Technical Diary

ORISSA POWER GENERATION CORPORATION

Technical Diary 2210 MW

IB THERMAL POWER STATION

BANHARPALI, JHARSUGUDA ORISSA, INDIA

TECHNICAL DIARY

ORISSA POWER GENERATION CORPORATION LIMITED.

IB THERMAL POWER STATION (2210 MW)

BANHARPALI, JHARSUGUDA. 768234

First Publication 2003

All rights reserved. No part of this publication may be reproduced, stored in a retrievalsystem, copied or transmitted in any form by any other means, electronic, mechanical,photocopying or otherwise without the prior permission of the copyright owner.

For private circulation only.

FOREWORD

"OPGCs vision is to become a leading profitable power utility by ensuring safe, environmentally responsible, commercially prudent, reliable and efficient power generation. To achieve this vision, it is essential to excel in the Operation and Maintenance of IB Thermal Power station. Our O&M team has brought out a Technical Diary compiling the technical details of the plant like design data, interlocks and protections, permissives covering all functions of the plant. It has been seen that a handy technical diary can serve as a valuable reference for use of plant personnel. I appreciate the efforts of the O&M team, in particular Shri P.K.Dora, for bringing out this edition of the Technical Diary in the shortest possible time. "

Sankaran Subramaniam DIRECTOR (OPERATION)

MESSAGE

"I'm happy and proud once more that OPGC is ready with a technical document, which is going to serve the long felt need of people to have a handy technical reference on the Ib Thermal Power Station.

My sincere thanks to Mr.P.K Dora and his team for the hard work they have put in to make this possible.

Anil K. Gupta,

Advisor, AES

MESSAGE

It is my pleasure to know that a technical diary of ITPS being brought out by the in house effort of our own staffs. This technical diary contains plant data, equipment design specifications, interlocks and protections. I hope this will be of great help as a reference hand book to all the employees.

A.Gochait,

DGM (PSM)

INTRODUCTION

1. Name & Location Orissa Power Generation Corporation. Ib Thermal Power Station.

Banharpali, Dist-Jharsuguda (Orissa), India.

Latitude-210 42 North Longitude- 830 52 East.

2. Station Capacity 420 MW(2x210 MW Units)

3. Climatic condition Max. Temp- 490C Min Temp- 70C Max relative humidity-95 %

4. Land utilization Main Plant 797.51 Acres Ash Pond (A+B) 493.16 Acres Ash Pipe Complex 13.01 Acres Merry Go Round System 85.96 Acres Town ship, Roads & Market 476.12 Acres

5. Fuel 100% Coal, oil support for initial starting & stabilization. i) Transportation from Lakhanpur mines 15 km distance by merry go round system in bottom discharge wagons. Loading point is approx.10 km from plant ii) Consumption8016 MT/day for design coal.

6. Start up Power Through 2x55 MVA, 220/6.9 K.V.3- station transformer.

7. Cooling Water System Closed Loop with forced draft cooling tower.

8. HP/LP By pass Capacity 60% of MCR. 9. Heat Rate 2500 Kcal/ Kwh.

10.Ash disposal Disposed to ash pond in form of ash slurry with 100% ash water recycling system.

11.Chimney RCC multi flue, 220 m. High.

SECTION 1

BOILER & AUXILIARIES

1.1 GENERAL SPECIFICATION

i) Manufacture BHEL (C.E. design). ii)Type Single reheat, natural circulation type, single drum, balanced draft, dry bottom type designed for firing coal as main fuel. iii) Boiler designation 13868 181 63.5 1778 NCRR, 10592 130 63.5 Design code: ISO-R 831

iv) Type of firing Tilting tangential. v) Design pressure, Ksc Drum 177 SH O/L 164 vi) Water volume, m3 Generating surface 125.00 Drum 40.00 Economiser 20.00 Super heater 95.00 Reheater 50.00_ Total water volume 330.00

vii)Heating surface, m2 Economiser 8087.00 Super heater 7416.00 Reheater 2656.00 Water wall 3493.00 Total heating surface 21652.00

viii) Minimum load at which steam generator can be

operated continuously with complete flame stability without oil support. 2 Mills at 50% capacity.

1.2 FURNACE SPECIFICATION

i) Type Fusion welded wall. ii) Dimension 10,592 x 13,868 x 43,130 mm (DWH) iii)Total volume 5240m3 iv) Combustion chamber volume 4100m3

iv)Bottom Dry v)Draft Balanced vi)Effective projected radiant surface 2100m3 vii)Design pressure 400mm wc @67% yield strength viii)Heat liberated by fuel 1,01,300 (Kcal/hr/m2) at 100% Per unit furnace vol. 65,550 (Kcal/hr/m2) at 60% ix)Fuel heat input 534.0 x 10 6 Kcal/hr.

1.3 WATER WALLS

Front wall Sidewall Rear wall Furnace roof 2nd pass i)No.of Tubes 181 130 181 120 120 ii)Dia(mm) 63.5 63.5 63.5 51.0 44.5 iii)Material --- -----------SA210 Gr.C--------------SA209T1 SA210Gr.A1 iv)Thickness -------------------5.5 mm-------------- 4.5 mm 4.5 m v)Design pr.(Ksc) --------- --------- 179.8 ---------------- 176.8 174.8

vi)Down comers. a)Nos 6 b)Dia(mm) 406.4 c)Pressure 179.5 Ksc. d)Material SA 105 Gr.C

vii)Water wall headers Bottom Ring header Water wall header a)Nos. 04 07 b)Dia (mm) 273.0 219.1 c)Material SA 106 Gr.C SA 106 Gr.C d)Design pr.(Ksc) 175.4 177.0

1.4 DRUM i) Material SA-299 ii) Design Pressure, Ksc 177.00 iii) Drum operating pr. Ksc 166.00 iv) Design temp 3540C v) Overall length, mm 15,000 vi) Shell length from weld to weld, mm 10,620 vii) I.D/O.D, mm 1778/2079 viii) Thickness, in mm (straight portion/dished portion) 170/135 ix) No of distribution headers 6 x) No of cyclone separator/ secondary drier 58/58 xi) Permissible temp difference between Top& Bottom 500C

xii) Drum level indicator Location Type No & make a) MCR Conductivity 2,BHEL b) Drum DWLG 2,Yarway c) Firemans floor Conductivity 2,BHEL

1.5 SUPER HEATER

LTSH PSH FSH

i) Type convection Radiant Radiant ii) Direction of flow counter parallel parallel iii) Heating surface (m2) 3035 1097 1543 iv) No of Tubes 480 232 357 v) O.D.(mm) 44.5 47.63 44.5 vi) No of elements/assembly 4 8 3 vii)Tube pitch, mm 114/96 457.2/57 114.3/96 (across gas path/along gas path) viii) Material SA210 Gr C SA213 TP347H SA213T22 SA 213T11 SA 213T22 SA 213T22

SH HEADER i) Max operative pressure, Ksc 155.00 ii)O.D, mm 406.4 iii)Thickness, mm 44.5 iv) Max SH steam temp. 540 + 50C

1.6 REHEATER

i)Type a)Front RH-Pendent b)Rear RH spaced. ii)Design pressure, Ksc 44.45. iii)Max operating pressure, Ksc 38.5 iv)Total heating surface, m2 2656 v)Control Burner tilt. vi) Gross length per tube 10,000 mm (approx.) vii) Total No of tube 59 assemblies viii) O.D, mm 54.00 ix) Tube thickness, mm 3.6 x) Tube material SA 213 T22,T11, T91, SA209 T1

xi) Tube pitch, mm a) across gas path-228.60 b) along gas path- 100.00

xii) Reheater Header a) Material SA-213 P22 b) O.D, mm Inlet-406.4, outlet-558.8 c) Thickness, mm Inlet-46.0, outlet-45.0

1.7 SUPER HEATER & REHEATER TEMP. CONTROL 1.7.1 SH ATTEMPERATOR

i)Type Spray mixing type. ii)Location Between LTSH & Platen SH. iii)No of stages One iv)Material SA 335 P 12 v)SH temp range that can be maintained between 60% to 100% of boiler MCR 5400C+5 vi) Spray water flow, T/hr max-34, normal-17, min-1.7 vii)Spray water source BFP discharge.

1.7.2 RH PRIMARY TEMP. CONTROL (BURNER TILT CONTROL)

i)Max. angle of tilt + 300 ii)Tilt mechanism Power cylinder. iii)RH temp range that can be maintained between 60% to 100% boiler MCR 5400C +5

1.7.3 RH EMERGENCY TEMP.CONTROL

i)Type Spray mixing type. ii)No. of stages One iii)Location Cold RH Line. iv)Material SA 106 Gr. B v)Spray water source BFP discharge.

1.8 ECONOMISER

i)Type Plain tube, seamless, continuous loop in line ii)No. of blocks 2 iii)Material SA 210 Gr. A iv) OD/thickness(mm) 44.5 / 4.5 v) Tube pitch (mm) a) across gas path-96

b) along gas path-130 vi ) Heating surface 8070 m2

vii) Gas velocity at 2nd pass of boiler at100% MCR 8.0 m/sec viii) Design pressure 181.9 Ksc. x) Economiser Header I/L Header O/L Header a)Material SA-106 Gr. C SA- 106 Gr. C b)Outer diameter, mm 323.9 323.9 c)Max. operating pr. Ksc 171.5 171.5

1.9 REGENERATIVE AIR PREHEATER

i) Type Bisector, Regenerative ii) Size 27 VIM 2000 (Bisector) iii) No. per boiler Two iv) Arrangement Vertical v) Element Height 2000 mm vi )Heating elements. a) Hot end/hot intermediate Element type DU (24 gauge) Height 850 mm Material carbon steel

b)Cold end /cold intermediate Element type DU (22 gauge) Height 300 mm Material corten A vii)Rotor Seals. a)Radial seals hot end 2.5 mm thick corten A Radial seals cold end 2.5 mm thick corten A b)Axial seals 2.5 mm thick corten A c)By pass seals 1.6 mm thick corten A d)Rotor post seal hot end 6 mm BM-C20 Rotor post seal cold end 6 mm BM-C20

viii)Bearings a)Support bearings Spherical roller thrust SKF/FAG- 294/500 b)Guide bearings Spherical roller SKF/FAG-23060 CCK/W 33 ix)Oil capacity. a)Support bearing 150 litres. b)Guide bearings 25 litres.

x)Oil circulation system Guide bearing a)Pump Hypo screw pump

No. per boiler 4 Model No. HSTR 3 Type 976 Size 1 x 1 Capacity 15 LMP b)Drive motor 0.55 Kw, 3, 50 HZ, 415V, 910 rpm, Insulation class F Support Bearing. a)Pump Hypo screw pump No. per boiler 4 Model No. HSTF 3 Type 976 Size 1 x 1 Capacity 15 LMP b)Drive motor TEFC rating 0.55 Kw, 3-,50 HZ, 415V, 910 rpm, insulation class F Heat exchanger Horizontal & shell & tubular type, capacity 7500 KL/hr. xi)Cleaning device Power driven soot blowing

a)Motor detail 0.18 kw,3,50 HZ,415 V,1380 rpm, insulation class F b)Reducer Allroyd gear, reduction ratio 4000:1 c)Steam consumption 2000 Kg/hr/service, at 18 Ksc,150oC x)Rotor stoppage Alarm Go switch APCO Input power 105-135 V, 50HZ Alarm power 120 or 230 V AC 10 Amps 10-150 V DC 2 Amps

1.10 ID FAN

i)Manufacturer BHEL ii)No.per boiler. 02 iii)Type NDZV 31 SIDOR, Orientation Top horizontal Delivery Radial, double suction,

central discharge. iv) Medium handled Flue gas v) Fan drive & type Hydraulic coupling SVNL 1150, Voith

vi)Fan regulation Hydraulic coupling vii)Fan design rating Capacity 224.15 m3/sec. Total head developed 445 mmwc viii)Temp. & specific wt. of medium 1500C & 0.7918 Kg/m3 ix)Fan reserve over MCR

Flow 26.3% Pressure 32.0% x) Fan Diameter of impeller 3255 mm No. of blades 11 Weight 51,000 kg. Moment of inertia referred to fan shaft. 48,870 kg/m2

xi)Bearings Sleeve bearing. Fixed bearing Thrust collar 2 nos. 8x c Expansion bearing 8 x c

x)Drive motor Make BHEL, Hardwar. Type Squirrel cage induction motor Rating 1500 KW, 6600V, 3-, 50 HZ, 750 rpm Duty type Continuous duty, 167.4A Efficiency at 100% load 95.6 % Weight of motor 11,600 kg.

1.11 FD FAN

i) Manufacturer BHEL, Ranipet ii) No. per boiler 02 iii) Type AP 1-20/11, axial reaction. iv) Medium handled Ambient air v) Location Ground level vi) Orientation Horizontal delivery vii) Type of fan regulation Blade pitch type viii)Fan Design Rating Capacity, m3/sec 150 Total head developed, mmwc 465 Temp. of medium 550C Specific wt. Of medium 1.0535 kg/m3 Speed 1480 rpm ix)Fan Reserve. Flow 30.7% Pressure 56.0% x)Fan Impeller diameter 1990 mm No. of blades 23 Aerofoil type Material of blade Al Mg Si lF 2

Hub diameter 1100 mm Wt. Of fan 8500 kg.

Fan drive coupling Regiflex type xi)Bearings

Fixed Bearings NU 230C3, 7230 BVA Expansion bearing NU 230 C3

xii)Drive motor. Make BHEL, Hardwar. Frame size LC 00710 H 04 AIH Type Squirrel cage induction motor Rating 920 KW, 6.6K V, 50 HZ, 1500 rpm, Continuous duty, 100.2A Weight of motor 7730 kg. xiii)Lubrication

Fan Forced oil lubrication Motor Grease lubrication

xiv)Lube Oil System No. of oil pumps Two Make Hypo gear pump Capacity 70 rpm Discharge pressure 12 bar Max. operating pressure 16 Ksc.

Alternative pump make IMO screw pump Lube oil pump motor 3.7 Kw,415 V,50HZ,1450 rpm, class of insulation B

No. of coolers Two Oil tank capacity 450 litres Oil heater Oil immersion type, 4 KW, 415V, 3-, 50HZ.

1.12 P.A. FAN

i) Manufacturer BHEL ii)No. per boiler 03 iii)Type NDZV 20 HERAKLES. iv)Medium handled Hot Air. v)Orientation Bottom delivery with 450 inclined suction chamber. vi)Location Ground mounted on concrete floor vii) Type Of Regulation Inlet damper control viii)Fan Design Rating Capacity, m3/sec 71.50 Total head developed, mmwc 808 Temp. of medium 3120C Specific wt. of medium 0.5817 Ksc. Speed 1480 rpm

ix)Fan Reserve Flow 24.3% Pressure 30.7% x)Fan Driving Coupling BHEL make pin type flexible xi)Fan Impeller dia 2113 mm Wt. Of fan(without motor & coupling) 8500 kg. xii) Drive motor Make BHEL, Hardwar. Frame size LC 00710 H 04 A-2H Type Squirrel cage induction motor Rating 800 KW, 6.6KV, 50 HZ, 15500 rpm Continuous duty, 85A Weight of motor 9540 kg.

xiii)Lubrication Fan Forced oil lubrication Motor Grease lubrication

xiv)Bearings Fixed Bearings Dodge sleeve 5 .7/16 RT Expansion bearing Sleeve bearing 5.7/16 RT

xv)Lube Oil System Pump type Screw pump. Design pressure, Ksc 8.0 LOP Motor. 1.5 KW, 415V, 3-, 1440 rpm, class of insulation B, Squirrel cage motor. Lub oil filter 2 nos. basket type, SS mesh, 60 microns. Lub oil cooler 2 nos. horizontal tubular type Oil tank capacity 315 litres

1.13 FUEL PREPARATION AND FIRING SYSTEM 1.13.1 OIL BURNER

L.F.O BURNER

i)Service Initial start up purpose. ii)No. of oil guns 4 nos. oil guns in each AB, CD, EF

elevation. . iii)Burner Tilting tangential, corner fired. iv)Atomiser media External mixed ,constant pressure service air. v)Atomiser designation Spray plate 90 J16, 90 J14 vi)Max. capacity 7.5% MCR heat input per elevation & total 22.5% MCR. vii)Min. allowable LFO pressure 2.1 Ksc viii)Min. allowable air 5.25 Ksc.

IGNITORS

Make Simmonds, USA Service Oil burner light off Type High energy arc ignitor (HEA) Location Burner mounting panel Input 110V AC, 50HZ, 5A rms Output Min. 4 sparks/sec, 12 joules/spark. Duty cycle 15 min. ON, 30 min. OFF. Spark rod 5/8 SS tube with flexible SS wire braid, 18ft long. Igniter tip, mm Length-191, Diameter-15.9 + 0.15 Operating temp. 650C max.

Retractor Assembly Air cycle stroke 300 mm Air pressure 5 to 7 Ksc.

Flexible cable Length 7.6 mtr. Max. Bend radius 100 mm

FUEL OIL SPEFICATION

LFO i)Standard LDO to IS-1460/1994 . ii)Flash point min (PMCC) 560C iii)Viscosity max. 2.5 to 15.7 CST at 380C iv)Total sulpher, max. 1.8% by weight v)Gross heating value(Typical) 10720 Kcl/kg

FUEL OIL PRESSURISING UNIT

i)Light diesel oil pump 2 nos per both units. Make Tushaco, Delta corp. Capacity 110 LPM at min cst. Drive motor 7.5 KW, 415V, 50HZ, 3-, 910 rpm, Insulation class B,15.4A ii) Heavy fuel oil pump 4 nos.for both units. Make Tushaco, Delta corp. Pressure 20 Ksc. Drive motor 22 KW, 415 V, 50HZ, 3-

Insulation class B, 1460 rpm.

FUEL OIL STORAGE TANK

Type Vertical cylindrical Vertical cylindrical Capacity 5000m3 1000m3 Numbers 02 02 Size, m 20.0 x 18.0 10.0 x 15.0

DATA CHART. LFO BURNER

LFO AIR BURNER TYPE

Pressure (Ksc) Flow (Kg/hr) Pressure (Ksc) Flow (Kg/hr) Max Rating 4.00 1000.00 5.25 135.00 Min Rating 2.1 600.00 5.25 145.00 During Scavenge 0 0 5.25 180.00

At present LFO is burned in all the elevations.

1.13.2 GRAVIMETRIC COAL FEEDER

i) Make BHEL, U/L Stock Equipment Company, USA ii)Type 36 GF 76CD, iii)Capacity 70 T/hr per feeder. vi)RPM 959 vii)Main drive 5.5 Kw,415V,3,50HZ. vii)Cleanout conveyor drive 0.25kw,415v,3, 50HZ,910rpm.

1.13.3 PULVERISER

i)Make BHEL ii)No. per Boiler 03 iii)Type BBD11-4760 iv)Capacity 105 T/hr./mill. v)Fineness 70% through 200 mesh. vi)Max. feed size to mill 25 mm. vii)Size of grinding roll 1/3-50mm 1/3-40 mm 1/3-30 mm viii)Min. mill capacity without chattering 30 T/hr.

ix)Mill operating temp. 80-900 C x)Design. Air flow 70 T/hr xi)Design pressure 1500 mmwc xii)Drive motor Make BHEL Rating 2250 KW, 6.6KV, 50 Hz, 3-, 266.5A, 993rpm, squirrel cage

induction motor, Insulation class-F Bearings DE NV 240 EM & 6240 MC3 NDE NV 240 EM. xii)Lub Oil System a) L.P. Pump Make / Type Allweiler Tushaco/ Screw Pump Number 02 per mill. Flow 135 lpm at 10 bar LP side 244 lpm Operating Pressure 6 Ksc. Drive details 7.5 kw,415V,50 HZ, 3-,

715rpm, Insulation class-F Electrical heaters in tank 1 W/cm2, 23 KW, 415V,One heater heats 1700 litres From 100 to 350C in 5 hours. b)H.P. Pump Number 2 Per Mill. Flow 4 x 10 Lpm. Max pressure 100 bar. Drive details 11 KW, 415 V, 50 Hz 3-, 960rpm, 22.7A c) B & S Pump Number 01 Per Mill. Flow 2 x 3.5Lpm. Max pressure 60 bar. Drive details 1.5 KW, 415 V, 50 HZ, 3-. d)Dual basket filter Quantity 01 per Mill. Type RFL DP 661F10B3, 1/50,8062+BM Filtration nominal 20 Micron. Normal flow 660 lpm. e) Oil Cooler Qty. One per Mill Type MAL 353 K2K3C. Oil flow rate 135 lpm. Oil pump inlet/out let. 550C/450C Fresh water flow rate 250 lpm. Water pump inlet/out let 380C /40.40C Heat exchanger surface 7.40 m2

f) Rectangular Oil Reservoir. Dimension 1.8m x 1.2m x 1m Capacity 1770 litres Qty One per Mill. Nominal capacity 950 litres. g) Aux Reducer Make C.Messian Durand, France. Reduction type H3 H19 High/ Low speed 1450/14.58 rpm Oil 80 litres. Drive details 37 kw,63A,50 HZ, 3, 415 V, Insulation class F. h) Fluid Coupling. Make Fluidomat ltd, Dewas Model SM 06 RPM 1500 i)Main Sped Reducer (MSR) Make Flender Macneil, India Type SZN 630 Pinion, mm 825.6 OD, 760.48 PCD. Length of teeth 560 mm Quantity One per Mill

j) MSR Lube Oil Pump Type Gear pump Flow 220 lpm. Drive details 5.5 kw,12A,50 HZ.3, 415 V,

Insulation class F, 945rpm. Quantity One per mill.

k) Girth Gear Greasing Unit. No.of spray Nozzles/valve manifold 06 Quantity One per Mill Flow 3.8 cm3/cycle Air consumption 5.0 m3/hr at 2 bar Drive 0.55 kw,50 HZ.3, 415 V, 1400rpm

1.13.4 COAL PIPE

i) Pipe Size, OD (mm) 558.0, thickness 12.5 ii) Material AP1 5L Gr B

1.13.5 COAL BURNER Type Tilting tangential No.per Boiler 24 Capacity 38 x10 6 Kcal/hr/burner Position Corner Control Air Damper.

1.13.6 SEAL AIR FAN

No. of fan/Mill 2(One working, one stand by) Type Single stage centrifugal Orientation Horizontal suction, Developed pressure 1662 mmwc Drive motor Crompton Greaves make,

120KW, 415V, 3, 50HZ, 2960 rpm, Insulation Class-B

1.14 SCANNER AIR FAN

No. per boiler 1 AC driven,1 DC driven Duty Continuous Medium to be handle Dust laden air Max.dust con 300 mg/m3 Capacity 5000 m3/hr. Presure developed 200 mmwc Driving motor 415V, 3,50HZ, 5.5kw 10A, Insulation class-B

D.C. motor 5.6 KW, KEC make,33 A, Insulation Class-F Fan speed 2850 rpm

1.15 SOOT BLOWERS

Type Fully automatic sequentially controlled micro processor

. based steam soot blowing.

Source of steam SHH-10 (LTSH-O/L Headers) / PRDS

Wall blower LRSB.

i)Number 56 18 ii)Type WBIE LRDIE iii)Motor power 0.56 KW 0.37 KW 0.45 KW iv)Cleaning medium Steam Steam Pressure 20 Ksc 20 Ksc Temperature 3000C 3000C Consumption (per cycle) 3292.8 kg 8013.6 kg. v)Blow duration 1.5 min/blower 9 min/ blower vi)Cycle 84 minute 162minute

1.16 ELECTROSTATIC PRECIPITATOR

i)Manufacture BHEL ii)Type FAA-6 x 45-2 x90135-2 iii)No.of precipitators/boiler Two iv)No. of gas path/boiler Two v)No. of fields in service in each gas path Six vi) In let design conditions Gas flow rate 351.27/m2/sec. Temp. 1430c Dust conditions 82.44 gms/Nm3

vii)Guaranteed collection efficiency for design conditions 99.82% viii)Pressure drop across the precipitator for design conditions 20 mmwc ix)Velocity of gas at electrode zone on total area 0.72 m/sec. x)Treatment time 37.5 Sec. xi)Collecting electrodes. a)No. of collecting electrodes per field 61 b)No. of collecting electrodes plates(six plates are arranged in each row per field) 366 c)Space between the centers of collecting electrodes across the gas path in mm 300 d)Nominal length of collecting electrodes per field in the direction of gas flow 4.5 m. e)Total No. of collecting plates per boiler 4392 f)Nominal length/Height of collecting plates 750/1350 mm g)Sp. Collecting area 249 m2/m3/sec.

h)Total projected collecting surface 87,480 m2

xii)Emitting Electrodes a)Type Spiral with hooks b)Size 2.7 mm diameter c)No. of the electrodes in the frame forming one row 54 d)No. of electrodes in each field 3240 e)Total No. of electrodes /boiler 38880 f)Total length of electrodes per field 18176.4 m. g)Plates/wire spacing 150mm xiii) Rappers for emitting electrodes a)No. & types of rappers One drop hammer for two nos. of electrodes. b)Rapper size 30 kg. c)Frequency of rap. 10 raps/hour d)Drive Geared electric motor controlled

by synchronous programmer. xiv)Hoppers a)Type & No. Pyramidial,48 b)Capacity 8 hours storage c)Heating Electrical heating provided for bottom of hoppers.

xv) Gas Distribution System Inlet Outlet Type perforated plate U-shaped thin

sheet Quantity 2 set 1 set

xvi) Electrical items. 1) Rectifier Rating 70KV(peak),1000mA(Mean) Number 24 Type Silicon diode, full wave bridge Connection. Location Top of precipitator. 2) Rectifier control panel Number 24 Type Thyristor. Location In control room at ground level 3) Motors for emitting and collecting rappers Quantity 24 nos. Rapping 415V, 3, 50HZ, 0.26kw 1A, 1310rpm, continuous rapping. Location On roof top of ESP.

4) Heating elements a)Hoppers for 48 hoppers @ 6 KW per hopper 288 Kw b)Shaft insulators for 24 insulators @ 1 KW per insulator 24 Kw. c)Support insulators for 96 insulators @ 1 KW per insulator 96 kw d)Estimated power consumption including heating elements & rappers 630 Kw. 5) Recommended current setting Fields 1 2 3 4 5 6 Current in mA 250 400 550 700 850 1000 xvii) Operating sequence of rapping mechanism Auto

1.17 PRESSURE REDUCING & DESUPERHEATING STATION (PRDS)

i)Steam source MS Line at 150 Ksc & 5400c ii)Flow capacity Design-80t/hr. Normal-56t/hr. iii)Spray water BFP discharge iv)Operating pressure 16 (Ksc) g v)Operating temp. 2200c vi)Header size 273 x 635 mm vii)Material SA 335 P22

1.18 MAIN PIPELINES

Main steam Hot reheat Cold reheat Feed water No. of lines 2 2 2 1 ID x Thickness, 255.6x47.0 508.6x28.0 457x20.0 323.9x36.0 (in mm) Material SA335P22 SA335P22 SA335P22 SA106Grc SA106Gr.c

1.19 BLOWDOWN VESSELS

IBD CBD Test Pressure 4.5 ksc 13.5 ksc Max working Pressure 3.0 ksc 8.0 ksc Operating Temp 200 0C 180 0C Capacity, m3 2.205 3.930

1.20 SAFETY VALVES

Sr No Valve Tag Location Type of Valve Size mm / inch Valve Set Pr. Ksc Blow Relieving Total Relieving Safety Valve

Down Capacity,kg / hr Capacity, kg / hr

INLET OUTLET OPEN CLOSE Butt Welded Flange Welded

1 SV1 Boiler Drum Consol 1750WB 76.2 / 3" 152.4 / 6" 177 169.9 4 180360 2 SV2 Boiler Drum Consol 1750WB 76.2 / 3" 152.4 / 6" 180.5 171.5 5 183924 1,2,3 550044 3 SV3 Boiler Drum Consol 1750WB 76.2 / 3" 152.4 / 6" 182.3 173.2 5 185760 4 SV4 Super Heater Consol 1740WD 76.2 / 3" 152.4 / 6" 163.75 158.8 3 161523 161523 5 SV5 ERV Consol 1538VX 63.5 / 2.5" 101.6 / 4" 162.1 158.8 2 101017 101017 6 SV6 CRH Consol 1786WB 152.4 / 6" 203.7 / 8" 45 42.75 5 176760 176760 7 SV7 HRH Consol 1786WD 152.4 / 6" 203.7 / 8" 42.35 40.23 5 140256 8 SV8 HRH Consol 1786WD 152.4 / 6" 203.7 / 8" 42.7 40.57 5 1411372 7,8,9 428868 9 SV9 HRH Consol 1786WD 152.4 / 6" 203.7 / 8" 44.5 42.23 5 147240

10 SVS8 S.B.Line Consol 1811JB 38.1 / 1.5" 63.5 / 2.5" 40 38.4 4 14590 14590

1.21 CHIMNEY

i)No. of flue 02 ii)Wind shield material Reinforced concrete iii)Flue material Steel iv)Chimney height 220 m v)Chimney base dia 28.948 m vi)Chimney raft dia 36.0 m vii)Flue dia 4.60 m

1.22 FUEL

The fuel data on which guarantees given are as follows:

PROXIMATE ANALYSIS

Description Performance Coal Fixed carbon % 23.0 Volatile material% 23.0 Ash % 42.0 Moisture 12.0

ULTMATE ANALYSIS. Fixed carbon % 31.29 Ash % 42.0 Moisture % 12.0

Hydrogen % 2.44 Sulphur % 0.50 Oxygen % 11.08 Nitrogen % 0.69

1.23 CHEMICAL COMPOSITION OF ASH GENERATED IN ITPS

Carbonate % 0.72 Higher heating value 3000 Kcal/kg Grindability index, HGI 55 Ash fusion temp. 1400c Initial deformation temp. 12000c

PREDICTED PERFORMANCES

I-FLOW T/HR.

DESCRIPTION HP.HEATERS IN SERVICE HP HEATERS OUT

MCR NCR CL 60% NCR.

STEAM

Supper heater out let 690 636.7 410 584.1 Reheater out let 597.9 572.9 377.6 577.4

WATER

Feed water 690 620.5 379.4 554.9

Supper heater spray 0 16.2 34.6 29.2

AIR

Air heater outlet(Primary) 190.24 175.54 131.37 209.6 Tempering Air 82.76 91.02 110.87 58.8 Air heater outlet(secondary) 563.72 508.39 270.41 529.7 Total combustion air 880.77 819 656.7 842.1

FUEL

Coal (HHV=3800 Kcal/kg) 178 165.6 112.5 170.2

Analysis in wt Maximum value Minimum value Average value

Sio2 61.76 47.98 54.5 Fe2O3 17.84 4.19 12 Al2O3 29.17 23.02 26.31 CaC 3.01 0.55 1.81 MgO 1.58 0.56 1.06 Na2O 2.51 0.34 1.425 K2O 0.9 0.66 0.78 TiO2 3.4 1.75 2.51 Slagging index of Ash Rba 0.27 0.08 0.2

FLUE GAS

Air heater out let 1048.5 972 665.3 1000.7 TOTAL HEAT TO BOILER (Heat Duty) Kcl /hr. 452.4 420.8 284.9 437.9

II.TEMP(0C)

STEAM

Standard Temp. in Drum 349 349 345 347 LTSH O/L 390 393 399 401 SH platen T/L 390 384 366 378 SH platen O/L 500 500 506 496 SH final O/L 540 540 540 540 RH I/L 342 342 330 351 RH O/L 540 540 540 540

WATER

Eco I/L 246 245 225 166.5 Eco. O/L 310 309 295 267

AIR

Ambient 40 40 40 40 AH O/L(Primary) 335 332 306 290 AH O/L(Secondary) 335 332 306 290

GAS

SH platen inlet 1184 1187 1139 1157 RH front inlet 1029 1023 950 1044 RH Rear inlet 885 876 796 865 LTSH inlet 652 643 583 641 Economiser inlet 549 541 498 541 Air heater inlet 359 353 314 311 Air heater outlet 114 143 147 124

III.PRESSURE (KG /CM2)

PRESSURE

SH outlet 155 154.1 151 153.2 LTSH outlet 162.9 160.9 154.3 159 Drum 166.1 163.7 155.5 161.4 Eco I/L 171.1 168.2 158.6 165.6 RH O/L 34.483 34.968 22.821 35.885

RH I/L 38.497 36.898 24.088 37.812

PRESSURE DROP

SH System 11.1 9.6 4.3 8.2 Re heater 2.014 1.93 1.267 1.927 Economiser(Including static head) 5 4.5 3.1 4.2 IV- PRESURE & DRAFT (AIR & GAS) MMWC.

PRIMARY AIR

PA Fan I/l 69 66 55 65 PA fan O/L 687 644 467 647 Mill I/L 632 595 436 596 Mill O/L 292 273 188 267

SECONDARY AIR

FD fan I/L -16 -14 -7 -15 FD fan O/L 282 258 167 263 AH I/L 227 210 146 212 AH O/L 157 150 123 151 Wind box pressure 100 100 100 Wind box to furnace diff. 125 125 125 125 Furnace -5 -5 -5 -5 SH platen I/L -5 -5 -5 -5 RH I/L -6 -6 -6 -6 LTSH I/L -22 -20 -13 -20 Eco. I/L -27 -24 -15 -24 AH I/L -62 -55 -32 -55 EP I/L -265 -235 -138 -230 ID fan I/L -303 -268 -143 -259 ID fan O/L 34 30 14 28 Flue gas velocity in second pass 8.00 m/sec.

V-MILL AND BURNER PERFORMANCE.

No.of Mill in operation 2 2 2 2 Coal flow/Mill(T/hr.) 89.5 82.6 56.1 85.1 Ball charge per Mill(T/hr) 96 96 96 96 Air flow/Mill (T/hr) 136.5 133.28 121.12 134.2 Air temp. at mill I/L(0c) 243 232 184 236 Mill output temp.(0c) 75 75 75 75 Fineness % (through 200 mesh) 76 79 79 77 Mill pressure drop including classifier(in mmwc) 340 322 248 329 Burner tilt (in degree) 0 9 24 -7

VI-O2, CO2 (DRY VOL) AND EXCESS AIR(%)

O2 in gas at Eco O/L% 3.55 3.55 3.55 3.55 CO2 in gas at Eco O/L % 15.57 15.57 15.57 15.57 Excess air gas at Eco O/L % 20 20 20 20

VII-HEAT BALANCE : LOSSES IN %

Dry Gas 4.31 4.27 4.48 3.43

H2o & H2 in fuel 7.05 7.04 7.07 6.93 H2o in Air 0.23 0.23 0.24 0.19 Unburnt carbon 2 2 2 2 Radiation 0.2 0.22 0.31 0.2 Unaccounted 0.5 0.5 0.5 0.5 Manufacturer's margin 1 1 1 1 Total loss 15.29 15.26 15.6 14.25 Guaranteed efficiency 84.71 84.74 84.4 85.75

SECTION 2

TURBINE & AUXILIARIES

2.0 MAIN TURBINE

2.1 TECHNICAL SPECIFICATION

2.1.1 STEAM TURBINE

i) Make BHEL, Kraftwerk Union Design ii) Type Tandem compound, regenerative, reheat, cylinder having single flow HP turbine, double flow IP & LP turbine

iii) No. of stages HP 25 no. IP 20 x 2 no. LP 8 x 2 no. iv) Type HP/IP/LP turbine HPT Reaction, barrel type, single flow

IPT Reaction, barrel type, double flow axially split type LPT Reaction, barrel type, double flow three shell design

v) Nominal rating 210 mw vi) Peak loading 230 mw vii) Rated speed 3000 rpm viii) Max./Min. speed 3090/2850 rpm (51.5 to 47.5 Hz) ix) Speed exclusion range 700 to 2850 rpm x) Over speed set value 11%

2.1.2 DIMENSIONS (IN MM)

HPT IPT LPT i) Height of first stage moving blade 43 66 75.5 ii) Mean dia. of 1st stage moving blade 643 756 1473.5 iii) Height of last stage moving blade 95 100 668.8 iv) Overall length of turbine 15.725 m v) Overall width with cross around pipe 10.5 m (approx.) vi) Total exhaust area (LP turbine) 6.3 x 4.75 m2

2.1.3 BEARINGS No.1 Journal, 280 x 140 mm No.2 Radial cum thrust, tilting pad 290 x No.3 Journal, 450 No.4 Journal, 400 No.5 Journal, 400 No.6 Journal, 400 No.7 Journal, 200 Lining material for all bearings Babbit

2.1.4 VALVES

i) 2 main stop & control valves Type EV160 ii) 2 reheat stop & control valves Type IV320 iii) 2 swing check valves in CRH line DN 450 iv) 2 bypass stop & control valves DN 200

Extraction Swing check valves: v) Extraction 1 No valve vi) Extraction 2 1 swing check valve with aux. actuator vii) Extraction 3 1 swing check valve viii) Extraction 4 1 swing check valve ix) Extraction 5 1 swing check valve x) Extraction 6 No valve

2.1.5 WEIGHTS (TONNES)

Rotor HPT IPT LPT Rotor 7.5 15.8 48.0 Cylinder assembled (with steam inserts)

56.0 37.0 81.0

2.1.6 CASING TEMPERATURE (0C)

Wall temperature Alarm at Machine must be shut down at

HP turbine casing exhaust

480 500

Outer casing of LP cylinder

90 110

Spray water to LP turbine

Must be switched on at 90oc

2.1.7 BEARING TEMEPRATURE (0C)

Normal operating Alarm at Machine must be shut down at

Below 75oc 90oc 120oc Above 75oc 100oc 120oc

2.1.8 TEMPERATURE DIFFERENCE (0C) (Between Upper & Lower casing section)

Alarm at Machine must be shut down at

HP turbine middle 30oc 45 IP turbine front 30oc 45 IP turbine rear 30oc 45

2.1.9 DIFFERENTIAL EXPANSION

Alarm Trip HP turbine differential expansion

+4.5, -2.50 +5.50, -3.50

IP turbine differential expansion

+5.00, -2.00 +6.00, -3.00

LP turbine differential expansion

+25.00, -5.00 +30.00, -7.00

2.1.10 VIBRATION (ABSOLUTE)

Of bearing housing Of shaft Nominal value for alarm 35m 30m above normal value Maximum value for alarm - 120m Limit value for tripping 45m 200m

2.1.11 LOW VACUUM TRIP SETTING

Hydraulic low vacuum Trip < 0.3 bar Electric low vacuum Trip < 0.3 bar Hydraulic low vacuum Trip < 0.6 bar (Bypass operation)

2.1.12 MW OUTPUT

HPT IPT LPT 56.40 MW 53.73 MW 93.03 MW 28% 26% 46%

2.1.13 STEAM PURITY

Continuous operation Start up Unit 1)Conductivity at 25oc continuous measurement at the sampling point. a)Direct measurement i)Alkaline method ii)Neutral method b)following a strongly acid cation exchange method i)Alkaline method ii)Neutral method

Not specified < 0.15

< 0.10 < 0.10

--

< 0.50

< 0.50 < 0.50

s/cm s/cm

s/cm s/cm

2)Silcic acid (SiO2) < 0.10 < 0.050 mg/kg 3)Total iron (Fe) < 0.005 < 0.050 mg/kg 4)Total Copper (Cu) < 0.001 < 0.010 mg/kg 5)Sodium (Na) < 0.005 < 0.020 mg/kg

2.2 TURBINE LUBE OIL SYSTEM

2.2.1 OIL SUPPLY

i) Oil tank capacity 32 m3 ii) Highest/lowest oil level from top of 800/850 mm the tank during operation iii) Lube oil temperature at cooler outlet Min 37oc, during operation Normal 45oc Max. 47oc iv) Oil temperature rise across bearings Normal 20oc

Max. 25oc v) Oil temperature at cooler O/L(under shutdown) Max. 75oc vi) First oil filling (estimated) 30m3 vii) Flushing of oil quantity (estimated) 20m3 viii) Pressure limiting value in

jacking oil system 120 bar ix) Safety valve in jacking oil system Max. 170 bar x) Jacking oil pump must be switched on at 510 rpm xi) Jacking oil pump must be switched off at 540 rpm

2.2.2 OIL PUMPS

M.O.P. A.O.P. DC E.O.P. JOP (AC) JOP (DC) Nos 1 2 1 1 1 Make BHEL KSB KSB Allweiler Allweiler

AG Type ETA 150-

50VL centrifugal

ETA 100- 33VL centrifugal

SDF 40- R54 GQW-112

SDF 40- R54 GQW-112

Rated capacity 139 m3/hr

152.24 m3/hr

108 m3/hr 76 LPM 76 LPM

Rated discharge pressure

8.2 ata 6.8 ata 2.3 ata 120 bar 120 bar

Speed, rpm 3000 1485 1425 2950 2950 Drive Turbine AC motor DC motor AC motor DC motor Make - GEC Crompton

Greaves Siemens Wirrkelmann

Voltage, V - 415 220 415 220 Frequency, Hz - 50 - 50 - Motor Power, KW

- 100 13 27.6 28

Rated current, Amp

- 175 128 47.5 152

2.2.3 OIL COOLER

i) Type & no. Shell & tube type, 2 x 100% ii) Cooling surface 218 m2 iii) Oil outlet temperature of cooler In operation Min. 38oc, Normal 45oc, Max. 47oc In shutdown Max 75oc iv) Tube material & no. of tubes Admirality Brass IS1545

Total no.1250 v) Design pressure & temperature

shell side 10 kg/cm2 & 100oc tube side 10 kg/cm2 & 100oc

2.2.4 OIL FILTER

i) Duplex oil filter type & no. DN 100 type, 2.82.9.200.500.10 ii) Filtration particle size of thrust bearing duplex filter 37 m iii) Filtration particle size of MOT filter 250 m

2.2.5 ESTIMATED OIL REQUIREMENTS OF BEARINGS

Bearing 1 (HPT) front pedestal) 0.8 dm3/s Bearing 2 9.1 dm3/s Bearing 3 4.0 dm3/s Bearing 4 3.5 dm3/s Front generator bearing 3.5 dm3/s Rear generator bearing 5.0 dm3/s

2.2.6 BARRING GEAR

i) Type of drive Hydraulic turbine ii) Method of engagement Hydraulic iii) Cut in/ cut out speed 240/210 rpm iv) Power to rotate turbine 45 KW v) Barring speed 80 210 rpm

2.2.7 MAIN OIL CENTRIFUGE

i) Manufacturer Alpha - Laval ii) Capacity 4500 Lph (2 nos) iii) Model MAB 205+54 KW Indirect heater iv) Centrifuge motor 5.5 KW, 415V, 2430 rpm, 11A, Cl.B. inst. v) Bowl speed 8425 rpm apprx. vi) Revolution/counter Rpm 118/125 vii) Antiflood tank capacity 45 lit viii) Feed pumps 4500 lit/hr, at 5 ksc ix) Capacity of dirty oil tank 35 m3 x) Capacity of clean oil tank 35 m3

2.2.8 OIL CHARACTERISTICS (As per IS: 1448)

i) Kinetic viscosity at 37.8oc 47.5 c.s. to 49.5 c.s. Kinetic viscocity at 50oc 28 c.s. ii) Specific gravity at 50oc 0.852 iii) Flash point Min. 200oc iv) Pour point -6oc v) Ash content 0.01 (% by weight) vi) Water content by weight Below the limit of quantitative detectability vii) Mechanical solid impurities - do - viii) Viscosity Index Min. 97

ix) Inorganic acidity Nil

Organic acidity Max. 0.14 mg of KOH per gm of oil x) Neutralization number Max. 0.2 mg of KOH per gm xi) Copper strip corrosion Not worse than no.1 test at 100oc for 3 hrs xii) Emulsion characteristics 40-40-0 (20 minute)

2.3 VACUUM SYSTEM

2.3.1 CONDENSER

i) Type Surface type, double pass with divided water box construction

ii) Design conditions: Steam side Water side a) Design pressure full vacuum 3.5 ksc & full vacuum b) Test pressure Filling by water up to 4.5 kg/cm2g 1.0 m above tubes

c) Design temperature 85oc 50oc

iii) Design CW flow 27,000 m3/hr iv) Design CW temperature 33oc v) Design back pressure vi) No. of tubes length of each tube 7600 mm vii) Tube O.D thickness 25.4 mm x 1 mm for top row (thickness) 1.2466 mm viii) Tube material 17,902 nos. -90/10 Cu-Ni to BS 2871 in condensing zone 1316 nos. SS ASTMA-249, T1304 in air air cooling zone ix) Surface area 11,495 m2 x) Pressure drop in CW side 3.6 mwc xi) CW temperature rise 8.8oc to 9oc xii) Water velocity in tube 1.9 m/sec xiii) Weight

Dry 320 MT Operating 530 MT Flooded (1.0 m above tubes) 640 MT

2.3.2 MAIN EJECTOR

i) Make BHEL, Hardwar ii) Steam required 1000 kg/hr iii) Min. condensate flow 103 T/hr

iv) Normal condensate flow 254.6 T/hr v) Tube side pressure 24 ksc vi) Tube side test pressure 36 kg/cm2g vii) Shell side test pressure 2.5 kg/cm2g viii) Motive steam pressure 6.5 ksc ix) Motive steam temperature 210oc x) Weight Empty 2875 kg Operational 3245 kg xi) Material: Tube plate steel 42W IS202 Diffuser stage I,II,III steel IS 2073 Gr.C-20 Tube Admirality Brass CZIII BS 2871 Nozzle Stainless steel SS 30CR 13 hot rolled Annealed 136603

2.3.3 STARTING EJECTOR

i) Steam requirement of the ejector 3300 kg/hr ii) Working pressure of steam 6.5 kg/cm2g at 210oc iii) Hydraulic test pressure 1.5 kg/cm2 iv) Air removal capacity at 500 mm Hg vacuum 7350 SCFM v) Design temperature 250oc

2.3.4 GLAND SEALING SYSTEM

i) Type of control Electro-Hydraulic ii) Model ESS HI iii) Oil used Servo control-46/HLP-68 iv) G.S. control valve actuator REINEKE, GMBH v) L.S. control valve actuator REINEKE, GMBH iii) Self sealing after 40% load

2.3.5 GLAND STEAM VAPOUR FAN

i) Fan Type SHSH ii) Make S.K.Systems, New Delhi iii) Capacity 1080 m3 /hr iv) Drive 3 H.P. 2840 rpm.

2.3.6 CONDENSER ON LOAD CLEANING DEVICE

Manufacturer GEA Energy Systems Debris Filter System i) Type 574 V type ii) Quantity / unit Two

iii) Perforation of screen 5 mm iv) Screen thickness 2.0 mm v) Flow, m3/hr 13,500 vi) Design DP for filter screen 2 bar (g) vii) Discharge during flushing, m3/hr 400 viii) Geared motor drive 415V, 3-, 50 Hz, 0.55 KW, 1.4A

Flushing Pump ix) Type Centrifugal, horizontal x) Capacity, m3/hr 170 xi) Motor 415V, 3- , 50 Hz, 11 KW, 1460 rpm

Tube Cleaning System Ball Separator i) Quantity / unit Two ii) No. of ball extraction points Two iii) No. of screens/ball separator Two iv) Normal flow, m3/hr 13,500

Ball Recirculation Pump i) Type Centrifugal horizontal non-clogging type ii) Quantity / unit Two iii) Capacity, m3/hr 60 iv) Design head mmwc 15 v) Design efficiency 60% vi) Motor 1440 rpm, Insulation class B

Cleaning Balls Normal Balls Abrasive Balls i) Type Soft Abrasive ii) Diameter, mm 26 25 iii) Density, g/m3 0.22 0.2759 iv) Design temperature, 0C 80 80

2.4 CONDENSATE SYSTEM

2.4.1 CONDENSATE EXTRACTION PUMP

i) Manufacturing BHEL, Hyderabad ii) No. of pumps & capacity 2 100% iii) Type EN5J40 (2 shaft), vertical centrifugal

canister type iv) No. of stages 5

v) Discharge capacity 675 m3/hr vi) Diff. Head 220 m vii) Input power to pump 494 KW viii) Density of medium handled 0.9896 tonne/m3 ix) NPSH required at the eye of the 1st impeller 3.0 mlc x) RPM 1482 xi) Efficiency of pump 81% xii) Coupling Flexible xiii) Direction of rotation viewed from drive end Clockwise xiv) Suction bore diameter 400 mm xv) Discharge bore diameter 300 mm xvi) Minimum flow through pump 175 m3/hr xvii) Bearings Taper roller bearing 29420E FAG/SKF xviii) Lub. Oil IOC turbine oil 46/Servo prime 46

xix) Motor Manufacturer BHEL, Hardwar Type Squirrel cage induction motor KW rating 600 KW Power supply 6600V, 3-, 50Hz Class of insulation F Efficiency at rated output 94.5% Rated speed 1485 rpm Full load current 66A Weight of motor 4010 kg Bearing DE 6226-c3 NU 224M cyl. Roller bearing NDE 7322-B 7322 B Angular, con. Ball bearing

2.4.2 DRAIN COOLER

i) Position Horizontal ii) No. 1 iii) Type Tube & shell type iv) Cooling surface area 35 m3 Tube side Shell side v) Design pressure 28.1 ksc, g Full vacuum & 3.5 ksc, g vi) Hydraulic test pressure 42.15 ksc, g 5.25 ksc, g vii) Design temperature 150oc 100oc viii) Tube OD Length 16 mm 1395 mm x) Tube material Austenitic S.S. welded xi) No. of tubes 501 xii) Operating weight 3185 kg

2.4.3 GLAND STEAM CONDENSER

i) Position Horizontal ii) No. 1 iii) Type Tube & shell type iv) Allowable/Design flow of main condensate: Minimum 180 T/hr Design 561.343 T/hr Max. 760 T/hr v) Tube ODX length 19 mm 1150 mm vi) Material Welded S.S. tubes, ASTM A249 TP304 vii) No. of tubes 313 viii) Surface area 20 m2 ix) Exhauster fan 2 nos, centrifugal, 1000 m3/hr, 2860 rpm,

3 HP

2.4.4 LOW PRESSURE HEATER

LPH-1 LPH-2 LPH-3 i) Type Shell & tube type ii) Position Horizontal Horizontal Horizontal iii) No. One One One iv) Operating pressure

shell side (ksc abs) 0.1992 0.8104 2.2671

v) Operating temp. shell side(0c) 59.54 107.8 200.0 vi) Tube OD thickness in mm 16 0.889 vii) No. of tubes 498 498 498 viii) Weight- Dry 7625 11096 9960 Operating 9165 13700 12250 Flooded 12550 19360 17200 ix) Tube material S.S.

2.5 FEED WATER SYSTEM

2.5.1 DEAERATOR

i) Manufacturer BHEL, Hyderabad ii) Type Spray cum Tray type iii) Design pressure/op. Pressure 7.4 ksc(g) / 6.83 ksc (g) iv) Design temp. / op. Temperature 250oc / 163.15oc

v) Shell ID thickness, mm 2400 16 vi) Feed water storage tank ID thickness, mm 3500 20 Total length, mm 22000 Steam inlet quantity, T/hr 38064 Inlet steam pressure ksc 6.827 Inlet steam temperature, 0C 313.4 Safety relief valve set pr. Ksc 6.77 vii) Total working weight 197000 kg (storage tank + header) Flooded weight 262000 kg

2.5.2 BOILER FEED PUMP

i) No. & capacity 3 50% ii) Make BHEL, Hyderabad

Pump data Booster Pump Feed Pump iii) Pump type FA1B-56 FK6D-30 iv) Liquid pumped -------Boiler feed water---------- v) SG at suction temp. kg/dm3 0.9046 0.9046 vi) Suction temperature, oc 163 163 vii) Diff. Head, m/c 99 2222 viii) Flow rate, m3/hr 455 455 ix) Efficiency, % 81.3 81.9 x) Speed, rpm 1485 5245 xi) Power, KW 136.5 3041 xii) NPSH required, m 4.05 24.68 xiii) Thrust bearing The Glacier Metal The Glacier Metal Co. Co. Ltd, Double thrust Ltd, Double thrust, CK CK range, size 811/2kp-2kp range size, 8159/2kp-2kp

xiv) Mechanical seal Durametallic/ sealol type 4.250 PTO/type 503 xv) Min. recirculation flow, T/hr 100 xvi) Direction of rotation viewed from drive end -------------- Anti-clockwise--------- xvii) No. of stages Six

DRIVE MOTOR

i) Make BHEL, Hardwar ii) Type Squirrel cage induction motor iii) Rating 4000 KW iv) Degree of protection, type of enclosure, method of cooling IP54, CACW, ICW 37A81

v) Power supply 6600V, 3-, 50 Hz vi) Rated speed 1500 (synch.) vii) Insulation class F viii) Efficiency 96.5% ix) F.L. current 407 A x) Weight 13360 kg xi) Winding temp. rise at rated output over cooling air 700C (by resistance), 80oc (RTD) xii) Bearing DE Sleeve bearing 160 140 NDE Sleeve bearing 125 115 (Insulated)

HYDRAULIC TURBO COUPLING

i) Manufacturer Voith , India ii) Type R16k-1 iii) Power requirement of

drive machine 3240 KW

iv) Gear ratio, type 148/41, step up gear unit v) Speed input/output 1485/5249 rpm vi) Regulating range 4:1 downwards vii) Full load slip 2.1% viii) Oil tank filling 700 lit (approx.) ix) Oil used Servo Torque 10 of IOCL.

AUX. LUB OIL PUMP

i) Type Gear pump ii) Lube oil flow Approx. 120 litres/min. iii) Pressure 2.5 bar iv) Motor 5.5 kw, 415 volt, 50 Hz

OIL/WATER HEAT EXCHANGER

WORKING OIL LUB OIL

i) Type L1 N1 09 17 04-D L1 N1 07 04-D ii) Heat exchange capacity 71 litres 47 litres iii) Cooling water inlet temp. 37 37 iv) Cooling water outlet temp. 47 47 v) Nominal oil flow rate 32 m2/hr 13.5 m2/hr vi) Oil I/L temp., 0C 95 69 vii) Oil O/L temp,0C 57 53 viii) Max. permissible working

pressure oil side, ksc 16 16 water side, ksc 10 10 x) Max. permissible working oil temperature, 0C 119 119

TYPE OF COUPLING

i) Turbo coupling / pump flexible coupling:

Manufacturer Torsiflex Ltd Type HBS1000-8x ii) Motor/turbo coupling flexible coupling:

Manufacturer Torsiflex Ltd Type HBS-3600-8 iii) Motor/Booster pump flexible coupling

Manufacturer Torsiflex Ltd Type HB4-140x (insulated)

2.5.3 HP HEATERS

HPH5 HPH6

i) Manufacturer BHEL BHEL ii) Type & arrangement ----- ------ U tube Horizontal---------- iii) No. of shell passes 3 zones 3 zones iv) No. of tube passes 2 2 v) Tubes: Type of tubes Seamless Seamless Total no of U tubes 830 830 Effective length of U tubes, mm 7915 9715 Outer dia., mm 15.875 15.875 Design pressure, ksc(g) 280 280 Design temp. 0C 215 265 vi) Shell I.D., mm 1250 1250 Design pressure, ksc(g) 19.0 & full vacuum 45.0 & full vacuum Design temp. skirt/shell, 0C 440/215 370/260 Shell side relief valve set Pressure kgf/cm2(g) 19.0 45.0 vii) Velocity through tubes at 2.14 2.25 670 T/hr flow, m/sec

viii) Tube side pressure drop at 0.85 1.15 670 T/hr flow, kg/cm2 ix) Surface area, m2 De superheating/Condensing/ Drain cooling zone 83/485/112 104/642/82 x) Total effective area, m2 680 828

2.6 HP/LP BYPASS SYSTEM

Capacity 60% MCR 420 t/hr of main steam flow at the inlet of HP bypass valve

HP BYPASS STEAM VALVE SPRAY VALVE i) Valves designation BP1/BP2 valve BPE1, 2 valves Design pressure 170/50 ata 280 Design temperature 540/485oc 175oc Body material 10 Cr MO910 15MO3 Nozzle material 10 Cr MO910 15MO3 Medium Main steam Spray water

ii) ACTUATOR Type Hydraulic Hydraulic system pressure 100 bar Positioning time 10/3 sec (3 sec for fast opening device)

iii) OIL SUPPLY UNIT Oil pump type OV-32 Supply capacity 24 lit/min. Motor detail 7.5 KW, 415V, 3-, 50 Hz, 1440 rpm,14.2 A Oil tank volume/usable volume 70/50 lit Oil pump cut in at 100 ksc Cut out at 16 ksc Back up protection cut in/cut out 110 ksc/170 ksc Relief valve setting 150 ksc

2.7 FLASH TANK/FLASH BOX

2.7.1 UNIT FLASH TANK

i) Type/Quantity Vertical cylindrical / one per unit ii) Design code ASME SEC VIII div.1 iii) Design pressure Full vacuum & 1.5 ksc (g) iv) Design temperature 210oc v) Fluid handled Steam/water vi) Shell material IS2062 Gr FE410 WB

vii) ODX height 1000 x 2700 mm viii) Shell thickness 12 mm ix) Corrosion allowance 3.2 mm

x) List of connections Vent to atmosphere 1 Drain to waste 1 Drain to manifold 2 Spray water 1 Manhole 1 Spare 1

2.7.2 CONDENSER FLASH BOX

FB-1 FB-2 FB-3 i) Type Vertical cylindrical ii) Design code ------------------ ASME Sec VIII div.1 --------------- iii) Design pressure 1.5 ksc(g) & full vacuum iv) Design temperature 0C 210 215 210 v) Fluid handled ----------------- Water / Steam ------------------ vi) Shell material ----------- IS2062 Gr.FE410.WB ------------- vii) Size OD height, mm 1400 x 2100 2200 x 3300 800 x 1800 viii) Shell thickness, mm 10 16 10 ix) Corrosion allowance, mm 3.2 3.2 3.2 x) List of connections: a) FB-1 Vent to condenser 1 Drain to hot well 1 LPH-2 alt. Drain 1 LPH-3 alt. Drain 1 LP ext. line drain manifold 1 Spare (blanked) 1 ` Manhole 1

b) FB-2 Vent to condenser 1 Drain to hot well 1 HPH-5 alt. Drain 1 HPH-6 alt. Drain 1 HPH ext. line drain manifold 1 HRH/CRH/LPBP line drain 1 Valve gland sealing header 1 Drain from Aux.5/CRH to gland sealing 1

Manhole 1 Spare (blanked) 1

c) FB-3 Vent to condenser 1 Drain to hot well 1 Drain cooler drain 1 GSC drain 1 Drain from main ejector 2 CEP discharge vent 1 Manhole 1 Spare (blanked) 1

PREDICTED PERFORMANCE OF TURBINE

STEAM PRESSURE (BAR)

DESCRIPTION Rated value (bar)

Long time operation (bar)

Short time operation (bar)

Initial steam 147.1 147.1 176.5 Before 1st HP drain stage

132.6 137.9 145.9

HP cylinder exhaust 39.23 45.11 47.08* IP cylinder stop valve inlet

34.13 39.59 40.96**

Extraction 6 39.23 45.11 47.08 Extraction 5 16.75 19.84 19.84 Extraction 4 7.06 8.46 8.46 Extraction 3 2.37 2.91 2.91 Extraction 2 0.858 1.09 1.09 Extraction 1 0.216 0.374 0.374 HP cylinder exhaust 0.118 0.3 0.3

*These values correspond to 210 MW with 3% make up and 0.1187 bar backpressure with all heaters in service & rated steam conditions.

**The safety valves are set such that these short-time values are not exceeded.

Long time operation: Upper limit value, permissible without the time limit.

Short time operation: Permissible momentary value. The aggregate duration of such swings must not exceed 12 hours in any one year.

STEAM TEMPERATURE, 0C

DESCRIPTION Rated value Annual mean value

Long time value but keeping within annual mean value

400 hr per annum

80 hr per annum max. 15 min in individual case

Initial steam 535 543 549 563 IP cyl. Stop valve inlet

535 543 549 563

DESCRIPTION Rated value Long time operation

80 hr per annum, max. 15 min. in individual case

In special cases at no load.

HP cylinder exhaust

343 359 425 500

Extraction 6 343 359 425 500 Extraction 5 433 438 473 Extraction 4 316 326 366 Extraction 3 200 211 255 Extraction 2 107 127 167 Extraction 1 62 82 127 LP cylinder exhaust 49 70 70 100

These values correspond to 210 MW load with 3% make up & 0.1187 bar back pressure with all heater.

Only valid for the no load period with high reheat pressure after trip-out from full load operation. For the individual case approx.15 min. The turbine is immediately re-loaded or the boiler immediately reduced to minimum load, if no-load operation is maintained.

Permissible differential temperature No time limitation- 170C. between parallel steam supply lines: Short time period (15 min.)- 280C.

In the hottest line the limitations indicated for initial steam & reheat temperature must not be exceeded.

CONDE NSAT E WAT E R

Description Pressure Kg/cm2 Temperature 0C Flow T/hr CEP suction 0.1033 46.1 508.83 CEP discharge 19.379 46.3 508.83 GSC outlet 1054 46.6 508.83 Drain cooler outlet 10.08 47.8 508.83 LPH 1 outlet 9.63 56.6 508.83 LPH 2 outlet 9.18 90.6 508.83 LPH 3 outlet 8.72 120.7 508.83

HE AT E R DRAIN

Description Temperature oc Flow T/hr GSC drain to FB-3 99.9 0.299 LPH3 to LPH2 123.5 27.589 LPH2 to LPH1 93.4 57.651 LPH1 to drain cooler 60.3 63.437 Drain cooler to FB-3 52.8 63.437 HPH 6 to HPH 5 206.0 61.091 HPH 5 to deaerator 170.0 95.807

FE E D WAT E R

Description Pressure Kg/cm2 Temperature oc Flow t/hr BFP suction 6.405 160.7 639.27 BFP discharge 205.0 164.1 639.27 HPH 5 outlet 204.09 200.0 639.27 HPH 6 outlet 203.18 247.0 639.27

Parameters are given when unit at 210 M W, 0% make-up water, 76 mm backpressure & constant pressure operation.

SECTION 3

GENERATOR &

AUXILIARIES

3.1 GENERATOR TECHNICAL SPECIFICATION

Make BHEL Type Two Pole, Cylindrical, Steam turbine

driven MW rating 210 MVA rating 247 Rated Terminal voltage 15.75 KV Rated Stator current 9050 A Rated p.f. 0.85 lag Rated speed/frequency 3000 rpm/50 Hz Negative sequence current capability (I2t) 8 Efficiency at MCR condition 98.55 % Short circuit ratio 0.49 Phase connection Double star No. of terminal brought out 9 (6 neutral & 3 phase) Generator stator winding resistance in each phase 0.00155 at 20 c Generator rotor winding resistance 0.0896 at 20 c Cooling of stator winding Directly water cooled Cooling of stator core & rotor Directly hydrogen cooled Direction of rotation Anti clockwise viewed from turbine end

STATIC EXCITATION EQUIPMENT

Make BHEL SEE Rating Voltage-310V DC Current-2600A DC Accuracy of Excitation control 0.5% Range of voltage control in auto 90-110% Range of voltage control in manual 80-110% No load field voltage 102V DC No load field current 917 A Max. continuous rated field voltage 355V DC Max. continuous rated field current 3000 A Ceiling voltage 620V DC (Excitation voltage at field forcing) Ceiling current 4500A Frequency range of operation 47.5 52Hz No. of parallel bridges including redundant bridge 4 No. of redundant bridge 1 Protection class IP20 Station battery supply 220V DC

Duration of field forcing 10 sec. Response time 40 msec.

EXCITATION TRANSFORMER DETAIL

Make BHEL Rating 3150 KVA Voltage rating 15750 / 575 V Vector group DYn5 Insulation level 50 KV RMS / min Cooling Natural

3.2DESIGN AND CONSTRUCTION FEATURES

MATERIAL

Rotor shaft Steel forging 35Ni 13cr 12Mo 35V12 Chromium nickel molybdenum & vanadium steel Rotor winding Silver bearing copper Rotor slot wedges Duralumin Rotor rating ring 60Mn Ni85Cr 35 W75, Non magnetic steel Stator frame ST42W Stator core stamping Cold rolled silicon steel Bearing body CSW C25 IS: 2856-64 Shaft seal ring ST-42W Bearing & seal Babbitt Grade 84 Carbon brushes Grade HM6R No. of brushes reqd. 112+1

WEIGHT AND OVERALL DIMENSIONS

i) Wt of the heaviest lift (Stator with Gas cooler & lifting trunions) 175.0 MT

ii) Wt of rotor 42.2 MT iii) Wt of gas cooler 1415 Kg iv) Wt of terminal bushings 85 Kg v) Wt of end shields 2000 Kg vi) Total wt. Of generator 270 MT (without exciter) vii) Overall dia of stator 3960 mm viii) Overall dia of rotor 1075 mm ix) Overall length of stator 6580 mm x) Overall length of rotor 9770 mm

TORQUES, CRITICAL SPEEDS ETC

i) Torque under normal working condition 76.32 T ii) Ratio of short circuit torque to F.L. torque 8 iii) Flywheel moment of rotor 21.1 TM2 iv) 1st critical speed of rotor (calculated) 1370 rpm v) 2ndcritical speed of rotor (calculated) 3400 rpm

OIL CONSUMPTION

i) Consumption of oil per generator bearing (excluding shaft seal) 300 lit/min ii) Oil pressure at inlet of bearing 0.3 to 0.5 Kg/cm2 iii) Consumption of oil in both shaft seals 77 lit/min

3.3 GENERATOR GAS SYSTEM

3.3.1 H2 IN STATOR CASING

i) Nominal pressure of H2 3.5 Kg/cm2 Permissible variation 0.2 Kg/cm2(g) ii) Max temperature of cold gas 44oc iii) Max permissible hot gas temperature 75 0C iv) Min. required purity of H2 97% v) Max. oxygen content 1.2% vi) Relative humidity of hydrogen at casing pr. (max) 30% vii) Max moisture content in generator casing 15 gm/m3 of H2 viii) Total gas volume of the generator 56 m3 ix) Max make up hydrogen per day 15 m3 x) Hydrogen cylinder capacity 6.8 m3 at 150 ata

3.3.2. GENERATOR FILLING QUANTITIES

M/c stand still M/c under rolling i) Amount of CO2 required to remove air expressed at NTP 120 m3 150 m3 ii) CO2 for expelling H2 120 m3 168 m3 iii) H2 filling quantity 300 m3 336 m3 iv) Compressed air required for purifying of CO2 from gen. 150 m3 v) Quantity of compressed air reqd. (at NTP) for carrying out air 500 m3 tightening test vi) Capacity of CO2 cylinder 27Kg

3.3.3 HYDROGEN COOLER

At rated Hydrogen pressure 3.5 ksc (g) i) No. of coolers/generator 4 ii) Gas flow per cooler 7-5 m3/sec iii) Max water inlet temperature 37oc iv) Design pressure water side of cooler 6 ksc(g) v) Max permissible operating pressure water side of cooler 3 ksc(g) vi) Pressure drop through cooler 17.5 mmwc vii) Material of tubes/fins Admiralty brass/copper viii) Material of water boxes/tube sheets Carbon steel ix) Heat load 528 KW x) No. of passes of water on water cooler 2

3.3.4 HYDROGEN DRIER

i) Type Refrigeration type, freon 12 ii) Working pressure 4 ksc max. iii) Dew point of dried gas at working pressure 3 to 5oc iv) Thermal load, ie. Compressor capacity 1100 Kcal/hr

3.3.5 SETTING VALUES FOR ALARM

i) Gen. Bearing & seal Babbitt temp. High V. High 750C 850C ii) Gen. Bearing oil oil O/L temp. 600C 700C iii) Stator winding temp. 750C ----- iv) Hot gas temp. 75oc ----- v) Cold gas temp. 45oc 55oc vi) Stator core temp 95oc ----- vii) Rotor temp 110oc 115oc viii) Temp of inlet water to gas cooler 38oc 48oc

3.4STATOR WATER SYSTEM 3.4.1 STATOR WATER COOLER

i) No. of coolers/system & type Two, shell & tube type ii) Max permissible operating pr.(Primary shell) 8.0 ksc iii) Max permissible operating pr.(cooling tube) 5.0 ksc iv) Primary water inlet/outlet temp 72.6/45oc v) Primary water flow 27 m3/hr

vi) Cooling water flow 110 m3/hr vii) Pressure drop in primary water 6.5 mmwc viii) Pressure drop in cooling water 0.8 mmwc ix) Max. cooling water inlet temperature 36oc x) Heat load 790 KW xi) Heat transfer area 33 m3 xii) Nominal gauge pressure at inlet of winding 3.3 ksc (g)

3.4.2 STATOR WATER PUMP

i) No. & make 2x100% single stage centrifugal with spiral casing & overhung impeller CPK CM50-200, KSB make ii) Flow 39.6 m3/hr iii) Head 45 mtr iv) Speed 2930 rpm v) Motor GEC make, 9.3 KW/12.5 hp, 415V, 3-, 50Hz, 18A Insl. Cl.B, 2930 rpm vi) Ambient temperature 50oc

STATOR WATER MAKE UP PUMP

i) No. & make 2 per unit, KBL make ii) Flow 1.39 L/s iii) Head 50 m iv) Motor 415V, 3- , 50Hz, 2.62KW, 2850 rpm, 7A,

Insulation class E

3.4.3 STATOR WATER FILTER

i) Make & type BHEL, Hardwar, Wiremesh Disc type, F-26 ii) No./unit 2 iii) Ratio Discharge 30 dm3/hr iv) Working pressure 6 Kg/cm2 v) Max. size of filter that can be filtered: 0.224 mm

3.4.4 MAGNETIC FILTER

i) No./unit 2 ii) Make Boll and Kirch Filter bar GmbH iii) Type P.53.1-MA.220 500DN 100 YQ-36 iv) Magnet type Permanent Magnet v) Working pressure 10 ksc vi) Working temperature 60oc vii) Capacity 36 m3/hr viii) Type of particles filtered Highly & medium magnetic

3.4.5 EXPANSION TANK

i) Type Hermetically sealed cylindrical type ii) Material Stainless steel iii) N2 pressure in the tank 0.2 ksc (g) iv) Wt. of the assembly 825 Kg

3.4.6 QUALITY OF DISTILLATE

i) Conductivity Less than 5 mho/cm preferably 1 mho/cm ii) PH 7 to 8.5 iii) Dissolved O2 Minimum preferably less than 50 ppb

but not greater than 100 ppb iv) Dissolved CO2 Should be nil v) Dissolved Cu content 25ppb to 200 ppb to avoid copper pick up vi) Content of ammonia, hydrazine, phosphate & chlorine Nil vii) Iron content preferably nil, but not more than 20 ppb (Dissolved & undissolved)

3.4.7 SETTING VALUES OF STATOR WATER SYSTEM

1 Expansion tank level Low 800 mm 2. Pressure in the expansion tank 0.4 ksc 3. Changeover from working pump to stand by pump due to pressure fall 4.5 ksc (g) 4. Pressure drop across water filter at which cleaning is recommended 0.4 ksc (g) 5. Distillate flow in stator winding Low 21 m3/hr Emergency 13 m3/hr 6. Distillate conductivity High 13.3 mho/cm V. High 20 mho/cm 7. Distillate outlet temperature High 85oc 8. Distillate inlet temp. to winding High 46oc V. High 48oc

3.5 SEAL OIL SYSTEM

i) Type of shaft seals Single flow ring type ii) H2 Pressure at generator casing 3.5 0.2 ksc iii) Seal oil-H2 diff. Pressure min 1.0, normal 1.5, max 1.7 ksc iv) Quantity of seal oil per seal 38.5 l/min v) Quantity of seal oil towards Air side rd Hydrogen side rd

3.5.1 SEAL OIL COOLER

i) Make BHEL, Hardwar No.of cooler/system: 2x100

ii) Type Surface type iii) Heat transfer area 14.3 m2 iv) Design pressure tube side/shell side 10.5 ksc v) Test pressure tube side/shell side 18 ksc

3.5.2 SEAL OIL PUMPS

I) A.C. Seal Oil Pump i) Make & type Tushaco,Delta Corp.,Three screw positive displacement ii) No./Unit 2 iii) Pump discharge 200 lpm0 iv) Pump speed 1450 rpm v) Pump head 12 ksc vi) Motor 415V, 3-, 50 Hz, 7.5 KW, 15.5A, 1450 rpm Insl. class B

II) D.C. Seal Oil Pump i) Pump Same as A.C. pump ii) Pump/unit 1 iii) Motor 220V DC, 11KW, 1450 rpm, Insl. Class F, Shunt wound self-excited D.C. motor

3.5.3 VACUUM PUMP

ii) Type Single stage, rotary vane type (SB-4) iii) Suction capacity 5.77 m3/hr iv) Ultimate pressure < 1.06 mbar v) Motor 415V, 3-, 50 Hz, 0.45 KW, 1500 rpm

3.5.4 OIL FILTER

i) Type Wire & mesh type ii) Flow rate 12 m3/hr max. iii) Mesh size 0.10 mm max. iv) Design pressure 16 ksc max.

3.6 SPECIFICATIONS OF TRANSFORMERS

3.6.1 GENERATOR TRANSFORMER

i) Manufacturing BHEL, Bhopal ii) No./Unit One iii) Rating 240 MVA iv) No load voltage HV/LV 230/15.75 KV v) Rated current HV/LV 602/45/8797.72 A vi) Frequency 50 Hz vii) No. of phase 3, type of connection - HV-Star, LV-Delta viii) Type of cooling ONAN/ONAF/OFAF cooled ix) Vector group Ynd1 x) Type of tap changer OFTC xi) Off load tap changer range -5% to +5% in steps of 2.5% xii) Impedance voltage at HV-LV 14% (normal tap) xiii) Temperature rises above an ambient temp. of 50oc Oil by thermometer 50oc Winding by resistance

ONAV/ONAF 50oc OFAF 50oc

3.6.2 STATION TRANSFORMER

i) Manufacturer BHEL, Bhopal ii) No. / unit 1 iii) Rated output 55 MVA iv) Voltage ratio HV/LV1/LV2 Star v) Winding connection HV/ LV1/LV2 144.5/972.1/3015.8 A vi) Line current HV/LV1/LV2 50 Hz vii) Type of tap changer & range OLTC, +10% to 10% in steps of 1.25% on HV winding, total 16 steps viii) Type of cooling ONAN/ONAF ix) Rating at different cooling 60% 80% 100% ONAN ONAF ONAF x) Temperature rise over ambient temp. 50oc in oil 40oc in winding 50oc xi) Bushing HV LV HV neutral Type oil immersed air insulated oil immersed Min creepage distance(mm) 6125 440 900

xii) Guaranteed positive sequence HV-LV1 HV-LV2 LV1-LV2 Impedance at 75oc with 100% Rating at principal tap 16.5% 16.5% 26.5%

3.6.3 UNIT AUXILIARY TRANSFORMER

i) Manufacturer TELK, Kerala ii) Type of construction Core type iii) No. / unit Two iv) Rating 16 MVA v) Voltage ratio 15.75 / 6.9 KV vi) Winding connection HV/LV Delta/Star vii) Vector group DY11 viii) Type of cooling ONAN ix) Rated frequency 50 Hz x) Phase 3 xi) Rated current HV/LV 587/1340 A xii) Type of tap changer & range OLTC, +10% to 10% in steps

of 1.25% on hv winding in 1 step xiii) Temperature rise above ambient of 50oc in oil 40oc in winding 50oc

xIv) Bushings HV LV LV neutral oil filled oil filled oil filled

3.6.4 VARIOUS SERVICE TRANSFORMERS

No. 12 i) Make Voltas, Pune ii) Type Dry type, cast resin, indoor type iii) Rated KVA 2000 & 1600 iv) Type of cooling AN v) Voltage ratio 6600V/433 V vi) Vector group Dyn 11 vii) Winding connection HV/LV Delta / Star viii) Percentage impedance ix) Tap changer type & range Gang operated off ckt. +5% to 5% in steps of 2.5% x) Temperature rise over an ambient of 50oc in oil 50oc in winding 55oc

3.7 H.T. MOTORS

Sl. Equipment Quantity Rating (KW) 1 ID fan 4 1500 2 FD fan 4 925 3 PA fan 6 800 4 Mill 6 2250 5 BFP 6 4000 6 CEP 4 600 7 CW 6 1470 8 BCW 6 275 9 RAW 6 304 10 Ash slurry pump motor 12 185 11 Ash recycling transfer water pump motor 3 700 12 Conveyor 7A/7B 2 520 13 Conveyor 5A/5B 2 400 14 Conveyor 2A/2B 2 330 15 Conveyor 1A/1B 2 300 16 Conveyor TRH 1A/1B 2 200 17 DE system 5&6 2 180 18 Conveyor 8A/8B 2 165 19 Ring granulator 4 825 20 Conveyor SR1 2 300

3.8 BATTERY & BATTERY CHARGER

3.8.1 220 V DC BATTERY

i) Make Amoco ii) Type Lead Acid, sealed type

No. of cells Unit 1-110, unit II-110, station-110, S.Y -110, CHP-110 Capacity 2000 AH (Unit-I, II & Station), 350 AH (S.Y), 400 AH (CHP)

Each cell voltage 2 V Specific gravity 1200

220 V FLOAT CUM BOOST BATTERY CHARGER

i) Manufacturer Chhabi Electricals Pvt Ltd & Caldyne Pvt Ltd (for CHP)

ii) Service Float & Boost charging

iii) A.C. input 3-, 50 Hz, 415V 10%

iv) D.C. output voltage Float Boost Plant 240 158-297 S.Y. 240 158-297 CHP 240 158-297

Current Plant 0-350 A 0-280 A S.Y. 0-100 A 0-49 A CHP 0-100 A 0-40 A

v) Ripple 3% vi) Efficiency at full load 80% vii) Voltage setting range 240 V viii) Current setting range 80 A ix) Cooling AN x) Response time Inst xi) Maximum ambient temperature 50oc

3.8.2 +24V DC BATTERY

i) No. of cells Unit I (main-13, standby-13) Unit II (main-13, standby-13)

ii) Capacity 1000 AH (U#1, 2 & CHP) iii) Each cell voltage 2 V

+24 V/1000 AH DC BATTERY CHARGER

i) Manufacturer Chhabi Electric ii) Type Float cum Boost iii) AC Input 41510%, 3-, 50 Hz iv) DC output Float Boost DC voltage 281%V 24 to 35V DC current 600 A 1402%A v) Number Two/unit vi) Max.ambient temperature 50oc

24V/600A FLOAT CHARGER

i) Make Amar Raja Power Systems Ltd ii) Number Two/unit iii) Input 41510%, 3-, 50 Hz, 50 A

iv) D.C. output 29.25 DC volt & 600 Amp v) Capacity 1455 AH vi) Max. ambient temp. 45oc

24V/175 A BOOST CHARGER CUM DC DB

i) Make Amar Raja Power Systems Ltd ii) Input 415V 10%, 3-, 50 Hz, 12.4 A iii) D.C. output 29.9 V DC & 175 A iv) Capacity 1455 AH v) Max. ambient temperature 45oc vi) Number Two/unit

48V DC/70A FLOAT CUM BOOST CUM DCDB

i) Input 415V 10%, 3-, 50 Hz, 19A, 5A ii) DC output 48V DC, 58A iii) Capacity 120 AH iv) Max. ambient temperature 500C v) Number One/unit

3.8.3 24V DC BATTERY

i) No. of cells Unit I(main-13, standby-13), Unit II(main-13, standby-13) ii) Capacity 200 AH (Unit # 1&2) iii) Each cell voltage 2 V

-24 V DC BATTERY CHARGER i) Manufacturer Chhabi Electric ii) Type Float cum Boost charger iii) AC input 415V 10%, 3-, 50 Hz iv) DC output Float Boost DC voltage 28.12% 24 to 35 DC current 0-110A 282%A

v) Max.ambient temperature 50oc vi) Ripple 3%

3.8.4 UPS SYSTEM

i) No. / Unit One ii) Rated output 2 x 60 KVA, 240V AC, 1-, 50 Hz

iii) Input 415V 10%, 3-, 4 wire, 506% Hz, 110A nominal iv) Output 240 1%V AC, 1-, 2 wire, 50 Hz, 250A v) Power walk in 10 to 15 seconds vi) Nominal DC bus voltage 405 V DC vii) Capacity 450 AH viii) Discharge battery voltage 315 V DC ix) No. of cells 180 cells x) Each cell voltage 2 V/cell xi) Battery float voltage/cell 2.25 V/cell xii) Ripple 3% (max. rms)

GENERATOR RELAY PANEL

Sr No Protection Designation Operating Remarks Time

1. Generator differential 87G Inst Generator winding protection insulation protection.

2. Generator negative phase 46G 4 sec. Generator unbalanced sequence protection current protection.

3. Generator loss of 40G Inst Generator field failure excitation protection protection.

4. Generator pole slipping 98G 50 msec Protection against protection generator falling out of slip

5. Generator back up 21G 1.5 sec Back up protection against impedance protection external faults

6. Generator stator interturn 95G Protection against insulation fault protection failure between two windings

7. Generator stator E / F 64G1 1 sec Main protection against protection generator windings.

8. Generator stator stand by 64G2 IDMT E / F protection

9. Generator rotor E / F Stg-II 2 sec protection Alarm 0.5 sec

10. Generator stator water 30P Inst conductivity high (20 mho)

11. Generator stator water 30P 50 sec flow low (13 m3/ hr)

12. Generator low forward 37A & B 2 sec Protection for generator power protection before motoring takes place

13. Generator overload 51G 20 sec protection

14. Generator U/F 81G 10 sec protection

15. Generator O/F 81G 10 sec protection

16. Generator O/V alarm 59G

GENERATOR TRANSFORMER

Sr No Protection Designation Operating Remarks Time

1. GT overall differential 87GT Inst Winding insulation protection protection

2. GT bay C.B. LBB 50Z 0.2 sec. protection

3. GT over fluxing 99GT Inst. Protection

4. GT bucholtz trip 63GT Inst. Protection against internal fault.

5. TBC LBB Protection 50L 0.2 sec

6. GT winding temp. Inst Protection for insulation high trip winding failure.

7. GT oil temp high Inst Protection for oil high trip degradation

UAT

Sr No Protection Designation Operating Remarks Time

1. UAT differential 87UAT Inst Protection protection against winding insulation failure

2. UAT over current protection 51 UAT Inst

3. UAT bucholtz trip 63 UAT Inst Protection against internal fault

SECTION 4

CONTROL &

INSTRUMENTATION

4.1 UNIT C & I SYSTEM

SG (FSSS) :-Procontrol P13/42(ABB) TG (ATRS) :-Iskamatic A & B(KWU, Germany)

Measurements Automation :-MOD 300 DAS :-MOD 300 Make :-ABB Supplier :-ABB

MOD-300 constitutes of: i)Open Loop control system ii)Close Loop Control system iii)Information system iv)Sequence of Event Recorder stand alone

OLCS/CLCS

System Configuration No. of groups (OLCS) 4 No. of groups (CLCS) 5 No. of function groups(OLCS) 12 No. of function group(CLCS) 16 No. of OLCS cubicles 19 No. of CLCS cubicles 12 No. of control loops 31 Processor for OLCS 32-bit, Motorola 68020 micro processor Processor for CLCS MC 68000 R8 (8 MHZ), Address Bus =24 Data bus =16 System Redundancy 100% Parallel operation available through CRT Key board and P.B. on the panel. Redundant power supply of

240V Ac through UPS for DAS, operator station, engineer station, history station for OLCS & CLCS.

INFORMATION SYSTEM

No. of memory nests 2 (consists of mass memory & redundant mass memory) Memory capacity hard disk 2 GB No. of control operating station 2 per Unit No. of monitoring st.(PS-U) 3 per Unit No. of CRT & Keybord(on desk) 4 CRT & 4 Key board.

IS. Configuration monitoring functions. Analog Inputs 384 (CLCS only)+903 (DAS) (1100 remote inputs) Digital Inputs 5100 (DAS) + 2120 (OLCS) 40 remote inputs+287 common inputs

STANDARD DISPLAYS

Alarm display 01 Curve display 20 Bar display 34 Op. area display 10 Graphic display 87 Function group op. display 29

SEQUENCE OF EVENT RECORDER

Make M/S Highland, Rochestor Instrument, Scotland. Model DEP 90 No. of active points 302 Input per card 16 (16 input circuits) Resolution 1 MS Alarm debounce time Responds to inputs greater than 40 ms duration. Contact integration voltage 48 V ungrounded. Acceptability of NO/NC contract Yes

Archiving facility WYSE make PC SER Terminal H-31 green WYSE, model WY-30+

INTERFACE WITH FSSS/ATRS THROUGH RELAY PANEL (Only Binary communication)

Model Procontrol P13/42 Make BBC Supplier BHEL, EDN, Bangalore Software language Procontrol10 No. of stations 19 No. of processors 20 Type of processor 70 PR 03(Dedicated type) Program memory 4096 bytes, (EPPDMS)

System Configuration

1. No. of Intra-planel bus 2 (max. 10) Hot redundant fuses for each IPB

2. No. of stations/IPB IPB1=15, IPB2=19 3. No. of stations/entire system 19 4.Modules per local bus Maximum 64

Data Communication

Local Bus Service address 2 is every 10 m sec. i) Useful Address Max. 256 ii)Time Cycle (Set) 20ms iii)Information bit rate 204.8 KBAVD iv)Type of modulation Pulse modulation v)Amplitude 10V low active vi)Data security Parity bit, clock monitoring, data valancy on local bus, address cycle, watchdog timer. vii)Distance bt. IPB & IB 3m (max.)

Intra-Panel Bus(IPB) i)No. of address 256 x No. of stations,16384 max. ii)Time required/one telegram 60 s iii)Information bit rate 266.7 KBAUD iv)Signal code DPDM v)Amplitude + 15 v vi)Data security Parity bit, counting of binary characters, monitoring of time & amplitude per bit.

vii)Transmission means Coaxial cable RG 213U of 50 characteristic.

Inputs/Outputs

Analog I/P 4-20 mA ,100 I/P resistance 10V to +10V, 100 K Analog O/P 4-20mA,500 , max. permissible load 10 to + 10 V, 4mA Binary I/P For 0 signal 30V to +30 V. For1 signal 11.2V to 30V. Binary O/P For 0 signal 0 to + 1V. For 1 signal 11.7V to 30V. All modules are protected against short circuit and over load.

Contact Inputs

Voltage between terminals with open contract 48 V DC Contact current for closed contact 5 mA Procontrol system is powered by 24V/1000A redundant charger with battery

backup. Interface with ATRS/MOD 300 through relay cabinet mounted inside FSSS cabinet

(Only binary communication)

ELECTRONIC AUTOMATION SYSTEM FOR STEAM TURBINE (EAST)

Manufacturer BHEL, Bangalore East package comprises ISKAMATIC A & B

ISKAMATIC-A ISKAMATIC-B 1.Turbine stress Evaluator 1.Logic subgroup control 2.Flectro hydraulic governing control 2.Limit valve monitoring (Linear, nonlinear, variables) 3.L.P. Bypass, seal/leak steam control 3.Drive control modules (valves, pumps/solenoids) 4.Vibration & position monitoring 4.Relay cabinets 5.Analog signal conditioning 6.Turbine protections 7.Auto synchronizer 8.Load shedding Relay.

COMMON FEATURES

1.Separate ref. voltages for analog (HQ) / Binary (M) signal conditioning. 2.Only one connection exists between M & HQ, at the cabinet power supply bus. 3.Decoupling of signal conditioning paths. 4.Selectivee fusing & use of ICs

Each package is powered by +24/-24 V redundant battery charger (chhabi make) with battery back-up with load current 231/100A with 1% ripple.

FSSS, MOD 300 & East are powered by their own dedicated power sources. Signal communication in between FSSS/MOD 300/East is done through coupling

relay cabinet CRA01 02 with complete isolation.

UNINTERRUPTED POWER SUPPLY

i)Make Tata libert ii)Capacity(KVA) 60 iii)Voltage rating 240 V AC + 1% output. iv)Frequency 50 HZ v)Battery Rating 405V DC (common for both UPS) Make Exide Type Gauntlet tubular Capacity 450 AH No. of cells 180 Each cell voltage 2.25 V (Float) 2.00V (Nominal)

LAN & IT

Network Local Area Network based on Fast Ethernet Fiber-Optic Switched Backbone and Structured Cabling System.

Connectivity 36 users. Network cabling is done for 66 nodal points. Remote Users 5. Coal handling Plant, MGR Systems, water Treatment Plant, Switchyard and Workshop. Facility exists for 16 remote users.

Main Application Server Compaq Prolient 3000, PIII 500MHZ, 512MB ECC SDRAM (upgradeable up to 2GB, 512KB L2 Cache, 3X9.1 GB Hot Swap

SCASI HDD, 10/100 TX PCI UTP Controller.

Exchange Server Compaq Prolient 1600, PIII 500MHZ, 128MB ECC SD RAM, 512 L2 Cache, 9.1GB SCSI HDD, 10/100 TX PCI UTP Controller.

Network Management 1 No Compaq Deskpro EP PIII 450MHZ, 64MB SD RAM Station 8.4GBHDD

LAN Node PCs: 41 Nos Datamini PIII 450MHZ, 64MB SD RAM 8.4GB HDD

Main Chassis Based 1 No Cabletron Smart Switch 6000 with 16X10/100Base Tx Switch Ports, 6X100 Base Fx Ports

Workgroup Switch: 5Nos Cabletron Smart Stack 100 with 22x10/100 BaseTx full Duplex auto negotiating ports + 2X100 Base Fx Ports.

Remote Access Server CISCO 2500, 1X10Base T + 16 Async. Sl. Ports For Dial up facility:

Modem for 33.6Kbps Dial-up/Leased Line Modem Remote Access:

FO Connection: 6 core Multimode Fiber Optic (Main Switch to Workgroup switch)

UTP Connection: E CAT5 UTP Cable. (Workgroup Switch to Nodes)

Network Management Cabletron NMS Software Software:

Main Sever System Operating System Win NT4, Database MS SQL Server 7.0 Application Software RAMCO e-Application 3.1

Logistic Modules Inventory Module Purchase Module Maintenance Module AP Module

Exchange Server System Operating System Windows 2000 Mail System Exchange Server 5.5 Antivirus Software Norton Antivirus for Server & PC Internet Access 64Kbps VSAT connection from HSCL

VSAT Router CISCO 2600 Proxy Server PIII PC with Linux System IB TPS DOMAIN www.opgc.co.in

4.2 INTERLOCK PROTECTION 4.2.1 BOILER AND AUX.

FURNACE SAFEGUARD SUPERVISORY SYSTEM

1. Purge Permissive a) All system power supply (AC & DC) ON b) At least one ID and one FD in service. c) A min. of 30% of full load air (>268 T/hr) d) A proper water level in drum e) LOTV closed f) HOTV closed g) All LONV closed h) All HONV closed i) No boiler trip condition permit j) All scanner no flame k) All mills off l) All PA fans off m) All O/L gates closed

2. Purge Sequence a. Purge ready (all purge permissives are satisfied) b. Purging (5 minute cycle) c. Purge complete

3. First Cause Trip (Master Fuel Trip) Alarm Trip a. Both ID fan off - - b. Both FD fan off - - c. Furnace pressure V. High +100 + 250mmwc d. Furnace pressure V. Low (2/3 logic) - 100 - 250mmwc e. Drum level V. High (for more than 10 sec.) +100 +300mmwc f. Drum level V. Hi (for more than 10 sec.) -100 -300mmwc g. Emergency trip h. Loss of 220V DC for more than 2 sec. I. Air flow less than 30% j. Reheat protection trip* k. Less than fireball and loss of A.C. power at any elevation in service** l. Loss of all fuel trip***

m. Flame failure trip**** n. Loss of unit critical power +24V DC

* Reheater Protection Trip 1. Generator breaker open or turbine tripped

OR Boiler working and turbine not working. Any HP or LP bypass valve is closed The reheater protections armed with time delay of 5 sec.

OR 2. HP bypass 1 or 2 or LP bypass 1 or 2 less than 2% open and turbine working and load

shedding relay operated with 11 sec. off delay than reheat protection is armed with time delay of 10 sec.

Turbine trip is armed if, All ESV and 4 IV open and first stage pressure more than 35 bar and any ESV or IV closes or turbine trip

Turbine working is armed if, All ESV and IV open and first stage pressure is greater than 35 bar.

Boiler working is armed if, a. Main steam pressure left is more than 50 bar and main steam temp left is more than

513 0C and b. Main steam pressure right is more than 50 bar and main steam temp right is more

than 513 0C and c. Boiler fire ON, provided

HP bypass valve 1 & 2, and LP bypass valve 1 & 2 opened more than 2% once.

** Less Than Fire Ball And Loss Of AC Power At Any Elevation In Service. Any elevation started and there is a loss of AC power at any elevation in service for more than 2 sec.

*** Loss Of All Fuel Trip a. Loss of fuel trip arming (i.e. elevation AB or CD or EF any nozzle valve open and no MFR

trip) and b. All coal outlet gates closed and c. LOTV does not open, or elevation AB all LONV closed and d. HOTV not does open, or elevation AB, CD, & EF back up trip.

**** Flame Failure Trip Elevation A, B, C, D, E, & F voted and unit flame failure trip armed (i.e. any mill outlet gate proven for more than 3 sec.)

Elevation A voted: a. Elevat