TECHNICAL DIARY

200 MW UNIT

KORBA SUPER THERMAL POWER STATION

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

R.BOSE
General Manager

From GM's Desk.....

Thermal Power plant is highly capital intensive and in order to derive sustained capacity utilization, with high availability & Plant Load Factors, sound O&M principles & practices are adopted in NTPC to run the stations in most cost effective manner. For dissemination of Plant Technical Data and Schemes pertaining to various systems to all O&M Engrs and related Functionaries, Tech Diaries and Schematic Diaries were published at Station & Corporate levels. A need is felt for review of the initially prepared Tech & Schematics Diaries, for incorporating the changes made so far and addition of Data like Interlock & Protections and schemes of new Ash handling system for Dhanras etc. This revised Technical/Schematic Diary is aimed at providing information & Data of the plant that may be necessary for day to day working and reference of O&M Engrs and also executives of other related functions. I appreciate the efforts made by the team of O&M Engrs in furnishing all useful data and reviewing the information available in existing Diaries and publishing the sume in revised form for the use of new entrants and executives of all functions.

Jamnipali

(R. Bose )

03/10/2001

General Manager (K&B)

P.K.CHAKRABORTY
Addl. GM (O&M)

FOREWORD Availability of technical information pertaining to equipments and process is of paramount importance for effective, efficient and reliable operation and maintenance of the plant. In this revised edition of the Technical Diary, addition of new sections like protections and interlocks, Relay settings, start-up/limit curves, data regarding new Ash Handling System inside Plant and at Dhanras etc., will make these 200 MW & 500 MW Technical Diaries more informative and useful. This will provide technical information that are necessary for day to day operation and serve as a reference documents to O&M personnel. I appreciate the MTP Team for acting as a nodal section and bringing out this informative diary from the available information and interaction with various sections.

Dated : 3rd October, 2001

P. K. CHAKRABORTY
ADDL. GM (O&M)

S. R. PATIDAR
Dy. GM (MTP)

PREFACE Thermal power station Operation & Maintenance practices in NTPC are framed through extensive documentation right from the inception of the plants. In our station all relevant O&M Instruction manuals, Operation Services Guidelines, Location Management Instructions, Tech & Schematic Diaries, Overhauling Reports etc are maintained in O&M Reference Library for ready reference of personnel. Existing Technical & Schematic diaries of both 200 & 500 MW Units, prepared at the time of Units commissioning, need revision. While making the revised editions of the Tech & Scematic diaries, additional Data like Protections & Interlocks, Relay Settings, Start up/Limit Curves etc and modification/additions of Schematics is considered. All requisite information were compiled by this section in association with respective area engineers, so as to make the revised Technical & Schematic diaries, pertaining to both 200 & 500 MW Units, quite informative. The revised Technical & Schematic Diaries are aimed at providing all information & Data of the plant, necessary for day to day working and reference of new entrants, Executives of O&M and other functions like FES, FQA and M&CS.

Jamnipali 03/10/2001 (SR Patidar)

Dy General Manager (MTP)

CONTENTS CONTENTS
Sl DESCRIPTION I
1.1
1. 2 1.3 1.4

NO. PAGE NO.

1-2
8 9 10 11 13 14 15 17 19 24 29

MAIN BOILER & AUXILIARIES

MAIN BOILER

ROTARY AIR HEATER SOOT BLOWERS PRESSURE REDUCING AND DESUPERHEATING STATION 1.5 FUEL OIL / OIL FIRING SYSTEM 1.6 F.D. FAN 1.7 I.D. FAN 1.8 P.A. FAN 1.9 ELECTRO STATIC PRECIPITATOR 1.10 MILL AND BURNER PERFORMANCE 1.11 BOILER PARAMETERS 1.12 CHEMICAL CONTROL LIMITS (WATER/STEAM CYCLE)

II.
2.1
2.2 2.3 2.4 2.5 2.6 2.7

MAIN TURBINE & AUXILIARIES

TECHNICAL SPECIFICATIONS
CONDENSER, EJECTOR, DRAIN COOLER Low pressure heaters Deaerator High pressure heaters BOILER FEED PUMP CONDENSATE EXTRACTION PUMP

31 - 32
38 39 40 40 41 43

III.

OFF SITE AUXILIARIES

FUEL OIL SYSTEM

3.1.
3.2 3.3 3. 4 3.5 3.6 3.7

44 - 45
47 53 55 56 64 71 76 - 77 84

IV.

WATER TREATMENT PLANT M.G.R. AND COAL HANDLING PLANT COMPRESSED AIR SYSTEM AIR CONDITIONING SYSTEM COOLING WATER SYSTEM EQUIPMENTS OF ASH HANDLING SYSTEM

GENERATOR & AUXILIARIES

4.1 4.2

SPECIFICATIONS AUTOMATIC VOLTAGE REGULATION

4.3

STATOR WATER COOLING SYSTEM

86

CONTENTS
Sl DESCRIPTION
4.4 4.5 4.6 4.7 4.8 4.9 GAS SYSTEM DATA SEAL OIL SYSTEM Generator Transformer TIE TRANSFORMER UNIT TRANSFORMER STATION TRANSFORMER

NO. PAGE NO.

86 87 88 90 92 94

V.

INTERLOCK & PROTECTION

BOILER
PULVERISER & FEEDERS ID FAN FD FAN PA FAN IGNITOR AIR FAN SCANNER AIR FAN SEAL AIR FAN AIR PREHEATER TURBINE BFP CEP INTERLOCKS FOR HP - BYPASS SYSTEM INTERLOCKS OF AUXILIARY PRDS GENERATOR TECHNICAL DATA PROTECTIONS GENERATOR TRANSFORMER UATS GENERATOR RELAY SETTING

1.1
1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.1 2.2 2.3 2.4 2.5 3.1 3.2 3.3 3.4 3.5

96 - 97
98 99 100 100 101 101 101 101 102 102 103 103 103 104 106 109 110 111

VI.
1.
2. 3. 4. 5. 6. 7.

GRAPHS, CURVES & TABLES

EQUIPEMENT - WISE OIL RESERV0IR CAPACITY 115 116
EQUIPEMENT - WISE OIL RESERV0IR CAPACITY (WTP) 117 TURBINE STARTUP CURVES 118 Steam Turbine Limit Curves 124 GENERATOR REACTIVE CAPABILITY CURVE 129 STEAM PROPERTIES TABLE I, II.III.IV 132 MOLLIER DIAGRAM 146

I MAIN BOILER & AUXILIARIES

1.1. MAIN BOILER

A.

GENERAL
i) Manufacturer ii) Design Code iii) Type BHEL, CE DESIGN ISO RAD,RH, NATURAL CIRCULATION SINGLE DRUM, SEMI OUT DOOR, BALANCED DRAFT, DIRECT FIRED. TILTING, TANGENTIAL PENDENT, PLATEN, HORIZONTAL 5400 KW at 91% MCR Min. load the Boiler can 40%

iv) Type of firing v) Type of super heaters vi) Total Aux. power vii) M.C.R. sustain without oil support (T/HR) viii) Min. mill load with oil 50% support % ix) Total Water content of 321.5 (Including Reheater) Boilor (T)

B.

FURNACE
i) Type FUSION WELDED WALLS ii) Comb, chamber volume (M3) 5200 iii) Furnace Height 43129 MM (Seal to Fur. roof) iv) Furnace width 13868 MM v) Furnace depth 10592 MM vi) Water walls a) Front wall (M2) (EPRS) 618 2 b) Side walls (M ) (EPRS) 757 c) Rear wall (M2) (EPRS) 620 2 d) Roof (M ) (EPRS) 122 e) Total Heat surface (M2) (EPRS) 211 2

vii) Furnace adjustment factors for surface. a) Front wall 1.0 b) Side wall 1.0 c) Rear wall 1.0 d) Roof 1.0 Specification of tube material.SA - 210, Gr.A1 O. D. x Thickness MM x MM 63.5 x 6.3 Margin of tube thickness Under normal opern. over & above the press. conditions 0.4 mm requirement. (As per I.S.O 0.2 mm) Design metal temp. 4040C Design Pr. of Tubes (Kg/cm2)a. 176.9 as per ISO Total wt. tonnes (water walls) 290 viii) Residence time of fuel particles in Furnace ix) Water wall header. Material SPN O.D. MM Thickness M.M. Design pr. kg/cm2 at Approx. total weight of headers x) Max. header unbalance C. BOILER DRUM i) Spn. of material ii) Elevation of drum mm iii) Overall length mm (Approx) iv) Mean O.D. mm v) Shell thickness mm vi) Design pressure Kg/cm2 vii) Design metal temp 0C 2.5 seconds

SA - 106, Gr. 'B' & Gr. 406.4, 273.0, 219.1 50.0, 45.0, 36/40 179.6 55 2%

SA - 299 53340 15000 1913.0 170/135 (Bt-thickness) 175.8 354

0 viii) Permissible max. temp. C diff. between any parts of drum a) Normal operation 55 b) Accelerated starting 55 xi) Drum wt. without Internals 107 (T) x) Drum wt. with all Internals 120 (T) xi) Water capacity with MCR 25 seconds (upto tripping) conditions (in sec) between normal and lowest water level permitted.

D.

SUPER HEATERS i) Heating surface LTSH M2 PLATEN SH M2 FINAL SH M2 ii) No. of stages iii) Spn. of material

6490 810 823 Three LT SH PLATEN FINAL SA 210Gr SA 213 TII SA 213 T A1 SA 209 T1 SA 213 T22

22 SA 347

213 TB SA 213 T11 H iv) Type of flow Counter Parallet Parallet (Counter or parallel) v) No. of coils 120 29 89 vi) O.D. x thickness. mm xmm 44. 5x4.5 51.0x5.6 51x8.8 (Thickness varies) vii) Max. Gas side metal temp 0C 490 570 585 viii) No. and type of themocouples fitted to S.H. Tubes Chromel / Alumel A) In gas path Nil SA 213 TB

4 b) In pent house Total wt. of S.H. tonnes (ix) Super heaters headers Spn. of Materials. Design Pr. (Kg/cm2) a Approx. total weight T Max. Header unbalance E. Permnt. 63 Tempr. 83 440 SA - 210 Gr. B. SA-335 P12, SA 335 P22 176.8 68 5.7 %

SUPERHEATER ATTEMPERATOR i) Type Spray type mixing ii) Stages of attemp. One iii) Position in steam circuit LTSH - Attem - Platen SH iv) Specification of material SA 335 p12 v) SH temp. range that can be 540 + 5 maintained between 60% and 100 % MCR of boiler (0C) vi) Spray nozzle material SA 213 T 11 vii) Max. spray water flow rate 15 x 103 at 60% MCR and corresponding steam output (kg/hr) REHEATERS i) Total heating surface M2 ii) No. of stages iii) Material iv) Max. gas to metal temp 0C v) Approx. wt. (Tubes) T vi) Reheater Headers : a) Material b) Design Pr. (Kg/cm2) at

F.

2630 One SA 269 T SA 233 T T22 SA 213 TP 304 H 585 120 SA - 106 Gr. 3 (INLET) SA - 335 P22 (OUTLET) 46.0

5 c) Design metal temp. 0C d) Wt. Tonnes vii) O.D. x thickness of tubes mm x mm viii) No. of coils G. 59 Inlet 350, Outlet 550 15.0 54 x 3.5, 4.0

REHEATER PRIMARY TEMP. CONTROL i) In case of tilting burners a) Angle of tilt (Max) b) Type of tillting c) RH steam temp. 60% 100% MCR + 300 Power tilting Cyl. 540 + 50C

H.

R. H. EMERGENCY TEMP. CONTROL i) ii) iv) v) Type Stages Material Max. flow of spray water T/hr. vi) Spray Nozzle material Body-SA-182 Gr. F11
Tip an Disc AIBI Gr. 420.

Spray type mixing One In cold RH Line SA - 106 Gr. B 22

iii) Position in steam ckt.

I.

ECONOMISER i) ii) Material (Tubes) O.D. x thickness mm x mm

0

SA 210 Gr. A1 44.5 x 4.5 145 295 210

iii) No. of coils iv) max. Gas side metal temp C v) Wt. (Tube and Reders) vi) Headers

a) Material 6 b) Design Pr. (Kg/cm2) c) Design metal temp 0C vii) Max. Header unbalance J.

SA - 106, Gr. B

181.1 310.0 2%

BOILER MOUNTINGS & FITTINGS 1) Drum safety valves Make Type No. Set Pr. (Kg/cm2) gauge Reset Pr. (Kg/cm2) gauge Relieving capacity T/hr M/s Dresser, USA Spring loaded Three 175.8, 179.3, 181.1 168.8, 170.3, 172.0 177.1, 180.6, 182.5 M/s Consolidated, USA Sp. loaded with relieving

2) S.H. safety valves Make Type & Rating capacity

of 154. 7 T/hr. No. One Set Pr. (Kg/cm2) gauge 163.3 Reset pressure kg/cm2 gauge 158.4 3) Reheater safety valves Type and ratting relleving Sp. loaded with combined

capacity of 494 T/hr at RH Inlet and 139 T/hr at Rh outlet. No. 3 at Inlet, 1 at outlet. HRH Set pressure (kg/cm2) gauge 45.0 45.5 46.3 42.7 Reset pressure kg/cm2 gauge 43.6 44.1 45.0 41.4 Flow capacity (T/Hr) 123.8 178.0 181.0 140.7 Material Body - ASTM A216 Gr. WCB ASTM - A217 WCB 4) Electromatic safety valve on S.H. outlet Make Type of actuator Number M/s DRESSER U.S.A. Solenoid One at S.H. outlet

Capacity of valve T/Hr 98.4 (14.7%) Set pressure (Kg/cm2) gauge 160.0 156.8

7 5) Drum level Gauges Make Type and No. portgauge) Nos. Yarway or equivalent. 1.Direct gauge

(colour 3

Location other

ii. Remote manometer - 1No. iii Remote hydrastep - 2 Nos. i. Two on one side, one on side ii Fire Man's floor iii U.C.B. 475 MM (MIN) visibility ST flow, FW flow, Oil flow SS SS Nozzle Nozzle Areameter.

Size Flow meters for material of flow meters Nozzle/ Orifice plate

1. 2 ROTARY AIR HEATER

A. ROTARY TYPE AIR HEATER i) No. per boiler/size 2 Nos. / 27Vt (T) 80'' (720) 0 ii) Max. opn. temp C 365 iii)Max. air leakage % 9.3 iv)Bearings guide and support Radial/SPH Roller thrust v) Rotor a) Effective heating surface b) Gas flow area M2 19000 M2 (per heater) 23.9

c) Air flow area M2 21.6 d) Size of electric 11.0 motor (KW) e) Speed of motor RPM 1500 f) Size of Air motor (HP) 5.0 g) Speed of air heater RPM 1.42

8 vi) Elements a) Length hot end/ cold end b) Material hot end/cold end c) Total Wt. of elements KG vii) Material - shaft Material - Seals 130000 kg/ heater Carbon steel Corten steel 'A' Corten 'A'/Corten 'A' 864 / 305 MM

B.

STEAM COIL AIR HEATERS(NOT In Use)

Air temp inlet/outlet 0C Air/steam flow (MM3/sec. kg/hr Steam pr/temp. Material 13.0 kg/cm2, 2100C Corten steel 30/100 57/13000

1.3 SOOT BLOWERS

Type Steam/Pr/Temp. (Design) Source Total operation time per group LRSB, Wall/deslagger 42.0kg/cm2(g), 3300C LTSH Outlet header LRSBs - 212.16 Min. Wall - 84 Min. Swivel - 45 Min. Power supply 415 V, 3 phase,

50 cps, 2.5 KVA a) Wall soot blowers No. of Travel MM Material Blowing pressure 56 305 ASTMA A 447 11.0 kg/cm2

b)

9 (SH and RH) / Eco soot blowers Nos. of Travel (Total) Travel (Dead) Material Blowing pressure 22/2 7200 mm 350 mm ASTM A - 447 9.0 and 12.0 kg/cm2

c)

AH Soot blowers No. of mat. of head Blowing press. Two/heater ASTM A48/CI 3C - Cast Iron 15 kg/cm2 - Normal 13 kg/cm2 - during starting.

1.4 PRESSURE REDUCING AND DESUPERHEATING STATION

a) Pr. PRD valves One Flow cap. of each valve T/hr 55 Type of actuator Electro hydraulic Body/trim material Alloy steel/11% Body design pres/Temp. Desuper heaters Flow capacity T/hr Design Temp. 0C Desup. water Press Temp. Quantity 161/540 Direct spray type 70 490 200 kg/cm2 1660C 15.0 T.H.

Cr.

steel b)

E. BLOW DOWN VESSEL vessel Design code Material Shell Dia/ Height MM Operating press/Temp. kg/cm2/0C F.

Unit Flash tank I.S. 2825 I.S. 2062 1496/1980 Vacuum/206

Blowdown

IS 2825 IS 2062 1498 / 1980 1.5/200

FUEL PREPARATION AND FIRING SYSTEM 1. COAL a) Bunker shut off gate Motor operated, 2.5 KW motor. Material IS 226/IS 2062 10

b) C)

R.C. Feeder Max. Capacity (T/HR) Output control Pulverisers Overall Dimensions Design Cap (T/HR) Size of coal inlet/ outlet Total Wt. Of Mill ( Tonnes) Grinding Rings and Rolls Pyrite/ plough Life of rolls/Grinding Rings (Hour) Mill fuel piping material pipes/Bends. Max. Vel of Gas Coal Bumers

d) e) f) g)

gravimeric type 45.0 PIV XRP 803, 6 Nos. 3600 x 5700 Height. 41.3 (58HGI). M 12 % 25 mm/70% Through 200 Mesh 75.0 Comb Alloy/NIHARD Manganese steel 3500 to 4000/7000 to 8000 IS : 226 IS : 4896 Gr. II 25 m/sec. Four x 6 Elevations Tip- AISI 304 SS Coal nozzle - ASTM A 536 Ductile Iron casing. +ve displ. Screw - Type steam jacketed. 23.4 m3/hr/30 kg/ cm2 1450 21/ 1000 centipoise 0.5

1.5 FUELOIL / OIL FIRING SYSTEM

a) Fuel Oil pumps Capacity/ Discharge Pump speed RPM Min/Max. absolute visc. of oil Min. NPSH Reg. (M) Material

Casting Shaft and impellers b) Fuel oil heaters Type/ No. Capacity (kg/hr) at Temp oC Heat transfer surface area

Carbon steel Fab. Body. Nitrided Steel U- tube/ one per boiler. 24000 at 110oC 45 m2

11 c) Filter Basket type-two nos. Oil Burners Type/ No/ Elevation Capacity (kg/hr) Press. kg./cm2 Oil visc. at Burner tip Max. turn down ratio Burner Body/ Tip material Ignitors. Type and Model Heat input/ Ignitor 50 Microm Mesh, Press. drop 0.5 (at 75 % clear)

d)

Steam Atomised/12/3 1250/13.2 12.5 to 16.0 centipoise. 3:1 Carbon steel / H.S.S.

e)

Non- RET, H.S.D. EDDY Plate. 0.5 millions Kcl/hr.

12

1.6 F.D. FAN

Type & Size Orientation Medium Handled Location No. per boiler 1. FAN DESIGN RATING Capacity Total Head developed Temp. of Medium Spec. wt. of medium Speed FAN RESERVE Flow Pressure FAN DRIVE COUPLING Make Type DRIVE MOTOR Make Frame Size Type Fan Weight Rating
Axial ReactionType API 18/11

Horizontal Atmospheric Air Ground Level 2 105 m3 / sec. 510 mmwc 50oC 1.619 kg/m3 1480 RPM 26.5% 50% Rigiflex coupling form 11 1001 BHEL, Hardwar AC 13240 H 41 Squirrel cage Induction Motor 8570 kgs. 750 KW 6600 V, 3 Phase

2.

3.

4.

Speed 5. LUBRICATING EQUIPMENT Fan Motor TYPE OF FAN REGULATION BEARINGS Mixed Bearing Expansion Bearing 13

50 Hz 1480 RPM Forced Lud. Oil System Capacty - 70 LPM Grease Lubricated Pitch Control NU 230 C 3 & 7230 EUA N 230

6. 7.

1.7 I.D. FAN

Type and size Orientation Medium Handled Location No. per boiler 1. FAN DESIGN RATING Capacity Total Head developed Temp. of Medium Spec. Wt. of medium Speed FAN RESERVE Flow Pressure FAN DRIVE COUPLING Make Type DRIVE MOTOR Make Frame size Type Fan Weight Rating Speed Axial Impulse Type AN 28 e6 Horizontal Flue Gas Ground Level 2 225m3/sec. 358mmwc 136 0. 7966 kg 740 RPM 25.7 % 37.7% M/S PSG PPC 180- 200 BHEL, Hardwar AC 15196 H 8 A squirrel cage Induction Motor 26186 kgs 1100 kw 6600 V, 3 Phase 50 Hz 740 RPM

2.

3.

4.

5.

6. Control

LUBRICATING EQUIPMENT Fan Grease Lubrication Motor Forced Oil Lubrication System 5 LPM - M/s Prakash TYPE OF FAN REGULATION Inlet Guide Vane

14 7. BEARINGS Fixed Bearing Expanstion Bearing

22328 C/C 3 222332 C/C 3

1.8 P.A. FAN

Type and size Orientation Medium Handled Location No. per boiler 1. FAN DESIGN RATING Capacity Total Head developed Temp. of Medium Spec. wt. of medium Speed FAN RESERVE Flow Pressure FAN DRIVE COUPLING Make Type DRIVE MOTOR Single Suction Radial Fan - NDFV 22b Horizontal Bottom Delivery Atmospheric Air Ground Level 2

75M3 /Sec. 1187 mmwc 500C 1.019 kg/M3 1480 RPM

2.

70.4% 55%

3.

M/s. PSG PPC 150 - 160

4.

Make Frame Type Fan Hetght Rating

BHEL, Hardwar MC 75288 M4 AIH

Squirrel Cage Induction Motor

Speed

9870 Kgs 1250 kw 6600 V,3 phase 50 Hz 1480 R. P.M.

5.

15 LUBRICATING EQUIPMENTS Fan Forced Lub. Oil System-5 LPM Motor Grease Lubricated Type of Fan Regulation Inlet Guide Vane Control BEARINGS Fixed Bearing Expansion Bearing Nu 332 C3 & 7234 BUA N 234 C 3

6.

OIL CIRCULATION SYSTEM OF P.A. FAN 1. Tank

The oil tank is 100 litres capacity,which has the following accessories : a) Oil level indicator b) Oil drain valve c) Sight glass d) Air breather cum oil filler e) Cleaning door opening a) b) c) d) e) f) g) h) I) Manufacturer Type and frame Output rating Supply full load speed Insulation Power factor Efficiency Bearing Crompton Greaves TEPC- AM 80 N4 1 HP - Continuous 415 Volts,1.8 Amps; 50 Hz, 3 phase 1400 rpm Class `B` 0.80 73% Ball bearing NDE 6204Z DE: B/B 2 OF 002 z

2. Motor

3. Pump

a) b) c) d) e) f) g) h) i) j

Manufacturer Delta Corporation , Bombay Type & Capacity Trochoidal pump ( 5 Ipm) Operating pr. 7 kg/cm2 (gauge) Relief valve Built in Speed 1400 rpm Ports 2 ' BSP Casing material C. I. Close grain Shaft EN- 8 Seal Oil Seal Hydraulic Test Pressure 10 ata 16

1.9 ELECTRO STATIC PRECIPITATOR

S. No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
hook

Technical Data Gas flow rate (m3/s) APH outlet temperature Dust concentration (gm/Nm3) Precipitator type

Stage-I 358.4 1360 59.02 2FAA -7 x 3211190-2 2 4 7 99.49 % 15

No. of precipitators per boiler No. of gas paths per boiler No. of fields in series in each gas pass Efficiency Pressure drop across the precipitator (in mm wc) Velocity of gas at electrode zone on 0.869 total area (m/s) Treatment time in seconds 24.975 No. of rows of collecting electrodes per field 38 No. of collecting plates per field 304 total number of collecting plates per boiler 8512 Nominal height of collecting plates in meters 9 Nominal length of the collecting plate (mm) 400 Specific collecting area (m2/m3/s) 166.5 Type of emitting electrodes Spiral Size (diameter in mm) 2.7 No. of electrodes in frame forming one row 32

with

19. 20.

21. 22. 23. 24. 25. 26. 27.

No. of electrodes in each field Total number of electrodes per boiler Total length of electrodes per field (m) Plate to wire spacing (mm) Rapper size (collecting) in Kg. Rapper size (emitting) in Kg. Rapping frequency (collecting) in raps/hr

1184 33152 6820 150 4.9 3.0 12 to 1

17

S. No. Stage-I
28. 29. 30. 31. 32. 33. 34. Rapping frequency (emitting) in raps/hr Type of hopper No. of hoppers Capacity of hopper No. of collecting rapping mechanisms per boiler (CRM) No. of emitting rapping mechanisms per boiler (ERM) No. of gas distribution rapping rechanisms per boiler (GDRM)

Technical Data
10 Pyramidal 56
8 hour storage

28 28 Nil

Details of Rapping mechanisms :

Statge - I CRM and ERM

Make Power Current PBL 0.26 KW 0.76 A Type Output speed S. No. 73B-32.1 KD71 K4 1.1 rpm 19153

18

1.10 MILL AND BURNER PERFORMANCE------------------------------------------------------------------------------------Description Heater Units MCR NCR Cont. HP

MW

210

Load out of 200 120

service 200 ----------------------------------------------------------------------------------------No. of burners in 16 16 12 16 operation

Burner tilt No. of mills in operation Mill loading Air flow per Mill

Digree

-0-

+5

+20

-0

% t/h

4 88 59.33

4 80

3 73

4 83 59.30

59.33 59.33

Air temp. at mill inlet Mill outlet temp. Fineness 00 mesh 70

0

C 260 240 77 70

220 77 77

240

77 70

% thru 70

19

PERFORMANCE DATA (OIL BURNERS, IGNITORS) Haavy Fuel oil Furners

i. Service Ignition of coal fuel; stabilisation of coal flame at low loads. Turbine synchronisation. ii Type a. Burner b. Oil gun c. Atomiser d. Air nozzie e. Diffuser iii. Oil gun Assembly Tilting tangential corner fired Concentric type-auto retractable External mix, constant Pressure steam atomised Square to round; 500 mm outlet 321 mm; 10 off 450 vanes with leading edge. k = 2287.5 mm.

Dlmension vi. Atomiser designation v. Atomiser spray angle vi. Fuel vii. Capacity-Maximum I9 900

Fuel oil to IS1593 : 1971 Grade LV -MV- HV 7.5 % MCR heat input on 4 guns 15 % MCR heat input on 12 guns

viii. Number off ix. Location

12 ( 4 per elevation ) Auxiliary air Nozzles AB, CD & EF

DATA CHART

20

gun

-----------------------------------------------------------------------------Max Rating Design Rating ----------------------------------------------------------------------------a. HFO flow per kg/ hr 1250 600 b. HFO Pressure kg/cm2 (g) 13.2 5.2 c. Atomising steam flow per gun kg/hr 162 184 d. Atomising steam pressure kg/cm2 (g) 8.75 Constant at all loads -----------------------------------------------------------------------------------xi. HFO burner turn down 3 to 1 approx. xii. Minimum allowable atomising 4.5 kg/cm2 (g) at the steam pr. xiii. Steam quality xiv. Cumbustion requirement NOTE Pressure are measured at the oil gun connection. Design firing rate is the minimum energy required for coal ignition and coal flame stabilisation. 10- 15 oc superheated Refer secondary air control system

fuel

Maximum firing synchronisation requirements. IGNITORS i. service ii. Type a. Basic b.. Pilot Bumer c. Spark plug d. Monitoring

rate

normally

based

on

turbine

Oil burner light off 150 mm side Eddy plate ignitor Light fuel oil, air atomised Corona type Ionic Flame Monitoring

21 iii. Assembly dimension exit to casing face iv. v. vi. vii. Fuel Capacity No. off Location Ignitor Horn mounting dimen sion = 273 mm Horn wind box x=584 mm. LDO to IS 1460 /1974 0.5 million kcal/hr/Ign. 12 ( 4 per elevation) On front & rear walls adjacent to oil burners at elevation AB,CD & EF

viii. Data chart ----------------------------------------------------------------------------------While While not firing firing ----------------------------------------------------------------------------------a. Oil flow per ignitor kg/hr 50 0 b. Oil pressure kg/cm2 (g) 12.5 -14 c. Atomising air flow perigniter Nm3 /hr 14.5 1.6 d. Atomising air pressure kg/cm2 (g) 5.5-7.0 5.5-7.0

e.

Combustion air flow per ignitor Nm3 /hr 560 720 f. Combustion air pressure ( Ignitor wind-box to furnace Differential ) mm wc 75 75 ---------------------------------------------------------------------------------ix. Ignitor turndown Nil x. Atomising air quality Service air, water free NOTE The oil and atomising air pressure are measured at the ignitor control cabinet inlet

Heavy Fuel oil Specification

i. ii. Service Standard Oil Burners IS 1593 / 1971 Grades LV-MV-HV 66 0C

iii. Flash point minimum ( lensky- martens sed cup )

22 iv. Viscosity maximum v. Total sulphur - maximum vi. API gravity (Typical) vii. Gross heating value ( typical) 80-120-370 CST at 500C 3.5-4.5% by weight 12, Specific gravity 0.986 at 15 oc 10270 Kcal/kg

Light Fuel oil (LFO) Specification i. ii. iii. iv. v. vi. Service Standard Pourpoint - Maximum Flashpoint Minimum ( Abel) Viscosity maximum Carbon residue maximum (Rams bottom) Ignitors Is 1460 /1974, High Speed Diesel oil (HSD) Grade 6 0C 38 0C 2.0-7 .5 at 38 0C 1.5 % by mass

vii. Total Sulphur-max viii API gravity (typical ) ix Gross heating value ( Typical)

1.5 % by mass 35, specific gravity 0.85 at 15 oc 10720 Kcal/kg.

23

1.11 BOILER PARAMETERS (1) FLOW t/hr

-------------------------------------------------------------------------------------Description MCR NCR Cont. HP Heater Load out of 200 120 service MW MW 200 MW -------------------------------------------------------------------------------------1. Steam Superhater outlet Reheater outlet 670.0 598.2 603.7 537.7 402.0 547.0 363.7 540.6

2.

Water Feed Water Spray 670 600.7 3.0 394.8 519.7 7.2 27.3

3.

Air Airheater outlet Airheater outlet (Secondary) Total combustion air 816.2 870.5 792.9 571.7 79.9 611.4 167.3 57.4 533.7 121.5 193.4 70.0 56.5 43.9 371.8 557.1 ( primary) Tempering air

4.

Fuel Coal 144.4 131.6 90.4 135.4

24

TEMPERATURE (OC)
Description MCR NCR 200 MW 1. STEAM Saturated temp. 349 In drum LTSH Outlet 426 SH platen outlet 520 SH outlet 540 RH Inlet 344 RH Outlet 540 WATER Economiser inlet 243 Economiser Outlet 286 AIR Cont. Load 120 MW HP Heater out of service 200 MW

384 421 520 540 339 540 241 284

344 417 523 540 328 540 223 270

346 435 518 540 345 540 164 234

2.

3.

Ambient Airheater Outlet (Primary) Airheater outlet (secondary) 4. GAS SH Platen inlet RH Front inlet (Furncace exit) RH rear inlet finish SH inlet Finish SH outlet LTSH Inlet Eco. Inlet AH Inlet AH outlet (corrected)

50 325 318

50 318 313

50 297 294

50 282 277

1135 1024 922 758 727 671 470 354 136 25

1132 1025 917 750 718 661 462 343 134

1080 945 837 682 658 603 433 124

1129 1008 907 747 716 660 467 312 121

307

PRESSURE & DRAFTS (AIR & GAS) mmwc

Description MCR NCR 200 MW Cont. HP Heater Load out of 120 service MW 200 MW

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

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

Air Heater inlet 291 Air Heater outlet 171 Aerofoil inlet 159 Windbox to fur. diff.

256 199 261 163 151 165 154 147 156 100 100 100 100

3. Gas (mmwc)
SH Platen inlet RH inlet Finish SH inlet LTSH inlet Eco. inlet AH inlet E.P. inlet ID Fan inlet (incl. static head) Fan delivery head -4 -5 -9 -14 -28 -50 -179 -227 +33 -4 -5 -8 -12 .24 -43 -151 -194 +27 -4 -4.5 -6 -8 .15 -24 -84 -113 +14 -4 -5 -9 -13 -25 -45 -154 -185 +29

26

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

Description MCR NCR 200 MW Cont. HP Heater Load out of 120 service MW 200 MW 151.00 153.7 155.3 158.1 22.54 23.54 152.7 158.7 161.6 165 37.36 37.36

1. Pressure
SH outlet LTSH outlet Drum Eco. Intet RH outlet RH inlet 155.00 161.9 166.1 170.2 37.19 38.69 154.00 159.8 163.2 166.9 34.85 36.2

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

HEAT BALANCE Unit : %

Dry gas loss 3.60 H20 & H2 in fuel 5.53 loss H20 in air loss Carbon loss Radiation loss 0.34 2.00 0.20 3.65 5.50 0.35 2.00 0.20 2.84 5.45 0.31 2.00 0.22 2.04 5.44 0.29 2.00 0.20

Unaccounted and Mfg. Margin loss 0.80 0.80 Total losses 12.47 12.5 Efficiency 87.53 87.5 Guaranteed efficiency 87.5 %

0.80 11.62 88.38

0.80 11.67 88.33

27

02 CO2 ( Dry Vol) AND EXCESS AIR

Description MCR NCR 200 MW 3.87 Cont. HP Heater Load out of 120 service MW 200 MW 4.69 4.3

Oxygen in gas at % 3.87 Eco. outlet (by dry Vol) Oxyen in gas at AH outlet ( by dry vol ) % Max. leakage of air across AH % 8.13 Total air to gas 77.3 leakege T/hr 77.3 Carbon-di- oxide in gas at Eco. 14. 94 outlet (by dry vol.) % Excess air in gas at Eco.outlet % 22

5.56 8.8 76.2 76.2 14.94

5.58 11.5 71.4 71.4 14.22

6.88 8.6 76.6 76.6 14.59

6.01

22

28

25

FUEL
The fuel data on which the guarantees given are as follows: ----------------------------------------------------------------------------------------Description Units Valve Remarks ----------------------------------------------------------------------------------------Fuel Coal Fixed carbn. % 26 Volatile matter % 18 Moisture % 12 Ash % 44 Grindability Hard Groove Index 58 Higher heating value Kcal/kg 3500 Size of coal to mill mm 25

28

1.12 CHEMICAL CONTROL LIMITS (WATER/STEAM CYCLE)

Parameters 200 MW (StageI) Cond. Feed Boiler Boiler Steam 8.89.0 9.2- 8.89.4 9.0 30.0 500 mW (Stage II) Steam Cond. Feed 9.09.2 9.09.2 9.19.4 20.0 9.0 9.2

pH at 250C 8.89.0 Sp. Conductivity /cm Cation Cond. <0.2 /cm Res. Hydrazine as N2H4 ppm

<0.3 <0.3

<0.3 <0.2 <0.2

.010.020 0.5 1.0 (Max) (Max) 2-4

.010.020 1.0

Ammonia as 0.5 NH3 ppm (Max) Phosphate as PO4 ppm

(Max) 1-2

Silica as SiO2 ppm Max. Total Iron as Fe ppm MaX. Total copper as Cu ppm Chloride as Cl ppm Max.

<.02 <.02 0.3 .010 .010 .005 .005 1.0

<.02 <.01 <.01 .010 .005 .010 .003 .010 .003

0.1 <.01 .010 .003 0.5

D.O. as 02, .040 .005 ppm Max. Sodium as Na, ppm Max TDS (mg/1) Ppm 15

.040 .005

.005 .005 10

29 parameters Alkaliser StageI StageII W/O Alkaliser With

GENERATOR STATOR COOLING WATER

PH at 250C 9.0 Cond. at 25 C us/cm D.O. (mg/1)
0

6.8-7.0 (6.5-7.0) (Lab) 5 >1.0

6.8-7.0

8.5-

<1.0 <0.1

<2.2 <0.1

GENERATOR SYSTEM
Hydrogen Purity (%) Dew Point (0C) at frame pressure ECW pH at 250C >97.0 >97.0 <24.0 (4.0kg/cm2)

<21.0(3.0kg/cm2)

(Controlled by dosing Caustic Solution)

9.0-9.5

1.13 RECOMMENDED LIMIT OF SILICA IN BOILER WATER AT pH 9.5 AT DIFFERENT OPERATING PRESSURE TO LIMIT SILICA 0.02 PPM IN STEAM

DRUM PRESSURE 60 80 100 120 130 140 145 0.48

SiO2 ppm PRESSURE 8.2 3.8 1.9 0.9 0.7 0.52

DRUM 150 155 160 165 170 175 180

SiO2 ppm 0.40 0.37 0.30 0.27-For Stage I 0.25 0.22 0.18 - For Stage II

30

II TURBINE & AUXILARIES

31

II. MAIN TURBINE

2.1 TECHNICAL SPECIFICATIONS1.
A) Steam Turbine

Make KRAFTWERK UNION, WEST GERMANY Type Three cylinder, reheat, condensing turbine Stages Nominal rating Peak loading Rated speed Max. / min. speed H.P. 25 nos. I.P. 20 x 2 Nos. L.P. 8 x2 Nos. 210 NW 229 MW 50.05 51.55
-1 -1

47.55

-1

(No time limit )

-1

Speed exclusion range

11.675-1 to 47.55

This speed range should be passed through in one smooth operation to avoid endangering the blades due to resonance B) Steam pressures and temperatures (Rated values ) pressure (b) H.P. stop valve inlet 147.1 H.P. cylinder exhaust I.P. stop valve inlet 34.13 Extraction 6 Extraction. 5 Exteaction 4 Extraction 3 Extraction 2 Extraction 1 39.23 16.75 7.06 2.37 0.858 0.216 Temp. 0C 535 39.23 535 343 433 316 200 107 62 49 334

L.P. cylinder exhaust 0.1187

32 C) Casing temperatures: 0C Wall temperatures Alarm at -------------------------------------H.P. turbine casing exhaust 480 Outer casing of LP cylinder 90 NOTE Spray water to L.P. turbine must be switched D) Differential Expansion 1. 2. H.P. Turbine diff. Expn. I.P. Turbine Diff. Alarm +4.50 -2.50 + 5.00 -2.00 M/c must be shut down at 500 110 on at 90 oC Trip +5.50 - 3.50 +6.00 -3.00

3.

L.P. Turbine diff. Expn.

+ 25.00 - 5.00

+30.00 - 7.00

E)

Temperature differences C: (Between upper and lower casing section ) Alarm at M/c must be shut down at H.P. turbine middle + 30 + 45 I.P. turbine front + 30 + 45 I.P. turbine rear + 30 + 45 Bearing temperature Normal opn. temp. below750C. Alarm at M/c must be shut down at 120 0C Of shaft 30 microns above normal

F)

900C Of bearing housing 35 microns

G)

Vibration (absolute vibration) Nominal value for alarm

level 33 B) Megawat output (Approx) 55.40 (28%) C) Bearings No. 1 No. 2 No. 3 No. 4 No. 5 53.73 (26%) 93.03 (46%)

Journal, 280 x 140 mm Redial cum thrust, tilting pad, 290 x 240 mm Journal, 450 x 320 mm Journal, 400 x 400 mm Journal, 400 x 400 mm

lining material for all bearings : Babbit

D) Turbine cloorances (MM) : 1) Min. axial cold cloorance axcluding thrust booring 2) Position of min. oxial cold clearance 3) Axial Clooorance at stage - 1 shroud (cold) 4. Radial clearance at rotor glands 5.) Min. radial clearance at shroud E) Materals of construction 1) Turbine casing H. P. turbine shell VS 11 l. P. turbine casing L . P. turbine casing 34

3.4 I.P. glades (-) 2.4 15.0 (I. P.) shaft 0.4 (I. P.) 0.5 (I. P.) 0.5 (I.P.) ................... I. S. (L.P.)

GS - 17 Cr. Mo GS - 22 Mo-4 St. 37 - 2

N) Barring Gear Type of drive Hydraulic turbine Method of engagement Hydraulic Power to rotate turbine 45 KW. Cutin/ Cutout speed 250/200 r.p.m. NOTE Turbine can be put on barring only when turbine is jacked up In the bearins. O) Steam purity (WU recommended values) Conductivity at 250C, alkalina o.15 s/cm. method, and by direct mesurment

01. Sillecic Acid (Sio2) Total Iron (to) and Sodium (Na) Total copper (Cu) 02. A) Dimensions : (In mm) HP Turbine Height of 1st stage moving vlade 43 Mean Dia. of 1st stage moving blade 634 Height of last stage moving blade 95 Steam dia of last stage moving blade 695 blade root T

< 0.010 mg/kg < 0.005 mg/kg each < 0.0001 mg/kg

IP Turbine 66 756 100

LP Turbine 75.5 1473.5 558.1

1041 2144.1 T T (Axial IIr-troo two stages) Total exhaust area (L.P. turbine) 2 x 5 M2

35 Press Limiting valve in jacking oil system Oil pumps Nos. Make Capacity (Rated) L/S Discharge press. (Rated ) atg. Speed r.p. m. Drive Make M.O.P. 1 K.W.U. 139 8.2 120 ata.

A.O.P. 2 KSB 78 6.8

(D.C.) E. O. P. 1 KSB 30 2.3

J. O. P. 2 Allweller 1.26 120

3000 1480 1460 2980 Turbine A. C. D.C. A.C. motor motor motor. Siemens Siemens Siemens

Enclosure Voltage V Frequency Hz Motor powe kw Rated current A

I.P. 44 415 50 90 154

I. P. 44 220 11 53

I. P. 44 415 50 27.6 49

Oil Cooler type 280 x 20 (Design dats for one cooler) Cooling surface/oil flow 280 m2, 27 L/s 0 Oil Inlet/outlet temp. 65/45 c Oil press. drop o.4 ats. Cooling water Inlet/ 36/39 0c. Outlet temp. Oc. Tube material Cuzn 28 Sn F 38 Max. value for alarm Limit value for tripping 45 microns 120 microns 200 microns

36 H) Moments of Inertis (Kg m2) Rotor of H. P. cylinder - 316.94 Rotor of I. P. cylinder - 1155.59 Rotor of L. P. Cylinder - 9794.13 Weights (Tonnes) Rotor Cylinder assembled Low vacum trip settings Hydraulic low vacum trip Electrical low vacum trip Hydroulic low vaccum trip H.P. I.P. I.P. Turbine Turbine Turbine 7.5 15.8 48.0 56.0 37.0 81.0 (with steam Insets) >0.3 ata. >0.3 ata. >0.6 ata.

(bypass oppration) Oil Supply Oil tank rated capacity : Highest/ lowest oil level from top of tank - 800/850 = at 3000 rpm. Lub. oil temp at cooler outlet - 380C (min), 450C (normal) 470C (Max.) Oil temp. rise across - 200C (normal), 250C (Max.) bearings Safety valve in jacking oil - 200 ata (max.)/180 ata (min.) system

37 2) BLADES: H.P. moving and stationary blade. I.P. moving and stationary blades L.P. moving blades L.P. stationary blades 3) SHAFTS H.P. rotor I.P rotor L.P. rotor 28 Cr. Mo Ni V 59 30 Cr Mo Ni V 511 26Cr. Mo Ni V 115 First stage Laststage

x22 Cr Mo V121 x20 Cr 13 x22 Cr Mo V121 x20 Cr 13 x20 Cr 13 x20 Cr13 x20 Cr 13 20 Mn5 x20 Cr Mo 13 x7CrA113

2.2 CONDENSER, EJECTOR, DRAIN COOLER A) Condenser

Type Dasign c.w. inlet temp. C.W. flow C.W. temp. rise C.W. press. drop. Condenser back pressure Terminal temperature difference Oxygen at hotwell outlet No. of tubes Tube O.D. x thichiness Tube length Tube material b) AIR ELECTORS Type Nos. Working steam press kg/ cm2 (g) Working Steam temp. 0C Working steam quantity

Surface type. single pass 330C 28570 M3 /Hr 8.29 0C 3.4 MWC 73.2 mm Hg at 200 Mw load 4.8 0C 0.02 cm2/L 17492 total 19 x 1 mm 9900mm 90/10 Cu - Ni Priming 1 Starting Main 2 2 3.5 -6.5 6.5 210 210 6.5

210

38 kg/hr Air relieving in capacity kg/hr C) Gland steam condenser Max. Min. condensate flow Tube material and Nos. Water velocity M/s Vent fans D) Drain coolers Design condition inlet 1100 3300 1000

220nm2/hr 700 60

T/hr 108/550 SS, 313 Nos. 1.95 2 Nos. centrifugal

200 MW load, 33o CW temp.

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

Tube material

Admiralty brass Description

2.3 Low pressure heaters

LPH -1 LPH-2 temp. OC Steam inlet press.ata Steam inlet temp. c
o

LPH-3 48.5/55.5 55.5/88.8,88.8/118.7 0.1953 0.83 0.7049 104.5 91.8 3.6 2.1283 196.1 121.6 3.0 2.9

Condensate inlet/outlet

Drip inlet temp c

o

Terminal temp.oc difference Press. drop across tubes MWC Shell/Tube side safety valve set press 8.5

7.8

------- 7/24kg/cm2 g---------3 LP 5 LP 7 LP

Extraction steam turbine stage

39

No. of water passes Tube O.D. x Thickness mm Material of tubes Brass-----

4 16x1

4 4 16x1 16x1 ---------Admiralty

2.4 Deaerator
spray cum Tray Design capacity Steam required at 314.5oc. Condensate temp. outlet Operating/Design press kg/cm2 (g) Operating/Design temp. oc Storage capacity at 2/3

Type

Horizontal type

783.1 MT/hr 5.44kg/cm2 1610C Deaerator 5.44/7.5 161/350 -

(g)

and

Feed tank 5.44/7.5 161/170 123

Dia. M3 I.D. x Th. x length 3340/16 20826 mm x mm x mm Spray system nozzles Pressure drop across nozzle No. of tray sub. assemblies Materials: Trays Shell

2000/14 /9812 50 Nos. NW 50 size 0.5 kg/cm2 (g.)

264 SS 304 IS 2002 gr. 2A 2.5 High pressure heaters Description H.P.H - 5 H.P.H - 6 Feed water inlet/outlet temp. oc 164.2 /197.8 197.8/240.9 Steam inlet pressure ata. 16.1 36.56 Enthalpy of extraction steam 794.1 733.6 K. cal/kg Qty. of extraction steam 33.4 58 T/ Hr Feed water inlet pressure ata 190 189.3 Effective surface area M2 581.6 662 Size of tubes 15.8 mm x15 BWG No. of U - tubes 804 804 Shell O.D. x Th x 1232x 16 x 1280x40 x Height mm 9665 10765 Material of shell DIN 17155 HII Carbon steel Material of tubes SA 556 Gr. C2 40 Carbon steel

2.6 BOILER FEED PUMP

A. Booster pump 1. Manufacturer 2. Type 3. Direction of rotation D.E.) 4. 5. 6. 7. 8. S.G. at suction temp. Suction temp. oc Suction pressure kg/cm2 Discharge pressure kg/cm2 Differential pressure Wier pumps Ltd. FAI F56 A.C.W. Design .904 163 7.263 15.118 7.118 Duty .906 161 7.07 16.02 7.95

(from

9. 10. 11. 12. 13. 14. 15. 16.

Differential head m 87 88 NPSH above impeller eye m 16.85 16.0 Flow rate m 3 /h 381.6 346.2 Leak-off flow, m3/h 95.4 Efficiency % 78 75.5 Speed RPM 1485 Power kw 104.5 99.4 Thrust bearing The Glacier Metal Co. Ltd. Type - Double Thrust, CK range. Size - 8112/2kp -2kp 17. Mechanical seal Crane packing Limited Type - T 109 B with `SC` seat 18. Motor/ pump flexible Torsifilex Limited, coupling Type - OHBS 120 x B. FEED PUMP 1. Manufacturer 2. Type 3. No. of stages 4. Direction of rotation 5. 6. 7. 8. 9. S.G. suction temp Suction temp. oc Suction press. kg/cm2 Discharge press. kg/cm2 Differential press. kg/cm2 Weir pumps Limited FK 8D 30 Eight A.C.W. (From D.E.) Design Duty 0.904 0.906 163 161 14.42 15.32 212.66 188.86 198.24 173.54

41 10. Differential head m 2196.8 1918.9 11. NPSH above impeller eye m 96.8 101.7 12. Flow rate, m3 /h 381.6 346. 2 13. Leak -off m3 /h 95.4 14. Efficiency % 81.0 15. Speed RPM 4750 16. Power KW 2542 2018 17.Thrust bearing The Glacier Metal Co.Limited Type - Double thrust CK range. Size - 8154 /2KP- 2KP. 18. Mechanical seal Crane packing Limited

Type : 003/ Vg RH / 13/ S 66981 19. Turbo coupling / pump flexible coupling 20. Motor/ Turbo coupling Flexible coupling C. DRIVE MOTOR FOR B.F.P. 1. Manufacturer 2. Type 3. 4. 5. 6. 7. 8. 9. 10. D. Output Current Supply Power Factor Efficiency Speed Insulation Type of cooling Torsiflex Limited, Type: HBS 1250 - 8x Torsiflex Limited Type:HBS 3600 -8 BHEL Squirrel cage induction AC 28380 AAW 3500 KW 361 amps 6600 V, 3 ph, 50 Hz 0.8 95.5 % 1485 r.p.m. Class F CACW

HYDRAULIC TURBO COUPLING 1. Manufacturer Voith Turbo GMBH and Co. 2. Type R 16 K 3. Rating KW 2737 4. Speed r.p.M. 1485 ( Input), 4750 (output) 5. Slip % 3.9 6. Step up gear unit 1:3.3

42

2.7 CONDENSATE EXTRACTION PUMP

A. PUMP 1) Manufacturer 2) Type KSB, West Germany WKTA 200/4, Vertical cam type 4 pump Four 1480 r.p.m

stage

centrifugal 3) 4) No. of stages Speed

5) 6)

No. of pumps / unit

2 x 100 % Duty Overload 610 190 402 710 170 429 0.9922 0.9922 40

Discharge capacity m3 /hr 7) Head m 8) Power KW 9) Density of medium Pumped T/M 3 10) Temp.of medium OC B. Motor 1) Make 2) Type 3) Power 4) Supply 5) 6) 7) 8) 9) Current speed Insulation Lubrication Bearing

40

BHEL 3Ph, Ind Motor AVC 12156 H4 470 K W 6600 V, 3 ph, 50 Hz. 0.87 p.f. 51 Amps. 1483 r.p. m. Class F. Servogem 2 (Grease ) Roller Bearing, NU 326 (D.E.) Angular contact Ball Bearing 1322 B (NDE). 43

III OFF SITE AUXILIARIES

44

3.1.

FUEL OIL SYSTEMHEAVY FUEL OIL HANDLING

One, steam traced 292 M. 400 mm 40x2 wagons can be con nected for unloading

a) Unloading Header 1. Nos. 2. Length 3. Diameter (Nb) 4. Capacity at a time.

5. Wagon heating heating B) Unloading pumps 1. Make 2. No. 3. Type 4. Capacity 5. Discharge press 6. Viscosity of oil handled 7. Power required at design point 8. Motor type 9. Motor rating 10. Type of strainers c) H.F.O. Storage tanks 1. No. of 2. Capacity 3. dia x height 4. Heating system i) Coil surface Heater

2 steam headers for each wagon. M/s Borneman W- Germany Five (3 running +2 standby ) Double -screw, steam & jacketed. 100 m3/hr. 4 bars 100 to 500 cst. 29 kw. 37 kw, 415V, 65 amps. 1480 rpm. 3 ph, flame proof, induction motor. Duplex strainer at suction to each pump. 3 2500 M3 each. 20 m x8.6 m. Steam at 4 ata, 190 0C, Fourcoils,(two pneumatically

controlled two manually controlled) 5. ii) Suction heater

and

Steam at 4 ata, 190 0C Pneumatically controlled 45

D) H. F. O. Pressuring pump
1. Type/make 2. 3. 4. 5. 6. 7. Nos. off Capacity Suction & Discharge press Speed power required Drive motor Tripple screw type, Bornemann. 3 430 Litres / Min at 370 cst. (-) 0.4 kg/cm2 (g) & 29 kg / cm2 (g) 1450 32.0 kw at 370 cst. Kirloskar make (E 250)

8.

Motor rating

50 kw, 415V, 3ph, 50Hz.

HIGH SPEED DIESEL HANDLING

A) HSD Storage Tank 1. Capacity 20 m3 x3 Nos. 2. Diameter /length 2.5 m x 4.5 M. 3. Installation Underground B) H.S.D.pumps 1) Type/make Tripple screw type/ Borne Mann 2) Nos off 2 3) Capacity at min/ max viscosity 130 /168 Litres / min. 4) Suction & discharge (-) 0.4 kg/cm2 (g) & 29.5 kg/ press. cm2(g) 5) Speed 2920 r.p.m. 6) Power required 10 kw. 7) Drive motor rating 13 kw. 415 v, 3 ph. 50 Hz. 8) Drive motor make Kirloskar (NE 180)

SUPPORT EQUIPMENTS

A.

Drain Tank 1) Size 2) Heating system Drain pump 1) Type 2) Make 3) Capacity 4) Discharge press 5) Speed 6) Motor r.p.m. 46

B.

4m3 , 2.5 L x 1.5 w x 1.5 H metres Condensate coil heater Screw type, steam jacketed Aroto gear pumps, bombay 4 m3 /hr at 50oc oil temp. 20 M.L.C. 1450 r.p.m. 3 kw, 415v, 5.6 amp. 3ph. 50 Hz, 1450

C.

Flash Tank 1) Size 2) Insulation 3) Installation Vertical sump pump 1) Type

D.

3.5 M3 , 2.0 x 2.0 metres. Mineral wool wrapped Underground. Centrifugal, vertical, submerged

2) Make 3) 4) 5) 6) 7) Rated flow Total head Speed Motor H.P. No. Installed

Kishor pumps Pvt. Ltd, Pune 30 M3/Hr. 7 MWC 1450 r.p.m 3 Two 3(2+1) Continuous duty 23.5 MWC 3600 m3 /hr each Submerged. Self 6.6 KV, 3 ph 50 Hz. TEFC, IP -54 4 (3+1) Centrifugal, cont serivce 1000 M3 / Hr 76 MWC Self 6.6 KV, 3 ph, 50 Hz 300 KW TEFC, IP - 54

3.2 A WATER TREATMENT PLANT1. RAW WATER

Nos. of pumps Service Discharge press. Capacity Suction Sealing/ cooling/lube Power supply Motor enclosure 2. CLARIFIED WATER Nos of pumps Type Capacity Discharge press. Sealing / cooling / lube Power supply Motor power Motor enclosure 3. PRETREATMENT PLANT A. Clarifier- cum Flocculator Nos. and type. Two, Rotating bridge type, Circular 47 Rated effluent flow Effluent turbidity Retention time at rated capacity. (i) floculation zone (ii) Clarifier zone O.D. at top O.D. clarification zone Dia of floculation zone 3000 M3 /hr Less than 20 NTU 30 minutes 2 Hrs 30 minutes 58.1 M 57.5 m 19 .34M

Agitator speed Bridge revolving speed B. Clarified Water storage tank Capacity Size Gravity filter Nos. Flow rate per filter Surface flow rate,

5 r.p.m. 0.015 RPM 1300 M3

C.

2 R.C.C. Construction 300 m3 /hr 5 M3 / hr/m2 (max.)

D.

Filter water Reservoir and transfer pumps Reservoir Capacity 300 M3 Nos. of pumps 4 Nos. vertical Capacity of pumps 120 M3/hr each. Chemical Dosing System (i) Alum Dosing system No. of tanks Capacity Strength of solution 6 R.C.C. construction 4 Hrs dosing capacity 10% Plunger type, 4 Nos.
0% to 100% automatically

E.

(ii) Alum dosing pumps Type Control (iii) Lime slaking tank Capacity Nos

Pneumatic control 3.6 M3 each with motor Driver agitator 2

48 iv) Lime slurry transfer pump Nos. Capacity v) Capacity Strength of solution Two ( one standby ) 5 M3 / hr Four nos. R.C.C. construction 6% W/v

Lime solution preparation tank

vi) Lime solution dosing dosing pump

Capacity

4 Nos. 50% capacity each plunger type, (+ve ) displacement

Control positioner

0% to 100% automatically by pneumatic

vii) Coagulant aid Preparation tank Nos vii) Coagulant aid dosing pump Nos. Control 2 (1 working +1 standby) 0% to 100% manually by micrometer dial. 2 MSRL of 1.0 M3 capacity each

F.

Chlorination System
Nos. Capacity Type of injector Water booster pump 3 ( one for each clarifier 1 standby 15 kg/hr, vacuum type MSRL 2 Nos. ( One working )

49

3.2 B D.M. PLANT

A. GENERAL No. of streams Normal flow through one stream D.M. water storage tanks ACTIVATED CARBON FILTER Three 100M3 /hr 4 Nos. of 1500 M3 each

B.

No.per stream Design flow rate Design surface flow rate Filled with Supporting material Shell size Material of shell Internal painting C. CATION EXCHANGER No. per stream Design flow rate Surface flow rate Filled with Qty. of resin. Regeneration by Shell size Material of shell D. DEGASSER SYSTEM i) Degasser Nos Type Normal flow rate Fill material

One 110 M3/hr 15 M3 /hr m2 Activated carbon Graded Gravel 310 Dia x 2500 CYL. Height Mild steel 3 coats of epoxy paint. One 100 M3 /hr 20 M3 hr/m2 (max.) Resin(IR -120 Strongly Acidic) 5.85 M3 Hydrochloric acid - 30% 2400 Dia x 3000 Cyl Height Mild steel

2 Nos. ( Common for 3 streams) Force draft type 180 M3/hr Polypropeline ( Rasching Rings)

50

ii)

CO2 content in effluent Shell material Rubber lining Size Degassed - water sump No. off Capacity

5 ppm (max) Mild steel 4.5 mm thick 2600 Dia x 4405 cyl. height One per Degasser 75 M3

installation size iii) Air Blowers and pumps Nos. Type pumps

Horizontal, below the Degasser 3200 Dia x 10,000 Cyl.long 3, (2 running, 1 standby Centrifugal, outdoor, continuous duty. 3 Nos. centrifugal, capacity 100 M3 /hr

E.

ANION EXCHANGER Nos. of Design flow rate Surface flow rate Shell lining Material of shell Size Filled with Qty of resin Regeneration

One per stream 100 M3 /hr 25 M3 /hr M2 (Max) 4.5 mm thick rubber lined Mild steel 2800 Dia x 400 cyl. Height Resin ( IRA- 900 - Strongly basic) 11.40 M3 48% NaOH

F.

MIXED BED UNIT Nos off Design flow Suface flow rate Material Rasin (Amberlite)

One unit per stream 100 m3 /hr 30 M3 /hr M2 (max.) Mild steel, 4.5 mm thich rubber lined Cation IR - 120 - 2.65 Anion - IRA- 402- 2.80 (Strongly basic). 1950 Dia x 3700 cyl. Height 51 Alkali 4 3600x7000 50 Rubber

M3 M/s Rohm & Hass M3 W Germany Size

G.

REGENERATION SYSTEM i. Storage tanks Acid Nos 4 Size Dia x Length Capacity M3 50 Lining Rubber Concentration of

3600x 7000

Chemical 30% 48% ii) Un loading pumps: Acid Alkali Nos. 2 2 Type 1 stage centrl. 1 stage centri. Service Intermittent Intermittent. CapacityM3 /hr 20 20 TDH MWC 10 10 Fluid handled. 30% HCl 48% NaOH iii) Transfer cum Recirculation pump ( for Alkali System ) Nos. 1 + 1 (standby). Capacity And Head 10M3 /hr at 10 MWC. Suction Flooded suction (5-50 % caustic lye or slurry) iv) Dosing pumps Acid Alkali Nos. 2 2 Capacity M3/hr 0-3.6 0-2.4 TDH MWC 35 40 H. NEUTRALISTION SYSTEM i) Nos.of pits ii) Two RCC, Acid/Alkali proof brick lined pits. Capacity 300M3 (3.5 m Liquid depth) Recirculation cum disposal pumps Nos. 2 for each pit. Capacity 150M3/hr at 15 MWC. Duty 2-3 hrs every shifts. Four 1500 M3 each. 13000 Dia. 12000 height. Mild steel. lined with two coat of epoxy paint.

1.

D.M. TANKS Nos. Capacity Size Material

52

3.3 M.G.R. AND COAL HANDLING PLANT

A. M.G.R. SYSTEM: 1) Capacity of each wagon 32 tonnes. 2) Two rakes of 33 wagons each make 3)
total 17 trips per day for 2100 MW. Average working hour per day/ idle

4) 5) 6) 7) 8) B.

time per shift. Loading time per wagon Unloading time per wagon Speed at loading /unloading station. Maximum/average speed M. G. R. Circuit

18 hrs/ 2hrs. 40 seconds ( 5500Tph) 20 seconds (3Tps) 4 Kmph /8 kmph 75 Kmph/45 Kmph

TRACK HOPPER: 1) No. of hoppers 2) Length of hoppers 3) Capacity 4) Maximum coal lump size PADDLE FEEDERS: 1) No. of feeders 2) Capacity 3) Dia of paddle feeders wheel 4) No. of vanes of feeder 5) Speed of feeder wheel 6) Max/min.speed of carriage. 7) Total travel of carriage CRUSHER HOUSE 1) No. of crushers 2) Type of crushers 3) Capacity 4) Max.coal size at inlet/outlet 5) Motor rating 6) Belt feeder Vibrating feeders feeder size

One

200 Metres. 3200 tonnes. 200 MM. 4 1000/Tonnes/hour each. 3200 mm 5 3.3 to 13 r.p.m. 0.06/0.04 M/s. 210 metres. Four. Ring hammer type. 1000 Tonnes/hour. each. 200 mm/20 mm 6.6 KV, 750 KW, 750 r.p.m. Four numbers of 1000T /hr capacity each. Four numbers of 1000 capacity each. 2700 x 7200 mm.

C.

D.

7) T/ hr 8)

53

E.

TRIPPER
1) 2) 3) 4) 5) 6) 7) Total number Capacity (each) Travel of tri pper Travelling speed Belt speed Motor for tripper Electrical linear actuator 2 ( 3x 200 MW) 2000 T/hr. 165 M 0.3 M/ s. 3.15 m/s. 2 motors per tripper 5.5 kw, 1000 r.p.m. 1No. push pull force = 750 kg stroke = 0 to 400 3.7 kw motors 2 Nos. drum dia= 250 mm Torque = 25 kg -m.

mm. 8) A.C. electro magnetic brake.

F.

BUNKER
1) 2) 3) Total Nos. Max. capacity of each bunker Bunker dia/height 18 ( 6 per unit ) 390 (Bunker+Hopper) 7.0 m/ 9.2 m.

G. STACKER/ RECLAIMER
1. 2. 3. No. of coal piles in stock yard Length/ height of each pile Total stack yard capacity Average capacity of reclaimer Length of the boom No. of reclaim hopper No. of vibrating feeder Capacity of each feeder Feeder motor rating 2 for 1st stage 2 for 2nd stage 530m/10m. 4,00,000 Tonnes ( 15days consumption for 2100 MW ). 2000 T/hr 28 M 6 6 500 tonnes/ hour 11 KW, 440 V, 1500 r.p.m.

4. 5. 6. 7) 8) 9)

54

3. 4. COMPRESSED AIR SYSTEM Instrument air Service compressor for Air T.G. and S.G. Compressor Service

Instrument compressor for Aux.

air

Manufacturer M/s Khosla M/s khosla M/s khosla Model No. 2 HA 4 Ter T 2 HY2 Bis T 2 HA4 Q Type of compressor Balanced Opposed Reciprocating Nos installed 4 2 4 3 Capacity NM /MIN 20 3 25 Discharge press kg/cm2 (g) 8 8 8 0 Design ambient temp C 50 50 50 2 Design ambient press kg/cm 0.998 0.998 0.998 Design humidity 100% RH 100% RH 100% RH Air temp From aftercooler 10oc higher than cooling water inlet temp. Motor rating KW 175 30 205 Crank shaft speed rmp 710 625 710 No. of stages 2 2 2 Cylinder bore mm LP 2x210 1x215 2x350 HP 2x185 1x140 2x210 Stock mm 150 115 150 Clearance in % of volume LP 9.0 11.9 11.5 HP 10.8 19.3 10.0 Thickness mm LP 12 11 20 HP 11 11 15 Method of cylinder Non-lub. Non-lub Lub. Lubrication Cooling method Water Water Water Nos of air recelvers 4 1 4 Water capacity of each 7 1.84 7 3 receiver M

55

3.5 AIR CONDITIONING SYSTEM

A. VAPOUR ABSORPTION SYSTEM

1. Number 2. Capacity (TR) 3. Type Double effect 4. Chilled water flow 5. Inlet chilled water temp. 6. Quiet Chilled water temp. 7. Cooling water flow 8. Material of construction a) b) c) d) e. f) g) Note High temperature generator tubes SS430 Low temperature generator tubes Absorber/Evaporator/Condenser tubes High temperature heat exchanger Cupro Nickel Low temperature heat exchanger Eliminators Shell Copper S.S M.S One TR is 3000 Kcal/hr. Copper DLP Copper As per TR rating 12.77 dg. C 7.0 deg. C As per TR rating One (1) 350 TR

: for the given chilled water and cooling water temperatures.

56

1. SOLUTION PUMPS QTY. 1 NO. Type Nikkiso Non seal pump Model 55491-5.5 H-B Head 9.5 m Cap 750 l/min Motor 5.5 KW, 3 = 1500 rmp , 415 v Nikkiso Co. Ltd, kyo Japan 2. REFRIGERANT PUMP Type Nikkiso Non Seal pump Model 5291 - 1.5 F - V001 Head 3.5, Cap 600 Lit/Min = Motor 1.5 KW, 415 V, 3 , 3000 rpm 3. E/P CONVERTOR Make Model Sl. No. Supply output CG - Hart mann & Braun Ltd. I/p Cnventor - Te IP 11 4217059 4 to 20 mAwps 0.2 - 1 kg/cm2

4. VACUUM PUMP (PURGE PUMP) Type Rotary Vacuum Pump Make Precise Vacuum System & Pvt. Ltd. Model VKC - 8, S l. No. 80064, Motor Cromption Greaves Model 2242 DVJ Zin Z5 74 (m) Rating 37 W, 415 v 3ph, 1350 RPM 5. PLUNGER PUMP Type Model No. SPM Flow rate Sl. No. Discharge Pr. Motor Make Rating Controlled Volume Pump WH - 1750/33 Stroke per minute - 144 LH - 150 14043/ 00 23.0 Kg./cm2 = Crompton Greaves 75 KW , 415 V + 10 % & 1400 rpm

57

B : ST I MAIN AC 1. AC COMPRESORS INSTALLED : 04 Normal Running : 02 Make : M/s. Kirloskar Pneumatics Co. Ltd.Pune. Model : K 60 x 110 Capacity of each Compressor : 130 TR Motor KW : 150 Refrigerant : Freon 22 2. COOLING WATER PUMPS INSTALLED : 03 Normal Running : 02 Make : Beacon Weir Model : 4L3 Capacity : 38.9 Litre per Second Motor KW : 22 3. CHILLED WATER PUMPS INSTALLED : 03 Normal Running : 02 Male : Beacon Weir Model : 4L3 Motor KW : 18.5 Capacity : 38.9 Litre per Second 4. AIR HANDLING UNIT : a) Unit 1 Numbers Installed Normal Running Make Capacity b) Unit 2&3 Nos Installed Normal Running Make Capacity of each AHU : : : : : : : : : :

02 02 Atlantic of each AHU 38000 Cubic Meter per Hour 04 04 Atlantic 33000 Cubic metre per Hour

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

58

C : SW YARD AC 1. AC COMPRESORS INSTALLED : 02 Normal Running : 01 Make : Accel Compressors, Ahmedabad Model : SMC 6 - 100 Capacity of each Compressor : 60 TR Motor KW : 52.5 Refrigerant : Freon 22 2. COOLING WATER PUMPS INSTALLED : 02 Normal Running : 01 Make : Beacon Weir Model : 3L3 Capacity : 16.7 Litre per Second Motor KW : 15

3. AIR HANDLING UNIT : Nos Provided Normal Running Make Capacity

: : : :

02 01 Atlantic of each AHU 24700 Cubic Meter per Hour

4. COOLING TOWER : Nos Installed Make Capacity of Each Cell

: 01 : Atlantic : 60 Cubic Meter per Hour.

59

D : ESP ST I (DATA OF ONE ESP - SAME FOR UNIT 1,2,3) 1. AC COMPRESORS INSTALLED Normal Running Make Model Capacity of each Compressor Motor KW Refrigerant : : : : : : : 02 01 Accel, Ahmedabad SMC 6 - 65 25 TR 22 Freon 22

2. COOLING WATER PUMPS INSTALLED : 02 Normal Running : 01 Make : Beacon Weir Model : 21/2 R 13 Capacity : 6.94 Litre per Seconds Motor KW : 5.5

3. AIR HANDLING UNIT : Nos Provided Normal Running Make Capacity

: : : :

02 01 Atlantic of each AHU 24000 Cubic Meter per Hour

4. COOLING TOWER : Nos Installed Make Capacity of Each Cell

: 01 : Atlantic : 25 Cubic Meter per Hour.

60

E : EDP AC 1. AC COMPRESOORS INSTALLED : 04 Normal Running : 02 Make : M/s. Kirloskar Pneumatics Co. Ltd., Pune Model : AC 1070 Capacity of each Compressor : 82 TR Motor KW : 175 Refrigerant : Freon 22 2. COOLING WATER PUMPS INSTALLED : 02 Normal Running : 02 Make : Kirloskar Brother Ltd. Model : DB 125/26 Capacity : 164 Litre per Seconds Motor KW : 18.5 3. CHILLED WATER PUMPS INSTALLED : 02 Normal Running : 01 Make : Kirloskar Brother Ltd. Model : DB 100/40 Motor KW : 15 Capacity : 98 Liters per Second 4. AIR HANDLING UNIT : a. Main AHU Numbers Installed : 03 Normal Running : 02 Make : Flakt Capacity : each AHU 68000 Cubico Meter per Hour b. UPS Room Nos Installed : 02 Normal Running : 02 Make : Flakt Capacity : 17000 Cubic Meter Hour 5. COOLING TOWER : Nos Installed : 01 No. of Cells : 02 No. of Cells Normally in service : 02 Make : Paharpur CoolingTowers Ltd. Model : 348-602 Single Flow Capacity of each cell : 2 x 125 Meter per Hour.

61

F : SIMULATOR AC
1. a)COMPUTER ROOM Normal 0 Running Make

: :

Model : Capacity of each compressor : Motor KW : Refrigerant : b) UNIT CONTROL ROOM AC COMPRESSORS PROVIDED Normal Running : Make : Model : Motor KW : Capacity of each compressor : 2.

01 Kirloskar Pneumatics Co Ltd. Pune AC 470 40 TR 37 Freon 22

: 02 02 Kirloskar Pneumatics Co Ltd. Pune AC 570 45 45 TR

COOLING WATER PUMPS INSTALLED : 02 Normal Running : 02 Make : Beacon Weir Capacity : Liters per Second Model : 2DM6 Motor KW : 5.5 Capacity : 9.7 Liters per Secod AIR HANDLING UNIT : FOR COMPUTER ROOM : Nos Provided Normal Running Make Capacity

3.

: : : :

02 01 Haji Moosa Patra Wala of each AHU 37000 Cubic Metre per Hour

62

4.

FOR CONTROL ROOM NOS PROVIDED Normal Running Make Capacity COOLING TOWER : NOS Installed Normal Running Make Model

: : : :

02 01 Haji Moosa Patra Wala of each Ahu : 39000 Cubic Meter per Hour 02 02 Paharpur Cooling Towers Ltd. Perma Tower 5931

5.

: : : :

63

3.6 COOLING WATER SYSTEMA.

PUMP & MOTOR

1. PUMP
i) ii) iii) iv) V) vi) vii) viii) ix) x) xi) xii)

SPECIFICATION OF C.W.

Make Type No. of pumps supplted No. of stages Pump Design Type of impeller Operating speed
Discharge Capacity

KSB SEZ 1200 -1020 Seven (2 per unit one standby) One Pull out type Open, Mixed flow 493 r.p.m.
15,000 M3 /hr

Total dynamic Head Shut-off head Bowl efficiency COUPLING a) Make b) Type c) Weight xiii) Foundation load xiv) Pump weight (G.P.) xv) GD2 of pump

12.2 MWC 30 NWC 89% KSB 16 300 62,000 kgs 2,600 kgs. 296 kg M2 BHEL AVC 15156 H 12 D 685/81.5A 6.6 KV 3 ph. 50Hz. 493 11,000 kgs, 1400 kgm2 93.1 % Star-wound 0.7 CACW F C.C.W. from D.E. 64

2. MOTOR
i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) Xii) xiii) Make Frame size KW/ Current Voltage R. P. M. Motor weight (GM) Motor GD2 Efficiency Stator Power factor Cooling Class of insulation Direction of rotation

B. COOLING TOWERS AND C.T. PUMP

SPECIFICATIONS

1) C.T. PUMP
i) Number 2 For each 200 MW 15,000 M3/hr 18.5 M.W.C. 493 rpm KSB Induction Motor 493 r.p.m. 1015 116.4 6.6 KV, 3 BHEL 1 for each 200 MW unit 16 ( Rows of 8 cells each) 27,000 M3 /Hr/Tower 100C Prestressed concrete Asbestos, corrugated 16 (8 per row) Axial Induced draft Gammon Axial Flow 7315 mm 7 65 50/s ii) Discharge iii) Head iv) Speed v) Make MOTORS i) Type ii) Speed iii) K.W. iv) Current v) Volts vi) Make

COOLING TOWER
i) Number ii) No. of cells/ tower iii) Rate of flow per unit iv) Cooling range v) Baffles vi) Drift eliminators

3. COOLING TOWER FAN

(i) Fans/tower (ii) Fan type a) Fan Impeller i) Make ii) Type iii) Diameter iv) No. of blades/fan

v) Blades variable pitch angle vi) Pitch angle vii) Speed viii) ix) Fan B.H.P. b) Reduction Gear i) Make

Yes 130 151 r.p.m. Air Quantity 35 KW ELECON Worm Gear 1470 r.p.m 151 r.p.m. Siemens Squirrel Cage 225 M. T.E.F.C. - IP 55 58 HP (43 KW) 415 V - 3 Ph - 50 C/s. 1470 r.p.m. Insulation 75 500C Class 'B' 9,97,200 CMH

ii) Type iii) Input Speed iv) Output speed c) Electric Motor i) Make ii) Type iii) Frame size iv) Enclosure v) Rating vi) Supply vii) Speed viii) ix) Amperes x) Ambient temp

66

C. TRANSFORMER C.W. SYSTEM 1. 2. 3. 4. 5. 6. 7. Rating Voltage ratio Frequency Impedence Service Duty Overload 25 MVA (2 wdg) 3 33/6.9 KV. 50 Hz. 0 10% at 75 C (No +ve toberance) Outdoor Continuous. As per IS 6600 - 1972 ONAN/ONAF/OFAF/ with 2 x 50% separately mounted rediators and 2 x 50% all pumps per cooler % rating at different cooling 60/80/100 above 50 0C In oil 40 0C.

8. Cooling

9. Temp. 10. Wdg. details

Neutral

HV LV Fault level MVA 1000 Basic IMP. level KVP. 170 60 Wdg. connection Delta Insulation Fully Fully Insulated Insulated. Vector group DY 1. IsolaNon ted effectively

350

Star

67

11. Tap changer

Tap range + 5% of 2-1/2% on HV Tap control - Off HV

to - 7 1/2% In steps neutral end. ckt top change switch LV Neutral

12. Bushing

Rated voltage KV 36 12 Rated current Amp. 800 3150 Basic impuIse level KVP. 170 75 Total Creepage Distance (mm) 666.8 222.3 mounting Tank Tank cover cover

12 300

75

222.3 Tank side/cover

13. Terminal details

H.V. connected to33KV PILC or XLPE L.V. connected to Segregated phase Bus duct. Neutral connected to PVC Al cable. No. of. Core 1 Service Protection Ratio 300/1 Accuracy SP 20. Burden 15VA (with skids inplace of wheel) 68

14. Bushing C.T.S.

Name and type of Transformer 15. Raw water and Clarified water Transformer (Outdoor) CKT. 16. Colony transformer 2 (Outdoor) 2

Qty.

Specification

12.5 MVA, 33/6.9KV, 50 HZ Imp. - % at 75 0C, ONAN, vector group - Dy 1 Tap changer - + 5% on HV side of Neutral - Isolated.

3 MVA, 33/11KV, 50 Hz., Imp - 7% ONAN, vector group - Dy. 1. Tap changer - + 5% - 7-1/2% Off Ckt. Neutral HV - Isolated LV - Solidty earthed

D. L.T. TRANSFORMERS

Outdoor L.T. Transformers.

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

2.

3. 4.

Clarified water 2 Service Transformer Ash Handling 2 Service Transformer

-do-do-

69

5. 6.

Ash Water Service Transformer. Workshop service Transformer

2 2

Neutral - LV solidly earthed 1600 KVa, 6.6/0 433 KV ONAN, IMP. 7% Tap changer -+ 5% Off ckt. Vector group Dy. 1 Neutral L.V. grounded solidly. 300 KVA, 6.6/0.433 KV ONAN Imp. - 5% Tap changer - + 5% Off Ckt. Vector group - Dy1 Neutral - LV solidly grounded. 1600 KVA 6.6/0 433 KV ONAN, Imp - 7% Tap changer - +5% Off ckt. Vector group - Dy. 1. Neutral - LV grounded. 500 KVA, 33/0.433 KV ONAN, Imp 7% Tap changer - +5% Vector group - Dy. 1 Neutral - LV solidly grounded. -do-

7.

Lighting Service Transformer. i) Clarified water ii) CW Area iii) Fuel oil area E.S.P. Service Transformer

1 1 1 6

8.

9.

Switch yard servce Transformer

10. Switch yard light Service Trfr.

11. Administrative Bldg. 1 Service Trfr.

-do-

70

3.7 EQUIPMENTS OF ASH HANDLING SYSTEM Sl. Description Make Model Type of Suction Motor Rating 1 Ash Slurry Disposal Pump St. - I Flooded (Max.) 522 (Rated) 286 (Min.) 75 KW 2 H.P. Ash Water Flooded 18.5 KW back pull out 3 Vaccum Pump 0.75 KW 4 713 Scoop type Variable speed Range of Speed regulation : 5 Instrument Air Compressor 630 KG Khosla 2HY2T 8.0 Kg 107.13 22KW Fluid Coupling Prembril 18SCR25-B Khaitan Axial Flow Supply fan Cu. Mtr/Hr SAM 25 Mtr. WP 125/320/ 160Cu. Mtr/Hr Head SAM 15 MWC Capacity AR 300/650 650 Cu. Mtr/Hr

Qty. Speed 4 572

2 1450

Booster Pump 4 1410 4 1425 to

2 Cu. Mtr/Hr

Collector Tank Size :1450 MM OD

DCIPS

Impingment typeAir seperation arrangement

4Nos. per unit

Mechanical Exhauster

Vacunair Water ring 300mm hg type Size-200 vaccum 4050 Cu. Mtr/H

Nos.

/unit 440

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

71

Sl.

Description Qty. Capacity Suction

Make Type of Speed

Model Head Motor Rating

Wetting Head Size : 10" NB Operating water Qty.:72 Cu.M./Hr. at Working Pressure:55MWC No. of Nozzels :16 Capacity of Dry fly Ash : 47.5 MTPH Slurry concentration at outlet : 4Nos 47 MTPH of (Ash:water)1:1.5 perunit Dry Fly Ash 10 CAP:5.0 T Span :4.3 Mtr. Make :Crompton Greaves Bridge Travel:12 Mtr. Type :Spuirrel Cage415 Trolly travel : 2.7 Mtr. V,3Ph, Max. lift :2.3 Mtr. Speed :1440 RPM Hoisting Speed : 3.15 m/Min. CrossTraverse :10m./Min.

Spray DCIPS Semi EOT Crane Trolly Drive Motor :

Water type

Reva

S/G Semi EOT

11

AirDrying Plant blower reactivated type) Speed :1440

MVS ENGG.LTD. MVS-559-150 2 60 N.C.U.

M/Hr.

RPM

72

Motor of Stage - I Equipments

No. Description PH 1 2 3 4 5 Ash slurry disposal Pump 450 H.P. Ash Water BoosterPump 415 Instrument Air compressor 415 Machenical Exhauster 415 Air Drying Blower 415 Make V Crompton Greaves 125 Crompton Greaves 334 Crompton Greaves 394 Crompton Greaves 149 Kirloskar 1.84 Qty. KW AMP. RPM 4 1480 2 1475 2 1475 4 1480 4 2520 75 18.5 22 90 0.75 3 3 3 3 3

73

DETAIL OF EQUIPMENTS OF ASH HANDLING SYSTEM Sl. 1 Equipment Make Sprinkler pumps KSB Qty. 02 nos. Capacity 100 m3 ; 10 kg/c m2

STAGE # I BOTTOM ASH

Sl.

Equipment Make. Scraper conveyor. Mahindra spricers. Clinker Grinders Manindra spicers.

Nos. Installed Specifications

1 2

06 nos. 06 nos.

Capacity Capacity

06 06

tons/hr. tons.

74

STAGE # I ASH SLURRY PUMPS ,SEAL WATER PUMPS HP , LP SERVICE WATER PUMPS SN. 1 m3/hr. 2 Equipments make. Make Ash slurry pumps SAM HP Ash water pump Kirloskar Discharge m3/hr. st 3 m3/hr. St. # II Model BHR 30-35 4 kg/cm2. m3/hr. 5 Kirloskar Service water pump Meghraj. Seal water pump Discharge 100 m3/hr. 03 nos. Head Discharge -2 nos. 10.15 -330 LP Ash water pump. 03 nos. # 4 Head - 60 mwcl. Power - 130 KW Discharge - 570 270 Installed 04 nos. Specifications. Head - 3.3 kg/cm2 power - 140 KW. Discharge 850 Head - 94.5 MWCL Power - 110 KW Model - BHR 30-35 ASH WATER PUMPS &

03 nos.

Head - 11 kg/cm2 St. # 5

SAM 6 Suction & discharge valves 10 nos. valve 125 PSI Vaas/ Dezuric 75

Knife Edge Gate

STAGE # I ASH SLURRY PUMPS ,SEAL WATER PUMPS HP , LP SERVICE WATER PUMPS SN. 1 m3/hr. 2 Equipments make. Make Ash slurry pumps SAM HP Ash water pump Kirloskar Discharge m3/hr. st 3 m3/hr. St. # II Model BHR 30-35 4 kg/cm2. m3/hr. 5 Kirloskar Service water pump Meghraj. Seal water pump Discharge 100 m3/hr. 03 nos. Head Discharge -2 nos. 10.15 -330 LP Ash water pump. 03 nos. # 4 Head - 60 mwcl. Power - 130 KW Discharge - 570 270 Installed 04 nos. Specifications. Head - 3.3 kg/cm2 power - 140 KW. Discharge 850 Head - 94.5 MWCL Power - 110 KW Model - BHR 30-35 ASH WATER PUMPS &

03 nos.

Head - 11 kg/cm2 St. # 5

SAM 6 Suction & discharge valves 10 nos. valve 125 PSI Vaas/ Dezuric 75

Knife Edge Gate

IV GENERATOR AND AUXILIARIES

76

IV. GENERATOR AND AUXILARIES

4.1

SPECIFICATIONS1.
Make Type Cooling, Stator Winding/ Stator Core, Rotor

GENERAL BHEL
2 - Pole, Steam Turbine Driven Direct Water Cooling/ Direct Hydrogen Cooling

2.

RATINGS : Output Rated power factor Rated Terminal Voltage Permissible vartation on Term Voltage Rated RPM, Frequency Permissible vartion in Frequency Phase connection No. of parallet paths per phase Rated casing Hydrogen pressure Stator current at MCR Short CKT. Ratio Generator conferms to Codes 210 MW 0.85 LAG 15.75 KV + 5% of Rated KV 3000, 50 HZ +2% to (-3)% Double Star 2 3.5 Kg/Cm2 9050 Amps. 0.49 IEC : 34-1 & 34-3, IS : 5422 GOST : 533

Rise in Voltage with 100% Load Throw 22.40 KV (without AVR)

3. TEMPERATURE AT RATED OUTPUT

T. Max at H2 Coolers outlet 0C 43 77 T. Max. of Water at H2 cooler Inlet 0C 36

T. Max of D.M. Water at Inlet to Stator T. Max of water at inlet of D.M. Coolers T. Max of D. M. water at Outlet of Stator T. Max of Stator core T. Max of Stator Winding

44 36 70 105 (BY R.T.D.) 105 (BY R.T.D.)

Saturated Unsaturated

4. REACTANCE

(PER UNIT VALUES)

Direct Axis SYN. React Xd Direct Axis Trans. React X'd Direct Axis Sub-Trans. React X''d NEG sequence React (X2) Zero SEQ. React (Xo) Zero SEQ. Resistance (Ro)

2.05 0.234

2.22 0.266

0.179 0.252 0.105 0.00193

0.214

5. TIME CONSTANTS (SECONDS)

Field TC with Open Ckt Stator SDG. - Cdo Field TC with 3 SC Stator WDG Cd3 '' '' '' with 1 Cd1 TC of aperiodic component of 3 SC C A3 2 SC CA2 1 SC CA1 Time constant of the periodic component of the Sub Transient current of 3 , 2 1 of short Circuit '' '' d 78 7.00 0.84 1.62 0.29 0.29 0.24 0.03

6. INERTIA CONSTANT H W SEC/KVA)

A. GEN B. Complete T. G. Unit Capacitance of Generator Allowable Stator earth fault Current & Duration 1.1 3.42 0.72 7 Amps for 10 Sec.

stator Winding to Ground (Micro F)

7. LOSSES AT DIFFERENT OUTPUTS WHEN RUNNING AT RATED SPEED VOLTAGE, POWER FACTOR AND HYDROGEN PRESSURE
Capper losses of stator and rotor at 75 C
O

(Stator)

(Rotor)

At 100% of rated output x80% 60 % 40 % - Iron Losses of Gen. Stator - Priction and windage loss In Gen. Efficiency & According to IEC Definitions, AT Rated Power Factor and H2 Pres. without any tolerance. AT 100% MCR AT 80% MCR 79

1014 KW 650 KW 365 KW 162 KW 550 720 KW

790 KW 571 KW 391 KW 256 KW - (KW)

98.55 98.53

Voltage Reg. under conditions of Rated speed. voltage and Out put (%) AT 0.85 of LPG AT 1.00 pf AT 0.90 pf Lead Saturation constant 7. 42 36.5 1.0 1.086

GEN. CAPABILITY AND DURATION IN AIR AND AT DIFF. H2 PRESSURES WHEN RUNNING AT RATED SPEED. VOLTAGE POWER CAPACITY In Air 0.03 ATG, H2 1.0 ATG H2 2.0 ATG H2 Rated H2 Press Max. Cont. KVA Capacity of Gen. with -Loss of Stator Cooling water flow One H2 Cooler out of service Nill 185000 KW NIL (KW) Nil 30000 115000 210000 DURATION NIL (Hr) Nil Continuous Continuous Continuous

AND FACTORS

GEN. REACTIVE ZERO LAG & ZERO (LEAD) AT RATED VOLTAGE AND H2 PRESS
Max. Line charging capacity (KVAR) Max. Inductive capacity (KVAR) 172000 75000

80

8.

SHORT CKT SUB TRANSTENT CURRENTS ON 3 SC ON 2 ON 1 SC SC 9.66 p.u. 7.56 p.u. 10.36 p.u. 3.76 3.58 5.10 1.39 2.19 3.63

SHORT CKT. TRANSIENT CURRENT (p.u.) ON 3 SC ON 2 SC ON 1 SC ON 3 SC ON 2 SC ON 1 SC Permissible cont. Neg. seq. current COMPONENT (I2) Allowable (I2) t valve
2

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

5% (Rated current) 8 84 MW for 15 Min. VOLTS 310 102 40 620 (For 10 Sec)

Permissible load and duratior of ASYN. OPN. 9.

Excitation Requirement at : AMPS Rated load No load At max capacity load (At O active Power) Under Field Forcing condition Deviation Factor of Voltage Wave/ Form 340 3900 2600 917

Not more than 10%

81

Short Ckt Tarque/ Full load Tarque Fly wheel moment (GD ) of
2

GEN. + Exciter (If any) KG. M2 Critical speeds for Generator First Second Third Capacity (In KW) of Space Heaters STATOR CORE (A) Type of spring Mounting (B) Grade of sheet steel (Thickness 2 loss FIG) STATOR WINDING (A) Class and type of insulation (B) Resistance per phase at 20 0C ( ) (C) Capacitance per phase (uF) (D) Shipping test voltage valve (KV) (E) Impulse voltage strength (KV) (F) Is the winding transposed In the ends No. 49 (PEAK) 34.5 0.24 0.00155 'B' Thermosetting Epoxy Mica Core mounted on Spring Core BARS 0.5 MM C.R. St. Steel 1.25 x 103 at 1.0 TESLA 21 at 415 V 10. DESIGN AND CONSTRUCTIONAL FEATURES 1370 2400 21100

82

TERMINALS
(A) No. of terminals Brought out (B) Type of cooling of terminals and connections (C) Type of terminal Bushings (D) Is provision made for Mounting CTs (E) Dielectric Test Voltage-KV (F) Impulse voltage Strength - KV ROTOR (A) Material of Rotor Forging Chrome-nickel-Molybdenum and Vanadium Steel Non - Magnetic Steel

9 Directly water cooled Porcelain YES 52 78

(B) Material or Retaining Ring Forging (C) Material of Rotor Wedge Duralumin (D) Type of mounting Retaining Ring Shunk Fitted only one end of Shaft Barrel (E) Material of Damper winding Silver plated copper segmental type (F) Over speed test value and 3600 RPM for 2 Mins. duration ROTOR WINDING (A) Class and Type of Insulation (B) Turns per pole (C) Resistance at 20 0C (D) Dielectric test voltage valve 'B' Epoxy class 63 0.0896 3.1 KV

83

BEARINGS
(A) Type of seal (B) Pressure of Seal oil (C) Grade of oil (D) Quality of oil per seal COOLERS Material of Tubes Fins Tube Plate Water Boxes Quantity of clarified water Req./Cooler Pr. Drop across cooler on water side Admiralty Brass Tinned copper wire Soft Drawn Steel ST. 42 w Steel St. 42 S 87.5 M3/hr. 17.5 (M.W.C.) Ring Type 5.0 KG/Cm2 DTE MED. of I.O.C. 1.5 M3/hr

4.2 AUTOMATIC VOLTAGE REGULATION

Manufacturer of AVR Type Power supply to the regulators Range of voltage adjustment % Auto position/Manual Frequency range of operation Temp. range of operation (OC) Accuracy (%) Dead Band BHEL K 17020 M 110 Volts + 10% / +10 40 to 70 Hertz 55 +0.5 Nil

84

Response time ( To apply field forcing voltage with A 5% Drop in Generator Terminal voltage, seconds STATIC EXCITATION SYSTEM Rectifler transformer Frequency Phase Capacity (KVA) Voltage High/Low Percentage impedance/ Vector group Mode connection between low voltage Terminals and Thyristor convertor Type of cooling Transformer weight Overall dimensions (lxBxH) Recommended location RECTIFIER ASSEMBLY Rated current/Voltage Ceiling current/Voltage Ceiling duty duration (Sec) Diode base temp. at rated output Rated peak Inverse voltage Diode used (voltage) 3000 Amp / 355 Voltage 4500 / 620 10 86.60C at 450C Ambient 2200 V May and Christe 50 Hz 3 2500 15750/575 5.82 / Y5 By cables Forced Air Cooling 7 tonnes. 3 M x 2 M x 3 M Approx. Below the Bus Duct at 0.OM level in Machine Hall. 40 Milli seconds

85

Frequency of supply Voltage (HZ) Voltage drop across Rectifier (V) Type of Connection Over voltage withstading capacity Spare capacity of Rectifler Overall dimensions of Assy. (M x M x M) Field suppression Arrangement Total loss in Excltation system Cooling, power requirement (KW) for Thyristor convertor required for cooling Max. Pr. at Inlet to winding (KG/Cm2) KM & Voltage rating of driving Motor for Pumps Quantity of water per cooler Pressure drop of water through coolers 0.08 KG/CM2 Volume of H2 Space in Gen. 1800 90 (M3) 86 4.0 KG/CM2 Gauge 9.3KW 415V, 3 50 HZ, 1 Stand By 110 M3 / Hr 45 KW DM
3

50 Hz 1.425/Thyrister 2.85 V Bridge 3 Full wave bridge 2.5 KV, Power 3000 KW On D.C. Side 19% 5 Nos. 0.68x1.2 x 2.6 IT IS PROVIDED 45 KW at Rated Output

4.3 STATOR WATER COOLING SYSTEM

27 M /HR.

water

4.4 GAS SYSTEM DATA

56 M3 Cooling gas glow (M3/Min) Vol. of Co2 at N.T.P. required for Displacing Air

Vol. of Co2 at N.T.P. required to displace H2 Volume of H2 at NTP required for displacing Co2 and to bring the casing to rated pressure Purity of H2 required Leakage of H2 by Vol./Day at rated Pr. Volume of Air at NTP required to displace CO2 in the casing(M3) Requirement of compressed Air for Gas Tightness test Standards to which the Cylinders conform H2/C02

120 M3

300 M3 99% Normal 97% MIN. Not more than 15 m3 150 500 M3 BS - 399 BS - 401

4.5 SEAL OIL SYSTEM

Seal oil Pump Motor Set Type Capacity (M3/Hr), Disch. Pr. Size of Motor (KW) Vapour extraction Unit (In seal oil Drain) Capacity of Unit/Motor MAIN WEIGHTS Heaviest Lift of Gen. Stator with Trunions Wt. of complete Stator/Rotor Wt. of complete Gen. Wt. of Lifting beam 175 Tonnes 163/42.2 Tonnes 239 Tonnes 20 Tonnes Centrifugal 400 M3/Hr, 1.5 KW Stand-by Regulator I.A.C. (Screw Type) I.D.C. (Screw Type) 7.8,10 4.2 7.8,10 4.0

87

4.6 Generator Transformer

1. Rating 2. Voltage Ratio 3. Frequency 4. Impedance 5. Service 6. Duty 7. Overload 8. Cooling 9. Temp. rise above 500C 10. Winding details Fault level MVA Basic Impulse level KVP Wdg. connection Insulation Insulated Vector group Neutral earthed YD II Solidly earthed Effecively Star Graded Delta Fully 25000 1300 3000 125 240 MVA 14 - 18 KV/400 KV 50 Hz. 14% at 750C Outdoor Continuous As per IS 6600 - 1072 OFAF with 3 x 50% Coolers and 3 x 50% oil pumps In oil In wdg. 400C 500C (Resist method) HV LV

88

11. Tap changer

Tap change(+) 7. 5% to(-)(2.5%) in steps of 2.5% on HV neutral end. Tap control-Full capacity off CKT. tap change switch. HV 420 KV 500 Amp 1300 8083.6 mm Tank cover LV 24 10000 125 446.6 Tank Neutral 36 500 170 666.8 Tank cover

12. Bushing
Rated Voltage Rated current Basic temp. level KVP Total creepage distance MW Mounting cover

13. Terminal details

HV connected to - Twin moose ACSR conductor LV connected to - Isolated phase duct. Neutral connected Mild steel to grounding flat. HV NEUTRAL 2 Protection 500A 1000/1 PS PS 1000V 2.5 Ohms

14. Bushing current

transformer

No. of cores 2 Service Protection Rated primary current 500 A Ratio 1000/1 Accuracy class Knee point voltage (Not less than) 1000 V Secondary wdg. resist (Not less than) 2.5 Ohms

15. Other requirements

Min. phase to phase a spacing of the Isolated phase bus duct is 1200 mm, LV terminal spacing shall match this.

89

4.7 TIE TRANSFORMER1. Voltage ratio 3. 4. 5. 6. 7. 8. Frequency Impedance Service Duty Overload Cooling

Rating 50 Hz.

75 MVA

400/34.5 KV 12.5% at 750C (with no +ve tolerance) Outdoor Continuous As per IS 6600 - 1972 ONAN/OFAF/with 2 x 50% separately mounted radiator banks and 2x 50% oil pumps/coolers % rating at different coolings 75/100.

9.

Temp. rise above 500C

In oil 400C In winding - 500C (Resistance) HV Fault level MVA Basic impulse 1300 Level Insulation Vector group Netural KVQ Star Insulated Yd 11 Solidly Insulated grounded Delta Graded Fully Wdg. connection LV 25000 170 KVP 1000

10. Winding details

Tap changer of

Tap range (+) 5% to 7-1/2% in steps 2-1/2% on HV neutrel

end. Tap control Off ckt. top change Switch

90

12. Bushing
Rated Voltage

HV Rated current 500 Basic temp. Level KVP. Total creepage 1300

LV 420 2000 170 8083.6

Neutral 3636 500 170 666.8

666.8 distance mw mm Mounting Tank cover Tank cover Tank cover

13. Terminal details HV connected to Twin moose ACSR conductor

LV connected to 33 KV PILC Or XLPE cable. Neutral connected to MS grounding flat.

14. Bushing current transformer

No. of cores Service Rated primary current Ratio Accuracy Knee point voltage (Not less than) Secondary winding resistance.

HV 2 Protection 200 200/1 PS 600 V 2.5 ohms

Neutral 2 Protection 200 200/1 PS 600 V 2.5 ohms (Not less than)

91

4.8

UNIT TRANSFORMER 1. Rating 16 MVA; 2 winding 3 2. Voltage ratio 14 - 18/6.9 KV 3. Frequency 50 Hz 4. Impedance 7 % at 750C 5. Service Outdoor 6. Duty Continuous 7. Overload As per I.S. 6660 - 1972 8. Cooling ONAN/ONAF with 2 x 50% separately mounted radiators. % rating at defferent cooling 75/1000 9. Temp. above 500C In oil 400C In winding 500C HV Fault level MVA Basic imp level Wdg. connection Insulation Fully Insulated Vector grouping Neutral Noneffectively 11. Tap changer Tap range LV 3000 350 125 KVP 60 Delta Star Fully Insulated DY 1 Noneffec tively

10. Winding details

KVP

+5% to 7-1/2% in steps of 1-1/2% on HV neutral end. Tap control Full capacity on load top changer suitable for local/remote, Independant elect./ manual operation. 92

12. Bushing Rated voltage Rated current amps. Basic impulse level KVP. Total creepage Distance mm Mounting

HV 24 1000 125 444.6 Tank cover

LV 12 1000 75 222.3 Tank cover

LV neutral 12 300 75 222.3 Tank cover

13. Terminal details

HV connected to - Isolated phase duct. LV connected to -- Segregated phase duct. Netural connected to PVC Insulated Al cable. 1 (LV Neutra) Protection 300/1 SP20 15 VA

14. Bushing CTSNo. of core Service Ratio Accuracy Rated

15. Other HV terminal arrangement :requirement (Minimum phase to phase spacing of the isolated phase duct is 1000 mm HV terminal will match this vactor group)

93

4.9 STATION TRANSFORMER 1. Rating 31.5 MVA 2 wdg.3 2. Voltage ratio 33/6. 9 KV. 3. Frequency 50 Hz. 4. Impedence 11% at 75 0C 5. Service Outdoor 6. Duty Continuous 7. Ovarload As per IS 6600 - 1972 8. Cooling ONAN/ONAF/OFAF with 2 x 50% separately mounted rediator and 2 x 50% oil pumps per cooler. % rating at different cooling 60/80/100. 9. Temp. above 500C In oil 40 0C In Wdg. 55 0C. (Resistance) HV LV Fault level MVA 1000 350 Basic impulse 170 KVP 60 KVP level Wdg. connection Delta Star Insulation Fully Fully Insula Insula ted ted Vector grouping DY 1 Neutral Isolated . Non effectivaly grounded.

10. Winding details

94

11. Tap changer

Tap range +10% to - 10% in steps on HV neutral end. Tap controlFull capacity 0n load tap change suitable for remot/local, Independent elect/manual operation. HV Rated voltage KV 36 Rated 800 current Basic 170 Impulse Level KVP. Total creepage distance Mountings Tank cover LV Neutral

12. Bushing

12 3150 75

12 300 75

66.8 Tank cover

22.3 222.3 Tank cover

13. Terminal details

HV connected to L.V. connected to Neutral connected to

33 KV PILC or XLPcable. Segregated phase duct. PVC Insulated Al cable. 1 (L.V. Netural) Protection 300/1 5P20 15 VA

14. Bushing C.T.s.No. of cores : Service : Ratio : Accuracy : Rated :

95

11. Tap changer

Tap range +10% to - 10% in steps on HV neutral end. Tap controlFull capacity 0n load tap change suitable for remot/local, Independent elect/manual operation. HV Rated voltage KV 36 Rated 800 current Basic 170 Impulse Level KVP. Total creepage distance Mountings Tank cover LV Neutral

12. Bushing

12 3150 75

12 300 75

66.8 Tank cover

22.3 222.3 Tank cover

13. Terminal details

HV connected to L.V. connected to Neutral connected to

33 KV PILC or XLPcable. Segregated phase duct. PVC Insulated Al cable. 1 (L.V. Netural) Protection 300/1 5P20 15 VA

14. Bushing C.T.s.No. of cores : Service : Ratio : Accuracy : Rated :

95

V INTERLOCK & PROTECTIONS

96

V - INTERLOCK & PROTECTIONS

1 BOILER & AUXILIARIES 1.1BOILER a. PURGE PERMISSIVES :1. Elevation AB, CD & EF all ignitor valves closed. 2. Elevation AB, CD & EF warm-up fuel nozzle valves closed. 3. Ignitor & warm-up fuel trip valve closed. 4. Elevation A,B,C,D,E & F pulverisers off. 5. No Boiler trip command from MFR- A&B 6. Elevation AB,CD & EF Discriminating scanner sense no flame. 7. Elevation A,B,C,D,E, & F Feeders off 8. Elevation AB, BC,DE & EF Fireball scanners sense No Flame 9. Elevation AB, CD, EF, AA, BC, DE, FF, Aux.Air Damper Modulating wind box to furnace differential pressure satisfactory (50 mm WC) 10. Both PA Fans off. 11. Elevation A,B,C,D,E & F hot air gates closed. 12. Burner tilt horizontal & Air flow less than 40 % After all above conditions are fulfilled. (Purge ready) will appear.

b. BOILER TRIP (FOR MFR A&B) :

1. Both FD fans off 2. Both ID fans off 3. Simulation trip 4. UTR & Load > HP Bypass A 5. UTR & Load > HP Bypass B 6. Loss of ACS power > 2 seconds 7. Drum level low-low for 15 seconds (-250 MMWCL) 8. Drum level high-high for 15 seconds (+250 MMWCL) 9. Loss of reheat protection with a time delay of 10 seconds. 10. Emergency push button trip 2/2 logic. 11. All BFPs trip. 12. Furnace pressure high-high (+250MM) 1/1 logic 13. Furnace pressure low-low (-150 MM) 1/1 logic 14. Loss of unit critical power for > 2 seconds. 15. Unit Flame failure. 16. Loss of 220 V DC for more than 2 seconds. 17. Loss of all fuel trip. 18. Less than fireball & loss of power at elevation in service. Air flow less than 30% for load > 30% 97

c. LOSS OF ALL FUEL TRIP :

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

d. UNIT FLAME FAILURE :

Flame failure will activate if the elevations AB, BC, DE, & EF are sensing no flame, 2/4 scanners not sensing & any feeder is proven (Feeder on in remote for more than 50 secs.) after 2 seconds unit flame failure will occur. ELEVATION SENSING, NO FLAME WILL VOTE : 1. If feeder is not proven for > 2 sec 2. Elevation 3 out of 4 fire ball scanner sense no flame 3. Elevation 2 out of 4 HFO nozzle valves not proven. (Elevation power available) 4. Elevation supply is not available. or and or

1.2 PULVERISER & FEEDERS a.

1. 2. 3. 4. 5.

PERMISSIVES :

Seal air to bowl diff. pressure of > 8'' wcl. Pulveriser ready. Pulveriser off. Pulveriser Ignition permit. Pulveriser start command from memory.

b. PULVERISER READY WILL APPEAR WHEN FOLLOWING ARE FUL FILLED1. Pulveriser start permit from FSSS. 2. Discharge valve open (All four corners) 3. Outlet temp. < 200 degree F 4. Feeder control switch is in remote 5. Cold air gate open. 6. No auto pulveriser unsuccesful start. 7. Tramp Iron Hopper valve open. 8. No. pulveriser trip. 9. Primary air permit or pulveriser ON

98

PULVERISER TRIP CONDITIONS : Auto pulveriser stop. Stop push button pressed in manual mode MFT Discharge valve not open Loss of primary air (both PA fans off) Mill Running and seal air header/pulveriser under bowl diff. Pressure lessthan 5 Inches with time delay of one minute. 7. Elevation power failure for more than 2 secs. 8. Loss of PA fan trip for elevation F,E,D. 9. Support Ignitor elevation lost (elevation warm-up nozzle valves not proven) and ignition permit reqd. and Ignition permit lost.

c. 1. 2. 3. 4. 5. 6.

d. FEEDER START PERMISSIVES 1. 2. 3. 4. 5. 6. No Master Fuel Trip. Elevation Power Available . pulverizer on. pulverizer ignition permit available. Coal on Belt. Feeder circuit ready includes the following permissives. a. Coal in feeder inlet. b. SCR ready. c. Silo gate open. d. Drag chain ready. 7. No. feeder trio signal/command persists. 8. Feeder speed signal set at minimum. 9. Coal air temperature set at 120 deg. ferhenhit. e. 1. 2. 3. 4. 5. 6. on. FEEDER TRIP LOGIC No. coal on belt. Feeder Discharge chute plugged. Lower down spout empty. MFT operated. Pulverizer not on. Pulverizer ignition permit is lost within three minuts of feeder

1.3
fan)

7. Pulverizer power not available (time delay 2 second). ID FAN a. START PERMISSIVES : 1. Flue gas path clear 2. Motor/fan bearing temp. not high (< 75 deg C. for motor & 3. 4. 5. 6. Lube oil pressure adequte>1.50 Kg/Cm2 Any APH running for 1 st fan IGV minimum position Emergency push button released

7. Inlet and outlet damper closed. 99

b. TRIPS
1. 2. 3. 4. 5. 6. 7. 8. 1.4 1. 2. 3. 4. 5. 6. b. 1. 2. 3. 4. 5. 6. 7. 1.5 1. 2. 3. 4. 5. Motor (DE/NDE) Brg Temp High-High (> 85oC ) Fan Brg (DE/NDE) Temp High-High (> 85 oC) Lub Oil Pr Low-Low<1.25 Ksc Air Pre heater Trip (cross & Parallel) Post purge trip EPB pressed Control switch Running FD trips FD FAN a. PERMISSIVES Motor/fan bearing remp. not high < 75 deg C. Blade pitch min. and discharge damper closed. Control oil pr. adequate > 8 KSC One ID fan is in service Lube oil temp. not high Emergency push button release. TRIP Motor bearing (DE/NDE) temp. High-High [> 85 Deg. C]. Fan bearing [DE/NDE] Temp. High-High [>85 Deg. C] Lube oil pressure low < 0.8 KSC ID fan trip [ cross/parallel ] Post purge trip E.P.B. pressed. Control switch PA FAN a. PERMISSIVES Motor & fan bearing temp. not high <75 deg C. Lube oil pr. adequate > 1.2 Ksc FSSS permit (no MFT & all CAD < 5% open) Discharge damper closed & IGV minimum Any FD fan running.

b. TRIPS
1. Motor bearing [DE/NDE] temp. high-high >85 deg. C. 2. Fan D.E. [ one thrust, two journal] bearing temp high -high > 85 deg. C. 3. Both FD fan trip. 4. Lube oil pressure low-low <0.6 KCS 5. Boiler trip 6. Emergency push button pressed. 7. control switch. 100

1.6 IGNITOR AIR FAN : a. PERMISSIVES 1. Any FD fan on [ both FD fans not off ] b. AUTO START 1. If running fan frips standby will come into sevice [ through ON/OFF status ] 2. If IOTV opens fan will take start. c. TRIPS 1. Both FD fan off. 2. Stop command from UCB or EPB pressed.

1.7 SCANNER AIR FAN :

a. AC SCANNER FAN/DC SCANNER AIR FAN AUTO START 1. Scanner air duct to furnace delta P < 6 '' for AC only. 2. If AC fan is not on. DC will come into service and vice versa. 3. If unit critical power is lost for > 2sec start command will go to both AC/DC fans. b. SUCTION DAMPER : Scanner air fan emergency damper will open if both FD fans are or Unit critical power is lost for > 2 seconds If any FD fan is on it will close.

off

1.8 SEAL AIR FAN :

a. PERMISSIVES : Either PA fan on for more than 2 seconds. [ for seal air fan-A only ] b. AUTO START - [For stand by fan-B only] 1. Either PA fan on for more than 2 seconds and seal air header to cold air duct delta p < 4 '' wcl fan-B, will start after 10 seconds. c. TRIP : 1. Seal air fan will Trip after 15 seconds of Tripping of Both PA fans. 2. from UCB stop command. 3. EPB pressed .

1.9 AIR PREHEATER :

start

If electric drive trips, air motor will take

101

2. TURBINE & AUXILIARIES 2.1 TURBINE a. PROTECTIONS 1. Turbine UCB manual trip. 2. Stator water conductivity high-high > 21 micromho/cm. LVM 2/2 3. Stator water flow low-low < 13 M3/ hour for > 60sec LVM 2/2 4. Boiler to turbine through UTR 5. Generator to Turbine through UTR. 6. Either ESV or IV closed & generator on line, through UTR 7. condenser vaccum lo-lo (220 MM / Hg Elect.) - 0.7 ksc, hyd vaccum trip - 0.3 ksc 8. Boilor fire- off. 9. Lube oil pressure low 2/3 logic < 1.2 KG/ Cm2 10. Fire protection ch. 1 MOT level <- 100MM 2 out of 3 sonar probe enable with MOT level > 50 mm 11. M.S. Temperature low-low < 480 Deg. Celsius (arming at) 510 Deg. celsius.) 12. Fire protection ch-2 MOT level <-100 mm 2 out of 3 sonar probeenabling with MOT level> - 50 mm 13. UTR manual trip 14. Fire protection push button - 1/2 15. Remote trip test relay (ATT) 16. ATRS shutdown programme b. MECHANICAL PROTECTION DEVICE : a. Axial shift high 1 out of 1 (Thrust bearing trip device) b. Condenser vaccum lo-lo (Hyd. low vaccum device) 1 out of 1 c. TG over speed trip device - 1 3300 RPM 1 out of 1 d. TG over speed trip device- 2 3330 RPM 1 out of 1 e. Main trip valve handle - 1 --------------- local/ governing rack f. Main trip valve handle- 2 ---------------- local/governing rack 2.2 B F P a. START PERMISSIVES :1. Deareator level not low 2. Lube oil pressure adequate > 1.5 ksc 3. Motor bearing temp. not high (<75 deg. C.) 4. Suction valve full open 5. Suction pressure of booster pump adequate > 2.0 KSC 6. Cooling water pressure adequate > 2.0 KSC 7. Emergency push button released 8. Discharge valve closed or header pressure > 90 Kg/cm2

102

b. TRIPS
1. Motor [DE/NDE] bearing temp. high > 85 deg. C 2. Main pump bearing temp. high > 85 deg. C 3. Lube oil pressure low <0.8 KSC. 4. Working oil temp high-high > 130 0 C. 5. BFP running & main pump suction pressure low < 8 KSC 6. Main pump casing diff. temp. high > 30 deg. C. 7. Pump flow high > 430 T/HR. 8. Deaerator level low-low 9. Motor vibration high-high. (not in service) 10. feed water differential temp. high > 13o C. (not in service) 11. Emergency push button.

2.3 CEP

a.

PERMISSIVES :

1. Suction valve full open 2. Hotwell level adequate 3. CEP released

b. TRIPS
1. Hot well level low-low 2. Suction valve not open 3. CEP running & descharge pressure low < 14.5 Ksc (at present not in service)

2.4 INTERLOCKS FOR HP - BYPASS SYSTEM

1. HP. bypass BP-1 or BP-2 opening less than 2% automaticaly closes bd valve. 2. If openings of either of the bypass valves BP-1 or BP-2 are above 2% the control of spray water valves- BD, BPE-1 & BPE2 shall be canged to ' auto' mode not withstanding their initial conditions. 3. If BP valve position drops to 2% open it will receive a close command to ensure positive shut off. 4. If the steam temperature downstream of the BP valve becomes > 380o C the closing signal for these valves are initiated, accom panied with an alarm, in this case, the BP controller will transfer itself from auto to manual.

2.5 INTERLOCKS OF AUXILIARY PRDS

01. When press cont. low range in service, the valve position 0-100 % corresponds to 0-27. Kg/cm2 of spray water pressure.

103

2. Steam pressure controller position 0 to 40% corresponds to 0 100% of pressure controller low range. 3. When pressure controller low range opens by 5% the BD2 and temperature controller are automatically switched over to auto. 4. When pressure controller. high range is in service the valve posi tion 0-100% corresponds to 27 to 40 kg/cm2 of spray water pressure. 5. Steam pressure controller position 40 to 100% corresponds to 0-100% of pressure controller high range valve. to there is no set point for spray water pressure. It is automatically set. (as per 01 & 04 the set point is fixed for low range valve / high range valve open condition.)

3 GENERATOR & AUXILIARIES

3.1 TECHNICAL DATA a. Generator Rated MW Capacity Rated MVA Capacity Rated Terminal Voltage Full Load Current Connection Synchronous reactance xd' unsat.) (sat.) Transient reactance xd "(unsat.)

: : : : : :

200 MW 247 MVA 15.75 KV 9054 A Double Star 205 % ; 2.06 /900 pri 28.77 /900 sec 22.5% 23.4%;0.235 /900 prim; 3.28 /900 sec 26.6 % : 17.9% 21.4 % 25.2 % 21.7 % 10.5 % 8.4 % 1.004 /900 prime 14.04 /900 sec 0.49 0.85

: : : : (sat.) : Sub Transient reactance xd (unsat.) (sat.) : Neg. Seq. reactance (Unsat.) : (sat.) : Zero Seq. reactance (Unsat.) : (sat.) : Gen. prim load impedance : : Short Circuit Ratio : Rated Power Factor : NGT Details

104

Make

: B.H.E.L. : 15.75 /240V, 50 KVA : Secondary mid pt. eathed : Secondary earthing resist. 0.42 , 330A 240V

b. Generator Transformer Rated MVA Capacity Voltage Ratio Vector Group Cooling % Impedance Grounding

: : : : : :

240 MVA 420 / 15.75 KV Yd5 OFAF 12.868 Solid

c. Unit Aux. Transformer

Rated MVA Capacity Voltage Rario Vector Group Cooling % Impedance Taps HV Grounding Resistance : 12.712 : 12 / 16 MVA : 15.75 / 6.9 KV : Dy 7 : OFAF : 7% at 16 MVA : OLTC; + 5% to-10% 0n

105

1. 2. 3.

4. 5. 6. 7.

8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

3.2 PROTECTIONS Generator differential 87G Generator & generator (transformer or overall differential) differential 87 GT Generator loss of excitation 40G Generator loss of excitation 2A/ 40G timer 2 sec Generator loss of excitation 2B/40G Timer Generator loss of excitation 40/27G under voltage relay Generator loss of excitation 40GZ tripping relay Generator loss of excitation 40GY auxiliary to 2B/40G GT over fluxing 99 GT Low forward power 32 G1 Low forward power 2.32 G1 timer 2 Sec Reverse power 32 G2 Reverse power 2B/32 G2 50 Sec Back up impedance 21G R,Y,B Back up Impedance 2A/21G timer 1.2 sec Back up Impedance 2B/21G timer 1.5 sec Stator earth fault St 1 64 G1 NGR Stator earth fault St 2 64 G2 Open Delta Inter turn fault 50 GI Rotor earth fault IWX - 161 (excitation system) Stg-I+Stg-II GT restricted E/F 64 GT GT standby E/F 51 NGT,IDMT Generator over voltage 59 G Generator over voltage 2/59 G timer O/H line differential 87 L Negative phase seq. 46G Generator overload 51 O/L alarm Local breaker backup 50Z timer swyd .2 sec Local breaker backup 2/50Z timer swyd 0.2 sec Pole slipping 95 G Pole slipping 98 G UAT differential 87 UTA UAT differential 87 UTB UAT backup 0/C 51 UTA UAT backup 0/C 51 UTB 106

a. GENERATOR PROTECTION 86G OPERATES UNDER THE FOLOWING CONDITIONS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. GT fire protection (disconnected) GT pressure release valve. GT BucholTZ Busbar protection zone ''C'' LBB protection. Exitation system fault (Class - A) Generator differential protection. Generator overhead line differential protection UTA diferential protection UTB differential protection Generator over voltage Generator inter-turn fault Generator earth fault main one GT restricted earth fault Generator pole slipping protection Low forward power protection this operates UTR-A / UTR- B 30 A 30 B 30C 30D 30E 30Z 87G 87L 87 UT 87UTB 59GC 50 GI 64 GI 64GT 98G 2/32G1

OPERATION OF 86G TRIP RELAY LEADS TO THE FOLLOWING :1. 2. 3. 4. 5. 6. 7. 8. 9. Trip unit bus 'A' 6.6 KV (intiate fast change over from UAT to station) Trip unit bus 'B' 6.6 KV (Intiate fast change over from UAT to station) Trip generator breaker / transfer coupler breaker Trip field breaker Trip UTR - A Trip UTR - B Trip 286G Trip 386 G / GX Trip 486 G 107

b. GENERATOR PROTECTION 286G OPERATERS UNDER THE FOLOWING CONDITINS 1. Generator transformer block overall differential protection 87GT 2. Generator stator standby earth fault protection 64G2 3. UAT A BuchholTz trip 30K 4. UAT B BucholTz trip 30 N 5. UAT A fire protection 30L 6. UAT B fire protection 30P 7. Generator negative sequence protection 46GT 8. L.B.B. protection 2/50/Z 9. From relay 86G 86G 10. UAT A Backup overcurrent protection 51 UTA 11. UAT B backup overcurrent protection 51UTB 12. GT over fluxing timer 99 GTT 13. Generator backup impedence protection through 2B/21G 2B/21G 14. generator reverse power protection 2/32G2 15. Low forward power protection 32G1 16. Field failure with machine under voltage 40GZ+40/27G OPERATION OF 286G TRIP RELAY LEADS TO FOLLOWING 1. Trip generator breaker / transfer bus coupler breaker 2. Trip field breaker 3. UTR A trip 4. UTR B trip 5. Trip unit bus 'A' 6.6 KV 6. Trip Unit bus 'B' 6.6 KV 7. Trip 386G 8. Trip 286G c. GENERATOR PROTECTION 386G OPERATES FOLOWING CONDITIONS 1. Generator backup impedence protection through 2A/21G 2. Trip relay 86G 3. Trip relay 286G 4. Generator transformer backup earth fault protection OPERATION FOLLOWING OF 386G TRIP RELAY UNDER THE 30RY,RB,BR 86G 286G 51NGT TO THE THE

LEADS

1. Generator Breaker Trip / Transfer bus coupler breaker trip 108

UTR-A OPERATES UNDER THE FOLLOWINGS 1. Trip relay 86G 86G 2. Trip relay 286G 286 G 3. Faulty excitation system 30F Regulation cubicle supply failure Thyrister fan supply fail Excitation transformer over temp stage 2 Supply to auto channel fail Rotor earth fault stage-II (2.2 K OHM) 4. G.T. winding temperature 2 nd stage 30G 5. 6.6 KV bus under voltage 30.H 6. VAT-A winding temperature 3rd stage 30R 7. VAT-B winding temperature 3rd stage 30V 8. Generator loss of excitation 9. Stator water flow low low (>60 sec) 10. Stator water conductivity hi-hi (21micro S/cm) 11. Boiler fire off. 12. Turbine trip. 13. All boiler feed pumps tripped. UTR-B OPERATES UNDER THE FOLLOWINGS 1. UAT- A winding temeprature 3rd stage 30U 2. UAT- B oil temeprature 3rd stage 30V 3. G.T. oil temperature 3rd stage 30J 4. Trip relay 86 G. 5. Trip relay 286G. 6. Generator loss of excitation. 40 GZ 7. Faulty excitation system. 30F as above 8. 6.6 KV bus, A/B under voltage. 30H 9. Stator water flow low-low (>60 sec). 10. Stator water conductivity Hi-Hi (21 micro s/cm.) 11. Boiler fire off. 12. Turbine trip. 13. All boiler feed pums tripped. 3.3 GENERATOR TRANSFORMER a. TRIP 1. Buchzhol tz trip 2. Pressure release device at a pressure of 0.35 kg/cm2. 3. winding temperature high Alarm at 90 deg.C Trip at 100 deg. C 4. Oil temperature high Alarm at 80 deg. C Trip at 90 Deg. C

109

b. GENERATOR TRANSFORMER COOLING FANS & PUMPS FAN AUTO START ( 4 FANS IN EACH GROUP) 1. 3 Fan groups. two are normally kept on auto one is kept as stand by. fan group selected on auto takes start at 65 deg. C winding temperature & stops at 55.deg.C. PUMP AUTO STARTING Out of three pumps two are normally selected for auto operation and third is kept as standby pump selected for auto operation takes start with closing of field breaker and stops only when winding tem perature is below 50 deg. C & field breaker is off. Pump - 1 Takes start instantaneously with closing of field breaker. Pump-2 Takes start after time delay of 30 seconds after field breaker is on. Pump- 3 Start after time delay of one minute after field breaker is on. 3.4 UATS 1. Bucholotz relay 2. On load tap changer bucholotz 3. Winding temperature high 4. Oil temperature high a. TRIP Alarm at 90 deg.C Trip at 100 deg. C Alarm at 80 deg.C Trip at 90 deg. C

b. FAN AUTO STARTING TWO GROUPS OF FANS Each group consists of three main fans and one reserve fan.Both the fan groups take start at 65 deg. winding temperature and stop at 55 deg.C winding temperature. If one of the main fan in any of the group trips due to any reason reserve fan of corresponding group takes start automatically.

110

3.5 GENERATOR RELAY SETTINGSl.

type settings No. 1. Gen Differential 87 G 18.5 2. Gen & Gen. Trafo (fixed) Overall Diff. 30 % 87 GT = 1000 % CTR / CT Core Remarks CAG 34 10,000 / 5A

Relay Desgn

Relay

PTR, PT Core Relay

0.5 A Rstab = 0.75 Blas A =

DTH 32

15.75 KV side 10.000 / 5 A 400 KV side

High Set

1000 / 1 A ICT 0.323/2.488 A 3. Gen. Loss of Excitation YCGF 11 10,000/5 A 15.75 KV/110 V Dia = 14.38 Dia = 1/2 Syn. react 40 G K1 = 0.77;
K5 = 18.6 Offset = K2 = K3 + K4 Offset = 3/4 trans rear

= 2.46 K3=o.5; K4=2.0 Primary values K2= 2.5; Dia = 1.03 Offset = 0.176 VTT 11 VTT 11 VTIG 12

2A/ 40 G sec. 2B / 40G sec. 40 / 27G = 80 Vac = 72.72%

ttrip = 2.0 ttreset = 10 P/u volts

111

40 GZ VAA 51 40 GY VAA 11 200 ms (fixed) delay 4. GT Over fluxing GTT 11 V/f = 1.2; trip = 12 sec 99 GT 0.5-1.0 sec (fixed) 5. Low forward Power WCD 13 10,000 / 5A p.u. < 0.5 % = 1.0 MW at UPF (Fixed) 32 G1 2/ 32G1 VTT 11 6. Reverse Power WCD 11 10,000/5 A p.u.<0.5%= 1.0 MW at UPF (Fixed) 32 G2 2A/32G1 VTT 11 5.0 sec 2B/ 32G2 VTT 11 50 sec. 7. Back up impedanceYCG 15 10,000/5 A K1 = 12;K2 = 0.71 Secondary = 9.0 21 G = 8.52 Primary = 0.644 Relay setting

180 15.75 kv/110 Alarm 15.75 KV/110

15.75

2.0 sec KV/110 V

AlarmTrip 15.75 KV/110 = V

K1 * K2

= 70 % Load impedar 2A/21G VTT 11 St1 : 1.5 sec 2B 21G VTT 11 St II : 2.0 sec 8. Stator Earth Fault VDG 14 NGT Ratio : PS : 1.5V 5.4V on open covers ST-I 64 G1 15.75 KV/240 V TMS : 0.2 about 96% of stator wdg

112

ST - II 64 G2 V 0.2 9. Inter Turn Fault (0.75 A) 50 GI 10. Field voltage 2.2K, 2.0 secs 11. 1000/1A 64 GT 12. 1000/1A 13. 15.75 KV/110 V 59 G 2/59 G secs. 14. A 15. 10,000/5A 46 G 1.0 : Alarm = 70 % 16. 10,000/5 A 17. A 50 Z

VDG 14

15.75KV/110VPS : 5.4 openTMS 15 : %

CAG 14 3000/5A Stab. resist not used Rotor Earth Fault St-I:5.5K, 1.5 secs IWX, B.B.C. = 300 V at rated output GT Restricted E/F CAG 0.1 A ; Rstab = 30 GT Standby E/F 51 NGT CDG PS : 0.1 A ; TMS : 0.2 Gen. Over voltage 110 % (121 V) VTT 11 O/H Line Diff. 87 L CAG 34 PS : 0.5 : Rstab = 30 Neg. Phase Seq. CTNM II25=5% ; K1 = 6.7 VTIG 12

St-II

14

11

3.0 1000/1 31 K3 = 12 1000/1

Gen. Overload 51 O/L CTU 5 A ; 15 secs Alarm only Local BKr. Backup CTIG 39 0.1 A

113

2 / 50 Z VTT 11 sces 18. Pole Slipping 10,000/5 A 15. 75 KV/110 V 98 G Reverse offset = 2.27 0.93 K2 = 0.61

0.2 ZTO 1set = 5 x 1.1 A 11

k1 t 52.5 ms 99 GY YTGM 14 K3 = 4 H1 =H 2 = 750 Forward reach = 2.0 Reverse reach = 2.9 K1 1.1 K2 = 0.91 K3 2.0 K4 = 1 K5
0

= = V

10,000/5 A

15,

75

KV/110

= = =

1.5 = 75 19. Gen. Under Freq. FIG 11 15 / 5KV/110 V 48.0 HZ Alarm only Presently 81 G p.u. / d.o. diff ; 0.2 removed 20. UAT Differetial DTH 31 (LT) : 1600/ 1 A op. curr : 0.15 A (fixed) 87 UTA ICT : 1.0/0.54 A Bias ; 30 % 87 UTB (HT) : 750/1 A High set : 1000 % 21. UAT Backup O/C CDG 31 750/ 1 A PS : 1.0 ; TMS : 0.3 UAT HV side Full Lc.

Current is 78% of CT primary rating. 114

VI GRAPHS, CURVES & TABLES

115

1. EQUIPEMENT - WISE OIL RESERV0IR CAPACITY Name of the Equipement Oil Brand Tank/ Reservair Capacity. 1. Coal Mill SMSP 320 1200 2. Coal Mill -Roller sembly SMSP 680 90 (3 Rollers) 3. Coal Feeder- Gear Box SMSP 320 03 4. Mill Reject conveyor ( MR) G/ Box SM SP 320 05 5. Mill Reject conveyor2 (MR2) G/Box SMCP 320 05 6. P.A. Fan S. Prime 68 80 7. F.D. Fan S. Prime 68 400 8. I.D. Fan S. Prime 68 300 9. APH Guide Brg. S. Cyl-C-800 30 10. APH Support Brg. S-cyl-C-800 100 11. APH M/D G/Box SS 220 50 12. Soot Blowers SMSP 320 01 13 HP Dosing Pump G/Box SMSP 320 10 14. Clinker Grinder B/Box SMSP 320 05 15. Clinker Grinder Fluid copling S. Prime 46 05 16. Scrapper Conveyor G/Box SMSP 320 60 17. Scrapper Conveyor Fluid copling S. Prime 46 05 18. HP Ash water pump S.S. 68 05 19. LP Ash water pump SS 68 05 20. Ash slurry pump SS 68 40 21. Service water pump SS 68 10 22. Boiler feed pump (BFP) S. Torque-101200 23. Condensor extiaction p/p (CEP) S. film- 16 15 24. Plant air Compressor (PAC) Lubrication SS150 05 25. Plant Air Compressor (PAC) Cromkare SS150 44 26. Instrument An Compressor (IAC) SS 150 44 27. ARCW Pump SS 68 02 28. Stator Water Pump SS 68 01 29. GDT vaccume pump S. Prime 46 01 30. LP Dossing pump G/Box SMSP 320 05 31. LP Dozing Pump Hydraulic Chamber S. Spin 05 32. MOT S. Prime 46 25,000 33. CT Fan G/Box SS 220 35 34. CT Pumps Thrust Brg. S Pride 20 50 35. CT Pump Motors Brg. (Top/Bottom) S Prime 46 120/60 36. CW Pump Thrust Brg. S. Prime 30 50 37. CW Pump Motors Brg. (Top/Bottom) S. Prime 46 120/60

116

2. EQUIPEMENT - WISE OIL RESERV0IR CAPACITY ST - 1 (WTP)S. No. Brand of Oil Name of Equipments Quantity (Ltr.) 1. S. S. 68 Compressor of sprinkler Dewatering pump near foa Alum Metering pump Effluent Disposal P/P Acid Metering pump Degasser water pump Compressor for Mulsifier Clarified water pump Drinking Water pump Fire water pump DM water make up pump Boiler Fill pump Lime transfer pump DM water regeneration pum Alkali Transfer Pump Alkali Metering Pump Acid Metering P/P (Ind.) Gravity filter air blowe Diesel fire water pump Mixed bed blower G/Box of lime prep. tank G/ B of alum soln. tank G/B of hoist of cl2 ton. 2 Ltr. 2 Ltr. 25Ltr. 2 Ltr. 25 Ltr. 2 lTR. 2 Ltr. 5 Ltr. 2 ltr. 3 ltr. 2 Ltr. 2 Ltr. 1 Ltr. 1 Ltr. 1 Ltr. 3 Ltr. 5 Ltr. 5 Ltr. 5 Ltr. 5 Ltr. 5 Ltr. 5 Ltr. 5 Ltr.

2.

S. S. - 68

3.

S.M.S.P. - 320

4. 5. 6. 7. 8.

S. P. - 46 S. Cyl. C-800 SAE - 10 S. S. - 150 Grease Servogem -3 G/Box of Agitatior of Clf G/ Box of Bridge Drive Mulsifier Jockey Pump Sump Pump Raw water pump Horticultire Pump Filter water pump Filter Drinking water Chlorine booster pump Degassar water pump 117 5 Ltr. 5 Ltr. 2 Ltr.

TURBINE STARTUP CURVES

118

119

120

121

122

123

4. Steam Turbine

Limit Curves

124

Steam Turbine Curves

Limit

125

Steam Turbine Curves

Limit

126

Steam Turbine Curves

Limit

127

128

129

6. a GENERATOR UNLOADING SCHEDULE DUE . TO HIGH STATOR WATER TAMPERATURE 130

6. b GENERATOR UNLOADING SCHEDULE DUE TO HIGH TAMPERATURE OF COLD GAS OR INLET WATER TO GAS COOLER 131

TABLE - I Properties of dry saturated steam

132

TABLE - I Properties of dry saturated steam

133

TABLE - II Total heat or enthalpy of superheated steam

Kcal/kg

134

TABLE - II Total heat or enthalpy of superheated steam

Kcal/kg

135

TABLE - II Total heat or enthalpy of superheated steam

Kcal/kg

136

TABLE - II Total heat or enthalpy of superheated steam

Kcal/kg

137

TABLE - III Specific volume of superheated steam

cu metre/kg

138

TABLE - III Specific volume of superheated steam

cu metre/kg

139

TABLE - III Specific volume of superheated steam

cu metre/kg

140

TABLE - III Specific volume of superheated steam

cu metre/kg

141