BADARPUR THERMAL POWER SATATION

TECHNICAL DIARY

210MW

NTPC

NATIONAL THERMAL POWER STATION

INDEX

Sr. No. Contents Page No. 1.0 BOLIER & AUXLIARIES 4-29 1.1 Specifications 1.2 Performance data 1.3 F.S.S.S 1.4 Fans (ID, FD, PA,Ignitor & Scanner) 1.5 Air Heater 1.6 Soot blower 1.7 Electrostatic Precipitator 1.8 Coal burners & oil guns 1.9 Coal mill 1.10 Raw coal feeder 1.11 Fuel oil transfer pump 1.12 Dosing system 1.13 Ash handling system 1.14 D.M. Make up system 1.15 Coal Mill Reject System 2.0 TURBINE & AUXILIARIES 30-46 2.1 Specifications 2.2 Governing system 2.3 Turbine lubrication system 2.4 Condensate system 2.5 L.P.Heaters & air ejection system 2.6 Feed water sytem 2.7 H.P. Heaters 2.8 C.W. pump & C.W. booster pump 2.9 HP & LP Bypass system 3.0 GENERATOR & AUXILIARIES 47-57 3.1 Generator Specification 3.2 Specification Of Static Excitation System Unit

IV & V

3.3 Generator Seal Oil System 3.4 Stator Water Cooling System 3.5 Generator & UAT Transformers 4.0 PROTECTION & INTERLOCK 58-72 4.1 Unit protections 4.2 Partial load conditions 4.3 Protection & interlock of unit auxiliaries 4.4 Electrical protection for unit auxiliaries 5.0 PROTECTION RELAYS SETTINGS 73-86 5.1 Recommended Settings of Generator, GT &

UATs 5.2 Recommended Settings Of 6.6 KV Sections 5.3 Recommended Setting Of MCB Relays 6.0 NEW C&I SYSTEM COMMISSIONED 87-89 7.0 OFF-SITE AUXILIARIES 90-132 7.1 Switchyard 7.2 Air compressors 7.3 Control structure pump house 7.4 Ash Handling Plant 7.5 Cooling Tower 7.6 Diesel generator 7.7 Water Treatment Plant 7.8 Old Coal Handling Plant 7.9 New Coal Handling Plant 7.10 Fuel Oil System

SECTION-I

BOILER

AND

AUXILIARY

1.1 SPECIFICATIONS 1.1.1 TYPE Natural circulation , Dry Bottom , Tangentially fired , Balanced Draft ,

Radiant Reheat type with direct fired pulverised coal system. 1.1.2 DESIGNED FUEL Indian Bituminous Coal

Fixed Carbon

Volatile Matter

Moisture

Ash Grindibility (HGI ) High Heating Value

38 % 26 % 8 % 28 % 55 4860 Kcal / Kg 1.1.3 FURNACE Fusion Welded Type

Width Depth Height Volume 13.86 m 10.59 m 42.79 m 5210 cu. m.

1.1.4 SUPERHEATER , REHEATER & ECOMOMISER

S. No.

Description Heating Surface ( sq. m )

No. of Coils / Tube

Size (mm) Material

1. Low Temp. S/H

8209.5 Upper Bank – 67 Lower Bank – 67 Terminal Tubes 67 x 6 = 402

44.5 x 5 44.5 x 4.5 44.5 x 4.5 44.5 x 4.5

1 Cr , ½ Mo ( SA 213 T11 ) SA210CrAl SA209T1 SA213T11

2. Platen S/H 944.5 29 a) 51 x 4.5/5.6/

7.1/8.8

1 Cr , ½ Mo ( SA 213T11 ) & SA213T22

3. Final S/H 1036 119 a) 47.6 x 7.1

b) 47.6 x 6.6

c) 47.6 x 8.6

2¼ Cr , 1 Mo ( SA 213T22 )

4. Ceiling & Enclosures

540 Roof Panels – 120 Front Wall –

54 x 4.5 51x 4.5

Carbon Mo (SA209T1) Carbon

181 Rear Wall – 136 Side Wall – 66 x 2

51 x 4.5

Steel (SA210GrA1) Carbon Steel (SA210GrA1

5. Reheater 2650 Front assembly

–59 Rear assembly - 89

54 x 3.6 47.6 x 3.4

Carbon Mo (SA209T) 2¼ Cr , 1 Mo ( SA 213T22 ) 1 Cr , ½ Mo ( SA 213T11 ) SA213T22 SA213Tp347A

6. Economiser 5440 67 44.5 x 4.5 Carbon Steel (SA210A)

1.1.5 ATTEMPERATOR

Type No. of Stages Location Medium of Spray Spray One Between Horizontal

& Platen S/H Feed Water

1.1.6 FUEL SPECIFICATIONS A) COAL i. Fixed Carbon 38.% ii. Volatile Matter 26% iii. Moisture 8.0% iv. Ash 28% v. Grindability 55HGI vi. High Heat 4860 Kcal/Kg vii. Coal size to Mill 20 mm

B) OIL i. Low Heat value 10000 kcal/kg ii. Sulpher 4.5% w/w iii. Moisture 1% w/w iv. Flash point 660 C. v. Viscosity 1500 redwood at 37.80 C . vi. Sp. Weight 0.98 at 380 C. 1.1.7 SAFETY VALVES Location Make &

type No. per boiler

Size Set pressure (kg/cm2)

Relieving capacity (t/hr.)

Drum a)dresser 1749wa b)dresser 1749wa

1 2

3” 3”

158.2 161 162.41

190.04 162.08 195.08

Super – Heater

dresser 1739wd

1 2 ½ “ 144 86.73

SH-electro magnetic Relief valve

dresser 1538-vx

1 2 ½ “ 142 88.06

Reheater inlet

a)dresser 1775wa b)dresser 1785

1 3

4” 6”

33.4 33.75 34 34.45

94.7 136.01 137.38 138.76

Reheater outlet

dresser 1705 rwd

1 6” 30.58 114.93

1.2 PERFORMANCE DATA

1.2.1 DESIGNED PARAMETERS Description Flow (t/hr) Load

MCR NCR 60%MCR 210mw

Temperature ( C0.) MCR NCR 60%MCR 210mw

Pressure (kg/ cm2) MCR NCR 60%MCR 210mw

Steam Steam at final SH Outlet

700 662 420 540 540 540 137 136 13.2

Steam at 580 575 375 540 540 540 24.5 24.7 14.9

Reheater Outlet Steam at Reheater

- - 332 331 293 26.4 26.5 16.0

Steam from Drum

- - 342 340 334 150.7 148 137.4

Steam leaving Horizontal SH

- - 430 433 452 146 144 135.5

Steam leaving Platen SH

- - 514 514 512 - -

Water Feed water entering economiser

700 643 371 247 246 220 153 150 139.2

Feed water leaving Economiser

- - 278 277 262 - -

Flue gas Flue gas leaving Furnace

- - 1125 1135 1118 - -

Flue gas entering Reheater

- - 1020 1017 981 - -

Flue gas entering Horizontal SH

- - 697 690 670

Flue gas entering Eco.

463 459 433

Flue gas entering APH

364 366 336

Flue gas leaving APH

146 143 129

Air PA flow at APH Outlet

96.7 77.8 70.3 338 336 316

SA flow at APH Outlet

678.3 624.5 481.5 330 329 311

Tempering 120.8 85.5 92.9 38 38 38

air Total combustion air

919.3 869.3 668.2

Fuel Coal(HHV=5000Kcal/Kg.)

110.1 105.1 71.5

1.2.2 PRESSURE AND DRAFT (AIR &GAS) PRIMARY AIR Description Units MCR NCR Control load

60% MCR P.A. Fan Outlet mmwc 740 734 700 A.H. Inlet mmwc 727 723 691 A.H.Outlet mmwc 672 672 661 Mill Inlet mmwc 634 634 634 Mill Outlet mmwc 228 228 228 SECONDARY AIR Description Units MCR NCR Control load

60% MCR F.D.FanOutlet mmwc 317 291 213 SCAH Inlet mmwc 312 286 211 SCAH Outlet mmwc 287 265 201 AH Inlet mmwc 282 261 198 AH Outlet mmwc 193 185 162 Aerofoil Inlet mmwc 180 174 157 Windbox Pr. mmwc 140 140 140 Windbox to Furnace Diff.

mmwc 140 140 140

FLUE GAS Description Units MCR NCR Control load

60% MCR SH Platen Inlet mmwc -5 -5 -5 RH Inlet mmwc -6 -6 -6 Finish SH Inlet mmwc -14 -13 -9

LTSH Inlet mmwc -20 -19 -12 Economiser Inlet

mmwc -37 -35 -20

A.H. Inlet mmwc -54 -49 -31 E.P. Inlet mmwc -184 -165 -84 I.D. Fan Inlet( Including Static Head)

mmwc -242 -222 -128

1.2.3 MILL AND BURNER PERFORMANCE Description Units MCR NCR Control load

60% MCR No. of Burner in operation

- 16 16 12

Burner Tilt Degree 0 +10 +30 No. of mills in operation

- 4 4 3

Mill Loading % 80 79 70 Air flow per Mill

T/hr 52.3 52.3 52.3

Air Temp. at Mill Inlet

0C 172 171 160

Mill Outlet Temp.

0C 77 77 77

Fineness % Thru’ 200 Mesh

70 70 70

1.2.4 O2, CO2 ( BY VOLUME ) AND EXCESS AIR Description Units MCR NCR Control load

60% MCR O2 in Gas at Economiser Outlet

% 4.3 4.3 5.5

CO2 in Gas at Economiser Outlet

% 14.9 14.8 13.7

Excess air in Gas at Economiser Outlet

% 25 25 36

1.2.5 DESIGNED PRESSURE DROPS Description Units MCR NCR Control load

60% MCR SH System Kg/cm2 13.7 12.0 5.4 RH System Kg/cm2 1.9 1.8 1.1 Economiser System

Kg/cm2 2.1 2.0 1.8

A. Air mmwc Wind-box 115 APH 94 Air-duct 63 Aero-foil 25 B Across Pulv. 305 Fuel Piping 308 C. Flue Gas mmwc Furnace 4 S/H & R/H 48 Eco 19 Flue gas Duct & Dampers 52 Regenerative APH 110 Static Head 20 Velocity Head & Exit Loss 20 ESPS 22 Total Loss 295 1.2.6 HEAT BALANCE

Dry gas loss 4.63% Carbon loss 2% Radiation loss 0.26% Unaccounted loss 1.5% H2 in air and H2O in fuel 4.9% Total loss 13.3% Efficiency 86.7%

1.2.7 RECOMMENDED FEED WATER LIMITS Drum operating Pr. in kg/cm2 61-100 101 & above 1. Hardness Nil Nil

2. ph at 250 C.(Copper alloy pre-boiler syms.) 8.8-9.2 8.8-9.2 3. ph at 250 C.(Copper free pre-boiler syms.) 9.0-9.4 9.0-9.4 4. Dissolved Oxygen(max) ppm 0.007 0.007 5. Total Iron(max)ppm 0.01 0.01 6. Total Silica(max)ppm 0.02 0.02 7. After Cation Column Conductivity at 0.5 0.3 250 C( micro-mhos/cm),online 8. Hydrazine residual(ppm) 0.02-0.04 0.02 - 0.04 9. Permanganate consumption(ppm) Nil Nil 10.Oil Not allowed Not allowed 11 Chlorides not allowed Not allowed Not allowed 12.Copper(max)ppm 0.005 0.005 1.2.8 RECOMMENDED BOILER WATER LIMITS Drum operating Pr. (kg/ cm2) 61-100 101 & above 1. Total dissolved solids (max)ppm 100 50 2. Conductivity at 250Cmicro-mhos/cm 200 100 3. Phosphate residual(ppm) <20 2-4 # 4. ph at 250C. 9.0-10.0 9.0-9.5 5. Silica(max)ppm 2.0 0.4 * 6. Chlorides(max.)ppb <4000 <2000 7. Total hardness Nil Nil Note: # If the Boiler water pH is not maintained in the prescribed limit, residual Phosphate may be increased but upto 10 ppm only.

• Silica value in Boiler water should commensurate with the drum pressure.

1.3 FURNACE SAFEGUARD SUPERVISORY SYSTEM (FSSS) FSSS facilitates remote manual/automatic control of fuel firing equipment through mechanized system and suitable interlocks/logics. The system provides protection against malfunctions of fuel firing equipment and associated air systems. 1.3.1 FSSS INTERLOCKS AND PROTECTION 1. PURGE READY CONDITIONS i) 220vDC and 110vAC supply to FSSS panel estd.(crl 53 and tdr 10 are both on) ii) Boiler Drum level normal(CR 169 is off) iii) At least one ID and one FD fan running(CR 151 is off) iv) Ignitor trip v/v proven closed(CR 263 is on) v) Warm-up trip v/v proven closed(CR 279 is on) vi) All Ignitors oil/air v/vs proven closed(CR12 is on) vii) All WO and HO nozzle hydromotor v/vs proven closed(CR16 is on)

viii)All Pulv. are off(CR 26 is on) ix) All RC Feeders are off (CR 28 is on) x) All mills HAGs closed and CADs open , less than 5%(CR 43 is on) xi) All Aux Sec. air dampers modulating to maintain adequate WB to furnace DP(CR 480 is on) xii) All el. Flame scanners show “No Flame”(CR 22 is on) xiii)No boiler trip command persisting(1CR 148 is off) SR. NO.

DESCRIPTION

PERMISSIVE INTERLOCK PROTECTION

1. Ignitor trip v/v

1. Ignitor Oil Supply Pr. Is Adequate (>13kg /Sq.Cm) 2. All Ignitor V/Vs are closed(cr12 on)

Pressing one pair (lo or ho) of oil gun start push button gives a starting impulse to all the four ignitors of that elev. The spark is applied for 10 sec. Only for every pressing of ignitor start push button.

a. ignitor oil header pr. Falls below 9kg for > 2sec. And ignitor V/v not closed.

b. Boiler trip command present(icrl 61 off)

c. When ignitor trip v/v is closed “v/v closed” green signal comes on (cr63 on)

2. Heavy Oil Trip Valve

1. Boiler trip circuit (MFR) is reset. (2 CRL 61 is ON)

2. All HO nozzle valves of AB, CD & EF oil guns are proven fully closed. (1 CRL 107 AB, CD, EF are ON)

3. HO supply pressure is adequate (more than 7 Kg/Sq.Cm)

4. HO pressure

1. HO header pressure is low for more than 2 secs (TDR 281 is ON) 2. Steam and heavy oil differential pressure is low (less than 0.3 Kg/Sq.Cm) for more than 2 secs and provided no guns are being started or stopped (TDR 287 is ON) 3. Boiler trip occurs (2 CRL 61 is OFF)

not low (less than 1.5 Kg/Sq.Cm for more than 2 sec. ) TDR 281 is OFF.

3. Heavy Oil Elevation start

1. DC power available (TDR 51 is ON)

2. Ignitor trip valve proven fully open (1 CRL 259 is ON)

3. No boiler trip command persists

4. Heavy oil temp above 100 deg C

5. Air flow adjusted between 30 to 40% of full load air flow

6. Burner tilt placed in horizontal position

4 Heavy Oil corner start

1. The main oil gun is inserted in guide pipe & coupled

2. The local maintenance control switch is placed in remote

3. HO manual isolation valve is open

4. Atomising steam manual isolation valve is open

1. In first 10 secs of pair start time trial the associated elevation ignitors are started. When ignitors are proven ignitor ON signal comes (CR 29 AB 1, 2, 3, 4 are ON) If the flame is not provend spark will cease and jamesbury valve will close after 10 secs.

1 When minimum 3 out of 4 ignitors at the associated elevation

are proven ON (1 CR131 AB is ON)

2 25 secs later a start command is sent to corner 3 (when pair 1&3 are started) or 4 (when 2&4 is started)

3 When the gun is fully advanced the atimising steam nozzle valve opens.

4 When the atomising steam valve is proven fully open the heavy oil nozzle valve opens placing HO gun in service. (Total time taken for proving the pair of guns is 90 secs)

5 HO elevation shut down

Depressing the associated elevation pair button will initiate a 375 secs stop time trial to shut down the scavenge the associated pair of LO guns as follows.

1.4 FANS 1.4.1 SPECIFICATIONS

Sr.No.

Description

Type No Of Boiler

Capacity m3/sec

Press. mmwc

Temp 0C

KW Motor Voltage KV/V

RPM

A ID Fan Axial Impulse Type

2 230.9 387 150 1300 6.6 990

B FD Fan Axial Reaction Type

2 103.8 520.5 50 800 6.6 490

C PA Fan Radial Backward Curved

2 65.3 1345.5 50 1250 6.6 1485

D Ignitor Air Fan

Centrifu Gal

2 400 Sefm

4’’WG - 11 415v 1460

E Scanner Air Fan

-do- 2 1100 M3

160 50 1.1 415v 3000

F Seal Air Fan

-do- 2 11000 M3

150 50 10 440V 2850

1.4.2 FAN LUBE SYSTEM AND CONTROL A : ID FAN LUBE OIL SYSTEM S.N. PUMP MOTOR FAN

I TYPE-Gear type Power-0.5HP II Capacity-5LPM Voltage-415v Frequency-50C/S,3

Ph. Inlet vane control

III Operating Press-2Kg/cm2 Speed-1380 RPM IV Relief Pr-7 Kg/cm2 Rated current- -1.08 Amps B: FD FAN LUB OIL SYSTEM: Pump Motor Fan control I Type-Gear type Power-4KW II Capacity-79.2 LPM Voltage-415V, Variable pitch blade Frequency-50c/s,3Ph control III Lub oil Pr. 0.8 to3ata (g) Speed-1400 rpm Rated Current-11

Amp

C: PA FAN LUBE OIL SYSTEM Sr.N PUMP MOTOR FAN

I TYPE-Gear type Power-0.5HP II Capacity-5LPM Voltage-415v Frequency-50C/S,3

Ph. Inlet Guide vane

III Operating Press-2Kg/cm2 Speed-1425 RPM contol IV Relief Pr-7 Kg/cm2 Rated current 1.2 Amps

1.5 AIR HEATER 1.5.1 STEAM COIL AIR PRE-HEATER

TYPE Steam Coil R2-10 No.Of Boiler 2 Medium Secondary Air

H.S. IN M2 770 per Air Heater 1.5.2 RE- GENERATIVE AIR PRE-HEATER Type Tri Sector Regenerative 27 vi 72 (T)

No. Boiler 2 Medium i)Primary Air

ii) Secondary Air iii) Flue gas H.S. IN M2 19000 per Air Heater HEATING ELEMENT ROTOR DRIVE CLEANING DEVICE i) Hot layer-864 mm i) Motor-GE 15 HP i) Motor-0.25 HP Open hearth steel ii) Intermediate ii) Voltage-415v ii) Speed reducer Layer-864mm 4800:1 Open hearth steel iii) Speed-960 rpm iii) Cold layer-305mm iv) Speed-110:1 reducer corten –A steel v) Oil Capacity-13G SUPPORTING BEARING GUIDE BEARING AUX.AIR MOTOR i) Type- Spherical Thurst Double roller Motor-4 BHP Bearing bearing ii) Lubrication-Oil Oil Bath Air Pr.-5.6 Kg/cm2 bath type iii) 18 Gallons Oil capacity-4 Speed-255 rpm Gallons iv) Motor rating-3/4 HP 1 to 0.5 HP

1.5.3 PERFORMANCE OF AIR PREHEATER 500 PA

NORMAL ROTATION

500 PA REVERSE ROTATION

720 PA REVERSE ROTATION

FLOW t/hr mmWC mmWC NORMAL

20% MORE

20% LESS

PRI Air In 180 165 163 182 144 SEC Air In 681 697 699 837 561 GAS Gas In 999 999 999 1199 799 PRI Air Out 97 97 97 116 78 SEC Air Out 680 680 680 816 544 GAS Gas Out 1084 1085 1085 1286 884 TEMPERATURE 0C 0C 0C 0C 0C PRI Air In 38 38 38 38 38 SEC Air In 41 41 41 41 41 GAS Gas In 369 369 369 369 369 PRI Air Out 337 325 326 321 331 SEC Air Out 329 333 334 332 338 GAS Gas Out 146 146 146 149 142 PRESSUR DROP mmWC C mmWC mmWC mmWC mmWC PRI Air 44 44 22 29 14 SEC Air 90 90 124 159 107 GAS 112 112 112 146 75

1.6 SOOT BLOWER Location Header Pr

(Kg/cm2) Type Qty./Boiler Medium

i) Furnace 30 Wall blowers RWSE

56 Super heated steam

ii) Platen,Convention Super heater & Re-heater

30 Long retractable

20 Super heated

ii) Air Heater 30 Swiveling 2 Super heated steam

1.7 ELECTOSTATIC PRECIPITATORS

1.7.1 DESIGN CONDITIONS UNIT # 4 UNIT # 5 i) Gas flow rate 1333709 m3/hr. 133380 m3/hr ii) Temprature 1500 C 1460 C iii) Dust concentraion 31.8 gm/m3 28.3 gm/Nm3 iv) Inlet pressure 2000mmwc 2000mmwc v) Type 2 FAAX .5x36-9590-2 2FAA. 5x32-11190-2 vi) NO. of boilers 2 2 vii) No. off fields in series 5 5 in each gas path viii) No. of parallel pass per 4 4 boiler ix) Design pressure drop 99% 99% across precipitator x) Design pressure drop 15MMWC 15MMWC across precipitator xi) Gas velocity at electrode 1.08 m/sec. 0.93 m/sec Zone xii) Treatment time 16.62 sec. 17.243 sec 1.7.2 COLLECTING PLATES EMITTING ELECTRODES i) No. of rows per field 38 No of electrodes in each rows 32

ii) No. of collecting plates 384 No of electrodes in each field 1184 per field (8plates in each row) iii) Total no. of plates/boiler 6080 No .of electrodes / boiler 23680 iv) Nominal height of 9 M Total length of electrodes 6829M Collecting plates per field v) Nominal length of 400 MM Size 2.5 mm Collecting plates vi) Specific collecting area 132.88 m2 Plate/wire spacing 150mm Type Spiral with hooks 1.7.3 RAPERS FOR COLLECTING RAPERS FOR EMITTING PLATES ELECTRODES i) No. & type of One drop hammer Type & no. Spiral hooks rappers Per row for collecting approx one Surface area of 57.6m2 dropHammer/ Two rows

ii) Rapper weight 4.9 kg. Rapper wt. 3 kg. iii) Frequency varies from 6 raps/hr.at Frequency 10 raps/hr Inlet field to 1 rap/hr. at Exit field iv) Drive ` Geared electric motor Drive Geared elec controlled by synchronous tric motor programmer with synch ronous programmer 1.7.4 HOPPERS

i) Type & quality Pyramidal ii) No. of hoppers 40 (2 per field) iii) Capacity 8 hrs. storage iv) Heating Electrical heating at hopper bottom

1.7.5 GAS DISTRIBUTION SYSTEM

i) Type & quality Perforated plate 25 sets ii) Location Inlet of precipitator

1.7.6 ELECTRICAL SYSTEM A) RECTIFIER UNIT # 4 UNIT # 5

i) Rating 60kv (peak/800 m.a.) 70 kv (peak/1000 m.a.) ii)Number 20 20 iii) Type Silicon diode full wave bridge connection iv) Location Mounted on precipitator top B) RECTIFIER CONTROL PANEL i) Type & control Thyristor/microprocessor based) on controller(PRECICON ii)Number 20 iii) Location In the control room at ground level C) AUX.CONTROL PANEL i)Number 4 ii)Equipment controlled Geared motors for rapping mechanism, heating elements om hoppers & shaft insulators. iii) Location In the control room at ground level

D) MOTORS For both emitting electrodes

i) Quantity 20 Nos. ii) Rating 0.5 HP,1.1 rpm at 3 ph,50 c/s , 415v iii) Location on the casing side panel E) HEATING ELEMENTS i) HOPPERS

For forty hoppers at the rate of 6 kw /hopper = 240 kw

ii) SHAFT INSULATORS

i) For 20 insulators at the rate of 1 kw = 20 kw ii) Support insulators for 80 insulators at the rate of 1 kw = 80 kw

1.8 COAL BURNERS,IGNITORS & OIL GUNS A) COAL BURNERS i) Type Titling tangential fired corner ii) No. of boiler 24 (4 each in 6 elevation) iii) Titling limit +/- 30 deg. Cent. B) IGNITORS i) Type 6 eddy plate oil side ignitors air atomised ii) NO. off 12 (4 per elevation) iii) Location Elevation AB,CD,EF iv) Capacity 0.5 millions k.cal./hour v) Turn down ratio Nil vi) Oil pr. At control cabinet 12.5 to 14 kg/cm2 vii) Oil firing rate 50 kg/hr/ignitor viii) Atomising air quality Water free service ix) Atomising air pr. 5.5 to 7 kg/cm2 x) Atomising air consumptio 14.5 Nm3 / hr/ ignitor-when off xi) Combustion air quality 560 Nm3 / hr / ignitor xii) Combustion air pr. At wind box 75 MMWC C LIGHT OIL (W.U.) GUNS i) Type Tilting, tangential, air atomized internal mix ii) No. off 4 iii) Location Elevation AB corners

iv) Capacity 10% of boiler MCR v)Turn down ratio 2.5 :1 vi) Oil firing rate 1265 kg / hr / gun vii) Atomising air quality Service air water free viii) Atomising air consumption 190 Nm3 hr / gun ix) Atomising air pr. 5.36 kg/cm2

x)Differencial pr. Between oil & air 1 kg/cm2 C) FUEL (LDO) OIL GUNS i) Type Tilting,tangential steam atomised internal mix ii) No. off 12 (4 per elevation) iii) Location Elevation AB,CD,EF corners iv) Capacity 20% of boiler MCR in total v)Turn down ratio 4 : 1 vi) Oil firing rate 1320 kg / hr / gun vii) Oil pr. At gun 8.5 kg / cm2 viii) Atomising steam quality Super heated by 10-15 deg.cent. ix) Steam consumption 150 kg / hr / gun x) Steam pressure at gun 9.5 kg / cm2

xi)Differential pressure 1 kg / cm2 between oil & steam 1.9 COAL MILL i) Type XRP 783 Bowl Mills ii) No. of boiler 6 iii) System pressurised iv) Capacity 39.7 mt / hr v) Coal grindibility 55 HGI vi) Max. moisture content 12% vii)Finness through 200 mesh 70% MOTORS i) Rating 340 kw ii) Voltage 6.6 kv 3 phase iii) Frequency 50 c/s iv) RPM 990 v) Rated current 41.7 Amps vi) No load current 15-16 Amps 1.10 RAW COAL FEEDER

i) Type chain type ii) Width 600 mm

iii) Length 12400 mm iv) Speed variation 1 : 6 v) Depth of coal bed 120-200 mm vi) Capacity max. 45 mt / hr. MOTORS i) Rating 7.5 kw ii) Voltage 415v iii) Current 15.5 Amps iv) Speed 975 rpm 1.11 FUEL OIL TRANSFER PUMPS DESCRIPTION TRANSFERPUMP DRAIN PUMPS i) Capacity 120 m3 /hr 5 m3 / hr ii) Discharge 80 MMWC 40 MMWC iii) Suction 5 MMWC 5 MMWC iv) Max. temp. of oil handle 600 C 600 C By the pump 1.12 DOSING SYSTEM

DESCRIPTION PHOSPHATE HYDRAZINE i) Soln. preparation tank 1 no. 600 ltr. 1 no. 500 ltr. ii) Metering tank 1 no. 600 ltr. 1 no. 500 ltr. A) PUMP I) No. of boiler 2 2 ii) Capacity 0-100 ltr./hr. 0-30 ltr./hr iii) Type Horizontal Horizontal reciprocating reciprocating iv) Head 195 kg / cm2 110 MMWC

MOTOR i) Rating 2.2 kw ii) Voltage 415 v,50 c/s iii) Speed 1430 rpm iv) Current rating 4.8 amps.

1.13 ASH HANDLING SYSTEM A) MAX.ASH COLLECTION RATE i) Bottom ash hopper: (1 No.) 12 ton/hr. ii) Air heater hopper (4 No.) 2.08 ton/hr. iii) Economiser hopper (4 No.) 1.74ton/hr iv) EP hopper (4 No.) 52.36 ton hr/ v) Stack hopper (2 No.) 0.79 ton/hr vi) Bottom ash 12 ton/hr. vii) Fly ash 56.97 ton/hr. viii) Total ash 66.97 ton / hr. ix) Gross storage volume 33 M3 of BA Hopper x) HP Water pressure 9.5 kg/cm2 xi) LP Water pressure 5.5 kg/cm2 B) ASH PUMP: i) Quantity of sealing water 15 m3/hr. ii) Pressure of sealing water 8 kg/cm2 iii) Pump capacity 1000 m3 / hr iv) Head developed 23-33 MMWC v) Speed 800 rpm C) ASH ANALYSIS i) Silica 55.09-68.8 % ii) Alumina 19.8-29.8 % iii) Iron oxide 3.05-18.3 % iv) Titanium oxide 10.0-2.05 % v) Lime 1.1-2.1 % vi) Magnesia 0.26-1.2 % vii) Sulfuric acid hydrous 0.4-1.8 % viii) Phosphoric Anhydride 0.19-0.28 % ix) Alkalis 0.16-3.04 %

1.14 MAKE UP SYSTEM No .of DM Water storage tank 5 1.14.1 MAKE UP PUMP MOTORS

i) No. 2 Make-Crompton greaves ii) Make: Mather & platt iii) Type: 4/5,two stage MEDI Type-Induction motor Voltage-415v,3 phase iv) Discharge-100 m3/hr. Current-49 amps v) Head-50 MMc Speed-1475 rpm vi) Speed-1480 rpm Connected to hot well, unit drain tank & deaerator. 1.14.2 FILL PUMPS MOTORS i) No.-2 nos Make-Crompton greaves ii) Make : IIIplurovane,5 CHR Type-AC induction motor iii) Discharge-200 m3/hr. KW/HP- 187/250,voltage-6000v 21 amps. iv) Head – 200 mwc v) Speed – 1480 rpm Speed – 1483 rpm Connected to-boiler drum & deaerator. 1.14.3 QUANTITY OF WATER REQUIRED FOR BOILER FILLING: SYSTEM UNIT ENTIRELY UNIT FILLED TO FILLED (M3) OPERATING LEVEL (M3) 1676 internal dia drum 37.20 11.53 Water walls 126.3 126.30 Super heater 97.18 ---- Reheater 48.10 ---- Economiser 25.17 25.17 Main steam piping 12.05 ---- ------------- ------------- TOTAL 345.00 163.00 ------------- -------------

1.15 COAL MILL REJECT HANDLING SYSTEM 1.15.1 CLIENTS ORDER REFERENCE: For Design, Manufacture & supply of imported equipments- A/T No. BTPS/PUR/P3/IMP/86-87/2427 dated 31-12-86. For Design, manufacturer & supply of indigenous equipment’s Erection, Testing & Commissioning of complete system. A/T No.BTPS/PUR/P3/IMP/86-87/2428 dt. 31-12-86 SUPPLIERS: FOREIGN: Simon-Macawber Limited,

Shawlane Industrial Estate Doncaster South Yorkshire DN2 4SE, UK

INDIGENOUS: Bakhtawar Singh Balkrishan & Co "Beekay House" L-8, Green Park extension New Delhi - 110016. 1.15.2 DESIGN BASIS & DATA

BASIS Normal Reject rate of mills < 5% Reject rate considered for design is 10%

DESIGN DATA:

Maximum Quantity of rejects per mill 3 TPH Normal Quantity of reject per mill 1.7 TPH Average Mean Reject rate per unit of 210 M 9.8 TPH Average quantity of rejects per day for 470 Tones 2 x 210 MW units Density of mill rejects is taken as 1.6 T/m3 for volumetric computations and 2.2 T/ m3 for load/strength computations. 1.15.3 DESIGN CAPACITY PROVIDED IN THE SYSTEM:

Removal capacity at each mill 3 TPH Removal from storage bunker to tube mill of 100 MW unit 5 TPH Storage bunker capacity 80 m3

1.15.4 COMPRESSED AIR REQUIREMENTS: Compressed air is required in the system for conveying and controls as below: For primary system at 9.8 TPH per unit of 210 MW 8.82 m3/min For Secondary system at 5.0 TPH per unit 10 m3/min Total Air required for the complete system (8.82x2)+(10x2)=37.64

m3/min Provided 4 Nos compressors with maximum 3 Nos working and 1 No as standby, each of 14.7 m3 capacity (FAD) delivering at 7 kg/cm2 (g)

1.15.5 AIR RECEIVERS:

Nos per Boiler : 2 Capacity each : 5 m3

SECONDARY SYSTEM:

From storage bins to stage-I mills 2C & 3C Air receiver capacity for secondary system: 10 m3

1.15.6 DENSEVEYOR

Model 12/8 System : batch conveying 12 Ft3

Vessel capacity: Pipe size 150 mm Design Code BS5500 Class III Safe working pressure 110 lb/in2 (7 kg/cm2) Hydraulic test pressure 150 lb/in2 (10 kg/cm2 )

1.15.7 AIR COMPRESSORS

Type Screw Model & Type SES-520 single stage Capacity 520 cfm +/- 5% Make Khosla Indair Drive Motors NGEF Discharge Pressure 7 kg/cm2 Speed 4500 RPM Actual Quantity of free air compressed FAD 520 +/- 5% cfm Volumetric efficiency 91% Brake HP required at Comp.shaft at 105.0 HP rated load Motor Rating 130.0 HP Type of bearings for rotors Cylindrical roller and 4 point

Bearings Details of lubrication Oil flooded (forced feed) Materials of construction: Rotors EN-8 Gears EN-41B Bearings Mfd.Std. Frame and running gear (coupling) forged steel,

rubber – flexible Shaft EN-8

Base plate MS Type and size of suction and Butterfly suction valves -

discharge valve MS (CI body) DK-100 (4") Details of special features After cooler and oil coolers Total cooling water quantity 150 LPM required at 360C Cooling water out let temp. 100 C above inlet temp. Oil

cooler and after cooler. 1.15.8 AIR FILTER CUM SILENCER

Type Dry filter type Max. particle size removed after 10 Microns

cooler and Inter cooler Type Shell and tube type

(water through tube) Material of construction

Shell IS-226 Tubes Copper 3/8" Tube sheets MS Tube support plates MS

No of passes 2 passes Cooling surface Oil Cooler 9.6 m2

After Cooler 5.5 m2

Air Pressure drop through the after cooler/oil cooler 2-3 psi Cooling water inlet/outlet size 1" & 3/4" BSP Cooling water quantity required at 360 C 150 LPM Air outlet temp. 100 C above cooling water temp.

1.15.9 VIBRATORY FEEDER

Equipment & Model Electromagnetic vibratory feeder - Model F-33 Duty For handling coal mill rejects Manufacturer Internal Combustion Quantity 2 Maximum capacity 25 T/Hr Particle size 30 - 35 mm (Max.) Bulk density of material 1600 kg/ m3

Inclination to horizontal 6/8 deg Power supply 400/440 V Power consumption 525 Watts Feeders through size 450 mm x 1100 mm Material of trough MS Type of suspension Suitable for suspension type arrangement

Approx. weight 940 lb Type of control panel Thyristor controller Type of protection of control Conforming to IP - 54.

panel

SECTION - II

TURBINE AND

AUXILIARIES

2.1 SPECIFICATION 2.1.1 TURBINE MAIN DATA Rated Power 210MW

Rated Speed 3000 rpm Rated Steam(Pressure) before ESV 130 Kg/cm2 abs Rated Steam Temp. before ESV 5350 C Rated Steam pressure Before IV 27 Kg/cm2 abs Rated Steam temp. Before IV 5350 C Rated Steam Flow 670 T/Hr HPT Exhaust Pressure 27 Kg/cm2

HPT Exhaust Temperature 3270 C Rated circulating water quantity 27000 M3

through condenser Condenser back pressure 0.09 Kg/cm2

Critical Speed 1585,1881,2017&2489 Rated condenser cooling water inlet 240 C to 330 C temperature Rated condenser cooling water 1.0 to 1 Kg/cm2

pressure Type of governing Hydro mechanical Nozzle type governing Type of turbine condensing, Tandom compound Three cylinder, Horizontal

Nos. of bearing 5 Nos.( for turbine side only & HPC front bearing

is combined thrust & journal bearing Barring gear 3.4rpm, ac motor of 30kw, 730rpm, 50c/s, 415v, 220:1 Ratio Location of anchor point of At the middle foundation frame of front the turbine exhaust part of the L.P. Cylinder 2.1.2 CONSTRUCTIONAL DETAILS

i) H.P. CYLINDER 12 stages (1st is governing stage) each stage Consists of a diaphragm & a set of moving Blades connected on a disc BODY In two valves made of Creep Resistance (Cr-Mo-V) steel

STUDS & NUTS High Creep Resistance (Cr-Mo-V) steel Forgings NOZZLE & STEAM 4 Nos (2 on Top & 2 on sides) made CHEST of High Creep resisting (Cr-Mo-V) Steel casting ii) I .P. CYLINDER 11 stages BODY 2 parts (a ) Pressure part made of Creep Resisting (Cr-Mo-V) steel

Casting in 2 halves (b ) exhaust part Made of fabricated steel structure In 2 halves. STUDS & NUTS Creep Resisting (Cr-Mo-V)

steel Forgings NOZZLE BOXES Cast integral with the casing. iii) L.P.CYLINDER Stages 4( double flow) last but

one stage on each sides are Baumanns satg

BODY In 3 parts (1 middle & 2 exhaust parts) All fabricated from weldable quality mild steel & divided in two halves horizontally.

iv) H.P.ROTOR All the discs integrally forged with the shaft of single (Cr-Mo-V) steel forging. H.P./I.P rotor coupling is rigid coupling. v) I.P.ROTOR Seven discs integrally forged with rotor & remaining four discs are shrank fit . shaft is (Cr-Mo-V) steel forging. & discs are high strength Ni- steel forging. IP/LP rotor coupling is (semi) flexible lens type coupling. vi) L.P. ROTOR All the discs are shrunk fit on the shaft. Shaft is (Cr-Mo-V) steel& discs are of high strength Ni steel forgings LP/Generator coupling is rigid coupling. vii) ROTOR BLADES High temp zone blades are of high (Cr-Mo-V) steel & rest are of stainless steel. 2.1.3 STEAM EXTRACTIONS No of extractions

Steam extraction stages

Connected to

Ext, steam press in Kg/ cm2

Ext.steam temp.in 0C in

Steam flow T/hr.

Ist (HPT) 9th HPH-7 39.06 337 400 Iind (CRH 12th HPH-6/D/A 26.2 314 77 IIIrd (IPT 15th HPH-5/D/A 11.96 433 16.2 IV (IPT) 18th LPH4 6.47 3680C 26 V (IPT) 21st LPH3 2.78 252 23 VI (IPT) 23rd LPH2 1.28 172 28 VII (LPT) 25th LPH1 0.28 - 12.6

2.2 GOVERNING SYSTEM TYPE: Hydro mechanical automatic governing. i) SPEED GOVERNOR:

Directly coupled to turbine rotor through coupling & hydraulically coupled to speed governor pilot block located front pedestal. PUPPOSE: Sensing of any speed due to difference between power generated by turbine & load on it. For this governor sleeve moves proportional to speed change. ( Range is 4+1% speed change.)

ii) FOLLOW PILOT VALVE:

FUNCTION: It follows the governor sleeve in case of change of speed & maintains the gap between governor sleeve & nozzle tip to move summation pilot valve accordingly.

iii) LOAD SPEED CONTROL PILOT VALVE:

PURPOSE: For initial charging of protections oil in governing system through emergency governor pilot valve & to open ESV, IV & control valve.

iv) SUMMATION PILOT VALVE:

PURPOSE: To receive movement signals from follow pilot valve & gives command to intermediate pilot valve to open or close the control valves.

v) INTERMEDIATE PILOT VALVE:

PURPOSE: To amplify the hydraulic signal form summation pilot valve, differentiator, electro hydraulic transducer and emergency governor pilot valve & transmit to control valve servomotor.

vi) CONTROL VALVE SERVO MOTOR:

PURPOSE: It receives hydraulic signal from intermediate pilot valve & actuates HPT and IPT control valves.

vii) LOAD LIMITER:

PURPOSE: To limit the load raising beyond set point by limiting the opening the control valve by speed governor.( its continuos operation is not recommended.)

viii) DIFFERENTIATOR: PURPOSE: It prevents undue speed rise in case of more than 50% load through off which causes anticipatory closure of control valve of HPT and IPT.

ix) ELECTRO HYDRAULIC TRANSDUCER:

PURPOSE: It converts electric signals of 2 seconds diverted from generator circuit breaker (when opens) into hydraulic signal & momentarily closes the control valve for 2 seconds to avoid overspeed.

x) INTIAL STEAM PRESSURE UNLOADING GEAR:

PURPOSE: When main steam pressure falls below 90% +/- 2% of rated value it throttles the control valves & when main stem pressure falls to 70%, completely closes the control valve.

xi) EMERGENCY GOVERNOR:

PURPOSR: It consists of two centrifugal strikers which operates and trip the turbine in case 11 to 12% of over speed by closing ESV, IV , HPT and IPT control valve.

xii) TURBINE SHUT DOWN SWITCH:

PURPOSE: TO manually trip the turbine locally or from UCB.

xiii) EMERGENCY GOVERNOR PILOT VALVE:

PURPOSE: It receives emergency signal from emergency governor & turbine shut down switch & trip the turbine.

xiv) BACK UP PROTECTION(SPEED GOVERNOR PIOLT BLOCK):

PURPOSE: It trips the turbine at 14 to 15% over speed if emergency governor fails to operate.

2.2.1 CONTROL GEAR: READING OF CONTROL GEAR DRUM EVENT 4.6mm IV begins to open 5.5 mm ESV begins to open 5.9 mm IV fully open 6.65 mm ESV fully open 9.6 mm IPT & HPT control valve begin to open

12.8 mm All control valves fully open

2.3 TURBINE LUBRICATION SYSTEM 2.3.1 LUBRICATING OIL SPECIFICATION: Type (Recommended oil for governing MOB DTE oil medium system and bearing) or Turbine oil -14 Or Servo prime -14 Or Turbinol-47 Specific gravity at 500C 0.852 Kinematic viscosity at 500C 28 Centistokes Neutralization number 0.2 Flash point 2010C(min) Pour point 66.600C(max) Ash percentage by weight 0.01% Mechanical impurities Nil Oil pressure in governing system 20 Kg/cm2 (Guage) Oil pressure for lubrication of bearings 1 Kg/cm2 (Guage) 2.3.2 MAIN OIL TANK Capacity 28000 Lts Oil capacity in systems 4000 Lts Main oil centrifuge capacity 6000 Lts/Hr Oil transfer pumps capacity for purifier unit 6000 Lts/Hr Polishing filter capacity 6000 Lts/Hr Impure and pure oil storage tank capacity 40 m3 each Impure and pure transfer oil pump capacity & head 45 m3 /Hr, 18 MWC 2.3.3 MAIN OIL PUMP Pressure corresponding to discharge of 4000lits/min 20 Atg Pressure corresponding to discharge of 7000lits/min 16 Atg Suction pressure 1Atg Power consumption 250 Kw Type of coupling with rotor Flexible gear type No. of injectors 2 Nos. Oil pressure developed by Ist injector 1 Kg/cm2

Oil pressure developed by IInd injector 3 Kg/cm2 Speed 3000 rpm

2.3.4 STARTING OIL PUMP FOR NORMAL OPERATION Type Plurovane III(Unit4) Plurovane III A(Unit 5) ( Multi stage centrifugal pump),Mather& Platt Capacity 200 m3 /Hr Head 200 MWC(20 Kg/cm2 ) A.C.MOTOR Capacity 200 Kw Speed 1000 rpm Voltage 6.6 KV,3 Ph, 50 C/s Arrangement Horizontal 2.3.5 A.C.STANDBY OIL PUMP PUMP MOTOR Type 150COAV ,BHEL Type 22F Q UE/O (multistage, centrifugal oil Pump, driven by motor) Power 25 Kw Capacity 150 m3 /Hr,(2500 L/Min) Speed 960 rpm Head 30 MWC Current 52 amps No. of stages 2 Voltage 415 volts,3 Ph, 50 C/S Arrangement Vertical Impeller material Bronze Min. oil pressure 0.6 Kg/cm2 For auto starting BEARING Type Single Row Deep Grove Ball Bearing ( Thrust anti friction bearing) Number S.K.F. 6306 Lubricant Mobile D.T.E. medium IOC 2.3.6 D.C. EMEGENCY OIL PUMP PUMP MOTOR Type 100 NCU centrifugal pump Power 13 Kw driven by D.C. motor Voltage 220 volts D.C. Min. oil pressure 0.5 Kg/cm2 Current 67.6 amps for starting Speed 1500 rpm interlock Type D-62

Capacity 108 m3 /Hr (1800 L/min) Head 22 MWC BEARING

1. 1 no double row self aligning ball bearing for free end. 2. 1 no. double row self aligning spherical roller bearing.

2.3.7 MAIN CENTRIFUGE (OIL PURIFIER) PUMP MOTOR Type of oil purifier MAB-206-S-20 KW(HP) 7.5(10) Capacity of purifier 6000 Lts/hr Frequency 50 Hz Capacity of transfer pumps 6000 Lts/ hr Voltage 440 Volt Oil pressure at inlet of separator 2.35 Kg/cm2 Current 13.6 amps Speed 1500 rpm (max) Speed 1440 rpm LUBRICANTS Lubrication points: (1) Worm gear housing (2) bowl (2) Bowl spindle(4) bearing of coupling (3) Gears of lifting devices (60 motor HEATER Type WH KW 120 Voltage 440 volts 2.3.8 MAIN OIL COOLERS No. of coolers 5 nos.(4 nos. at a time in service) Cooling surface area of oil coolers 63 m2

Quantity of oil cooled 1500 Lit/min or 90 m3 /Hr Water consumption 130 m3 /Hr No. of water paths 4 Designed oil pressure 5 Kg/cm2 Designed water pressure 5 Kg/cm2 Working pressure of oil 3 Kg/cm2

Working pressure of water 2.5 Kg/cm2 Inlet oil temperature 550C Outlet oil temperature 450C Inlet water temperature 330C(max360C) Outlet water temperature 35.640C Rated oil velocity 1.1 M/sec

Rated water velocity in tubes 1.25 M/sec Frictional drop for the bank of operative 1.6 MWC oil coolers on the cooling water side Dia. of tubes 19/17 mm Heat transfer coefficient 400 Kcal/m2 Hr 0C Hydraulic resistance on oil side 1.48 Kg/cm2 No. of oil circulation passes 22 No. of partitions 21 Hydraulic test pressure of oil coolers 8 Kg/cm2

2.4 CONDENSATE SYSTEM 2.4.1 CONDENSER 2 (Nos, 50% capacity of 2 pass/condenser) Design pressure (steam space) 0.1 Kg/cm2

Cooling water consumption 2*13500 m3/hr No. of cooling tubes 2*7810=15620 Length of cooling tubes 10 mts Dia of cooling tubes 30/28 mm Weight of condenser without water 305 tonnes Tube material Cooling Zone Cupronickel 190/10 Air zone Cupronickel 70/30 Water boxes material Rolled steel plates Max. permissible design pressure of cooling tubes 5 Kg/cm2 Gauge 2.4.2 CONDENSATE PUMP PUMP MOTOR 3 nos (50% capacity each) Type AVM450M4 Type Multistage, vertical turbine type, 3 ph, 50 C/S, cos0 0.84 Centrifugal pump, Voltage 6.6 KV low specific speed, Insulation Class B medium head, medium capacity Current 25 amp DHRC 28, size300*250 Power 220Kw, HP-300 Stages 8 RPM 1489 Direction Clockwise viewed Space heater 2 nos. of 250w,240w of rotation from motor end Discharge 281 tones/hr Ambient temperature 500C Manometric head 201 mts Weight of motor 3000 Kg RPM 1489 B.H.P. 256 Caution Not to run below 193 mt manometric head Normal discharge 20 Kg/cm2

header pressure

Max thrust bearing oil temperature 75 0C Max motor bearing temperature 75 0C Max vibration of gland housing 40 microns & thrust bearing Max condensate temperature 180 0C

2.5 LP HEATERS & AIR EECTION SYSTEM 2.5.1 L.P.HEATERS LPH No.

Type Location Tube material

Shell Material

Tube plate material

No. of relief valve

1 Inside upper part of each condenser( in two halves)

Horizontal surface type

U. shape brass 16*10

Fabricated from MS plates

Mild Steel 2 Nos.(1 for steam side& 1 for cond. side

2 Mezzine floor Vertical surface type

--DO-- --DO-- --DO-- --DO--

3 --DO-- --DO-- --DO-- --DO-- --DO-- --DO-- 4 --DO-- --DO-- --DO-- --DO-- --DO-- --DO-- 2.5.2 GLAND STEAM COOLER I FUNCTION

a. Eject steam and air mixture from turbine seals b. Eject spindle leak off from ESV, IV & control valves Gland sealing steam pressure 1.03 to 1.05 Kg/cm2

Source of gland sealing steam 16 ATA header or D/A Temperature of sealing steam 1300C to 1500C Type of seals Labyrinth glands of radial clearance type

2.5.3 GLAND STEAM COOLER NO II Connected to HPC and IPC leak off ( Construction same as LPH 2,3,&4) 2.5.4 DRIP PUMP PUMP MOTOR Nos. 2(100% capacity) Output 90 KW Type 100 CJH, multistage centrifugal Voltage 415 V Horizontal pump No. of stages 9 Current 148 amp

Delivery quantity 1416 L/min Speed 1475 rpm Manometric head 195 MWC Frequency 50C/S Speed 1475 rpm Temp. of liquid 1000C max 2.5.5 DEAERATOR Deaerator pressure 7 Kg/cm2

Deaerator temp. 1700C Quantity of limiting 0.005 cc/Lit gases (mainly O2) in feed water Steam source Aux source( In starting)/2nd or 3rd Extraction of turbine Design Direct contact type heater in two parts (a) Deaerating Coulmn: Horizontal spray cum tray type fabricated from boiler quality steel plates, meant for deaeration of gases(O2) from water (b) Feed storage tank : Horizontal, fabricated from boiler quality steel plates. Means for water storage and heating Source tank capacity 87.5 m3

Deaerating capacity 759.110 kg/hr Test 200 Psig. (14 kg/cm2) 2.5.6 AIR EJECTOR SYSTEM Type of ejector

Nos. Range Aux. source of steam

Steam pressure in kg/cm2

Steam temp. in 0C

Steam consumption in kg/hr

A) Starting ejector

1 Up to 450 mm Hg column in condenser

D/A or 16 ATA header

4.5 250 1100 kg/hr

B) Main ejector

2 Up to 760 mm Hg column in condenser

--Do-- 4.5 250 750 each

C) Priming ejector

1 Up to 200 mm Hg column in condenser

--Do-- 4.5 250 1100

D) Gland steam cooler No.1

1 Eject steam and air mixture from end gland seals of main turbine

--Do-- 4.5 250

2.6 FEED WATER SYSTEM 2.6.1 BOILER FEED PUMP A) PUMP

No. of pumps 3 Nos. (50% capacity) Type Multi stage , Horizontal high pressure, Barrel type pump 200 KHI Nos. of stages 6 Max. rated suction pressure 12.3 ata Discharge capacity 430T/hr Head 1830MWC Feed water temp. 164.20C Speed 4320 rpm Lubrication Forced Stuffing box Mech seal Quantity of water for 100 T/hr minimum take off Min. suction pressure of BFP 6 Kg/cm2

Quantity of water for 8 T/hr Heating take off Cooling water consumption 280 T/min.(Approx) Net weight of pump 5850 Kg Drive Electric motor through hydraulic coupling B) MOTOR

Manufacturers M/S BHEL Hardwar Type ATD-4000 Output 4000 KW Rated Voltage 6.6 KV Current 421 amp Speed 1483 rpm Frequency/ power factor 50 C/S, 0.914 2.6.2 OPERATING DETAILS Water pressure in equalizing pipe of balancing Disc 3 to 4 kg/cm2 more than suction branch pressure ( but not ore than 5 kg/cm2) No. of bearings 2 Radial sleeve bearing and 1 thrust bearing Motor bearing 2 Radial sleeve bearing Hydraulic coupling bearing 4 Radial bearings and 2 tilting pad bearings No. of oil coolers 2 nos.( one for hydraulic coupling working oil and one for lubricating oil of bearings)

Auxiliary oil pump 415 V, 3 Ph, 50 C/S Type of Aux. oil pump Gear type Type of main oil pump Gear type Oil pressure in radial bearing 0.8 to 1.00 Atg Bearing temperature 650C(max) Oil pressure for thrust bearing 0.5 Atg Min. discharge pressure of BFP 120 kg/cm2

Max feed water temperature at BFP discharge 1750C Max BFP flow 475 T/hr Max motor bearing temperature 800C Max temperature difference of 30 0C feed water and BFP body Max motor hot air/ temp. 80 0C (600C normal) Normal BFP discharge pressure 170 kg/cm2

Seal water temp. 650C-700C 2.6.3 BOOSTER PUMP No. of pump one for each BFP Use 1. To provide a positive suction pressure to BFP & to avoid possibility of cavitations 2.To reduce the BFP stages Make M/S Mather & Platt. Type 8”/10” Delivery quantity 460 T/hr Speed 1475 rpm Drive Main motor Min. booster pump suction pressure 3.5 kg/cm2

Delivery head 31 MWC 2.7 H.P.HEATERS (DESIGN SPECIFICATION) Description H.P.HEATER No.5 H.P.HEATER No6 H.P.HEATER No7 Feed water inlet temp. in 0C

166.76 184.92 220.90

Enthalpy of F.W. inlet in Kcal/kg

170.70 189.51 227.48

F.W. outlet temp in 0C

184.92 220.90 242.78

Enthalpy of F.W. at outlet in Kcal/kg

189.51 229.48 251.41

F.W. flow (kg/hr) 643165 643165 643165 Ext. stem inlet pressure in kg/cm2

11.96 26.20 39.06

Ext. stem inlet temp. in 0C

433 314 377

Enthalpy of Ext. steam in Kcal/kg

796 727 754

Steam flow (kg/hr) 16271 44777 29880 No. of coils 292 288 288 Load at which H.P. Heaters are taken into service 60 to 70 Mw Without H.P. Heaters ma. Curtis wheel pressure 89 kg/cm2

Full load Curtis wheel pressure with H.P. Heaters 102 kg/cm2

2.8 CW PUMPS & CW BOOSTER PUMP

2.8.1 CIRCULATING WATER PUMP No. of pumps 2 Nos.(100% capacity) Make FLOWMORE Number of stage One Capacity of pump 15000 m3 /hr Total dynamic head 11.5 MWC Efficiency 86% Speed 420 rpm B.H.P. 740 HP Motor BHEL, 950HP,6.6 KV splash proof type Type of pump lubrication Self water lubricated Direction of rotation Anti clock wise (from top) Coupling of motor & pump Rigid type CW water is used in Condenser, Main oil coolers& H2 gas coolers 2.8.2 C.W. BOOSTER PUMPS PUMP No. of pump 2 Nos.(100% capacity) Lubrication in board & Mobilux grease No.2 Outboard bearing Speed 1487 rpm Make Mather Greaves Pvt. Ltd. Discharge pressure 2.5 kg/cm2

Normal bearing temperature 600C Normal pump vibration 40 microns MOTOR Output 55 KW Speed 1487 rpm Amps 96

Voltage 415 V Make NGEF 2.9 H.P.& L.P. BYPASS SYSTEM

(i) Provided to increase the rate of steam temperature rise and warm up the HRH,CRH, IPT & transfer pipe lines ( at 60% MCR full pressure & temp. can be obtained i.e. 60% capacity)

(ii) All the HP & LP BYPASS valves are hydraulically operated for which oilat about 50 kg/cm2 is supplied by a separate oil supply unit.

2.9.1 DESIGN CAPACITY OF H.P. BYPASS STATION Injector water Boiler feed water Nos. of H.P. Bypass valve 1 for each MS line Total capacity 200T/hr steam flow Capacity of each bypass valve 100T/hr steam flow Max. MS temp. 5400C Max MS pressure 140 ATA Down stream temp 3800C 2.9.2 DESIGN CAPACITY OF LP BYPASS STATION Injector water Condensate water Nos. of LP Bypass valve 1 for each HRH line Capacity of each LP bypass valve 112T/hr steam flow Total capacity 224T/hr steam flow Design temp. 5400C Down stream temp 2000C (max) Steam pressure at upstream side 6 kg/cm2

2.10 TURBINE ROLLING & LOADING GUIDE LINES

2.10.1 TURBINE ROLLING GUIDE LINES S. No. If max metal temp of HPT

casing is less than 1500C If max metal temp is less than 1500C-3500C

If max metal temp is more than 3500C

1 Speed from 0-500 rpm = 5 mts

Speed from 0-500 rpm = 5 mts

Speed from 0-1200 rpm = 5 mts

2 Hold at 500 rpm =10 mts Hold at 500 rpm =5 mts for checking differential expansion, bearing vib etc.

Hold at 1200 rpm =5 mts for checking differential expansion, bearing vib etc.

3 Speed from 500 rpm to 1200 rpm @ 50 rpm = 14 mts

From 1200 rpm to 3000 rpm = 5 mts without any pause

4 Hold at 1200 rpm (Soaking)= 20 mts

Raise the speed from 500 rpm to 1200 rpm = 5 mts

5 Speed from 1200 rpm to 3000 rpm =5 mts

Hold for 3 mts for checking differential expansion, bearing vib etc.

6 Hold at 3000 rpm (Soaking)= 20-25 mts

Raise the speed from 1200 rpm to 3000 rpm = 3 mts without any pause

7 Hold the turbine at this speed (3000 rpm) for checkings.

8 Total = 75 mts Toatl = 26 mts Total = 15 mts

2.10.2 TURBINE LOADING GUIDE LINES S. No. If the max. casing metal temp. is

less than 1500C If the max. casing metal temp. is less than 1500C-3500C

If the max. casing metal temp. is

more than 3500C 1 Load up to 5 to 7 Mw after

synchronization Steam pr =30 Kg/cm2

Steam temp. =3500C Steam temp. before IV=3200C Soaking time =30 mts

Load after synch. = 20 to 30 Mw Steam pr. =70 Kg/cm2 Steam temp = 3500C Soaking time=10mts.

Load after synch. 20 to 30 Mw. After taking mills ( one by one) in service load can accordingly be raised to 210 Mw depending upon other conditions.

2 5 Mw to 30 Mw @ 3 Mw/10 mts in 70 mts. Steam pr before ESV =65 Kg/cm2

Steam Temp =4300C Steam temp before IV =4200C Soaking time = 20 mts ( All the drain valves in extraction lines of LP heaters to be closed.)

From 30 Mw to 65 Mw in 35 mts. Soaking time =35 mts. Steam pr =90 Kg/cm2

Steam temp =4500C

3 Raise from 30 Mw to 70 Mw @ 1 Mw/ min in 50 mts. Steam pr before ESV =105 Kg/cm2

Steam temp before ESV=4900C Steam temp before IV=4800C Soaking time= 30 mts

From 60 Mw to 210 Mw = 45 mts Depending upon other conditions

4 Raise from 70 Mw to 210 Mw in

70 mts. @ 2 Mw/ min Pr before ESV= 130 Kg/cm2

Temp before ESV= 5350C Temp before IV= 5350C

SECTION-III

GENERATOR

AND

AUXLIARIES

3.1 GENERATOR SPECIFICATION

3.1.1 GENERATOR MAIN DATA (at rated H2 pressure and cooling water temperature) i) Maximum continuous KVA Rating 247000 KVA ii) Maximum continous KW rating 210000 KW iii) Rated terminal voltage 15750 V iv) Rated stator current 9050 A v) Rated Power factor 0.85 lag vi) Excitation current at MCR condition 2600 A vii) Slip ring voltage at MCR condition 310 V viii) Rated speed 3000 rpm ix) Rated frequency 50 Hz x) Short circuit Ratio 0.49 xi) Efficiency at MCR condition 98.49% xii) Negative sequence current capability 12

2t notsxiii) Direction of rotation viewed from slip ring end Anticlockwise xiv) Phase connection Double star xv) No. of terminals brought out 9(6neutral & 3 phase) xvi) Type THW-210-2 3.1.2 MAIN PARAMETERS OF THE COOLING MEDIUM A. HYDROGEN IN STATOR CASING i) Nominal hydrogen pressure 3. 5 Kg/cm2

ii) Permissible variation +/- 0.2 Kg/cm2 (G) iii) Nominal cold gas temperature 440C iv) Hydrogen purity 97% v) Relative humidity hydrogen at normal pressure 60% vi) Oxygen content 1.2% B. DISTILLATE TO STATOR WINDING i) Nominal pressure at stator winding inlet 3.5 Kg/cm2

ii) Permissive variation +/- 0.5 Kg/cm2

iii) Cold distillate nominal temperature at stator winding inlet 450C iv) Permissible variation +30C (-100 C with unloading) v) Rated distillate flow 27 m3/Hr vi) Permissible variation +/- 3 m3/Hr vii) Nominal specific resistivity of distillate 200 Kohm-cm viii) Minimum permissible specific resistivity 75 Kohm- cm C. WATER TO GAS COOLER

i) Nominak inlet cooling water temperature 370C ii) Minimum allowable water temperature 150C iii) nominal water flow 350 m3/Hr iv) Maximum permissible cooling water 4 Kg/cm2 (G) pressure in the gas cooler D. WATER TO STATOR WINDING WATER COOLER i) Nominal consumption of cooling water at temp. of 350C 95 m3/Hr ii) Nominal consumption of cooling water at temp. of 370C 110 m3/Hr iii) ) Nominal consumption of cooling water at temp. of400C 130 m3/Hr 3.1.3 ELECTRICAL DATA i) Resistance of stator winding per phase at 200C 0.00155 ohm ii) Resistance of rotor winding per phase at 200C 0.0896 ohm iii)Capacitance of the stator winding in hot condition (Calculated value) 0.69 microfarad iv) Line charging capacity 75 MVAR v) Basic impulse insulation level between turns 49,000 (Peak) vi) Basic impulse insulation level with respect to body 49,000(peak) 3.1.4 GENERATOR EXCITATION DATA i) Ratio of ceiling voltage to the rated excitation voltage 2.0 ii) Ratio of thre field forcing current to the nominal current 1.6 iii) Duration of field forcing 10 Secs iv) Response Time 100 milisecs 3.1.5 SHORT CIRCUIT CURRENTS i) Sub transient current on three phase short circuit 10 Pu ii) Transient current on three phase short circuit 3.3 Pu iii) Steady state current on three phase short circuit 1.4 Pu 3.1.6 REACTANCES i) Direct axis sub transient reactance ( x”d) 0.214 Pu ii) Direct axis transient reactance (x’d) 0.305 Pu iii) Direct axis synchronous reactance (xd) 2.22 Pu iv) Negative phase sequence reactance (xd2 ) 0.26 Pu v) Zero sequence reactance (xo) 0.105 3.1.7 PERMISSIBLE TEMPERATURE RATINGS i) Maximum temperature of stator core 1050 C

ii) Maximum temperature of stator winding 1050 C iii) Max temp of rotor wdg. 1150 C iv) Permissible temperature rise of rotor winding 710 C over cold gas temperature v) Maximum temperature of hot gas 750 C vi) Maximum distillate temperature at stator winding outlet 850 C vii) Maximum stator winding temperature 750 C 3.1.8 TIME CONSTANTS i) Field time constants with open circulated stator winding (Tdo) 7 secs ii) Field time constants with three phase sort circuit 0.96 secs current of stator winding(T’d3) iii) ) Field time constants with two phase sort circuit 1.5 secs current of stator winding(T’d2) iv) Field time constants with one phase sort circuit current of stator winding 1.73secs v) Time constant of the aperiodic component for 3 phase short circuit(Ta3) 0.29 secs vi) Time constant of the aperiodic component for 2 phase short circuit(Ta2) 0.24 secs vii) Time constant of the aperiodic component for one phase short circuit(Ta1) 0.25 secs viii) Time constant of the periodic component of the sub transient current for 3 phase : 2 phase and 1 phase short circuit(T”d) 0.121 secs 3.1.9 GENERATOR VOLUME AND FILLING QUANTITIES i) Total gas volume of the generator 56 M3

ii) CO2 for expelling hydrogen with unit at standstill 120 M3 iii) CO2 for expelling hydrogen with unit under rolling 168 M3 iv) H2 filling quantity with unit at standstill 300 M3 v) H2 filling quantity with unit rolling 340 M3 vi) Make up Hydrogen required per day 15 M3

(max) 3.1.10 TORQUE, CRITICAL SPEED ETC i) Torque under normal working condition 76.32 Tons ii) Ratio short circuit torque to full load torque 8 iii) Flywheel moment of the rotor 21.1 T.M2

iv) Ist critical speed of the rotor( calculated) 1370 rpm v)2nd Critical speed of the rotor (calculated) 3400 rpm 3.1.11 OIL CONSUMPTION i) Consumption of oil per generator bearing (Excluding shaft seals) 300lit/min ii) Oil pressure at bearing inlet 0.3to 0.5 Kg/cm2

iii) Consumption of oil in both the shaft seals 160 lit/min

3.1.12 OVERALL DIMENSION AND WEIGHTS i) Overall stator diameter 3960 mm ii) Length of the stator 6580 mm iii) Length of the rotor 9770 mm iv) Diameter of the rotor barrel 1075 mm v) Weight of the heaviest lift (Stator with gas coolers and turnions) 175,000 Kg vi) Weight of gas cooler 1415 Kg vii) weight of rotor 42,000 Kg viii) Weight of bearings with brush gear along with foundation plates 49,500 Kg ix) Weight of end terminals 85 Kg x) Weight of end shield 2000 Kg xi) Total weight of generator 239,000 Kg 3.2 SPECIFICATION OF STATIC EXCITATION SYSTEM UNIT IV & V The Static Excitation Equipment has been designed and manufactured for machine having following technical details

A) TYPE OF MACHINE TURBO ___________________________________________________________________________ Sl.No Description Abbreviation Unit Value 1. Rated OUTPUT - MW/MVA 210/247 2. Stator voltage Un VAC 15750 3. Stator Current IN AAC 9094 4. Synchronous speed Ns rpm 3000 5. Power factor Cos - 0.85LAG 6. System frequency Hz c/s 50 7. Machine reactance:

a) Synchronous reactance i) Direct acxis unsaturated xd p.u. 2.225 ii) Quadrature xq p.u. 2.11 b) Direct axis transient reactance i) Saturated x’d p.u. 0.234 ii) Unsaturated x’du p.u. 0.266 c) Direct axis sub-transient reactance i) Saturated x’d p.u. 0.179 ii) Unsaturated x’du p.u. 0.214 8. Machine Time Constants: i) Direct axis transient open ckt T’do sec. 7

ii) Direct axis transient close ckt T’do sec. 0.84 iii) Sub-transient T”d sec 0.03 iv) Armature Ta sec. 0.29 9. Field winding resistance at 20 oC Rf 20 ohm 0.0878 10 Field excitation requirement i) No load field voltage ufo VDC 102 ii) No load field current Ifo ADC 917 iii) Nominal field voltage Ufn VDC 310 iv) Nominal field current Ifn ADC 2600 v) Max. cont. rated field voltage Ufmax VDC 338 vi) Max. cont. rated field current Ifmax ADC 2830 vii) Ceiling voltage Ud VDC 620 viii) Ceiling current Id ADC 4500 ix) Duration of field forcing -- Sec. 10 11. Field test voltage - Kvrms - 12. Synchronising slip - % - 13. AVR CT Ratio - AAC/AAC 10,000/5 14. AVR PT ratio - VAC/VAC 15750/110 15. Ambient - oC 50 16. Altitude - meters 1000 B) SPECIFICATION OF STATIC EXCITATION EQUIPMENT 1. Accuracy of excitation control - % + 0.5 2. Range of voltage control in auto - % 90 Ugn -110 Ugn 3. Range of voltage control man. - % 70 Ufo-110 Ifn 4. Range reactive current compensation - % upto + 15 5. Frequency range of operation - Hz 47.5-52 6. Total No of parallel THY. Bridges - No 4 * 7. No of redundant THY bridges - No 1 * 8. Protection class IP 31 9 Excitation equipment rating a) Voltage - VDC 338 * b) Current - ADC 2830 * 10 Range of MAVR regulation -MAX. LEAD-O-MAX-LAG 11 Station battery supply - VDC 220 • Equipment not part of DVR supply

3.3 GENERATOR SEAL OIL SYSTEM 3.3.1 SPECIFICATION i) Type of shaft seals Radial flow, double chamber, thrust type ii) Hydrogen pressure 3.5 Kg/cm2

iii) seal oil pressure 4.1 to 4.4 Kg/cm2

iv) Inlet seal oil temperature 40 0 C v) Quantity of seal oil/seal 80 lit/min vi) Thrust oil pressure 1 to 2.2 Kg/cm2

vii) Oil required to fill the system 4000 liters 3.3.2 OIL INJECTION i) Pressure of oil at inlet to injector from 20 Kg/cm2

governing oil system ii) Lub. Oil system 1 to 1.5 Kg/cm2

iii) Injector nozzle size 8 mm iv) Oil pressure at injector outlet 10 Kg/cm2

3.3.3 SEAL OIL PUMPS A.C. SEAL OIL PUMPS D.C. SEAL OIL PUMPS i) Type : Multistage vertical split i) Type : Multistage vertical split centrifugal type centrifugal type ii) Discharge: 3.34 lit/sec ii) Discharge: 4.16 lit/sec iii) Head: 120 MWC iii) Head: 194 MWC iv) Speed: 1465 or 2900 rpm iv) Shut off head: Not more than 12% of rated head v) Shut off Head: Not more than 12% v) Min seal oil pressure : 5.5 Kg/cm2 of the rated head below which DC pump will start vi) Minimum governing : 6.5 Kg/cm2

oil pressure below which AC pump will start MOTOR MOTOR i) Type: Squirrel cage induction i) Type: Compound wound self excited type ii) Voltage: 415V+/- 10% ii) Rating: 26 KW iii) Frequency: 3 Phase, 50c/s iii) Voltage: 220VDC+10% & -20% iv) Rating: 15 KW/20 HP iv) Speed: 1800 or 2900 rpm v) Speed: 1465 or 290 rpm v) Rated current: 139 Amp. vi) Rated Current: 27 Amp. vi) Operation Speed: 70-80% of rated speed

3.3.4 SEAL OIL COOLER i) No. of coolers 2 Nos. ii) Inlet temperature of oil 500C iii) Temperaure of oil at cooler outlet 400C iv) Quantity of oil to be cooled 160 lit/min v) Inlet pressure of oil to cooler 10 Kg/cm2

vi) No of cooling tubes 420 vii) Material & size of cooling tubes 15*1 mm, copper viii) Pressure drop in the oil cooler 5 mwc ix) Inlet cooling water temperature 330C x) Outlet cooling water temperature 37.500C xi) Cooling water designed pressure 5 Kg/cm2 (Max) xii) Cooling water quantity required 95 m3/Hr xiii) Cooling water quality Clarified water 3.3.5 PRESSURE REGULATOR Differential pressure regulator Thrust oil regulator i) Type: Plunger type Plunger type ii) Inlet oil pressure: 6 to 9 Kg/cm2 6 to 9 Kg/cm2

iii) Differential pressure maintained: 0.6 to 0.9 Kg/cm2 1.0 to 2.2 kg/cm2

iv) Clearance between plunger and body : 0.03 mm 0.03 to 0.05 mm

3.4 STATOR WATER COOLING SYSTEM

A. STATOR WATER COOLING PUMP PUMP i) Type: Horizontal spindle, end suction directly driven, centrifugal type ii) Discharge: 40 m3/Hr iii) Head: 45 mwc iv) Make: Kirloskar Brothers Limited MOTOR i) Type: Squirrel cage induction type ii) Rating: 9.3 Kw iii) Rated voltage: 415V+/-10V, 3 phase,50 c/s iv) Rated current: 17 amp. v) Speed: 2900rpm vi) Make: Kirloskar Electric

B. STATOR WATER COOLERS

i) Nominal temperature of primary water to be cooled 650C ii) Nominal temperature of cooled primary water 400C

iii)Nominal tempearure of cooling D.M.water 330C at inlet on the secondary side iv)Nominal temperature of cooling water 36.50C at the outlet on the secondary side v) Quantity of D.M. Water on the secondary side 95m3/Hr vi) Secondary side D.M.water inlet pressure 5 Kg/cm2(max) vii) Tube dimensions 15*1mm viii) Length of cooling tubes 1720mm ix) No. of tubes per cooler 420 x)Tube material Copper C. EXPANSION TANK i) Material: Stainless Steel ii) Tank volume 2.1 m3

iii) Volume inside the tank 250 to 300 mmof Hg iv) Water level under normal operating 850 mm conditions( from the bottom of the tank) v) High water level which gives signal 1200mm ( from the bottom of the tank) vi) Low/ emergency water level requiring tripping of TG 500mm ( from the bottom of the tank) D. WATER JET EJECTOR i) Quality of water Clarified ii) Quantity of water required 7 to 10m3/Hr iii) Pressure 2 Kg/cm2

iv) Temperature 330C

3.5 GENERTATOR & UAT TRANSFORMERS

3.5.1 GENERTATOR TRANSFORMER (T4) TRANSFORMER RATING Make M/S TELK, Kerala Type of cooling OFB/OB/ON MVA 240/168/120 MVA Voltage (HV) 236 KV Voltage (LV) 15.75 KV

Current (HV) 587/411/293 A Current (LV) 8798/6158/4399 A Phase HV/LV 3 / 3 Impedance 15.55 % Frequency 50 Hz Vector Group Yd1 Connection HV/LV Star / Delta Max temp rise in oil 45 Deg C Temp rise in winding 55 / 60 Deg C Weight of core and winding 133000 Kg Weight of oil 43100 Kg Total weight 238900 Kg Quantity of oil 42500 liter Tap Off load BUSHING CT Ratio 600 / 1 Amp Continuous current 800 Amp Accuracy class P.S. Minimum knee point voltage 1000 Volt Max exciting current at knee point voltage 0.14 Amp. Max secondary wdg. Resistance at 75 Deg C 3 Ohm 3.5.2 GENERTATOR TRANSFORMER (T5) TRANSFORMER RATING Make M/S BHEL, Bhopal Type of cooling OFB/OB/ON MVA 240/168/120 MVA Voltage (HV) 236 KV Voltage (LV) 15.75 KV Current (HV) 587/411/293 A Current (LV) 8798/6158/4399 A Phase HV/LV 3 / 3 Impedance 14.75 % Frequency 50 Hz Vector Group Yd1 Connection HV/LV Star / Delta Max temp rise in oil 45 Deg C Temp rise in winding 55 / 60 Deg C Weight of core and winding 138800 Kg Weight of oil 37850 Kg Total weight 234000 Kg Quantity of oil 49540 liter

Tap Off load BUSHING CT Ratio 600 / 1 Amp Continuous current 800 Amp Accuracy class P.S. Minimum knee point voltage 1000 Volt Max exciting current at knee point voltage 0.14 Amp. Max secondary wdg. Resistance at 75 Deg C 3 Ohm 3.5.3 UNIT AUXLIARY TRANSFORMERS (Unit 4 & 5) RATING No. 2 / Unit Make EMCO, Mumbai Capacity 12500 KVA Voltage HV / LV 15.75 / 6,9 KV Current HV / LV 458.2 / 1045.8 Amp No. of phases HV / LV 3 / 3 Type of cooling ON Vector Group Dd0 Impedance 7.877/7.57 (UAT4A/4B) Impedance 7.762/7.725 (UAT 5A/5B) Frequency 50 Hz. Tap Changer On Load Max rise in oil temp above ambient 45 Deg C Weight of core and winding 12000 Kg Weight of Oil 6430 Kg Total weight 27100 Kg

SECTION –IV

PROTECTION AND

INTERLOCK

4.1 UNIT PROTECTIONS Sl.No. DESCRIPTION ANNUNCIAT

ION TRIPPING VALUE

TIME DELAY

1 Drum level low -100 mm -175 mm - 2 Drum level high +100 mm +175 mm - 3 Furnace pressure high +25 mmwcl +175 mmwcl - 4 Furnace vacuum high -25 mmwcl -175 mmwcl - 5 Loss of 220 V

D.C.supply of FSSS More than 2

secs 6 Less thanfire ball and

loss of 110V D.C. Supply

7 Loss of all fuel trip 8 On flame failure 9 Air flow less than 30% 10 Both ID fan tripped 11 Both FD fans tripped 12 Both PBS on FSSS

pressed

13 Reheater protection( This protection will act when there is no flow through R.H. & furnace outlet temperature more than 5380C)

14 Condenser vacuum 650 mm Hg 540 mm Hg 15 H.P. heater level very

high 750 mm 4250 mm

16 All BFPs tripped - - 15 secs 17 T.G.babbit metal

temperature 750C 800C

18 Turbine rotor axial shift +1.2 mm -1.7 mm

-

19 Loss of voltage on unit auxiliary bus bar

50% of rated value

5 to 10 secs

20 Emergency governor overspeed tripping

11% and 12% overspeed

21 Emergency governor backup

14% overspeed

22 Turbine lub oil pressure A.C. lub oil pump starts at 0.6 kg/cm2, D.C. lub oil pump starts at 0.5 kg/cm2

0.3 kg/cm2

23 M.S. Temperature low 5200C 4500C 24 Turbine shut down

switch - -

25 Manual tripping(UCB) through push buttons

4.2 PARTIAL LOAD CONDITION 1. One if two ID fans trips. 2. One if two FD fans trips. 3. One if two PA fans trips 4. One of the two BFPs trips and standby does not come up in more than 60 secs. 5. One of the two CW pump trips. 6. One of the two condensate pump trips and standby does not come up in more than 60 secs. When this relay acts following sequential actions take place: (a) Turbine load is reduced. (b) One of the PA fans trips (c) FSSS reduce boiler output 4.3 PROTECTION & INTERLOCK OF THE UNIT AUXLIARIES 4.3.1 BOILER AUXLIARIES Sl. No.

Description

Permissives Ineterlocks Protections

1 ID Fans a. Regulating vane FG-10 in minimum position

b. Outlet damper FG-12 closed

c. Fan/fan motor bearing temperature is not very high

a. Opening of outlet damper FG-12 after a time delay of 60 secs.

b. Connecting the regulating vane (FG-10) to regulator

c. Opening the interconnecting damper FG-5& FG-18

d. Closing the inlet damper FG-17& outlet

a. Bearing temperature too high

b. Motor bearing temperature too high

c. Lub. Oil pressure for motor bearing low with T.D. of 0-3 mts.

d. Both A.H. A&B off ( Provided de-interlocking in inter locked position)

damper FG-13 of other fan

e. Bringing the other fan inlet vane to minimum position

f. Permiisive to start selected FD fan

2 FD fans a. ID fan is started

b. Control oil pressure is adequate(8 kg/cm2)

c. Fan impellar blades are in min. position.(BA-1)

d. Outlet damper (BA-3) is in closed position.

e. FD fan bearing temp. is not high.

f. FD fan motor bearing temp. is not high.

a. Opening the outlet damper BA-3 with T.D. of 60 secs.

b. Connecting the impellar blade (BA-1) control drive to regulator.

c. Opening the inter connecting damper BA-2.

d. Closing the outlet damper of other fan.

e. Bringing the impeller blades of other fan to min. position.

a. Bearing temp. too high

b. Motor bearing temp. too high

c. Both ID fans trips d. If lub oil pressure

continues to be below a preset value for 30 mts.

e. If ID fan A or B trips and FD is selected in combination with ID fan.

3 Air Heater

Establish electric supply to A.H. motor. Take out the push button of the motor.

Wherever A.H. trips impulse is given for starting air motor provided guide/support-bearing temp. is less than 700C. When A.H. trips impulse is given for closing the flue gas inlet and outlet dampers FG-1 & FG-3 and air inlet & outlet dampers

Temp. of support and guide bearing 700C. Air motor also trips if temp. of support/guide bearing 700C.

BA-12, 14,22&24. Tripping of corresponding ID fans.

4 Ignitor fan

At least one ID and one FD fan must be in service. When start push button is pressed.

Discharge damper will open & damper of standby fan closes. The fan will start automatically when any ignitor or oil elevation is initiated.

5 Scanner fan

a. The scanner duct to furnace differential pressure is less than 115 mmwcl.

b. When start push button is pressed.

Discharge damper will open & damper of standby fan closes with T.D. of 5 secs.

Scanner air fan emergency damper opens automatically when both FD fans are off.

6 Primary air fan

a. Purge complete & NO boiler trip condition is present.

b. Regulating vanes BA-17 in min. position.

c. Outlet damper BA-19 in closed position.

d. Lub oil pressure is adequate around 2 kg/cm2

e. PA fan bearing temp not very high.

a. Fan discharge damper BA-19 opens with T.D. of 60 secs.

b. Fan inlet regulating inlet vane BA-17 is connected to regulator.

c. Inter connecting damper BA-21 opens.

d. Regulating vane of other PA fan closes to min. position(BA-18)

e. Outlet damper of other PA fan closes.(BA-20)

f. Load is reduced by tripping bottom mills

a. Fan bearing temp. too high.

b. PA fan motor bearing temp. too high.

c. Lub oil pressure to motor bearing low after a time delay of 0-5mts.

d. P.A. fan shall trip when one of the two FD fans trip and this fan is selected.

e. Motor protection operated.

leaving top three mills in service when one PA fan is running.

g. When both PA fan trips all running mills will trip.

h. When one PA fan is running partial load relay is energised.

7 Seal air fan

One PA fan is running

Manually fan can be tripped only if all the mills are stopped. Only one seal air fan can be started at time.

Running seal air fan will trip automatically after 60 secs time delay when both PA fan trips.

8 Pulveriser

a. Discharge valve are open.

b. Seal air valve is open.

c. Cold air shut off gate is open.

d. Feeder inlet gates are open(Check only)

e. Tram iron hopper valve is open

f. Primary air pressure is aduquate.

g. D.C.power to FSSS is available.

h. Pulveriser outlet temp. is less than 940C.

a. Permissive to open the hot air gate.

b. Permissive to start R.C.feeder.

c. Permissive for regulators impulse to act on hot air dampers.

a. Boiler trip condition is present.

b. Discharge valve are closed.

c. Loss of elevation A.C. for more than 2 secs.

d. Support ignition energy is removed within 3 mts of feeder starting.

e. PA fan tripping. f. Low primary air

pressure for more than 5 secs.

g. Motor protection operates.

h. PA pressure very low will trip all mill instantaneously.

i. Burner tilt is horizontal and air flow is less than 40%.( This is applicable only to the first mill to be started.)

j. Pulveriser ignition energy is available.

Pulveriser A*

a) A min of 3 out of 4 elevation AB light oil(or heavy oil) noozle valve proven open.

b) Boiler loading is greater than 30% and pulveriser B is in service at greater than 50% loading.

9 Raw coal feeder

1) No boiler trip condition persists

2) Elevation D.C. is available

3) Elevation A.C. is available

4) Ignition energy is available.

5) Pulverisor is on

6) Hot air gate is open

7) No stop signal 8) Fuel damper

closed

1) To release speed control to auto after 50 secs.

2) To modulate fuel air dampers according to feeder speed after 50 secs.

R.C.Feeder will trip if: 1) Boiler trips 2) Elevation D.C. fails

after2 secs time dealy 3) Elevation A.C. fails 4) Ignition energy

disappears beforev 180 secs from the start of the feeder.

5) Pulverisers trips 6) Loss of coal flow and

pulveriser amp. Low( this impulse will act only after 5 secs from feeder start.

When R.C. Feeders trip A) To close hot air gate

when either the pulverisar amps is

above maximum set point.

B) Pulveriser bowl differnencial pressure is high an impulse will be given to bring R.C. Feeders speed to minimum.

ID fan motor lubrication oil system

Pump A will start automatically if pump B trips provided A/M switch is in auto position. Pump A will start automatically with a time delay of 60 secs if oil pressure falls below a set value and pump B is worki9ng provided A/M switch in auto position. Whenever the lub oil pressure at entry to ID fan motor bearing falls below a set value impulse shall be given after a time of 0-3 mts to trip the ID fan.

3)

FD fan lub oil system

Pump A will start automatically if pump B trips provided A/M switch is in auto position. Pump A will start automatically with a time delay of 0-60 secs if oil

4)

pressure below a set value and pump B is working provided A/M switch is in auto position. Pump B will start automatically after 1 secs if pump A trips provided A/M switch is in auto position.

11 PA fan Pump A will start automatically if pump B trips provided A/M switch is in auto position . Pump B will start on auto with time a delay of 1 secs if pump A trips provided A/M switch is in auto position.

12 Furnace temp probe

Furnace temp probe shall be prohibited from being advanced further into the furnace if furnace temp sensed by it is more than 5400C

If furnace temp probe is inside the furnace and temp. exceeds 5400C it will be retracted back automatically

*For pulveriser B to F all conditions regarding their permissive to start, interlock and protection will be similar as for pulveriser A., except the adjacent elevation nozzle valves proven open or adjacent pulveriser should have loading more than 50%. 4.3.2 TURBINE AUXLIARIES Sl.No.

Description Permissive Interlock Protections

1 Boiler feed pump

1. Lubricating oil pressure at bearing

1. If lub oil pressure is below 1 kg/cm2 A.O.P. will come.

1.Main BFP will trip if lub oil pressure is below 0.5 kg/cm2

should be 1 kg/cm2

2. Suction pressure at suction of booster pump should be more than 3 kg/cm2 in hot start up. 3. If suction pressure at suction at booster pump is less than 3 kg/cm2 for more than 20 secs. Pump will trip. 4. Suction valve (BF1/2/3) is fully open. 5. Recirculation valve (BF-22/23/24) is fully closed.

2. If BFP tripped it’s A.O.P. will come in auto as soon as lub oil pressure drops 1 kg/cm2 . When any BFP put on “standby” it’s A.O.P. will come. 3. A.O.P.will trip after 10 secs when BFP lub oil pressure goes to 4 kg/cm2. 4. At 200T/hr discharge flow pump recirculation valve should open & at 220 T/hr it should get closed. 5. Standby BFP will come on auto as soon as either working BFP trips or common header pressure at discharge side is low.

2.Pump will trip if its motor bearing temperature is more than 800C 3.Pump will trip if discharge flow is more than 500 T/hr. 4. Pump will trip if water temperature at delivery of BFP is more than1750C 5.Pump will trip if discharge pressure is less than kg/cm2 for 12 secs. 6.Pump will trip if suction pressure of main BFP is below 6 kg/cm2

for 20secs, though it will start. 7.On turbine trip one BFP will trip if two are in operation.

2 Circulating water pump

1. Corresponding condenser outlet valve (CW1&2) is fully open.

1. When any CW pump is started its corresponding valve (CW3/4) on CW line to unit oil coolers shall open. 2.when one CW pump trips the corresponding valve CW1& CW3 or CW2&CW4 shall close and partial load relay will operate.

1. On closing of discharge valve CW-1&2 pump will trip.

2. CW pump will trip if its motor bearing temperature is more than 800C

3. When both CW pumps trip CW booster pump trips.

3 CW boosr\ter pump(Gas cooler booster

1. At least one CW pump should be inservice.

1. If both CW pumps trip booster pump will trip. 2.When running pump trip reserve pump will start immediately

1. CW booster pump will trip if both CW pump trip. 2. Pump will trip if motor current goes

pump) 3.If discharge pressure falls below 2 kg/cm2 standby pump will start.

beyond 100 Amp.

4 Condensate pump

1. Reserve pump will start as soon as running pump trips. 2. Reserve pump will start when common discharge header pressure falls below 10 kg/cm2. 3. If all condensate pump trips solenoid valve DM-105 on DM water sealing line will open for providing condensate pump sealing by DM water. 4. As soon as any one condensate pumps starts DM-105 gets closed. 5.If one of the two condensate pump trips & standby does not come in auto within 60 secs, partial load relay should be energized.

1. Working pump will trip if discharge pressure before its NRV becomes low(10 kg/cm2) after 30 secs of pump starting.

5 A.C. Lube oil pump

A.C lube oil pump will come in auto if bearing oil pressure goes down to 0.6 kg/cm2

6 D.C. lube oil pump will come in auto if bearing oil pressure goes down to 0.5 kg/cm2

7 Barring gear Barring gear will start only if lub oil pressure is more than 0.3 kg/cm2

Barring gear will engage only if rotor is in engage condition.

B/G will trip if lube oil pressure goes to 0.3 kg/cm2

8 Drip pump Pump will start only if HD-3( discharge valve) is closed & opening of regulating valve HD-3 is more than a preset value.

1. HD-3 discharge valve will be fully closed if no drip is running but will start opening as soon as drip pump starts. 2. Reserve drip pump will start as soon as running drip pump trips or discharge pressure of working pump falls below a preset value for 10 secs.

Working drip pump will trip if LPH-2 drip level falls to 200 mm for 20 secs or HD-2 & HD-3are in closed position.

9 Heater 6 1.If HPH-6 extraction pressure falls tp preset value its drip valve cascade to deaerator & HD-29(to HPH-5) will close & HD-30 will open. 2.If HPH-6 extraction steam pressure is above the preset value HD-29 (to HPH-5) will open & HD-30 will close.

10 HP Heater 5 1.If HPH-5 extraction steam pressure falls below a preset value its drain will cascade to LPH-4 i.e.HD-21(to LPH-4) will open & HD-31(to D/A) will close. 2. if HPH-5 extraction steam pressure is above the preset value its drain cascade to deaerator i.e. HD-31(to D/A) will open & HD-21(to LPH-4) will close. 3.If drip level in any HPH rises up to 750 mm solenoid valve (MC101&MC102) for NRV of extraction lines will open. 4. Back up feed water bypass valve (BF-40) will open. 5. After full opening of

1.HPH will be bypassed through group bypass protection valve at 750 mm drip level. 2.Turbine will trip at HPH level 4250 mm.

BF-40, inlet and outlet valve BF-38 & BF39 will close. 6. Steam extraction valve Es-3, ES-4, ES-5 to HPH will close.

11 Deaerator Deaerator drain valve DW-136 will open & close when D/a level goes higher & lower than preset value respectively.

12 H.P.& L.P. Bypass system

1. “Generator circuit breaker close” signal should not be there. 2.Condenser vacuum too low (600 mm of Hg column) signal should not be there.

1. When turbine is running or not running & HP bypass control is on manual the memory 1.05 will get closing signal through AND logic, if valve position is less than 2%. 2. If turbine is not running and control is on Auto the memory 1.05 will get closing signal through AND logic if valve position is less than 2%. 2. If turbine is not running and control is on Auto then is no closing signal to memory 1.05 independent of valve position. 4. If temp. After outlet of HP&LP bypass station becomes too high the closing signal to HP bypass valve forwarded &pressure loop changes from auto to manual. 5.If any of the bypass valve are open more than 2% a signal is available through OR logic to indicate that valve is open & same signal is used to change the control of valve from manual to Auto if previously it was on

manual. 6.When HP bypass valve is less than 2% open a tight closure signal is given to valve 03.01 when it is not in operation so that spray water temp valve02.01 is not subjected to high water pressure.

13 Extraction Auxiliary steam to D/A through ES-7,ES-6&As-57

1. When extraction steam pressure build up to the preset value (9 kg/cm2) for 3rd extraction (Es-7) will open & Es-6 & AS-57 will close. 2.When set value of extraction pressure is more than 3rd extraction set value but less than 2nd extraction then ES-6 will open & ES-7 & AS-57 will close. 3. When extraction pressure of 3rd & 2nd extraction is less than the set value ES-6 & ES-7 will close & AS-57 will open. 4. On turbine tripEs-6 & ES-7 will close &AS-57 will open.

14 Chamber heating valve As-43& 44 verses spindle leak off valve

1. If As-43 is open then As-47 will close. 2. If As-44 is open then As-48 will close.

15 I.S.P.U.G.(Initial steam pressure unloading gear)

M/C load reduced when steam pressure drops to 117 kg/cm2 & fully unloaded at 91 ata.

16 Extraction NRV on extraction lines

NRV closes when ESV closes i.e. solenoid valve MC-53&54 will open.

17 Load limiter Prevent further opening of

C.V. Beyond set point but does not prevent closing of C.V.

18 A.C. Seal oil pump

When seal oil pressure drops to 6.5 kg/cm2 A.C. seal oil pump will start.

19 D.C. Seal oil pump

When seal oil header pressure drops to 5.5 kg/cm2 D.C. seal oil pump will start.

SECTION –V

PROTECTION RELAYS

SETTINGS

5.1 RECOMMENDED SETTINS OF GENERATOR, GT & UATs

5.1.1 RECOMMENDED RELAY SETTING OF GENERATOR, GENERATOR TRANSFORMER AND UAT (UNIT 4) Sr. No.

Relay Relay Type

CTR / PTR

Range Setting

1. Generator Differential (87 G)

CAG 34 10000/5 Amp 0.25 - 1 A 0.25 Amp

2. Generator Inter Turn Fault (87 TG)

CAG 14 3000 / 5 Amp 1 - 4 A 4.0 Amp

3. Over All Differential (87 GT).

DTH32 GEN &UAT- 10000/5 Bushing & Switchyard - 600/1 ICT – 1.0 / 2.6 A

15% of 5 A Bias – 15,30 & 45 % High set – 1000 % Fixed

15 % of 5 Amp. 30 % 1000 % Fixed

4. GT Back up Earth fault (51 NT)

CDG 11 600/1 0.1-0.4 A PS-0.2 A, TMS-0.4

5. GT Restricted E/F (87 NT)

CAG 14 600/1 0.2-0.4 A 0.2 Amp.

6. Gen Over Voltage (59 G)

VAGM 22

VTT 11

15750/110 V 110 – 140 %

1.0 to 10 sec

121 Volt

2.0 Sec.

7. Gen Over Load Alarm (51 G1)

CTU 12 10000/5 A 50 – 200 % 05 – 5 Sec

102 % 2.5 Sec

8. Gen Back up Impedance (21 G)

YCG 15 VTT11 VTT11

10000/5 A, 15750/110 V

0.5 – 5 Sec 1 – 10 Sec

K1=6 K2 = 1St-I– 2.5 Sec St-II- 3Sec

9. UAT Over load alarm (51 T4A & T4B)

CAG 19 VTT 11

600/5A 2.5-5 A 1 – 10 Sec

4.375 A 4.0 Sec

10. Generator Negative Phase Sequence (46)

CTN 31

VTT 11

10000/5A

6 – 60 Sec

A - 70% T – 15% 60 Sec

11. UAT B/U O/C (50 T4A & 50 T4B)

CAG 37 VAT 11 VTT 11

600/5 A 10-40A 0.5 – 3 Sec 0.5 – 3 Sec

12 A 0.5 Sec 0.5 Sec

12. UAT Differential (87 T4A & T4B)

DTH31 HV=600/5 A LV=1250/5A

Current -15% of 5A Bias

15,30,45% High Set =

1000 %

Current - 15%

Bias=30% High Set =

1000 % Fixed

Sr. No.

Relay Relay Type

CTR / PTR

Range Setting

13. Stator Earth Fault (64G)

VDG14

15750/110 V V=5.4-20 V

PS=12.5V TMS=0.3

14. 1ST Rotor E/F (64F1) VME VTT 11

- 4 mA 0.5 – 5 Sec

4 mA 2.0 Sec

15. 2ND Rotor E/F (64 F2) CAEM - 1.1 mA 1.1 mA 16. Generator

Transformer Over Fluxing (99)

GTT21 15750/110 V K=1-1.25 T=12-120 Sec

K=1.125 T=15 Sec

17. Low Forward Power ( 37)

WCD 11 VTT 11

15750/110 V 10000/5A

0.5 % 1 - 10 Sec

0.5% 2 Sec

18. Reverse Power ( 32) 2/ 32 A 2/32 B

WCD 11VTT 11 VTT 11

15750/110 V 10000/5A

0.5 % 1 – 10 Sec 12 - 120 Sec

0.5% 2 Sec 120 Sec

19. Anti Motoring Protection (2/32 YA & 2/32YT)

VAT11 VTT 11

0.5 – 5 Sec 6 – 60 Sec

5 Sec 10 Sec

20. Generator Loss of Field (40)

YCGF 11 VTT 11 VTT 11

15750/110 V 10000/5A

1-10 Sec 5-25 Sec

K1=0.845, K2=3.5, K3=0.5, K4=3, K5=18.6 2Sec 10Sec

21. Generator Under Voltage (27)

VAGM 22

15750/110 V 44 – 88 Volt PS-80.5 V

22. Generator Pole Slipping (98)

ZTO 11 15750/110 V 10000/5A

5.2 Amp 75 Deg elect Offset= 3.156 Ohm, T=52.5mSec

23. Check Synchronizing Relay (25)

SKE 11 Phase Angle=10%, Voltge=6%, F=0.11%

5.1.2 RECOMMENDED RELAY SETTING OF GENERATOR, GENERATOR TRANSFORMER AND UAT (UNIT 5) Sr. No.

Relay Relay Type

CTR / PTR

Range Setting

1. Generator Differential (87 G)

CAG 34 10000/5 Amp 0.25 - 1 A 0.25 Amp

2. Generator Inter Turn Fault (87 TG)

CAG 14 3000 / 5 Amp 1 - 4 A 4.0 Amp

3. Over All Differential (87 GT).

DTH32 GEN &UAT- 10000/5 Bushing & Switchyard - 600/1 ICT – 1.0 / 2.6 A

15% of 5 A Bias – 15,30 & 45 % High set – 1000 % Fixed

15 % of 5 Amp. 30 % 1000 % Fixed

4. GT Back up Earth fault (51 NT)

CDG 11 600/1 0.1-0.4 A PS-0.2 A, TMS-0.4

5. GT Restricted E/F (87 NT)

CAG 14 600/1 0.2-0.4 A 0.2 Amp.

6. Gen Over Voltage (59 G)

VTU 21

15750/110 V 105 – 110 % 0.5-5 Sec

V=110 % 2 Sec

7. Gen Over Load Alarm (51 G1)

CTU 12 10000/5 A 50 – 200 % 05 – 5 Sec

4.75 A 5 Sec

8. Gen Back up Impedance (21 G)

YCG 15 VTT11 VTT11

10000/5 A, 15750/110 V

0.5 – 5 Sec 1 – 10 Sec

K1=6 K2 = 1St-I– 2.5 Sec St-II- 3Sec

9. UAT Over load alarm (51 T5A & T5B)

CTU12 600/5A 2.5-10 A 1 – 10 Sec

4 A 5 Sec

10. Generator Negative Phase Sequence (46)

CTN 31

VTT 11

10000/5A

6 – 60 Sec

A - 70% T – 15% 60 Sec

11. UAT B/U O/C (50 T5A & 50 T5B)

CAG 37 VAT 11 VTT 11

600/5 A 10-40A 0.5 – 3 Sec 0.5 – 3 Sec

12 A 0.3 Sec 0.3 Sec

12. UAT Differential (87 T5A & T5B)

DTH31 HV=600/5 A LV=1250/5A

Current -15% of 5A Bias

15,30,45% High Set =

1000 %

Current - 15%

Bias=30% High Set =

1000 % Fixed

Sr. No.

Relay Relay Type

CTR / PTR

Range Setting

13. Stator Earth Fault (64G 1)

VDG14

15750/110 V V=5.4-20 V

PS=5.4V TMS=0.3

14. 100 % Stator E/F (64 G2)

RAGEA T(119)-1 Sec, T(149)-5 Sec

15. 1ST Rotor E/F (64F1) VAEM VTT 11

- 1.1 mA 0.5 – 5 Sec

1.1 mA 2.0 Sec

16. 2ND Rotor E/F (64 F2) CAEM - 1.1 mA 1.1 mA 17. Generator

Transformer Over Fluxing (99)

GTT21 15750/110 V K=1-1.25 T=12-120 Sec

K=1.1 T=12 Sec

18. Low Forward Power ( 37)

WCD 11 VTT 11

15750/110 V 10000/5A

0.5 % 1 - 10 Sec

0.5% 2 Sec

19. Reverse Power ( 32) 2/ 32

WCD 11VTT 11

15750/110 V 10000/5A

0.5 % 1 – 10 Sec

0.5% 2 Sec

20. Anti Motoring Protection (2/32 YA & 2/32YT)

VAT11 VTT 11

1-10 Sec 12-120 Sec

5 Sec 60 Sec

21. Generator Loss of Field (40)

YCGF 11 VTT 11 VTT 11

15750/110 V 10000/5A

1-10 Sec 5-25 Sec

K1=0.845, K2=3.5, K3=0.5, K4=3, K5=18.6 2Sec 10Sec

22. Generator Under Voltage (27)

VAGM 22

15750/110 V 44 – 88 Volt PS-80.5 V

23. Generator Pole Slipping (98)

ZTO 11 15750/110 V 10000/5A

5.2 Amp 75 Deg elect Offset= 3.156 Ohm, T=52.5mSec

24. Check Synchronizing Relay (25)

SKE 11 Phase Angle=10%, Voltge=6%, F=0.11%

5.2 RECOMMENDED SETTINGS OF 6.6 KV SECTIONS

5.2.1 RECOMMENDED RELAY SETTING OF 6.6 KV STATION SECTION STAGE - II Sr. No.

Name of Feeder Relay Type CTR Range Setting

1. Main Incoming Supply from Station T/R – 3 (3SA1 & 3SB1)

CAG 37 VTT 11

U/V

2000 / 5 A

10 – 40 Amp 0.5 – 5 Sec

13.7 A 1.1 Sec 20%,1.5

Sec 2. Main Supply to CSA from

3SA at 3SA CAG 37 VTT 11

U/V

800/5 A 10 – 40 A 0.5 – 5 sec

10 Amp 0.8 Sec No Trip

3. Reserve Supply to CSA from 3SB at 3SB

CAG 37 VTT 11

U/V

800/5 A 10 – 40 A 0.5 – 5 sec

10 Amp 0.8 Sec No Trip

4. Main Supply to CT3 (Cooling Tower) from 3SA at 3SA

CAG 37 VTT 11

U/V

800/5 A 10 – 40 A 0.5 – 5 sec

10.8 A 0.8 Sec No Trip

5. Main Supply to CT3 at CT3 CAG 37 VTT 11

U/V

800/5 A 10 – 40 A 0.5 – 5 sec

10.8 A 0.5 Sec 20%,1.5

Sec 6. Main Supply to CSA at CSA CAG 37

VTT 11 U/V

400/5 A 10 – 40 A 0.5 – 5 sec

12 A 0.5 Sec 20%,1.5

Sec 7. Reserve Supply to CSA at

CSA CAG 37 VTT 11

U/V

400/5 A 10 – 40 A 0.5 – 5 sec

12 A 0.5 Sec 20%,1.5

Sec 8. Main Supply to WCA from

CSA at WCA CAG 37 VTT 11

U/V

400/5 A 10 – 40 A 0.5 – 5 sec

10 A 0.5 Sec 20%,1.5

Sec 9. Reserve Supply to WCA from

CSA at WCA CAG 37 VTT 11

U/V

400/5 A 10 – 40 A 0.5 – 5 sec

10 A 0.5 Sec 20%,1.5

Sec 10. Reserve Supply feeder for

Unit bus 4A,4B,5A & 5B from 3SA & 3SB (3SA2 & 3SB2)

CAG 37 VTT 11

1250/5 A 10 – 40 A 0.5 – 5 sec

22 A 0.8 Sec

11. Interconnecting feeder between Stage – I & Stage – II (4A01 & 4B01)

CAG 37 VTT 11

1250/5 A 10 – 40 A 0.5 – 5 sec

10 A 0.8 Sec

Sr. No.

Name of Feeder Relay Type CTR Range Setting

12. Station Auxiliary T/R 1 &2 (TS3 & TS4 / 1600 KVA)

CAG 37 VTT 11 CAG 37

200 / 5 A 10 – 40 Amp 0.5 – 5 Sec 25 – 100 A

18.7 A 0.5 Sec 75 A

13. Stand By T/R 1 &2 (TR3 & TR4 / 1600 KVA)

CAG 37 VTT 11 CAG 37

200 / 5 A 10 – 40 Amp 0.5 – 5 Sec 25 – 100 A

18.7 A 0.5 Sec 75.7 A

14. Stand By T/R (TR5 / 1000 KVA)

CAG 37 VTT 11 CAG 37

150 / 5 A 10 – 40 Amp 0.5 – 5 Sec 25 – 100 A

15.5 A 0.5 Sec 66.7 A

15. Control Structure Transformer (1000 KVA)

CAG 37 VTT 11 CAG 37

150 / 5 A 10 – 40 Amp 0.5 – 5 Sec 25 – 100 A

15.5 A 0.5 Sec 67.4 A

16. Lighting Transformer (TL3 / 1000 KVA)

CAG 37 VTT 11 CAG 37

150 / 5 A 10 – 40 Amp 0.5 – 5 Sec 25 – 100 A

15.5 A 0.5 Sec 68 A

17. Cooling Tower Transformer (1600 KVA)

CAG 37 VTT 11 CAG 37

200 / 5 A 10 – 40 Amp 0.5 – 5 Sec 25 – 100 A

18.7 A 0.5 Sec 77 A

18. Coal Handling Transformer (TC3 / 1000 KVA)

CAG 37 VTT 11 CAG 37

150 / 5 A 10 – 40 Amp 0.5 – 5 Sec 25 – 100 A

15.5 A 0.5 Sec 66.7 A

19. Water Treatment Plant T/R (1000 KVA)

CAG 37 VTT 11 CAG 37

150 / 5 A 10 – 40 Amp 0.5 – 5 Sec 25 – 100 A

15.5 A 0.5 Sec 66.7 A

20. Clarifier Water Transformer (630 KVA)

CAG 37 VTT 11 CAG 37

100 / 5 A 10 – 40 Amp 0.5 – 5 Sec 25 – 100 A

14.7 A 0.5 Sec 65 A

21. CT Pumps (930 KW) Full load current = 111 A Starting current = 577.2 A Starting time = 1.67/4.76 Sec

CDGM 62

U/V

150/5 A 3.6 – 6.2 A 25 – 100 A

PS = 3.95 TMS=0.2

30 A 70%, 0.5

Sec 22. HP Flush Water Pumps

(187 KW) Full load current = 23 A Starting current = 115 A Starting time = 2.66/5.25 Sec

CDGM 62

U/V

30/5 A 3.6 – 6.2 A 25 – 100 A

PS = 3.95 TMS =

0.25 30 A

70%, 0.5 Sec

23. Clarified Water Pumps (280 KW) Full load current = 111 A Starting current = 577.2 A Starting time = 1.67/4.76 Sec

CDGM 62

U/V

40/5 A 3.6 – 6.2 A 25 – 100 A

PS = 4.35 TMS=0.5

30 A 70%, 0.5

Sec

Sr. No.

Name of Feeder Relay Type CTR Range Setting

24. Clarified Raw Water Pumps (280 KW) Full load current = 31.5 A Starting current = 173.5 A Starting time = 2.0 Sec

CDGM 62

U/V

40/5 A 3.6 – 6.2 A 25 – 100 A

PS =3.95 TMS=0.2

37.5 A 70%, 0.5

Sec 25. Boiler Fill Pumps (250 HP)

Full load current = 20.4 A Starting current = 133 A Starting time = 2.2 Sec

CDGM 62

U/V

30/5 A 3.6 – 6.2 A 25 – 100 A

PS =4.35 TMS=0.2

42.5 A 70%, 0.5

Sec

5.2.2 RECOMMENDED RELAY SETTING OF 6.6 KV UNIT SECTION

STAGE - II (Unit - 4) Sr. No.

Name of Feeder Relay Type

CTR Range Setting

1. Unit Auxiliary T/R (T4C & T4D / 1000 KVA)

CAG 37 VTT 11 CAG 37

150 / 5 A 10 – 40 A 0.5 – 5 sec 25 – 100 A

18.7 A 0.5 Sec 68 Amp

2. EP Transformer (1600 KVA)

CAG 37 VTT 11 CAG 37

200 / 5 A 10 – 40 A 0.5 – 5 sec 25 – 100 A

18.7 A 0.5 Sec 75.7 A

3. Reserve Incomer from ( For Bus 4A & 4B)

CAG 37 VTT 11

1250 / 5 A 10 – 40 Amp 0.5 – 5 Sec

22 Amp 05 Sec

4. ID FAN A & B (1300 KW) Full Load Current = 138 A Starting Current = 717.6 A Starting Time = 7/10 Sec

CDGM 62 U/V

200 / 5 A

3.6 to 6.2 A

25 – 100 A

PS = 3.6 TMS=0.35

30 Amp No Trip

5. Bowl Mills A,B,C,D,E & F (335 KW) Full Load Current = 41.7 A Starting Current =270 A Starting Time = 4.76 Sec

CDGM 62 U/V

50 / 5 A 3.6 – 6.2

25 – 100 A

PS = 3.95 TMS=0.2 40 Amp 70%,0.5

Sec 6. PA Fans A & B (1250 KW)

Full Load Current = 132.5 A Starting Current =795 A Starting Time = 24.5/33 Sec

CDGM 62

CTU 12 U/V

150 / 5 A

a. – 6.2 25 – 100 A

PS = 4.35 TMS=1.0

40 A 9A,15 Sec 50%,9 Sec

7. SOP (200 KW) Full Load Current = 21.8 A Starting Current = 128.4 A Starting Time = 3/5 Sec

CDGM 62

U/V

30 / 5 A

3.6 – 6.2 25 – 100 A

PS = 4.35 TMS=0.25

34 A 70%,0.5

Sec

Sr. No.

Name of Feeder Relay Type

CTR Range Setting

8. FD Fans A & B (800 KW) Full Load Current = 84.9 A Starting Current = 509.4 A Starting Time = 5.5/8 Sec

CDGM 62

U/V

100 / 5 A

3.6 – 6.2 25 – 100 A

PS = 4.35 TMS=0.35

40 A 50%,9 Sec

9. C W Pumps A & B (950 HP) Full Load Current = 82.8 A Starting Current = 422 A Starting Time = 1.45/2.1 Sec

CDGM 62

U/V

100 / 5 A

3.6 – 6.2 25 – 100 A

PS = 3.95 TMS=0.2

33 A No Trip

10. CEP Pumps A,B,C (220 KW) Full Load Current = 25 A Starting Current = 135 A Starting Time = 2.5 Sec

CDGM 62

U/V

30 / 5 A

3.6 – 6.2 25 – 100 A

PS = 4.35 TMS=0.2

42.5 A 50%,9Sec

11. BFP A,B & C (4000 KW) Full Load Current = 421 A Starting Current = 2020 A Starting Time = 5/9 Sec

CDGM 62

CAG 34 U/V

500 / 5 A

3.6 – 6.2 25 – 100 A 0.1 – 1 A

PS = 3.95 TMS=0.2

33 A 0.1 A

50%,9 Sec

5.2.3 RECOMMENDED RELAY SETTING OF 6.6 KV STATION SECTION STAGE - III

Sr. No.

Name of Feeder Relay Type CTR Range Setting

1. Main Incomer to CT4 (Cooling Tower) from 3SB at 3SB

CAG 37 VTT 11

U/V

800/5 A 10 – 40 A 0.5 – 5 sec

10 A 0.8 Sec No Trip

2. Main Incomer for CT4 at CT4 Bus

CAG 37 VTT 11

U/V

800/5 A 10 – 40 A 0.5 – 5 sec

10 A 0.5 Sec 20%,1.5

Sec 3. Bus coupler between CT3 &

CT 4 Bus CAG 37 VTT 11

800/5 A 10 – 40 A 0.5 – 5 sec

10 A 0.5 Sec

4. Station Auxiliary T/R

(TS5 / 1600 KVA) CAG 37 VTT 11 CAG 37

200 / 5 A 10 – 40 Amp 0.5 – 5 Sec 25 – 100 A

10 A 0.5 Sec 66 A

5. Stand By T/R (TR6 / 1600 KVA)

CAG 37 VTT 11 CAG 37

200 / 5 A 10 – 40 Amp 0.5 – 5 Sec 25 – 100 A

10 A 0.5 Sec 66 A

6. Lighting Transformer (TL4 / 1000 KVA)

CAG 37 VTT 11 CAG 37

150 / 5 A 10 – 40 Amp 0.5 – 5 Sec 25 – 100 A

10 A 0.5 Sec 65 A

Sr. No.

Name of Feeder Relay Type CTR Range Setting

7. Cooling Tower Transformer (1600 KVA)

CAG 37 VTT 11 CAG 37

200 / 5 A 10 – 40 Amp 0.5 – 5 Sec 25 – 100 A

10 A 0.5 Sec 66 A

8. CT Pumps (960 KW) Full load current = 115 A Starting current = 632.5 A Starting time = ¾.5 Sec

CDGM 32

CAG 37

U/V

150/5 A 3.6 – 6.2 A 25 – 100 A

PS = 3.6 TMS=0.2

34 A 70%, 0.5

Sec

5.2.4 RECOMMENDED RELAY SETTING OF 6.6 KV UNIT SECTION

STAGE - II (Unit - 5) Sr. No.

Name of Feeder Relay Type

CTR Range Setting

1. Unit Auxiliary T/R (T5C & T5D / 1000 KVA)

CAG 37 VTT 11 CAG 37

150 / 5 A 10 – 40 A 0.5 – 5 sec 25 – 100 A

10 A 0.5 Sec 65 Amp

2. EP Transformer (1600 KVA)

CAG 37 VTT 11 CAG 37

200 / 5 A 10 – 40 A 0.5 – 5 sec 25 – 100 A

10 A 0.5 Sec 66 A

3. Reserve Incomer from ( For Bus 5A & 5B)

CAG 37 VTT 11

1250 / 5 A 10 – 40 Amp 0.5 – 5 Sec

22 Amp 0.3 Sec

4. ID FAN A & B (1100 KW) Full Load Current = 116.5 A Starting Current = 855 A Starting Time = 7/10 Sec

CDGM 32 CAG 37 U/V

150 / 5 A

3.6 to 6.2 A

25 – 100 A

PS = 4.35 TMS=0.4 43 Amp No Trip

5. Bowl Mills A,B,C,D,E & F (340 KW) Full Load Current = 41.7 A Starting Current =250.2 A Starting Time = 2.9/6.1 Sec

CDGM 32 CAG 37 CTU 12 U/V

50 / 5 A 3.6 – 6.2

25 – 100 A

PS = 3.95 TMS=0.2 40 Amp

8.1A,3 Sec 70%,0.5 S

6. PA Fans A & B (1250 KW) Full Load Current = 135.3.A Starting Current =811.8 A Starting Time = 19/28 Sec

CDGM 32

CAG 37 CTU 12

U/V

150 / 5 A

b. – 6.2 25 – 100 A

PS = 4.35 TMS=0.8

40 A 9A,10 Sec 50%,9 Sec

7. SOP (200 KW) Full Load Current = 22 A Starting Current = 132 A Starting Time = 3.5/5 Sec

CDGM 32

CAG 37 U/V

30 / 5 A

3.6 – 6.2 25 – 100 A

PS = 3.6 TMS=0.2

34 A 70%,0.5

Sec

Sr. No.

Name of Feeder Relay Type

CTR Range Setting

8. FD Fans A & B (750 KW) Full Load Current = 79.5 A Starting Current = 477 A Starting Time = 6.5/10 Sec

CDGM 32

CAG 37 U/V

100 / 5 A

3.6 – 6.2 25 – 100 A

PS = 3.6 TMS=0.5

38 A 50%,9 Sec

9. CEP Pumps A,B,C (220 KW) Full Load Current = 25 A Starting Current = 135 A Starting Time = 2.5 Sec

CDGM 32

CAG 37 U/V

30 / 5 A

3.6 – 6.2 25 – 100 A

PS = 3.95 TMS=0.3

36 A 50%,9Sec

10. BFP A,B & C (4000 KW) Full Load Current = 421 A Starting Current = 2020.8 A Starting Time = 5/9 Sec

CDGM 32

CAG 37 CAG 34

U/V

500 / 5 A

3.6 – 6.2 25 – 100 A 0.1 – 1 A

PS = 3.95 TMS=0.3

32 A 0.1 A

50%,9 Sec

5.3 RECOMMENDED SETTING OF MCB RELAYS

Sr. No.

Name of Feeder Type of Protection

Relay Type CTR/PTR Range Setting

Distance Protection

Quadro mho

- Z1=1.792 Ohm Z2=2.24 Ohm (t2=350 ms) Z3=2.56Ohm (t3=1.05ms) Z3’=0.4 Ohm

1

IP1&IP2

Backup Protection

CDD21 (Directional)

600/1 A 220KV/110V

O/C 50-200%

E/F 20-80%

E/F Comp.=130% (R-Ph)O/C=150% (B-Ph)O/C=150% E/F =20% TMS=0.3 sec

Distance Protection

RR3V Scheme

- Z1=1.68 Ohm Z2=3.15 Ohm (t2=350 ms) Z3=5.76Ohm

(t3=1.0 sec)

2

Mehrauli 1&2

Backup Protection

IDMT (Directional)

600/1 A

220KV/110V

O/C 50-200%

E/F 20-80%

(R-Ph)O/C=150% (B-Ph)O/C=150% E/F =20% TMS=0.2 sec

Sr. No.

Name of Feeder Relay Type

CTR Range Setting Sr. No.

Distance Protection

MM3V Scheme

- Z1=2.396 Ohm Z2=3.355 Ohm (t2=350 ms) Z3=9.1Ohm

(t3=1.0 sec)

3 Ballbhagarh 1&2

Backup Protection

IDMT (Directional)

600/1 A

220KV/110V

O/C 50-200%

E/F 20-80%

(R-Ph)O/C=125% (B-Ph)O/C=125% E/F =20% TMS=0.3 sec

Distance Protection

RR3V - Z1=1.63 Ohm Z2=2.44 Ohm (t2=350 ms) Z3=4.89Ohm (t3=1.0 sec)

4 Okhala – 1

Backup Protection

IDMT (Directional)

600/1 A 220KV/110V

O/C 50-200%

E/F 20-80%

(R-Ph)O/C=125% (B-Ph)O/C=125% E/F =20% TMS=0.3 sec

Distance Protection

RR3V - Z1=0.834 Ohm Z2=1.44 Ohm (t2=200 ms) Z3=2.952Ohm

(t3=1.0 sec)

5 Okhala – 2

Backup Protection

IDMT (Directional)

600/1 A 220KV/110V

O/C 50-200%

E/F 20-80%

(R-Ph)O/C=125% (B-Ph)O/C=125% E/F =20% TMS=0.3 sec

Distance Protection

- - Z1=2.65 Ohm Z2=4.51 Ohm (t2=220 ms) Z3=8.29Ohm

(t3=1.0 sec)

6 NOIDA

Backup Protection

IDMT (Directional)

600/1 A 220KV/110V

20-80% E/F =20% TMS=0.3 sec

Sr. No.

Name of Feeder Relay Type

CTR Range Setting Sr. No.

Distance Protection

MM3V Scheme

- Z1=13.44 Ohm Z2=20.16 Ohm (t2=450 ms) Z3=26.88Ohm

(t3=1.0 sec)

7 Alwar

Backup Protection

IDMT (Directional)

600/1 A 220KV/110V

O/C 50-200%

E/F 20-80%

(R-Ph)O/C=125% (Y-Ph)O/C=125%(B-Ph)O/C=125% E/F =20% TMS=0.3 sec

Distance Protection

Quadro mho - Reqired setting can be set

8 Bypass

Backup Protection

IDMT (Directional)

600/1 A 220KV/110V

O/C 50-200%

E/F 20-80%

Reqired setting can be set

4A 50A(R-Ph) 50C(B-Ph)

Instantant O/C

E/F

CAG33

4 – 16 Amp.

2 – 8 Amp 2A

50N

1.8 A (51A,51C)

9 Bus Coupler

Instantant Dead time

O/C E/F

CAG39

1200/2 A 220KV/110V

0.5-2Amp

0.5-2Amp

0.5 A (64)

Backup Protection

IDMT O/C 50-200%

E/F 20-80%

(R-Ph)O/C=50% (B-Ph)O/C=50%

E/F =20%

10 Station Tr. 1&2

Biased Diff.

Protection

DMH

600/1 A 220KV/110V

15-50% 30%

Backup Protection

IDMT E/F 10-40%

(R,Y,B-Ph) O/C 20%

Differential Protection

DTH-31 - 15%

11 Station Tr. 3

Rest. E/F CAG-14

600/1 A 220KV/110V

5-20% 10% 12 Bus Bar

Differential Bus Bar

DifferentialCAG-34 600/1 A

50-200% 125%

NOTE: All feeders, Station transformers, Bus coupler, Bypass breaker and units are having LBB protection- tripping defective breaker bus after 200 ms.

SECTION –VI

NEW C&I SYSTEM COMMISSIONED

6.1 NEW SYSTEMS COMMISSIONED IN STAGE II UNITS

6.1.1 ELECTRONIC DRUM LEVEL INDICATORS: (#4,5) Make :Levelstart Total no. of probes : 14 Range : 0-500 mmWCI Drum Pressure :200 kg/cm2 Temperature : 4000 C Power supply : Dual for odd & even set of

electrodes Indication local and UCB for left & right side. 6.1.2 VARIABLE FREQUENCY DRIVE IN RC FEEDERS:(#4,5) Make : L&T Rating : 7.5 KW,415V 3Ph Feeders :6 nos. Features : Remote speed indication & facility

for auto control 6.1.3 RC FEEDER SPEED INDICATION AND STOPPAGE ALARM : ( # 4,5) Make : Masibus Sensor : Inductive proximity switches Indication : Digital speed indication in UCB for

each feeder Alarm : An immediate alarm is given in

case of stoppage of the feeder in UCB

6.1.4 LP/HP HEATER DRIP LEVEL CONTROLLERS (#4)

(Single loop PID controller)

Make : Fuji Tosdic Output : 24 V pulsating 6.1.5 ANNUNCIATION SYSTEM :(#4,5) Make : ILK Mark –II (CMOSbased) I/P supply : 230V AC

6.1.6 DISTRIBUTED CONTROL SYSTEM (DCS): (#5) Make : Siemens Teleperm ME Plus. 1. Closed loop controls including: a) PA header pressure b) Furnace draft c) SH attemperation d) RH attemperation 2. Analog & Digital Measurements 6.1.7 SEQUENCE OF EVENTS LOGGER (#5) Make : Siemens Mode : Sieser No. of points : 256 Time stamping : 1 msec

SECTION –VII

OFF-SITE

AUXLIARIES

7.1 SWITCHYARD 7.1.1 STATION TRANSFORMER (#1) TRANSFORMER RATING Make BHEL MVA 31.5 Date Of First Charging 11-10-1982 Voltage Ratio HV/LV (kV) 220/7 Current HV/LV (Amps.) 82.67/2598.15 Phases 3 Frequency (Hz) 50 Vector Group Yd1 Type Of Cooling ON Tap Changer Type OLTC Impedance % 13.67 7.1.2 STATION TRANSFORMER (#2)

TRANSFORMER RATING Make BHEL MVA 63/43/20 Date Of First Charging 1973 Voltage Ratio HV/LV (kV) 220/6.9 Current HV/LV (Amps.) 163.3/1673 Phases 3 Frequency (Hz) 50 Vector Group Yd1 Type Of Cooling OFB Tap Changer Type OLTC Impedance % 16.75 7.1.3 STATION TRANSFORMER (#3)

TRANSFORMER RATING Make BHEL MVA 25 Date Of First Charging 15-06-1977 Voltage Ratio HV/LV (kV) 220/7 Current HV/LV (Amps.) 65.6/2062 Phases 3 Frequency (Hz) 50

Vector Group Yd1 Type Of Cooling ON/AB Tap Changer Type OLTC Impedance % 12.62 7.1.4 BUS BARS SCHEME

The arrangement in the 220KV switchyard comprises of a 220 KV double bus bar system with a bus coupler and by pass bus. With this arrangement it is possible to take out any one breaker on By Pass for maintenance without interruption of supply. 7.1.5 NORMAL OPERATION

The two bus bras (Bus-I and Bus-II) should normally be kept coupled through the bus coupler. The fixed distribution for bus differential protection should not normally be disturbed. 7.1.6 MAINTENANCE OF BUS-I AND BUS-II

For maintenance of a particular bus all feeders connected to the bus requiring maintenance shall be transferred to the other bus by closing one bus isolator and opening the other. The bus coupler shall be tripped in the last. 7.1.7 220KV CIRCUIT BREAKERS

The Air Blast Circuit Breakers (ABCB) are of M/S BHEL and ABB make. The operating pressures are 26 kg/ cm2and 31 kg/ cm2respectively and their lock-out pressures are 21 kg/ cm2and 27 kg/ cm2. 7.1.8 220 KV CURRENT TRANSFORMERS

220 KV, single phase, 4 core current transformers are of M/S ABB and BHEL are in the switchyard. 1ST Core used for Differential protection (Station transformer and Generator Transformer) Distance Protection (in case of feeders) 2nd Core used for Back up protection and local breaker back up protection (LBB) 3rd Core used for Metering 4th Core used for Bus bar Differential Protection In case of feeders, distance scheme covers phase to ground, phase to phase protection with zone indications. In case of failure of main (distance protection), back up IDMT

type of relay trips the line. And if the protection relay comes and breaker fails to operate due to control circuit or any other problem, LBB protection operates after 200 ms and makes the 220KV Bus I or II dead (as the case may be). Similarly in case of 220 KV Bus fault, all feeders of the faulty Bus trip and make the Bus dead through Bus bar Differential protection. In the Zone protection: - 1st Zone Instantaneous 2nd Zone 0.35 sec (delay) 3rd Zone 1.0 sec (delay) 7.1.9 INTERLOCKS

1 ABCB can not be closed from remote, if

1 Lockout relay (186) is not resetted 2 Low Air Pressure 3 Control Circuit faulty (DC not available)

2 Bus and line isolators can not be operated electrically if breaker of that Bay is in closed position.

3 2nd Bus isolator of any Bay can only be closed (electrically) when Bus coupler breaker and its both isolators are in closed position.

4 By Pass Isolator of any Bay can be operated (electrically) only when By Pass Bay Breaker is in open position.

5 Earthling switches have electrical/mechanical interlocks with isolators. 6 Electrical interlock provided for closing only one by pass isolator at a time. 7.1.10 UNDER FREQUENCY PROTECTION (Islanding)

At 47.8 c/s - 220KV Badarpur / Sahibabad feeder will trip At 47.6 c/s - 220 KV Badarpur / Ballabhgarh I, II and Alwar feeders will trip. 220KV BUS-I AND II (as the case may be) may become dead if any of the five unit breakers is under trip position and its Bus and line Isolators are in closed position and the air pressure drops to 16 kg/ cm2 (approx.)

7.1.11 IMPORTANT ANNUNCIATIONS (required immediate attention)

1 Control Circuit faulty 2 Breaker Air Pressure Low 3 V.T. fuse faulty 4 Line V.T.fuse faulty 5 Bus Protection Bus wire faulty 6 Bus connection disturbed 7 Bus Differential protection DC faulty 8 Bus protection zones combined

9 Bus bars paralleled by isolators. There are 20 Bays in 220KV switchyard connected to 220KV Bus-I and Bus-II as per following description:- BUS-I 1 IP-I 2 Station I, III 3 Okhla-I 4 Ballabhgarh-I 5 Units-I, III, V 6 Jaipur 7 Mehrauli-I BUS-II 1 IP-II 2 Station-II 3 Okhla-II 4 Ballabhgarh-II 5 Units-II, IV 6 Sahbabad 7 Mehrauli-II By Pass Bay can be connected to either of these buses and bus coupler is used for coupling both the buses.

7.2 AIR COMPRESSORS 7.2.1 STATION AIR COMPRESSOR

Total Nos. 3 Jacket water pressure 4.2 kg/cm2 (Max.) H.P. Cylinder outlet 1100 F to 1200 F Water Temp

7.2.2 COMPRESSOR NO. 1 & 2

Make Pneumatic Tool company (India)Ltd., Mumbai. Type Slow speed, Horizontal straight

Line & Double Acting Type Speed 300 RPM Nos. of Cylinder 2 Pressure 100 Psig

Max. working pressure 120 Psig No. 2 Capacity 21m3/hr MOTOR

Motor capacity 126 KW Voltage 415V RPM 1500 Amps 221 Make Siemens

RECEIVER

Capacity 250C.F. Working pressure 125 Psig Test pressure 185 Psig

7.2.3 COMPRESSOR NO 3

Make Consolidated Pneumatic

Tool company(India)Ltd., Mumbai.

Type Slow speed, Two cylinders Horizontal & double acting type.

Speed 300 RPM Capacity 741 CFM at 100Psig

( 20.926M3/min) Working pressure 100 Psig ( 7 kg/cm2) Max. Unloading Pressure 100 Psig ( 7 kg/cm2) No. One RECEIVER Capacity 10 M3. Design pressure 9.2 kg/cm2

Test pressure 13.8 Kg/cm2 MOTOR Capacity 132 KW Voltage 415V+ 10% RPM 1500 Amps 227 Make Siemens

7.2.4 PLANT AIR COMPRESSORS(ST-II & III)

No 2 Capacity 30 m3/min Pressure 70 MWC Make Kirlosker Pneumatic MOTOR Capacity 200 KW Voltage 6.6 KV RPM 988 Amps 23 Make Kirlosker 7.2.5 INSTRUMENTAIR COMPRESSOR (U#4)

Make K.G.Khosla Compressor Ltd. Type KHOSLA – CRPELLE Double acting, Horizontal/cross

heads two opposite cylinders.

Speed 750 RPM Free air Delivery 14.6 m3/min. Working/cut-off 8.0 kg/cm2

Pressure Re-starting Pressure 7 kg/cm2

No. of compressor 2 Lubrication oil 1.5 to 2 kg/cm2

Pressure Jacket water pressure 8 kg/cm2

HPC outlet water 1100 F to 1200 F Temperature

MOTOR

Capacity 100 KW Voltage 415 Volts Amps 173/177 Make Kirlosker Electric Speed 1500 RPM RECEIVER

Capacity 5 M3

Hydraulic Test Pressure 16.19 kg/cm2

Working Pressure 10.15 kg/cm2

AIR DRYING UNIT

1) Type Purge Reactivation 2) Flow Rate 14.6 kg/cm2

3) Inlet Pressure 8 kg/cm2

4) Outlet pressure 7.6 kg/cm2

5) Inlet Temp. 440 C 6) Outlet Temp. 540 C 7) Outlet Moisture 22 ppm content 8) Cycle Time a) For absorption 6 Hrs b) For regeneration 2 ½ Hrs c) For cooling 3 ½ Hrs 9) Service Continuous 10) Drying Agent Silica 11) Design Pressure 10 kg/cm2

7.2.6 INSTRUMENT AIR COMPRESSORS (U#5) 7.2.7 COMPRESSURE 1&2

Make Kirlosker Pneumatic Capacity 3./min (2 Nos) Pressure 7 kg/cm2 MOTOR Capacity 120 KW Voltage 415 V RPM 1000 Amps 212 Make Kirlosker 7.2.8 COMPRESSURE 3

Make K.G.Khosla Compressor Ltd. Type KHOSLA – CRPELLE Double acting, Horizontal/cross

heads two opposite cylinders.

Speed 750 RPM Free air Delivery 14.6 m3/min.

18 m

Working/cut-off 8.0 kg/cm2

Pressure Re-starting Pressure 7 kg/cm2

Lubrication oil 1.5 to 2 kg/cm2

Pressure Jacket water pressure 8 kg/cm2

HPC outlet water 1100 F to 1200 F Temperature MOTOR Capacity 100KW Voltage 415 V RPM 1500 Amps 173 Make Kirlosker AIR DRYING UNIT

1) Type Purge Reactivation 2) Flow Rate 14.6 kg/cm2

3) Inlet Pressure 8 kg/cm2

4) Outlet pressure 7.6 kg/cm2

5) Inlet Temp. 440 C 6) Outlet Temp. 540 C 7) Outlet Moisture 22 ppm content 8) Cycle Time a) For absorption 6 Hrs b) For regeneration 2 ½ Hrs c) For cooling 3 ½ Hrs 9) Service Continuous 10) Drying Agent Silica 11) Design Pressure 10 kg/cm2

7.3 CONTROL STRUCTURE PUMP HOUSE

7.3.1 HP FLUSH WATER PUMP

No -I, II, III, IV 4 Make Worthigton Type Multistage Vertical Turbine Pump Capacity 500 m3/Hr Head 94.5 MWC Speed 1500 RPM

MOTOR Make Kirloskar Type Induction Motor Rating 6.6 KV,187 KW ,22Amp. RPM 1485 7.3.2 H.P. WATER PUMPS

No-V, VI 2 Make Kirloskar Type Multistage Vertical Turbine Pump Capacity 400 m3/Hr Head 94.5 MWC MOTOR Make Kirloskar Type Induction Motor (IP23/IC01) Rating 6.6 KV,150 KW RPM 1485 7.3.3 FIRE & SCREEN PUMP Make Worthigton No 2 Type Multistage Vertical Turbine Pump Capacity 500 m3/Hr Head 94.5 MWC MOTOR Make Kirloskar Type Induction Motor Rating 6.6 KV,185 KW RPM 1485 7.3.4 DEISEL FIRE PUMP Make Kirloskar Type DHR-35 Three Stage Capacity 500 m3/Hr Pressure 10 Kg/cm2

Engine Model Model NTA-855-F Rating 132 Kw

7.3.5 LP FLUSH WATER PUMPS

No 3 Make Jyoti Type B400 D3F 300, Multistage vertical turbine pump Capacity 600 m3/Hr Head 55 MWC Speed 1440 RPM MOTOR Make Jyoti Limited, Baroda Type Induction Motor (IP23/IC01) Rating 415 V,132 KW ,230Amp RPM 1470 7.3.6 CLARIFIED RAW WATER PUMP(CRW) Make Kirloskar,(CRW1)/Flowmore(CRW2,3) No 3 Capacity 3500 m3/Hr Head 20.5 MWC MOTOR Make Kirloskar. Type Induction Motor Rating 6.6 KV,280 KW RPM 985 7.3.7 TRAVELLING WATER SCREENS Make BSBK Total no of screens 7 nos Capacity 20000 cu mt /hr 7.3.8 SCREEN WASH PUMPS Make Mather and Platt. Capacity 300 cu mt/hr Pressure 6.0 kg/cm2 Motor 75KW/1485RPM/131Amp 7.3.9 CHLORINATION PUMP No 1

Type Vertical Capacity 200 m3/Hr Head 66.75 MWC Drive Motor 55KW/85HP, 415V, 1500RPM, 93Amp . 7.3.10 MAKE-UP PUMP AT AGRA CANAL

Drive Motor 1425RPM, 14.1Amp, 415V 7.3.11 DEDS PUMPS No. 3 Type Vertical Turbine Pump Capacity 200 m3/Hr Head 120MWC Speed 1480 Motor 110KW/1485RPM/197Amp/Kirlosker

7.4 ASH HANDLING PLANT

7.4.1 ASH PUMP (OLD)

Make Flowmore Model D85 Capacity 1000 m3/hr Pressure : 3.3 kg/cm2 Quantity 1 . Speed 800 RPM Motor 194 KW MOTOR Capacity 194 KW Voltage 415 V RPM 1000 Amps 331 Make Siemens

7.4.2 ASH SLURRY PUMPS ( NEW) Make Indure Model D85D Capacity: 1300 m3./hr Pressure 5.0 kg/cm2 Quantity 3

MOTOR Capacity 322 KW Voltage 6.6 KV RPM 991 Amps 35 Make Kirlosker

7.4.3 BOTTOM ASH PUMPS

Quantity 2 nos. Make Beacon Weir Model SDC 200/200 Capacity 410 m3/hr Pressure 8.0 kg/cm2 Motor 160KW/1485RPM/220Amp/NGEF

7.5 COOLING TOWER

Intake Channel Level (Normal) 202 mtrs 7.5.1 C.T PUMP Nos 2 for each 210 MW unit Dischrge 4160 L/sec or 15000 m3 /hr Head 17.855 mwc Speed 405 rpm Make FLOWMORE(U4) KIRLOSKAR BROTHERS LTD. (U5) MOTOR Type Induction motor Speed 421 rpm KW 930 Current 108.5 amps Volts 6600 volts, 3 Ph. 50 C/S Make BHEL 7.5.2 COOLING TOWER Make Gammon(U4)/ Paharpur(U5) Number 1 for each unit of 210 MW No. of cells/tower 16 Rate of flow /unit 27000 m3 /hr/Tower

Cooling Range 100C Max. operating inlet water temp. 500C 7.5.3 COOLING TOWER FANS Fan Type Axial Induced Draft No. off fans/Tower 16 No. off blades/fan 9 No. off row of fan 2 (8 in each row ) Dia. 7315 mm Reduction gear Ratio 10:1 L.X. Fan speed 151 rpm Type V-1400C.T. Make Radicon worm Reducer Lub oil Enklo-120 or Servo-40 MOTORS Make N.G.E.F. Volts 415V Current 130 amps K.W. 75 Speed 1475 rpm

7.6 DIESEL GENERATOR

• One Diesel Engine is directly coupled with generator for producing power. Diesel generator set is capable of supplying power to Barring gear motors of unit I,II,III,& IV A.C. standby lub. oil pump & Hydrogen seal oil pump of unit IV.There are 10 numbers of outgoing feeders panels for supplying power of different motors and emergency lighting Boards when supply to any of feeder panels fails signal impulse starts the diesel generator set automatically & it supplies power through solenoid operated air circuit breaker provided in M.C.C.

• The control circuit is such that the set can be stopped only manually and also this can be achieved only when the set is not supplying load to any of the feeder. A provision is there to start the set manually. However, supplying of load to the feeders will be automatic through the solenoid operated breakers.

10.6.1 SPECIFICATION

10.6.2 GENERATOR No 2 Make Jyoti Ltd. Rated output 250KVA

Power Factor/ Voltage 0.8/415 Frequency 50 Hz , 3 ph. Insulation Class B Speed 1500rpm Current 348 Amps Ratings CR Excitation 85V 50 Amp.

No. of space heaters One Rated KW 200W Rated Voltage 230V

7.7 WATER TREATMENT PLANT

7.7.1 WATER ANALYSIS as CaCo3 p.p.m.

COMPONENTS RAW WATER MODIFIED FOR DESIGN Calcium 240 300 Magnesium 64 64 Sodium & Potassium 306 312 Total Cations 612 676 Total Hardness 304 265 M.C. Alkalinity 326 363 Sulphate 72 97 Chlorides 214 216 Total Anions 612 676 Iron as Fe 0.1 0.1 Silica ( Reactive) as SiO2 13.0 13.0 Turbidity J.T.U. 3500 - Permanganate No or B.O.D. 72 - Conductivity at 25 C 1300 -

Note: Modified analysis is after 50 ppm Alum, 37ppm lime & 2ppm sodium sulphite done.

7.7.2 TREATED WATER QUALITY

ANION EXCHANGER Silica (Reactive) as SiO2 0.2 ppm (max.) Conductivity at 20 C 10 micro-mhos/cm Total dissolved solids 2ppm as such

7.7.3 PRETREATMENT SECTION Description Alum Prep.

Cum storage tank

Const. Head tank for Alum

Lime solution tank

Const. Head tank for lime

Nos. off 2 1 1 1 Dimensions 12300x1200D 765Lx380Wx380H 16200

x1480D 765Lx380Wx380H

Concentration of solution

10% 10% 10% 10%

High Speed Mixture

2 Nos. Nil 1 Nos. Nil

7.7.4 CLARIFLOCULATOR

Nos. One Size 168000 x 4000D Capacity 400 m3/Hr.

7.7.5 FLASH MIXER MECHANISM Nos. One set Make Hindustan Door Oliver

7.7.6 CHLORINATOR Nos. 2 Capacity 0.1 to 5.5 kg/cm2 (Max.) Model Banaco Mark II Type Press Gaseous Chlorinator Capacity (0.1 – 5.5 ) kg/Hr Operating Pressure/ 2.0 kg/cm2

Unit Operating water 3m3/Hr. Qty/Unit

7.7.7 TANKS

LOCATION MODEL HP/RPM MAKE/FRAM

E SIZE QTY.

Alum Prepn. Cum. Storage Tank

PH 5 0.5/1440 Kirloskar/N80 3

Lime Soln.Tank for

PM 1 1.0/1000 Kirloskar/N90L 1

clarifloculator Sodium sulphite Soln. Tank

PM 5 0.5/1440 Kirloskar/N80 2

Alkali dilution tank

PM 10 1.0/1000 Kirloskar/NPOL 2

Lime prepn. Tank for neutraliasation

PH 5 0.5/1440 Kirloskar/N80 1

7.7.8 DESCRIPTION CLARIFIED WATER

PUMP SLUDGE DISPOSAL PUMP

Nos. 2 Capacity 250M3/hr. 250M3/hr. Discharge Head 36 MWC 15 MWC Model No. 6 DC 124 3x2x10 BPO Make Best & Crompton Best & Crompton Motor 2 2 HP/RPM 60/1440 5/1440 Make Kirloskar Kirloskar D.P. 2.5 kg/cm2 7.7.9 DEMINERALISATING SECTION

DESCRIPTION PRESSURE

FILTER(DUEL MEDIA) ALKALI CARBON FILTER

Nos. 4 1 Size 30000 x 1350H 8000 x 2300H

Filtering Media Sand+Anthracite Active Carbon Max/min. Treatment flow m3/Hr.

55/28 -

Back wash flow rate m3/Hr. 170 10 Duration of back wash 5 mints 5 mints Air scour flow rate m3/Hr. 4.65 -

DESCRIPTION BACKWASH WATER PUMP

AIR BLOWER SODIUM SULPHATE DOSING PUMP

Nos. 2 2 2 Capacity 170 M3/Hr. 4.65 m3/min 227 Lit/Hr. Discharge Head 20 MWC 0.21 kg/cm2 7 kg/cm2

Medium Water Air Sodium sulphite

soution Motors HP/RPM 25/1440 7.5/1440 0.5/1440

DESCRIPTION BACKWASH WATER PUMP

SODIUM SULPHATE SOUTION TANKS

Nos. 1 2 Size 1000Lx6000Wx2580H 12200 x 1200D Concentration of Soln. - 10 % High speed Mixture - 2

DESCRIPTION CATION UNIT ANION UNIT MIXED BED UNIT Nos. 4 4 4 Type Strongly Acidic Strongly basic Strongly Acidic &

Basic Shell Design Pressure(kg/cm2)

4.0 5.3 5.3

Max./Min. Treatment flow (m3/Hr.)

80/28 70/28 47/28

Average Treatment flow (m3/Hr.)

35 35 35

Capacity between Regeneration M3 “ GROSS”

850 706 700

Wastw water / Regeneration M3

110 80 25

Time per Regeneration

55 mints. 115 mints. 115 mints.

Type of Chemical Hcl NaOH Hcl & NaOH 100% chemical Regeneration per unit(kg)

880 500 38.5

Type of Resin 2K 225 DANIP ZK225/DAFFIP Resin qty. M3/unit 12.5 6.695 0.77/2.10

7.7.10 REGENERATION FLOW UNIT OPERATION FLOW-M3/HR. TIME-MIN 3K Back wash (once in a

week) 55.4 5

Acid Injection 5% w/v

52.8 20

Down flow 79.8 20 Acid Rinse 52.8 25 Down flow 79.2 25 Final Rinse 35.0 5 D.A. Back wash 13.6 5 Alkali Injection 22.2 30 Alkali Transfer 22.2 5 Alkali Rinse 67.0 60 M.B. Middle Collector

wash 14.0 1

Back wash 14.0 6 Alkali Injection 15.3 30 Up flow 6.9 30 Alkali Transfer 14.9 5 Up flow 6.9 5 Alkali Rinse 25.2 20 Acid Injection 5%

W/V 7.5 6

Down Flow 3.5 6 Acid Rinse 7.4 10 Drain Down - 5 Air Min. 3.0 M3/Min. 10 Final Rinse 3.5 10 7.7.11 DESCRIPTION DEGASSER TOWER DEGASSED WATER-

SUMP Nos. 2 2 Size 2000Lx2000Wx3400H 7500Lx7500Wx2750H DESCRIPTION

DEGASSER AIR- BLOWER

MIXED BED AIR BLOWER

DEGASSED WATER PUMP

Nos 4 2 3 Capacity 75 m3/min. 3m3/min. 120 m3/min. Discharge Head 100MWC 0.4 kg/cm2 45 MWC Medium Air Air Acidic water MOTOR HP/RPM 5/1440 7.5/1440 40/1440 MOTOR-Make Kirloskar Kirloskar Kirloskar

DESCRIPTION

ALKALI PREPARATION TANK

BULK ALKALI STORAGE TANK

ALKALI DILUTION TANK FOR DA/MB

BULK ACID STORAGE TANK

ACID MEASURING TANK FOR ZK

ACID MEASURING TRANSFER MB

Nos. Two One Two Five Two Two Size 12000

x1200D 16000 x 4500L

16000 x1500D

34000 x6200L

18000 x1500D

4570 x762D

Solution Concentration in Tank

- - 20% 30% 30% 30%

DESCRIPTION

ACID TRANSFER PUMP

EFFLUENT DISCHARGE PUMP

ALKALI TRANSFER PUMP

ALKALI INJECTION PUMP

Nos. 1 2 2 2 Capacity 25 150 15 5 Discharge Head MWC

17.5 18 20 25

Media 32% Hcl Acid/Alkali 20% NaOH Alkali MOTOR-HP/RPM

5/1440 20/1440 5/1440 7.5/1440

Motor make Kirloskar Kirloskar Kirloskar Kirloskar DESCRIPTION

PRIMING CHAMBER

LIME PREPN. TANK

NEUTRALISING PIT

Nos One One One Size mm. 6000 x900D 12000 x1200D 10000Lx10000Wx3000H DESCRIPTION STRONGLY

ACIDIC CATION UNIT

STRONGLY BASIC ANION UNIT

MIXED BED UNIT

Nos. Four Four Four Type Strongly Acidic Strongly Basic - Size(mm) 2800 x3600H 2400 x2600H 1400 x3000H Max.Working Pr.(kg/cm2)

3.6 4.6 4.6

Min.Treatment flow(M3/Hr.)

28 28 28

Max. Treatment flow(M3/Hr.)

80 70 47

Average Treatment flow(M3/Hr.)

35 35 35

Capacity between regeneration(M3)

850 706 700

Period between regeneration(Hrs.)

20 20 20

Waste Water per regeneration (M3)

110 80 25

Type per regeneration(Mints)

55 115 115

RESINTYPE INDIAN 225 INDIAN NIP ANION

INDIAN FFIP CATION INDIAN 225

Resin Quantity (Lts.)

12500 6695 2100 770

Regenerant Chemical

Hcl NaOH NaOH Hcl

100% Chemical/Regeneration(kgs)

880 544 Through fan with 5BA

38.5

7.7.12 REGENERATION FLOWS UNIT OPERATION FLOW(M3/Hr.) TIME(Min.) Strong Acidic cation unit

Middle collector flushing

55.4 1

Down Flow 79.2 20 Back wash 55.4 5 Acid Injection @ 5% 52.8 20 Down Flow 79.2 25 Acid Rinse 52.8 25 Final Rinse 35.0 5 Strong basic Anion Unit

Back wash 13.6 5

Caustic Injection @ 5%

22.2 30

Caustic Transfer 22.2 5 Caustic Rinse 67.0 60 Mixed Bed Flushing/ Back wash 14.0 6 Up flow 6.9 30 Caustic Injection 7.2

% 15.3 30

Up flow 6.9 20

Caustic Rinse 25.2 20 Up flow 6.9 5 Caustic Transfer 6.9 5 Down flow 3.5 10 Acid Injection @

5% 7.4 10

Drain Down - 5 Air Mix. 180 10 Final Rinse 35 10 7.7.13 GEO-MILLER CLARIFLOCULATOR Nos. 2 Type Radial flow clarifloculator Capacity 3200 m3/Hr./unit Overload 20 % (Max.) Size 54300 Dia x4915 Deep. 7.7.14 FLASH MIXER MECHANISM Nos. 2(one/unit) Make Geo-Miller Private Ltd. Detension Time 60 Secs. Dia. 3.7 mts. Gate 2/unit Draining Service valve 150 DA. 7.7.15 ALUM DOSING UNIT Nos. 3/unit Capacity/Tank Soln. (10 % strength ) to last for 8 Hrs.

operation while flow of 3200 m3/hr. Size Alum dosing basket – 3.2x1.09x0.75mts. Alum dosing Tank- 3.33x3.2x3.4 mts. Total No. – 3 7.7.16 DRIVING PADDLE Motor 2 H.P R.P.M. 1550 Gear base ratio 1:50 7.7.17 OPERATING HOIST FOR ALUM Nos 2 .

Capacity 1 Ton each Type Gear operated travelling trolley are fitted on monorails. 7.7.18 LIME DOSING UNIT TANK 2/Unit Type Semi Circular Size 3.35(Dia.)x3.600L Capacity 12 hrs. to dose 80% pure hydrated lime slurry Of 10% strength at the rate of 35 ppm to a normal flow of 3200 m3/hr. PADDLES Material M.S. Type Rotation about horizontal axis Motor 2 H.P., 1500r.p.m., gear ratio 7.7.19 DESLUDGING PUMP Capcity 300 m3 /hr Total Head 15 M. BHP absorbed 23.4 MOTOR HP 30 Speed 1450 rpm 7.7.20 ECHNICAL SPECIFICATION OF ACTIVATED CARBON

FILTERS (ACF) SR NO. FEATURES 1. Quantity (No.) Four 2. Type Vertical down flow. 3. Normal operating flow 55.00 m3/Hr 4. Operating Pressure 3.5 – 4.00 (kg/cm2) 5. Dimensions Dia x HOS 2200mm x 2650mm 6. Material of construction M.S. 7. Back wash Time 15-20 min. or till the effluent is clear. 8. Max. allowable Pressure drop. 0.8-1.0 kg/cm2 9. Type of operation Manual.

1:

7.7.21 DETAILS OF FILTER MEDIA IN ACF SR. MATERIAL SIZE QUANTITY NO. 1. Pebble 2”x 1½” 2164.00 x 4 kgs 1½” x 1” 541.00 x 4 kgs 1” x ¾” 541.00 x 4 kgs ¾” x ¼” 541.00 x 4 kgs 2. Quartz cylex ½” x ¼” 513 x 4 kgs 3. Mixed sand - 93500 x 4 kgs 4. Activated Carbon - 2508 x 4 kgs

7.8 OLD COAL HANDLING PLANT

7.8.1 COAL CHARACTERISTICS AT BTPS Description At relative humidity 60 % & air temp. 400 C Moisture 6-9% Ash 24-33% Volatile Matter 24-28% Gross calorific value 4778-4944 kcal/kg Hard grove grindability Index 45-50 Bulk density 0.8 Tonne/m3

Size 250 mm 7.8.2 DESIGN CAPACITY OF COAL HANDLING PLANT ( 3X100MW + 2X210MW UNITS) DESCRIPTION UNIT 3X100MW 3X100+2X210MW Coal consumption Tonnes/Hr 187.5 450 Max.daily Tonnes 4500 10800 Consumption Average daily Tonnes 3600 8000 Coal consumption Annual Coal Tonnes 1312500 315,00,00

7.8.3 WAGON TIPPLER Nos. 2

Make Tata Robins-Fraser Ltd. Type Weighing Type with recording,

Side discharge Total Time for Tripping 4 minutes (For 1 wagon) Max.angle of rotation 1350 C (giving 450 angle at

Side of wagon ) Total Weight 125 tonnes Capacity 85 tonnes

MOTOR

R.P.M. 1480

Amps 100 H.P. 75 Voltage 415V,50c/s, 3 Phase Induction Motor. (Power is transmitted through Traction type fluid coupling.) 7.8.4 STEEL WIRE ROPES a) Counter weight Rope Dia-40mm Nos. –2

Length – 123 ft.(3 b) Hoisting Rope Dia – 38mm

Nos. –4 Length – 24.28 mts Construction-6X41

7.8.5 CAR PULLER

Rope Size 1-3/8” (35mm) Braking Electro Magnetic Coupling Clutch Type Speed Reducer V-1400 Worm reducer

MOTOR Capacity 30KW/40 HP Amps 52.5 RPM 960 7.8.6 COAL CRUSHERS Make TRF Type Non-reversible ring granulator type Coal size input 250 mm Coal size output 20mm

Capacity 600 MT/Hr. per crusher Nos. 2 Working oil temp. 500C-850C Limit Rotor Speed 720 rpm Rotor dia 360 mm Rotor length 3875 mm

MOTOR Voltage 6.6KV Amps 33.5 RPM 1490 Capacity 300KW 7.8.7 BELT CONVEYERS

Carrying Capacity 600 Tons/Hr Speed 2.3 mts/sec Width 1 mt.(For all) Material Nylon Fabric with Dead WT. 7.8.8 CONVEYER NO.

LENGTH & MM PLY RAISE OF INCLINATION

1A & 1B 171548 4 150

2A & 2B 164345 4 140

3A & 3B 156371 4 11698 mm at 150C & rest is horizontal

4 92087 4 130

5 100262 4 120

6 223778 4 10562 mm at 150C & rest is horizontal

7 177000 4 Horizontal 8 153832 4 150

9 20900 4 180

10A&10B 4 Horizontal MOTOR SPECIFICATIONS Speed 1440 rpm Voltage 415 V CONVEYOR NO. CAPACITY REDUCTION RATIO 1A & 1B 150 HP 35.5:1

2A & 2B 150 HP 35.5:1 3A & 3B 100HP 20:1 4 60 HP 25:1 5 75 HP 25:1 6 60 HP 20:1 7 50 HP 20:1 8 100 HP 25:1 9 30 HP 20:1 10A & 10B 75 HP 20:1 7.8.9 TRIPPER

Type Motor Propelled Tripper Quantity 5 Nos. Belt width 1mt. Drum Dia 600 mm Speed 30 to 35 ft/min

MOTOR Type 3 ph.Squirrel cage Induction Motor Capacity 7.5 H.P. (Traverse Drive) Speed 1500rpm Voltage 415 V Telescopic Chute 5 H.P. drive capacity 7.8.10 ROTORY PLOUGH FEEDER Quantity 2 Overall Length 11700 mm Height 3500 mm Width 1980 mm MOTOR TRAVERSE MOTOR PLOUGH MOTOR Type Induction Motor Induction Motor Capacity 7.5 H.P. 40 H.P. Speed 720 rpm 1430 rpm Voltage 415 V 425V Speed 20 to 30 ft/minute - 7.8.11 BELT WEIGHER SR. NO. DESCRIPTION SPECIFICATION 1.0 Location Belt conveyor 2 A,2B 2.0 Quantity 2

3.0 Type Mechanical 4.0 Make Gillanders Arbuthnot & Co. Ltd. 5.0 Type of speed sensor Mechanical 6.0 Type of load sensor Mechanical 7.0 No. of load cell per weigher 8.0 Capacity 8.1 Rated 600 MTPH 8.2 Maximum(Designed) 750 MTPH 8.3 Minimum 120 MTPH 9.0 Accuracy 10.50% 10.0 Calibration By test chain 10.1 Weight per unit length of chain 46.85 Kg / m 11.0 Remote Panel 11.1 Type of flow indicator Moving coil meter 12.0 Type of totalising counter EM counter 13.0 No. of Digits 6 14.0 Whether zero reset button provided Yes 15.0 Local 15.1 Type of flow indicator NA 15.2 Type of totalising counter Mechanical

15.3 Power supply 230V AC +/- 10%, 50 Hz 7.8.12 MAGNETIC SEPERATOR Make Electro ZAVOD Type Suspended Nos. 2 Size 1500mm x 1350mm x 800 mm Power Required 8.5 KW/11.0 KW (Hot/Cold) Operating Voltage 220 VDC 7.8.13 METAL DETECTOR Metal detector specification for OCHP is same as NCHP. 7.8.14 LIST OF FLUID COUPLINGS

S.NO.

TYPE OF COUPLINGS

1 2 3

STD – 08 ] STD – 07 ] STD – 06 ] M/s Fludomate make

4 STD - -5A ] (Conveyors)

5 6 7 8

FCU – 17.75 ] FCU – 16.5 ] M/s Pembril Greaves make FCU – 14.5 ] (Conveyors) FCU – 12.75 ]

9 10

HFD – 10 B ] M/s Fludomate make (Crushers). HFD – 14B ]

11 SCR – 41 R ] M/s Pembril make (Crushers)

7.8.15 ROTECTION & INTERLOCKS

DESC

RIPTION

PERMISSIVE INTERLOCK PROTECTION

Belt Conveyor

i)No Conveyor belt can be started before the belt ahead of it is kept running. ii) No. belt will run if its delivery gate is opened to the belt not in service.

i) If any belt trips the whole system behind it will trip.

ii) No second belt of same pair can run with other belt in service(But for 1A & 1B this interlock can be by passed when yard & BKR feeding both are in service.)

iii) If any belt trip the feeders to corresponding 1st belt will trip.

iv) If any belt trip the feeders to corresponding 1st belt will trip.

v) If conveyor after crusher trips the screen & conveyor before crusher will trip along with feeder.

i) If one belt runs out of alignment more than limit,the swaying switch will trip the belt & whole system behind it.

ii) Belts are provided with emergency trip belt sway switch to avoid eccentric movement ,centrifugal switch for excessive slipping,skewing & breaking of belt.

iii) Any conveyor loaded beyond 600T/hr will trip.

iv) If the belt is cut or the belt speed reduces below a certain limit belt trips.

Screens If screen trips the system after screen will trip.

Tripper Respective conveyor

should be in operation.

Plough Feeder

Respective conveyor should be in service.

The traverses can not be effected unless the blade cutter is previously started.

Car Puller & Beetle Charger

Wagon trippler should not be in operation.

Wagon Trippler

Car puller or Beetle charger should not be in operation.

Motors Provided with over load protection ,short circuit protection, single phase protection.

7.9 NEW COAL HANDLING PLANT

7.9.1 WAGON TIPPLER SR. NO. DESCRIPTION SPECIFICATION 1.0 Manufacturer Elecon Engineering Company Ltd. 2.0 Type & Model No. Rota side 3.0 Gross Load Capacity 90T 4.0 Minimum nos. of tippling/hr 17 5.0 Maximum angle of rotation 150 Degree 6.0 Type of brakes Automatic Electro Hydraulic Thrust

Operated 7.0 Type of Inhaul Machine Beetle Charger 8.0 Type of Outhaul Machine Beetle Charger 9.0 Type of Reduction Unit Helical Gear Box 10.0 Dust Suppression System

provided Yes

11.0 Wagon Tippler Drive system Through 98KW slip ring motor, reduction gear unit, fluid coupling, flexible brake coupling, spur and pinion gears

12.0 Control system From control desk provided in the wagon tippler control room.

7.9.2 RING GRANULATOR (CRUSHER)

SR. NO. DESCRIPTION SPECIFICATION 1.0 Type Ring Type Granulator

2.0 Make Mcnally Bharat Engineering Co. Ltd. 3.0 Model No. RG-729 4.0 Quantity 2 5.0 Capacity- Rated

-Design 600 MT/hr 750Mt/hr

6.0 Material to be handled R.O.M.Coal 7.0 Maximum RPM 750 8.0 Hard Grove Index 50-70 9.0 Maximum lump size (-) 100 mm 10.0 Maximum moisture content 20% 11.0 Bulk density of coal O.B.T./m 12.0 Guaranteed output of lump

size at specified input size and moisture

100% (-) 20 mm

13.0 Material of Parts 13.1 Material of rotor shaft EN-19 13.2 Material of upper breaker

plate Tiscral

13.3 Material of breaker plate Cast MN steel IS-276, Gr.III 13.4 Material of suspension bars EN-19 13.5 Material of side liners Tiscral 13.6 Material of ring hammers IS-276 Grade-III 14.0 Bearing No. Torrington “22238” 15.0 Method of lubrication of

crusher bearing and life Manual grease lubrication and 40,000 working hours

16.0 Specification of motor 16.1 Power rating 550 KW 16.2 Speed(RPM) 750 16.3 Duty cycle Continous, 24 Hours/Day operation 16.4 Method of mounting Coupled through fluid coupling with the

crusher 17.0 Granulator weight 28 T

7.9.3 VIBRATORY FEEDER

Sr.No. Description Specification Specification Specification

1 Location Below wagon tippler hopper

Below reclaim hopper

Above coal crusher

2 Type Mechanical turflo type

Mechanical turflo type

Mechanical turflo type

3 Manufacture Tata Robins Fraser Ltd.

Tata Robins Fraser Ltd.

Tata Robins Fraser Ltd.

4 Model No. & size TE-9 3’X8’

TE-9 4’X8’

TE-11 5’X10’

5 Numbers 6 Nos. 4 Nos. 2 Nos. 6 Guaranteed capacity 200 TPH 300TPH 600 TPH 7 Designed capacity 250 TPH 375 TPH 750 TPH 8 Length of tray 2438 mm 2438 mm 3038 mm 9 With of tray 915 mm 1219 mm 1524 mm 10 Slope of tray 100 down hill 100 down hill 100 down

hill 11 Operating Speed 800 rpm 800 rpm 800 rpm 12 Feeder stroke ½” ½” ½” 13 Material of

construction

Tray M.S. IS-226 M.S. IS-226 M.S. IS-226 Liner 10 mm thick tiscral 10 mm thick

tiscral 10 mm thick tiscral

14 Type of feed rate controller

By changing the rpm of feeder

By changing the rpm of feeder

By changing the rpm of feeder

15 HP rating of each feeder

10 15 20

16 Approximate weight 1960 Kg 2520 Kg 3750 Kg 17 Recommended

clearance between feeder and stationary chute

51 mm 51 mm 51 mm

7.9.4 BELT WEIGHER

SR. NO.

DESCRIPTION SPECIFICATION

1.0 Location On conveyor 12 A,12B,15A &15B 2.0 Quantity 4 3.0 Type Electronic load cell single idler sensing

system with rate indicator and integrator (Totalizer)

4.0 Make Integrated process automation 5.0 Type of speed sensor AC Digital Tacho 6.0 Type of load sensor Strain gauge 7.0 No. of load cell per weigher 1 8.0 Capacity 8.1 Rated 600 MTPH 8.2 Maximum(Designed) 750 MTPH 8.3 Minimum 120 MTPH 9.0 Accuracy

9.1 At rated ty(Guaranteed) +/-0.5% F.S. 9.2 At maximum

capacity(Guaranteed) +/-0.5% F.S.

9.3 At minimum pacity(Guaranteed) +/-0.5% F.S. 10.0 Calibration By test chain 10.1 Weight per unit length of chain 49.5 Kg / m 11.0 Type of flow indicator Moving coil meter 12.0 Type of totalising counter EM counter 13.0 No. of Digits 6 14.0 Whether zero reset button

provided Yes

15.0 Remote Panel 15.1 Type of flow indicator Moving core type indicator 15.2 Type of totalising counter EM counter 16.0 Power supply required 230V+/- 10%, 50 Hz, +/- 2% Single phase 17 .0 Power Demand 100 VA

7.9.5 METAL DETECTOR

SR. NO. DESCRIPTION SPECIFICATION 1.0 Type Electronic 2.0 Make Unique Electromag, Mumbai 3.0 Model No. Type SCTA 4.0 Location 15A, 15B 5.0 Quantity 2 nos in each conveyor 6.0 Sensitivity at normal working

condition 25 mm dia MS/AL sphere

6.1 At maximum capacity with maximum moisture content

25 mm dia MS/AL sphere

6.2 Particular to sensitivity to other non ferrous material

Depends on conductivity properties and electrical characteristic of materials. Sensitivity is adjustable.

6.3 Power requirement (Watt) 150 VA 6.4 Power supply required 230 V +/- 10% C/S +/- 5%(Combine

+/- 10%) 6.5 Enclosure material and

thickness Search coil 3 mm, Pane 2 mm

6.6 Degree of protection IP-54 6.7 Hooter Provided 7.9.6 MAGNETIC SEPARATOR

SR. NO. DESCRIPTION SPECIFICATION 1.0 Type Overband, inline magnetic separator 2.0 Manufacturer Electrometike

3.0 Number & Location 2 Nos, for 14A, 14B 4.0 Tramp iron size & weight

(both maximum & minimum ) to be separated

Max weight upto 50 Kg of tramp iron to MS rod or L/D ratio upto5 with min. weight of 100 grams or MS cubes of 2 cm weighing around 62 gms shall be lifted from anywhere of coal bed at a distance of 400 mm from the face of the magnet.

5.0 Type of drive system Chain drive 6.0 Details of cross belt 6.1 Make Dunlop 6.2 With 1200 mm 6.3 Number of plies 4 6.4 Top/ Bottom cover

thickness 3/1.5 mm

6.5 Material specification 32 OZ fabric 7.0 Weight of equipment Total 9 Tons approx, 8.0 Type of rectifier Silicon 9.0 Magnetic core material Mild Steel (High permeability type) 10.0 Field density 800 gauss at distance of 400 mm from the face

plate of the magnet 11.0 Magnet coil material Aluminum with class –H insulation 12.0 Total power requirement 15 KW for magnet

5.5 KW for motor 13.0 Details of drive 13.1 Rating Motor- 5.5 KW TEFC, 3 Ph AC motor

Gear Box- 15:1 Reduction ratios, Warm gear box 13.2 Make Motor- GEC make

Gear Box- NAW make 14.0 Operating voltage

Of magnet 190 V DC

7.9.7 CONVEYER BELT

Sr.No. Description Specification 1.01 Designation 11A/B 12A/B 13A/B 14A/B 15A/B 16 17A/B 18A/B 1.02 Capacity

Rated Design

600 TPH 750 TPH

1.03 Width 1000 mm 1.04 Belt position

length C/C (M) A 210.29 B 209.98

210.3

51.25

248.25

170.9

124.45

A 128.09 B 108.82

116.7

1.04.02 Total lift (M) 23.35 21.05 6.0 29.8 28.4 15.7 14.75 14.966 1.04.03 Type of fabric Nylon 1.04.04 Is belt flat or Troughed

troughed 1.04.05 Trughing angle

(Deg) 35

1.04.06 Belt joints Vulcanised 1.05.05 Cover grade Fire resistance 1.06.00 Belt type/ No.

of plies 800/4 800/4 80/4 800/4 800/4 800/4 800/4 800/4

1.09 Thickness of covers (M)

1.09.01 Top (mm) 5 5 5 5 5 5 5 5 1.09.02 Bottom (mm) 2 2 2 2 2 2 2 2 1.10.00 Belt

speed(m/sec) 2.9 2.9 2.5 2.5 2.5 2.5 2.5 1.0

1.11.00 Allowable working tension (KN)

48 44.64 24.72 64.8 56.76 40.68 38.04 26.04

1.12.00 Supplier data of working tension (KN/m)

50 50 40.1 70 50 50 40 40

7.9.8 FLUID COUPLING (SCOOP TYPE)

Sr. No. Description Specification 1 Location Ring granulator (Crusher) 2 Type Scoop type 3 Nos. 2 4 Manufacturer PEMBRIL FLUIDRIVE LTD,

Auranagabad 5 Model No. 41 SWGR 25W Scaled version 6 Rating of motor 550 KW 7 Rated KW transmitted 500 KW 8 Rated torque transmitting capacity with

torque 150 to 275% of full load torque

9 Rated input speed 750 rpm 10 Rated Slip 3% 11 Temperature at which plug fuses 1800 C+/-50 C 12 Weight of the coupling unfilled (Kg) 1654 Kg 13 Type of bearing and life Spherical roller bearing Approx.

Life-3000 working hours 14 Quantity of oil for coupling 184 Lits of SHELL TELLOS

OIL-29 15 MATERIAL OF CONSTRUCTION

a. Impeller Aluminum alloy b. Runner Aluminum alloy c. Casing Aluminum alloy

d. Shaft EN-8 e. Flanges for input and output coupling Forged Steel

16. Coupling shall be capable of rotating in both directions. 17. Equipment should be dynamically balanced. 7.9.9 FLUID COUPLING (TRACTION TYPE)

Sr. No. Description Specification 1 Manufacturer Fluidomat 2 Type Traction type 3 Type of prime mover Direct on squirrel cage

induction motor 4 Input rpm 1470 Approx 5 Max. no. of starts per hour 2 consecutive starts or 3

starts/hr spaced

6 Whether Acceleration torque limitation desired

No

7 Whether fusible plug to be provided Yes 8 Maximum slip 3% 9 Max .torque transmitting Adjustable in the range of

150% to 275 % of full required torque

10 Direction of rotation Should be capable of rotation in both direction

11 Bearing lubrication Lubrication of bearing should preferably be done with the fluid itself

12 Output coupling Flexible/Semiflexible 13 Balancing Dynamically balanced 14 Material of construction

a. Impellar High tensile aluminum alloy

b. Runner High tensile aluminum alloy

c. Casing High tensile aluminum alloy

d. Shaft EN-8 e. Flanges for input and output couplings Forged steel

7.9.10 SCHEDULE OF FLUID COUPLING (TRACTION TYPE)

Sr.No. Location Conveyor

Quantity Motor rating(KW)

RPM Coupling input rating (KW)

Gear box

input rating (KW)

Model No.

1 11A/B 2 125 1470 116.8 113.3 STD/E/08 2 12A/B 2 125 1470 109.0 105.7 STD/E/08 3 13A/B 2 55 1470 44.0 42.7 STD/E/06 4 14A/B 2 150 1470 135.6 131.5 STD/E/08 5 15A/B 2 150 1470 119.1 115.5 STD/E/08 6 16 1 110 1470 85.1 82.9 STD/E/07 7 17A/B 2 110 1470 79.0 76.6 STD/E/07 8 18A/B 2 37 1470 22.0 21.3 STD/E/05A

7.9.11 BELT FEEDER

Sr.No. Description Specification

1.0 Location Crusher house Breaker house 2.0 Capacity 2.1 Rated capacity (TPH) 600 750 2.2 Designed capacity (TPH) 750 750 3.0 Quantity & Type 2 (Unidirectional) 2(reveesible) 4.0 Manufacturer M/S McNally Bharat engineering Co. Ltd. 5.0 Feeder Length (M) 6.0 11.0 6.0 Material handled 100 mm crushed coal 20 mm crushed coal 7.0 Bulk density (T/m3) 0.8 8.0 Design ambient temperature

(0C) 50

9.0 Moisture content of coal (%) 20 (max) 10.0 Hours of operation per day 24 11.0 Belt 11.1 Belt width 1200 mm 11.2 Belt Speed (m/min) approx 24.0 11.3 Type of fabric Nylon 11.3.1 Cover thickness (mm/min)

Top/Bottom 9/2

11.4 Cover grade Fire resistant 11.5 Type of loading & Discharging Through chutes 12.0 Idlers 12.1 Carrying idlers 12.1.1 Type 152.4 mm dia rubber disc single roll, impact

type

12.1.2 Configuration Flat 12.1.3 Spacing 400 mm at loading points & 500 mm at other

portion 12.1.4 Disc material Special resilient rubber having greater shock

absorbing capacity 12.1.5 Type of fixing arrangements

for discs Mounting on slotted pipe sleeves on shaft to provide friction grip by spring action & located by collars

12.1.6 Lubrication & seal Antifriction bearing with labyrinth type seal. All grease fitting shall be rutton head type having plastic caps.

12.2 Return idlers 12.2.1 Type 152.4 mm dia steel tube flat idler 12.2.2 Spacing 2000 mm 12.3 Type of idler seal Double labyrinth seal 12.4 Min. tube thickness )mm) 4 12.5 Applicable standard IS-4776 latest edition 12.6 Shaft material EN-8 or Equivalent 13.0 Pulleys 13.1 Pulleys construction Heavy duty welded steel as per IS-8531 13.2 Pulley shaft material Forged steel to IS-1875 Class-V 13.3 Type of bearing & plummer

block Antifriction double row self aligning spherical roller bearing in split type plummer block with labyrinth seal. 4000 hours working life.

13.4 Type of lubrication Grease 13.5 Quantity & type of pulleys 1 no. drive, 1 no. tail pulley per feeder 13.6 Pulley dia & width (mm) 630 drive & tail pulley per feeder 13.7 Type of lagging on drive

pulley 12 mm thick vulcanized natural rubber herringbone type lagging

13.8 Type of lagging on other pulley

12 mm thick vulcanized plain natural rubber lagging

13.9 Height of USOB from supporting floor

1200 mm

14.0 Skirt Board 14.1 Length Continuous 14.2 Material

a. Main plate 16 mm thick MS plate b. Liner 10 mm thick MS scral c. Cover plate 4 mm thick MS plate

15.0 Gear Box 15.1 Type Worm 15.2 Type of enclosure Totally enclosed dust proof 15.3 Type of lubrication Splash 15.4 Additional requirements Draining plug & oil level guage

16.0 Coupling 16.1 Type Flexible pin-bush type 16.2 Location Between drive pulley & gear box and motors 16.3 Coupling guard Provided 17.0 Tail pulley guard Standard wire mesh guard for all the feeders 18.0 Take up unit 18.1 Type Screw type 18.2 Location Tail end of feeder 18.3 Travel To suit 19.0 Scrappers 19.1.0 External 19.1.1 Location Inside head end chutes 19.2.0 Internal Rubber edge V- type 19.2.1 Location Near tail pulley 20.0 Belt protection Drive 20.1.0 Zero Speed switch 20.1.1 Quantity 1 no. at each conveyor 20.2.0 Quantity 20.2.1 Belt Sway switch 2 pair at suitable location of feeder per feeder

7.9.12 LOCO WDS-4 No. 4 Type 6M 282 A(k) Model 01/21 Working method 4 stroke, single acting Fuel injection Direct injection Weight of engine without water & oil 7150 Kg Maximum length 2876 mm Maximum Width 2035 mm Total Height 2035 mm with oil sump 1550 mm without oil sump Number of cylinder 6 Cylinder bore 240 mm Piston stroke 280 mm Total swept volume 76 Lit Swept volume per cylinder 12.7 Lit Compression ratio 12:2:1 Nominal output 650 HP Rotating speed at nominal load 1000 rpm Idling speed 440 rpm Torque at nominal load 541 Mkg Mean effective pressure 8.6 Kg/cm2

Sense of rotation viewed at flywheel Anticlockwise Engine cooling water circulation

Cooling water temp- Engine inlet 800C Engine outlet 85 to 900

Lub oil pressure Lowest under load 1.8 to 2.1 Kg/cm2

Rated engine speed 2.4 to 3.0 kg/cm2

At idling speed 0.75 Kg/cm2

Suction Height 1.5 m 7.9.13 ELECTRIACL STARTER Type TF-24 V1595 Bosch Voltage 24 V Output 1000 watts 7.9.14 DOZER (D155A-1)

Total 6 Nos. Make BEMLD155A-1 No. 2 Model KOMATSU S6D 155-4D

Diesel Engine Rated RPM 2000 Rated Horse Power 320 HP Maximum torque ( at about 1400 rpm) 144 KgM Start system- starting motor 24 V, 11 KW Equipment weight 5780 Kg Maximum tilt 1000 mm 7.9.15 CUMMINS DIESEL ENGINE – KT(A)1150 No. 4 No. of cylinder 6 Bore stroke (mm) 159 x 159 Displacement CID/Lit 1150/18.9 Maximum HP 525 Rim 2100 Peak torque (Ft-Lb) 1550

7.10 FUEL OIL SYSTEM

7.10.1 FUEL OIL UNLOADING SYSTEM The fuel oil station in BTPS is located near the coal handling plant. In conjunction with old receiving header which can unload six nos. oil tankers, another header of 225M length has been installed in between two rail tracks. From each rail track 25 nos. of oil tankers can be unloaded at a time. For transferring the LDO from the header to storage tank there are three transfer pumps each of 120m3 /hr. capacity.

7.10.2 STORAGE FACILITIES

Three light oil storage tanks of 2,000 m3 capacity each have been installed at the back of the fuel oil pump house. Each tank is provided with immersion type steam heater to keep the oil temp. at around 500 C in case of HFO unloading.

SPECIFICATION OF EQUIPMENT

7.10.3 FUEL (L.D.O.) TRANSFER PUMPS

No. of pumps available 3 Type of model no. Rotary Gear Liquid to be pumped L.D.O. Capacity m3/hr 120 Suction pressure MWC 5 Discharge pressure MWC 80 Total Dynamic head MWC 85 Efficiency 45.50% Pump speed 975 rpm Maximum Temp. Of liquid to 600 C be pumped Setting pressure in kg/cm2 9

MOTORS

Type/Make TEFC/Crompton RPM 1000 Voltage 415 V, 3PH, 50 c/s H.P. 100 Temp. rise over an ambient temp. of 650 C 450 C

FILTERS No. Of coarse filters 3 Type/Manufacturer Duplex/Technique Design Pressure 1 kg/cm2

Maximum pressure drop at 75 % 35 kg/cm2

Cleanliness 7.10.4 FUEL (LDO) PRESSURE PUMP No. off 4 Type Multi screw positive displacement Discharge pressure 225 kg/cm

Capacity in. MOTOR Manufacturer M/s Kirloskar Type 3ph. Induction motor. Rating 37 KW, 1500 . 7.10.5 LIGHT OIL (HSD) UNLOADING PUMP (STAGE II &III) No. off 1 Make AROTA Capacity 40 m3/hr MOTOR Type 3ph. Induction motor. Rating 18.5KW, 1500 rpm 7.10.6 LIGHT OIL (HSD) PRESSURE PUMP (STAGE II &III) No. off 2 Model No. PDE-45-4 GR-22 AU2 Capacity 250 Lit/min at 2 CST Pressure 25 Kg/cm2

MOTOR Type 3ph. Induction motor. Rating 18.5KW, 1500 rpm 7.10.7 FUEL OIL (LDO) PRESSURE PUMP (UNIT #4) No. off 2 Type Multi screw positive displacement , Horizontal Make TUSHACO Model No. PDHU-5-4 Capacity 250 lit/min. Discharge pressure 25 kg/cm2

MOTOR Manufacturer M/s Siemens Type 3ph. Induction motor. Rating 18.5KW, 3000

250 lit/m

rpm

7.10.8 FUEL OIL (LDO) PRESSURE PUMP (UNIT #5) No. off 2 Type Multi screw positive Displacement, Vertical Make TUSHACO Model No. PDH-60-SDEF Capacity 250 lit/min. Discharge pressure 25 kg/cm2

MOTOR Manufacturer M/s Siemens Type 3ph. Induction motor. Rating 18.5KW, 3000 7.10.9 LIGHT OIL CHARACTERISTICS 1. Flash point 660 C minimum 2. Pour point maximum 120 C for winter 3. Kinematic Viscosity in Cent. 2.5 to 15.7

Stocks at 380 C 4. Ash content 0.02 max. by wt. 5. Carbon residue content 1.5 by wt. 6. Sediment content 0.10 by wt. 7. Sulpher content 1.8 by wt. 8. Moisture content 0.25 maximum by volume 9. Acidity Nil.