0.72 m/sec. x)Treatment time 37.5 Sec. xi)Collecting electrodes. a)No. of collecting electrodes per field 61 b)No. of collecting electrodes plates(six plates are arranged in each row per field) 366 c)Space between the centers of collecting electrodes across the gas path in mm 300 d)Nominal length of collecting electrodes per field in the direction of gas flow 4.5 m. e)Total No. of collecting plates per boiler 4392 f)Nominal length/Height of collecting plates 750/1350 mm g)Sp. Collecting area 249 m2/m3/sec.
h)Total projected collecting surface 87,480 m2
xii)Emitting Electrodes a)Type Spiral with hooks b)Size 2.7 mm diameter c)No. of the electrodes in the frame forming one row 54 d)No. of electrodes in each field 3240 e)Total No. of electrodes /boiler 38880 f)Total length of electrodes per field 18176.4 m. g)Plates/wire spacing 150mm xiii) Rappers for emitting electrodes a)No. & types of rappers One drop hammer for two nos. of electrodes. b)Rapper size 30 kg. c)Frequency of rap. 10 raps/hour d)Drive Geared electric motor controlled
by synchronous programmer. xiv)Hoppers a)Type & No. Pyramidial,48 b)Capacity 8 hours storage c)Heating Electrical heating provided for bottom of hoppers. xv) Gas Distribution System Inlet Outlet Type perforated plate U-shaped thin
sheet Quantity 2 set 1 set xvi) Electrical items. 1) Rectifier Rating 70KV(peak),1000mA(Mean) Number 24 Type Silicon diode, full wave bridge Connection. Location Top of precipitator. 2) Rectifier control panel Number 24 Type Thyristor. Location In control room at ground level 3) Motors for emitting and collecting rappers Quantity 24 nos. Rapping 415V, 3∅, 50HZ, 0.26kw 1A, 1310rpm, continuous rapping. Location On roof top of ESP.
4) Heating elements a)Hoppers for 48 hoppers @ 6 KW per hopper 288 Kw b)Shaft insulators for 24 insulators @ 1 KW per insulator 24 Kw. c)Support insulators for 96 insulators @ 1 KW per insulator 96 kw d)Estimated power consumption including heating elements & rappers 630 Kw. 5) Recommended current setting Fields 1 2 3 4 5 6 Current in mA 250 400 550 700 850 1000 xvii) Operating sequence of rapping mechanism Auto
1.17 PRESSURE REDUCING & DESUPERHEATING STATION (PRDS) i)Steam source MS Line at 150 Ksc & 5400c ii)Flow capacity Design-80t/hr. Normal-56t/hr. iii)Spray water BFP discharge iv)Operating pressure 16 (Ksc) g v)Operating temp. 2200c vi)Header size 273 x 635 mm vii)Material SA 335 P22
1.18 MAIN PIPELINES Main steam Hot reheat Cold reheat Feed water No. of lines 2 2 2 1 ID x Thickness, 255.6x47.0 508.6x28.0 457x20.0 323.9x36.0 (in mm) Material SA335P22 SA335P22 SA335P22 SA106Grc SA106Gr.c
1.19 BLOWDOWN VESSELS
IBD CBD Test Pressure 4.5 ksc 13.5 ksc Max working Pressure 3.0 ksc 8.0 ksc Operating Temp 200 0C 180 0C Capacity, m3 2.205 3.930
1.20 SAFETY VALVES
Sr No Valve Tag Location Type of Valve Size mm / inch Valve Set Pr. Ksc Blow Relieving Total Relieving Safety Valve Down Capacity,kg / hr Capacity, kg / hr INLET OUTLET OPEN CLOSE Butt Welded Flange Welded
1 SV1 Boiler Drum Consol 1750WB 76.2 / 3" 152.4 / 6" 177 169.9 4 180360 2 SV2 Boiler Drum Consol 1750WB 76.2 / 3" 152.4 / 6" 180.5 171.5 5 183924 1,2,3 550044 3 SV3 Boiler Drum Consol 1750WB 76.2 / 3" 152.4 / 6" 182.3 173.2 5 185760 4 SV4 Super Heater Consol 1740WD 76.2 / 3" 152.4 / 6" 163.75 158.8 3 161523 161523 5 SV5 ERV Consol 1538VX 63.5 / 2.5" 101.6 / 4" 162.1 158.8 2 101017 101017 6 SV6 CRH Consol 1786WB 152.4 / 6" 203.7 / 8" 45 42.75 5 176760 176760 7 SV7 HRH Consol 1786WD 152.4 / 6" 203.7 / 8" 42.35 40.23 5 140256 8 SV8 HRH Consol 1786WD 152.4 / 6" 203.7 / 8" 42.7 40.57 5 1411372 7,8,9 428868 9 SV9 HRH Consol 1786WD 152.4 / 6" 203.7 / 8" 44.5 42.23 5 147240
10 SVS8 S.B.Line Consol 1811JB 38.1 / 1.5" 63.5 / 2.5" 40 38.4 4 14590 14590
1.21 CHIMNEY
i)No. of flue 02 ii)Wind shield material Reinforced concrete iii)Flue material Steel iv)Chimney height 220 m v)Chimney base dia 28.948 m vi)Chimney raft dia 36.0 m vii)Flue dia 4.60 m
1.22 FUEL
The fuel data on which guarantees given are as follows: PROXIMATE ANALYSIS Description Performance Coal Fixed carbon % 23.0 Volatile material% 23.0 Ash % 42.0 Moisture 12.0 ULTMATE ANALYSIS. Fixed carbon % 31.29 Ash % 42.0 Moisture % 12.0
Hydrogen % 2.44 Sulphur % 0.50 Oxygen % 11.08 Nitrogen % 0.69
1.23 CHEMICAL COMPOSITION OF ASH GENERATED IN ITPS Carbonate % 0.72 Higher heating value 3000 Kcal/kg Grindability index, HGI 55 Ash fusion temp. 1400c Initial deformation temp. 12000c
PREDICTED PERFORMANCES I-FLOW T/HR.
DESCRIPTION HP.HEATERS IN SERVICE HP HEATERS OUT
MCR NCR CL 60% NCR. STEAM
Supper heater out let 690 636.7 410 584.1 Reheater out let 597.9 572.9 377.6 577.4
WATER
Feed water 690 620.5 379.4 554.9 Supper heater spray 0 16.2 34.6 29.2
AIR
Air heater outlet(Primary) 190.24 175.54 131.37 209.6 Tempering Air 82.76 91.02 110.87 58.8 Air heater outlet(secondary) 563.72 508.39 270.41 529.7 Total combustion air 880.77 819 656.7 842.1
FUEL
Coal (HHV=3800 Kcal/kg) 178 165.6 112.5 170.2
Analysis in wt Maximum value Minimum value Average value Sio2 61.76 47.98 54.5 Fe2O3 17.84 4.19 12 Al2O3 29.17 23.02 26.31 CaC 3.01 0.55 1.81 MgO 1.58 0.56 1.06 Na2O 2.51 0.34 1.425 K2O 0.9 0.66 0.78 TiO2 3.4 1.75 2.51 Slagging index of Ash Rba 0.27 0.08 0.2
FLUE GAS
Air heater out let 1048.5 972 665.3 1000.7 TOTAL HEAT TO BOILER (Heat Duty) Kcl /hr. 452.4 420.8 284.9 437.9 II.TEMP(0C)
STEAM Standard Temp. in Drum 349 349 345 347 LTSH O/L 390 393 399 401 SH platen T/L 390 384 366 378 SH platen O/L 500 500 506 496 SH final O/L 540 540 540 540 RH I/L 342 342 330 351 RH O/L 540 540 540 540 WATER Eco I/L 246 245 225 166.5 Eco. O/L 310 309 295 267 AIR Ambient 40 40 40 40 AH O/L(Primary) 335 332 306 290 AH O/L(Secondary) 335 332 306 290 GAS SH platen inlet 1184 1187 1139 1157 RH front inlet 1029 1023 950 1044 RH Rear inlet 885 876 796 865 LTSH inlet 652 643 583 641 Economiser inlet 549 541 498 541 Air heater inlet 359 353 314 311 Air heater outlet 114 143 147 124 III.PRESSURE (KG /CM2)
PRESSURE SH outlet 155 154.1 151 153.2 LTSH outlet 162.9 160.9 154.3 159 Drum 166.1 163.7 155.5 161.4 Eco I/L 171.1 168.2 158.6 165.6 RH O/L 34.483 34.968 22.821 35.885
RH I/L 38.497 36.898 24.088 37.812 PRESSURE DROP SH System 11.1 9.6 4.3 8.2 Re heater 2.014 1.93 1.267 1.927 Economiser(Including static head) 5 4.5 3.1 4.2 IV- PRESURE & DRAFT (AIR & GAS) MMWC. PRIMARY AIR PA Fan I/l 69 66 55 65 PA fan O/L 687 644 467 647 Mill I/L 632 595 436 596 Mill O/L 292 273 188 267 SECONDARY AIR FD fan I/L -16 -14 -7 -15 FD fan O/L 282 258 167 263 AH I/L 227 210 146 212 AH O/L 157 150 123 151 Wind box pressure 100 100 100 Wind box to furnace diff. 125 125 125 125 Furnace -5 -5 -5 -5 SH platen I/L -5 -5 -5 -5 RH I/L -6 -6 -6 -6 LTSH I/L -22 -20 -13 -20 Eco. I/L -27 -24 -15 -24 AH I/L -62 -55 -32 -55 EP I/L -265 -235 -138 -230 ID fan I/L -303 -268 -143 -259 ID fan O/L 34 30 14 28 Flue gas velocity in second pass 8.00 m/sec. V-MILL AND BURNER PERFORMANCE.
No.of Mill in operation 2 2 2 2 Coal flow/Mill(T/hr.) 89.5 82.6 56.1 85.1 Ball charge per Mill(T/hr) 96 96 96 96 Air flow/Mill (T/hr) 136.5 133.28 121.12 134.2 Air temp. at mill I/L(0c) 243 232 184 236 Mill output temp.(0c) 75 75 75 75 Fineness % (through 200 mesh) 76 79 79 77 Mill pressure drop including classifier(in mmwc) 340 322 248 329 Burner tilt (in degree) 0 9 24 -7
VI-O2, CO2 (DRY VOL) AND EXCESS AIR(%)
O2 in gas at Eco O/L% 3.55 3.55 3.55 3.55 CO2 in gas at Eco O/L % 15.57 15.57 15.57 15.57 Excess air gas at Eco O/L % 20 20 20 20 VII-HEAT BALANCE : LOSSES IN %
Dry Gas 4.31 4.27 4.48 3.43 H2o & H2 in fuel 7.05 7.04 7.07 6.93 H2o in Air 0.23 0.23 0.24 0.19 Unburnt carbon 2 2 2 2 Radiation 0.2 0.22 0.31 0.2 Unaccounted 0.5 0.5 0.5 0.5 Manufacturer's margin 1 1 1 1 Total loss 15.29 15.26 15.6 14.25 Guaranteed efficiency 84.71 84.74 84.4 85.75
SECTION – 2
TURBINE & AUXILIARIES
2.0 MAIN TURBINE
2.1 TECHNICAL SPECIFICATION
2.1.1 STEAM TURBINE
i) Make BHEL, Kraftwerk Union Design ii) Type Tandem compound, regenerative, reheat, cylinder having single flow HP turbine, double flow IP & LP turbine iii) No. of stages HP 25 no. IP 20 x 2 no. LP 8 x 2 no. iv) Type HP/IP/LP turbine HPT – Reaction, barrel type, single flow
IPT – Reaction, barrel type, double flow axially split type LPT – Reaction, barrel type, double flow three shell design
v) Nominal rating 210 mw vi) Peak loading 230 mw vii) Rated speed 3000 rpm viii) Max./Min. speed 3090/2850 rpm (51.5 to 47.5 Hz) ix) Speed exclusion range 700 to 2850 rpm x) Over speed set value 11%
2.1.2 DIMENSIONS (IN MM)
HPT IPT LPT i) Height of first stage moving blade 43 66 75.5 ii) Mean dia. of 1st stage moving blade 643 756 1473.5 iii) Height of last stage moving blade 95 100 668.8 iv) Overall length of turbine 15.725 m v) Overall width with cross around pipe 10.5 m (approx.) vi) Total exhaust area (LP turbine) 6.3 x 4.75 m2
2.1.3 BEARINGS No.1 Journal, ø 280 x 140 mm No.2 Radial cum thrust, tilting pad ø 290 x No.3 Journal, ø 450 No.4 Journal, ø 400 No.5 Journal, ø 400 No.6 Journal, ø 400 No.7 Journal, ø 200 Lining material for all bearings Babbit
2.1.4 VALVES
i) 2 main stop & control valves Type EV160 ii) 2 reheat stop & control valves Type IV320 iii) 2 swing check valves in CRH line DN 450 iv) 2 bypass stop & control valves DN 200 Extraction Swing check valves: v) Extraction 1 No valve vi) Extraction 2 1 swing check valve with aux. actuator vii) Extraction 3 1 swing check valve viii) Extraction 4 1 swing check valve ix) Extraction 5 1 swing check valve x) Extraction 6 No valve
2.1.5 WEIGHTS (TONNES) Rotor HPT IPT LPT Rotor 7.5 15.8 48.0 Cylinder assembled (with steam inserts)
56.0 37.0 81.0
2.1.6 CASING TEMPERATURE (0C)
Wall temperature Alarm at Machine must be shut
down at HP turbine casing exhaust
480 500
Outer casing of LP cylinder
90 110
Spray water to LP turbine
Must be switched on at 90oc
2.1.7 BEARING TEMEPRATURE (0C)
Normal operating Alarm at Machine must be shut down at
Below 75oc 90oc 120oc Above 75oc 100oc 120oc
2.1.8 TEMPERATURE DIFFERENCE (0C) (Between Upper & Lower casing section)
Alarm at Machine must be shut
down at HP turbine middle ±30oc ±45 IP turbine front ±30oc ±45 IP turbine rear ±30oc ±45
2.1.9 DIFFERENTIAL EXPANSION
Alarm Trip HP turbine differential expansion
+4.5, -2.50 +5.50, -3.50
IP turbine differential expansion
+5.00, -2.00 +6.00, -3.00
LP turbine differential expansion
+25.00, -5.00 +30.00, -7.00
2.1.10 VIBRATION (ABSOLUTE)
Of bearing housing Of shaft Nominal value for alarm 35µm 30µm above normal value Maximum value for alarm - 120µm Limit value for tripping 45µm 200µm
2.1.11 LOW VACUUM TRIP SETTING
Hydraulic low vacuum Trip < 0.3 bar Electric low vacuum Trip < 0.3 bar Hydraulic low vacuum Trip < 0.6 bar (Bypass operation)
2.1.12 MW OUTPUT
HPT IPT LPT 56.40 MW 53.73 MW 93.03 MW 28% 26% 46%
2.1.13 STEAM PURITY
Continuous operation Start up Unit 1)Conductivity at 25oc continuous measurement at the sampling point. a)Direct measurement i)Alkaline method ii)Neutral method b)following a strongly acid cation exchange method i)Alkaline method ii)Neutral method
Not specified < 0.15 < 0.10 < 0.10
-- < 0.50 < 0.50 < 0.50
µs/cm µs/cm µs/cm µs/cm
2)Silcic acid (SiO2) < 0.10 < 0.050 mg/kg 3)Total iron (Fe) < 0.005 < 0.050 mg/kg 4)Total Copper (Cu) < 0.001 < 0.010 mg/kg 5)Sodium (Na) < 0.005 < 0.020 mg/kg
2.2 TURBINE LUBE OIL SYSTEM
2.2.1 OIL SUPPLY i) Oil tank capacity 32 m3 ii) Highest/lowest oil level from top of 800/850 mm the tank during operation iii) Lube oil temperature at cooler outlet Min 37oc, during operation Normal 45oc Max. 47oc iv) Oil temperature rise across bearings Normal 20oc
Max. 25oc v) Oil temperature at cooler O/L(under shutdown) Max. 75oc vi) First oil filling (estimated) 30m3 vii) Flushing of oil quantity (estimated) 20m3 viii) Pressure limiting value in
jacking oil system 120 bar ix) Safety valve in jacking oil system Max. 170 bar x) Jacking oil pump must be switched on at 510 rpm xi) Jacking oil pump must be switched off at 540 rpm
2.2.2 OIL PUMPS
M.O.P. A.O.P. DC E.O.P. JOP (AC) JOP (DC) Nos 1 2 1 1 1 Make BHEL KSB KSB Allweiler Allweiler
AG Type ETA 150-
50VL centrifugal
ETA 100- 33VL centrifugal
SDF 40- R54 GQW-112
SDF 40- R54 GQW-112
Rated capacity 139 m3/hr
152.24 m3/hr
108 m3/hr 76 LPM 76 LPM
Rated discharge pressure
8.2 ata 6.8 ata 2.3 ata 120 bar 120 bar
Speed, rpm 3000 1485 1425 2950 2950 Drive Turbine AC motor DC motor AC motor DC motor Make - GEC Crompton
Greaves Siemens Wirrkelmann
Voltage, V - 415 220 415 220 Frequency, Hz - 50 - 50 - Motor Power, KW
- 100 13 27.6 28
Rated current, Amp
- 175 128 47.5 152
2.2.3 OIL COOLER i) Type & no. Shell & tube type, 2 x 100% ii) Cooling surface 218 m2 iii) Oil outlet temperature of cooler In operation Min. 38oc, Normal 45oc, Max. 47oc In shutdown Max 75oc iv) Tube material & no. of tubes Admirality Brass IS1545
Total no.1250 v) Design pressure & temperature
shell side 10 kg/cm2 & 100oc tube side 10 kg/cm2 & 100oc
2.2.4 OIL FILTER
i) Duplex oil filter type & no. DN 100 type, 2.82.9.200.500.10 ii) Filtration particle size of thrust bearing duplex filter 37 µm iii) Filtration particle size of MOT filter 250 µm
2.2.5 ESTIMATED OIL REQUIREMENTS OF BEARINGS
Bearing 1 (HPT) front pedestal) 0.8 dm3/s Bearing 2 9.1 dm3/s Bearing 3 4.0 dm3/s Bearing 4 3.5 dm3/s Front generator bearing 3.5 dm3/s Rear generator bearing 5.0 dm3/s
2.2.6 BARRING GEAR
i) Type of drive Hydraulic turbine ii) Method of engagement Hydraulic iii) Cut in/ cut out speed 240/210 rpm iv) Power to rotate turbine 45 KW v) Barring speed 80 – 210 rpm
2.2.7 MAIN OIL CENTRIFUGE
i) Manufacturer Alpha - Laval ii) Capacity 4500 Lph (2 nos) iii) Model MAB 205+54 KW Indirect heater iv) Centrifuge motor 5.5 KW, 415V, 2430 rpm, 11A, Cl.B. inst. v) Bowl speed 8425 rpm apprx. vi) Revolution/counter Rpm 118/125 vii) Antiflood tank capacity 45 lit viii) Feed pumps 4500 lit/hr, at 5 ksc ix) Capacity of dirty oil tank 35 m3 x) Capacity of clean oil tank 35 m3
2.2.8 OIL CHARACTERISTICS (As per IS: 1448)
i) Kinetic viscosity at 37.8oc 47.5 c.s. to 49.5 c.s. Kinetic viscocity at 50oc 28 c.s. ii) Specific gravity at 50oc 0.852 iii) Flash point Min. 200oc iv) Pour point -6oc v) Ash content 0.01 (% by weight) vi) Water content by weight Below the limit of quantitative detectability vii) Mechanical solid impurities - do - viii) Viscosity Index Min. 97 ix) Inorganic acidity Nil
Organic acidity Max. 0.14 mg of KOH per gm of oil x) Neutralization number Max. 0.2 mg of KOH per gm xi) Copper strip corrosion Not worse than no.1 test at 100oc for 3 hrs xii) Emulsion characteristics 40-40-0 (20 minute)
2.3 VACUUM SYSTEM
2.3.1 CONDENSER
i) Type Surface type, double pass with divided water box construction ii) Design conditions: Steam side Water side a) Design pressure full vacuum 3.5 ksc & full vacuum b) Test pressure Filling by water up to 4.5 kg/cm2g 1.0 m above tubes c) Design temperature 85oc 50oc iii) Design CW flow 27,000 m3/hr iv) Design CW temperature 33oc v) Design back pressure vi) No. of tubes length of each tube 7600 mm vii) Tube O.D × thickness 25.4 mm x 1 mm for top row (thickness) 1.2466 mm viii) Tube material 17,902 nos. -90/10 Cu-Ni to BS 2871 in condensing zone 1316 nos. – SS ASTMA-249, T1304 in air air cooling zone ix) Surface area 11,495 m2 x) Pressure drop in CW side 3.6 mwc xi) CW temperature rise 8.8oc to 9oc xii) Water velocity in tube 1.9 m/sec xiii) Weight
Dry 320 MT Operating 530 MT Flooded (1.0 m above tubes) 640 MT
2.3.2 MAIN EJECTOR i) Make BHEL, Hardwar ii) Steam required 1000 kg/hr iii) Min. condensate flow 103 T/hr
iv) Normal condensate flow 254.6 T/hr v) Tube side pressure 24 ksc vi) Tube side test pressure 36 kg/cm2g vii) Shell side test pressure 2.5 kg/cm2g viii) Motive steam pressure 6.5 ksc ix) Motive steam temperature 210oc x) Weight Empty 2875 kg Operational 3245 kg xi) Material: Tube plate steel 42W IS202 Diffuser stage I,II,III steel IS 2073 Gr.C-20 Tube Admirality Brass CZIII BS 2871 Nozzle Stainless steel SS 30CR 13 hot rolled Annealed 136603
2.3.3 STARTING EJECTOR i) Steam requirement of the ejector 3300 kg/hr ii) Working pressure of steam 6.5 kg/cm2g at 210oc iii) Hydraulic test pressure 1.5 kg/cm2 iv) Air removal capacity at 500 mm Hg vacuum 7350 SCFM v) Design temperature 250oc
2.3.4 GLAND SEALING SYSTEM i) Type of control Electro-Hydraulic ii) Model ESS HI iii) Oil used Servo control-46/HLP-68 iv) G.S. control valve actuator REINEKE, GMBH v) L.S. control valve actuator REINEKE, GMBH iii) Self sealing after 40% load
2.3.5 GLAND STEAM VAPOUR FAN
i) Fan Type SHSH ii) Make S.K.Systems, New Delhi iii) Capacity 1080 m3 /hr iv) Drive 3 H.P. 2840 rpm.
2.3.6 CONDENSER ON LOAD CLEANING DEVICE
Manufacturer GEA Energy Systems Debris Filter System i) Type 574 – ‘V’ type ii) Quantity / unit Two
iii) Perforation of screen 5 mm iv) Screen thickness 2.0 mm v) Flow, m3/hr 13,500 vi) Design DP for filter screen 2 bar (g) vii) Discharge during flushing, m3/hr 400 viii) Geared motor drive 415V, 3-ø, 50 Hz, 0.55 KW, 1.4A Flushing Pump ix) Type Centrifugal, horizontal x) Capacity, m3/hr 170 xi) Motor 415V, 3- ø, 50 Hz, 11 KW, 1460 rpm Tube Cleaning System Ball Separator i) Quantity / unit Two ii) No. of ball extraction points Two iii) No. of screens/ball separator Two iv) Normal flow, m3/hr 13,500 Ball Recirculation Pump i) Type Centrifugal horizontal non-clogging type ii) Quantity / unit Two iii) Capacity, m3/hr 60 iv) Design head mmwc 15 v) Design efficiency 60% vi) Motor 1440 rpm, Insulation class B Cleaning Balls Normal Balls Abrasive Balls i) Type Soft Abrasive ii) Diameter, mm 26 25 iii) Density, g/m3 0.22 0.2759 iv) Design temperature, 0C 80 80
2.4 CONDENSATE SYSTEM
2.4.1 CONDENSATE EXTRACTION PUMP i) Manufacturing BHEL, Hyderabad ii) No. of pumps & capacity 2 ×100% iii) Type EN5J40 (2 shaft), vertical centrifugal
canister type iv) No. of stages 5
v) Discharge capacity 675 m3/hr vi) Diff. Head 220 m vii) Input power to pump 494 KW viii) Density of medium handled 0.9896 tonne/m3 ix) NPSH required at the eye of the 1st impeller 3.0 mlc x) RPM 1482 xi) Efficiency of pump 81% xii) Coupling Flexible xiii) Direction of rotation viewed from drive end Clockwise xiv) Suction bore diameter 400 mm xv) Discharge bore diameter 300 mm xvi) Minimum flow through pump 175 m3/hr xvii) Bearings Taper roller bearing 29420E FAG/SKF xviii) Lub. Oil IOC turbine oil 46/Servo prime 46 xix) Motor Manufacturer BHEL, Hardwar Type Squirrel cage induction motor KW rating 600 KW Power supply 6600V, 3-Ô, 50Hz Class of insulation F Efficiency at rated output 94.5% Rated speed 1485 rpm Full load current 66A Weight of motor 4010 kg Bearing DE 6226-c3 NU 224M cyl. Roller bearing NDE 7322-B 7322 B Angular, con. Ball bearing
2.4.2 DRAIN COOLER
i) Position Horizontal ii) No. 1 iii) Type Tube & shell type iv) Cooling surface area 35 m3 Tube side Shell side v) Design pressure 28.1 ksc, g Full vacuum & 3.5 ksc, g vi) Hydraulic test pressure 42.15 ksc, g 5.25 ksc, g vii) Design temperature 150oc 100oc viii) Tube OD × Length 16 mm × 1395 mm x) Tube material Austenitic S.S. welded xi) No. of tubes 501 xii) Operating weight 3185 kg
2.4.3 GLAND STEAM CONDENSER
i) Position Horizontal ii) No. 1 iii) Type Tube & shell type iv) Allowable/Design flow of main condensate: Minimum 180 T/hr Design 561.343 T/hr Max. 760 T/hr v) Tube ODX length 19 mm × 1150 mm vi) Material Welded S.S. tubes, ASTM A249 TP304 vii) No. of tubes 313 viii) Surface area 20 m2 ix) Exhauster fan 2 nos, centrifugal, 1000 m3/hr, 2860 rpm,
3 HP
2.4.4 LOW PRESSURE HEATER LPH-1 LPH-2 LPH-3 i) Type • Shell & tube type • ii) Position Horizontal Horizontal Horizontal iii) No. One One One iv) Operating pressure
shell side (ksc abs) 0.1992 0.8104 2.2671 v) Operating temp. shell side(0c) 59.54 107.8 200.0 vi) Tube OD × thickness in mm • 16 × 0.889 • vii) No. of tubes 498 498 498 viii) Weight- Dry 7625 11096 9960 Operating 9165 13700 12250 Flooded 12550 19360 17200 ix) Tube material • S.S. •
2.5 FEED WATER SYSTEM
2.5.1 DEAERATOR
i) Manufacturer BHEL, Hyderabad ii) Type Spray cum Tray type iii) Design pressure/op. Pressure 7.4 ksc(g) / 6.83 ksc (g) iv) Design temp. / op. Temperature 250oc / 163.15oc
v) Shell ID × thickness, mm 2400 × 16 vi) Feed water storage tank ID × thickness, mm 3500 × 20 Total length, mm 22000 Steam inlet quantity, T/hr 38064 Inlet steam pressure ksc 6.827 Inlet steam temperature, 0C 313.4 Safety relief valve set pr. Ksc 6.77 vii) Total working weight 197000 kg (storage tank + header) Flooded weight 262000 kg
2.5.2 BOILER FEED PUMP
i) No. & capacity 3 × 50% ii) Make BHEL, Hyderabad Pump data Booster Pump Feed Pump iii) Pump type FA1B-56 FK6D-30 iv) Liquid pumped • -------Boiler feed water----------• v) SG at suction temp. kg/dm3 0.9046 0.9046 vi) Suction temperature, oc 163 163 vii) Diff. Head, m/c 99 2222 viii) Flow rate, m3/hr 455 455 ix) Efficiency, % 81.3 81.9 x) Speed, rpm 1485 5245 xi) Power, KW 136.5 3041 xii) NPSH required, m 4.05 24.68 xiii) Thrust bearing The Glacier Metal The Glacier Metal Co. Co. Ltd, Double thrust Ltd, Double thrust, CK CK range, size 811/2kp-2kp range size, 8159/2kp-2kp xiv) Mechanical seal Durametallic/ sealol type 4.250” PTO/type 503 xv) Min. recirculation flow, T/hr 100 xvi) Direction of rotation viewed from drive end • -------------- Anti-clockwise---------• xvii) No. of stages Six
DRIVE MOTOR
i) Make BHEL, Hardwar ii) Type Squirrel cage induction motor iii) Rating 4000 KW iv) Degree of protection, type of enclosure, method of cooling IP54, CACW, ICW 37A81
v) Power supply 6600V, 3-ø, 50 Hz vi) Rated speed 1500 (synch.) vii) Insulation class F viii) Efficiency 96.5% ix) F.L. current 407 A x) Weight 13360 kg xi) Winding temp. rise at rated output over cooling air 700C (by resistance), 80oc (RTD) xii) Bearing DE Sleeve bearing 160 × 140 NDE Sleeve bearing 125 × 115 (Insulated)
HYDRAULIC TURBO COUPLING
i) Manufacturer Voith , India ii) Type R16k-1 iii) Power requirement of
drive machine 3240 KW iv) Gear ratio, type 148/41, step up gear unit v) Speed input/output 1485/5249 rpm vi) Regulating range 4:1 downwards vii) Full load slip 2.1% viii) Oil tank filling 700 lit (approx.) ix) Oil used Servo Torque 10 of IOCL.
AUX. LUB OIL PUMP
i) Type Gear pump ii) Lube oil flow Approx. 120 litres/min. iii) Pressure 2.5 bar iv) Motor 5.5 kw, 415 volt, 50 Hz
OIL/WATER HEAT EXCHANGER
WORKING OIL LUB OIL i) Type L1 N1 09 17 04-D L1 N1 07 04-D ii) Heat exchange capacity 71 litres 47 litres iii) Cooling water inlet temp. 37 37 iv) Cooling water outlet temp. 47 47 v) Nominal oil flow rate 32 m2/hr 13.5 m2/hr vi) Oil I/L temp., 0C 95 69 vii) Oil O/L temp,0C 57 53 viii) Max. permissible working
pressure oil side, ksc 16 16 water side, ksc 10 10 x) Max. permissible working oil temperature, 0C 119 119
TYPE OF COUPLING
i) Turbo coupling / pump flexible coupling:
Manufacturer Torsiflex Ltd Type HBS1000-8x ii) Motor/turbo coupling flexible coupling:
Manufacturer Torsiflex Ltd Type HBS-3600-8 iii) Motor/Booster pump flexible coupling
Manufacturer Torsiflex Ltd Type HB4-140x (insulated)
2.5.3 HP HEATERS
HPH5 HPH6
i) Manufacturer BHEL BHEL ii) Type & arrangement ----- ------ U tube Horizontal---------- iii) No. of shell passes 3 zones 3 zones iv) No. of tube passes 2 2 v) Tubes: Type of tubes Seamless Seamless Total no of U tubes 830 830 Effective length of U tubes, mm 7915 9715 Outer dia., mm 15.875 15.875 Design pressure, ksc(g) 280 280 Design temp. 0C 215 265 vi) Shell I.D., mm 1250 1250 Design pressure, ksc(g) 19.0 & full vacuum 45.0 & full vacuum Design temp. skirt/shell, 0C 440/215 370/260 Shell side relief valve set Pressure kgf/cm2(g) 19.0 45.0 vii) Velocity through tubes at 2.14 2.25 670 T/hr flow, m/sec
viii) Tube side pressure drop at 0.85 1.15 670 T/hr flow, kg/cm2 ix) Surface area, m2 De superheating/Condensing/ Drain cooling zone 83/485/112 104/642/82 x) Total effective area, m2 680 828
2.6 HP/LP BYPASS SYSTEM
Capacity 60% MCR 420 t/hr of main steam flow at the inlet of HP bypass valve
HP BYPASS STEAM VALVE SPRAY VALVE
i) Valves designation BP1/BP2 valve BPE1, 2 valves Design pressure 170/50 ata 280 Design temperature 540/485oc 175oc Body material 10 Cr MO910 15MO3 Nozzle material 10 Cr MO910 15MO3 Medium Main steam Spray water ii) ACTUATOR Type Hydraulic Hydraulic system pressure 100 bar Positioning time 10/3 sec (3 sec for fast opening device) iii) OIL SUPPLY UNIT Oil pump type OV-32 Supply capacity 24 lit/min. Motor detail 7.5 KW, 415V, 3-ø, 50 Hz, 1440 rpm,14.2 A Oil tank volume/usable volume 70/50 lit Oil pump cut in at 100 ksc Cut out at 16 ksc Back up protection cut in/cut out 110 ksc/170 ksc Relief valve setting 150 ksc
2.7 FLASH TANK/FLASH BOX
2.7.1 UNIT FLASH TANK
i) Type/Quantity Vertical cylindrical / one per unit ii) Design code ASME SEC VIII div.1 iii) Design pressure Full vacuum & 1.5 ksc (g) iv) Design temperature 210oc v) Fluid handled Steam/water vi) Shell material IS2062 Gr FE410 WB
vii) ODX height 1000 x 2700 mm viii) Shell thickness 12 mm ix) Corrosion allowance 3.2 mm x) List of connections Vent to atmosphere 1 Drain to waste 1 Drain to manifold 2 Spray water 1 Manhole 1 Spare 1
2.7.2 CONDENSER FLASH BOX
FB-1 FB-2 FB-3 i) Type • Vertical cylindrical • ii) Design code ------------------ ASME Sec VIII div.1 --------------- iii) Design pressure • 1.5 ksc(g) & full vacuum • iv) Design temperature 0C 210 215 210 v) Fluid handled ----------------- Water / Steam ------------------ vi) Shell material • ----------- IS2062 Gr.FE410.WB -------------• vii) Size OD ×height, mm 1400 x 2100 2200 x 3300 800 x 1800 viii) Shell thickness, mm 10 16 10 ix) Corrosion allowance, mm 3.2 3.2 3.2 x) List of connections: a) FB-1 Vent to condenser 1 Drain to hot well 1 LPH-2 alt. Drain 1 LPH-3 alt. Drain 1 LP ext. line drain manifold 1 Spare (blanked) 1 Manhole 1
b) FB-2 Vent to condenser 1 Drain to hot well 1 HPH-5 alt. Drain 1 HPH-6 alt. Drain 1 HPH ext. line drain manifold 1 HRH/CRH/LPBP line drain 1 Valve gland sealing header 1 Drain from Aux.5/CRH to gland sealing 1
Manhole 1 Spare (blanked) 1 c) FB-3 Vent to condenser 1 Drain to hot well 1 Drain cooler drain 1 GSC drain 1 Drain from main ejector 2 CEP discharge vent 1 Manhole 1 Spare (blanked) 1
PREDICTED PERFORMANCE OF TURBINE STEAM PRESSURE (BAR)
DESCRIPTION Rated value (bar)
Long time operation (bar)
Short time operation (bar)
Initial steam 147.1 147.1 176.5 Before 1st HP drain stage
132.6 137.9 145.9
HP cylinder exhaust 39.23 45.11 47.08* IP cylinder stop valve inlet
34.13 39.59 40.96**
Extraction 6 39.23 45.11 47.08 Extraction 5 16.75 19.84 19.84 Extraction 4 7.06 8.46 8.46 Extraction 3 2.37 2.91 2.91 Extraction 2 0.858 1.09 1.09 Extraction 1 0.216 0.374 0.374 HP cylinder exhaust 0.118 0.3 0.3
*These values correspond to 210 MW with 3% make up and 0.1187 bar backpressure with all heaters in service & rated steam conditions. **The safety valves are set such that these short-time values are not exceeded. Long time operation: Upper limit value, permissible without the time limit. Short time operation: Permissible momentary value. The aggregate duration of such
swings must not exceed 12 hours in any one year.
STEAM TEMPERATURE, 0C
DESCRIPTION Rated value Annual mean value
Long time value but keeping within annual mean value
400 hr per annum
80 hr per annum max. 15 min in individual case
Initial steam 535 543 549 563 IP cyl. Stop valve inlet
535 543 549 563
DESCRIPTION Rated value Long time operation
80 hr per annum, max. 15 min. in individual case
In special cases at no load.
HP cylinder exhaust
343 359 425 500†
Extraction 6 343 359 425 500‡ Extraction 5 433 438 473 Extraction 4 316 326 366 Extraction 3 200 211 255 Extraction 2 107 127 167 Extraction 1 62 82 127 LP cylinder exhaust 49 70 70 100
†These values correspond to 210 MW load with 3% make up & 0.1187 bar back pressure with all heater. ‡Only valid for the no load period with high reheat pressure after trip-out from full load operation. For the individual case approx.15 min. The turbine is immediately re-loaded or the boiler immediately reduced to minimum load, if no-load operation is maintained. Permissible differential temperature No time limitation- 170C. between parallel steam supply lines: Short time period (15 min.)- 280C. In the hottest line the limitations indicated for initial steam & reheat temperature must not be exceeded.
• CONDE NSAT E WAT E R
Description Pressure Kg/cm2 Temperature 0C Flow T/hr CEP suction 0.1033 46.1 508.83 CEP discharge 19.379 46.3 508.83 GSC outlet 1054 46.6 508.83 Drain cooler outlet 10.08 47.8 508.83 LPH 1 outlet 9.63 56.6 508.83 LPH 2 outlet 9.18 90.6 508.83 LPH 3 outlet 8.72 120.7 508.83
• HE AT E R DRAIN Description Temperature oc Flow T/hr GSC drain to FB-3 99.9 0.299 LPH3 to LPH2 123.5 27.589 LPH2 to LPH1 93.4 57.651 LPH1 to drain cooler 60.3 63.437 Drain cooler to FB-3 52.8 63.437 HPH 6 to HPH 5 206.0 61.091 HPH 5 to deaerator 170.0 95.807
• FE E D WAT E R Description Pressure Kg/cm2 Temperature oc Flow t/hr BFP suction 6.405 160.7 639.27 BFP discharge 205.0 164.1 639.27 HPH 5 outlet 204.09 200.0 639.27 HPH 6 outlet 203.18 247.0 639.27
• Parameters are given when unit at 210 M W, 0% make-up water, 76 mm backpressure & constant pressure operation.
SECTION – 3
GENERATOR &
AUXILIARIES
3.1 GENERATOR TECHNICAL SPECIFICATION
Make BHEL Type Two Pole, Cylindrical, Steam turbine
driven MW rating 210 MVA rating 247 Rated Terminal voltage 15.75 KV Rated Stator current 9050 A Rated p.f. 0.85 lag Rated speed/frequency 3000 rpm/50 Hz Negative sequence current capability (I2t) 8 Efficiency at MCR condition 98.55 % Short circuit ratio 0.49 Phase connection Double star No. of terminal brought out 9 (6 neutral & 3 phase) Generator stator winding resistance in each phase 0.00155 Ù at 20ï c Generator rotor winding resistance 0.0896 Ù at 20ï c Cooling of stator winding Directly water cooled Cooling of stator core & rotor Directly hydrogen cooled Direction of rotation Anti clockwise viewed from turbine end
STATIC EXCITATION EQUIPMENT
Make BHEL SEE Rating Voltage-310V DC Current-2600A DC Accuracy of Excitation control ±0.5% Range of voltage control in auto 90-110% Range of voltage control in manual 80-110% No load field voltage 102V DC No load field current 917 A Max. continuous rated field voltage 355V DC Max. continuous rated field current 3000 A Ceiling voltage 620V DC (Excitation voltage at field forcing) Ceiling current 4500A Frequency range of operation 47.5 – 52Hz No. of parallel bridges including redundant bridge 4 No. of redundant bridge 1 Protection class IP20 Station battery supply 220V DC
Duration of field forcing 10 sec. Response time 40 msec.
EXCITATION TRANSFORMER DETAIL Make BHEL Rating 3150 KVA Voltage rating 15750 / 575 V Vector group DYn5 Insulation level 50 KV RMS / min Cooling Natural
3.2DESIGN AND CONSTRUCTION FEATURES
MATERIAL Rotor shaft Steel forging 35Ni 13cr 12Mo 35V12 Chromium nickel molybdenum & vanadium steel Rotor winding Silver bearing copper Rotor slot wedges Duralumin Rotor rating ring 60Mn Ni85Cr 35 W75, Non magnetic steel Stator frame ST42W Stator core stamping Cold rolled silicon steel Bearing body CSW C25 IS: 2856-64 Shaft seal ring ST-42W Bearing & seal Babbitt Grade 84 Carbon brushes Grade HM6R No. of brushes reqd. 112+1
WEIGHT AND OVERALL DIMENSIONS i) Wt of the heaviest lift (Stator with
Gas cooler & lifting trunions) 175.0 MT ii) Wt of rotor 42.2 MT iii) Wt of gas cooler 1415 Kg iv) Wt of terminal bushings 85 Kg v) Wt of end shields 2000 Kg vi) Total wt. Of generator 270 MT (without exciter) vii) Overall dia of stator 3960 mm viii) Overall dia of rotor 1075 mm ix) Overall length of stator 6580 mm x) Overall length of rotor 9770 mm
TORQUES, CRITICAL SPEEDS ETC i) Torque under normal working condition 76.32 T ii) Ratio of short circuit torque to F.L. torque 8 iii) Flywheel moment of rotor 21.1 TM2 iv) 1st critical speed of rotor (calculated) 1370 rpm v) 2ndcritical speed of rotor (calculated) 3400 rpm
OIL CONSUMPTION i) Consumption of oil per generator bearing (excluding shaft seal) 300 lit/min ii) Oil pressure at inlet of bearing 0.3 to 0.5 Kg/cm2 iii) Consumption of oil in both shaft seals 77 lit/min
3.3 GENERATOR GAS SYSTEM
3.3.1 H2 IN STATOR CASING i) Nominal pressure of H2 3.5 Kg/cm2 Permissible variation ±0.2 Kg/cm2(g) ii) Max temperature of cold gas 44oc iii) Max permissible hot gas temperature 75 0C iv) Min. required purity of H2 97% v) Max. oxygen content 1.2% vi) Relative humidity of hydrogen at casing pr. (max) 30% vii) Max moisture content in generator casing 15 gm/m3 of H2 viii) Total gas volume of the generator 56 m3 ix) Max make up hydrogen per day 15 m3 x) Hydrogen cylinder capacity 6.8 m3 at 150 ata
3.3.2. GENERATOR FILLING QUANTITIES
M/c stand still M/c under rolling i) Amount of CO2 required to remove air expressed at NTP 120 m3 150 m3 ii) CO2 for expelling H2 120 m3 168 m3 iii) H2 filling quantity 300 m3 336 m3 iv) Compressed air required for purifying of CO2 from gen. 150 m3 v) Quantity of compressed air reqd. (at NTP) for carrying out air 500 m3 tightening test vi) Capacity of CO2 cylinder 27Kg
3.3.3 HYDROGEN COOLER
At rated Hydrogen pressure 3.5 ksc (g) i) No. of coolers/generator 4 ii) Gas flow per cooler 7-5 m3/sec iii) Max water inlet temperature 37oc iv) Design pressure water side of cooler 6 ksc(g) v) Max permissible operating pressure water side of cooler 3 ksc(g) vi) Pressure drop through cooler 17.5 mmwc vii) Material of tubes/fins Admiralty brass/copper viii) Material of water boxes/tube sheets Carbon steel ix) Heat load 528 KW x) No. of passes of water on water cooler 2
3.3.4 HYDROGEN DRIER i) Type Refrigeration type, freon 12 ii) Working pressure 4 ksc max. iii) Dew point of dried gas at working pressure 3 to 5oc iv) Thermal load, ie. Compressor capacity 1100 Kcal/hr
3.3.5 SETTING VALUES FOR ALARM
i) Gen. Bearing & seal Babbitt temp. High V. High 750C 850C ii) Gen. Bearing oil oil O/L temp. 600C 700C iii) Stator winding temp. 750C ----- iv) Hot gas temp. 75oc ----- v) Cold gas temp. 45oc 55oc vi) Stator core temp 95oc ----- vii) Rotor temp 110oc 115oc viii) Temp of inlet water to gas cooler 38oc 48oc
3.4STATOR WATER SYSTEM 3.4.1 STATOR WATER COOLER
i) No. of coolers/system & type Two, shell & tube type ii) Max permissible operating pr.(Primary shell) 8.0 ksc iii) Max permissible operating pr.(cooling tube) 5.0 ksc iv) Primary water inlet/outlet temp 72.6/45oc v) Primary water flow 27 m3/hr
vi) Cooling water flow 110 m3/hr vii) Pressure drop in primary water 6.5 mmwc viii) Pressure drop in cooling water 0.8 mmwc ix) Max. cooling water inlet temperature 36oc x) Heat load 790 KW xi) Heat transfer area 33 m3 xii) Nominal gauge pressure at inlet of winding 3.3 ksc (g)
3.4.2 STATOR WATER PUMP i) No. & make 2x100% single stage centrifugal with spiral casing & overhung impeller CPK CM50-200, KSB make ii) Flow 39.6 m3/hr iii) Head 45 mtr iv) Speed 2930 rpm v) Motor GEC make, 9.3 KW/12.5 hp, 415V, 3-ø, 50Hz, 18A Insl. Cl.B, 2930 rpm vi) Ambient temperature 50oc
STATOR WATER MAKE UP PUMP i) No. & make 2 per ø unit, KBL make ii) Flow 1.39 L/s iii) Head 50 m iv) Motor 415V, 3- ø, 50Hz, 2.62KW, 2850 rpm, 7A,
Insulation class E
3.4.3 STATOR WATER FILTER i) Make & type BHEL, Hardwar, Wiremesh Disc type, F-26 ii) No./unit 2 iii) Ratio Discharge 30 dm3/hr iv) Working pressure 6 Kg/cm2 v) Max. size of filter that can be filtered: 0.224 mm
3.4.4 MAGNETIC FILTER i) No./unit 2 ii) Make Boll and Kirch Filter bar GmbH iii) Type P.53.1-MA.220 500DN 100 YQ-36 iv) Magnet type Permanent Magnet v) Working pressure 10 ksc vi) Working temperature 60oc vii) Capacity 36 m3/hr viii) Type of particles filtered Highly & medium magnetic
3.4.5 EXPANSION TANK
i) Type Hermetically sealed cylindrical type ii) Material Stainless steel iii) N2 pressure in the tank 0.2 ksc (g) iv) Wt. of the assembly 825 Kg
3.4.6 QUALITY OF DISTILLATE i) Conductivity Less than 5µ mho/cm preferably 1µ mho/cm ii) PH 7 to 8.5 iii) Dissolved O2 Minimum preferably less than 50 ppb
but not greater than 100 ppb iv) Dissolved CO2 Should be nil v) Dissolved Cu content 25ppb to 200 ppb to avoid copper pick up vi) Content of ammonia, hydrazine, phosphate & chlorine Nil vii) Iron content preferably nil, but not more than 20 ppb (Dissolved & undissolved)
3.4.7 SETTING VALUES OF STATOR WATER SYSTEM
1 Expansion tank level Low 800 mm 2. Pressure in the expansion tank 0.4 ksc 3. Changeover from working pump to stand by pump due to pressure fall 4.5 ksc (g) 4. Pressure drop across water filter at which cleaning is recommended 0.4 ksc (g) 5. Distillate flow in stator winding Low 21 m3/hr Emergency 13 m3/hr 6. Distillate conductivity High 13.3 µmho/cm V. High 20 µmho/cm 7. Distillate outlet temperature High 85oc 8. Distillate inlet temp. to winding High 46oc V. High 48oc
3.5 SEAL OIL SYSTEM i) Type of shaft seals Single flow ring type ii) H2 Pressure at generator casing 3.5 ±0.2 ksc iii) Seal oil-H2 diff. Pressure min 1.0, normal 1.5, max 1.7 ksc iv) Quantity of seal oil per seal 38.5 l/min v) Quantity of seal oil towards Air side • rd Hydrogen side • rd
3.5.1 SEAL OIL COOLER i) Make BHEL, Hardwar
No.of cooler/system: 2x100 ii) Type Surface type iii) Heat transfer area 14.3 m2 iv) Design pressure tube side/shell side 10.5 ksc v) Test pressure tube side/shell side 18 ksc
3.5.2 SEAL OIL PUMPS I) A.C. Seal Oil Pump i) Make & type Tushaco,Delta Corp.,Three screw positive displacement ii) No./Unit 2 iii) Pump discharge 200 lpm0 iv) Pump speed 1450 rpm v) Pump head 12 ksc vi) Motor 415V, 3-Ö, 50 Hz, 7.5 KW, 15.5A, 1450 rpm Insl. class B II) D.C. Seal Oil Pump i) Pump Same as A.C. pump ii) Pump/unit 1 iii) Motor 220V DC, 11KW, 1450 rpm, Insl. Class F, Shunt wound self-excited D.C. motor
3.5.3 VACUUM PUMP ii) Type Single stage, rotary vane type (SB-4) iii) Suction capacity 5.77 m3/hr iv) Ultimate pressure < 1.06 mbar v) Motor 415V, 3-Ö, 50 Hz, 0.45 KW, 1500 rpm
3.5.4 OIL FILTER i) Type Wire & mesh type ii) Flow rate 12 m3/hr max. iii) Mesh size 0.10 mm max. iv) Design pressure 16 ksc max.
3.6 SPECIFICATIONS OF TRANSFORMERS
3.6.1 GENERATOR TRANSFORMER i) Manufacturing BHEL, Bhopal ii) No./Unit One iii) Rating 240 MVA iv) No load voltage HV/LV 230/15.75 KV v) Rated current HV/LV 602/45/8797.72 A vi) Frequency 50 Hz vii) No. of phase 3, type of connection - HV-Star, LV-Delta viii) Type of cooling ONAN/ONAF/OFAF cooled ix) Vector group Ynd1 x) Type of tap changer OFTC xi) Off load tap changer range -5% to +5% in steps of 2.5% xii) Impedance voltage at HV-LV 14% (normal tap) xiii) Temperature rises above an ambient temp. of 50oc Oil by thermometer 50oc Winding by resistance
ONAV/ONAF 50oc OFAF 50oc
3.6.2 STATION TRANSFORMER
i) Manufacturer BHEL, Bhopal ii) No. / unit 1 iii) Rated output 55 MVA iv) Voltage ratio HV/LV1/LV2 Star v) Winding connection HV/ LV1/LV2 144.5/972.1/3015.8 A vi) Line current HV/LV1/LV2 50 Hz vii) Type of tap changer & range OLTC, +10% to –10% in steps of 1.25% on HV winding, total 16 steps viii) Type of cooling ONAN/ONAF ix) Rating at different cooling 60% 80% 100% ONAN ONAF ONAF x) Temperature rise over ambient temp. 50oc in oil 40oc in winding 50oc xi) Bushing HV LV HV neutral Type oil immersed air insulated oil immersed Min creepage distance(mm) 6125 440 900
xii) Guaranteed positive sequence HV-LV1 HV-LV2 LV1-LV2 Impedance at 75oc with 100% Rating at principal tap 16.5% 16.5% 26.5%
3.6.3 UNIT AUXILIARY TRANSFORMER i) Manufacturer TELK, Kerala ii) Type of construction Core type iii) No. / unit Two iv) Rating 16 MVA v) Voltage ratio 15.75 / 6.9 KV vi) Winding connection HV/LV Delta/Star vii) Vector group DY11 viii) Type of cooling ONAN ix) Rated frequency 50 Hz x) Phase 3 xi) Rated current HV/LV 587/1340 A xii) Type of tap changer & range OLTC, +10% to –10% in steps
of 1.25% on hv winding in 1 step xiii) Temperature rise above ambient of 50oc in oil 40oc in winding 50oc xIv) Bushings HV LV LV neutral oil filled oil filled oil filled
3.6.4 VARIOUS SERVICE TRANSFORMERS No. 12 i) Make Voltas, Pune ii) Type Dry type, cast resin, indoor type iii) Rated KVA 2000 & 1600 iv) Type of cooling AN v) Voltage ratio 6600V/433 V vi) Vector group Dyn 11 vii) Winding connection HV/LV Delta / Star viii) Percentage impedance ix) Tap changer type & range Gang operated off ckt. +5% to –5% in steps of 2.5% x) Temperature rise over an ambient of 50oc in oil 50oc in winding 55oc
3.7 H.T. MOTORS
Sl. Equipment Quantity Rating (KW) 1 ID fan 4 1500 2 FD fan 4 925 3 PA fan 6 800 4 Mill 6 2250 5 BFP 6 4000 6 CEP 4 600 7 CW 6 1470 8 BCW 6 275 9 RAW 6 304 10 Ash slurry pump motor 12 185 11 Ash recycling transfer water pump motor 3 700 12 Conveyor 7A/7B 2 520 13 Conveyor 5A/5B 2 400 14 Conveyor 2A/2B 2 330 15 Conveyor 1A/1B 2 300 16 Conveyor TRH 1A/1B 2 200 17 DE system 5&6 2 180 18 Conveyor 8A/8B 2 165 19 Ring granulator 4 825 20 Conveyor SR1 2 300
3.8 BATTERY & BATTERY CHARGER
3.8.1 220 V DC BATTERY
i) Make Amoco ii) Type Lead Acid, sealed type No. of cells Unit 1-110, unit II-110, station-110, S.Y -110, CHP-110 Capacity 2000 AH (Unit-I, II & Station), 350 AH (S.Y), 400 AH (CHP) Each cell voltage 2 V Specific gravity 1200
220 V FLOAT CUM BOOST BATTERY CHARGER i) Manufacturer Chhabi Electricals Pvt Ltd & Caldyne Pvt Ltd (for CHP) ii) Service Float & Boost charging
iii) A.C. input 3-ø, 50 Hz, 415V ±10% iv) D.C. output voltage Float Boost Plant 240 158-297 S.Y. 240 158-297 CHP 240 158-297 Current Plant 0-350 A 0-280 A S.Y. 0-100 A 0-49 A CHP 0-100 A 0-40 A v) Ripple 3% vi) Efficiency at full load 80% vii) Voltage setting range 240 V viii) Current setting range 80 A ix) Cooling AN x) Response time Inst xi) Maximum ambient temperature 50oc
3.8.2 +24V DC BATTERY i) No. of cells Unit I (main-13, standby-13)
Unit II (main-13, standby-13) ii) Capacity 1000 AH (U#1, 2 & CHP) iii) Each cell voltage 2 V
+24 V/1000 AH DC BATTERY CHARGER i) Manufacturer Chhabi Electric ii) Type Float cum Boost iii) AC Input 415±10%, 3-ø, 50 Hz iv) DC output Float Boost DC voltage 28±1%V 24 to 35V DC current 600 A 140±2%A v) Number Two/unit vi) Max.ambient temperature 50oc
24V/600A FLOAT CHARGER i) Make Amar Raja Power Systems Ltd ii) Number Two/unit iii) Input 415±10%, 3-ø, 50 Hz, 50 A
iv) D.C. output 29.25 DC volt & 600 Amp v) Capacity 1455 AH vi) Max. ambient temp. 45oc
24V/175 A BOOST CHARGER CUM DC DB i) Make Amar Raja Power Systems Ltd ii) Input 415V ±10%, 3-ø, 50 Hz, 12.4 A iii) D.C. output 29.9 V DC & 175 A iv) Capacity 1455 AH v) Max. ambient temperature 45oc vi) Number Two/unit
48V DC/70A FLOAT CUM BOOST CUM DCDB i) Input 415V ±10%, 3-ø, 50 Hz, 19A, 5A ii) DC output 48V DC, 58A iii) Capacity 120 AH iv) Max. ambient temperature 500C v) Number One/unit
3.8.3 –24V DC BATTERY
i) No. of cells Unit I(main-13, standby-13), Unit II(main-13, standby-13) ii) Capacity 200 AH (Unit # 1&2) iii) Each cell voltage 2 V
-24 V DC BATTERY CHARGER i) Manufacturer Chhabi Electric ii) Type Float cum Boost charger iii) AC input 415V ±10%, 3-ø, 50 Hz iv) DC output Float Boost DC voltage 28.1±2% 24 to 35 DC current 0-110A 28±2%A v) Max.ambient temperature 50oc vi) Ripple 3%
3.8.4 UPS SYSTEM i) No. / Unit One ii) Rated output 2 x 60 KVA, 240V AC, 1-ø, 50 Hz
iii) Input 415V ±10%, 3-ø, 4 wire, 50±6% Hz, 110A nominal iv) Output 240 ±1%V AC, 1-ø, 2 wire, 50 Hz, 250A v) Power walk in 10 to 15 seconds vi) Nominal DC bus voltage 405 V DC vii) Capacity 450 AH viii) Discharge battery voltage 315 V DC ix) No. of cells 180 cells x) Each cell voltage 2 V/cell xi) Battery float voltage/cell 2.25 V/cell xii) Ripple 3% (max. rms)
GENERATOR RELAY PANEL Sr No Protection Designation Operating Remarks Time 1. Generator differential 87G Inst Generator winding protection insulation protection. 2. Generator negative phase 46G 4 sec. Generator unbalanced sequence protection current protection. 3. Generator loss of 40G Inst Generator field failure excitation protection protection. 4. Generator pole slipping 98G 50 msec Protection against protection generator falling out of slip 5. Generator back up 21G 1.5 sec Back up protection against impedance protection external faults 6. Generator stator interturn 95G Protection against insulation fault protection failure between two windings 7. Generator stator E / F 64G1 1 sec Main protection against protection generator windings. 8. Generator stator stand by 64G2 IDMT
E / F protection
9. Generator rotor E / F Stg-II 2 sec protection Alarm 0.5 sec
10. Generator stator water 30P Inst conductivity high (20 µmho)
11. Generator stator water 30P 50 sec flow low (13 m3/ hr) 12. Generator low forward 37A & B 2 sec Protection for generator power protection before motoring takes place 13. Generator overload 51G 20 sec protection 14. Generator U/F 81G 10 sec protection 15. Generator O/F 81G 10 sec protection 16. Generator O/V alarm 59G
GENERATOR TRANSFORMER Sr No Protection Designation Operating Remarks Time 1. GT overall differential 87GT Inst Winding insulation protection protection 2. GT bay C.B. LBB 50Z 0.2 sec. protection 3. GT over fluxing 99GT Inst. Protection 4. GT bucholtz trip 63GT Inst. Protection against internal fault. 5. TBC LBB Protection 50L 0.2 sec
6. GT winding temp. Inst Protection for insulation high trip winding failure.
7. GT oil temp high Inst Protection for oil high trip degradation
UAT Sr No Protection Designation Operating Remarks Time 1. UAT differential 87UAT Inst Protection protection against winding insulation failure 2. UAT over current protection 51 UAT Inst 3. UAT bucholtz trip 63 UAT Inst Protection against internal fault
SECTION – 4
CONTROL &
INSTRUMENTATION
4.1 UNIT C & I SYSTEM
SG (FSSS) :-Procontrol P13/42(ABB) TG (ATRS) :-Iskamatic A & B(KWU, Germany) Measurements Automation :-MOD 300 DAS :-MOD 300 Make :-ABB Supplier :-ABB MOD-300 constitutes of: i)Open Loop control system ii)Close Loop Control system iii)Information system iv)Sequence of Event Recorder stand alone
OLCS/CLCS System Configuration No. of groups (OLCS) 4 No. of groups (CLCS) 5 No. of function groups(OLCS) 12 No. of function group(CLCS) 16 No. of OLCS cubicles 19 No. of CLCS cubicles 12 No. of control loops 31 Processor for OLCS 32-bit, Motorola 68020 micro processor Processor for CLCS MC 68000 R8 (8 MHZ), Address Bus =24 Data bus =16 System Redundancy 100% Parallel operation available through CRT Key board and P.B. on the panel. Redundant power supply of
240V Ac through UPS for DAS, operator station, engineer station, history station for OLCS & CLCS.
INFORMATION SYSTEM No. of memory nests 2 (consists of mass memory & redundant mass memory) Memory capacity hard disk 2 GB No. of control operating station 2 per Unit No. of monitoring st.(PS-U) 3 per Unit No. of CRT & Keybord(on desk) 4 CRT & 4 Key board. IS. Configuration monitoring functions. Analog Inputs 384 (CLCS only)+903 (DAS) (1100 remote inputs) Digital Inputs 5100 (DAS) + 2120 (OLCS) 40 remote inputs+287 common inputs
STANDARD DISPLAYS Alarm display 01 Curve display 20 Bar display 34 Op. area display 10 Graphic display 87 Function group op. display 29
SEQUENCE OF EVENT RECORDER Make M/S Highland, Rochestor Instrument, Scotland. Model DEP 90 No. of active points 302 Input per card 16 (16 input circuits) Resolution 1 MS Alarm debounce time Responds to inputs greater than 40 ms duration. Contact integration voltage 48 V ungrounded. Acceptability of NO/NC contract Yes
Archiving facility WYSE make PC SER Terminal H-31 green WYSE, model WY-30+
INTERFACE WITH FSSS/ATRS THROUGH RELAY PANEL (Only Binary communication)
Model Procontrol P13/42 Make BBC Supplier BHEL, EDN, Bangalore Software language Procontrol10 No. of stations 19 No. of processors 20 Type of processor 70 PR 03(Dedicated type) Program memory 4096 bytes, (EPPDMS) System Configuration 1. No. of Intra-planel bus 2 (max. 10) Hot redundant fuses for each IPB
2. No. of stations/IPB IPB1=15, IPB2=19 3. No. of stations/entire system 19 4.Modules per local bus Maximum 64 Data Communication Local Bus Service address 2 is every 10 m sec. i) Useful Address Max. 256 ii)Time Cycle (Set) 20ms iii)Information bit rate 204.8 KBAVD iv)Type of modulation Pulse modulation v)Amplitude 10V low active vi)Data security Parity bit, clock monitoring, data valancy on local bus, address cycle, watchdog timer. vii)Distance bt. IPB & IB 3m (max.) Intra-Panel Bus(IPB) i)No. of address 256 x No. of stations,16384 max. ii)Time required/one telegram 60µ s iii)Information bit rate 266.7 KBAUD iv)Signal code DPDM v)Amplitude + 15 v vi)Data security Parity bit, counting of binary characters, monitoring of time & amplitude per bit.
vii)Transmission means Coaxial cable RG 213U of 50 Ω characteristic. Inputs/Outputs Analog I/P 4-20 mA ,100 Ω I/P resistance –10V to +10V, 100 KÙ Analog O/P 4-20mA,500 Ω, max. permissible load –10 to + 10 V, 4mA Binary I/P For 0 signal –30V to +30 V. For1 signal 11.2V to 30V. Binary O/P For 0 signal 0 to + 1V. For 1 signal 11.7V to 30V. All modules are protected against short circuit and over load. Contact Inputs Voltage between terminals with open contract 48 V DC Contact current for closed contact 5 mA Procontrol system is powered by 24V/1000A redundant charger with battery
backup. Interface with ATRS/MOD 300 through relay cabinet mounted inside FSSS cabinet
(Only binary communication) ELECTRONIC AUTOMATION SYSTEM FOR STEAM TURBINE (EAST) Manufacturer BHEL, Bangalore East package comprises ISKAMATIC A & B
ISKAMATIC-A ISKAMATIC-B
1.Turbine stress Evaluator 1.Logic subgroup control 2.Flectro hydraulic governing control 2.Limit valve monitoring (Linear, nonlinear, variables) 3.L.P. Bypass, seal/leak steam control 3.Drive control modules (valves, pumps/solenoids) 4.Vibration & position monitoring 4.Relay cabinets 5.Analog signal conditioning 6.Turbine protections 7.Auto synchronizer 8.Load shedding Relay.
COMMON FEATURES 1.Separate ref. voltages for analog (HQ) / Binary (M) signal conditioning. 2.Only one connection exists between M & HQ, at the cabinet power supply bus. 3.Decoupling of signal conditioning paths. 4.Selectivee fusing & use of IC’s
Each package is powered by +24/-24 V redundant battery charger (chhabi make) with battery back-up with load current 231/100A with 1% ripple.
FSSS, MOD 300 & East are powered by their own dedicated power sources. Signal communication in between FSSS/MOD 300/East is done through coupling
relay cabinet CRA01 02 with complete isolation.
UNINTERRUPTED POWER SUPPLY
i)Make Tata libert ii)Capacity(KVA) 60 iii)Voltage rating 240 V AC + 1% output. iv)Frequency 50 HZ v)Battery Rating 405V DC (common for both UPS) Make Exide Type Gauntlet tubular Capacity 450 AH No. of cells 180 Each cell voltage 2.25 V (Float) 2.00V (Nominal)
LAN & IT Network Local Area Network based on Fast Ethernet Fiber-Optic Switched
Backbone and Structured Cabling System. Connectivity 36 users. Network cabling is done for 66 nodal points.
Remote Users – 5. Coal handling Plant, MGR Systems, water Treatment Plant, Switchyard and Workshop. Facility exists for 16 remote users.
Main Application Server Compaq Prolient 3000, PIII 500MHZ, 512MB ECC SDRAM (upgradeable up to 2GB, 512KB L2 Cache, 3X9.1 GB Hot Swap
SCASI HDD, 10/100 TX PCI UTP Controller. Exchange Server Compaq Prolient 1600, PIII 500MHZ, 128MB ECC SD RAM,
512 L2 Cache, 9.1GB SCSI HDD, 10/100 TX PCI UTP Controller.
Network Management 1 No Compaq Deskpro EP PIII 450MHZ, 64MB SD RAM Station 8.4GBHDD LAN Node PCs: 41 Nos Datamini PIII 450MHZ, 64MB SD RAM 8.4GB HDD Main Chassis Based 1 No Cabletron Smart Switch 6000 with 16X10/100Base Tx Switch Ports, 6X100 Base Fx Ports Workgroup Switch: 5Nos Cabletron Smart Stack 100 with 22x10/100 BaseTx full
Duplex auto negotiating ports + 2X100 Base Fx Ports. Remote Access Server CISCO 2500, 1X10Base T + 16 Async. Sl. Ports For Dial up facility: Modem for 33.6Kbps Dial-up/Leased Line Modem Remote Access: FO Connection: 6 core Multimode Fiber Optic (Main Switch to Workgroup switch) UTP Connection: E CAT5 UTP Cable. (Workgroup Switch to Nodes) Network Management Cabletron NMS Software Software: Main Sever System Operating System Win NT4, Database MS SQL Server 7.0 Application Software RAMCO e-Application 3.1 Logistic Modules Inventory Module Purchase Module Maintenance Module AP Module
Exchange Server System Operating System Windows 2000 Mail System Exchange Server 5.5 Antivirus Software Norton Antivirus for Server & PC Internet Access 64Kbps VSAT connection from HSCL
VSAT Router CISCO 2600 Proxy Server PIII PC with Linux System IB TPS DOMAIN www.opgc.co.in
4.2 INTERLOCK PROTECTION 4.2.1 BOILER AND AUX.
FURNACE SAFEGUARD SUPERVISORY SYSTEM
1. Purge Permissive a) All system power supply (AC & DC) ON b) At least one ID and one FD in service. c) A min. of 30% of full load air (>268 T/hr) d) A proper water level in drum e) LOTV closed f) HOTV closed g) All LONV closed h) All HONV closed i) No boiler trip condition permit j) All scanner no flame k) All mills off l) All PA fans off m) All O/L gates closed 2. Purge Sequence a. Purge ready (all purge permissives are satisfied) b. Purging (5 minute cycle) c. Purge complete 3. First Cause Trip (Master Fuel Trip) Alarm Trip a. Both ID fan off - - b. Both FD fan off - - c. Furnace pressure V. High +100 + 250mmwc d. Furnace pressure V. Low (2/3 logic) - 100 - 250mmwc e. Drum level V. High (for more than 10 sec.) +100 +300mmwc f. Drum level V. Hi (for more than 10 sec.) -100 -300mmwc g. Emergency trip h. Loss of 220V DC for more than 2 sec. I. Air flow less than 30% j. Reheat protection trip* k. Less than fireball and loss of A.C. power at any elevation in service**
l. Loss of all fuel trip***
m. Flame failure trip**** n. Loss of unit critical power +24V DC * Reheater Protection Trip 1. Generator breaker open or turbine tripped
OR Boiler working and turbine not working. Any HP or LP bypass valve is closed The reheater protections armed with time delay of 5 sec.
OR 2. HP bypass 1 or 2 or LP bypass 1 or 2 less than 2% open and turbine working and load
shedding relay operated with 11 sec. off delay than reheat protection is armed with time delay of 10 sec.
Turbine trip is armed if,
All ESV and 4 IV open and first stage pressure more than 35 bar and any ESV or IV closes or turbine trip
Turbine working is armed if,
All ESV and IV open and first stage pressure is greater than 35 bar. Boiler working is armed if,
a. Main steam pressure left is more than 50 bar and main steam temp left is more than 513 0C and
b. Main steam pressure right is more than 50 bar and main steam temp right is more than 513 0C and
c. Boiler fire ON, provided HP bypass valve 1 & 2, and LP bypass valve 1 & 2 opened more than 2% once.
** Less Than Fire Ball And Loss Of AC Power At Any Elevation In Service. Any elevation started and there is a loss of AC power at any elevation in service for more than 2 sec. *** Loss Of All Fuel Trip a. Loss of fuel trip arming (i.e. elevation AB or CD or EF any nozzle valve open and no MFR
trip) and b. All coal outlet gates closed and c. LOTV does not open, or elevation AB all LONV closed and d. HOTV not does open, or elevation AB, CD, & EF back up trip. **** Flame Failure Trip Elevation A, B, C, D, E, & F voted and unit flame failure trip armed (i.e. any mill outlet gate proven for more than 3 sec.)
Elevation A voted: a. Elevation A coal O/L gates do not open >2 sec. b. Elevation AB started & loss of AC power > 2 sec. c. Elevation AB 2/4 nozzle valves are not proven open and elevation AB ¾ scanner show no
flame. Elevation B voted; a. Elevation B coal O/L gates do not open > 2 sec. b. Elevation AB started & loss of AC power > 2 sec. c. Elevation AB 2/4 nozzle valves are not proven open, and d. Elevation AB ¾ scanners show no flame, and elevation BC ¾ scanners show no flame. Elevation C voted: a. Elevation C coal O/L gates not open > 2 sec. b. Elevation CD started & loss of AC power >2 sec. c. Elevation CD 2/4 nozzle valves are not proven open and elevation CD ¾ scanners show no
flame and elevation BC ¾ scanners show no flame. Elevation D voted: a. Elevation D coal O/L gates not open >2 sec. b. Elevation CD started & loss of AC power > 2 sec. c. Elevation CD 2/4 nozzle valves are not proven open and elevation CD ¾ scanners show no
flame and elevation DE ¾ scanner show no flame. Elevation E voted: a. Elevation E coal O/L gates not open > 2 sec. b. Elevation EF started & loss of AC power > 2 sec. c. Elevation EF 2/4 nozzle valves are not proven open and elevation EF ¾ Scanner show no
flame and elevation DE ¾ scanner show no flame. Elevation F voted: a. Elevation F coal O/L gates not open > 2 sec. b. Elevation EF started and loss of AC power > 2 sec. c. Elevation EF 2/4 nozzle valves are not proven open and elevation EF ¾ scanner show no
flame.
PULVERISER
1. PERMISSIVE a. Purge air dampers closed. b. Electromagnetic brake is released.
c. Girth gear seal air fan motor on. d. Mill lubrication is OK. e. Mill starting sequence step-1 completed. f. Any seal air fan on & mill/seal air Pressure DP OK. g. Aux. Motor off (Initially aux. Motor is on, it stops when main motor starts) h. No MFT. i. Mill side-1 or side-2 START order. j. Mill ignition energy available. k. PA fan ON. l. PAD & BAD dampers closed. PROTECTION a. Ignition energy not available b. MFT relay operated c. Centrifugal switch d. PA fan OFF e. E.M. Brake engaged f. Aux. Motor ON g. Bearing temp very HI (650C) h. Seal air pressure NOT OK i. P.A. pressure Very low j. Mill lubrication NOT OK k. Mill main motor trip l. Seal air Fan A & Fan B trip m. Emergency trip from Mill FSSS/Local trip 2.Mill Lubrication Mill lubrication OK When all the following conditions are present: a. Mill bearing lubrication OK. b. Mill reducer lubrication OK. c. Girth gear greasing sequence OK. Mill lubrication NOT OK a. Mill bearing lubrication not OK > 2 se b. Mill reducer lubrication not OK for > 10 sec. c. Girth gear greasing sequence not OK for > 15 min. Mill bearing lubrication Mill bearing lubrication OK is generated if all the conditions present i) Any LP pump is in operation. ii) Lube oil flow in LP circuit OK. iii) Any HP pump in operation and pressure at HP pump discharge OK (>20 Ksc) Mill bearing lubrication NOT OK is generated if any of the above conditions is not present.
Mill reducer lubrication Mill reducer lubrication OK is generated if, i) Reducer lube oil pump ON ii) Reducer oil flow is OK iii) Reducer oil temp is OK. Mill reducer lubrication NOT OK condition is generated if any one of the above is not present. Girth Gear Greasing System Girth gear greasing sequence OK is generated if all the following conditions are present. i) Grease pump motor ON ii) Time between two successive limit switch activations does not exceed two minutes. iii) Grease atomizing air pressure correct (>4Ksc) after 2 sec of energizing the solenoid
valve. 3. Ignition Permit Coal Elevation A: i) ¾ nozzle valves proven in Elevation AB OR ii) Elevation B air flow > 24 T/hr AND boiler load > 30% MCR
Coal Elevation B: i) ¾ nozzle valves proven in elevation AB or ii) Elevation A or C air flow > 24 T/hr AND boiler load > 30% MCR. Coal Elevation C: i) ¾ nozzle valves proven in AB AND elevation B air flow > 24 T/hr OR
Elevation B or D air flow > 24 T/hr AND boiler load > 30% MCR. Coal Elevation D: i) Elevation C or E air flow > 24 T/hr AND boiler load > 30% MCR OR ii) ¾ nozzle valves proven in Elevation CD Coal Elevation E i) ¾ nozzle valves proven in elevation EF OR ii) ¾ nozzle valves in elevation CD is proven in service and elevation D air flow > 24 T/hr
OR iii) Elevation D or F air flow > 24 T/hr AND boiler load >30% MCR. Coal Elevation F i) ¾ nozzle valves in elevation EF is proven in service OR ii) Elevation E air flow > 24 T/hr AND boiler load > 30% MCR.
COAL FEEDER
Start Permissive 1) Feeder switch in remote condition.
2) No MFR trip 3) Elevation DC power available 4) Mill elevation on. 5) Coal on belt. 6) Mill outlet temp OK. 7) No stop command for feeder.
OIL GUN HEAVY OIL TRIP VALVE Open Permissive 1) No MFR trip. 2) HFO supply pressure adequate. 3) All HONV closed. 4) Atomizing steam pressure not low. 5) Heavy Oil Trip Valve not open. 6) No stop command for HOTV
OR HORV open and all HONV closed. Close Protection 1) Loss of unit 24 DC 2) MFR trip 3) HFO header pressure low or atomizing steam pressure very low for more than 2 Sec. and HORV does not open. LIGHT OIL TRIP VALVE Open Permissive 1) No MFR trip 2) LFO supply pressure adequate 3) All LOVT closed. 4) Atomizing air pressure not low 5) LOVT does not open and no stop command. Close Protection 1) Loss of unit 24 V DC power 2) MRF trip 3) Any LONV open and LFO pressure very low (2.1 Ksc) for more than 2 Sec OR any LONV open and atomizing air pressure very low (2.5 Ksc) for more than 2 Sec. and at the same elevation no start /stop command.
FUEL OIL SELECTION Either light oil or heavy oil can be fired at elevation AB when selected. Heavy oil can be fired at elevation CD & EF. But presently in ITPS, LFO is fired at all the elevations.
I) ELEVATION MODE OPERATION Elevation mode operation is automatically selected when either of the adjacent coal elevations associated with warm up (L.O./H.O.) oil elevation is in service. II) PAIR MODE OPERATION Pair mode operation is selected when, All coal elevations are not in service
OR Both coal elevations A & B are not in service and elevation AB back up trip exists. START SEQUENCE (Typical for AB 1&3 pair) 1) Start command given to pair 1 & 3 .The seventy second elevation start (for corner 1 & 3) counting period is rest. The elevation back up trip signal is removed, positioning the associated elevation dampers for warm up oil firing. 2) AB 1 steam/air atomizing valve open. 3) HEA igniter advance feed back available. 4) HEA spark command if HEA fully advance feed back available and HONV 1 open. 5) Spark for 15 Sec. 6) Scanners show flame, gun hold. 7) After 15 Sec. of AB 1 command to AB3 start.
SCANNER AIR FAN Interlock 1. AC scanner air fan trips, DC scanner air fan starts. 2. AC scanner air fan in service & scanner air duct to furnace DP is less than 150 mmwc,
DC scanner fan starts. 4. Both FD fans off, emergency air damper opens.
REGENERATIVE AIR PRE HEATER
Permissive i) Any guide bearing LOP healthy or lub oil temp NOT HI ii) Any support bearing LOP healthy or lub oil temp NOT HI iii) All ESP I /L, O / L, Flue gas I / L & Secondary air O / L dampers open. iv) For air motor, air pressure before solenoid valve more than 5.0 kg / cm2
Interlock If electric motor trips and air pressure more than 5.0 kg / cm2, air motor starts.
ID FAN Permissive i) Fan & motor bearing temperature less than 800C ii) Hydro coupling bearing temperature less than 1100C iii) RAPH A/B ON iv) Hydro coupling oil cooler outlet temperature less than 700C v) Stack path available vi) ID fan inlet gate closed vii) ID fan outlet gate closed viii) Scoop tube control minimum ix) Hydro coupling DP across filter NOT HI x) Electrical switchgear OK Damper Interlock i) Fan starts, inlet & outlet dampers open ii) Fan stops/trips, inlet & outlet dampers close Protection i) ID fan bearing temperature more than 850C ii) ID fan ON & lube oil pressure very LOW (0.2 Ksc) iii) Hydro coupling working oil cooler outlet temperature very HI 900C iv) Hydro coupling scoop tube out let temperature very HI 1100C v) DP across filter very HI (0.6 Ksc)
FD FAN
Permissive i) Lube oil pressure more than 0.9 kg/cm2 ii) Control oil pressure more than 9.0 kg/cm2 iii) Fan bearing temperature less than 80oc iv) ID fan A/B motor ON v) Blade pitch minimum vi) Discharge damper closed vii) Lube oil pump A/B ON viii) Electric switchgear OK Interlock i) Discharge damper interlock: a) Fan starts, discharge damper opens b) Fan motor OFF, discharge damper close
ii) LOP interlock a) LOP B trip, LOP A starts & vice versa
b) LOP B on & lube oil pressure less than 0.8 kg/cm2, LOP A starts with time delay of 5 seconds & vice versa c) LOP B fails to start when start command is given, LOP A starts with time delay of 5 sec. & vice versa Protection i) Lube oil pressure less than 0.4 kg/cm2 ii) Bearing temperature fan very HI (850C) iii) Discharge damper closed with time delay of 60 sec. iv) Both ID fan off v) Electrical switchgear protection
PA FAN
Permissive i) Fan bearing temperature less than 800C ii) Lube oil pressure more than 0.8 kg/cm2 iii) Either FD fan on iv) Electrical switchgear O.K. v) Regulating vane (I.G.V) minimum Interlock i) Damper interlock: a) Fan starts PA General gate open b) Fan trips PA General gate closed ii) LOP interlock: a) LOP B trips, LOP A starts & vice versa b) LOP B on and lub oil pressure less than 0.6 kg/cm2, LOP A starts with time delay of 1 second & vice versa for LOP A c) LOP B fails to start when start command is given, LOP A starts with time delay of 2 seconds & vice versa. Protection i) Fan bearing temperature very HI (850C) ii) Lube oil pressure less than 0.4 kg/cm2 iii) Tripping of corresponding mill iv) MFR trip
4.2.2 TURBINE AND AUXILIARIES TURBINE PROTECTION
Sl. Description Alarm value Trip value Remarks 01. Drum level v. high +125 +225 02. M.F.T. channel ½ --- --- 03. Generator protection channel ½ --- --- 04. Lube oil pressure very LOW, ksc --- 1.20 2/3 logic 05. Condenser vacuum LOW, ksc 0.80 0.70 arming at 0.80 06. Low vacuum mech. Trip, ksc 0.80 0.76 kg/cm2 07. Fire protection channel -50 -100 mm 08. M.O.T. level low -50 -100 mm
(Zero level 800 mm down from top of M.O.T.)
09. Main steam temperature low 5000C 4800C arming at 5100C 10. Axial shift --- --- 11. Local trip --- --- 12. Emergency push button trip from --- --- unit control board 13. Over speed trip --- 3330 rpm 14. Fire protection 1 operated Turbine trip gear operated & vacuum breaker opens 15. Fire protection 2 operated Turbine trip gear operated, Vacuum breaker opens
AOP1, AOP2, AC JOP OFF & DC EOP, DC JOP ON with SLC ON. Gate gearing valve closed.
16. M.O.T. level low Same as fire protection 2 & Thrust bearing trip device operated.
TURBINE OIL PUMP
i) AOP1 starts on Auto : SLC AOP1 is on and AOP2 trips, or lube oil pressure less than 4.50 kg/cm2 ii) AOP2 starts on Auto : SLC AOP-2 is ON & AOP1 trip or lube oil pressure is less than 4.50 kg/cm2 iii) EOP starts on Auto : Lub oil pressure less than 1.20 kg/cm2 iv) JOP1 starts on Auto : SLC of JOP on & turbine speed less than 510 rpm. JOP1 stops on Auto : Turbine speed > 540 rpm v) JOP2 starts on Auto : SLC JOP on & JOP1 trip OR
Jacking oil pr. < 100 kg/cm2 & turbine speed < 510 rpm
TURNING GEAR i) Turning gear valve open on auto SLC of turning gear is on and turbine speed < 210 rpm. ii) Turning gear valve closes on auto Turbine speed more than 247, OR
Both AOP1 & AOP2 OFF, OR Fire protection 2 operated, OR
MOT Level Low protection operated, OR Lub oil pressure after duplex filter LOW.
BOILER FEED PUMP Permissive i) Suction/Discharge temperature not HI (120C) ii) Lube oil pressure O.K. (2.0Ksc) iii) Recirculation valve open iv) DP across oil filter not HI v) Electrical switchgear OK vi) AOP ON vii) Discharge valve Closed for standby pump. viii) Suction valve open ix) Scoop tube control minimum x) Working oil temperature not HI < 85oc xi) Deaerator level normal xii) Bearing temperature < 85oc xiii) Hydraulic coupling bearing temperature less than 85oc (for bearing No.1&2) Interlocks i) BFP motor ON, motor cooling water valve opens ii) BFP motor ON, Discharge valve opens iii) AOP cut in oil pressure 1.5 kg/cm2 AOP cut out oil pressure 2.9 kg/cm2 Protection i) Lube oil pressure less than 1.0 kg/cm2 ii) Deaerator level very LOW iii) Working oil temp at cooler inlet more than 1300C iv) Working oil temp at cooler outlet more than 850C v) Lube oil temp after cooler 600C vi) Thrust Bearing temperature more than 950C
vii) Suction/Discharge differential temp very HI (150C) viii) Hydraulic coupling bearing temperature > 950C & for bearing 3&4 temp > 900C ix) Suction valve open and BFP booster pump suction pressure less than 10 kg/cm2 x) DP across filter very HI (0.6 kg/cm2) xi) Recirculation control valve is open & feed water flow < 110 T/hr
CONDENSATE EXTRACTION PUMP
Permissive i) Suction valve open ii) Hot well level normal iv) Hot well recirculation valve open v) Discharge valve close & the equalizing valve open vi) Electrical switchgear O.K. Interlock i) 1st CEP motor ON, discharge valves of both the pumps open. Protection i) Hot well level very low (-1250 mm) ii) Pump bearing temp very HI (850C) iii) CEP discharge header pressure very low, standby pump auto starts on SLC. HP/LP BYPASS SYSTEM
HP Bypass system i) HP bypass oil pump cut in at 100 kg/cm2 oil pump cut out at header pressure 160 kg/cm2 ii) HPBP valves can be open if condenser vacuum > 0.67 kg/cm2 AND priority closure at condenser vacuum < 0.67 kg/cm2 iii) HPBP downstream temperature exceeds 3760C-HPBP valves closes. iv) HPBP valve position less than 2% auto closure of HPBP. LP Bypass System Permissive i) Condenser vacuum more than 0.67 kg/cm2 ii) Condensate header pressure more than 18.5 kg/cm2 iii) Steam pressure upstream of LP bypass valve more than 21.2 kg/cm2 Protection i) Condenser vacuum less than 0.67 kg/cm2 ii) Condensate header pressure less than 18.5 kg/cm2 iii) Condensate wall temp. at exhaust hood > 90oc (LP injection valve opens) iv) LP bypass upstream steam pressure less than 21.2 ksc
MAIN OIL CENTRIFUGE Interlock i) Booster pump motor can be started if main centrifuge motor ON ii) Centrifuge motor trip, solenoid valve in oil suction line de-energise. Solenoid valve opens when centrifuge motor ON iii) Centrifuge motor overload or booster pump motor overload, both motors trip and heater II & III cut off, heater I remains ON. iv) Broken liquid seal, centrifuge, booster pump, heater II & III trip, heater I remains ON. v) Polishing filter choke, centrifuge, booster pump, heater II & III trip, heater I remains ON. vi) Centrifuge motor ON, heater II & III can be made ON vii) Oil temperature more than 60oc, heater III cut off. viii) Oil temperature more than 70oc, all heater cut off. Water temperature more than 90oc – all heaters cut off Water level low – all heaters cut off.
REGENERATIVE HEATER SYSTEM
Low Pressure Heater-1 i) Very high drip level Cascade drain control valve DR 21 closes & heater is bypassed from condensate side by opening CD25 & closing CD26 & CD27. Extraction block valve closes. Low Pressure Heater-2 i) Very high drip level - Extraction block valve Ex 10 closes 300 mm above normal- Extraction drain valve Ex.101 & Ex. 102 opens water level) - Normal cascade drain control valve DR16 closes - Extraction line NRV closes - Alternate drain control valve DR 24 opens. Low Pressure Heater-3 i) Very high drip level - Extraction block valve Ex.11 closes (300 mm above - Extraction drain valve Ex.103 opens normal water level) - Extraction NRV closes - Alternate drain control valve DR19 opens
Deaerator Deaerator pressure control: a) Cold start up - 2.5 ata by auxiliary steam.
b) Hot and warm start up & bypass operation- 3.5 ata by auxiliary steam. c) Turbine load more than More than 3.5 ata to 6.6 ata by FY 15 valve 55% when extraction steam pressure exceeds pegging steam pressure High Pressure Heater-5 (HPH) i) Very high heater level - Extraction block valve Ex.13 closes. (335 mm above LWL)- Extraction NRV closes - Extraction drain valve Ex.112 opens - Repeat command to full open alternate
drain control valve DR14 & normal drain control valve DR11
- Heater bypassed from feed water side by opening bypass valve FD9 and closing FD7 & FD8.
- Normal drain control valve of HPH-6, DR2 closes. ii) Pressure falls below - Overriding command to close DR2 a preset value High Pressure Heater-6 i) Very high heater level - Extraction steam block valve EX12 & (345 mm above NWL) NRV closes. - Extraction drain valve Ex.110 opens - Alternate drain valve DR39 and normal drain valve DR2 opens fully. - Heater bypassed from feed water side by opening bypass valve FD12 & closing FD10 & FD11. - Repeat command to open alternate drain valve DR39 and normal drain valve DR2 / DR6.
STATOR WATER PUMP Permissive i) Expansion tank level more than 410 mm Interlock i) Header pressure less than 4.5 ksc standby pump starts. Protection i) Expansion tank level low, less than 350 mm.
SEAL OIL SYSTEM Interlock i) Seal oil header pressure less than 4.1 kg/cm2, D.C. SOP starts.
AIR CONDITIONING PLANT
AC COMPRESSOR Permissive i) BCW flow adequate. ii) Chilled water pump in service. iii) AHU in service. iv) Oil reset switch activated. Protection i) BCW flow LOW. ii) Suction gas pressure LOW < 35 psi iii) Discharge gas pressure HI < 260 psi iv) DP between oil & gas suction pressure < 0.9 bar v) Chilled water flow LOW. vi) Anti freezing protection (<30C)
SECTION – 5
OFFSITE AUXILIARIES
5.1 RAW WATER SYSTEM
i) Raw Water source Hirakud reservoir through intake channel ii) Intake channel Length 5450 m Bed width 3.5 m Width at top 7.0 m Bed level 174.5 m RL at down stream end
RAW WATER PUMP
i) Manufacturer Kirloskar Brothers, Pune ii) Type BHR 50-22½ ISTG (vertical) iii) No. of pumps 6 for both units (4 working, 2 stand by) iv) No. of stages One v) Capacity 1400 m3/hr vi) Head 60.35 m vii) Speed 1485 rpm viii) Discharge size 450 mm ix) Motor Make KEC Rating 304 KW, 6.6 KV, 3-ø, 50 Hz, Insulation Class F
5.2 CIRCULATING WATER SYSTEM
5.2.1 C.W. PUMP i) Manufacturer KBL ii) No. of pumps 6 for both units (4 working, 2 stand by) iii) Type BHQ 92 (vertical) iv) Outlet size 1200 v) Min. fore bay water level 193.5 m vi) Max. fore bay water level 195.5 m viii) Duty Condition:
Capacity 15000 m3/hr Total head at pump discharge 27.5 m Total head loss from suction 0.11 mwc ball to discharge flange Rated speed 494 rpm Pump efficiency at design capacity 89.1% Pump input design capacity 1268.8 KW
Bowl head 27.61 m ix) Motor
Make BHEL Rating 1470 KW, 6.6 KV, 3-ø, 50 Hz, continuous duty Insulation Class F, 166.8 A
x) Discharge valve Butterfly tight, shut off type, 1600 mm NB
5.2.2 COOLING TOWER
i) Type Induced draft type ii) No. of cells/unit 11 (10 working, 1 stand by) iii) Model 1514-11 (RCC fill) iv) Height excluding diffuser 10.345 m v) Width 25.21 m vi) Length 154.25 m vii) Total no. of towers 2 (1 for each unit) viii) Cooling water flow 9166.67 LPS ix) Hot water inlet temperature 420C x) Range of cooling 100C xi) Re-cooled water temperature 320C xii) Ambient wet bulb temperature 26.20C xiii) Drift loss % 0.05 xiv) Evaporation loss % 1.676 xv) Blow down for 2% conc. 1.63 xvi) Blow down for 4% conc. 0.509 Fans i) Type Axial flow propeller type ii) Design exit air temperature 39oc iii) Air flow rate / cell 31978 m3/min. Flow Control Valves i) No. 4 per cell ii) size 500 Nb iii) Drive 48 KW, 415V, 3-ø, 50 Hz, Insulation
Class F Chlorinators i) No. 2 nos ii) Capacity 112.5 kg/hr iii) Type ‘V’ notch vacuum feed
Chlorinator Booster Pump i) No. 2 nos ii) Capacity 9 m3/hr iii) Head 50 mwc
5.3 BEARING COOLING WATER SYSTEM
5.3.1 BCW PUMP
i) Make KBL ii) No. 6 for both units (4 working, 2 standby) iii) Type BHR 42-30 (2 stage) iv) Rated capacity 930 m3/hr v) Total dynamic head 80.2 mwc vi) Size 350 mm vii) Pump input 238.492 KW viii) Speed 1450 rpm ix) Motor Details: Duty Continuous
Rating 6.6 KV, 3-ø, 50Hz, 275 KW, 29.5 A, 1486 rpm, Insulation Class F.
BCW Supply i) Plant DG set ii) A/C for switchyard iii) BCW overhead tanks iv) Compressor house v) H2 cooler of the generator vi) Stator cooler of the generator BCW supply to Headers (for each unit) Size Flow (m3/hr) i) Boiler BCW Header 250 NB 294 ii) Turbine BCW Header 500 NB 1070 iii) Air conditioning plant 250 NB 330 (common for both units) BCW Sump i) Capacity 1500 m3 ii) Size 24.0 m x 15.0 m 4.0 m iii) Bottom level 195.00 mtr RL BCW Overhead Tank i) Nos 1 for each unit ii) Type Rectangular iii) Capacity 210 m iv) Size 17.0 m x 4.5 m x 3.25 m
5.3.2 PLATE HEAT EXCHANGER
Primary side Secondary side i) Fluid circulated Filtered water Raw water ii) Total fluid entering, m3/hr 950 814 iii) Inlet temperature, 0C 40 32 iv) Outlet temperature, 0C 34 39 v) No. of pass One One vi) Heat exchanged --- 5650240 Kcal/hr
5.4 SERVICE WATER SYSTEM
Service Water Pump i) No. Three (1 working, 2 standby) ii) Type Single stage horizontal centrifugal pump iii) Capacity 60 m3/hr iv) Total head 90 m v) Motor detail 415V, 3-ø, 50Hz, 30 KW, 52A, 2955 rpm,
Insulation Class F. Service Water Overhead Tank i) No. 1 for each unit ii) Type Rectangular, vertical iii) Capacity 75 m3 iv) Size 10.0 m x 3.5 m x 3.0 m
5.5 WATER TREATMENT PLANT
5.5.1 PRE-TREATMENT PLANT
RAW WATER QUALITY
i) PH value 7.5-8.5 ii) TDS, mg/l 200 iii) Permanganate value 02 ppm iv) Iron as Fe, mg/l 1.5 v) P. Alkalinity as CaCo3 Nil vi) M. Alkalinity as CaCo3 90.0
TREATED WATER QUALITY Constituent As Analysis i) Calcium (ca) CaCo3 90 ppm ii) Magnesium CaCo3 40 ppm iii) Sodium & Potassium (mg) CaCo3 40 ppm vi) Sulphate (So4) CaCo3 60 ppm v) Chloride (Cl) CaCo3 15 ppm Total Anions CaCo3 172 ppm vi) Iron Fe 0.2 ppm vii) Free carbon dioxide CO2 Not traceable viii)Silica SiO2 9 ppm (colloidal) 6 ppm (reactive) ix) pH value ---- 7.5 to 8.5 x) Turbidity NTU ---- Not to exceed 10 xi) Organic matter, ppm ---- Traces xii) Manganese content, ppm ---- Not traceable FLASH MIXER i) No of units 2 (one for each clariflocculator) ii) Material of construction RCC iii) Size 2.5 m2X 4.1 mswd iv) Rated flow to each unit 1200 m3/hr v) Agitator One, 7.5 HP, 1500 rpm CLARIFLOCCULATOR i) No of units 2 ii) Material of construction RCC iii) Rated flow of each ccf 1200 m3/hr iv) Overall size 31 m2 X 2.7 mswd v) Detention time (for rated flow) Flocculator zone 30 min Clarification zone 158 min (approx) FILTER BEDS i) No of units 5 ii) Material of construction RCC iii) Capacity (each) 500 m3/hr iv) Size 7.2 m X 4.375 m v) Rate of filtration 500 m3/hr FILTER BACK WASH i) Duration of air scouring 3 to 5 min ii) No of air blowers 2 (1 working + 1 stand by) iii) Capacity 1350 m3/hr
iv) Backwashing By backwash pump No of pumps 3 (2 working + 1 stand by) Make/ model Worthington, C18 TC Capacity (each) 610 m3/hr Motor 55 kw/ 4 pole CHLORINATION SYSTEM (PT) i) No of chlorinator 3 ii) Make/ model V-711 ii) Capacity (each) 10 kg/hr iv) Booster Pumps No 2 Capacity 9 m3/hr at 50 mwc Motor 5.5 Kw
5.5 .2 D. M. PLANT
EFFLUENT QUALITY a) Activated carbon filter outlet Free chlorine & iron Not detectable Turbidity Not to exceed 0.5 NTU b) Cation exchanger outlet
Sodium as Na < 0.05 ppm c) Degasser outlet Free carbon dioxide as CO2 < 5 ppm d) Anion outlet Silica as SiO2 (reactive) Not to exceed 0.1 mg/l Chloride BDL Conductivity at 250C Not to exceed 2 micro mho/cm Organics Nil e) Mixed bed outlet Total electrolyte Not to exceed 0.1 mg/l Silica as SiO2 (reactive) Not to exceed 0.02 mg/l Free CO2 as CO2 Not detectable Iron as Fe < 0.01 Total hardness Not detectable PH value 6.8 – 7.2 Conductivity at 250C < 0.2 micro mho/cm
ACF & EXCHANGER DATA
Activated carbon filter
Strong acidic cation exchanger
Strong basic anion exchanger
Mixed bed exchanger
i)No. of units 3 3 3 3 ii)Normal flow rate m3/hr
75 75 75 75
iii)Max. flow rate m3/hr 90 90 90 90 iv)Regeneration interval hours
20 20 20 160
v)Net output between two regeneration, m3
1500 1500 1500 12000
vi)Filling media Activated T-42 Thermax A-27 (MP) Thermax
A-27 (MP) & T-42, Thermax
vii)Quantity of Operating Media (m3)
Operating Inert
-- --
5.38 0.318
4.46 0.312
1.27 & 1.27 --
RELEVANT DATA FOR REGENERATION 1. Chemical Required Cation Anion MB MB for Regeneration group group cation Anion a) 100% HCl, kg 215.2 -- 88.9 -- b) 30% HCl, kg 718 -- 296 -- c) 30% HCl, litres 624 -- 257 -- d) 100% NaOH, kg -- 156.1 -- 88.9 e) 45% NaOH, kg -- 347 -- 198 f) 45% NaOH, litres -- 240 -- 136 2. Acid dilution water 21.5 -- 6.0 -- flow rate, m3/hr 3. Alkali dilution water -- 15.0 -- 4.0
flow, rate m3/hr
LIMITING VALUES OF BOILER WATER CHEMISTRY
Silica limit for Drum is given at maximum operating drum pressure i.e.160 ksc. However at drum pressure <160 ksc, the silica in drum may be allowed >300 ppb. The exact relationship of silica to drum pressure can be referred from the Drum Pressure vs Silica graph.
DM WATER TRANFER PUMP i) No. & type 3, centrifugal ii) Manufacturing Kirloskar iii) Design capacity, m3/hr 85 iv) Total head 40 m v) Speed, rpm 1475 vi) Motor 22 KW, Crompton Greaves make
CONDUCTIVITY
In micro siemens
SiO2 PO4 N2H4 TH Cl-
As NaCl
DO NH3 Fe Cu Sample pH
DC ACC ppb ppm ppb ppm ppm ppb ppb ppb Boiler Drum 9.2-9.8 <50 <300 1 to 6 0 <2
Sat. Steam 8.8-9.2 <6 <0.3 <20 0 BDL
Main Steam 8.8-9.2 <6 <0.3 <20 0 BDL Condensate 8.8-9.1 <6 <0.3 <20 0 BDL <20 <0.5 Feed Water 8.8-9.2 <6 <0.3 <20 20 0 BDL <7 <0.5 <10 <5
DM-Make up
6.8-7.2 <0.2 <0.2 <20 0 BDL
MISCELLANEOUS PUMPS
5.6 STANDARD LIMITS OF ENVIRONMENTAL EMISSION (CONSENT REQUIREMENT)
STACK EMISSION Quantity of Flue Gas 90×104 Nm3/hr/unit Suspended Particulate Matter <150 mg/Nm3
AMBIENT AIR QUALITY STANDARDS Pollutant Time Weighted Concentration in Ambient Air
Average Industrial Residential Area Area
1 2 3 4 Sulphor Dioxide Annual avg. 80 µg/m3 60 µg/m3
(SO2) 24 hours 120 µg/m3 80 µg/m3
Oxides of Nitrogen Annual avg 80 µg/m3 60 µg/m3
As NOX 24 hours 120 µg/m 80 µg/m
Blower Filter back wash pump
Degassed water pumps
Acid transfer pump
Caustic transfer pump
Waste water disposal pump
Degas air blower
Mixed bed air blower
i)No. 3 5 2 2 4 4 2 ii)Make Worthingto
n Kirloskar Antico Kirloskar -- Universal Kay
International iii)Type/ stages
Vertical turbine/single
Centrifugal/ single
Centrifugal/ single
Centrifugal/ single
Centrifugal/ single
Centrifugal/ one
Rotary/single
iv)Operation continuous continuous intermittent intermittent intermittent -- -- v)Discharge head
20 mwc 50 mwc 20 mwc 20 mwc 30 mwc 100 mm WG suction-2200 m3/hr
Suction- 480 m3/hr
vii)Shut off head
26.6 mwc 50.3 mwc -- 20.5 mwc 30.4 mwc -- --
viii)Drive motor
55 kw 30 kw 3.7 kw 7.5 kw 11 kw 2.2 kw --
Suspended Particulate Annual avg. 360 µg/m3 140 µg/m3
Matter (SPM) 24 hours 500 µg/m 200 µg/m Respirable Particulate Annual avg. 120 µg/m3 60 µg/m3
Matter (Size less 24 hours 150 µg/m3 100 µg/m3
than 10 µg/m3) (RPM) Lead (Pb) Annual avg. 1.0 µg/m3 0.75 µg/m3
24 hours 1.5 µg/m3 1.0 µg/m3
Carbon Monoxide 8 hours 5.0 mg/m3 2.0 mg/m3 (CO) 1 hour 10.0 mg/m3 4.0 mg/m3 COMBINED INDUSTRIAL EFFLUENT pH 5.5 to 9.0 TSS, ppm 100 max BOD, ppm 30 COD, ppm 250 Oil & Grease, ppm 10 Cl, ppm 1000 Quantity 1500 KL/day (max.)
5.7 COAL TRANSPORTATION AND COAL HANDLING SYSTEM
5.7.1 COAL TRANSPORTATION SYSTEM
i) Source of coal Ib Valley Lakhanpur mine ii) Means of transportation Merry Go Round System iii) No. of wagons 36 (including 6 standby) iv) No. of rakes required per day 4 v) Total cycle time of one rake 4 hours 32 minutes vi) Total distance 19.3 km vii) Total cycle length 25.25 km viii) Track length 33.6 km ix) Track gauge 1676 mm x) Type of wagon & make Bottom discharge type, Texmaco make xi) Tare weight of wagon 27.5 T xii) Locomotive: Make Diesel Locomotive Works, Varanasi Nos. 2 Model / type WDM2/ Co-Co
Horsepower 2400 hp Max speed 120 kmph Gear ratio 65/18 Max. Radius of curvature 73.2 m
FILLING STATION FOR DIESEL LOCOMOTIVE Location MGR Workshop panel building Capacity 2×70 KL
5.7.2 COAL HANDLING SYSTEM
Track Hopper: i) No. of hoppers One ii) Type of hopper RCC underground iii) Length of track hopper 200 m iv) Breadth of track hopper 6.8 m v) Height of track hopper 7.15 Paddle Feeder i) Location Underneath Track hopper ii) No. of paddle feeder 4 iii) Type of paddle feeder Rotary type iv) Design/Rated capacity 1200 / 1000 T/hr v) Range of travel 210 m Vibration Grizzle Feeder i) Location At crusher house ii) No. of vibrating grizzly feeder 4 nos iii) Capacity rated / design 1000 / 1200 T/hr iv) Frequency 1000 rpm (nominal) v) Motor 25KW, 415V, 3-ø, 50 Hz, KEC make Crusher House i) No. & make of crusher 4, Elecon Engineering Co. ii) Type & size Ring granulator, EKK 48” x 114” iii) Main crusher capacity 1000 TPH each iv) Max. coal size before crusher 300 mm v) Coal size after crusher 20 mm vi) Motor rating KEC make, 825 KW, 6.6 KV, 3-Ø,
50 Hz, 720 rpm, 92 A, Insulation Class F
Conveyor i) No. of belt conveyors 26 ii) Design / rated capacity 2200 TPH / 2000 TPH Main belt conveyor
TRH1A/ 1B
1A/1B 2A/2B 3A/3B 5A/5B 7A/7B 8A/8B SR1
iii)Belt speed (m/sec)
2.9 3.02 3.02 2.97 3.02 3.02 2.97 3.02
iv)Belt width (mm)
• 1600 •
v)No. of plies 4 4 4 4 4 4 4 4 vi)Top cover thickness (mm)
5 5 5 5 5 5 5 5
vii)Bottom cover thickness (mm)
3 3 3 3 3 3 3 3
viii)Cover grade • ----------- Fire resistant (FR) ------------------------•
ix)Conveyor motor: Rating (KW) F.L. Current, (A) Power supply
200 23 • ………..
330 34 • ……
330 35 6.6KV,
157 26 3ø,
400 43.5 50Hz
520 66 …..•
165 19 …..•
300 34 …•
x) No. of metal detectors 5 (on conveyor 2A/2B, 7A/7B & SR-1) xi) No. of belt weigher 6 (on conveyor 1A/1B, 2A/2B, 7A/7B) xii) No. of sampling unit 4 xiii) No. & type of magnetic separators 5, suspended type xiv) No. of suspended magnet 2 Tripper i) Type Travelling type ii) No. 2 iii) Capacity 2200 t/hr iv) Travel speed 14.5 m/min. v) Motor for tripper 11 KW vi) Brake Thruster operated Stacker / Re claimer i) No. 1 ii) Model ASK 965 iii) Stacking capacity (rated/design) 2000 / 2200 TPH iv) Reclaiming capacity 2000 TPH v) Travel Motor Reversible slip ring motor, 6 nos, 10 KW each
vi) Bucket motor Squirrel cage, 125 KW, 415 V, 3ø, 50 Hz vii) Boom conveyor speed 3 m/sec viii) Boom conveyor motor Type & Rating Squirrel cage reversible type,110
KW, 415V, 3ø, 50 Hz ix) Slew speed 6 m/min. to 32 m/min. (step less) x) Slew motion motor D.C. type, 2 x 14 KW Dust Extraction System i) Total No. of units DE-1 to 6 for section-I & DE-7 to 13 for Section-II ii) Fan Centrifugal iii) Dust velocity 4 m/sec. (at hood) iv) Cyclone collecting efficiency 85% (base on 10 microns) Stock Yard i) Capacity 45 days, coal storage requirement 450000 m3 of coal approx ii) Length/height of each pile 505 m / 9.5 m
5.8 ASH HANDLING SYSTEM
5.8.1 BOTTOM ASH HOPPER
i) Quantity One ii) Shape W type iii) Capacity 200 m3 (effective) iv) No. of outlet opening Four v) Maximum level up to which 300 mm below hopper overflow nozzle ash can be stored elevation.
5.8.2 CLINKER GRINDER
i) Location Feed Gate housing ii) Capacity 75 TPH iii) Quantity Four per unit iv) Hopper evacuation time 70 minutes FEED GATE HOUSING No. 4 per unit HYDROEJECTOR No. 4 per unit
5.8.3 HORIZONTAL ASH WATER PUMPS
Fly Ash Pump (HP)
Fly Ash Pump (LP)
Bottom Ash Pump
Seal Water Pump
i)Location Ash Water Pump House ii)Type Horizontal, Centrifugal iii)Quantity 3 3 3 3 iv)Fluid Handled Clear Water v)Capacity(m3/hr) 250 600 400 60 vi)Total Dynamic Head (mwc)
75 55 75 180
vii)Speed (rpm) 1480 viii)Suction condition
Flooded
ix)Duty Continuous x)Coupling Flexible xi)Drive Details: Supply
415 V, 3-ø, 50 Hz
Rating (KW/A) 75/132 125/213 120/204 50/88
5.8.4 ASH DISPOSAL PUMP
i) Make Indure ii) Type D-85-D Horizontal, Centrifugal & non-log type iii) No. 6 (3 working, 3 standby) iv) Capacity 850 m3/hr v) Total dynamic head (mwc) 37.5 vi) Drive Details: Make NGEF Rating 6.6 KV, 3-ø, 50 Hz, 185 KW, 21A, 1481 rpm, Insulation class F
5.8.5 ASH COLLECTION RATE
Collection point No. of Collection rate of Ash Hoppers each hopper (kg/hr) Temp. 0C
i) Furnace bottom hopper One 19200 1000 ii) Economizer hopper 4 4800 361 iii) Air heater hopper 6 4800 144 iv) Duct hopper 2 2400 144 v) ESP hopper:
First field 8 61440 144 Second field 8 11212.8 144 Third field 8 2611.2 144 Fourth field 8 998.4 144 Fifth field 8 307.2 144 Sixth field 8 88.32 144 Stack 1 Balance 144 For two units at full load i) Bottom ash collection 36.8 TPH ii) Coarse ash collection 18.4 TPH iii) Fly ash collection 147.2 TPH iv) Total collection 202.4 TPH maximum
5.9 ASH POND AND ASH WATER RECYCLE SYSTEM POND‘A’ ∗∗POND‘B’ i) Gross area, acres/m2 150/6,07,040 242/9,80,000 ii) Top elevation of dyke, m (RL) 197.00 202.00 iii) Average base level, m (RL) 187.00 189.00 iv) Average height of dyke, m 10.00 13.00 v) Max. level of ash deposit, m (RL) 197.00 200.50 vi) Minimum freeboard, m 1.50 1.50 vii)Available depth of ash deposition, m 8.50 11.50 viii)Area covered by bund, m2 2,47,760 2,94,000 ix) Net area (excluding settling tank), m2 3,41,280 6,86,000 x) Capacity, m2 29,00,880 76,82,000 ∗∗ Presently ash pond ‘B’ is receiving ash effluent from the two units of the power plant. Ash water is collected through collector well & treated in primary settling tank. Then it is taken to secondary settling tank by gravity through one no. 600 M.S. pipe. Secondary settling tank comprises two sections & each section has got three cascading / decanting chambers for settlement of remaining ash. Decanted water flows in to the Transfer water sump from which pumping is done through two nos. vertical turbine pumps for reuse in the plant. Transfer Water Pump i) Nos. 3 ii) Manufacturer Voltas Ltd iii) Type Vertical Turbine Pump iv) Model BK 450-022
v) No. of stages 4 vi) Rated capacity, m3/hr 1000 vii) Total dynamic head, mwc 180 viii)Recommended min./max. flow through the pump, m3/hr 700/1400 ix) Thrust bearing Antifriction type, SKF/FAG 29428E x) Coupling Pin & Bush type, NBCB (Fenner) xi) Material Suction bell Cast steel, WCB, ASTM A-216 Impeller CF8M, ASTM A-743 Motor i) Manufacturer BHEL, Hardwar ii) Rating 6.6 KV, 50 Hz, 78.9 A, 1485 rpm Insulation class-F iii) Driven equipment demand Normal / Maximum, KW 609.21 / 620.86 33KV / 6.9KV, 450 KVA Transformer i) Manufacturer K.E.C. Ltd, Bangalore ii) Continuous rating 4.5 MVA, 50 Hz, 3-Φ iii) Rated no load voltage HV winding 33KV LV winding 6.9KV iv) Connection HV winding Star LV winding Star v) Vector group Ynyno vi) On load/off circuits On-load tap changer vii) No. of steps 8 steps – 9 positions viii)Type of cooling ONAN 150 KVA AUX. Transformer i) Continuous rating 150 KVA ii) Type Dry iii) Type of cooling AN iv) Rated voltage HV 6.6 KV LV 433 V v) Vector group Dyn11 vi) Type of taps Off circuit vii) No. of taps 5 (±2 X 2.5%)
5.10 FIRE FIGHTING SYSTEM
5.10.1 FIRE DETECTION AND ALARM SYSTEM
Microprocessor Based Detector System The plant is divided in to 22 no. of loops connected to zones with BS-100 type control panel suitable to addressable analogue type sensors. ____________________________________________________________________________ Panel No of loops Location SIP-A 11 Main control room of unit 1 & 2 SIP-B 6 Service building, ESP control room, CW
pump house, 220 KV switch yard SIP-C 4 CHP control room SIP-D 1 Fuel oil pump house All these BS-100 panels (SIP-A & SIP-B) are interfaced to EA-2 computer and Video Display Unit (VDU) located in main control room. In addition to above, a separate panel is provided for ROR (Thermocouple Type) detectors used for conveyor protection. This panel is located at CHP control room and interfaced with SIP-C located in the same area and with EA-2 computer. Zone fire relay contact (from each zone) of ROR panel is connected to individual interface unit in the addressable loop of SIP-C. Detector Types
Area Type Of Detectors Used i) Cable trench, cable gallery. ISD, PSD, LHS cable, Quatrozoid bulb. ii) Generator seal oil unit, oil tank, oil purification unit. HVW, Quatrozoid bulb iii) Boiler burner fronts. Manual Call Point iv) Generator Transformer, Station Transformer, UAT HVW, Quatrozoid bulb v) HT/LT switchgear, battery room, MCC room ISD, Heat Detector vi) MCR, DAS room, UPS room ISD, PSD vii) SWAS room ISD viii) CHP control room & building ISD
ix) Coal conveyor LHS cable, ROR (Thermocouple type) x) Switch yard ISD xi) Service Building ISD, Heat Detector
5.10.2 FIRE SUPPRESSION SYSTEM
FIRE HYDRANT PUMP i) No. 3 2 Electrical driven, 1 diesel engine driven ii) Location circulating water pump house iii) Make Warthington Pump India Ltd iv) Area where used Total plant area, bunkers, track hoppers
Electric driven Diesel engine driven v) Rated capacity (m3/hr) 273 273 vi) Total dynamic head (mwc) 90.84 90.84 vii) Size of pump discharge (mm) 200 NB 200 NB viii) Speed 1470 rpm 1500 rpm ix) Power required at coupling 88.57 87.62 at duty point (kw) x) Drive detail:
Make KEC Kirloskar Cummins Ltd Rated Power 110 KW, 415 V 173 bhp
3-Ø, 50Hz, 182A, Insulation class B, Speed 1482 rpm 1500 rpm
AUTOMATIC MULSIFIRE FIRE SYSTEM i) Area where used Generator Transformer Station Transformer, Unit Auxiliary Transformer, Turbine Oil tank & Coolers, Clean & dirty oil
tank, Cable gallery, Coal conveyors, FO Tanks ii) No. of pumps 2 iii) Location C.W. pump house iv) Make Worthington Pump India Ltd v) Type Wet pit non-pullout type vertical turbine pump Electrical driven Diesel driven vi) Rated capacity (m3/hr) 410 410 vii) Total head (mwc) 91.4 91.4 viii) Size of pump discharge (mm) 250 250 ix) Speed (rpm) 1470 1500 x) No. of stages 5 5 xi) Drive detail:
Make NGEF Ruston & Hornsby (India) Ltd
Power 160KW, 415V, Rated bhp 230 at
3-Ø, 50Hz,1500 rpm 1500 rpm JOCKEY PUMP i) No. of pump 2 ii) Stage 7 stages iii) Rated capacity (m3/hr) 11 iv) Total dynamic head (mwc) 92.8 v) Drive 7.5 KW, 415V, 3-Ø, 50Hz, 2900 rpm
HYDRO PNEUMATIC TANK i) Type Vertical cylindrical ii) Capacity 10 m3 iii) Design pressure 192 psi iv) Working pressure 175 psi AIR COMPRESSOR i) Make Ingersol Rand ii) Type Single stage, single cylinder, reciprocating iii) Quantity 1 iv) Capacity 0.56m3/min v) Head 10 Kg/cm2 vi) Air receiver capacity 225 litre vii) Working pressure 175 psi FOAM SYSTEM i) Area where used HFO/LDO system ii) Type of system Fixed foam low expansion delivered gently in oil surface iii) Application rate 5 lpm/m2 liquid surface area iv) Foam concentration 30% profein based v) Type Foam maker with vapour vi) Foam delivery rate 393 & 768 LPM vii) Foam compound consumption 3%
HALON SYSTEM i) Make Cerberus Guinard ii) Area where used Main control room, Instrumentation pane rooms, UPS, DAS & excitation rooms iii) Extinguishing agent Halon1301 gas iv) Concentration 5% at design temperature v) Gas discharge duration 30 sec.
5.11 AIR COMPRESSOR
Manufacturer : Kirloskar Pneumatics Ltd Type : Reciprocating, horizontal, balance opposed,
oil free type No. of compressors : 4 per unit CONSTRUCTION FEATURES i) No. of stages Two ii) Cylinder arrangement Balanced opposed iii) Cylinder bore LP 1 x 355 mm HP 1 x 215 mm iv) Stroke 150 mm v) Cooling water pressure 2.5 ksc – 3.5 ksc vi) Inter cooling water pressure 3.5 ksc vii) Type of drive Direct through belt drive viii) Main bearing type Split sleeve ix) Method of lubrication Forced feed by gear pump x) Max. allowable lube oil temp. 80oc xi) Cross head lubrication HPC/LPC By gear pump/splash type xii) Lube oil pressure 2 to 4 kg/cm2(g)
PERFORMANCE DATA i) Volumetric efficiency at design condition 78.9% iii) Air temp. after first/last stage of
Compressor 153oc / 147oc iii) Outlet air temp. (After after-cooler) 8oc above BCW inlet temperature AIR DRYING PLANT i) No. 3 for both units ii) Desiccant Silica gel as per IS 4301 iii) Duty Continuous iv) Drying cycle 6 hours v) Type of drying Absorption vi) Type of reactivation Open thro-system Type of change Automatic with provision for manual Motor i) Manufacturer KEC Ltd., Bangalore ii) Rated output 125 KW
iii) Frame size LD 315 MMK 11 iv) Class of insulation B v) Rated speed 1484 rpm vi) Power supply 415 V, 3-Ø, 50 Hz
REGENERATION CYCLE i) Depressurisation 10 min ii) Heating 3 hours iii) Cooling 1 hour iv) Re pressurising 15 min
5.12 AIR CONDITIONING PLANT
Description Main chilling plant Switchyard A.C. plant Control room/Service bldg. (Direct expansion AHU) Capacity (tons) 7034 7032 3032(condensing units) Refrigerant used R-22 R-22 R-22 Compressor No. 4 2 2 Make ----------------------Kirloskar Pneumatic Ltd--------------------------- Model AC-880 AC-880 AC-470 No. of cylinders 8 8 4 Cylinder bore(mm) 95 95 85 Stroke (mm) 70 70 70 Direction of rotation ----------------------Both directions permitted---------------------------- Max. operating pressure (bar) 21 21 21 Capacity control(%) ----------------------25, 50, 75, 100----------------------------------------- Lube oil ----------------------Servofiz F-57 (10C )--------------------------------- Motor GEC make, 415 volt, 3-ω, 50Hz GEC make, 415 volt, 3-ω, 93 kw, 169A, 1485 rpm 50Hz,37kw,69A,1470rpm Shell And Tube Condenser Make ---------------------------------Blue star Ltd-------------------------------- Model CDS-1686 CDS-1686 CDS-1260 No. 4 2 2 No of tubes 172 172 110 No of passes 3 3 4 Tube material Copper Copper Copper Max Working pressure i) Water side (kg/cm2) 7 7 7 ii) Refrigerant side
(kg/cm2) 21 21 21 Mode of flow -------------------------Water through tubes------------------------------- Heat rejection rate ------265313 kcl/hr----------------- 110185 kcl/hr Chiller Make --------Blue star Ltd---------------- No chiller as direct expansion AHU Model ---------DXC-2009------------------ Mode of flow ------Refrigerant through tubes---- No of tubes 252 252 No of passes 8 8 Water inlet temp (0C) 12.78 12.78 Water outlet temp (0C) 7.22 7.22 Total water flow (m3/hr) 38 38 Air Handling Unit Make -------------------------- Blue star Ltd---------------------------------- No 4 4 1 Model Size-12 Size-9, 11 Size-11 Fan type --------------------Centrifugal forward curved------------------------ Air quantity (m3/hr) 40,000 21367 (size-9) 22700 31600 (size-11 Electric strip heaters 3318kw 339kw 239kw Motor ------------------GEC make, 415 volt, 3-Ø, 50Hz --------------------- Rating 15kw 7.5/5.5 kw 7.5 kw Packaged Air Conditioners Location ESP control room U#1 & 2 (3 Nos. each) Capacity 7 ton each Make Blue star Ltd Model PWC-711 Electric strip heater 236kw Condenser cooling Water cooled (shell & tube type) Compressor Hermatically sealed, Copeland make, 3-ω motor Compressor speed 2900 rpm Suction / condensing temp 4.4/ 42 0C
SPLIT AIR CONDITIONER Location Annunciation panel room of unit –2 and Halon cylinder room No 3 Capacity 7.5 ton
Make Blue star Ltd Model SAC 711A Condenser type Air cooled fan coil type Compressor Hermatically sealed, Copeland make, 3-ω motor.
5.13 MAIN PLANT DG SET Total Nos. 3 Diesel Engine: i) Make Kirloskar Cummins ii) Model KTA-2300 G iii) No. of cylinders 12 iv) Displacement, cub inch(litres) 2300 (37.8) v) HP at 1500 rpm 890 vi) Engine breathing Turbocharged after cooled vii) Method of cooling of engine & lube oil Radiator water cooled / forced air blast Alternator: i) Make Kirloskar Electric Co. Ltd. i) Rated capacity at 40oc 750 KVA ii) Rated terminal voltage & frequency 433 V, 50 Hz iii) Rated stator current 1000 A iv) Class of insulation F v) Excitation current & voltage at rated output & power factor 20A, 64.1 V Diesel Tank: Capacity 900 litres
SECTION – 6
ANNEXURE
ANNEXURE - 1
TURBINE ROLLING CURVE-1 DT (HP ESV1 – HP CASING) >5.1
STEP / CRITERIA 11/4
DT (HP ESV 1 - HP Casing)
0
100
200
300
400
500
600
0 200 400 600 800
HP casing temp
Met
al te
mp
ESV
Not Recommended
Recommended
TURBINE ROLLING CURVE-2 DT (HP ESV2 – HPSHAFT) >5.2
STEP / CRITERIA 11/5
DT(HP ESV2-HP Shaft)
0
100
200
300
400
500
600
0 200 400 600 800
HP Shaft mean metal temp
Met
al te
mp
ESV
2
TURBINE ROLLING CURVE-3 DT (HP BP1 – HP SHAFT) < X6
STEP / CRITERIA 14/2
DT (HP BP - HP Shaft)
0
100
200
300
400
500
600
700
0 200 400 600 800
HP shaft metal temp
MS
tem
p be
fore
HPB
P Not Recommended
Recommended
TURBINE ROLLING CURVE-4
DT (LP BP1 – IP SHAFT) < X7
STEP / CRITERIA 19/2
DT (LP BP1 - IP Shaft)
0
100
200
300
400
500
600
700
0 200 400 600 800
IP shaft mean wall temp
HR
H st
eam
tem
p be
fore
LPB
P
Recommended
Not Recommended
TURBINE ROLLING CURVE -5
STEAM BEFORE ESV1 S/H > X 4.1 STEAM BEFORE ESV2 S/H > X 4.2
STEP / CRITERIA 11/2 11/3
Steam Before HP ESV1 S/H
0
50
100
150
200
250
300
0 10 20 30 40 50 60 70Pressure (bar)
Tem
pera
ture
(C)
TURBINE ROLLING CURVE-6
DT (HP BP1 –HPCV1) < X1.1 DT (HP BP2 –HPCV2) < X1.2
STEP / CRITERIA 4/6
4/7
DT(HP BP - Control Valve)
0
100
200
300
400
500
600
0 200 400 600 800
HP CV mean metal temp
MS
tem
p be
fore
HP
BP
TURBINE ROLLING CURVE-7
DT (WET STEAM – HP CV1) <X2.1 DT (WET STEAM – HP CV2) < X2.2
STEP / CRITERIA 4/9 4/10
DT (Wet Steam - Control Valve)
0
100
200
300
400
500
600
0 100 200 300 400 500 600
HP CV mean metal temp
MS
tem
p be
fore
HP
BP
ANNEXURE - 2
GENERATOR OPERATING LIMITS
DESIGN POINT OUT PUT 147 MVA OUT PUT 210 MW POWER FACTOR 0.85 LAG STATOR VOLTAGE 15.75 KV STATOR CURRENT 9050 AMP SPEED 3000 RPM H2 PRESSURE 3.5 KG/CM2
GENERATOR CAPABILITY
0
50
100
150
200
250
-100 -50 0 50 100 150 200
Series1Series2Series3Series4Series5
←←-------Leading MVAR Lagging MVAR ---------------→
Series 1 Turbine Limit (210MW) Series 2 Rotor Heating Limit Series 4 Rotor Angle Limiter Series 5 Rotor Current Limiter
ANNEXURE -3
UNLOADING SCHEDULE DUE TO HIGH DISTILLATE TEMPERATURE
8100
8200
8300
8400
8500
8600
8700
8800
8900
9000
9100
42 44 46 48 50
TEMP OF DISTILLATE AT INLET OF STATOR WINDING DEGREE C
PE
RM
ISS
IBLE
STA
TOR
CU
RR
EN
T-A
MP
Series1
Series2
Series3
Series4
Series5
Series6
Series 1 POWER OUTPUT Series 2 NORMAL TEMP OF DISTILLATE – 450C Series 3 RATED STATOR CURRENT 9050A Series 4 STATOR CURRENT Series 5 RATED OUTPUT Series 6 MVA OUTPUT Note – Operation of Generator with distillate temperature more than 480C is not permitted.
ANNEXURE – 4
STEAM TABLE
SATURATED PROPERTIES OF WATER AND STEAM WITH PRESSURE AS PARAMETER
---------------------------------------------------------------------------------------------------
Pressure Temp Specific Volume Specific Enthalpy Specific Entropy P Kcal/kg-k Kcal/kg-k Kcal/kg-K
ata oC Vf, Vg, lit/kg m3/kg hf hfg hg sf sg --------------------------------------------------------------------------------------------------- 0.02 17.204 1.003 68.26 17.25 587.6 604.9 0.0612 2.0849 0.05 32.35 1.0053 28.73 32.58 578.9 611.5 0.1127 2.0065 0.06 35.82 1.0064 24.18 35.84 577.2 613.0 0.1233 1.9912 0.08 41.16 1.0084 18.45 41.17 574.0 615.2 0.1402 1.9664 0.10 45.45 1.0101 14.95 45.45 571.6 617.0 0.1540 1.9480 0.20 59.67 1.0169 7.789 59.65 563.0 623.0 0.1976 1.8903 0.30 68.68 1.0221 5.324 68.66 558.0 626.0 0.2242 1.8567 0.40 75.42 1.0261 4.066 75.41 554.1 629.5 0.2438 1.8338 0.50 80.86 1.0296 3.299 80.86 550.7 631.6 0.2593 1.8149 0.60 85.45 1.0327 2.781 85.47 548.0 633.5 0.2722 1.8003 0.70 89.45 1.0355 2.409 89.49 545.6 635.1 0.2833 1.7881 0.80 92.99 1.0381 2.126 93.05 543.4 636.4 0.2931 1.7772 0.90 96.18 1.0405 1.904 96.25 541.3 637.7 0.3019 1.7675 1.0 99.09 1.0428 1.725 99.18 539.5 638.7 0.3097 1.7589 1.5 110.79 1.0521 1.180 110.99 532.1 643.1 0.3409 1.7267 2.0 119.62 1.0600 0.9019 199.9 526.4 646.3 0.3640 1.7040 2.5 126.79 1.0666 0.7319 127.3 521.4 648.7 0.3823 1.6860 3.0 132.88 1.0726 0.6160 133.5 517.3 650.8 0.3976 1.6716 3.5 138.19 1.0780 0.5338 138.9 513.5 652.4 0.4109 1.6592 4.0 142.92 1.0829 0.4708 143.7 510.2 653.9 0.4226 1.6488 4.5 147.20 1.0875 0.4215 148.1 507.1 655.2 0.4331 1.6394 5.0 151.11 1.0918 0.3818 152.1 504.2 656.3 0.4426 1.6309 6.0 158.08 1.1000 0.3214 159.4 498.9 658.3 0.4594 1.6164 7.0 164.17 1.1071 0.2778 165.7 494.2 659.9 0.4740 1.6040 8.0 169.61 1.1140 0.2448 171.4 489.8 661.2 0.4868 1.5930 9.0 174.53 1.1202 0.2190 176.5 485.8 662.3 0.4983 1.5833 10.0 179.04 1.1262 0.1980 181.2 482.1 663.3 0.5088 1.5749 15.0 197.36 1.1524 0.1342 200.7 466.0 666.7 0.5508 1.5412
20.0 211.38 1.1751 0.1016 215.9 452.6 668.5 0.5822 1.5162 25.0 222.90 1.1953 0.08150 228.6 440.7 669.3 0.6078 1.4962 30.0 232.76 1.2142 0.06798 239.6 429.9 669.5 0.6295 1.4793 35.0 241.42 1.2320 0.05819 249.5 420.0 669.5 0.6484 1.4646 40.0 249.18 1.2493 0.05078 258.4 410.6 669.0 0.6654 1.4515 --------------------------------------------------------------------------------------------------
Pressure Temp Specific Volume Specific Enthalpy Specific Entropy P Kcal/kg-k Kcal/kg-k Kcal/kg-K
ata oC Vf, Vg, lit/kg m3/kg hf hfg hg sf sg ---------------------------------------------------------------------------------------------------
50.0 262.70 1.2826 0.04026 274.3 393.2 667.5 0.6950 1.4289 60.0 274.09 1.3147 0.03312 288.4 377.0 665.4 0.7203 1.4089 70.0 284.48 1.3466 0.02798 301.0 361.6 662.6 0.7428 1.3911 80.0 293.62 1.3787 0.02405 312.8 346.6 659.4 0.7632 1.3747 90.0 301.92 1.4115 0.02097 323.8 331.9 655.7 0.7817 1.3589 100.0 309.53 1.4453 0.01846 334.3 317.4 651.7 0.7992 1.3439 110.0 316.58 1.481 0.01638 344.2 302.9 647.1 0.8157 1.3293 120.0 323.15 1.518 0.01462 353.9 288.5 642.4 0.8316 1.3154 130.0 329.30 1.558 0.01314 363.3 274.0 637.3 0.8466 1.3031 140.0 335.09 1.600 0.01182 372.6 259.0 631.6 0.8614 1.2872 150.0 340.56 1.644 0.01067 381.9 243.7 625.6 0.8758 1.2729 160.0 345.74 1.693 0.00963 391.0 227.9 618.9 0.8901 1.2583 170.0 350.66 1.750 0.00868 400.4 211.0 611.4 0.9045 1.2427 180.0 355.35 1.812 0.00780 410.1 192.7 602.8 0.9192 1.2258 190.0 359.82 1.889 0.00697 420.2 172.7 592.9 0.9347 1.2075 200.0 364.08 1.99 0.00618 431.4 149.7 581.1 0.9515 1.1864 210.0 368.16 2.13 0.00535 444.6 121.4 566.0 0.9713 1.1606 220.0 372.1 2.39 0.00438 463.0 79.3 542.3 0.9993 1.1222
PROPERTIES OF SUPERHEATED STEAM Temperature, 0C --------------------------------------------------------------------------------------------------------------------- ata 200 220 250 270 300 320 350 370 400 450 500 550 600 650 t, --------------------------------------------------------------------------------------------------------------------- 15.0 v 0.1352 0.1436 0.1550 0.1624 0.1731 0.1800 0.1901 0.1970 0.2070 0.2234 0.2397 0.2559 0.2720 0.2880 (197.4) h 668.4 681.1 698.0 708.8 724.7 735.2 751.2 761.8 777.5 803.5 829.6 855.8 882.3 909.0 s 1.5445 1.5699 1.6036 1.6241 1.6527 1.6709 1.6970 1.7137 1.7375 1.7748 1.8098 1.8427 1.8739 1.9038 20.0 v 0.1043 0.1138 0.1197 0.1281 0.1334 0.1412 0.1465 0.1542 0.1667 0.1790 0.1913 0.2035 0.2156 (211.4) h 674.4 693.1 704.6 721.3 732.4 748.8 759.4 775.5 801.9 828.3 854.7 881.3 908.2 s 1.5280 1.5645 1.5863 1.6166 1.6354 1.6621 1.6791 1.7035 1.7414 1.7767 1.8100 1.8415 1.8715 25.0 v 0.0891 0.0940 0.1010 0.1055 0.1120 0.1162 0.1225 0.1328 0.1426 0.1527 0.1624 0.1722 (222.9) h 687.9 700.2 717.8 729.1 746.1 757.1 773.4 800.4 827.0 853.7 880.5 907.5 s 1.5325 1.5556 1.5874 1.6071 1.6345 1.6518 1.6767 1.7152 1.7509 1.7844 1.8160 1.8462
30.0 v 0.0123 0.0768 0.0829 0.0868 0.0924 0.0960 0.1013 0.1101 1.1185 0.1269 0.1350 0.1432 (232.8) h 682.1 695.5 714.2 726.1 743.5 754.8 771.4 798.7 825.7 852.6 879.6 906.7 s 1 .5038 1.5289 1.5624 1.5827 1.6112 1.6290 1.6542 1.6934 1.7295 1.7632 1.7950 1.8254 40.0 v 0.0510 0.0550 0.0602 0.0634 0.0678 0.0707 0.0749 0.0816 0.0882 0.0946 0.1008 0.1071 (249.2) h 669.7 685.7 706.6 719.6 737.9 749.7 767.2 795.4 823.0 850.4 877.7 905.1 s 1.4530 1.4825 1.5201 1.5423 1.5729 1.5914 1.6177 1.6583 1.6953 1.7296 1.7617 1.7924 50.0 v 0.0416 0.0465 0.0493 0.0531 0.0555 0.0590 0.0646 0.0700 0.0752 0.0803 0.0853 (262.7) h 674.2 698.4 712.5 732.2 744.7 762.9 792.0 820.3 848.2 875.8 903.4 s 1.4410 1.4842 1.5087 1.5412 1.5609 1.5885 1.6302 1.6681 1.7029 1.7356 1.7666
--------------------------------------------------------------------------------------------------------------------- ata 300 320 350 370 400 420 450 470 500 550 600 650 700 750 t, --------------------------------------------------------------------------------------------------------------------- 60.0 v 0.0371 0.0399 0.0432 0.0454 0.0485 0.0505 0.0533 0.0551 0.0579 0.0623 0.0666 0.0708 0.0749 0.0791 (27403) h 689.0 705.1 726.4 739.7 758.7 770.9 788.5 800.1 817.5 845.8 873.8 901.7 929.9 958.3 s 1.4512 1.4788 1.5140 1.5349 1.5635 1.5813 1.6065 1.6225 1.6453 1.6809 1.7138 1.7451 1.7750 1.8035 80.0 v 0.0250 0.0276 0.0308 0.0326 0.0351 0.0367 0.0390 0.0405 0.0427 0.0461 0.0494 0.0527 0.0559 0.0590
(293.6) h 667.0 688.0 713.9 428.8 749.5 762.6 781.5 793.8 811.8 841.1 869.8 898.4 927.1 956.0 s 1.3875 1.4239 1.4665 1.4902 1.5217 1.5408 1.5676 1.5844 1.6082 1.6449 1.6788 1.7107 1.7411 1.7700 100.0 v 0.0199 0.0231 0.0248 0.0271 0.0285 0.0305 0.0317 0.0335 0.0364 0.0392 0.0418 0.0444 0.0470 (309.5) h 666.0 669.0 716.5 739.8 754.4 774.4 787.3 806.1 836.3 865.8 895.0 925.3 953.5 s 1.3688 1.4231 1.4508 1.4858 1.5065 1.5353 1.5532 1.5781 1.6161 1.6509 1.6835 1.7142 1.7434 120.0 v 0.0178 0.0195 0.0217 0.0229 0.0247 0.0258 0.0274 0.0299 0.0323 0.0346 0.0368 0.0289 (309.5) h 681.5 703.0 729.5 745.5 766.9 780.4 800.1 831.5 861.8 891.7 921.5 951.1 s 1.3798 1.4137 1.4537 1.4765 1.5074 1.5261 1.5522 1.5916 1.6273 1.6606 1.6917 1.7211 150.0 v 0.0120 0.0140 0.0161 0.0173 0.0189 0.199 0.0213 0.0234 0.0254 0.0273 0.0291 0.0309 (340.6) h 6 47.6 678.0 712.2 731.2 754.8 769.7 791.0 824.1 855.6 886.6 917.0 947.4 s 1.3083 1.3567 1.4083 1.4364 1.4698 1.4905 1.5188 1.5604 1.5976 1.6319 1.6639 1.6941 200.0 v 0.0746 0.0103 0.0116 0.0131 0.0139 0.0151 0.169 0.0185 0.0201 0.0215 0.0229 (364.1) h 610.5 676.0 702.2 732.7 750.6 775.0 811.4 845.3 878.2 910.1 941.3 s 1.2320 1.3327 1.3710 1.4140 1.4385 1.4709 1.5168 1.5567 1.5930 1.6265 1.6578
ANNEXURE - 4
STATUATORY CLEARANCES
Subject Clearance Authority
1. Certificate of Incorporation as Registrar of Companies, OPGC under Companies Act. Orissa. 2. Generating Company under Govt. of Orissa in I & P
Electricity (supply) Act, 1948 Deptt.
3. Orissa river board clearance for Director of Industries, Effluent discharge. Orissa.
4. Water availability from Hirakud E.I.C. Irrigation, Govt. of Orissa,
Reservoir I & P Deptt. 5. Environmental Clearance State Prevention & Control Pollution Board, Orissa. 6. Forest Clearance Ministry of Forest, Fisheries & Animal Husbandry, Govt. of Orissa. 7. Principle Clearance Govt. of India, Deptt. of I & P. 8. In principle Clearance Planning Commission, Govt. of India. 9. Techno-Economic Clearance Central Electricity Authority, Govt. of India. 10. Power Evacuation Central Electricity Authority, Govt. of India. 11. Civil Aviation Clearance National Airport Authority, India 12. Coal Linkage Deptt. of Coal & Mines, Govt. of India.
13. Financing by Financial Institutions Govt. of India.
ANNEXURE - 5
LICENSES
License License No.
1.Factory Registration under JH 78 Factories Act 2.Boiler Registration under U # 1 - 512 Indian Boiler Act U # 2 – 516 3.Registration under Contract 3199 Labour (R&A) Act 4. Fuel Oil Tank inside Main Plant P-12 (14) / OR-1551 5. Filling Station for Diesel Locomotive P-12 (14) 442 6. Storage of Chlorine Cylinder GC- (OG) S-138/OR 7. Consumer Pump OR- 1616 8. Waste Management Authorization under Hazardous Waste Management Handling Rule, 1989 Ind/TV/HW/187(70)/10531 9. E.P.F. Coverage under EPF (MP) Act. SRO/RKL/7395/292/19-01-98