NationalCapital Power Station

4 x 210 MW UNIT (THERMAL)

National Thermal Power Corporation Ltd.

National Capital Power Station

210 MW UNIT

National Thermal Power Corporation Ltd.

PREFACE

Technical Diary for NTPC-Dadri, 4x210 MW Coal Unitswas first compiled by Operation Department after commissioningof first unit. Thereafter, many modification and improvementshave been done in all areas of Power Station to improve safetyof men & machine for enhancing the reliability and performanceof plant systems. This new edition of Technical Diary incorpo-rates all those changes, addition of new systems and sugges-tions from users.

Due care has been taken during compilation of this new ver-sion, however, errors & omissions if observed may please bebrought out to our notice.

(R.K. GAUR)Add. General Manager (O&M-Coal)

FOREWORD

In the competitive knowledge based enviornment, it isessential to make available correct information in readily avail-able format for quick and correct decision making.

Technical Diary for 4 x 210 MW Coal Units, which was firstcompiled after commissioning of first unit has greatly helped inright decision making and improving station performance sig-nificantly. I highly appreciate the efforts y O & M staff to up-grade the technical diary in view of several modifications andincorporation of new systems.

(T.V. RAO)(General Manager)

ACKNOWLEDGEMENT

I am happy to learn that the a new updated version ofTechnical Diary for 4x210 MW Dadri-Coal is being brought outby the Operation Department.

For efficient, reliable and safe operation of the units, we areoften required to refer to the plant data like specified param-eters, set point values of protection and interlocks and otherrelevant details. Efforts have been made to cover all the tech-nical aspects of 4x210 MW Units in this Technical Diary. I amsure that it will also serve as a reference handbook for check-ing the design data required for solving the day-to-day plantproblems.

I congratulate the Operation team for bringing out the updatedversion of Technical Diary.

(SANJEEV KISHORE)Dy. General Manager (O&M-Coal)

CONTENTSSECTION DESCRIPTION PAGE NO.

1 INTRODUCTION 11. BOILER AND AUXILIA RIES

1.1 GENERAL SPECIFICATION 21.2 FURNACE SPECIFICATION 21.3 WATER WALLS 31.4 DRUM 41.5 SUPERHEATER 51.6 REHEATER 51.7 SUPERHEATER AND REHEATER 6

TEMPERATURE CONTROL1.8 ECONOMISER 81.9 BOILER MOUNTING AND FITTINGS 91.10 REGENERATIVE AND STEAM COIL 10

AIR PREHEATER1.11 ID FAN 121.12 FD FAN 141.13 PA FAN 151.14 GR FAN 161.15 FUEL PREPARATION AND FIRING 18

SYSTEM1.16 ELECTROSTATIC PRECIPITATOR 221.17 BOILER PREDICTED PERFORMANCE 261.18 SCANNER AIR FAN 341.19 SOOT BLOWER 341.20 FURNACE TEMPERATURE PROBE 341.21 BOILER CHEMICAL DOZING 351.22 PRESSURE REDUCING AND 35

DESUPERHEATING STATION1.23 BLOW DOWN VESSEL 351.24 PIPLE LINES - M.S., C.R.H., H.R.H., 361.25 CHIMNEY 361.26 BOILER AND AUX. COOLING 36

WATER FLOW1.27 RECOMMENDED FEED WATER AND 37

BOILER WATER IIMITS

2. TURBINE AND AUXILIARIES2.1 TECHNICAL SPECIFICATION- 38

MAIN TURBINE2.2 TURBINE LUB OIL SYSTEM 432.3 VACCUM SYSTEMS 462.4 CONDENSATE SYSTEM 482.5 FEED WATER SYSTEM 512.6 PREDICTED PERFORMANCE 57

OF TURBINE2.7 EQUIPMENT COOLING WATER 59

SYSTEM2.8 HP/LP BYPASS SYSTEM 602.9 HP AND LP FLASH TANKS 612.10 L.P. DOZING SYSTEM 612.11 TURBINE AND AUX. COOLING 62

WATER FLOW

3. GENERATOR AND AUXILIARIES31. GENERATOR TECHNICAL 64

SPECIFICATION3.2 DESIGN AND CONSTRUCTION 65

FEATURES3.3 GENEARATOR GAS SYSTEM 673.4 STATOR WATER SYSTEM 683.5 SEAL OIL SYSTEM 703.6 SPECIFICATION OF TRANSFORMER 713.7 HT MOTORS 773.8 BATTERY AND BATTERY CHARGER 77

4. OFFSITE AUXILIARIES4.1 RAW WATER SYSTEM 804.2 WATER TREATMENT PLANT 814.2.1 PRETREATMENT PLANT 814.2.2 DM PLANT 874.2.3 WATER SOFTENING PLANT 974.3 CIRCULATING WATER SYSTEM 1024.4 AIR COMPRESOR PLANT 1064.5 FUEL OIL HANDLING PLANT 1084.6 COAL TRANSPORTATION AND

HANDLING PLANT 1134.7 ASH HANDLING PLANT 1194.8 FIRE FIGHTING SYSTEM 1294.9 AIR CONDITONING SYSTEM 1354.10 DIESEL GENERATOR SETS 1424.11 CENTRAL LUB OIL STORAGE AND

PURIFICATION SYSTEM 1444.12 MISCELANEOUS WATER SYSTEM 1454.13 COAL MILL REJECT SYSTEM 1464.14 OFFSITE - II 148

5. CONTROL AND INSTRUMENTATION5.1 UNIT C& I SYSTEMS 1505.2 INTERLOCK AND PROTECTION5.2.1 BOILER AND AUXILIARIES 1565.2.2 TURBINE AND AUXILIARES 1715.2.3 GENERATOR AND AUXILIARIES 1805.2.4 OFFSITE AUXILIARIES 190

6. ANNEXUREI TURBINE ROLLING CURVES (9 Nos.) 193II GENERATOR CAPABILITY DIAGRAM 202III UNLOADING SCHEDULE DUE TO

HIGH DISTILLATE TEMPRATURE OFSTATOR WATER 203

IV LUB OIL SCHEDULE 204V STEAM TABLE 208VI ATRS START-UP PROGRAMME 211

INTRODUTION(SALIENT FEATURES)

i) Type of station Thermalii) Station capacity 840 MW (4 x 210 MW units)iii) Fuel 100% coal or 100% oiliv) Coal, Source Piparwar Block of North Karanpura coal

fields in Bihar, about 1200 km.Transportation Indian Railways by means of Bottom Dis

charge WagonsConsumption 3.66 million tonnes per year assuming 6500

hours of operation.v) Cooling water, Source Upper Ganga Canal Dehra headworks,

During closure of UGC through network oftube wells.

Consumption 50 cusecsMethod Close cycle with natural cooling tower

vi) Start up power Through 3 x 167 MVA, 400/220/33 kv singlephase auto transformer

vii) Ash disposal Dry Ash Disposal system.viii) Chimney RCC multiflue chimney with steel flue-225 m

high.ix) Heat Rate 2600 Mcal/kwhx) HP/LP Bypass capacity 60% of MCRxi) Land requirement (in acres)

a. Plant area and green beltbetween plant and ash area 1130 acres

b. Ash disposal 480 acresc. Township 250 acresd. Reailway siding 225 acrese. Approach road, intake canal

and contractos township 115 acres.Total 2200 acres

SECTION -1

BOILER & AUXILIARIES

1

1.1 GENERAL SPECIFICATION

(i) Manufacturer BHEL (C.E. design)(ii) Type Natural circulation, balanced draft,

smooth tube double pass, single drum,single reheat direct pulverised coal/oilfired,dry bottom type.

(iv) Capacity 700t/hr.FW. inlet temp -246 C Steam pr./tempSH - 154.0 kg/cm2; 5400cRH - 38.8 kg/cm; 3400cBoiler Efficience - 87.28%13868 181 63.5(iv) Boiler designation ______ _______ _____ NCR10592 130 63.5

(v) Type of firing Tilting tangential(vi) Water volume

(a) Generating surface 116 m3(Water walls)

(b) Drum (full) 34 m3(c) Economiser 47 m3(d) Superheater

(Drum to SHO heater) 77 m3(e) Reheater 50 m3(f) Total water volume of 324 m3

boiler(vii) Minimum load at which

Steam Generator can beoperated continuosulywith complete flame stability 2 adjacent mill at 50% capacity.without oil support

(viii)Minimum load at whichSteam Generator can beoperated continuously withcomplete flame stabilitywith oil support 20% MCR

(ix) Minimum load for individualmill beyond which no oilsupport is required 50%

1.2 FURNACE SPECIFICATION

(I) Type Fusion welded walls(ii) Bottom Dry(iii) Draft Balanced(iv) Tube arrangement Membrane(v) Furnace width 13.868 m(vi) Furnace depth 10.592 m(vii) Furnace height (Ring header

to furnace roof) 43.136 m(viii)Furnace volume 5570 m3

(ix) Furnace projected are 3275 m2(x) Fuel heat input 519.3 MK Cal/hr(xii) Residence time for fuel

particles in furnace 3.14 sec.(xii) Effective volume used to

calculate the residence time 4200 m3(xiii) Combustion temperature

used to calculate theresidence time (overage)

(xiv) Explosion/Implosion withstand capacity at 67%yield point + 660 mmwc

1.3 WATER WALLS

Front Side Rear Roof Roofwall wall wall 1st 2nd

(i) Number 181 260 181 120 120(ii) O.D., mm 63.5 63.5 63.5 51.0 44.5(iii) Pitch, mm 76.2 76.2 76.2 114.3 114.3(iv) Actual thickness, mm.................................... 5.5 ..................................(v) Material SA210C.(vi) Total projected

surfaces (ERPS), m2 615.3 803.4 480.6 121.5(vii) Design pressure

of tubes .............................. 175.8 kg./cm2 ...........................(viii) Maximum pressure

of tubes .............................. 167.2 kg./cm2 ...........................(ix) Erosion allowance

provided on tubethickness, mm .................................... 0.6 .....................................

(x) Method of joining Butt welded.long tubes

WATER WALL HEADERS

Bottom Ring w/w Outlet Feed materHeader Header Pipe Line

(i) No. of headers 1 5 -(ii) Outside dia, mm 40.64 219./273.0 323.9x36(iii) Design pressure of

header, kg./cm2 (g) ............................. 175.8 ...................................32

(iv) Max. working pressureof headers, kg/cm2 (g) 170.4 167.4

(v) Material ............................. SA 106 Gr C...................................

1.4 DRUM

(i) Construction Fusion welded(ii) Material specification SA-299(iii) Design pressure,

kg/cm2 abs. 176.4(iv) Max. operating

pressure, kg/cm2 abs. 167.2(v) Design temperature, 0C 354.0(vi) Actual thickness of

straight portion, mm 170/135(vii) Actual thickness for

dished end, mm 135(viii)Overall length of

drum mm 12200(ix) O.D. of Drum, mm 2083(x) Internal dia. of Drum, mm 1778(xi) Corrosion allowance, mm 0.75(xii) No. of distribution

headers 6(xiii)No. of cyclon separator/

secondary drier 58/58(xiv)No. of final driers Through out the length(xv) Max. permissible

temperature differencebetween any two points ofdrum, 0C 55

(xvi)Water capactiy at MCR betweennormal level andlowest water levelpermitted (upto low-low trip, in seconds) 25

(xvii) Normal water level 250 mm below drumin drum centreline.

1.5 SUPER HEATER

LTSH Platen FinalPendant S.H. S.H.Horizontal

(i) Type Convection Radiant Convection(ii) Direction of flow Counter Parallel Parallel(iii) Effective heating surface

area, m2 3700 1097 1543(iv) Gas flow path area, m2 73 138.9 72(v) Total no. of tubes 480 203 238(vi) O.D., mm 44.5 47.63 44.5(vii) Margin on tube thickness, mm ............ 0.6 corrosion allowance ............(viii) Effective length, mm 26466 8900 8360(ix) Gross length, m 34700 10100 9760(x) No. of elev/section 4 7 2(xi) Tube pitch

(a) Parallel of gas flow, 96 57 95/96 mm(b) Across gas flow, mm 114.3 457.2 114.3

(xii) Material SA 210GrC SA 213T11 SA 213T11SA 213T11 T22, 304H SA 213T11

(xiii) Method of joininglong tubes ....................... Butt welded ...................

(ivx) Total ND of assemblies 120 29 119

SUPERHEATER HEADERS

(i) Material SA121 A, SA 335 P-12, P22(ii) Max. operating pressure,

kg/cm2 167.4(iii) O.D., mm 219.1, 273.0 32.9, 406.4(iv) Thickness, mm 28, 32, 40, 45(v) Final outlet header

connection End outlet.(vi) Main steam ID-255.6x49.2

Pipe line

1.6 REHEATER

(I) Type Spaced, single stage(ii) Max. operating pressure,

kg/cm2 42.08(iii) Design pressure, kg/cm2 50.00(iv) Total circumferential

heating suface, m2 2858(v) Gas flow path area, m2 118

54

(vi) Space between two banksin direction of gas flow, mm 900

(vii) Mean effective lengthper one tube, mm 20.000

(viii)Gross lennngth per tube, mm 22,000(ix) Total no. of tubes 354(x) Acutal tube thickness

used, mm 3.6 4.0, 5.0(xi) O.D., mm 47.63/54.00(xii) Margin on tube

thickness, mm 0.6 Erosion allowance(xiii)Tube material SA 210 Gr A1, SA 213T11, T 22(xiv)Tube pitch

(a) Parallwt to gas flow, mm 101.6(b) Across gas flow, mm 228.6

(xv) Depth of each bank in thedirection of gas flow, mm 1400/1900

(xiv)Method of joininglong tubes Butt welded

REHEATER HEADERS(i) Material SA210 B, SA 335 P 22(ii) O.D. mm 406.4, 558.8(iii) Thickness, mm 46.0, 45.0(iv) Design pressure, kg/cm2 50.0(v) Max. operating

pressure, kg/cm2 40.08(vi) HRH Pipe line- ID-508x28(vii) CRH Pipe line- ID-457.2x127

1.7 SUPERHEATER & REHEATER TEMP. CONTROL1.7.1 SUPERHEATER & REHEATER TEMP.CONTROL FOR COAL FIRING

1.7.1.1 SUPERHEATER ATTEMPERATOR

(i) Type Spray mixing type(ii) Stages of attemperation One(iii) Position in steam circuit LTSH- Attemp.- PLTN S.H.(iv) Material specification SA 335 P12(v) Superheater steam temp.

range that can bemaintained between 54.90%

to 100% of boiler MCR, 0C 540 +_ 5(iv) Max. spray water flow

rate & correspondingsteam out put, kg/hr 28,000 at 54.43 % of MCR

(vii) Min. spray water flow rate &correspondeing steamout put, kg/hr 0 at 100% of MCR

(viii) Spray nozzle material SA 182 T 12(ix) Spray water source BFP discharge

1.7.1.2 REHEATER PRIMARY -TEMP. CONTROL ( BURNER -TILT CONTROL)(i) Max. angle of tilt

upwards/downwards + _ 30O(ii) Tilt mechanism Power cylinder(iii) Reheat steam range

thai can be maintainedbetween 54.9% to 100%MCR, OC 540 + 5

(iv) Burner tilt used forreheat temp. controlwith(a) Cool firing yes(b) Oil firing yes

1.7.1.3 REHEATER EMERGENCY TEMP CONTROL

(i) Type Spray mixing type(ii) No. of stages One(iii) Position Cold reheat line(iv) Spray nozzle material Weldment(v) Spray water source BFP discharge

1.7.2.1. GAS RECIRCULATION CONTROL

(i) Type of Control InIet damper control of G.R fan(ii) Range of control Above 25% Ioad.

CAUTION: GR fan should not run below 25% Ioad it may Ioad tounstable furnace condition.

76

1.8 ECONOMISER

(i) Type Plain, drainable, non-steaming,in line

(ii) No. of blocks Two(iii) Tube material SA210 GrA1(iv) O.D. of tubes, mm 44.5(v) Actual thickness of

tubes, mm 4.5(vi) Erosion allowance,mm 1.0(vii) Length of tubes, mm 32100(viii)Tube pitch

(a) Parallel to gas path,mm 130(b) Across gas path, mm 96

(ix) Water side effective heatingsurface area, m2 3580

(x) Gas side effective heatingsurface area, m2 5617m2

(xi) Gas flow path area m2 62.8(xii) Gas velocity at boiler

100% MCR, m/sec 8.9(xiii)Min. temp of feed water

which economiser canhandle safely, Oc 150

(xiv)Design pressure of tubes,kg/cm2 (g) 161.0

(xv) Type of tube joints Butt welded

ECONOMISER HEADER

Inlet Header Outlet Header(i) Material specification ........... SA 106 GR C............(ii) Outer diameter, mm 323.9 323.9(iii) Actual thckness, mm 32.0 32.0(iv) type of construction Plate formed/Seamless(v) Max. header unbalance .....................2%....................(vi) Max. working pressure,

kg/cm2 (g) ....................171.5..................

98

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1.9.2 DRUM LEVEL INDICATOR

Location Type No. & Make

Drum DWLG 2,Yarway

Firemans floor RWL1 1,YarwayFIBRE OPTICS 1,Yarway

UCB Conductivity type 2,Solartron,(Hydrastep)Remote level indicator 1Remote level recorder 1

1.10 REGENERATIVE & STEAM COIL AIR PREHEATER1.10.1. REGENERATIVE AIR PREHEATER

Type Vertical inverted modulur trisector typeSize 27.5 VIMT-2000No. per boiler Two

1. Main and stand byMotor types Squirrel cage motor,

frame size D160LIP 55 enclosure, F class insulation

Rating 11kwMotor speed 1450 rpm

Motor power supply 415 v,3, 50 HZ

Speed reducer Type- I, Japan, Nissawai

Coupling 11.50 FCU (PERMBRIL)Speed reduction ratio 110:1

2. Auxiliary Drive Assembly Air motor Chicago pneumatic

RSM 400Coupling Bibby 124 ASolenoid valve AVCON3/4 BSP 220 v,DCCL-H-INSflter lubrication Velgan or Norgreen 1 BSPAir pressure 5.3 kg/cm2 (g)Air consumption 6.37 Nm3/minute at approximate 0.5 rpm.

3. Heating ElementsTotal heating surface 2252.7m2Element type hot/ DU (22 guage) /DU (22

intermediate/cold end guage)/Enamelled NFElement height hot/intermediate/cold end 850mm/650mm/500mmMaterial hot/ Carbon steel/carten-A/Intermediate/cold end enomelled iron.

4. Rotor SealsRadial seals-hot end 2.5 mm thcik, carten-ARadial seals-cold end 2.5 mm thick, carten-AAxial seals 2.5 mm thick, carten-ABypass seal 1.6 mm thick, carten-ARotor post seal-hot end 6.0 mm thick, carbon steelRotor post seal-cold end 6.0 mm thick, carbon steel

5. BearingsGuide bearing Spherical roller bearing

SKF/FAG 23060 CCK W 33Support bearing Spherical roller thrust bearing

SKF/FAG 294 / 500being SKF/FAG 294/500

6. Oil CapacityGuide bearing housing 25 litresSupport bearing housing 150 litres

7. Oil Circulation SystemMotor-TEFC guide bearing 0.55 kw, 415v, 30, 50HZ, 920 rpm,

horizontal foot cum flange mounted.

Motor-TEFC support bearing 0.75 kw, 415v, 30, 50HZ, 920 rpm,IP 55 enclosure, insulation class B,horizontal foot cum flange mounted.

Pump Screw pump from M/s IMO, Sweden,capacity 15 lpm.

Cooler Universal heat exchanger, watercirculating rate 1 m3/hr, operatingpressure 5 kg/cm2

8. Rotor Stoppage AlarmGo switch 110v, M/s APCO, USA

9. Fire Sensing Device,Type Infra-red detection system.

10. Clearing DeviceType Power driven twin nozzle soot blowingMotor 0.18 kw, 3 phase, 415 v, 50 HZ,

1350 rpm, insulation class B, squirelcage motor

Clearing media Steam/air

1110

Steam pressure range 10.6-17.6 kg/cm2Steam consumption 2100 kg/hr at 17.6 kg/

cm2, 1500csuperheat.

Time required fornozzle to make one pass 50 minute.

11. Air Receiver TankNo. per boiler 2Internal diameter 1700 mmHeight 7654 mmCapacity 17.5 m3

1.10.2 STEAM COIL AIR PREHEATERNo. of per boiler 2Size 4030 x 4710 x 300 mmInstalled position VerticalDesign steam pr/temp 16kg/cm2/210c.Weight of each SCAPH 4600 kg.

1.11 ID FANManufacturer BHELNo. per boiler TwoType NDZV 31 SIDOR

Axial double suction radialdischargeLadisl Aischang

Medium handled Flue gasLocation Ground mountedOrientation Bottom delivery with 450

inclined suctionType of fan regulation Inlet damper control +

Hydraulic coupling1. Fan Design Rating

Capcity 222 cu.m/secTotal head developed 418 mmwcTemp. of medium 1450cSpecfic weight of medium 0.7896 kg/cu/.mSpeed 740 rpm

2. Fan ReserveFlow 32.6%Pressure 50%

3. Fan Drive CouplingMake TACKEType Gear

4. Drive Motor Unit.1 & 2 Unit-3 & 4Make BHEL, Bhopal BHEL BhopalFrame size 1 LA-7804-8FH-70-Z IDQ 3735-8BD Q4-2 Type Squirel cage Synchronous

induction motor 1325 KWRating 1400 kw 704 rpmSpeed 750 rpm (syn.) 2 x 120 V x 3 Power supply 6600v, 30, 50 HZ continousType of duty Continuous 269 AmpFull load curreent 157.8 amp. -No. load current 57 amp.Insulation class F FWeight of motor 9800 kg 13,000 Kg.

5. Brg NDE NV234 M NU228 M6. Brg DE NV234 M NU240M

62343C.3 6240C.37. Fan

Nominal diameter 3.1 mFan weight 47,380 kgMoment of inertarefered to fan shaft 42000 kgm2

8. LubircaitonFan Forced oil lubrication.Motor Grease lubrication

9. BearingFixed bearing Sleeve bearing GLYCOExponsion bearing Sleeve bearing GLYCOBearing loss 11 kw

10. Seals Lobyrinth seals11. Lube OIl System

No. of oil pumps 2capacity 2,144 lpm, Boreman makeLube oil pump motor 415v, 30, 50HZ, 5.6 kw, (7.5hp)

103. ASpeed 2875 rpminsulation class B, induction motor

Filter flow rate &working pr 200 lpm, 10 kg/cm2Working oil cooler VOITH turbo L1N1 071304-DDesign pr./temp. 16 bar/ 1000cOil tank capacity 800 litreOil heater 4 kw, 415v, 30, 50HZ-For Unit 3 and 4 AC synchronous motor drive having

variable frequency control incorporat-ing load commuted inverter controlsystem is provided.

1312

1.12 FD FAN

Manufacturer BHELNo. per boiler TwoType AP1-19/11Medium handled Clean airLocation Ground mounted on concrete floorOrintation Horizontal axisType of fan regulation Variable pitch controlFan Design Rating Coal firing Oil firingCapacity 144.7 cu.m/sec 126.8cm.m/secTotal head developed 334 mmwc. 544 mmwc.Temp. of medium 500cSpecific weight of medium 1.04 kg/cu.mSpeed 1480 rpm

2. Fan ReserveFlow 3.8%Pressre 43.9%

3. Fan Drive CouplingMake THYSSENType Rigiflex

4. Drive MotorMake BHEL/BhopalFram size 1LA-77124HF-70-ZRating 1000kwSpeed 1500 rpm (syn.)Power supply 6600v, 30, 50 HZType of duty ContinuousFull load current 108 ampNo load current 30 ampPower consumption at 100%MCR per fan at fan shaft 390 kwWeight of motor 6700 kgmotor brg NDE NU 224MBrg DE NU 228M

6228 C-35. Fan

Norminal diameter 1884 mmHub diameter 1100 mmWeight of the fan withoutmotor and coupling 8500 kg (statro-rotor)Moment of inertia of fan(at shaft level) 500 kg m2

6. LubricationFan Forced oil lubricationMotor Grease lubrication

7. BearingsFixed bearing Nu 230 c3,7230 BUAExpansion bearing Nu 230 C3Bearing loss 8 kw

8. Lube OIl SystemNo. of oil pumps TwoType of oil pump & make Screw type, Borneman makeCapacity 70 lpmDischarge pressure 12 barLube oil pump motor 415v, 30, 50 HZ, 2860 rpm class of

insulation B, induction motor, 4.0 kw,(5.5 hp), 7.6. A

No. of coolers TwoOil tank capacity 450 litreControl oil quantity 56 lpm (Theoritically calculated value)Lub oil quantity 4 lpm (Theoritically calculated value)Oil heater 4 kw, 415 v, 30, 50 HZ,

1.13 P.A. Fan

Manufacturer BHELNo. per boiler TwoType NDZV 19 HERKALES

Axial double suction radial dischargesimply supported

Medium handled Clean air from FD fan dischargeLocation Ground mounted on concrete floorOrientation Top delivery with 450 inclined suction

chamber.1. Fan Design Rating

(i) Capacity 77.4 cu.m/sec.(ii) Total head developed 931 mmwc(iii) Temp. of medium 530c(iv) Specific weight of medium 1.0515 kg/cu.m(v) Speed 1480 rpm

2. Fan ReserveFlow 52.9%Pressure 37.5%

3. Fan Drive CouplingMake TACKEType Gear

4. Drive MotorMake BHEL/BhopalFrame size 1LA-7712-HF-70-ZType Sq. cage induction

1514

Rating 1050 kwSpeed 1500 rpm (syn.)Type of duty ContinuousPower supply 6600v, 30, 50HZInsulation class FFull load current 113.5 amp.No loac current 30 amp.Weight of motor 6700 kg.

5. FanNominal diamater ofimpeller 1.8m.

6. LubricationFan Forced oil lubricationMotor Grease lubrication

7. Type of Fan Regulation Inlet damper control+Hydraulic coupling.

8. Bearings

7Fixed bearing Sleeve bearing 4 ----- RT

16 7

Expansion bearing Sleeve bearing 4 ----- RT 16

Bearing Loses 8 Kw

9. Lube Oil SystemPump capacity & make 30 lpm, Bornomen pumpenDesign pressure & type 8kg/cm2, PDHU 32.-4Lube ol pump motor 1.5 Kw (2hp), 3.3.A, 1405 rpm

class B insulation, NGEF inducationmotor

Lube oil filter 2 no. basket type simplex filterLube oil cooler 2 no. Design pr. & temp 10kg/mc2 &

1000c(shell & tube side)

Oil tank capactiy 315 litre.

1.14 GR FAN

Manufacturer BHEL/RanipetNo.per boiler TwoType NDZV33 SIDOR

Radial double suction simply supportedfan

Medium handled Flue gasLocation Ground mountedOrientation Bottom delivery with 450 inclined

suctionFan regulation Inlet damper control

1. Fan Design RatingCapactiy 165.8 cu.m/secTotal head developed 246 mm wc

Temp of medium 4230cSpecific weight of medium 0.41914 kg/cu.mSpeed 580 rpm

2. Fan ReserveFlow 20%Pressure 32%

3. Fan Drive CouplingMake BHEL/BhopalFrame size 1LA-790-3KF-7903

4. Fan Drive CoplingMake BHEL/BhopalFrame size 1LA-7903-3KF-70-ZType Squirel cage indutionSpeed 600 rpm (syn.)Power supply 6600c, 30, 50 HZClass of insulation FWeight of motor 15000 kg

5. FanNominal diameter 3350 mmFan weight 53, 120 kgMoment of inertiarefered to fan shat 62,415 kg m2

6. LubricationFan Forced oil lubricationMotor Grease lubrication

7. BearingFixed bearing sleeve bearing GLYCOExpansion bearing sleeve bearing GLYCO

8. BarringMotor 15.kw, 415 v, 30, 50Hz, 20.5 amp.N1 / N2 1455/61 rpm

9. Lube oil systemNo. of lub oil pumps 2Make & type Bornomenn pumpen, PDHU-38-4Capacty 144 lite / min.Disch.Pressure 8 barMotor NGEF lnduction motor, 5.5 kw, (7.5

hp),10.3 A2875 rpm, class B insulation.

Lub oil filter Basket type simplex filter, 2 no.Lub oil cooler 2 no. 10 kg/ cm 2 & 100 0 c (shell side

tube side)design pr & temp.

Oil tank capacity 800 litreOil heater 4kw, 415v, 3050HZ

N.B:-GR fan should not run below 25% load as it may lead to unstablefurnace condition.

1716

1.15 FUEL PREPARATION AND FIRING SYSTEM1.15.1 OIL BURNER

HEAVY FUEL OIL BURNER

(i) Type Air cooled steam atomising non-retractabletilting tangential corner fired.

(ii) Oil gun design Paralle pipe(iii) Atomiser External mixed, constant pressure steam

atomised(iv) Air nozzle Rectangular(v) Diffuser 250 mm, 10 off. 450 vanes with leading edge

with scanner cutting and lignitor cutting.(vi) Oil gun assembly kf=k+20.5=2308 mm(vii) Atomiser designation Spray plate 90J16(vii) Atomiser spray angle 900(ix) NO. of guns. 16 (4per elevation)(x) Location of oil guns AB, CD, DE, and EF elevation.(xi) Gun capacity 31.9x106 kcal/hr/burner(xii) Minimum allowable

oil pressure 2.1kg/cm2 at oil gun connection(xiv)Minimum allowable

steam pressure 3.5 kg/cm2 at oil gun connection

(xv) Oil viscosity at gun 15 to cst(xvi)Steam quality 10 to 150 superheat

LIGHT FUEL OIL BURNER(i) Service Initial start up purpose(ii) No. off oil guns Same 4 heavy oil fired gun in AB elevation(iii) Atomiser designation Spray plate 90 J 16(iv) Atomiser media Service air,(v) Fuel Light fuel oil IS 1460(vi) Oil gun capacity, 7.5%MCR heat input,(vii) Minimum allowable

LFO pressure 2.1 kg/cm2 (g)(viii) Minimum allwable

atomising air pressure 3.5 kg/cm2

1918DA

TA CH

ART

Type

of B

urne

r H

.F.O

.LF

O B

urne

r

HFO

Stea

mLF

OA

irPr

essu

reFl

owPr

essu

reFl

owPr

essu

reFl

owPr

esur

eFl

owK

g/cm

2K

g/hr

Kg/

cm2

Kg/

hrK

g/cm

2K

g/hr

Kg/

cm2

Kg/

hr

Max

imum

ratin

g10

.545

506.

030

04.

010

006.

013

5

Min

imum

ratin

g10

.545

506.

030

04.

010

006.

013

5

Min

imum

ratin

g2.

111

406.

043

02.

160

06.

014

5

Dur

ing

Scav

ange

..

6.0

480

..

6.0

180

IGNITORS

(i) Make Simmonds USA(ii) Service Oil burner light up(iii) Type High energy arc ignitor (HEA)(iv) Location Burner mounting panel(v) Input 110 volts AC, 50hz, 5 amp rms,(vi) Output Min 4 sparks/second, 12 joules

nom./spark, duty cycle 15 minute on,30 minute off.

(vii) Spark rod constrution 5/8s/s tube with s.s. wire braid,flexible 5/8, 5/8, s/s tube (rigid)5/8s/s tube (rigid)

(viii) Ignitor tip dimension 191+ 3mm length, 15.9+0.15 mmdiameter

Operating temperature of tip 6500(ix) Retraction assembly

Air cylinder stroke upto 300 mmAir pressure 5-7 kg/cm2

(x) Flexible spark rod B = 100 inckdimension

(xi) Flexibele guid pipe L= 69 inchdimension

FUEL OIL SPECIFICATION

HFO LSHS LFO(i) Standard IS-1593/1971 Nil LDO to IS1460

Grade HV(ii) Flash point, minimum 660c 750c 660c(iii) Viscosity, maximum 370 cst at 500c 180cst at 500c 2.5 to 1.5 cst(iv) Total sulpur, maximum 4.5%by weight 1.0%by weight 1.8%by weight(v) Gross heating value (typical) 10270kcal/kg 11000Kcal/kg 10720Kcal/kg

1.15.3 COAL BUNKER

(i) Type Cylindrical with conical cum hyper bolichopper at bottom.

(ii) Material of construction 8 mm M.S. plate(iii) Height 16m cylindrical and 8 m conical cum

hyperbolic at bottom(iv) Diameter (I.D.) of cylindrical

portion 7.6 m

1.15.3 BUNKER SHUT OFF GATE

(i) Size and type 36 motor operated coal valve2-67-272-00138

20

(i) No. per boiler 6(ii) Location Bunker outlet

1.15.4 GRAVIMETRIC COAL FEEDER

(i) Feeder size 36 inch inlet 7CD(ii) Capacity Max. 60 t/hr

Min. 6 t/hr(iii) Gear box ratio 203:1(iv) Main drive AC motor 5.5 kw, 11A, 1440 rpm

and eddy current cluch with reducer,415v, 50HZ, 30 power supply, speedrange 100-1200 rpm

(v) Clean out conveyor drive AC motor, 0.25 kw, 950 rpm with reducer(1041:1), 415v, 3, 50 HZ, power supply.

(vi) Working pressure 500 mm wc.

1.15.5 PULVERISER

(i) Make BHEL(ii) No. per boiler 6(iii) Type XRP 883(iv) Capacity 49 T/hr(v) Coal size-inlet 25 mm

- outlet 70% through 200 mesh(vi) Grinding roll

material Ni -Hard Gr II(vii) Bull ring material Modified Ni-Hard/Hi-chrome(viii)Coupling Gear type flexible coupling betwen mill

and motor(viii)Cooling system Immersed in oil bath, cooling water

9.0m3/hr at 360c & 3kg/cm2 pressure.(ix) Mil bearing

(A) Vertical ShaftUpper radial brg C-8159-A TorringtonLower radial brg 220-RU-O-03-R3 TorringtonThru brg. T-11000 Timken(B) Journal AssyUpper radial brg HH 249949/10Lower radial brg EE350750/351687 Timken(C) Warm ShaftThrust brg SKF-29438Radial brg 170 RM03 Torrington

(x) Drive MotorFrame size, Type 1 LA-7716 - 3, HA74-7Rated output 425 KwPower supply 6600 v, 3, 50 HZSynchronous speed 600 rpmClass of insulation FNo load current 27.2 A

Full load current 54.7 AWeight of motor 7500 kg.Bearing DE NU 230 M and 6230 C3

NDE NU 226 M(x) Lub oil system

No. of pumps 2

Make and type ALEKTON, tripple screw pumpCapacity 50 lpmDrive motor NGEF make, 2.2 kw (3 hp), TEFC type,

955 rpm, 4.6 A, class B insulation.

1.15.6 COAL PIPE

(i) Pipe size 558.8 x 15.0(ii) Material AP1 5L gr B

1.15.7 COAL BURNER

(i) Type Tilting tangential(ii) No. per boiler 24(iii) Capacity 32.5 x 106 kcal/hr/burner(iv) Control Air damper(v) Position Corner

1.15.8 SEAL AIR FAN

(i) Make BHEL/Ranipet(ii) No. and capacity 2 x 100%(iii) Type Radial fan(iv) Pressure developed 508 mmwc(v) Drive motor Kirloskar Elect, Co. make, 37 kw,

2900 rpm, 415 v, 3 , 50 HZ,class B insulation

1.16 ELECTROSTATIC PRECIPITATOR(i) Manufacturer BHEL(ii) Type FAA-6x45-69135-2(iii) Design conditions

Gas flow rate 312.7 cu.m / secTemperature 1360cDust concentration 64.4 gms/N cu.m

(iv) No. of precipitators per boiler Four(v) No. ofgas paths per boiler Four(vi) No. of fields in series Six

in each gas pass(vii) Pressure drop across the

precipitator for designconditions 20 mm wc

2221

Design pr. & temp. of ESP + 600 mm wc, temp 2000CWorking pr, & temp of ESP + 162 mm wc, 1360C

(viii) Treatment time 32.18 seconds.

(iv) Veloctiy of gas atelectrode zone ontotal area 0.839 m/sec

(x) Guarantee of collection 505 kwefficiency for designconditions 99.9%

(xi) Power consumption 505 kw

(xii) Collecting Electodesa) No. of rows of collecting electrodes per field 24b) No. of collecting electrode plates per field 144c) total no, of collecting plates per boiler 3456d) Nominal height of collecting plate 13.5 me) Nominal length of collecting plate 750 mmf) Specific collecting area (with one field out of service) 214.48 sq.m/cu.m/sec

(xii) Emitting Electodesa) Type Spiral with hooksb) Size Dia 2.7 mmc) No. of electrodes in the frame forming one row 54 fieldsd) No. of electrodes in each field 1242e) Total no. of electrodes per boiler 29808f) Total length of electrode per field 6967.62 m.g) Plate / wire spacing 150 mm

(xiv) Rappers for Collecting Electrodea) No. & type of rappers One drop hammer per row

of collecting electrodeshaving a collectingsurface of 121.5 sq. m.

b) Rapper size 4.9 kgs.c) Frequency of rap Varying from 20 raps/hr a the inlet field to

2raps/hr at the exit field. The frequencyof rapping for the intermediate fields canbe adjusted between 10 and 3 per houraccording to requirement.

d) Drive General electric motor controlled bymicroprocessor based rapper controller.

(xv) Rapper for emitting electodesa. No. & type of rappers Approximately one drop hammer for two

rows of electrodes.b. Rapper size 3.0c. Frequency of rap 10 raps/hourd. Drive General electric motor contrlled by

microprocessor based rapper controller.

(xvi) Hoppersa. Type & no. of hoppers Pyramidal, 6b. Capacity 8 hour storagec. Heating Electrical heating provided for the

bottom of hoppers.

(xvii) Gas distribution system Inlet OutletType & quantity Perforated plates, U shape thin

2 sets sheets - one setLocation Inlet of ESP Outlet of ESP

(xvii) Electrical ItemsI. Rectifiera. Rating 70 KV (peach, 800 mA (mean)b. Numbers 24c. Type Silicon, diode, full wave bridge connec-

tionII. Rectifier control panela. Type of of control Thyristorb. Number 24III. Auxilary control pannela. Number Fourb. Equipment controlled Collecting & emitting rapping motors,

hopper insulation & shaft insulatorheating.

IV. MotorsEmitting Rapper Collecting Rapper

a. Quantity 24 24b. Rating 0.33 hp 0.33 hpc. RPM 2.5 rpm 1.1 rpmd. Power supply 415v, 3, 50 HZ, 415v, 3, 52HZ

24 23

V. Heating elements(a) Hoppers For 24 hoppers/Boiler at the rate of 10 kw/happer 240 kw(b) Shaft Insulator For 24 Insulators at the rate of 1 Kw 240 kw(c) Support Insulator For 96 Insulator at the rate of 1 kw 96 kw

(xix) Recommended current settingFields 1 2 3 4 5 6current in mA 150 250 400 500 600 700

(xx) Operation sequence ofrapping mechanism Auto

2625

1.11

7 PR

EDIC

TED

PERF

ORM

ANCE

1. F

LOW

T/H

r

12

34

56

78

910

11ST

EAM

Supe

rhea

ter o

utle

t70

0.00

645.

051

8.6

394.

861

1.4

700.

064

5.0

518.

639

4.8

611.

4R

ehea

ter o

utle

t59

7.2

571.

046

2.0

353.

660

0.0

597.

257

1.0

462.

035

3.6

600.

0

WAT

ERFe

ed w

ater

700.

0065

9.0

529.

440

1.6

622.

770

0.00

659.

452

9.4

401.

662

4.7

SH s

pray

-1.

712

.32.

413

.20

3.2

16.0

26.3

18.1

AIR

Air h

eate

r out

let

(Prim

ary)

--

--

-18

317

515

412

822

1Te

mpe

ring

air

--

--

-83

9152

1650

Air h

eate

r out

let

711.

066

0.4

534.

340

3.1

712.

253

148

339

731

452

9To

tal c

ombu

sion

Air

753.

370

2.8

516.

744

5.5

754.

584

579

164

550

084

2

OIL

FIR

ING

COAL

FIR

ING

HP

HEA

TER

S IN

SRV

ICE

BOTH

HP

HEA

TER

IN S

ERVI

CEBO

THD

ESCR

IPTI

ON

BMCR

210

MW

6

8 M

W

126

MW

HP

BM

CR

210

MW

168

MW

1

26 M

WH

PHE

ATER

SHE

ATER

SO

UT

OU

T

2827

(III) TEMPERATURE, 0C1 2 3 4 5 6 7 8 9 10 11STEAM(I) Saturatd temp.in drum 350 349 346 344 348 350 349 346 344 348(ii) LTSH outlet 400 406 413 408 407 396 398 400 403 407(iii) SH platen outlet 501 498 48 506 498 506 506 509 513 502(iv) SH Finish outlet 540 540 344 337 362 352 350 344 337 362(v) RH inlet 352 350 344 337 362 352 350 344 337 362(vi) RH outlet 540 540 540 540 540 540 540 540 540 540

WATER

Economiser inlet 248 246 236 224 168 248 246 236 224 168Economiser outlet 303 306 305 295 249 294 292 284 276 243

AIR

Ambient 27 27 27 27 27 27 27 27 27 27AH outlet(Secondary) 331 333 327 310 289 326 324 307 288 284AH outlet(Primary) - - - - - 322 320 304 286 280

1 2 3 4 5 6 7 8 9 10 11FUELOil (HHV=11,000 46.1 43.3 35.5 27.4 46.5 - - - - -Kcal/kg)Coal (HHV=3500 - - - - 148 139 113 89 148Kcal/kg)

II PRESURES (STEAM & WATER) Kg/cm2 (g)PRESURESuperheater outlet 156.0 154.9 152.8 151.2 154.3 156.0 154.9 152.8 151.2 154.3LTSH outlet 164.4 162.1 157.7 154.0 160.6 164.4 162.1 157.7 154.0 160.6Drum 168.0 165.2 159.7 155.4 163.6 168.0 165.2 159.7 155.4 163.6

Economiser inlet 172.0 169.0 162.7 157.8 167.1 172.0 169.0 162.0 157.8 167.1Reheater outlet 38.8 37.2 29.9 22.7 39.6 38.8 37.2 29.9 22.7 39.6Reheater Inlet 40.4 38.7 31.1 23.7 41.3 40.4 38.7 31.1 23.7 41.3

PRESSUR DROPSuperheater system 12.0 10.3 6.9 3.9 9.3 12.0 10.3 6.9 3.9 9.3Reheater 1.6 1.5 1.3 1.0 1.6 1.6 1.5 1.3 1.0 1.6Economiser 2.0 1.7 1.1 0.6 1.3 2.0 1.7 1.1 0.6 1.5

3029

1 2 3 4 5 6 7 8 9 10 11

VIII HEAT BALANCE

Air heater inlet 319 292 229 177 312 228 207 174 149 223

Air heater oulet 145 139 125 114 145 125 121 114 109 125

Windbox pressure 100 100 100 100 100 100 100 100 100 100

Windbox to furnace diff. 105 105 105 105 105 105 105 105 105 105

GAS

Furnace -4 -4 -4 -4 -4 -4 -4 -4 -4 -4

Super heater platen inlet -4 -4 -4 -4 -4 -4 -4 -4 -4 -4

RH inlet -5 -5 -5 -5 -5 -5 -5 -5 -5 -5

LTSH inlet -22 -23 -21 -15 -20 -20 -18 -14 -10 -20

Economiser inlet -36 -38 -34 -24 -32 -32 -29 -21 -14 -32

Air heater inlet -74 -76 -68 -49 -66 -68 -62 -46 -34 -68

EP inlet -174 -160 -131 -91 -161 -192 -174 -123 -84 -186

ID fan inlet -198 -185 -144 -99 -184 -226 -203 -143 -97 -220

ID fan outlet +41 +36 +28 +22 +41 +52 +47 +35 +27 +52

1 2 3 4 5 6 7 8 9 10 11GAS

SH Platen inlet 1134 1103 1032 957 1143 1156 1165 1143 1120 1138RH Front inlet 1015 992 932 862 1014 1008 1008 973 931 993RH Rear inlet 889 874 824 759 884 869 864 824 775 859SH Finish inlet 787 777 738 681 779 761 754 717 673 754LTSH inlet 667 663 636 594 658 645 637 607 573 540Economiser inlet 561 560 514 485 523 499 493 473 451 498Air heater inlet 375 375 363 338 326 356 351 332 310 314Air heater outlet 146 139 136 132 133 136 136 123 107 116

IV PRESSURES & DRAFTS (AIR & GAS), MMWCPRIMARY AIRPA fan inlet 242 217 181 153 237PA fan outlet 764 752 748 754 777Air heater inlet ............................ Not applicable .......................... 756 744 743 751 769Air heater outlet 710 703 711 728 711Mill inlet 558 532 566 635 557Mill outlet 240 228 244 279 240

SECONDARY AIRFD fan inlet -13 -11 -7 -4 -13 -17 -15 -10 -6 -17FD fan outlet 365 334 257 194 362 258 232 191 160 253SCAPH inlet 352 321 248 189 246 245 221 183 155 240SCAPH outlet 327 299 233 180 320 232 210 176 150 227

(V) FUEL

The Fuel data on which guarantee is given are as follows

ULTIMATE ANALYSIS

Description Oil Coal

Carbon, % 85.5 37.03Hydrogen, % 10.95 2.26Oxygen, % 0.5 6.53Sulphur, % 2.5 0.33Nitrogen, % - 0.85Ash, % 0.05 41.00Water/Moisture, % 0.5 12.00HHV Kcal/kg 11,000 3500

PROXIMATE ANALYSIS OF COAL

Fixed carbon, % 24.00Valatile matter, % 23.0Moisture, % 41.0Ash, % 41.0Sulphur, % 0.33Grindability index, HGI 57Ash fusion temperature, 0c 1400

3231

12

34

56

78

910

11

(VIII)

HEA

T B

ALA

NCE

Dry

gas

,%4.

213.

983.

923.

863.

754.

754.

774.

273.

653.

89

H20

& H

2 in

fuel

,%5.

725.

705.

685.

675.

675.

835.

835.

785.

715.

75

H20

in a

ir,%

0.11

0.10

0.10

0.10

0.10

0.12

0.12

0.11

0.09

0.10

Unbu

rnt C

arbo

n,%

0.50

0.50

0.50

0.50

0.50

1.2

1.2

1.2

1.2

1.2

Redi

atio

n,%

0.11

0.11

0.13

0.16

0.11

0.11

0.11

0.12

0.17

0.11

Unac

coun

ted

&

Manu

factur

ers m

argin,%

0.48

0.46

0.46

0.45

0.46

1.13

1.11

1.09

1.06

1.08

Tota

l Los

ses,%

11.1

310

.85

10.7

910

.74

10.5

913

.14

13.1

412

.57

11.8

812

.13

Heat

Cre

dit,%

0.43

0.44

0.43

0.44

0.43

Effic

iency

(with

heat

cred

its),%

88.8

789

.15

89.2

189

.26

89.4

187

.29

87.3

087

.86

88.5

688

.30

Gua

ran

teed

effi

cienc

cy,%

87.2

887

.72

LOSS

ES

1.18 SCANNER AIR FAN

(i) No. per boiler Two, one A.C. driven, one D.C. driven(ii) Type Radial backward curved blade single suction centrifugal(iii) Duty Continuous(iv) Mounting On structural steel floor(v) Medium to be handled Dust ladden air(vi) Max. dust concentration 300 mg/cu.m(vii) Capacity 6000 cu. m/hr (1.67 m3/sec)(viii)Pressure developed 200 mmwc(ix) Suction pressure 0 to 559 mmwc(x) Efficiency of fan 81.86%(xi) Driving motor

AC motor 5.5 kw, TEFC, KEC make415v, 3, 50 HZ supplyClass of insulation - B.

DC motor 5.5 kw, 2 pole, TEFC, KEC make,(xix)Fan speed 2900 rpm(xii) Fan moment of inertia 1.52 kg m2

1.19 SOOT BLOWERType Fully automatic sequentially controlled

microprocessor based steam sootblowing

Source of steam LTSH outlet headerWall Blower LRSB

i) Number 56 18ii) Type WB 1E LRD1Eiii) Blow radius 1.5m 2.4 miv) Direction 900 900v) Motor Power 0.56 kw 0.37 kw Travers motorvi) Cleaning medium Steam Steam

Pressure 20kg/cm2 20kg/cm2Temperature 3200c 3200cConsumption 2400 Kg/m 6000 Kg/m

vii) Blow duration 1.5 minute/blower 9.0 minute/blowerviii) Cycle duration 84 min. 162 min.

1.20 FURNACE TEMPERATURE PROBE

(i) Type FTP - 1E(ii) Travel 5.1 m

3433

12

34

56

78

910

11

VI

MIL

L &

BU

RN

ER P

ERPO

RM

AN

CE

No.

of m

ills in

ope

ratio

n4

43

24

Mill

load

ing,

%71

.166

.572

.484

.070

.8

Air f

low

per m

ill, t/

hr.................. N

ot a

pplic

able

....

......

......

......

......

......

......

......

...68

6668

7268

Air t

empe

ratu

re m

ill in

let,

0 c23

522

423

725

823

5

Mill

outle

t tem

p, 0 c

7777

7777

77

Fine

ness

%(th

rough

200 m

esh)

7070

7070

70

Burn

er ti

lt, D

eg.

-15

+2

+12

+24

-25

(VII)

O 2, C

O2 (D

RY VO

L.)AN

D EXC

ESS A

IR

(i)O

xyge

n in

gas

at

Econ

omise

r out

let%

2.03

2.03

2.03

2.03

3.54

3.54

3.54

3.54

3.54

(i)CO

2 in

gas

at

Econ

omis

er o

utle

t%13

.56

13.5

613

.56

13.5

613

.56

15.8

615

.86

15.8

615

.86

15.8

6

(iii)

Exc

ess

air i

n ga

s at

Econ

omis

er o

utle

t,%10

.010

.010

.010

.010

.020

2020

2020

(iii) Traversing speed 2.9 mpm(iv) Max. gas temp. measured 8150c(v) Max. gas temp. measured 5370c

without air cooling 1.1 m3

1.21 BOILER CHEMICAL DOZINGPHOSPHATE DOZING

(i) No. off pumps 1 working + 1 stand by(ii) Model PR-35(iii) Make VK pumps industries ltd.(iv) Capacity 120 litre/hr(v) Discharge pressure 210 kg/cm2 (g)(vi) Pump motor 1.5 kw, 1400 rpm; 3.4 A, 415v, 3, 50HZ supply(vii) Phosphate preparation

tank capacity 1.1 m3(viii)Phosphate metering

tank capacity 1.1 m3

1.22 PRESSURE REDUCING & DESUPERHEATING STATION

High Capacity PRDS RightCapacityPRDS PRDS

(i) Steam source Main steam line CRH line at 41kg/cm2at 155.4 kg/cm2 pressure & 3510c& 5400c temperature temperature

(ii) Flow capcity / hr 55 30(iii) Type of actuator Penumatic Penumatic(iv) Spray water BEP discharge BFP discharge

Low temp unit High temp. station Low temp stationaux. steam header aux. steam header aux.steamheader

Operating pressure 15.0 ksc 15.0ksc 15.0 kscOperating temperature 2100c 3250c 2100c

1.23 BLOW DOWN VESSELCBD IBD SCAPH

Drain Tank(i) No. One One One(ii) Design code 1328525 152825 15285(iii) Shell diameter 1500 x16 1922 2082 x 16 x 19000 1800 x16 1800

x thickness andheight, mm

(iv) Working pressure 10.0kg/cm2 1.5 kg/cm2 1.5 kg/cm2(v) Design temperature 2000c 2000c 2000c(vi) Capacity 900 litre 7000 litre 5800 litre

1.24 MAIN PIPE LINES

Main Steam Hot Reheat Cold Reheat Feed WaterSize ID 255.6x49.2 598.0x28.0 457.2x12.7 323.9 x36.0No of lines 2 2 2 1

1.25 CHIMNEY(i) No. of fuel 4 NO.(ii) Wind shield material Reinforced concerete(iii) flue material Steel(iv) Chimney height 220 m(v) Chimney base diameter 32.975(vi) Chimney raft diameter 43.120 m(vii) Flue diameter 4.5 m

1.26 BOILER AND AUXILIARIES COOLING WATER FLOW

S.No Equipment Decription Equipment/Unit Flow Quantity/coolerworking + standby m3 /hr

(i) ID fanWorking oil cooler 2 + 2 40.0Lube oil cooler 2 + 2 6.0

(ii) FD fanLube oil 2 + 2 12.0

(iii) PA fanWorking oil cooler 2 + 2 40.0Lube oil cooler 2 + 2 12.0

(iv) GR fanLube oil cooler 2 + 2 10.0

(v) Pulveriser cooler 4 + 8 9.0(vi) APH lube oil cooler 4 + 4 1.0(vii) Access door in furnace

hopper zone 2 1.0(viii) Sample cooler - 10(ix) Oil carry over probe 2 0.5(x) Fire detection system

for Air heater 2 1.5

3635

1.27 RECOMMENDED FEEDWATER AND BOILER WATER LIMITS

RECOMMENDED FEED WATER LIMITS

(i) Drum operating pressure, 61.00 101 & aboveKg/cm2

(ii) Hardness Nil Nil(iii) pH at 250c (copper alloy

pre-boiler system) 8.8-9.2 8.8-9.2(iv) Oxygen (max.), ppm 0.007 0.007

(Coper free pre boiler system) 9.0-9.4 9.0-9.4(v) Oxygen (max.), ppm 0.007 0.007(vi) Total iron (max.), ppm 0.01 0.0(vii) Total coper (max.), ppm 0.01 0.005(viii)Total CO2 Nil Nil(ix) Total silica (max.), ppm 0.02 0.02(x) Specific electrical conductivity

at 250c measured aftercation exchanger in the H+form and after C02 removal(max.) s/cm 0.5 0.3

(xi) Hydrqzine residual, ppm 0.01-0.02 0.01-0.02(xii) Permanagnate consumption, ppm Nil Nil(xiii)Oil ........... Not allowed ................

RECOMMENDED BOILER WATER LIMITS

(i) Drum operating pr. 61-15 126-165 166-180 181-205kg/cm2(g)

(ii) Total dissolved solids(max.), ppm 100 50 25 15

(iii) Specific electricalconductivity (max.) 200 100 50 30

(iv) Phosphate residual, ppm 5-20 5-10 5-10 2-6(v) PH at 250c 9.1-10.1 9.1-90.8 9.1-9.8 9.1-9.6(vi) Silica (max.), ppm To be controlled on the basis of silica in

boiler water & drum pressure relationship to be maintained less than 0.02ppm in the steam leaving the drum.

SECTION - 2

TURBINE & AUXILIARIES

37

2.0 MAIN TURBINE2.1 TECHNICAL SPECIFICATION

21.1 STEAM TURBINE

(i) Make BHEL, KRAFTWERK UNION DESIGN(ii) Type Tandem compound, regenerative, reheat,

condensing, three cylinder having singleflow HP turbine, double flow IP & LPturbine.

(iii) No of stages HP 25 no.IP 20 x 2 no.LP 8 x 2 no.

(iv) Type of HP/IP/LP turbine HPT-Reaction, barrel single flow typeLPT-Reaction, double flow axially split typeLPT-Reaction, double flow three shelldesign

(v) Nominal rating 210 MW(vi) Peak loading 229 MW(vii) Max./Min. speed 3090/2850 rpm (47.5 to 51.5 HZ)

Permissible for a maximum of 2 hoursoperation during the life of the LP bladingspeed below 47.5 HZ & speed above 51.5HZ.

(ix) Speed exclusion range 700 to 2850 rpm(x) Weight of turbine 475 tonne (approx.)(xi) Over speed set value 11%

2.1.2 DIMESNSIONS (IN MM)

HPT IPT LPT(i) Height of first stage moving blade 43 66 755(ii) Mean dia. of first stage

moving blade 643 756 1473.5(iii) Height of last stage

moving blade 95 100 668.8(iv) Mean dia. of last stage

moving blade 695 1041 2144.8(v) Overall length 16.975m(vi) Overall width (with cross 10.5 (approx.)

around pipes)(vii) Total exhaust area (LP Turbine) 2 x 5 m2

3938

2.1.3. TURBINE CLEARANCES (IN MW)

(i) Min. axial cold clearanceexcluding thrust bearing 3.4

(ii) Position of min. axial cold clearance IP glands ( - ) 2.4(iii) Axial clearance at stag - I

shroud (cold) 15.0 (LP shaft)(iv) Radial clearance of rotor 0.4 (HP)

gland 0.5 (IP)0.5 (LP)

(v) Min. radial clearance at 1.5 (LP)shroud

2.1.4 BEARINGS

No 1 Journal, 280 x 140 mmNo. 2 Radial cum thrust, tilting pad,

290 x 240 mmNo.3 Journal, 450 x 320 mmNo. 4 Journal, 400 x 320 mmNo. 5 Journal, 400 x 320 mmNo. 6 Journal, 400 x 350 mmNo. 7 Journal, 200Lining material for all bearing - Babbit

2.1.5 VALVES

2 Main stop and control valves Type EV 1602 Reheat stop and control valves Type IV 3202 Swing check valves in cold reheat line DN 3202 Bypass stop & control valvesExtraction swing check valcesExtraction 1 : No valveExtraction 2 : 1 swing check valve with auxiliary

actuator, 1 swing check valve.Extraction 3 : 1 Swing check valce with auxilary actutor,

1 swing check valve.Extraction 4 : 1 Swing check valve with axiliary actutor,

1 swing check valve.

Extraction 5: 1 Swing check valve with auxiliary actutor,1 swing check valve.

Extraction 6 : No valve.

2.1.6. MATERIAL OF CONSTRUCTION

(i) Turbine cosingHP turbine shell GS-17 Cr Mov 511IP turbine cosing GS - 22 Mo 4LP turbine cosing St 37 - 2

(ii) BladesFirst stage Last stage

HP moving & stationary blades x22 Cr Mov 121 x20 Cr 13IP moving & stationary blades x22 Cr Mov 121 x20 Cr 13LP moving blades x20 Cr Mo 13 X7 Cr A 113

(iii) Shaft 28 Cr mo Niv 59HP rotor 28 Cr Mo Niv 59IP rotor 30 Cr MoNiv 511LP rotor 26 Cr Mo Ni V 115

2.1.7 WEIGHTS (TONNE)

HPT IPT LPTRotor 7.5 15.8 48.0Cylinder assembled 56.0 37.0 81.0

(With steam inserts)Moment of inertia (kgmw2)Rotor of HP cylinder 31694 kgm2Rotor of IP cylinder 115559 kgm2Rotor of LP cylinder 979413kgm2

2.1.8 CASING TEMPERATURE (0c)

Wall temperature Alarm at M/c must be shutHP turbine casing exhaust 480 500Outer casing of LP cylinder 90 110Spray water to LP turbine mustbe switched on at 900c

2.1.9 DIFFERENTIAL EXPANSION

Alarm TripHP turbine diff. expansion +4.50 - 2.50 +5.50, - 3.50IP turbine diff. expansion +5.00 - 2.00 +600, - 3.00LP turbine diff. expansion +25.00, - 5.00 + 30.00, - 7.00

2.1.10 TEMPERATURE DIFFERENCES (0C)(Between upper & lower Casing Section)

Alarm TripHP Turbine middle + 30 + 45IP Turbine front + 30 + 45IP Turbine rear + 30 + 45

Permissible differential temp betweenParallelSteam supply lines : not more than 1.70cShort time period 280c(15 minute)

2.1.11 BEARING TEMPERATURE (0C)Normal Operating Alarm M/c must betemperatues down at

Belwo 750c 900c 1200cAbove 750c 1000c 1200c

2.1.12 VIBRATION (ASBOLUTE)

of bearing of shaftNominal value for alarm 35 m 30 m above normalvalueMaximum value for alarm - 120 m

Limit value for tripping 45 m 200 m

4140

2.1.13 LOW VACUUM TRIP SETTING

Hydraulic low vacuum trip 0.3 ataElectric low vacuum trip 0.3 ataHydraulic low vacuum trip (Bypass operation) 0.6 ata

2.1.14 MEGAWATT OUTPUT (APPPROX)

HPT IPT LPT56.40 MW 53.73 MW 93.03 MW28% 28% 46%

2.1.15 FEED WATER HEATER OUT OF SERVICE

HP Heater 6 out of service MW rating 210 MWHP heater 5 & 6 out of service 209.1MW

2.1.16 STEAM PURITY

Continuous Start up Unitoperation

(i) Conductivity at 250c,continuous measurementat the sampling pointa. direct measurement alkaline method No specified - s/cm Neutral method

M.O.P A.O.P. DC J.O.P. J.O.P.E.O.P. (AC) (DC)

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

Make - GEC crompton Siemens siemensgreaves

Enclosure - - IP44 IP54 IP54Voltage, V - 415 220 415 220Frequency, HZ - 50 - 50 -Motor power, kw - 100 15 27.6 28Rated current, amp - 175 128 47.5 152

2.2.3 OIL COOLER

(i) Type & no. Shell & tube type, 2 x 100 %(ii) Cooling surface/oil flow 280 m2/ 27lit/s

per cooler(iii) Oil outlet temp. of per cooler

In operation Min 38, normal 45, max 470cIn shutdown 750c

(iv) Oil pressure drop acrosscooler 0.4 ata

(v) Tube material & no. of tubes CuZn 28 Sn F38, 1251 no.(vi) Design pr. & temp. shell &

tube side 10Kg/cm2 & 1000c (both)

2.2.4. OIL FILTER

(i) Duplex oil filtertype & no. DN 100 type, 1 no.

(ii) Filteration particle sizeduplex filter 37 m

(iii) Filteration particle size MOTfilter 250 m

2.2.5 ESTIMATED OIL REQUIREMENTS OF BEARING

Bearing 1 (HPT front pedestal) 0.8 dm3/s2 9.1 dm3/s3 4.0 dm3/s4 3.5 dm3/s

Front Generator bearing 3.5 dm3/sRear Generator bearing 5.0 dm3/s

2.2.6 BARRING GEAR

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

2.2.7. MAIN OIL CENTRIFUGE

(i) Manufacturer ALFA-LAVAL (India)(ii) Supplier BHEL Hardwar(iii) Capacity 6000 lph purifier(iv) Centrifuge Flame proof induction motor, Crompton

Greaves make, 7.5 kw, 1460 rpm, 15A,Class B, insulation, Frame E 160 LD,3, 415v, 50 Hz Power supply,Ref. IS : 325/1978

(vi) Bowl speed 8425 rpm approx.(vii) Revolution counter (RPM) 118-125(viii) Booster pump type Gear pump, type 206(ix) Booster pump motor Crompton Greaves make, 3.3 kw

1430 rpm, 7.5A, Fram E 132 M(x) Oil heater Indirect type 72 kw

Heater J/II/III 36 kw/ 18kw/ 18 kw(xi) Quantity of water for heater 450 litre approx. for first filling(xii) Sealing water for centrifuge 3 litre for first filling of Centrifuge

2.2.8 OIL CHARACTERISTICSAS per IS : 1448

(i) Kinetic viscosity at 37.80c 47.5 CS. to 49.5 C.S.Kinetic viscosity at 500c 28 C.S.

(ii) Sp. gravity at 500c 0.852(iii) Flash point Min 2000c(iv) Pour point -60c(v) Ash content 0.01 (% by weight)

4544

(vi) Water content Below the level of quantitiativedeteclibility

(vii) Mech. solid impurities -do-(viii)Viscosity index Min 97(ix) Inorganic acidity Nil

Organic acidity Max. 0.14 mg of KOH per gm of oil(x) Neutralisation no. Max. 0.02 mg of KOH per gm of oil(xi) Copper strip corrosion test

at 1000c for 3 hrs. Not worse than no1(xii) Emulsion characteristics 40-40-0

(20 minute)

2.3 VACUUM SYSTEM2.3.1 CONDENSER

(i) Type Surface type, double pass with dividedwater box construction.

(ii) Design conditions Steam side Water sideDesign pressure Full vaccum/1.08 kg/ 5 kg/cm2 (g) &

cm2 (g) full vacuumTest pressure Filling by water up to 7.5kg/cm2 (g)

(iii) Design c.w. flow 22,500 m3/hr

(iv) Design cold wate temp. 320c 600c

(v) Design back pressure 76 mm of Hg (abs)

(vi) No. of tubes 15330 nos.Tube O.D. x thickness, 25.4 x 0.7 thickFor top row thickness 1.0 mm

(vii) Tube material Stainless steel weldedASTM A 249 TP 304

(viii)Surface area 13727 M2

(ix) C.W. velocity 1.83 m/s

(x) Pressure drop C.W. side 4.18 mwc

(xi) C.W. temp rise 10.80c

(xii) T.T.D. 2.960c

(xii) Weight Dry 343 tonnes Operating 540 tones Flooded (1.0 m above tubes) 785 tonnes

2.3.2. VACUUM PUMP

(i) No. & capacity 2 x 100 %

(ii) Make NASH

(iii) Type AT 2004 NASH, two stage liquid ring airpump

(iv) Coupling drive make Wellman - BIBBY Type E - FLEX Size 290 / F8

(v) Unit weight, Empty 6639. kg

Operating 7074 kgFlooded 7619 kg

(vi) Vacuum pump motor ABB MotorType Totall enclosed, fan cooled.

squirrel cage induction motorPower supply 415v, 3, 50HZPoer rating 93 kw/125 hpFull load current 190 AFrame size MAFull load rpm 493

(vii) Seal water pumpType Single stage, centrifugal, foot

mounted type.Manufacturer Worthingaton simpsonFlow End suction typeMotor Totally enclosed, fan cooled cage

induction motor, 1.5 kw (2hp)2700 rpm, 3 A, 415v, 3, 50 HZpower supply, frame size 90 DL

(viii) Heat exchanger Size 1244

4746

Type Single pass, counter flow, tube &shell typeShell side Tube side

Design pressure 10.54kg/cm2 10.54kg/cm2Design temp. ( - ) 6.6-1490c ( - ) 6.6 -1490c

2.3.3 GLAND SEALING SYSTEM

(i) Type of control Electro-hydraulic seal steampressure controller

(ii) Gland sealing temp. above 1200c cold start1500c hot start

(iii) Self sealing after 40% load.

2.4.1 CONDENSATE EXTRACTION PUMP

2.4.1. CONDENSATE EXTRACTION PUMP

(i) Manufactuer BHEL(ii) No. of pumps & capacity 2x100%(iii) Type NESJ14OD (2shaft), vertical

centrifugal connister type(iv) No. of stages 5(v) Discharge capacity 655 m3/hr(vi) Diff. head 190 mlc(vii) Input power to pump 422 kw(viii) Density of medium handled 0.9897 tone/m3(ix) Temperature of medium 46.30c(x) Liquid NPSH required at the

eye of the first impeller 2.8 mlc(xi) RPM 1485(xii) Efficiency of pump 79.5%(xiii) Direction of rotation

viewed from drive end Clockwise(xv) Suction bore dia. 400 mm(xvi) Discharge bore dia. 300 mm(xvii) Cooling water to thrust

bearing flow 10 lpm

(xvii) Sealing water to glands flow 20 lpm(xix) Thrust bearing type Michell 7 SNT(xx) Motor

Manufacturer BHEL/BhopalType Squirel cage induction motorFrame 1LA 7636 - 4 HE 7 4ZKW rating 550 kwPower supply 6600v, 3, 50 HZClass of insulation FConnection stator StarEfficiency at rated output 94.2%Rate speed 1487 rpmNo load current 21.4 AFull load current 62.2 ATotal weight of Motor 4900 kgBearing DE 6224-c3NDE 7322 - B

2.4.2. DRAIN COOLER

(i) Position Horizontal(ii) No. of One(iii) Type Tube & shell type(iv) Design code ASME Sec VII DIV I

Tube side Sheil side(v) Design pressure 30kg/cm2 (g) Full vacuum & 3.5 kg/

cm2 (g)(vi) Design temperature 1500c 1000c(vii) Max. working pressure 30 kg/cm2 0.4521 ata(viii) Hydraulic test pressure

(duration 30 minute) 45 kg/cm2 (g) 5.25 kg/cm2 (g)(ix) Hydraulic resistance at 0.8 mwc 0.3 mwc

design flow(x) No. of water path (tube side) one(xi) Tube O.D. x. thickness x length, 16 x 0.889 x 1540

mm(xii) Tube material Austenitic S.S. welded(xiii) No. of tubes 501(xiv) Discharge of main condensate

(design) 540 t / hr(xv) Drain quantity (design) 68.789 t / hr(xvi) Operating weight of drain cooler 3250 kg.(xvii) Cooling surface area 35 cm2

2.4.3. GLAND STEAM CONDENSER

(i) Position Horizontal(ii) No. One

4948

(iii) Type Tube & shell type(iv) Design code ASME Section VIII Div. I(v) Design pressure shell

& water box side Full vacuum/30kg/cm2(g) & 30 kg/cm2(g)(vi) Design temperature shell/

tube side 4000c/1500c(vii) No. of water path tube side one(viii) Surface area 20 m2(ix) Shell side design flow 0.3 metric tonne/hr.(x) Allowable/design flow

of main condensateMinimum 108 /hrDesign 546/hr at V.W.O., 3% makeupMaximum 780 t / hr

(xi) Hydrauic resistance at minimum/design / maximum flow 0.2 mwc/1.0 mwc/2.3 mwc

(xii) Tube dimenssion x th x l,mm x mm x mm Material Welded S.S. tubes

ASTM 249 TP 304No. 325

(xiii) Exhauster fans 2 no., centrifugal, 1080m3/hr,2840 rpm, 3 hp

2.4.4 LOW PRESSURE HEATER

(i) Type LPH-1 LPH-2 LPH-3(ii) Position/location ............... Shell & tube type ................

condenser neck(iii) No. one one one(iv) Design code ............ ASME SEC VIII DIV I .................(v) Design pressure shell side ............ 3.5 kg/cm2 / Full vacuum ............

waterbox side ....................... 30 kg/cm2 .......................(vi) Design temperature shell 150 210

side(vii) No. of tubes 429 429

LPH-1 LPH-2 LPH-3(ix) Weight, Dry 11100 11100

Operating 13700 13700Flooded 19170 19170

(x) Test pressure kg/cm2Shell side 5.25 5.25W/B side 45 45

(xii) Shell assy IS 2002 Gr A BQ STEELWater box IS 2002 Gr A BQ STEELWater box cover IS 2002 Gr A BQ STEEL

2.5.1 DEAERATOR

(i) Manufacturer BHEL, Hyderabad

(ii) Type Spray cum tray type

(iii) Design pressure and temp. Spray cum tray type

(iv) Shell diameter and thicknessa. Dearator ID 2200 x 16 thk, mmb. Storage tank ID 3600 x 20 thk, mm

(v) Straight length and overalllength of shella. Deaerator 6632, 7882, mmb. Storage tank 21000, 22900, mm

(vi) No. of trays provided 240

(vii) No. of spray valves 48.

(viii) Storage capacitya. At normal water level with a filling capacity of 2/3 of cross- sectional area of the storage tank 141.4 m3b. Normal water level to low level 131.4 m3

(ix) Water level from centre line ofhorizontal vessel

5150

a. Normal 610 mm aboveb. Low 118 mm abovec. Low-High 1300 mm aboved. High 860 mm abovee. High-High 1035 mm above

(x) Feed water outlet temperature 1610c(xi) Deaerator operation condition 6.85 kg/cm2 abs. 163.80(xii) Oxygen guarantee 0.005 cc/liter as measured by ASTM-D-888.(xiii) Safety valve 2 no., spring loaded, 40 t / hr capacity

each, BHEL trichy make, 6.8 kg/cm2 (g)set pressure.

(xiv) Total weightEmpty/operating/flooded 80/210/310 tonne

BOILER FEED BOOSTER PUMP

(i) Pump type FA 1B 56(ii) Liquid pumped Boiler feed water(iii) S.G. at suction temperature 0.90665(iv) Suction tempreature 160.70c(v) Differential head 100m(vi) Flow rate 450 m3 / hr(vii) Efficiency 79 %(viii) Speed 1485 rpm(ix) Power 141 kw(x) NPSH, required 4.03 m.(xi) Thrust bearing The Glacier Metal Co. Ltd.

Double thrust, CK range size811/2KP-2KP

(xii) Mechanical seal Durametalic/sealEd type4.250 PTO/type 503

BOILER FEED PUMP

(i) No and Capaciy 3 x 50%(ii) Make BHEL, Hyderabad(iii) Pump type FK 6 D 30(iv) No. of stages 6(v) Liquid pumped Boiler feed water(vi) S.G. at suction temperature 0.90665(vii) Differential head 2123m(viii) Design flow rate 450 m3 / hr(ix) Minimum recirculation flow 110 m3 / hr(x) Efficiency 81%(xi) Speed 5150 rpm.(xii) Power 2911 kw(xiii) Direction of rotation viewed

on drive end Anti-clock wise(xiv) NPSH required 24.0 mlc(xv) Thrust bearing The Glacier Metal Co. Ltd., Double Thrust,

CK range, Size 8159/2KP-2KP

DRIVE MOTOR

(i) Make BHEL, Bhopal(ii) Type Squirrel cage induction motor(iii) Frame size 1 RN7 714-4HE 70-Z(iv) Rating 3500 kw(v) Degree of protection, type

of enclosure and methodof cooloing IP 54, CACW, ICW 37 A 81

(vi) Power supply 6600 volt, 3 phase, 50 HZ(vii) Rated speed 1500 (synch.)(viii) Insulation class F(ix) No load current 80 A(x) Full load current 356.5 A(xi) Weight 12800 kg(xii) Winding temperature rise at

rated output over cooling air 700c (by resistance), 800c (by ETD)(xiii) Bearing - DE Sleeve bearing 160 x 14 Q

- NDE Sleeve bearing 125 x 115 (Insulated)

5352

TYPE OF COUPLINGS

(i) Turbo coupling / pump flexiblecoupling Manufacturer Torsi flex Ltd.Type HBS 1000-8x

(ii) Motor / turbo coupling flexiblecouplingManufacturer Torsi flex Ltd.Type HBS-3600 8

(iii) Motor / turbo coupling flexiblecouplingManufacturer Torsiflex Ltd.Type HB4-140X (Insulated)

HYDRAULIC TURBO COUPLING

(i) Manufacturer Vaith Turbo GMBH and Co.(ii) Type R16 K.1(iii) Power requirement of driven

machine 3245 kw(iv) Gear ratio, type 181/51, step up gear unit(v) Speed input / output 1485/5155 rpm.(vi) Full load slip 2.2%(vii) Regulating range 5:1 down wards(viii)Oil tank filling Approx. 700 litre(ix) Working oil flow rate 47 litre / min.

AUX. LUB OIL PUMP

(i) Type Gear pump(ii) Lube oil flow Approx. 120 litres/min.(iii) Pressure 2.5 bar,(iv) Motor 5.5 kw, 415v, 50 HZ, 1500 rpm

IP 55

OIL/WATER-HEAT EXCHANGER

(i) Type WORKING OIL LUB OIL(ii) Heat exchanger capacity L1 N1 09 17 04-D L1 N1 07 17 04-D(iii) Cooling water flow, V rated 52 m3/hr 38m3/hr

V / min 25 m3/hr 15 m3/ hr(iv) Cooling water inlet temperature 380c 380c(v) Cooling water outlet temperature 480c 400c(vi) Normal oil flow rate 31m3/hr 13.2m3/hr(vii) Oil inlet temperature 1000c 610c(viii) Oil outlet temperature 610c 450c(ix) Maximum permissible working

pressure, oil side 16 bar 16 bar water side 10 bar 10 bar

(x) Maximum permissible workingoil temperature 1200c 1200c

COOLING WATER FLOW

Cooler Quantity/ Pressure Temperaturecooler drop risem3 /hr kg/cm2 0c

(i) Booster pump stuffingbox cooler 2 x 1.8 0.4 2.0

(ii) Motor cooler 24 0.5 5.0(iii) Working oil cooler 52 0.5 10.0(iv) Lub oil cooler 38 0.5 2.0(v) Mech. seal cooler 6.0 0.2 3.0(vi) BFP stuffing box cooler 2x2.4 0.2 2.0

2.5.2 HIGH PRESSURE HEATERS

HP Heater No.5 6

(i) Manufacturer .............. BHEL Hyderabad .............(ii) Type and arrangement .............. U Tube Horizantal .............

5554

(iii) No. of shell passes 3 Zones 3 Zones

(iv) No. of tube passes 2 2

(v) TubesType of tubes provided Seamless SeamlessTotal no. of U tubes 757 757Effective length U tubes, mm 17270 20075Outer diameter, mm 15.875 15.875Design pressure, kgf/cm2 (g) 280 280Design temperature, 0cDesuper heating zone 235 285Other zones 215 265Design pressure, kgf/cm2 (g) 280 280Design temperature, 0cDesuper heating zone 235 285Other zones 215 265Tube side relief setpressure, kg/cm2 (g) 280 280

(vi) ShellOutler diameter / wallthickness, mm 1240/20 1264/32Length of despuer heating, mm 1980 2515Length of drain cooling, mm 3048 2515Design pressure, kg/cm2 (g) 19.0 and 50 and full

full vacuum vacuumDesign temperature skirt/shell,0c 440/215 370/265Shell side relief valve, set pr.,kgf/cm2(g) 19.0 50.0

(vii) Velcity through tubes at 670 t /hr flow, kg /cm2 2.22 2.29

(viii)Tube side pressure drop at670 t / hr flow, m/sec 0.9 1.1

(ix) Total heat transferrel, kcal/hr 23.73 32.31

(x) Drain level in heaters, mm(From C.L. of heater)a. Normal 410 410b. Maximum 100 100C. Minimum 495 495

(xi) Surface area, m2Desuperheating / condensing /drain cooling zone 75/ 446 / 115 95/ 562 / 95Total effective area, m2 636 752

2.6 PREDICTED PERFORMANCE

STEM PRESSURE (BAR)Rated Long time Short time

Description value operation operationbar bar bar

Initial steam 147.1 147.1 176.5Before 1st HP drum stage 132.6 137.9 145.9HP cylinder exhaust 39.23 45.11 47.08IP cylinder stop valve inlet 34.13 39.59 40.08Extraction 6 39.23 45.11 47.08Extraction 5 16.75 19.84 19.84Extraction 4 7.06 8.46 8.46Extraction 3 2.37 2.91 2.91Extraction 2 0.858 1.09 1.09Extraction 1 0.216 0.374 0.374HP cylinder exhaust 0.118 0.3 0.3

STEAM TEMPERATURE (0c)

Rated Long time 400 hr 80 hr.value value but per per

Description Annual keeping annum annum max.mean value within annual 15 minutes

mean value in individualcase

initial steam 535 543 549 563IP cylinder stop 535 543 549 563valve inlet

5756

Rated Long time 80 hr pr. In specialDescription value operation annum max. case at

0c 0c 15 min. in no loadindividual

case

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

**CONDENSATE WATER

Description Pressure Temp. Flowkg/cm2 0c 1/hr

CEP suction 0.1033 46.1 508.83CEP discharge 19.379 46.3 508.83GSE oulet 10.54 46.6 508.83Drain cooler oulet 10.08 47.8 508.83LPH 1 oulet 9.63 56.6 508.83LPH 2 oulet 9.18 90.6 508.83LPH3 oulet 8.72 120.7 508.83

**HEATER DRAIN

Description Temp. Flow0c t/hr

GSC drain to LP Flash box 99.9 0.299LPH3 to LP2 123.5 27.589LPH2 o LPH1 93.4 57.651

LPH1 to drain cooler 60.3 63.437Drain cooler to LPFB 52.8 63.437HPH6 to HPH5 206.0 61.091HPHS to deaerator 170.0 95.807

**FLEED WATER

Pressure Temp. FlowDescription kg/cm2(g) 0c 1/hr

BFP suction 6.405 160.7 639.27BFP discharge 205.0 164.1 639.27HPH5 outlet 204.09 200.0 639.27PHP6 outlet 203.18 247.0 639.27

Long time operation Upper limit value permissible without timelimit.

Short time operation Permissible momentary value the aggregateduration of such must not exceeds 12hr/annum

Rated value These value corresponds to 210 mw load with3% make up and 0.1187 bar back pressure withall heaters in service and rated steamconditions.

* Only valid for no load period with high reheat pressure after trip out fromfull load for the individual cases approx. 15 minutes.

** Parameters are given when unit 210 mw, 0% make up water, 76 mm backpressure and constant pressure operation.

2.7 EQUIPMENT COOLING WATER PUMPS

(i) Manufacturer Mother & platt(ii) No. of/unit and type 3, 8/10 CME MK -1(iii) Design capacity 100 m3/hr(iv) Total head 60 m(v) Speed 1482 rpm(vi) Pump weight 750 kg.(vii) NPSH 6.4 mtrs.

5958

(vii) MotorManufacturer Crompton GreavesFrame HMHAC-400/6Type 3AC induction motorMotor rating 215 kw (288 hp)Power supply 6600v, 3, 50 HZRPM 1482 rpmInsulation class FFull load currentq 23.5 ABeaing DE NU 321 - 1 NDE 6321

2.8 HP / LP BYPASS SYSTEM

Capacity 60 % MCR420 t/hr of main steam flow at the inletof HP bypass valve

HP Bypass

(i) Valves BP1/ BP2 Valves BPE 1,2 ValvesDesign pressure 170/50 ata 280 ataDesign temperature 540/4850c 1750cBody material 10Cr Mo 10 15 Mo3Nozzle material 10 Cr Mo 910 15 Mo3Medium Main steam spray water

(ii) ActuatorType HydraulicHydraulic system pressure 100 barpositioning time 10/3 sec (3 sec for fast opening device)

(iii) Oil supply unitOil pump type OV-32Supply capacity 24 l/min.Motor rating 7.5 kw, 415v, 3, 50 HZ, 1440 rpm,

14.2 AOil tank volume/useablevoulme 70l/50lOil pump cut in at 100 ksc

Cut out at 160 kscBack up protectioncut in/cut out 110 ksc/170 kscRelief valve setting 190 ksc

2.9 H.P. & L.P. FLASH TANK

H.P. FLASH TANK L.P. FLASH TANK1. Type Vertical cylindrical, Vertical cylindrical

leg supported, leg supported.2. Desing code ASME Sec VIII Div. I ASME SEc VIII Div I3. Design pressure Full vacuum & 3.5 Full vacuum & 3.54. Design temperature 2100c 2100c5. Fluid handled Water/steam Water/steam6. Shell material ASTM A 285 Gr.c/ ASTM A 285 Gr.c/

IS : 2002 Gr 2 IS : 2002 Gr. 27. Internal diameter 220 mm 1600 mm8. Shell thickness 12 mm 1600 mm8. Shell thickness 12 mm 12 mm9. Overall height 3300 mm 2400 mm.10. Corrosion allowance 3.2 mm 3.2 mm11. Thining allowance 1.5 mm (max.) 1.5 mm (max.)

2. 10 LP DOZING SYSTEM (HYDRAZINE & AMMONIA)

LP Dozing (Hydrazine) LP. Dozing (Ammonia)

1 Mixing tankDimension 750 mm dia. x 100mm 1400 mm dia.x 1000 mm

H.O.S. H.O.S.Capacity 340 litres (Net) 1200 litres (Net)Material Stainless steel as per Stainless steel as per

SS - 304 SS - 304Stirrer motor 0.37 kw, 1395 rpm. 0.75 kw, 1395 rpm

2. Metering tankDimension 750 mm dia x 1000 1400 mm dia x 1000

6160

mm H.O.S. mm H.O.S.Capacity 340 litres (Net) 1200 liters (Net)Material Stainless steel as per Stainless steel as per

SS - 304 SS - 3043. Dozing pumps

Type 2 x 100% positive 2 x 100% positivedispacement displacement

Capacity Max. 13 13 liters/hr 61 liters/hrDischarge pressure 30 bar 30 barMotor rating 0.25 kq 0.55 kw

4. Transfer systemTank no. and capacity - 2 x 3 m3Transfer pump - 2 x 100% for 4

units

2.11 COOLING WATER FLOW

S.No. EQUIPMENT EQUIPMENT/ TOTAL PRESSURE TEMPDESCRIPTION UNIT QTY./ DROP RISE REMARKS

WORKING+ UNIT mwc 0CSTANDBY m3/hr

1. Turbine lub oilcoolers 1+1 360 8.8 2.53

2. Hydrogen cooler 4+0 350 8.2 5.23. Seal oil cooler 1+1 72 1.8 0.64. Startor water

cooler 1+1 200 2.5 3.15. CEP brg cooling 1+1 1.2 3 3 Flow through stand by

CEP also considered6. BFP AUX6.1 Booster pump

stuffing boxcooler 2+1 10.8 4.0 2.0 Flow through stand-

by CEP also considered

6.2 BFP workingoil cooler(Duplex viz1+1per BFP 2+4 98 5.0 0.0

6.3 BFP motoroil cooler 2.1 48 5.0 5.0

6.4 BFP lub oil cooler Flow through standby(Duplex viz1+1 per BFP) 2+4 114 5.0 2.0 also considered

6.5 BFP seal water 2+1 18 2.0 3.0cooler

6.6 BFP stuffing box 2+1 14.4 2.0 2.0cooler

7.0 Vacuum pump 1+1 182 2.5 2.08.0 Water jel ejector 1+1 10 - 2.09.0 V.E. oil separate

(seal oil system) 2+1 5 4 2.0

ACW pressuresHydrogen cooler < 3.5 kscOil separator < 2 kscSeal oil cooler < 4.5 kscWater jet ejector < 2 kscStator water cooler < 4 kscCEP < 3 ksc

6362

SECCTION - 3

GENERATOR&

AUXILIARIES

3.1 GENERATOR TECHNICAL SPECIFICATION

(i) Make BHEL(ii) Type THW - 201-2

Two pole, cylindrical, steam turbinedriven

(iii) Code IS : 5422(iv) Cooling Stator winding Directly water cooled

Stator core and Rotor Directly hydrogen cooled(v) MW rating 210(vi) MVA rating 247(vii) Rated terminal voltage 16.5 kv(viii) Rated terminal voltage 8,645 A(ix) Rated power factor 0.85 log(x) Ratd speed/frequency 300 rpm/50 HZ(xi) Negative sequence current

capability (l2 t) 8(xii) Efficiency at MC Condition 98.55%(xiii) Short circuit ratio 0.49(xiv) Phase connection Double star(xv) No. of terminals brought out 9 (6 neutral, 3 phase)(xvi) Generator stator winding

resistance in each phast 0.00155 ohm at 200c(xvii) Generator rotor winding

resistance 0.0896 ohm at 200c

STATIC EXCITATION EQUIPMENT

Make BHELSEE Rating Voltage - 310 v DC

Current - 2600 amp DCAccuracy of excitation control + 0.5 %Range of voltage control in auto 90.110 %Range of voltage control inmanual 80.110 %No load field voltage 102 V DCNo load field current 917 ampMax. continuous rated fieldvoltage 355 V DCMax. continuous rated fieldcurrent 3000 amp

Ceiling. voltage 620 v DCCeiling current 4500 ampFrequency range ofoperation 47.5 - 52 HZNo. of parallel bridgesincludingredundant bridge 4No. of redundantbridge 1Protection class IP 20Station battery supply 220c DCDuration of field forcing 10 secResponse time 40 m Sec

EXCITATION TRANSFORMER DETAIL

Make MAY and CHRISTERating 2500 kvaVoltage rating 16500/575 v ACVector group Dyn 5Insulation level 50KV/RMS/MINCooling AN-with two blower provided extra.

3.2 DESIGN & CONSTRUCTIONAL FEATURESMATERIAL

(i) Rotor shaft Steel forging 35 Ni 3 Cr 12 Mo 35V 12chromium nickle molybdenum andvanadium steel

(ii) Rotor winding Silver bearing copper(iii) Rotor slot wedges Duralumin.(iv) Rotor retaining ring 60 Mn Ni85 Cr W75, Non magentic steel(v) Stator frame ST-42w(vi) Stator core stampings Cold rolled silicon steel(vii) Bearing body CSW C25 Is:2856-64(viii) Shaft sealing ST-42w(ix) Bearing and seal babbit Grade 84(x) Carbon brushes

6564

a. Grade HM 6Rb. No. of brushes required 112+1

WEIGHT & OVERALL DIMENSIONS

(i) Weight of the heaviestlift (stator with gas cooler& lifting trunions) 175,000kg

(ii) Weight of the rotor 42,200 kg(iii) Weight of the gas cooler 1415 kg(iv) Weight of the end terminal 85 kg(v) Weight of the end shield 200 kg(vi) Total weight of the generator 239000 kg(vii) Overall dia. of stator 3960(viii) Length of stator (overall) 65822 mm(ix) Length of rotor (overall) 9770 mm(x) Diameter of rotor barrel 1075 mm

TORQUES, CRITICAL SPEEDS ETC

(i) Torque under normal working conditions 76.32 tonnes(ii) Rotio of short circuit torque to full load

torque 8(iii) Flywheel moment of the rotor 21.1 m2(iv) 1st critical speed of the rotor (calculated) 1370 rpm(v) 2nd critical speed of the rotor (calculated) 3400 rpm

OIL CONSUMPTION

(i) Consumption of the oil per generaterbearing (excluding shaft seal) 300 lit/ minute

(ii) Oil pressure at the inlet of bearing 0.3 to 0.5 kg/cm2(iii) Consumption of oil in both shaft seals 77 lt/min

3.3 GENERATOR GAS SYSTEM

3.3.1 HYDROGEN IN STATOR CASING

(i) Nominal pressure of Hydrogen 3.5 kg/cm2 (g)permissible variation +0.2 kg/cm2 (g)

(ii) Maximum temperature of cold gas 440c(iii) Maximum permissible hot gas 650c

temperature(iv) Minimum required purity of hydrogen 9.7%(v) Maximum oxyen content 1.2%(vi) Relative humidity of hydrogen

casing pressre (maximum) 30%(vii) Maximum moisture content in

Generator casing 15 gm/m3 of H2(viii) Total gas volume of the Generater 56 m3(ix) Maximum make up hydrogen per day 15 m3

3.3.2 GENERATOR FILLING QUANTITIES

M/c at stand M/c under-still rolling

(i) Amount of carbon-di-oxide requiredto remove air expressed at NTP 90 m3 112 m3

(ii) Carbon-di-oxide for expelling hydrogen 120 m3 168 m3(iii) Hydrogen filling qunatity 300 m3 336 m3(iv) Compressed air required for purging of

carbon-di-oxide from the generator 150 m3(v) Quantity of compressed air required

(at NTP) for carying out air tightness test 500 m3(vi) Max. no. of H2/Co2 cylinder can e conected

at a time 8/8

3.3.3. HYDROGEN COOLER

At Rated Hydrogen Pressure 3.5 kg/cm2 (g)

6766

(i) No. of coolers/ Generator 4(ii) Gas flow per cooler 7.5 m3/ sec(iii) Max. water inlet temperature 370c(iv) Pressure drop through cooler 17.5 mwc(v) Design pressure water side of cooler 6 kg/cm2 (g)(vi) Max. permissible operating pressure

water side of cooler 3.0 kg/cm2 (g)(vii) No. of passes of water in gas cooler 2(viii) Material of tubes/fins Admiraly brass/copper(ix) Material of water boxer/Tube sheats Carben steel(x) Heat load 528 kw

3.3.2 HYDROGEN DRIER

(i) Working pressure and volume 5bar, 39 dm3, silica gel filled(ii) Heater rating 2.5kw, 415v,3,50 HZ supply(iii) Blower Siemens make, 1.1 kw,

2855 rpm, 2.3A

3.4 STATOR WATER SYSTEM

(i) Nominal gauge pressure at inlet to winding 3.3kg/cm2 (g)(ii) Flow of distillate through stator winding 27+3m3/hr(iii) Nominal temperature of distillate at

Inlet to winding 45 + 30c -10

(iv) Stator winding distillate filling quantity 0.35 m3(v) Nominal conductivity of distillate

EXPANSION TANK

Type Hermetically sealedcontainer, TGSC-E

Material Stainless steelVacuum 250 -300 mm of HgWeight 902 Kg.Volume (capacity) 2 m3

QUALITY OF DISTILLATE

Conductivity less than 5 mho/cm preferobly1 mho/cm

pH 6.5 to 8.5Dissolved O2 Minimum, preferably less than

50 ppb but not greater than 100 ppbDissolved CO2 NilAmmonia Minimum, preferably zeroChloride Minimum - preferably zeroDissolved/undissolved Cu less than 20 ppbDissolved /undissolved Fe less than 20 ppmDissolved solids The water should be free of any

chemicals from treatmentprocess such as hydrazine,morphoine, levoxine phosphate etc.

3.5 SEAL OIL SYSTEM

(i) Type of shaft seals Single flow ring type(ii) Hydrogen pressure of Generator

casing 3.5 + 0.2 kg/cm2(iii) Seal oil - H2 diff pressure min. 1.0, normal 1.5 max 1.7 kg/

cm2

(iv) Quantity of seal oil per seal 38.5l/min(v) Qty of seal oil towards

Air side 2/3 rdHydrogen side 1/3 rdoil system press 7.5 Kg/cm2

3.5.1 SEAL OIL PUMPS

(i) Type TUSHCO pump TUSHCO pump3-52-46 IBSCS1x2 3.52-46-18SCSx2

(ii) Pump discharge flow 130 l/m 125 l/m(iii) Pump head 12 kg/cm2 12 kg/cm2(iv) Pump speed RPM 1000 1000(v) Motor type Ac motor DC motor

Make Crompton Greave Kirloskar RPM 945 960 Kw 4.85 kw 5.6 kw Power supply 415 v, 3, 50 HZ 220v DC+10%20% Amp 10.6 A 42 A

SEAL OIL COOLER

Make BHEL, HaridwarSurface area 14.3 m3Tube side/shell side designperssure 10.5 kg/cm2Tube side/shell side test 16.0 kg/cm2pressureType Surface type

VACCUM PUMP

Make LEYBOLD W. GermonyType S4-BFlow 4m3/hrUltimat pressure

FILTER

Make Boll & Kirch Filter ba GmbHPressure 16 bar, 500cType 170/32F 200

OIL TANKS

Intermediate tank 75 LtSeal oil storage tank 500 LtSeal oil tank 1000 Lt

3.6 SPECIFICATIONS OF TRANSFORMERS3.6.1 GENERATOR TRANSFORMER

(i) Manufacturer BHEL, Bhopal(ii) No. One per unit(iii) Rating 270 mva(iv) No load voltage, HV 235 kv(v) No load voltage, LV 16.5 kv(vi) Rated current, HV 664.12 A(vii) Rated current, LV 9458.15 A(viii) Frequency 50 HZ(ix) Vector group Ynd 11(x) Off load tap changer range -5% to + 5% in steps of 2.5%(xi) Impedance voltage at

Max tap 13.82%Normal tap 13.81%Minimum tap 13.91%

(xii) Type of cooling OFAF(xiii) Temperature rise above on

ambient of 500c - In oil 500c In winding 550c

3.6.2 UNIT AUXILIARY TRANSFORMER

(i) Manufacturer NGEF Ltd., Banglore(ii) Type OFTR 16000/22(iii) No. of transformers 2 per unit(iv) Rating 16 mva(v) Voltage ratio 16.5/6.9 kv(vi) winding connection HV/LV Delta/star(vii) Vector group Dyn 1(viii) Type of cooling onan/onaf WITH 2X50%

separately mounted radiators(ix) Rating available at different cooling 125/16 mva (78%/100%)(x) Temperature rise above ambient of

500c - In oil 500c In winding 550c

(xi) Tap changer type and range On load, + 10% to - 5%In steps of 1.25 % on HV windingNo. of steps 12

(xii) Percentage impedance 7% (+ 10%)(xiii) Bushings HV-oil filled

LV-oil filledLV neutral - oil filled

3.6.3 STATION TRANSFORMER

(i) Manufacturer NGEF Ltd. Banglore(ii) No. 2(iii) Maximum rating HV/LV1/LV2 55/27.5/27.5 mva(iv) Winding connection HV/LV1/LV2 Star/star/star(v) Voltage ratio 220/6.9/ 6.9 kv(vi) Vector group Yn YnOY n0(vii) Tap changer type and range On load tap changer,

+10% to - 10% in steps of 1.25%on HV Winding, total 16 steps.

(viii) Type of cooling ONAN/ONAF/OFAF

7372

steps of 1.25%(vii) Cooling Type ONAN ONAF OFAF

Rating available 40% 60% 100%

3.6.5 MISCELLANEOUS SERVICE TRANSFORMER

(i) Make Voltas Ltd. Pune(ii) Rating 10 mva(iii) Voltage ratio 11.5/6.6 kv(iv) Vector group Ynd 11(v) Winding connection HV/LV Star / delta(vi) type of cooling ONAN(vii) Tap changer type and range Gang operated off ckt. 5% in

steps of 2.5% each(viii) Percentage impedence 8% + 10%(ix) Temperature rise over an ambient In oil 500c

of 500c In winding 550c

7574

(ix) Rating at different cooling 60% 80% 100%ONAN ONAF OFAF

(x) Temperature rise over anambient of 500c-In oil 500c In winding 550c

(xi) Bushing HV LV HV netural LV neutralType condenser oil filled condenser oil filledMin creepage dist. (mm) 5635 385 1170 385

(xii) Neutral bushing CT detailNo. of cores LV1-one, LV2-oneService ProtectionRatio 100/1Acuracy class 5P 20Rated burden VA 15

(xiv) Guaranteed positive sequenceimpedonce at 750c with 100% HV-LV1 HV-LV2 LV1-LV2rating at principal tap 23% 23% 41%

3.6.4 INTER CONNECTING TRANSFORMER

(i) Make Crompton Greaves Ltd.(ii) Rating 167 x 3 = 500 mva(iii) No. 2

3 single phase transformer ineach set with one spare for both.400 200 33 kv(iv) Voltage Ratio ___ ___ ____3 3

(v) Current HV-723.1 AmpIV-1314.8 AmpLV-Reactive- 1681.8 AmpActive-151-.5 Amp

(vi) % age of impedance HV/IV 9.55%HV/LV 6.1%

(vii) Tap changer On load type having 17 stepsfrom + 10% to - 10% in the

3.7 H.T. MOTOR

S.No. Equipment Quantity Rating(i) ID fan 4 1400 kw unit 1 & 2

4 1325 kw unit 3 & 4(ii) FD fan 8 1000 kw(iii) PA fan 6 1050 kw(iv) GR fan 6 700 kw(v) Coal mill 24 425 kw(vi) CEP 8 550 kw(vii) BFP 12 3500 kw(viii) ECW pump 8 215 kw(ix) CW pump 8 900 kw(x) fire hydrant/sprinkler pump 4 175 kw(xi) Crusher motor 4 590 kw(xii) Conveyor 1 A/B 2 280 kw(xiii) Conveyor 2 A/B 2 240 kw(xiv) Conveyor 3 A/B 2 430 kw(xv) Conveyor 4 A/B 2 200 kw(xvi) Conveyor 5 A/B 2 250 kw(xviii) Conveyor 7 A/B 2 320 kw(xviii) Transport air compressor (AHP) 8 545 kw(xix) HP water pump (AHP) 6 320 kw

3.8 BATTERY AND BATTERY CHARGER

3.8.1 220 V D.C BATTERY

(i) Manufcaturer Exide(ii) No of battery bank in eah unit 2(iii) No of cells 109(iv) Cell designation As per IS 1651 T 8004(v) Normal voltage of each ell 2.0 volts(vi) Capacity 800 AH-10 hour(vii) Specilic gravity 1200 at 270c

7776

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