Technical Diary


JHAJJAR
3 x 500 MW TECHNICAL DIARY
INDIRA GANDHI SUPER THERMAL POWER PROJECT,

JHARLI, JHAJJAR
1
CONTENTS
Sl. No. DESCRIPTION PAGE NO.
1. MAIN BOILER
1.1 General Specification 01
1.2 Furnace Specification 02
1.3 Water Walls 03
1.4 Drum 04
1.5 Superheaters 05
1.6 Reheaters 05
1.7 Headers 06
1.8 Superheater and Attemperator 06
1.9 Reheater Emergency Temperature 07
Control Attemperator.
1.10 Economiser 07
1.11 Safety Valves 08
1.12 Predicted Performance 12
1.13. Recommended Chemical Control Limits 17
1.14 Recommended Boiler Water Silica Limits. 18
2. BOILER AUXILIARIES
2.1 Boiler Water Circulating Pumps 20
2.2 I. D. Fan 21
2.3 F. D. Fan 24
2.4 P. A. Fan 44
2.5 Scanner Air Fan 29
2.6 Air Heater 30
2.7 Steam Coil Air Preheaters 33
2.8 Seal Air Fan 33
2.9 Coal Mills 34
2.10 Raw Coal Feeder 37
2.11 Coal Burners 38
2.12. Oil Burners 38
2.13 Fuel Oil Ignitors 39
2.14 Fuel Oil Pump 40
2
2.15 HFO Steam Heat Exchanger 40
2.16 H. P. Dosing System. 41
2.17 Pressure Reducing and 41
Desuperheating Stations
2.18 Thermal Insulation 42
2.19 Soot Blower 42
2.20 Electrostatic Precipitator 44
2.21 Blow-off Valve (M/s. Yarway) 47
2.22 Cooling Water Requirements for 48
Boiler & Auxiliaries (DM Water)
2.23 Blow Down Vessels 51
3. TURBINE
3.1 Specification of Main Turbine 52 - 53
3.2 Limiting Values 54
3.3 Material of Construction 57
3.4 Lub. Oil System 59
3.5 Control Oil System 63
3.6 Turbine Oil Purifier System 65
3.7 Boiler Feed Pump and Auxiliaries 69
3.8 L.P. Heater Specification 77
3.9 H.P. Heater Specification 79
3.10 Deaerator 81
3.11 Gland Steam Condenser 82
3.12 Vacuum Raising System 83
3.13 Condensate Extraction Pump 85
3.14 Condenser 88
3.15 Condenser Tume Cleaning System 89
3.16 Circulating Water System 92
4. GENERATOR
4.1 General 95 - 96
4.2 Voltage Regulating System 97
4.3 Generator Protection 99
3
4.4 Seal Oil System 100
4.5 Gas System 102
4.6 Primary Water System 103
4.7 Waste Gas System 104
4.8 Excitation System 105
4.9 Cooler Data 107
4.10 Specifications of Transformers 112
5. WATER TREATMENT PLANT
5.1 Pretreatment Plant 117 - 118
5.2 Chemical Dosing System 119
5.3 D. M. Plant 120
6. COAL HANDING PLANT

6.1 Crusher House 125
6.2 Tripper 125
6.3 Silos 125
6.4 Track Hoppers 126
6.5 Conveyors 126
7. ASH HANDLING SYSTEM
7.1 Hoppers Specification 127 - 128
7.2 Pumps Specification 128
7.3 Ash handling Equipments Data 131
7.4 Booster Pump House Equipment Details 135\
7.5 Equipment of Silo Area 142
8. HEAVY FUEL OIL HANDLING SYSTEM
8.1 Unloading Header 144 - 145
8.2 Transfer Pump 145
8.3 HFO Storage Tank 145
8.4 Drain Tank 145
8.5 Drain Pump 146
4
8.6 Flash Tank 146

8.7 Vertical Sump Pump 146
8.8 Fuel Oil Characterstics 146
9. COMPRESSED AIR SYSTEM 147
10 EQUIPMENT COOLING WATER SYSTEM
10.1 ECW Pumps (D.M. Water) 151
10.2 Plate Type Heater Exchanger 152
10.3 Equipment Cooling Water Storage Tankk 152
10.4 Chemical Dosing System 152
10.5 ECW Booster Pump 153
11. DIESEL GENERATING SET

11.1 Manufacturer 154 - 155
11.2 Engine 155
11.3 Alternator 155
11.4 Impedance 156
12. PLANT COMMUNICATION SYSTEM

12.1 Public Address Sytem Devices & 175 - 58
Accessories.
12.2 Microphone 158
12.3 Receiver 158
12.4 Amplifers 158
12.5 Current Consumption 159
12.6 Rand set Control Box 159
13. FIRE FIGHTING SYSTEM
13.1 Sprinkler System 160 - 161
13.2 Jockay Pump 161
13.3 Hydrant System 161
13.4 Booster Pump in Hydrant Line 161
5
14. AIR CONDITIONING SYSTEM
14.1 Compressor 162 - 163
14.2 Condenser 163
14.3 Air Handling Systerm 164
14.4 Pumps 164
14.5 Cooling Towers. 165
14. 6 ESP A/C Equipments Data 166
15. INTERLOCKS & PROTECTION
A. BOILER & AUXILIARIES
1.0 Air Preheater 167 - 168
2.0 ID Fan 168
3.0 FD Fan 169
4.0 PA Fan 170
5.0 Scanner Fan 171
6.0 Seal air Fan 172
7.0 Pulverisers 173
8.0 C C Pump 179
9.0 MFT 179
10.0 Boiler 186
B. TURBINE & AUXILIARIES
1.0 Mechanical 189
2.1 Electrical 189
2.2 Extended Turbine Protection 189
2.3 Fire Protection 1 x 2 190
3.o Mot Level 191
4.0 C.E.P. 191
5.0 FRF Level 192
6.0 TD BFP 192
7.0 MD BFP 193
6
C. GENERATOR PROTECTION Recommended Relay
Setting 195 - 201
D. OFF SITE EQUIPMENT PROTECTION

1.0 C W Pumps 205
2.0 CT Pumps 206
3.0 ARW Pumps 206
4.0 ECW Pumps 206
16 . GRAPHS, CURVES & TABLES

1.0 Equipment wise Oil Reservoir Capacity ST-II 207
2.0 Equipment wise Oil Reservoir Capacity ST-II (WTP) 208
3.0 Turbine Startup Curves & Criteria 209
4.0 Generator Reactive Capability Curve 213
5.0 Generator Unloading Schedule 214
6.0 Steam Properties Table I,II.III.IV 216
7.0 Mollier Diagram 230
7
MAIN BOILER
&
AUXILIARIES
8
1.0 MAIN BOILER
1.1 General Specification

Manufacture-M/s BHEL (C.E. Design)
Type - Balanced Draft, Dry bottom, Single drum Controlled
Circulation plus.
Type of FIRING - Tilting TANGENTIAL
Minimum load at which steam generator can be - 2 adjacent,

Millsoperated continuously with complete flame, at 50% capacity.
stability without oil support (& MCR)
Minimum load at which the steam generator can

be operated continuously with complete flame - 20%
stability with oil support (% MCR)
Maximum load for which individual mill beyond- 50%

wich no oil support is required
1.2 Furnace Specification

Type - Controlled Circulation
Wall - Water Steam cooled
Bottom - Dry
Draft - Balanced
Tube arrangement - Membrane
Explosion/Implosion
Withstand capacity at 67%
Yield point - +/- 660 mm/wc
Residence time for fuel particles
in the furnace - 3 second
Effective volume used to calculate
the residence time (M3) - 14790
Height from furnace bottom ash
hopper to furnace roof (M) - 62. 735
Depth (M) - 15.289
Width (M) - 18.034
Furnace projected area (M2) - 7610
Frnace volume (M3) - 14790
9
1.3 Water Walls
Front walls
Number - 299
OD (MM) - 51.00
Design thickness (MM) - 5.19
Pitch (MM) - 63.5
Actual thickness used (MM) - 5.6
Material - SA 210C
2
Total projected surface (M ) - 1160
Method of joining long tube - Butt weld
Total wt. of tubes (Kgs) - 181000
Design pr. of tubes Kg/cm2 (ABS) - 207.3
Max. pressure of tubes Kg/ cm2 (ABS) - 197.3
Design metal temp oc
Side walls, Rear walls & Roof

Side walls Rear walls Roof
Number 444 283 142

OD (MM) 51 51 57
Design thickness (MM) 5.19 5.19 5.54
Pitch (MM) 63.5 63.5 127
Actual thickness used (MM) 5.6 5.6 5.7
Total projected surface area of 1430 930 220
Tubes (M )2
Method of joining long tube ------ BUTT WELD --------
Total wt. of tubes (Kgs) 277000 186000 45000
2
Design Pr. of tubes Kgs/ cm (ABS) 207.3 207.3 204.9
2
Max pr. of tubes Kgs/cm (ABS) 197.3 197.3 192.3
Design metal Temp c o 417 417 416
Water wall Headers
Lower Headr Outlet Header

No. of headers 4 5
Outside Dia (MM) 914.4 273
Design thickness (MM) 89 38.5
Actual thickness (MM) 89 45
10
Total wt. of headers (Kgs.) 199000 37300
Design pressure of headers 207.3 204.9
2
Kg/cm (ABS)
Max working pressure of headers 197.3 192.4
Kg/Cm2 (ABS)
Material specification SA-299 SA-106 Gr-B
1.4 Drum
Material specification SA - 299
Design pressure Kg/cm2 (ABS) 209 KSC
Design metal temp 368OC
Max operating pressure Kg/cm2 (ABS) 192.4
Actual thickness used for dished
ends (MM) 152.4
Overall Lenght of Drum (MM) 22070
OD of Drum (MM) 2130
Internal dia (MM) 1778
Thickness Minimum 185
Corrosion allowance (MM) 0.75
Number of distribution headers 6
No. of Cyclone separator 96
No. of Secondary driers 96
Shroud material Carbon Steel
Max permissible temp. differential 50
between any two parts of the drum
(0C)
Water capacity at MCR conditions 10
(in seconds) between normal and
lowest water level permitted up to LL trip
Drum wt. with internels (tonnes) 246
Drum wt. without internels (tonnes) 224
11
1.5 Super Heaters LTSH pendant Panel- 1
Platen
Horizontal Stage-II Stage-III
Stage - IType Convection Radiant
Radiant
Platen (Drainable/Non- ------ Non --- Non----
drainable)
drainable drainable
Pendant (drainable/Non-) Drainable ------ -----
drainable)
Horizontal LTSH (--do--) <----------- drainable ----------->
Effective heating surface 5903/ 1350/ 1465/
2
area (M )/ modified 12500 1660 1730
Total circumferential heating 5703 ------ -----
surface area (M2)
Gas flow path area (M2) 147 ---- 286
Max steam side metal temp 408 509 575
0
( C)
Max gas side metal temp 450 570 690
0
( C)
Type of flow (counter of Counter Parallel Parallel
Parallel)
Matl of tube support ss ss ss
OD (MM) 51.00 44.5 54.00
Total Number of Tubes 708 444 408
Tube pitch (MM)
a) Parallel to gas flow 101.6 54.00 63.5
b) Across gas flow 152.4 254.00 762
Method of Joining long tube <--------- Butt weld ------------>
Total wt. of tubes (T)/modified <--------1130/919 --------------->
1.6 Reheaters
State-I Stage -II
RH Radiant Pendant Reheater
Total circumferential/Modified 275/ (proj.) 6600/

6139
Heating surface (M2) 219
Max operating pressure 47.68 47.00
(Kg./cm2)
12
Design pressure Kg/cm2 (ABS) 53.73 53.73`
Max steam side metal temp 0C 370 557
Max gas side metal temp 0C 430 620
OD (MM) 63 63.5
Mean effective length (Per 17500 28750
one tube) MM (approx.)
Gross length (per one tube) 18300 39750
MM (approx.)
Total number of tubes/ modified 248/392 644/736
Total Wt. (Kgs.)/Modified 440000 415000
Method of Jointing long tube <------- Butt weld ------>
1.7 Headers
Superheater Reheater
Max. Operating pressure Kg/Cm2 192.3 47.68
(ABS)
Design pressure (Kg/cm2) (ABS) 204.9 53.73
Location (outside/inside gas out side Out side
path)
Total Wt. (Kgs.) 218200 61500
1.8 Superheater Attemperator
Type - Spray
Stage - One
Position in steam circuit - Between Lt pendants and SH.panels
Specification of Mat. - SA335 P12
Super heater steam temp
Range that can be maintanied - 540
between 54.43% to
100% of Boiler MCR 'C"
Spray tube material - SA-213 T11
Max spray water flow rate - 101000 a MCR with HP heaters out
and corresponding steam
output (Kgs./hr.)
Min spray water rate and - Nil at MCR
corresponding steam steam
out put Kg/hr
13
6
1.9 Reheat Emergency temp. control attemperator
Type Spray
No. of stages of attemperator - One
Position in the steam circuit - Cold reheat lines
Specification of the Material - SA - 106 Gr - B
Spray nozzle Material - SA- 213T & SS Tips
1.10 Economiser
Type - Non Steaming

Heating Surface 19000 Sq.m
Gas flow path area (M2) - 128
Design pressure of tubes - 209.8
Kg/Cm2
OD of Tubes (MM) - 51.00
Actual thickness tubes (MM) - 5.6
Lengh of Tubes (MM) (approx.) - 2,15,000/245100
Pitch (MM) - 101.6
>Total Wt. of Tubes (Kg.) - 4,82,200
Headers
Lenght (MM) - 18.000

2
Design Pt. (Kg/Cm ) (abs) - 209.8
2
Max Working Pressure (Kg/Cm ) - 196
(abs)
14
1.11 SAFETY VALVES
Location Valve Name and Value set Reset Pr. %

of Blow down Relievieng
Tag No. make prkg/cm2(G) kg/cm2(G) n
1. B1 Consol 204.00 195.8 4

1750 WB
2. B2 Consol 206.00 195.8 5
1750 WB
BOILER 3. B3 Consol 208.1 197.7 5
DRUM 1740 WB
4. B4 Console 208.1 197.7 5
1740 WB
5. B5 Consol 210.1 199.6 5
1740 WB
6. B6 Consol 210.1 199.6 5
1740 WB
SUPER 7. S129 Consol 187.0 181.3 3

HEATER 1740 WB
8. S130 Consol 187.0 181.3 3
1740 WB
Location S. No. Valve Name and Value set Reset Pr. %

of Blow Relievieng
Tag No. make prkg/cm2(G) kg/cm2(G)
Down Capacity
9. s132 Consol 185.1 181.39 2

1538 VX
ERV ON 10. S138 Consol 185.1 181.39 2
SUPER 1538 VX
HEATER 11. S162 Consol 185.1 181.39 2
12. S168 Consol 185.1 181.39 2
1538 VX
15
SAFETY VALVES

of Blow Relievieng
Down Capacity
(Close)
13. R1 Consol 54.84 53.2 3

1786 WB
14. R2 Consol 55.39 53.73 3
REHEATER 1786 WB
INLET 15. R3 Consol 55.94 54.26 3
1786 WB
16. R4 Consol 56.45 54.8 3
1786 Wb
17. R19 Consol 49.00 47.58 3

1786 WD
REHEATER 18. R20 Consol 49.50
48.05 3 162496
OUTLET 1786 WD
19. R21 Consol 50.00 48.53 3
1786 WD
20. R22 Consol 50.00 48.53 3
1785 WD
of Blow Relievieng
Down Capacity
(Close)
21. R130 Consol 48.07 45.15 4

1533 VX
ERV ON 22. R132 Consol 48.07 46.15 4
RH 1533 VX
16
OUTLET 23. R118 Consol 48.55 46.60 4
1525 VX
24. R124 Consol 48.55 46.60 4
1525 VX
17
1.12 PREDICTED PERFORMANCE
1.12.1 FLOW
HP Heaters in HP
Description Unit ----------------------- Heaters
MCR 88.72% 70.84% 53.59% out
MCR MCR MCR NCR
Steam
Superheater Outlet t/h 1725 530.4 1221.9 924.5 1566

Reheater Outlet t/h 1530 373.5 1106.1 845.0 1536.5
Water
Feed Water t/h 1725 1507.9 1181.1 179.1 1434.5

SH Spray t/h 0 22.5 40.8 45.4 131.5
Air
Airheater Out let (Primary) t/h 422.9 393.7 341.1 281.8 505.0
Tempering Air t/h 157.3 163.4 119.5 82.7 84.2
Airheater Outlet (Secon- t/h 1456.6 1252.6 1078.7 923.2
1534.4
dary)
Total Combustion Air t/h 2089.0 1861.9 1591.5 1340.0
2175.6
(Including furnace leak)
Fuel
Coal (HHV=3500 kcal/kg) t/h 367.0 327 266.3 206.2 382.1
Gas
AH (Outlet Primary) t/h 659.2 622.0 542.4 432.6 737.7

AH (Outlet Secondary) t/h 1883.6 1583.8 1355.7 1189.3 1821.5
18
1.12.2 TEMPERATURES
HP Heaters in HP
MCR 88.72% 70.84% 53.59% out
MCR MCR MCR NCR
Steam
Sat Temp. in Drum oCC 361 359 356 354 360

L.T.S.H. Outlet 0C 406 408 410 412 436
SH Panel Inlet 0C 406 400 394 389 393
SH Panel Outlet 0C 474 472 468 466 463
SH Finish Outlet 0C 540 540 540 540 540
RH Inlet 0C 344 343 335 327 344
RH Outlet 0C 540 540 540 540 540
Water
Economiser Inlet 0C 256 253 243 229 174

Economiser Outlet 0C 307 304 297 290 266
Air
Ambient 0C 25 25 25 25 25
AH Outlet (Primary) 0C 354 343 325 304 314
AH Outlet (Secondary) 0C 325 319 303 288 288
Gas
SH Platen Inlet 0C 1116 1091 1037 972 1126

RH Front Inlet OC 1017 990 939 881 1027
RH Rear Inlet 0C 900 873 827 776 910
LTSH Inlet 0C 730 705 666 626 740
Economiser Inlet 0C 546 529 506 482 553
Air heater Inlet 0C 378 366 346 325 340Air heater Outlet
0C 139 135 123 117 122
(Corrected)
19
1.12.3 PRESSURES (STEAM & WATER)
HP Heaters in
Description Unit ----------------------- HP Heaters
MCR 88.72% 70.84% 53.59% out
MCR MCR MCR NCR
Pressure
Superheater Outlet kg/cm2 178 176.08 173.5 171.6 176.4
LTSH Outlet kg/cm2 188.3 184.4 178.9 174.9 185.0
Drum kg/cm2 193.4 188.4 181.6 176.4 189.3
Economiser Inlet kg/cm2 197.2 191.9 184.6 179.1 192.9
Reheater Outlet kg/cm2 43.46 41.05 32.93 24.99 46.60
Reheater Inlet kg/cm2 45.85 43.20 34.66 26.31 49.00
Pressure Drop
Superheater System kg/cm2 15.4 12.3 8.1 4.80 12.9
Reheater kg/cm2 2.39 2.15 1.73 1.32 2.40
Economiser kg/cm2 1.60 1.30 0.80 0.50 1.4
Excluding static head
1.12.4 PRESSURES (DRAFTS (AIR&GAS)

Primary Air
P.A. Fan Inlet MMWC -7 -7 -6 -4 -8
P.A. Fan Putlet MMWC 749 687 658 636 771
Airheater Inlet MMWC 737 676 651 631 758
Airheater Outlet MMWC 715 657 635 621 730
Mill Inlet MMWC 686 631 613 600 700
Mill Outlet MMWC 314 285 276 269 321
Secondary Air
FD Fan Inlet MMWC -16 -12 -7 -6 -18
FD Fan Outlet MMWC 263 212 163 149 270
SCAPH Inlet MMWC 254 205 159 146 260
SCAPH Outlet MMWC 241 195 153 141 245
Airheater Inlet MMWC 235 192 151 140 239
Airheater Outlet MMWC 181 156 122 120 189
Windbox pressure MMWC 101 101 101 101 101
Windbox Furnace.Diff MMWC 140 140 140 140 140
20
HP Heaters in HP
MCR 88.72% 70.84% 53.59% out
MCR MCR MCR NCR
Gas
Furnace MMWC
Superheater Platen Inlet MMWC -4 -4 -4 -4 -4
RH Inlet MMWC -5 -5 -5 -5 -5
LTSH Inlet MMWC -19 -17 -15 -12 -19
Economiser Inlet MMWC -39 -31 -26 -20 -41
Airheater Inlet MMWC -76 -63 -46 -33 -80
E.P. Inlet MMWC -235 -180 -156 -126 -240
ID Fan Inlet MMWC -285 -236 -190 -152 -292
ID Fan Outlet MMWC +26 +21 +14 +9 +28
1.12.5 FUEL
The fuel data on which the guarantees given are as follows :
Description Unit
Fuel Design Coal
Proximate Analysis
Fixed Carbon % 25.00
Volatile Matter % 19.00
Moisture % 12.00
Ash % 44.00
Grindability Index HGI 58
Higher Heating Value kcal/kg 3500
Size of coal to mill mm 25
21
1.12.6 MILL AND BURNER PERFORMANCE
HP Heaters in
Description Unit --------------------------------- HP Heaters
MCR 88.72% 70.84% 53.59% out
MCR MCR MCR NCR
No. of mills in operation- 6 6 5 4 6

Mill loading % 86.9 77.4 75.6 73.21 90.0
Air flow per mill t/h 96.8 92.8 92.1 91.1 98.2
Air temp. at mill Inlet 0C 268 253 249 245 275
Mill Outlet temperature 0C 77 77 77 77 77
Fineness% thro 200 mesh - 70 70 70 70 70
Burner Tilt Deg 0 +10 +25 +25 0
1.12.7 02, Co2 (DRY VOL) AND EXCESS AIR

Oxygen in gas at
Economiser Outlet % 3.6 3.6 3.6 4.9 3.6
Carbon-di-oxide % 15.7 15.7 15.7 14.2 15.7
in gas at Economiser
Outlet
Excess air in % 20 20 20 30 20
gas at Economiser
Outlet
1.12.8 HEAT BALANCE
Losses
Dry Gas % 4.86 4.77 4.35 3.96 3.89
H20 and H2 in fuel % 5.95 5.95 5.89 5.74 5.79
H20 in air % 0.11 0.11 0.10 0.09 0.10
Unburnt Carbon % 1.50 1.50 1.50 1.50 1.50
Radiation % 0.17 0.19 0.24 0.34 0.19
Unaccounted % 0.50 0.50 0.50 0.50 0.50
Manufacturer's % 0.50 0.50 0.50 0.50 0.50
Total Losses % 13.59 13.51 13.08 12.63 12.47
Heat Credits % 0.19 0.20 0.21 0.19 0.19
EFFICIENCY% 86.60 86.69 87.13 87.56 87.72
22
1.13 CHEMICAL CONTROL LIMITS (WATER/STEAM CYCLE)
Parameters 200 Mw (Stage I) 500MW (Stage II)

Cond. Feed Boiler Steam Cond. Feed
Boiler Steam
pH at 250C 8.8- 8.8- 92- 8.8- 9.0- 9.0 9.1 9.0
9.0 9.0 9.4 9.0 9.2 9.2 9.4 9.2
Sp. 30.0 20.0

Conductivity
us/cm
Cation Cond. <0.3 <0.3 <0.3 <0.2 <0.2 <0.2

US/ CM
Res. Hydrazine .010- .010-

as N2 H4, PPm 020 020
Ammoma as 0.5 0.5 1.0 1.0

NH3 PPM (Max) (Max) (Max) (Max)
Phosphate as 2-4 1-2

PO4 ppm
Silica as Si02 <.02 <.02 0.3 <0.2 <0.1 <0.1 <0.0.1 <.01
ppm Max.
Total Iron as Fe 010 010 010 010 010 010

ppm Max.
Total copper as .005 .005 .005 .003 .003 .003

Cu ppm
Chloride as CI 1.0 0.5

ppm Max.
D.O as 02 .040 .005 .040 .005

ppm Max.
Sodium as Na 005 .005

ppm Max.
TDS (mg/i) 15 10 PPM
23
Parameters StageI StageII
W/O Alkaliser With Alkaliser
GENERATOR STATOR COOLING
WATER
pH at 250C 6.8-7.0 (6.5-7.0) 6.8-7.0 8.5-9.0

(Lab)
Cond. at 250C 5 <10 <2.2

us/cm
D.O. (mg/!) >1.0 <0.1 <0.1
GENERATOR SYSTEM
Hydrogen Purity >97.0 >97.0

(%)
Dew Point (0C) at <21.0 (3.0kg/cm2) <24.0(4.0kg/cm2)

frame pressure
ECW pH at 250 C
(Controlled by) 9.0-9.5
dosing Caustic
Solution)
24
1.14 RECOMMENDED LIMIT OF SILICA IN BOILER WATER AT pH
9.5 AT
DIFFERENT OPERATING PRESSURE TO LIMIT SILICA 0.02
PPM IN STEAM
DRUM SiO2 ppm DRUM SiO2 ppm

PRESSURE PRESSURE
60 8.2 150 0.40

80 3.8 155 0.37
100 1.9 160 0.30
120 0.9
165 0.27- For Stage I
130 0.7 170 0.25
140 0.52 175 0.22
145 0.48 180 0.18 - For Stage II
25
BOILER
AUXILIARIES
26
2.0 BOILER AUXILIARIES
2.1 BOILER WATER CIRCULATING PUMP
Number off : 3 Nos. (2+1)

Electrical Supply : 3.3kiloVolts - 3 phase - 50 Hz.
Characteristics
Type : Single suction-Double Discharge
Design pressure : 207.55 Kg/cm2
Design temp : 366.20C
Normal 0perating Duty
Suction pressure : 193.27 kg/cm2

Suction temp. : 348.90C
Specific gravity at pump suction
at pumping temp. : 0.5993
Qty. pumped : 47994.2 lit/min
Differential head : 28.65 M
Differential pressure : 1.708 Kg/cm2
Minimum NPSH required above
Vapour Pressure : 16.15 M
Pump efficiency : 84% Hot Duty - 84% Cold Duty
BHP absorbed : 215 Hot duty-358 Cold test.
Motor Characteristics
Type : Wet Stator-Squirrel Cage-Induction

Output : 400 H.P.
Service factor : 1.0
winding insulation : XLPE
Motor case design temp. : 343.340C
: Hot duty Cold Duty
Motor efficiency : 85% 88.5%

K.W. Input : 187 302
Power factor : 0.7 0.805
27
Overall efficiency : 72.2% 74.3%
Full load speed : 1450 RPM
Line current@ 6.6 KV : 23.3 amp 32.8 amp
Full load current : 36 amps
Motor starting current : 190 amps
Heat Exchanger
: Hot Duty
H.P Inlet temp (max) : 550C
Allowable pr. drop : 0.7 kg/cm2
Heat transfer - hot duty : 28980 kcal/hr.
Heat transfer - cold duty : 30240 kcal/hr.
H.P. cooling water flow : 200.62 lit/min
Weight (Approximate)
Pump case : 3541.2 kgs
Motor complete : 9534 kgs
Total weight : 13075.2 kgs
2.2 I.D. FAN

Type : Radial fan double suction NDZV 45
SIDOR
Make : BHEL
Orientation : Suction at 450 Delivery at Bottom
Horizontal
Medium handled : Flue Gas
Location : Ground level
No. per Boiler : 2+1 standby
Fan Design Rating

Capacity : 533.8 M3/sec
Total head developed : 409 MMWC
Temp. of medium : 1500C
Sp. wt. of medium : 0.796 kg/m3
Speed : 550 rpm
28
Margin
Fan flow : 20%
Fan pressure : 44%
Fan drive coupling

Type of fan coupling : Hydraulic
Make : M/s Voith, West Germany
Fan Weight : 100 tonnes
Lubrication
Fan lubrication : Stand oil lubrication
Motor lubrication : Stand oil lubrication
Type of fan regulation : Variable speed through Hydraulic
coupling plus damper control.
Bearings
Fixed bearing : Dodge sleeve oil RT - 20 size - 9''
Expansion bearing : Dodge sleeve oil RT-20 size-9''
I.D FAN MOTOR

Manufacturer : BHEL
Type : Synchronous
Rating : 3600 KW
P.F 0.85 lead
Speed 530 RPM
Stator Volt 2x2.3 kV
Excitation voltage 96.6 V
Connection Double Star
Stator Current 2x553 Amps
Excitation current 325 Amps
Insulation Class F
Brushless Excitor:
Manufacturer BHEL
Rating 30 KW
Xcitation current 61 Amps AC
Xcitation Voltage 330 Volts AC
29
Connection Star
DC Side (Output of motor)

Voltage 97 volts
Current 325 Amps(DC)
Speed 550 RPM
Frequency 97.8 Hz
Direction of rotation as viewed

from driving end : Clockwise
Derated rating for specified : 3400 kw
0
Water inlet temp. of 38 C
30
Permissible variation of
a) Voltage (volts) : +/-10%
b) Frequency (Hz) : 50 Hz +/- 5%
c) Combined voltage and frequency : +/-10%
Minimum permissible starting

Voltage : 80% Rated
Rated speed : 596 rpm
At rated voltage and frequency

a) Full load current : 379 A
b) No. load current : 139 A
Starting time with minimum premissible voltage of 80% of rated

a) Without fan : 1.7 second
b) with fan : 2.5 second
Bearings
Type : I) Drive end : Sleeve air cooled
II) Non drive end : Sleeve ring
Recommended Lubricant : IOC Gr. servo prime-46 or
equivalent
Quantity of Oil flow : 52 lit/min. per motor
Cooling water requirement for CACW motor

a) Quantity required M3/hr : 20.6 per motor
b) Max. permissible inlet water
temp : 380C
c) Pressure of water at inlet
to coolers : Upto 7.5 bars
d) Outlet temp. of water at
full load (anticipated) : 430C
Combined wt. of motor of stator : 100800 kgs.

and rotor
31
2.3. F.D. FAN
Type : Axial reaction API-26/16
No. per Boiler : Two
Fan design rating

Medium Handled : Fresh air
Total Head Developed : 378 MMWC
Temp. of medium : 500C
Specific wt. of medium : 1.046 kg/m3
Fan speed : 980 rpm
Type of coupling : Flexible
Fan wt. : 25.84 tonnes
Fan efficiency at 100% MCR : 81%
Lubrication equipment
Fan lubrication : Forced oil circulation
Motor lubrication : Grease lubricated
Type of fan regulation : Blade pitch control
Bearings
Fixed bearings : Cyl. Roller Brg NU 248 C3, Ang.
contact Ball Bearing 7248 B
Expansion bearings : Cyl-Roller Brg. NU 248C3
Design Margin
Fan Flow : 20%
Fan Pressure : 44%
32
F. D. FAN MOTOR
Manufacturer : M/s SIEMENS/BHEL
Motor type : SQ motor
from Non driving end : CCW
Standard conditions rating at
400C ambient temp : 1670 kw
Derated Rating for specified
normal condition i.e. 500C : 1400 kw
Rated voltage : 6600 V
a) Voltage (volts) : +\- 10%
b) Frequency (Hz) : 50 Hz +/- 5%
c) Combined voltage and frequency : +/- 10%

Voltage : 80%

b) No load current : 42.5 A
Starting time with Minimum permissible

voltage of 80% of rated
a) Without driven equipment
coupled : 2 Second
b) With driven equipment : 18 second
coupled Bearings
Drive end Non Drive end
Typ: Ny 232 6232-C4 Nu 228
Recommended lubricant - Grease-Servo gem 3 of IOC

Wt. of Stator : 6800 Kg. (approx.)
Wt. of rotor : 2200 kg.
33
2.4 P.A : FAN
Type : Axial reaction AP-2-20/12
Orientation : Horizontal
Medium Handled : Fresh Air
No. per Boiler : 2
Fan design rating

Total head developed : 1158 mmwc
Temp. of medium : 500c
Speed at design point : 1480 rpm
Fan Margin
Fan flow : 35.5%
Fan pressure : 30%
Fan drive coupling

Type of fan coupling : Thyssen form 13 size 2501
Fan weight : 17.5 tonnes
Lubricating equipment
Fan Lubrication : Forced Oil circulation
Motor Lubrication : Gresse
Type of Fan Regulation : Blade Pitch Control
Bearings
Fixed Bearing : Cyl roller Brg.Nu 236 C3 Ang
contact Ball bearing 7040
Expansion bearing : Cyl roller Brg Nu 236 E
P.A. FAN MOTOR

Manufacturer : M/s SIEMENS/BHEL
Motor type : SQ motor
from non driving end : CCW
Standard Continuous rating at
400C ambient temp. : 2500 KW
Rated voltage : 6600
Derated rating for specified normalcondition i.e., 500c
Ambient temp. : 2100 KW
34
a) Voltage : +\-10%
b) Frequency : 50 Hz +/- 5%

Voltage : 80%

b) No load current : 15.5 A
Starting time with minimum

Permissible volatage or 80% or rated
value :
a) Without fan : 1.5 sec
b) With fan : 13 sec
For Bearings Drive end Non-drive end

Type : NU-232 NU 228
6232 C4
Weight of
Motor stator (kg) : 7500 kg
Motor rotor (kg) : 2100 kg
recommended lubricant-Grease-Servogem 3 of IOC
Lub oil circulation system of P. A. fan

Tank capacity : 400 litres
Type of motor : A - 112-MA-4F
Output rating (motor) : 5.5 kw
Supply (motor) : 415 V+/- 10% 3 Ph, Delta-
connection
Full load speed : 1425 rpm
Frequency : 50 Hz +/- 5%
Pump
Make : BORNEMANN
TYPE AND CAPACITY : E4V 045 KIF 215/1 363 dm3/s
Speed : 1450 rpm
Discharge pressure : 16 bar
35
MAKE
Main tube heat exchanger : HALBERG
Double Switch filter : INTERNORMEN.
Pressure relief valve : KRACHT
Oil level Gauge : FLUTEC
Oil Tank Level Switch : Magnet Rol
Oil Header : SCHNIEWINDT
Hydraulic Accumulator : Integral Hydraulic
Flow Switch : ER HARD - Flotect
Fine throttle : Rexroth
Lube Oil properties
Quality : L - TD 68
Pour point : 60C or lower
Flash point : min 2050C
Water content : Less than 0.lg/100 lit. of oil
Contents/solid foreign matter : Less than 0.05 gm/100 lit.of oil
Viscosity at +400C : 61.2-74.8 mm2/s
36
2.5 SCANNER AIR FAN Nos. : 2
One is A.C driven
Other is D.C.driven 100% standby
Boosting pressure : 254 mmwc
Design capacity of each : 3600 m3/hr
Design temp. : 500C
Motor rating : 7.5 HP - 2 Pole
Speed : 2900 rpm
Type : Radial Back ward Curved
Blade Single Suction
Medium to be handled : Dust laden air
Max. Dust concentration : 300 mg/M3
Air Qty. : 1.30 m3/s
Air density considered at 200C : 1.2 kg/M3
Air density at operating : 1.09 kg/M3
condition
Static pressure developed at
air density of 1.2 kg/M3 and
at 200C. : 285 MMWC.
Static pressure developed at air : 280 MMWC
density of 1.09 Kg/m3 and at
200C
Power Consumption at fan shaft
at air density of 1.2 kg/M3
and at 200C : 6.4 HP.
Power Consumption at fan shaft at
air density of 1. 09kg/M2& at 200C : 5.78 HP.
Direction of rotation of
impeller when viewed from drive end : Clockwise.
Discharge Angle : Vertically upward.
37
2.6 AIR HEATER
PRIMARY AIR HEATER
Type : Ljungstrom Bisector
Air Heater Size : 27 VI (M) 80''
Rotor Drive Motor : 11 kw GEC, 1500 RPM, 415 V, 3 phase
50 Hz.
Speed Reducer : 5, APC (FALK) 110:1
Approx. oil Capacity : 50 Litres
Coupling : 11.5 FCU (Fluid Coupling)
Bushings : Taper lock Bush & Adapter
No. per Boiler : 2
Filter Lubricator : Valjan 1 '' BSP
AUXILIARY DRIVE
Air Motor : R.S.M. 400 (APCO) 1''x NPT CHICACO
Pneumatic Air Motor.
Coupling : Bibby Coupling 124 - A
Rotor Support Bearing : SKF Spherical Roller thrust Bearing SKF
- 294/500
Rotor Guide Brg. : 23060 Spherical Roller
RTD : RTD Thermo Electric Co.
Oil Capacity of support brg housing : 150 litres
Oil Capacity or guide brg housing : 20 litres
OIL CIRCULATING SYSTEM (SUPPORT BRG.)

Motor (TEFC) : 0.75 kw, 1400 RPM, Frame, 90 flange,
415 V,
50 Hz, 3 phase foot mounted
Pump : Delaval - 1'' x 1'' NPT (APCO )
Filter : John Fowler 1'' BSP
Cooler : Universal Heat Exchanger
Coupling : Lovejoy L – 095
38
OIL CIRCULATING SYSTEM (GUIDE BRG)
Motor (TEFC) : 0.55 kw, 905 RPM, 80 GEC. 415 V 50 Hz, 3

phase GEC.
Pump : Delaval - 1'' x 1'' MPT
Filter : John Fowler 1'' BSP
Cooler : Universal Heat Exchanger
Coupling : Lovejoy L - 095
CLEANING DEVICES
Motor (TEFC) : 0.18 kw, 1380 RPM, GEC - 71,
415 V 50 Hz, 3 phase
Reducer All Royed 4200:1
Coupling : Lovejoy Flexible Coupling L-075 & L-110
SECONDARY AIR HEATER

Nos. per Boiler : Two
Heater size : 30.5 VI (M) 62'' (68'')
ROTOR DRIVE
Motor TEFC : 15 KW, GEC, 180 M 1500 RPM, 415 V, 3
PHASE,
50 HZ, 29.54 A (FL)
Speed Reducer : 7 AP, FALK 130.36:1
Oil Capacity : 98 Litres ( approx)
Couplings : 11.5 FCU (Fluid coupling)
Bushings : Worthingdon Hub
Filter Lubricator : Valjan 1'' BSP
AUXILIARY DRIVE
Air Motor : R.S.M. 270 (APCO) Chicaco Pneaumatic Air
Motor
Coupling : Bibby Coupling - 124 C
Rotor Support brg. : 294/710 Spherical roller thurst brg.
Rotor Guide Brg. : Spherical Roller bearing SKF 230
RTD : 1'' HPT Netherland Thermo Electro
39
Oil capacity of support brg housing : 250 litres
Oil capacity of Guide brg. housing : 25 litres.
OIL CIRCULATING SYSTEM (SUPPORT BRG.)

Motor TEFC : 0.75 KW, 80 GEC, 1400 RPM, 415 V, 50 Hz, 3 Ph
Pump : DELAVAL (APCO) 1'' X 1'' BSP
Filter : John Fowler 1''x1'' BSP
Cooler : Universal Heat Exchanger 1'' X 1'' Flange Coil
Coupling : Lovejoy, L-095
OIL CIRCULATION SYSTEM (GUIDE BRG)

Motor TEFC : 0.55 KW, 80 GEC, 905 RPM, 415 V, 50 HZ, 3 Ph
Pump : DELAVAL (APCO) 1'' x 1'' NPT
Filter : JOHN FOWLER 1'' x 1'' BSP
Cooler : Universal Heat EXchanger Flange - con 1'' X 1''
Coupling : Love joy L-095
CLEANING DEVICES
Motor TEFC : 0.18 KW, NGEF, 750 RPM,
Reducer : All Royed 4200:1
Coupling : Love Joy - L - 075 & L - 110
40
2.7 STEAM COAL AIR PREHEATER
PRIMARY SECONDARY
1. Design pr (Kg/cm2) 15 15
2. Hyd Test pr (Kg/cm ) 2 30 30
3. 0
Design temp ( c) 200 200
4. Wt. of steam coil air 1340 3340
preheater (kg)
5. Supplier's Name M/s Doctor & Co. M/s. Doctor & Co.
Pvt. Ltd. Pvt. Ltd.
6. No. of steam coil air Two Two
preheater per boiler.
7. Size of steam coil air 4318x2590x200 560x3334x225
preheater (mms)
8. Installed Operation Horizontal Horizontal
2.8 SEAL AIR FAN

Manufacturer : BHEL
Type : Centrifugal fan NDM-11 motor
mounted.
No. of Fans per Boiler : 2
Location : Ground Level
Arrangement : Horizontal Shaft
Fan Weight : 1365 kgs.
Capacity : 6.38 M3/Sec.

Density of Medium : 1.09 Kg/M3
total head developed : 508 MMWC
Speed : 1475 RPM
Drive Motor :
Make : HBB or Equivalent
Frame : 280
Rating : 55 kw
Type : Squirrel cage Induction.
Motor TEFC.
41
2.9 COAL MILL
BOWL MILL
Type of Pulveriser :
1003 XRP
No. of Mills/Boiler :
9
No. required for full load: 6
Base capacity of Mill :
70 Tonnes/hr for a Pulverised
Fuel fines 70% through 200 mesh
with a raw coal of grindability.
Index 55 HGI and a total
moisture of not more than 8%.
Mill motor : M/s. BHEL, 525 KW, 6.6 kv, 600
RPM
Coupling a. Type : Gear type flexible coupling with
spacer assembly between mill &
Motor.
b. Supplier : M/s FAST'S U.S.A.
Bearings : Antifriction bearings for main

vertical shaft assembly journals
shaft assembly and worm shaft
assembly.
Cooling System : Immersed in oil bath
No. of Oil Coolers/Mill : Two
Cooling water requirement for oil : Clean colourless, and
ammonia
Coolers. contamination free cooling water
of Qty given below for the
respective temp.
Temp. C0 : 210C 320c 410c
Qty. Litres/Min. 106 140 170
Maximum pressure : 10 kg/cm 2
42
Wear Surface : Griding rolls, bullring segment
and liners made of High Quality
Ni hard (Comb alloy-N) casting,
Venturi vanes and classified
Cone inner surface are lined
with ceramic liners.
Life of rolls/grinding rings : 4000/8000
Speed pulveriser (RPM) : 42
Normal capacity with design coal : (T/hr) 61.00
Speed of pulveriser (RPM) : (T/hr) 70.00
Normal capacity with design coal : (T/hr) 51.00
Max capacity with worst coal : (T/hr) 57.00
Max crushed coal size the mill can : (MM) 30.00
accept (mm)
43
BOWL MILL MOTOR
Manufacturer : M/s Siemens West Germany/BHEL

Bhopal.
Motor Type : SQ - Motor
Standard continuous rating at 400C : 560 kw
ambient temperature as per Indian
Standard
Derated rating for specified normal : 525 kw
0
condition i.e. 50 c ambient temp.
Rated voltage : 6600 Volts
a. Voltage (Volts) : +/- 10%
b. Frequency (Hz) : 50 +/- - 5%
c. Combined Voltage & Frequency : +/- 10%
Minimum permissile starting voltage : 90% rated

Rated speed : 590 RPM
Starting time with minimum permissible : Without driven : 2
Sec.
Voltage of 90% or rated voltage with driven : 3.9 Sec.
At Rated voltage and frequency

a. Full load Current : 66A
B. No load Current : 33 A
FOR BEARINGS
DRIVE END NON DRIVE END
a. Type : NU -230 6230 C3 NU - 226
B. Recommended lubricant : Grease - Servo Gem 30 F IOC
Wt. of Motor Stator : 5700 Kgs
Wt. of Motor Rotor. : 2000 Kgs
44
2.10 RAW COAL FEEDER
Type : SECO - 36'' Gravimatric (with

Mechanical Weighing)
Capacity : Minimum - 11350 Kg/hr.
Maximum - 87820 Kg/hr
Supplier : SECO. U.S.A.
Nuclear Monitor : 2 in No. (Upper and Lower)
Quantity Required : 18 RH
Density of material to be handled
Kg/m3 : 720 to 1280
Drive Motor (KW) : 5.6
Clean out motor (KW) : 0.22
Power supply : 415V, 3 , 50 Hz
Gear reduction : 130.5:1 at 1375 rpm
Special features : Free standing control cabinet
Tropical service, water sprays
motion monitor, Purge air
valve.
SECOAL VALVES
TYPE LOCATION
36" pressurised Coal Valves
a. Limitorque operated : At Raw Coal bunker outlet
b. Chain operated : At Raw coal feeder inlet.
Bunker Shut off Gates:
Manufacturer : Stock Equipment Co.
Type : Rack and Pinion ( pressurised)
Motor rating : 0.492 kw
Mat of gate : Stainless Steel
45
Pulverised Fuel Piping :
Mat of straight pipe : Carbon Steel
Mat of Bends Cast Steel/Besalt lined
2. 11 COAL BURNERS
Type : Tilting tangential
Make : BHEL
No. of Coal Burners feed by each : 4
Pulveriser.
No. of elevation of Burners : 9
Total No.of Coal burners : 36
Temp. of Coal Air Mixture : 66- 770C
Max allowable temp. of Burners : 8500 C
Turn down ratio : 4:1
2. 12 OIL BURNERS (Heavy Oil )

manufacturers : BHEL
Type : J - (type)
No . of Oil Burners per Boiler : 16 ( 4 per elevation)
Atomising medium : Steam
Scavenging medium : Steam
Duration of Scavenging : 5 MIN
o
Temp. of oil at burner inlet C : 120
Oil pr. range at Burners kg/cm2 : 3.7. to 13
Turn down ratio : 3:1
Oil viscosity before the burners (cst) : 15 - 28
Combustion air temp c o 0
: 325 C max.
Copacity of each Burner (kg/hr) : 2250
46
2.13 FUEL OIL IGNITORS
Enclosure Construction : Heavy duty corrosion

resistant steel, NEMA-4
rated
Manufacturer : M/S C.E., U.S.A.
Type : High Energy arc Ignitor
Heat in put per ignitor : 12 joules/spark
No : 16 ( 4 per corner)
Input Voltage : 110 VAC + 10%
50 +/- 5 c/s
Output Voltage : 2500 + 150 VDC
Input current : 5 Amps Rms (max.)
Sprak rate : 4/ sec.
Duty cycle : 15 mts. ON, 30 mts. OFF
Operating temp. : - 400C to 75 0C
Spark temp. : - 400C to 950C
Flexibel cable
Construction : Nickel braid shielded conduit
Length : 7.6 m ( Max.)
Bend radius : 100 mm
Operating voltage : 3000 VDC ( Max.)
Spark Rod
Construction : 5/8" s/s tube with s/s
wire braid ( flexible ) 5/8"
: 5/8" S/S tube (rigid)
Length : 18 " Max.
Total flexible section to 42 Max.
Operating voltage : 3000 VDC Max.
Operating temp. ( cable end ) : 100 0C
47
Operating temp . ( tip end ) : 540 0C
Ignitor tip
Operating temp. : 650 0C ( max).
Length : 191 +/ - 3 mm
Dia. :159 +/- 0-15 mm
2. 14 FUEL OIL PUMP

Make :Allewiler
Type : Screw
No. off : 3 ( 1 standby )
Rotation : Clockwise from Motor end
Capacity : 1140 l pm at 150 cst.
Pressure : 30 kg / cm2
Speed : 1450 rpm
Pump BHP : 65 kw at Min. cst.
73 kw at max. cst.
Motor : 85 kw
Suction Filter Mesh : 500 Micron
Discharge Filter mesh : 250 Micron
2. 15 HFO STEAM HEAT EXCHANGER

TYPE : U Tube hair pin type type, Oil
on shell side, condensing type.
No : 5 +1
Heater area : 45 M 2
Oil flow rate : 1125 l pm
Oil temp, range : 150 0c ( oil )
Design pressure ( Oil ) : 32 kg / cm2 ( oil side )
Relief valve set pressure : 32 kg / cm2
Steam parameters
Design pressure : 16 kg / cm2
Hydraulic Test pressure : 24 kg/ cm2
Hydraulic Test pressure : 24 kg/ cm2
Design Temperature : 220 0C
48
2.16 H. P. DOSING SYSTEM
TANKS PREPRATION METERING TANK
Capacity ( M3) : 1. 25 1.25
Mat of mixer shaft : SS SS
Tank Plate Mat : Fibre Fibre glass
Dosing pumps
Make : V. K. Pumps
Type : Reciprocating plunger type
No. of pumps per Boiler : Reciprocating Plunger type
No. of pumps per Boiler : 2
No. of pumps standby : 1
Fluid handled : Trisodium phosphate
2
Rated Discharge Pr. (kg./cm ) : 220
Max Discharge pr. (kg /cm2 ) : 250
Capacity ( at full stroke) : 163 litres/ hr
Rated discharge : 150 litres / hr.
Speed ( stroke / Min) : 200
Size of Motor ( kw) : 3. 0
2. 17 PRESSURE REDUCING AND DESUPERHEATING STATION

PRD Valves : One per unit
Flow Capacity of each valve : 110. 3 T/hr.
Type of actuator : pneumatic
Body Material : WCB
Trim Material : S4 S420 J2 + H2
Body design pressure : 600 lbs class
Design Temp. : 3550C
Desuperheating water :
pr. : 314 kg/cm2
Temp. : 1850C
Qty. : 13 Ton / hr.
49
2. 18 THERMAL INSULATION
H. P. PIPING OTHER EQUIPMET TURBINE

Insulation Material Mineral Wool Mineral
Wool Minerial wool
(Rockwool)
type of Insulation Boded type Boded Type Spray Type
Mat (LRB -8183) Mattress Max temp
insulating
Mat. can withstand 7500C 750 0C 7500C
Insulating Mat IS- 8183 IS- 8183 IS-8185
Standard
Density of 150 kg/ m 3
Insulating Mat.
Thermal Conductivity as per IS 8183Kcal/ M/hr /oc at meantemp of

1. 500C o.43
2. 0
100 C 0.52
3. 150 C0 0.62
4. 0
200 C 0.68
5. 250 C0 0.80
6. 300 C0 0.90
Resistance in Micro organison ( yes/ No) : Yes
In combustibility : Yes
2.19 SOOT BLOWER

Source of steam for soot Blowing Panel : Tap off after division
Set pressure on pressure reducing valve : 30 kg/cm2
Set pressure of safety valve : 39.5 kg/ cm2 (g)
Maximum flow Rate : 21000 kg/ hr
Steam pressure for soot blowing : 26 kg / cm2
50
DESCRIPTION TYPE OF BLOWER
WB IE LRD II E LRD II E LRD II E

Blower numbers 1 to 88 105 & 106 107 to 120 121 to
138
Travel in MM 305 9200 9200 9200
Dead Travel in MM - 350 350 350
Nozzle in MM 26 32 25 25
2
Blowing pr. in kg / cm (g) 10 12.5 12 9
No of groups 44 1 7 9
Blowing time per group 1.4 11.42 11.42 1 11.42
( 2 Blowers) in Min.
Operating time per Group 1.5 11.87 11.87 11.87
(2 Blowers) in Min.
Operating time per Cycle 66 11.87 83.09 106.83
in Min.
Blowing rate per Group in 83.3 293.33 176.66 143.3
kg/ Minutes
Consumption per group in kg 107 3349 2017.45
1636. 48
Steam consumption per cycle 4709 3349 14122 14728
in kgs
Total steam consumption : 36907 kgs.
per cycle
WBIE : Wall Deslagger Electrically operated
LRD II E : Load Retractable Soot Blower Electrically
operated
Steam temp for : 250 0C
soot Blowing
Steam consmp. rate : 5000 kg/hr
kg/hr per group of wall Blower
Type of wall Blower : RW 5E
51
2.20 ELECTROSTATIC PRECIPITATOR
Design condition
Gas flow rate : 1030 M3/ Sec
Temperature : 140 0C
Dust Concentration : 82.56 gm/NM3
Type : FAA - 6x45- 4x48125 -2
No of precipitator per boiler : Four
No. of Gas path per boiler : Four
No. of fields in series in each gas : Six
Path
pressure drop across the precipitator : 18 MMWC
for design condition
velocity of gas at electrode zone : 1.0 M/Sec
on total area
Treatment time : 27 Sec.
2 3
Specific collection area (M /M /sec) : 167.7
Guaranted collection efficiency (%) : 99.52
Guaranted air-in-leakage rate (M3/sec) : 2.8
Collecting Electrodes
Total No. of Collecting plates per : 2340
gas stream.
Nominal height of collecting plate : 12.5 Meter
Nominal width of collecting plate : 750 mm
Emitting Electrodes
Type : Spiral with Hooks.
Size : 2.7 mm Dia
No. of electrodes per : 20736
EP
Total length of elec- : 331776
trodes per boiler.
52
RAPPERS FOR COLLECTING ELECTRODES
No. and type of Rappers : One drop Hammer per row of collecting
electrodes having a collecting surface of 90.0 m2.
Rapper Size : 4.9 kgs
Frequency of Rap. : Varying from 10 raps/hr at the inlet field
to 1 rap/hr
at the exit field. The frequency of
rapping for the
intermediate field can be adjusted between 10 and
1 per hour according to
requirements.
Drive : Geared electric Motor controlled by
synchronous programmer.
Location : On the side wall of EP.
Rappers for Emitting electrodes

No. and type of rappers : One drop hammer per two rows of
Electrodes
Rapper Size : 3.0 kgs.
Frequency of Rap : 10 raps/hr.
Drive : Geared Electric Motor Controlled
synchronous
programmer.
Location : On the roof of EP
Rapper for Gas Distribution System

Qty : 4
53
Rating : Geared MOTOR 0.5 HP 1.1 RPM at 3
Phase
415 V, 50 Hz.
Location : On the G.D. Housing side pan
panels of the
casing.
Hoppers
Type : Pyramidal
No. of hoppers/ Boiler : 96 (4 per field)
Capacity : 8 hrs storage + 10% Excess
Heating : Electric heating provided forthe bottom
of
hoppers.
Baffling arrangement : 2 Sets of deflector Plates for each
hopper.
Rectifier
Rating : 75 KVA
N0. Per Boiler : 48
Type : silicon Diode, Full wave bridge
connection ` ON` type
Location : Mounted on the top of
precipitator
Motor
Qty : 112 Nos.
Rating : Geared Motor 0.33 H.P. /2 .5 RPM, 3
Phase,
415V, 50 Hz.
Rapping of collecting electrods
No. of rapping gear shafts : 48
Rating : Geared MOTOR 0.5 HP/ 1.1 rpm. at 3
ph. 415v, 50 Hz .
2.21 BLOW OF VALVE ( M/S YARWAY )

Valve type : Unit temden 6983 MS 83 MS
54
Service : Emergency Drain
Operation : Motor operation
Design pr kg/ cm2 (g) : 226
Design temp 0C : 371
Operating pressure Kg/cm2 : 199
kg/ cm2 (g)
Operating temp 0C : 360
Medium to be handled : Boiler water
Flow kg/hr : Min 80,000
Max 250, 000
Manufacturer : Rotork
Duty cycle : 15 Minute
Rated output (kw) : 0.75
Rated Voltage V : 415
Rated frequency Hz : 50
Full load Current : 4.5 Amp.
full load speed : 1725
App wt in kg : 74
2.22 COOLING WATER REQUIREMENTS FOR BOILER & AUXILARIES

( D. M. WATER )
Parameters: 6 kg/cm2 (g) 380C (Max.)
55
1. Pulveriser Oil Coolers 18 16+2 12 192
2x50 % capacity
2. Regenerative Air preheaters:

Guide bearing Oil 8 4+4 1 4
cooler
Support Bearing Oil 8 4+ 4 1 4
Cooler
3. Water cooled access door 2 2 1 2

in furnace hopper Zone
4. Fan lube Oil coolers:
a) FD Fans cooler 4 2+2 5 10
b) PA Fans Cooler 4 2+2 5 10
5. ID Fan Bearing Cooling 3 2+1 6.0 12.0
6. ID Fan Motor Stator Cooling 3 2+1 30 60
7. ID Fan hydraulic coupling 6. 2+4 76 152

cooler
8. Airheater fire sensing 4 4 1.5 6.0

Device cooling
9. Circulating pumps:
a) LP Cooler for motor 3 3 13 39
b) Hp fill & purge cooler 1 1 17 17 2
56
10. Scaffold door 2 2 1.5 3.0 1
11. Oil carry over detector 4 4 0.5 2.0 0
2.23 BLOW DOWN VESSELS

CBD TANK IBD TANK
Design Code IS- 2825 IS-2825

Operating pressure kg/cm2 (abs) 9.00 1.20
Design pressure kg/cm2 (abs) 11.00 2.70
Operating temp 0C 175 105
Design Temp 0C 200 150
Hydraulic test Pressure Kg/cm2 (g) 18 3.0
Shell thickness (MM) 16 16
Shell Dia (MM) 1500 2500
Shell Ht (MM) 2850 3000

wt when empty (T) 2.0 4.0
Material Specifiction SA- 515 SA -515
GR- 70 GR- 70
Nozzie necks SA- 106 GR-B SA - 106 GR B
or equivalent
Nozzle Flanges SA 515 GR 70 SA - 515 GR- 70
57
TURBINE
&
AUXILIARIES
58
3.0 TURBINE AND AUXILIARIES
3.1 Specification of main turbine
a) make : KRAFTWERK UNION, WEST
GERMANY
B) Type : Three Cylinder, reheat, Condensing
turbine
c) Stages : HP 17 Nos.
IP 12x2 Nos.
LP 6x2 Nos.
d) Nominal rating : 500 MW
e) Peak Loading : 536.7 MW
f) Rated Speed : 3000 rpm
g) Max/ Min Speed : 3090 / 2850 rpm
h) Speed exclusion range 400 to 2850 rpm .
Steam Pressures & Temperature ( Rated Values )
Pressure (at) Temperature (0C)
a) Initial steam : 170 537

b) First Stage Pressure : 151.79 537
c) HP cylinder Exhaust : 45 342. 5
d) IP stop valve inlet : 40.5 537
e) Extraction 6 : 45 342. 5
f) Extraction 5 : 19.52 428. 3
g) Extraction 4 : 7.57 302
h) Extraction 3 : 2.76 197. 8
i) Extraction 2 : 1.42 138. 8
j) Extraction 1 : 0.286 67.6
k) L.P. Cylinder exhaust :0.0884 43. 1
59
Weight (tonnes)
HP IP LP
a) Rotor : 11.6 21.8 84.6
b) Cylinder Assembled : 80.0 32.5 86.0
c) Main stop & control valve : 10
d) reheat stop & control valve : 17
Moments of Inertia (kg/m2)
a) Rotor of HP Cylinder : 713.0

b) Rotor of IP Cylinder : 2145.6
C) Rotor of LP Cylinder : 22981.0
3.2 LIMITING VALUS

Casing Temperature (0c)
Alarm M/C Must be shut down

at.
a) HP Turbine Exhaust : 480 500

b) Outler Casing of LP : 90 110
cylinder
(Spray water to LP cylinder must switched on at 900C )
60
Temperature Difference ( 0K )
(Between upper and lower casing section)
Alarm m/c must be shut down

at.
a) I. P. Turbine middle : +/- 30 +/ - 45
b) I.P. Turbine Front : +/- 30 +/- 45
c) L.P. Turbine Rear : +/- 30 +/ - 45
Steam purity ( KWU Recommended Values )
a) Conductivity at 25 0C : < 0.15 Ms/CM

Alkaline method
b) Silica Acid (Sio2 ) : < 0.010 mg/kg
c) Total iron (Fe) : < 0.005 mg/kg
d) Total copper : < 0.010 mg/kg
e) Sodium (Na) : < 0.02 mg/kg
Bearing temperatures (0C)
Alarm M/C must be shut

down at.
a) Normal operating temperature : 90 120
Below 75 0C
b) Normal operating temperature : 100 120

above 750
61
Vibration ( Absolute Vibration )
Bearing Housing Shaft
a) Nominal valve for Alarm : ----- 30 microns
above
normal level
b) Max. Value for alarm : 35 microns 120 microns
c) Limit value for tripping : 45 microns 200 microns
(Manual )
Differential Expansions
a) H.P. Turbine : + 5mm - 3mm
b) I. P. Turbine : +8mm - 2mm
c) L.P. Turbine : +30mm - 3mm
62
3.3 MATERIAL OF CONSTRUCTION
Casings
H.P. Outer Casing/ Barrel Casing : GS 17 Cr Mov 511
H.P. Blade carrier : GS 17 Cr Mov 511
I.P. Casing : GS 22 MO 4
L.P. Casing : Outer St. 37-2 N
: Inner I- GS M04,H II, 15 M03
: Inner II St. 37- 2N
Shafts
H.P. Shaft : 28 Cr. MONI 59
I.P. Shaft : 30 Cr. MONIV 511
L.P. Shaft : 26 Ni Cr. NOV 145
Moving Blades
H.p. Turbine first stage : x 22 cr Mov 121
H.P. Turbine other stages : x 20 cr 13 / x 22 cr Mov121
I.P Turbine stages : x 20 cr mo 13 / x 20 cr 30
L.P. Turbine stages : x 20 cr 13
Fixed Blades
H.P. Turbine First stage : x 22 Cr MOV 121
H.P. Turbine other stage : x 22 Cr MOV 121x20Cr MO 13

IP : x 22 Cr 13 /x 20 Cr MO 13
LP : x 20 Cr 13 /x 20 Cr MO
1320 Mn5/x 7 Cr MO 13
Casing Joint Bolts
H.P. Cylinder : 21 Cr MOV 57
IP : 21 Cr MOV 57
LP : St. 50/24 Cr. M0 5
Shaft couplings same material as shaft

IP/Lp cross over/ cross around piping ST. 37/ St 42 W
No. of bearings including Thrust Bearing of Turbine
4 Journal + 1 Thrust
63
Size of bearing
I II III IV
Diameter mm 280 380 560 560
Length mm 140 290 500 560
Anifriction material used in Bearings Babbit
Type of thrust bearing combined journal mitchel thrust bearing.
3.4 LUB OIL SYSTEM

Lub . Oil Specification
Sl.No. properties / test Numberical Value. Unit
1. Forming Characteristics at Max. 400 CM3
0
25 C Foaming
foam Stability ( 0 cm3 ) Max. 450 S
2. Water content Max . 0.1 wt%
3. Steam emulsion test Max. 300 S
4. Solid foreign Matter Max. 0.05 wt %
5. Cleaniness to SAE A - 6D
a) with survo valves Min. 3 Filter class
b) without survo valves Min . 3 - do -
6. Flash point
a) TD - 32 Min . 160 oC
b) TD- 46 Min . 185 0C
7. Pour point Min. 6 0C
8. Demulsibility max. 20 Min.
9. Color Max. 2 -
10. Copper strip test Max. 2-100 A3 Corrosiveness
11. Corrosion resistance to Max. 0-A Mg KOH / g
Steel
12. Oxidation characteristics, Max. 2.0 mg KOH/ g
increase in neutralization
number
64
13. kinematic viscosity at 400C
a) TD- 32 Min. 28.8 mm2/s (cst)
Max. 35.2
b) TD - 46 Min. 41.4
Max. 50.6
14. Density at 150C Max. 0.900 g/cm3
15. Neutralizaion Number Max. 0.2 mg KOH/g
16. Air Release at 50 0C Min. 5 Min.
Oil Supply System

a) Oil tank rated capacity : 25/40 m3
b) Highest Oil level from top of : 900 mm
tank.
c) Lowest oil level from top of : 950mm
tank.
d) First oil filling : 38 m3
e) Flushing Oil quantity : 25m3
Oil Requirement of Bearings ( M3/Hr.)

Bearing No. 1 : 2.88
Bearing No. 2 : 55. 44
Bearing No. 3 : 45.36
Bearing No. 4 : 30. 96
Gen. Bearing Front : 28.44
Gen. Bearing Rear : 28.44
Exciter Bearing : 5.04
Duplex Oil filter for thrust bearing
a) number : 2x100%
b) Filteration Particle Size : 37 Microns
65
Shaft Lift pump
a) Safety Valve Setting : 200/ 180 ata
b) Pressure limiting valve setting : 180/ 140 ata
c) pump starts at a turbine speed of : <510 rpm
d) pump stops at a turbine speed : > 540 rpm
Specification of Oil pumps
MOP AOP DC Bearing SHAFT lilft

Oil pump Oil pump
Number 1 2 1 2 + 1 DC
Make KWU KSB KSB ALLWEILER
Type - ETA 150 ETA100-26 SDF 80
50 VI VL
Capacity (Rated) 80 76 32 1.8
3
dm ,/s
Discharge pressure Kg/Cm2 8.67 5.8 1.7 140
(gauge) at
Speed/Second 50 24.26 25.2 49.16
Drive Turbine AC Motor DC motor AC Motor DC
Motor
Make Siemens Siemens Siemens Siemens
Voltage 415 220 415 220
Motor Power ( kw) 90 10.1 37 37
Rated Current (A) 158 53 70 190
Starting Current (A) 948 265 420 1140
Lub. Oil Cooler
a) Number : 2x100%
b) Cooling Surface : 640m2
c) Oil flow : 240 m3/Hr.
d) Heat dissipating capacity : 552.15 K.cal/s.
e) Oil inlet temperature : 65 0c
66
f) Oil outlet temperature : 45 0C
g) Oil pressure drop (approx) : 0.22 at
h) cooling water inlet temp. : 38 0C
i) Cooling water outlet temp. : 40.20C
j) Cooling water Pressure drop : 0.1 at
(Approx)
k) Tube material : Admirality Brass
1) Tube sheet material : Leaded Brass (60.40)
m) Permissible gauge Pressure : 9.8 ata
during operating water side.
n) Test guage pressure water : 14.7 ata
side
0) Permissibe gauge Pressure : 7.85 ata
during operation Oil side
p) Test gauge pressure Oil side : 11.77 ata
3.5 CONTROL FLUID SUPPLY

A fire resistant fluid is used for the control system
a) Control fluid tank rated capacity. : 12.5/20 M3
B) Highest fluid level from top of tank : 700 mm
c) Lowest fluid level from top of tank : 750 mm
d) First Oil filling : 19 M3
e) Flushing fluid quantity : 12.5 M3
Filters
a) Numbers. : 2 Nos.
b) Earth filling : 30/60 Mesh
c) Fine mesh filter : 1 No.
d) Filteration Particle size : 3 to 5 micron
e) Filter Material : Cotton.
Control Fluid Cooler

a) Numbers : 2x100 %
b) Cooling Surface : 19.6 m2
67
c) Fluid flow : 82.4 M3/Hr.
d) Heat dissipating capacity : 24.55 k.cal /s.
e) Fluid inlet temperature : 55 0C
f) Fluid pressure drop : 0.25 at
g) Cooling water inlet temperature : 38oC
h) Cooling water outlet temperature : 41.80C
i) Cooling water pressure drop : 0.1 at
j) Tube material : Admirality Brass
k) Tube sheet material : LeadedBrass (60:40)
1) Permissible gauge pressure : 9.8 at

during operation water side.
m) Test gauge pressure water side : 14.7 at
n) Permissible gauge pressure during : 7.85 at
Opertion fluid Oil side
0) Test gauge Pressure fluid side : 11.77 at
Barring Gear
a) Type of Drive : Hydraulic turbine
b) Method of engagement : Hydraulic
c) Cut in / cut speed : 210/240 rpm
d) Barring spped : 80-200 rmp
Governing
There are two speed controlling devices Speed Sensor
i) Hydraulic speed Governor : Primary Oil pump
ii) Electro- Hydraulic controller : Hall Generator.
( There are 3 in Nos.
One in spare.)
68
iii) Over Speed Set Value : 10- 11 %
Gland Sealing System

a) Electro - Hydraulic, self sealing after : 40% Load
3.6 TURBINE OIL PURIFIER SYSTEM

Centrifuge.
Max Capacity : 12500 Litres/hr.
Rated capacity : 8100 litres /hr.
speed of bowl : 7605 R.P.M.
Oil temp. inlet to electric heater : 550C(through regenerative
heat exchanger)
Oil temp. at oulet to electric heater : 650C
Water temp. in the heater tank. : 90 0C
Material of Construction
Bowl body : Tinned alloy steel with SS - 316

lining.
Bowl Cover : SS - 316
Separating discs : SS- 316
Bowl spindle : EN -9
Gear : Gun metal /Tin Bronze
Worm : EN- 8/ EN- 9
Oil injection Nozzle : S.S. 316
Electric Heater Quantity : 1 No per unit
Kilowatts : 48 Kw (24+12+12)kw.
Voltage A.C. : 415v/50 cycle/3 phase.
No. of thermostats : 3 Nos.
Thermostat settings : for water 900C +/- 20C.
for Oil 630C+/ - 20C
69
Heater Tubes
Material : copper
Number : Coil of one tube bundle
Length (mm) : 150000
Outside diameter (mm) : 12.7
Tube wall thicknes (SWG) : 16
Surface area of heater (M2) : 6.25
Capacity of heater tank ( M3) : Approx 0.25
Centrifuge Feed pump

Type : Positive displacement
Capacity (Lit/hr.) : 12,500
Speed (rpm) : 1440
Discharge pressure (Kg/cm2) : 1.5
Material
casing : Cast Iron
shaft : EN 8/9
Impellers : EN 8/9
Motor rating : 5.5 KW for Centri fuge
: 3.7 kw for feed pump and booster pump
70
Centrifugal Discharge pump (Booster pump).
Discharge pressure (kg/cm2) : 1.5

Capacity (Lit/hr.) : 7500
Speed (rpm) : 1440
Relief Valve setting ( kg/cm2) : 5
Material
Impellers : EN 8/9 B.S. 970 part- I

Motor rating : 3.7 kw
Plate Heat Exchanger
Model : AlFA - LAVAL TYPE P 2FH.

Application : Lub. Oil regenerative heating
/cooling.
Capacity : 7500 Lit./hr
Quantity : One per unit
Plate material : AISI 316
Gasket material : Nitrile Rubber
Working Data
Inlet temp. 500C 700C

Outlet 600C 600C
pr. drop 7.5 mwc 7.5 mwc
71
No. of plates : 91 nos. each with
0.12 M2 heat transfer area.
Total heat transfer area : 10.92 M2
Effective Heat transfer area : 10.68 M2
LMTD : 100C
Heat Load : 39.25 kw=33750 Kcal hr.
Centrifugal Oil polishing filter
Make : Ball Industrial Hydraulics

Type : HH 8610 C24UPTAS
ROTOLOCK FILTER
No. of filter in elements : One per filter
Filter Element Length : 407 mm
Filtering size : Microns
Materials
Head : Cast Iron

Bowl : Carbon Steel
Ring : Carbon steel
72
3.7BOILER FEED PUMPS AND AUXILIARIES
TDBFP
Booster pump
Manufacturer BHEL
Type FA IB 75
DOR (Viewed on NDE) Anticlockwise
Liquid pumped DM Water
S.G. at suction temperature 0.9045
Suction temperature 161.7 Dec C
NPSH 4.5 KSC
Differential Head (design) 205 M
Flow rate 990.0 m3/hr
Efficiency 81.50%
Speed 1495 rev/m
Power absorbed 613 KW
Main pump
Manufacturer BHEL
Type FK 4E 36
Suction Flow 990 cum/hr
Kicker Flow 150cum/hr+
30cum/hr
Suction pressure 6.85 kg/cm2
Design Head 205.0 kg/cm2
Kicker Head 209.0 kg/cm2
Speed 5465 rpm
Efficiency 81%
Thrust Bearing
Manufacturer Mitchell Bearing
Type Double thrust.
Mechanical seal Bergman
73
MOTOR DRIVEN BOILER FEED PUMP
Booster pump
Manufacturer BHEL Hyderabad 2009

Direction of rotation (Viewed on NDE) Anticlockwise
Liquid pumped DM Water
S.G at suction temperature 0.9045
Suction temperature 161.7 Dec C
NPSH 4.5 KSC
Differential Head (design) 205 M
Flow rate 990.0 m3/hr
Efficiency 81.50%
Speed 1495 rev/m
Power absorbed 613 KW
Main pump
Manufacturer BHELHyderabad
Frame FK4E 36
Pump no P2002-052
Suction Flow 990 cum/hr
Kicker Flow 150cum/hr+ 30 cum/hr
Suction pressure 6.85 ata
Design Head 2025 m
Kicker Head 209.0 ata
Speed 5465 rpm
Efficiency 81%
Temperature 161.7
Thrust bearing
Manufacturer Mitchell Bearing
Double thrust.
Mechanical seal
Manufacturer Eagle Poonawala, Pune
74
Motor
Manufacturer BHEL
Type 3 phase synchronous
Power 10 MW
Voltage 11 kv
Current 601.5 amps
Speed 1495 rpm
BFP Turbine
Manufacturer : Delaval - Stork
Type/ :KJ- MV- SF- 7R
Output (KW) : 7262
Max. Cont. Speed (rpm) : 5567
rotation ( Seen in Direction of : C.C.W.
steam flow )
Ist Lateral critical speed ( rpm) : 3710
Steam Inlet pressure (ata) : 7.486
Auxiliary steam inlet press (ata) : 26.5
Steam inlet temperature, (0C) : 299
Auxiliary steam Inlet Temp. (0C) : 340
Exhaust pressure (ata) : 0.1
Overspeed Trip at, (rpm) : 5900
Gear Box (T.D.)
Manufacturer : Tacke
Type : TNB 200
Input speed, (rpm) : 5406
Output speed, ( rpm) : 1740
power (kw) : 401
Agma Service factor : 2.0
75
MOTOR DRIVEN
TURBINE DRIVEN
Design Run- Out emergency Design

Run - Out Emergency
......... ............ .............. ..........
.............. ...............
Feed Water
Speed (rpm) 5395 5450 5600

5366 5427 5567
Power at coupling (kw) 7248 8097 7723
7262 8103 7739
power efficiency (%) 81.9 79.5 81.7
81.7 79.4 81.6
Turbine (BFP)Operating Detail
DESIGN RUN-OUT EMERGENCY

Steam
inlet pressure (ata) 7.486 26.5 26.5

Inlet remperature (0C) 299 340 340
Inlet enthalpy (kcal)/kg) 730.1 741.2 741.2
Inlet flow (kg/hr) 41579 40225 38725
Exhaust Pressure (ata) 0.1 0.1 0.1
Exhaust enthalpy ( kcal/kg) 577.1 565.4 566.7
Exhaust enthalpy isentropic 549.8 513.0 513.0
(Kcal/kg)
Exhaust flow (kg/hr) 41579 40225 38725
Turbine efficiency (%) 83.2 75.9 75.3
76
Lube and Control Oil for BFP.
Tank capacity (Max) 5750 Liters.

Capacity ( Operating level) 4050 liters
Main Lube Oil / control Oil Pump

make : Alweiler
Type : SNDA 440 -46
Number : 2x100%
Capacity : 855 Liters/ Min.
Discharge press. : 15 kg/cm2 (g)
power consumpt. : 27 kw
Motor
Make : GEC
Type : D225 MD
Power : 37 kw
speed : 3000 rpm
Power supply : 240/415 V, 3 ph, 5o Hz
Insulation : Class B
Emergency lube Oil pump ( D.C)

Make : Allweiler
Type : SNDA 210-46
Number : One
Capacity : 414 Liters/min.
Discharge Press. : 4.5 kg/cm2 (g)
Power consumpt : 5.2 kw
Motor
Make : GEC
77
Type : YD 200 LAD
Power : 7.5 kw
Speed : 3000 rpm
Power suppely : 220 VDC
Oil Cooler
Make : Funke
Typer : cp 1007
Heat capacity : 218 KW
Surface : 23.5 m2
- Flow : Min. 515 liter/min
- inlet temp. : 600C Max.
Exit temp. : 500C Max.
- Design. : 20 KG/CM2 max.
Materials:
Shell : Carbon steel
Channel/Cover : Carbon Steel
Tubes : St. Steel, AISI 316
Tube Sheets : St.Steel, AISI 316
Duplex Oil Filter

Make : Arlon
Type : BDGM - 4-1000
Filter : Cartridge
Mesh width : 25 mircon
Oil Vapour Extractor, (Oil Reservoir)

Make : Kiekens
Type : Oil lmaster, 1102
Capacity : 300 M3/hr.
Depressure : 130 mm water col.
Filter area : 2.4 m2
Motor
Make : ROTOR
Type : 4 AP71-25
78
Power : 0.37 kw
Speed : 300 rpm
Power Supply : 240/ 415v, 3 ph, 50 hZ
Nom. Curr. : 0.84 Amps.
Insulation : Class F
Oil Separator
Make : Westfalia
Type : OTB 2-00 -066
Capacity : 450 liter/hr
Filtration : Solids=2 micron will be re
moved.
Motor
Power : 0.75 kw
Speed : 1500 rpm
Power supply : 240/415V, 3 ph, 50Hz
3.8 L.P. HEATER SPECIFICATION

------------------------------------------------------------------------------------------------
Description Unit Drain LPH1 LPH2 LPH3
Cooler
------------------------------------------------------------------------------------------------
1. Type U tube U tube U tube
2. Number One One One One
3. Position/ Location Hori- Hori- Hori- Hori-

Zontal in cond. zontal zontal
4. No. of Passes
Tube side one two two two
Shell Side (zone) One One Two Two
5. Extraction Steam
Flow T/Hr. N.A. 38.515 81.19 44.669
Pressure 2
kg/cm -do- 0.268 1.32 2.592
79
Temperature 0C N.A. 66.1 136.2 195.4
Enthalpy Kcal/kg N.A. 598.9 655.9 682.7
6. Condensate
Flow Heater T/hr 1208.671 1208.671 1208.671
1208.671
Inlet temperature 0C 43.7 46.1 63.30 104.2
Inlet Enthalpy Kcal/kg 43.9 46.3 63.5 104.5
Outlet temp. 0C 46.1 63.30 104.2 125.199
Outlet Enthalpy Kcal/kg 46.3 63.5 104.5
125.7
-----------------------------------------------------------------------------------------
Description Unit Drain LPH1 LPH2 LPH3
Cooler
------------------------------------------------------------------------------------------
------
7. Drain - Inlet to Heater
Flow T/hr 164.374 125.859 44.669 -

Temperature 0C 66.1 68.2 109.1 NA
Enthalpy Kcal/kg 66.1 68.2 109.3 -
Outlet of Heater
Flow T/hr 164.374 164.52 125.859 44.669
Temperature 0C 48.7 66.1 68.2 109.1
Enthalpy Kcal/kg - 66.1 68.2 109.3
8. Design Pressure
Tube side kg/cm2 41 39 41 41
Shell side -do- 3&Vac. 3&Vac. 3&Vac. 4&Vac
9. Test pressure
Tube side kg/cm2 61.5 50.7 61.5 61.5
Shell side -DO- 4.5 3.9 4.5 6.
80
10. Design Temp.
Tube Side 0C 133 150 153 163
Shell side -do- 133 120 150 210
11. Surface Area

Condensing Zone M2 --- 952.7 1108 806.4
Drain Cooling Zone d0 148 --- 179 47
12. Number of tubes 650 737 867 789
13. Extra Tubes 25 25 25 25
3.9 H.P. HEATER SPECIFICATION
------------------------------------------------------------------------------------------------
Description Unit HPH 5A & 5B HPH 6A & B
-----------------------------------------------------------------------------------------
1. Type U-Type U-Type
2. No. off 2 2
3. Position / Location Horizontal Horizontal
4. No. of passes
Tube side 2 2
Shell side (Zone) 3 3
5. Ext. Steam
Flow T/hr 47.942(x2) 73.383(x2)
Pressure kg/cm2 18.523 42.75
Temperature 0C 428.4 342.3
Enthalpy Kcal/kg 791.4 733.5
6. Feed Water
Flow/ Heater T/hr. 1530.375 1530.375
81
Inlet temp. 0C 166.50 207.899
Enthalpy Kcal/kg. 171.0 214.0
Outlet temperature 0C 207.899 253.4
Enthalpy Kcal/kg 214.0 263.4
0C 212.7
Enthalpy Kcal/kg 217.5
8. Design pressure
Tube side kg/cm2 325 325
Shell side - Do - 24& Vac. 56.5&Vac.
. Test pressure
Tube side kg/cm2 487.5 487.5
Shell side - Do - 36& Vac. 84. 75
10 Design temperature
Tube side 0C 241 290
Shell side 0C 228 275.0
11. Surface Area

De-superheating M2 108.8 137.1
zone
condensing zone M2 826.8 619.5
Drain cooling zone M2 211 144.5
12. Number of tubes 1104 1227
13. Extra tubes 25 25
14. TTD 0C -0.3 -0.3
15. DCA 0C 4.8 4.8
H.P. Heater bypass valve will open 50% if one string is to be by passed
82
3.10 DEAERATOR
Manufacturer I. A. E.C India Ltd.
Type SPRAY
Design pressure ( internal) 8.8 kg/cm2&Vac.
Design pressure (external) 1.055 kg/cm2
Design temperature 325 oc
Feed water outlet temperature 164.6 0c
Operating pressure & Temp. 7.218 kg/ cm2 (a) & 298.7
0C
Storage capacity 170 M3 at 2/3 CSA( Excluding
Heads)
Outlet capacity 1530.375 T/hr
Oxygen Guarantee 0.005 ML/ L ( 7 ppb)
Number of holes on Steam line 5120
Number of condensate 2
Spray valves
Number of safety valves 3 (8.8kg/cm2, 8.4
2
kg/cm ,
and their set pressures 8.0 kg/cm2)
Number of supports 3 (fixed and 2 roller
supports)
Outside dia of shall 3636 mm
Straight length of shell 26660 mm
Overall length of shell 28550 mm
Deaerator operating condition at 100 % TG load,

65mm Hg back pressure and Zero make up
Condensate inlet to Condensate / Feed water Extraction

D/A Outlet from D/A Steam toD/A
Flow ( T/ hr ) 1208. 671 1530.375 79. 055

2
Pressure (kg/cm ) - - 6.955
Temperature C 0 125.2 163.0 300.3
Enthalpy (kcal/kg) 125. 2 164. 5 731.1
3.11 GLAND STEAM CONDENSER

83
Parameter Design Valve
Shell Full vacuum

Sube side 41 kg/ cm2g
Design Temperature:
Shell side 350 0C

Tube side 1000C
Hydraulic test pressure
Shell side 62kg/cm2 g

Weight
Empty 1300 kg.
Flooded 1750 kg.
Operating 1525 kg.
Set Pressure of water expansion 41kg/cm2 g.
relief value
Heat transfer Area 30m2
Tube side pressure drop= 1.6 mwc.
Full load condensate flow = 1250 T/hr
84
3.12 VACUUM RAISING SYSTEM-2 Nos of 100%EACH
1. Capacity of Vacuum pumps in free dry air at Standard

conditions with pump operating at saturated in take
condition of 25.4 mm Hg abs pressure and sub cooled to
4.17 0C below temperature corresponding to absolute
suction pressure = 50 Nm3 /hr.
2. Capacity as above but absolute suction pressure 50.8 mm

Hg abs in place of 25.4 mm Hgabs = 85
Nm3/hr.
3. Discharge pressure = 1.033 Ksc abs.
4. Cooling water inlet temperature

a) For l above = 12.3 0C
b) for 2 above = 24.5 0C
5. Design TTD (Difference of Saturation temp, -

cooling water inlet temperature) = 13.9 0C.
6. Blank off pressure with CW temperature 360C at

a) Pump Suction = 51 mm Hg abs
b) Ejector suction = 30 mm Hg. abs
7. Minimum suction pressure at pump inlet (allowed) at

36oC = 65 mm Hg abs
8. No of stages = One
9. Pump rated speed = 590 rpm

10 Rotor/ vane tip Speed = 21.9 m/sec
85
11. Power required ( at pump)
a) Maximum = 120 kw
b) As per condition 1 = 80 kw
c) As per condition 2 = 92 kw
12. Cooling water required = 75 m3/hr
13. Sealing water flow (closed circuit) 32 m3 /hr
14. Sealing water pressure = 0.2 KSC (g)
15. Cooling water pressure = 6.0 KSC (g)
16. Volume of condenser steam space to be evacuated = 2120m3
17. Pump detail.

a) pump model No. 2 BE 1 353 - OBL 4
B) Suction and discharge size = 200mm NB
18. Heat Exchanger

Tube size OD x thickness x length in mm 31.5 mmx
1.3mmx13500 mm
19. Air ejector size = 150 mm
20. Separator size = 1600 litres.
21. Guaranteed Performance
a) Capacity at 50.8 mm Hg abs and water vapour to saturate in

addition to 7.50F under cooling = 85 nm3/hr.
b) Inlet pressure 25.4 mm Hg abs
c) power at motor terminal box at 25.4 mm abs= 80 kw
d) pump runing time to evacuate initial condenser volume = 14 mins.
22. Motor Standard Continuous rating155 kw, 50 Hz, 0.4 kv, 3 phase
a) Rated speed 590 rpm
b) Full load current 280 Amps
c) power factor at rated 0.82 load
d) type squirrel cage, induction motor.
86
3.13 CONDENSATE EXTRACTION PUMP
Supplier BHEL Hydrabad
Type of First Impeller Double Suction
Number of stages 4
Design Flow rate capacity 817. 36 m3 /hr
Inlet - Temperature 43.1 0C
Inlet - specific Gravity (specific wt. ) 0.991 kg/dm3
NPSH required 3.4 meter
Discharge pressure 32 ata
Total dynamic Head 320 meters
shut off Head 398 meters
pump Speed 1485 rpm
Power Consumption at design condition

i) Power input at the motor 886.1kw
Driver H.P.
ii) Losses in the motor 34.1 kw
iii) Power input to the pump 852 kw
iv) Efficiency of the pump alone 82.8 %
v) Overall efficiency of the 79. 6%
pump motor
Guaranteed power consumption with a 756 kw
flow rate of 6,22,000 kgs/hr.
Sealing water requirement

i) Flow 2M3/hr
ii) pressure 3 to 10 ata
iii) Temperature 30-500C
87
Minimum flow for continuous stable 210 m3/ hr
operation
Cutless rubber bearings lubricated with 7 Nos.
Water
Motor of Condensate Extraction pump
Manufacturer TIBB - ITALLY

Motor type
ORNVG X 630 ia 4
Direction of rotation as
COUNTERCLOCKWISE
Viewed from non- driving end
Standard continuous rating 1120

at 40 0C ambient temperature
as per Indian Standard ( KW)
Derated rating for specified 1015

normal condition i. e. , 500C
ambient temperature ( kw)
Rated voltage ( Volts) 6600
Permissible rariation of
a) Voltage(Volts) +/- 10 %
b) Frequency (Hz) +/- 5%
Minimum permissible 4620

starting voltage
88
Rated speed at rated voltage and 1490
frequency ( r.p.m.)
At rated vlotage and frequency and kw 6600/50/ 1015
a) full load current 102 amp

b) No load current 25.1 amp
Power factor at
a) 100% load 0.91

b) 75 % load 0.9
c) 50% load 0.85
d) No load 0.80
Efficiency at rated voltage and frequency at
a) 100% load 96.2

b) 75% load 96.1
c) 50% load 95
Starting current (amps) at
a) 100% Voltage 612
Constructional Features:
a) Insulation type F MICADUR COMPACT
Space heaters
a) Number 1
b) Location AT THE BOTTOM
c) Power requirement ( kw) 0.3
Oil Cooler
a) Type OIL-WATER
b) Number Provided 1
c) Temperature of Oil at 500C
outlet of oil cooler (OC)
89
3.14 Condenser
Type Single
Area of Condenser surface Area 26612 sq. meters
Number of cooling tubes 24398
Lenghth of each tube 13500 mm
Size of tubes - 31.75mmx0.7112 mm
(OD X tickness in mm)
Tube material - welded SS
Weight of empty condenser 686 ton
Weight of tubes 144.8 TE
C.W. flow 58310 M3 /hr
C.W. velocity 1.8288 M/sec.
C.W. design 28oC
C.W. Max temperature 36oC
C.W. Max outlet temp 46oC
Back Pressure at MCR 65.278 mm of of Hg
at 28oC
Condenser Temperature rise max 10.00C
Terminal temperature Difference with 5.15oC
C.W. flows with steam
Pressure loss condenser 3.331 MWC
Fouling factor 90%
Cleanliness factor 0.90
90
3.15 Condenser tube cleaning system
Name of the supplier TAPROGGE
No. of cleaning systems 2
No. of Balls 1300
Strainer Section
Quantity per TCS 2 Nos.
Slope of Screen 250C
Width of Gap 7mm
Cooling water 9.015 kg/sec.
Actuation. Motor operated
Ball recirculating pump
No. 1 per unit

Type KRP-80-200
Normal capacity 12.8 kg/sec.
Normal discharge 1.0 bar
Pump motor Siemens
Operating Voltage 415 V/50 Hz
Rated output 4.0 KW
Full load speed 24
Ball Collector
Type S- 18
No. 2
Actuation Motor operated
Ball Valves Make- Bitter

Inlet/ outlet ball collectorType k820. 8-30. 2 AP
91
Material - housing/Ball/ Spindle GG25/1. 45721/1.4462
Actuation inlet Motor operated
Outlet. manually, by iNstalled switch
Vent and drain of ball collector
Type K820.8 -25.2 AP
Material- housing/Ball/spindle GG25/1.4572/ 14462
Actuation Manually
Sorting
Type K820.8- 502.2 AP
Material- Housing /Ball/Spindle GG25/1.4572/14462
Actuation Motor operated
Ball discharge
Type K820. 8-50.2 AP
Material- housing/Ball/Spindle GG25/1.4572/1.4462
Actuation Manually
Diaphram Valve
Type A 19a/ Taprogge
Actuation Manually
Actuators
Manufacturer Siemens
Operating voltage 415 V/50 Hz
Insulation class B
92
Screen actuation
Type 2 SA 1005
Output torque to open position 75 NM
Output torque to close position 75 NM
Actuation of Ball catching flap

Type M 77325- C34
Actuation of inlet ball Valve

Type M 77325- E34
Actuation of Sorting ball valve DN -50

Type M-77325- E32
Output torque to close position 200 Nm
Actuation of 3 way ball valve

Type M 77325- B37
Ball recirculating monitor BRM -1

Supplier Taprogge
Operating voltage 24 VDC
93
Control System
Type EL3 Simatic S5-110A
Operating Voltage 415 V 50 Hz
Control Voltage 24 V DC
Auxiliary voltage 240 V 50 Hz
3.16 CIRCULATING WATER SYSTEM

C.W. Pumps
1. Name of Manufacturer Ebara Corporation
2. Type Vertical Mixed flow,pull out
type
3. Number of pumps 6 Nos.

4. Discharge Capacity 30000M3 /Hr.
5. head at pump 27 M
6. Rated speed 370RPM
7. Thurst brg.
Name of Manufacturer Toshiba Corpn.
Type of thurst brg. Tilting pad type
Method of Lubrication & cooling Self lubrication
with cooling water tubes.
8. Coupling
Name of Manufacturer Ebara Corpn.
Type of coupling Rigid coupling
94
Manufacturer Toshiba Corp.
Type Squirrel cage Induc
tion MOTOR
Standard Continous - rating at 400C App 1500 kw
ambient temp.
Rated votage & frequency 6.6 KV & 50 Hz
Rated speed at rated Voltage 296 rpm

& Frequency.
Full load current 181 A
Bearing Lubrication water & drive
pumps
No. Provided 8
Manufacturer Kirloskar Brother Ltd.
Model No DB 32/ 20
Rated capacity 6.12 M3 /hr
Rated Head 42 MWC
Over head tanks 2 Nos
capacity of tank 15 M3
Motor
Manufacturer Kirlosker Electric
Ltd.
Type A/C Induction
MOTOR
Rating at 500C ambient tap. 3.7 Kw
Rated voltage, phase & frquency 415V, 3 phase,50 HZ
Rated speed 2900 rpm
95
Butterfly Valve
i) Name of Manufacturer Fouress Engg. (India) Ltd.
ii) Opening time from full close to 45 to 60 sec. for pump Discharge
full open position and 51+5 sec. for
duct inter connection valve.
iii) Closing time for full closed position 40 to 60 sec.

for pumpdischarge and 51+5 sec.
for duct inter connection valve.
Motor ( Valve Operating)
Type Squirral cage.
Rating & full load current 7.5kw.& 30 Amp
Design Torque 2.47 kg/m
power supply 415v, 3, 50 Hz
Gear Rate 22.4 : 1
Electric Hydraulic Actuator

Type Gear / Vane Type
No One. with one
standby.hand pump
Rated capacity & Head of each pump 48 LPM at 150 kg/cm2
No. of Oil tank One
Capacity of Oil tank 0.25 M3
Accumulator capacity 95 Litres
Max. working Pr. of accumulator 150 kg / cm2
96
GENERATOR
&
AUXILIARIES
97
4.0 GENERATOR
4.1 General
Make BHEL (KWU)

Type THDF 115/59
Code IEC 34-1, VDE 0530
Cooling , stator winding Directly water cooled.
Stator core , rotor Directly hydrogen cooled.
RATING
Apparent power 588 MVA

Active Power 500 MW
Power factor 0.85 (lag)
Terminal voltage 21 kv
permissible variation in + 58 %
Voltage.
Speed/ Frequency rpm/Hz 3000/50
Stator corrent 16200 Amps.
Hydrogen pressure kg / cm 2 4
Short Circuit Ratio 0.48
field current ( Calculated value) 4040 A
Field Voltage 340V
Class and type of Insulation MICALSTIC (Similar to class F)
No. of terminals brought out 6
Resistance in ohms at 20oC
Stator winding between terminals u-x 0.001414
v-y 0.0014 17
w-z 0.001420
Rotor winding F1- F 2 0.068293
98
MAIN EXCTTER
Active Power 3780 Kw

Current 6300 A
Voltage 600 V
speed 3000 rpm
Pilot Exciter
Apparent power 65 KVA

Current 195A
Voltae 220V (1+ 10%)
Frequency 400 Hz
P.F. 0.6
4.2 Voltage Regulating System

1. Type Thyrisiam 04-2
2. Maximum output voltage 250 V
3. Output current for field forcing 152 A
4. Output current for rated 88A
Generator load.
5. Auxiliary Voltages from three phase supply. 220 v,
Pilot exciter for thyristor sets 400 Hz.
6. D. C. Voltage From station 220V
for contactors & drives.
7. Power input continuously < O.1 Kw
8. Power input, short time < 1 kw
9. DC Voltage from Station Max. 15 A Positive
batterY 2x24 for control Max. 6A negative
and regulation.
10. Rated secondary voltage 120v
11. Power input of Voltage 2 VA
trnsformer per phase
12. Rated secondary current 5A
99
13 .Power input of current 6.5 VA (Plus losses
transformer per phase in connecting leads)
14. Accuracy of control Better than + - 0.5%
15. Setting range of voltage +58 - 15% of
Point potentio meter nominal
generator voltage.
16. Setting range of drop + 0-10% dependent on the
compensation or compunding
setting of the potentio meter
and proportional to reactive curent*
------------------------------------------------------------------------------------------
* Direction of reactive current compensatin depend on the phase
relation which is determined by connection of CT's to TVR
terminals.
TORQUE, CRITICAL SPEEDS
1. Maximum short circuit 1488 kpm

torque of stator at line
to line single phase short
circuit.
2. Moment of intertia of 10,000 kgm2

generator shaft.
3. Critical speed ( Calculated ) nk1 14.4 s-1 (VGEN)

nk2 30. 1 S-1 (V-EXC)
nk3 39.8 s-1 ( S-GEN)
GENERATOR VOLUME AND FILLING QUANTITIES
1. Genertator volume ( Gas Volume) 80 m3

2. Co2 filling quantity *** 160 M3 ( STP) *
3. H2 filling quantity ** (to 4 bar) 520 M3 (STP) *
* STP = Standard temperature and pressure.

100
O 0C and 1.013 bar to DIN 1343.
** volume required with unit at stand still with the unit on
turning gear, the volume will be higher.
*** Co2 quantity kept on stock must always be sufficient fot
removal of the existing hydrogen filling . All values are approximate.
4.3 GENERATOR PROTECTIONS

Generators are high quality machines for securing the best possible
continuity of power supply. In addition to a suitable technical design and
responsible mode of operation, provision has therefore been made for
automatic protection facility the following protections have been provided
in the 500 MW T. G.
1. Generator Differential protection (87G)

2. Generator Low forward power protection ( 37G )
3. Negative phase sequence protection (46G)
4. Pole slipping protection ( 98 G)
Under frequency protection ( 81 G)
6. L.B.B. Protection (50 G)

7. Gen field failure protection (40G)
8. Stator Earth fault protection (64 G1 & 64G2)
9. Inter turn fault protection (95 G)
10.Over load protection ( 51g)
11.Over Voltage protection ( 59G)
12. Gen. Back up impedance protection ( 21G)
4.4 SEAL OIL SYSTEM

------------------------------------------------------------------------------------------
Design Data
------------------------------------------------------------------------------------------
Seal Oil pump 1 and 2, air side -
kind of pump screw pump

Make Tushaco
101
Capacity 258LPM
Discharge pressure 12 bar
Speed 1455 RPM
pump motor type

Type Sq.Cage Induction motor
Rating 7.5 Kw/10 HP
voltage / frquency 415v, 50 Hz
Current 13.6 Amp
Speed 1455 RPM
Type of enclosuer IP 55
Insulation Class F
Duty S1
No. 2 Nos. full-capacity
DC Seal Oil Pump

No. 1
kind of pump screw pump
Make Tushaco
Capacity 258LPM
Discharge pressure 12 bar
Speed 1455 RPM
DC pump motor type

Type Shunt
Rating 8.5 Kw
Armature V/G 150 V
Armature Current 67 amp
Field V/G 150 V
Field Current 1.40Amp
-------------------------------------------------------------------------------------
102
Seal Oil filter unit, air side and H2 side
Kind of pump Strainer type filter

Type 2.62.9 Ma
(B0ll+Kirch)
Volumetric flow rate 3.3 dm3 /s
Degree of filtration 100 microns
Pressure drop across filter 0.3 bar with clean filter*
No. for air side 2 Nos. full capacity
No. for H2 side 2 Nos. full capacity
* 1.2 bar with 100 % fouling.
4.5 GAS SYSTEM
C02 Flash evaporator
Rating 18 Kw ( 6x3 kw)

Voltage 240 V
Heat transfer liquid Marlotherm
Volume of heat transfer 25 dm3
liquid.
Hole in orifice 2.8 mm
Relief Valve on high-pressure 80 bar
side.
Relif valve on low- pressure side 8 bar
No. 1No. full capacity.
--------------------------------------------------------------------------------------
GAS DRYER
Type 8.70 ( Boll) + Kirch)

Motor ILA 3073 -2AA93 (siemens)
Rating 1.1 Kw
Voltage / frquency 415V, 50 Hz
Current 2.5A
speed 48.5 S -1
103
102
Type of enclosure IP 5 4
Volume of absorbent material 20 dm3
Heater rating 2.5 kw
Regenetation air flow tate 65 m3/hr
No. 1 No. full capacity
------------------------------------------------------------------------------------
Compressed air filter
Type AH ( Hundt and We
ber)
Volume of activated carbon 13 dm3
Service hours approx. 1,500 hrs
to 2,000 Hrs
Throughput 80 m3/hrs at 8 bar
-----------------------------------------------------------------------------------------
Main filter SSll N 531
Kind of filter Strainer type filter

with magnet bars.
Type 1.53.1 (Boll+Kirch)
Volumetric flow rate 25 dm3 / s max
Degree of filtration 150 Microns
pressure drop across filter 0.1 bar with clean
filter
1.2 barwith100%fouling
Fine filter SS11 N 526
Kind of filter 1 plug, 1 cartridge
Type 1.55.1 (boll+Kirch)
Volumetric flow rate 0.42 dm3/s max
Pressure drop across filter 0.15 bar with clean
filter 1.2 bar with
100% fouling
Ion exchanger SS11 N520
volume 83 Liters (Bischoff)
Resin Lewatit
104
Resin Volume 56 Liters (45 kg)
No. 1 No. full capacity.
4.7 WASTE GAS SYSTEM
Design Data
Bearing Vapor Exhauster
type 4036 Mx 80112
(Anton piller KG)
Motor eM 80-2
Rating 0.75 kw
Voltage/ frequency 415 v, 50 Hz
Current 1.65 A
Speed 49 S -1
Type of enclosure Radial- flow
Volumetric flow rate 380 m3 / h at 10m
bar
No. 2 Nos. full capacity.
4.8 EXCITATION SYSTEM

Design Data
A- wheel (negative polarity)

No./ type of diodes 60 Nos./ssi1 12 120
S3 (Siemens)
No./ Type of fuses 30 Nos./3 NC 9 538
Resistance/ Voltage / Current Approx. 150/ 800V,
800 A
Per fuse
No. of RC networks 6 Nos.
B- Wheel ( Positive Polarity)

No. Type of diodes 60 Nos. /SSil 13 120
D3 (Siemens)
No./ Type of fuses 30 Nos./3 NC 9 538
Resistance/ Voltage / Current approx. 150/ 800v,
800 A
Per fuse
No. of RC networks 6 Nos.
Stroboscope
105
Type Lx5-30/36-2
(Biochinger)
Voltage 240 V
Frequency 50/60 Hz.
No. of stroboscope 1 No.
Exciter air dryer
Type M 120 (Berner Inter

national Gmbh)
Rating 1.28 KW
Voltage 240 V
Frequency 50/60 Hz
Absorption air flow tate 120 m3 /h
Regeneration air flow rate 35 m3/h
Type of enclosure IP 54
No. of dryer 1 No.
Actuator for emergency cooling damper in base frame

Type VD6-AG100 (LEWA)
Motor ILA3063-2AA92
ZK17 (Siemens)
Rating 0.25 kw
Voltage/frequency 415V,50 Hz
Current 0.71 A
Speed 50S-1
Type of enclosure IP55
No. Of actuators 2 Nos.
Actuator for emergency cooling damper in enclosure
Type VD6-CK 350(LEWA)

Motor ILA3063 -
2AA92 k17
(siemens)
Rating 0.25 kw
voltage / frequency 415V, 50 Hz
Current 0.71 A
Speed 50 s -1
No. of actuator 1 No.
106
4.9 COOLER DATA
Design Data for the H2 Cooler,

Type: 2x KG12-356/29/6/2-NSV-SR20 Units Materials and
(4 Sections, 25% each) Pressures
Hydrogen pressure 4 bar
Gas flow 33 m3/s Fins Cu
Tubes CuZn28Sn
-----------------------------------------------------------------------------------
Heat dissipating capacity 4.859 Gcal Tubesheets Cuzn40
----------------------------------------------------------------------------------
Cold gas temperature 43 0C Steel Channels with

Protective coating
-----------------------------------------------------------------------------------
Hot gas temperature 75 0C
----------------------------------------------------------------------------------
Gas pressure drop 6.6 mbar
----------------------------------------------------------------------------------
perm. Operating Pressures 10 bar
Cooling water flow 150 dm3

----------------------------------------------------------------------------------
Test pressure 15 bar
Maximum water inlet temperature 38 0C

-----------------------------------------------------------------------------------
Water outlet temperature 47 0C

-----------------------------------------------------------------------------------
Water pressure drop 200 mbar
Design Data for the Exciter Cooler

Type : 2x KG11-280/19/10/2-NSV-SR50 Units Materials
and
2- Sections, 50% each) Pressures
--------------------------------------------------------------------------------------
107
Air flow 15.5 m3/s Materials
--------------------------------------------------------------------------------------
Heat dissipating capacity 0.43 Gcal Fins Cu
Tubes Cuzn28sn
----------------------------------------------------------------------------------
Hot air temperature 71.7 0C Tubesheets Cuzn40
----------------------------------------------------------------------------------
Cold air temperature 43 0C Steel Channels with
Protective coating
----------------------------------------------------------------------------------
Air pressure drop 4.9 mbar
---------------------------------------------------------------------------------
Cooling water flow 23.88 dm3/s
----------------------------------------------------------------------------------
Maximum water inlet temperature 38 0C
Pressures
----------------------------------------------------------------------------------
Perm. Operating 10 bar

Water outlet temperature 43 0C Press.
----------------------------------------------------------------------------------

Water pressure drop 50 mbar
---------------------------------------------------------------------------------
-
Design Data for one Seal Oil Cooler (Air Side)
Type : 3C2720 - 4050 - 060AD Units Materials and
(1 Section) Pressures
----------------------------------------------------------------------------------
Oil flow 3.33 dm3/s
----------------------------------------------------------------------------------
Heat dissipating capacity 0.12 Gcal Tubes SoMs 71

108
TubesheetsMuntz metal
-------------------------------------------------------------------------------
Steel Channels with
Oil Inlet temperature 70 C0 Protective coating
----------------------------------------------------------------------------------
Protective
Oil outlet temperature 450C
----------------------------------------------------------------------------------
Oil pressure drop (approximate) 0.833 bar
----------------------------------------------------------------------------------
Cooling Water Side
Cooling Water flow 3
8.1 dm /s Pressures
---------------------------------------------------------------------------------
perm. Operating
Maximum water inlet temperature 30C Pressure 16 bar
----------------------------------------------------------------------------------
----------------------------------------------------------------------------------
Oil side pressures
Water pressure drop (approximate) 0.440 bar Pern.Operating
------------------------------------------------------------- 16 Bar.
Design Data for one Seal Oil Cooler (H2 Side)
Type : 3C2222 - 4050 - 050AD Units Materials and
(1 Section) Pressures
--------------------------------------------------------------------------------------
Oil flow 2.17 dm3/s

--------------------------------------------------------------------------------------
Heat dissipating capacity 0.069 Gcal Tubes SoMs71

Tubesheets Muntz metal
------------------------------------------------------------- Water Steel
109
Oil Inlet temperature 70 0C Channels with
----------------------------------------------------------- Protective
Oil Outlet temperature 45 0C Coating
----------------------------------------------------------
Oil pressure drop (approximate) 0.850 bar
--------------------------------------------------------- Cooling Water Side
Cooling water flow 5.43 dm3/s Pressures
-------------------------------------------------------- Perm. Operating 16
bar
Maximum water inlet temperature 38 0C Press.
------------------------------------------------------- Oil side pressures
Water pressure drop (approximate) 0.300 bar Perm. Operating
press
------------------------------------------------------ 16 Bar.
Design Date for the Primary Water Cooler,

Type : Ns 36/280/23/14/1.2/1 Units Materials and
(2 Sections) Pressures
--------------------------------------------------------------------------------------
------
Primary water flow 18.06 dm3/sMaterisls
--------------------------------------------------------------------------------------
------
Heat dissipating capacity 2.15 Gcal Shell 1.4541

Tubes SF-Cu
110
-------------------------------------------------------------- Tubesheets
CuNi10Fe
Primary water inlet temperature 81.50C Water HII
with
------------------------------------------------------------- Channels
Protective
Primary water outlet temperature 480C coating
------------------------------------------------------------Primary water side
Primary water pressure drop 510 mbar
-----------------------------------------------------------
Cooling water flow 96.4 dm3/s Pressure
----------------------------------------------------------- Perm. Operating
Maximum cooling water inlet temp. 380C Press. 10 bar
----------------------------------------------------------- Test pressure 15
bar
Cooling water outlet temperature 44.2 0C
----------------------------------------------------------- Cooling water side
Cooling water pressure drop 160 mbar Pressures.
----------------------------------------------------------- Perm. Operating
Press
16 bar.
4.10 SPECIFICATIONS OF TRANSFORMERS
Generator Transformer
1. Manufacturer AREVA
2. Nos. of units 10 Nos. (10)
3. Rating 200 MVA
4. Rated Voltage, HV 420 KV
111
5. Rated Voltage. LV 21 KV
6. Rated current, HV 825.00 Amps
7. Rated current, LV 9520 . 00 Amps
8. No. of phases 1
9. Frequency 50 Hz
10. Type of cooling OF AF
11. Connection symbol when YND11
formed a bank.
12. Impedance at principal tap 13.5%
(750C)
13. OFF CKT Tap Changer OCTC +/- 5% tolerance

Grounding Resistence
Station Transformer
1. Manufacturer AREVA
Type of Cooling ONAN ONAF
Rated Power(MVA) HV 48 80
LV1&LV2 24 40
Line Current HV 209.94
349.9
LV1&LV2 1204.9 2008.17
Rated voltage HV 132 KV
LV 11.5KV
2. No of phase 3
5. Vector group YNyn0yn0

Frequency 50 hz
Untanking Mass 12000 Kg
Core&Coil weight 50000 kg
Tank and fitting weight 25000 Kg
Mass of oil 30000Kg
112
Shipping weight 73000 Kg
Unit Transformer
Number 3
Make Areva
Capacity(ONAF/ONAN) 45/36 MVA
Rated voltage 21/11.5 KV
On load tap changer OLTC +7.5% to -12.5
In step of 1.25%
Impedence 11.5%
Vector group DYN1
Unit Auxiliary Transformer
1. Manufacturer EMCO
2. Nos. off 6
3. Capacity 16MVA
4. Voltage Ratio 11/3.45 KV
5. Vector group Dyn1
6. Cooling ONAN/ONAF
7. Percentage impedance 12.5%
ESP Transformer
1. Manufacturer EMCO
2. Nos. off 5
3. Capacity 1.6 MVA
4. Voltage Ratio 11 KV/0. 433 KV
113
5. Vector group Dynl
Ash handling Transformer

MAKE
1. Nos. off 3
2. Capacity 1 MVA
3. voltage Ratio 11KV/3.45KV
4. Percentage impedance 10
Vector group
Tap changer OCTC +/-
5%(2.5%step)
Station Service Transformer
1. Make Volt AMP

2. Nos. off 6(2 per unit)
3. Capacity 2000 KVA
4. Voltage Ratio 11 KV/0. 433 KV
5. Vector group Dynl
6. Percentage impedance 10%
Unit Service Transformer

Make VoltAmp
1. Nos. off 6
3. Voltage Ratio 11 KV/433 V
4. Vector Group Dyn 1
CWPH Transformer
1. Nos. off 2
2. Capacity 1.5 MVA
3. Voltage Ratio 11 KV/433 V
114
4. Vector Group DYn1
PT/DM/service water Transformer
1. No. 2
2. Capacity 2 MVA
3. Rating 11/0.433KV
Clarified Water Service Transformer
1. Manufacturer M/s. Ingra

2. Nos. off 2
4. Voltage Ratio 6.6 KV/0.433 KV
5. Vector Group Dyn1
Fuel Oil Service Transformer

2. Nos. off 2
4. Voltage Ratio 11/0. 433 KV
5. Vector group DYnl
TIE TRANSFORMER
1. Manufacturer
2. Nos of units ONE
3. Rating 55/75 MVA (30)
115
5. Rated Voltage. LV 34.5 KV
6. Rated current. HV 1260 Amps
7. Rated current, LV 108 Amps
8. No. of phases 3
9. Frequency 50 Hz
10. Type of cooling ONAN/ONAF
11. Connection symbol YND11
12. Impedance at principle tap 11.74%
(750C)
13. Tap Changer 7.5% to + 5% in steps of 2.5% on
OFF CKT (HV neutral side) in 6 equal
steps.)
14. Temerature rises 400C
(as per test results) Wds. 450C
Fuel Oil Service Transformer

2. Nos. off 2
4. Voltage Ratio 11/0. 433 KV
5. Vector group DYnl
TIE TRANSFORMER
1. Manufacturer TOSHIBA
2. Nos of units ONE
3. Rating 55/75 MVA (30)
5. Rated Voltage. LV 34.5 KV
6. Rated current. HV 1260 Amps
7. Rated current, LV 108 Amps
116
8. No. of phases 3
9. Frequency 50 Hz
10. Type of cooling ONAN/ONAF
11. Connection symbol YND11
12. Impedance at principle tap 11.74%
(750C)
13. Tap Changer 7.5% to + 5% in steps of 2.5% on
OFF CKT (HV neutral side) in 6 equal
steps.)
14. Temerature rises 400C
(as per test results) Wds. 450C
117
OFF SITE
WATER TREATMENT PLANT
&
AUXILIARIES
118
5.0 WATER TREATMENT PLANT
Supplier Driplex water engineering
5.1 Pre-treatment Plant

Clarifier-cum-Floculater :
No. and type One (1)

Rated effluent flow 3000m3/hr.
Effluent Turbidity 20 NTU
Retention Time at rated speed
Floculation Zone 30 min.

Classified Zone 2 hrs. 30 min.
O.D. at top 20.6
Bridge revolving Speed 0.038
Gravity Filter
Nos. 2
Flow rate per filter 300 M3/hr.
Surface flow rate 4.845 M3/hr/m2
Filter water reservoir and transfer pump :
Nos. of pump 3 working+1 stand by.

Capacity of pump 110 M3/hr.
TDH 50MWC
Type of pump Vertical Turbine pump
Make FBM pumps india ltd
Pump speed 1460RPM
No of stages 4
NPSHr 2.1 mtrs
119
Serivce/Clarified water tank
Service water pump (APH Washing)

Type Centrifugal pump(HSC Type)
No. 2
Make Sam Turbo Industry Ltd.
Size 350x250
Capacity 500 M3/Hr
Total head 110 Mtrs
Speed 1486 RPM
Pump Motor Details:-
Make: marathon Electric Motor Ltd

KW/HP Rating 225KW
Speed 1486 RPM
Voltage 3.3 KV
S1, IP 55, Class F insulation,IP 55, 0.86 PF, 96% efficiency
Service water pump (HVAC)

Type Centrifugal pump(HSC Type)
No. 2
Make Sam Turbo Industry Ltd.
Size 150x125
Capacity 150 M3/Hr
Total head 60 Mtrs
Speed 1470 RPM
Pump Motor Details:-
Make: marathon Electric Motor Ltd

Type 3 Ph, 415 V Sq cage Induction motor
KW/HP Rating 37KW/50 HP
Speed 1486 RPM
120
Voltage 415 V
S1, IP 55, Class F insulation,IP 55, 0.86 PF, 96% efficiency
DE/NDE Bearing 6319 C3/6319C3
Drinking Water pump System –
DW pump for Coloney------

Pump details:-
Type Vertical turbine pump

Make - WPIL Ltd.
Discharge 270 M3/Hr
Head 70.5 Mtrs
Speed 1485 RPM
Motor Details:-
Make marathon Electric Ltd.

Type 3 Ph. 415 V, Sq cage induction motor
Rating 75KW/100 HP
Current 128 Amps
Speed 1485 RPM
94.7% eff., S1 rating, IP55, PF 0.86
DE/NDE 6317/6317
DW pump for Plant------

Pump details:-
Type Vertical turbine pump

Make - WPIL Ltd.
Discharge 20 M3/Hr
Head 70Mtrs
Speed 1455 RPM
121
Motor Details:-
Make marathon Electric Ltd.

Type 3 Ph. 415 V, Sq cage induction motor
Rating 9.3KW/12.5 HP
Current 18.8Amps
Speed 1455 RPM
94.7% eff., S1 rating, IP55, PF 0.86
DE/NDE 6308/6308
5.2 CHEMICAL DOSING SYSTEM

Alum Dosing Pump
Nos. of Tanks 3
Capacity 8 Hrs. each for clarifier.
Strength of solution 10%
Alum Dosing System
Type Positive displacement
Control 0-100% automatically by pneumatic
stroke positioner.
Nos. 2 each of 100% cap.
Lime Slaking Tank
Capacity 12 hrs. consumption of clarifiers at 10%
strenght.
Nos. 2
Lime Slurry Transfer Pump
Nos. 2
Capacity 4M3/hr.
Lime Solution Preparation Tank
Capacity 6 hrs. consumption of clarifier
at 6% strengthw/v.
strenght of solution 6%
Nos. 4.
122
Lime Solution Dosing Pump
Type positive displacement

Control 0-100% automatically by pneumatic
stroke positioner.
No. 2 each of 100% cap.
Coagulant aid preparation Tank
Nos. 2 each of 100% cap.

Control 0-100% mannualy by micrometer dial.
Type Positive displacement type.
Chlorination System
Nos. of chlorinators 4
Capacity 10 Kg/hr.
Type of Injector Vacuum type
Water Booster pump 3 Nos. (2 w+1 s)
Horizontal, centrifugal type.
5.3 D.M. PLANT

GENERAL
Nos. of stream 3
Normal Flow through one stream 100m3/hr
D.M. water storage tank 2nos. of 2000 m3 each.
DEGASSED - WATER PUMP
No. : 4 (3W+1S)
Make : KBL
Capacity 110 Cum/Hr
Discharge Pr 5KSC
NPSHa/NPSHr 8/1.5 mts
Speed 1450 RPM
Power 22.36KW
123
Pump Rating
Type- 3ph 415V, induction motor
Rating 30KW
Speed 1450 RPM
Duty S1
IP 55
Degasser Blower
No. 6(3W+3S)
Make CB Doctors
Capacity 3600 cum/hr
Suction/Discharge Pr Atm/50 mmWC
Type Centrifugal
Type of impeller Rackward inclined
Speed 1415RPM
Motor Detail:-
Type 3 Ph sq.cage induction motor
Motor rating 1.15 KW/1.5 HP
Voltage 415 V
Speed 1415 RPM
Current 2.52 amp
IP55, Duty S1, 95% efficiency, Class F insulation,
DE/NDE 6205zz/6205zz
ANION EXCHANGER
No. off/stream 2
Desogn flow rate 130 m3/hr.
Shell lining 4.5 mm thick
Shell Material IS - 226.
Size WBA 2100 x 4688
SBA 2100 x 5320
Qty. WBA 4.4 m3 - IRA - 93 RE
SBA 5.17 m3-IRA-40 RC
Regeneration NAOH
124
MIXED BED UNITS
No. off 3
Design flow 130 m3/hr.
Surface flow rate 40 m3/hr/m2
material IS-226 shell.
Resin Cation+anion 2 M3+ 2m3
IR-120 = MB + IR 402 MB
Degasser Blower Details:-

Type Twin Lobe Compressor
Number 02 No.s
Make Everest Transmission
Capacity 450M3/Hr
Pressure 4000mmWC
Speed 1160 RPM
Motor Details:-
Rating 9.3KW/12.5HP
Make Crompton Greaves Ltd
Type 3 ph. Squirrel cage induction motor
Voltage/current 415Volt
S1, class F,IP55.88.5% efficiency
DE/NDE 6309-2RC
REGENERATION SYSTEM
Storage tanks Acid Alkali

No. 2(1 for MB 1for SAC) 2(1 for MS,1 for
SBA)
Size Dia & Length 1500/1500mm 1500/1500mm
Capacity 2 cum 2 cum
Lining RL-4.5 mm RL 4.5 mm in 3 layers
125
Concentration of chemical 30%HCL 48%NaOH
BRINE Tank
No. 01
Size Dia&Length 1600mm&1800mm
Capacity 3 Cum
Lining 3 layers of 4.5 mm rubber gasket
Concentration of chemical
UNLOADING PUMP
Nos. Acid Alkali

2(1W+1S) 2(1W+1S)
Type Horizontal Horizontal
Centrifugal Centrifugal
Capacity 15 M 3 15M3
TDH MWC 12.5 13
Transfer cum recirculation pump: for Alkali
Nos. 2(1W+1S)
Make KBL
Capacity and head 15 M3/hr. &1.5 KSC
Suction Flooded
Pump Speed 1450RPM
NPSHr 2 mtrs
Impeller semi Open
Acid Dosing pump :

No.s 3 No.s(2W+1S)
Type Positive Displacement Diaphragm Type
Capacity 500 LPH
Make Swellore
Head 3.6 KSC
Fluid Handled Sulphuric Acid
126
Neturalisation System :
Lime tank( neutralization Pit)
No. of pits 1
Capacity 2 cumecs
Size 1400Lx1400Bx1300D
Liquid Stored 60% NaOH
Back Wash waste Recirculation cum disposal pump :
Nos. 2(1W+1S)
Make SU Motors
Capacity 150 M3/hr
Type Horizontal centrifugal Single Stage
TDH 2.2KSC
Location Near nutralisation Pit
Duty Intermittent
NPSHa/NPSHr Flooded/3.25 Mtrs
Fluid Pumped DM plant Regenration waste
Back Wash waste Recirculation cum disposal pump :
Nos. 2(1W+1S)
Capacity 50 M3/hr
TDH 25MWC
Location Back wash filter sump
Duty Intermittent
NPSHa/NPSHr Flooded/2.5 M
127
D.M. Tanks :
No. 2
Capacity 2000 M3 each
Size 14 M x 14.M – Ht.
Material MS I. S. – 226.
Activated Carbon Flter :
No per stream 1
Design Flow rate 145 M3/hr.
Design Surface flow rate 15 M3/hr/m2
Filled Ht. 1200 MM
Supporting Material Graded Gravel- 225 mm (Ht.)
Material of shell IS 2002 Gr. II
Internal painting epoxy
Cation Exchanger :
No per stream 2
Design Flow rate 130 M3/hr.
Design surface flow rate 35 M3/hr/M2
Filled Ht. WAC-1.00 m, SAC 1.610 M
Qty. of resin WAC -3.46 M3 m3-IRC-84RF
SAC 5.54 M3-IR-120 RF
Regeneration by Hydrochloric Acid
Shell size – 2100 mm (wac)
Material of shell IS -226 Rubber Lined.
128
Degasser System :
Nos. of 3
Type Forced draft type)
Normal Flow rate 130 M3/hr
Filled Material P.P.N.
CO2 content in effluent 5 PPM (Max.)
Shell material IS – 226
Rubber Lining 4.5 mm thick
Size 2000 x 5575 ht
(Degasser tower)
Boiler Fill Pump Specifications:
Make
Total head 150 mtrs
Total Discharge 125cum/hr
Motor Specifications:
Capacity- 125KW
Volt 415V
IP 55
Bearing DE/NDE 6319
AMP 199
DM MAKE UP PUMP
Make KBL Limited
Type Horizontal Centrifugal type
No 4(3W+1S)
Capacity 85Cum/hr
Discharge Pressure 6 KSC
Operation Continous
Pump Speed 1450RPM
Bearing Antifriction
NPSHa/NPSHr 8M/4.4M
129
Motor Specifications
Condesate Transfer Pump

Make KBL Ltd
Type Horizontal Centrifugal single stage
No 3(2W+1S)
Capacity 300Cum/Hr
Discharge Pressure 7 KSC
Opreation Continous
Pump Speed 1450RPM
Bearing Antifriction
NPSHa/NPSHr 3.6m/flooded
130
6.0 COAL HANDLING PLANT
6.1 CRUSHER HOUSE
No. of Crusher Four (4) Nos.

Type of Crusher Ring Hammer Type
Capacity 1000 MTPH
Max. Coal size at inlet 200 mm
Belt feeder Nos./capacity 4 Nos./1000 MTPH
Vibrating feeder Nos./capacity 4 Nos./1000 MTPH
Feeder size (MM) 7000 x 1600
Crusher motor Details
Motor Rating 900 KW
Make BHEL Bhopal
No.of motor 04
Type 3 ph, Sq cage induction
Duty S1
Stator Volt 3.3 KV
Stator current 209 Amps
RPM 742
Insulation Class F
Connection Stator –star
IP 55
6.2 TRIPPER
Total Number 6 Nos.

Capacity of tripper conveyer 2000 MTPH
(each).
Travel of trippler 165 M.
Travelling speed 0.3 M/sec.
Belt speed 3.15 M/sec.
Motor of tripper 2x5.5 kw.
131
6.3 SILOS
Total Nos. 18 Nos.

Cylinderical portion 9.2 M.
Conical 3.485 M
Hypher Bolic 3.3 M
Dia. (internal) 7.0 M (cylinderical)
6.4 TRACK HOPPERS
No. of Hopper One

Max. coal lump size 200 mm
Paddlefeeder capacity 100 MTPH
6.5 CONVEYORS
Conveyor capacity T/hr. 2000 MTPH
Belt speed M/Sec. 2.8/3.15 M/Sec.
Belt Width (Min) 1600 mm
132
HEAVY FUEL OIL HANDLING SYSTEM
&
AUXILIARIES
133
8.0 HEAVY FUEL OIL HANDLING
8.1 Unloading Header

Nos : One
Length : 25 M (Additional)
Dia : 400 Nb
82. Transfer Pumps

Make : Bornemen
Nos : Two (2)
Type : Two spindle screw pump
Capacity : 100 M3
Discharge pr : 40 MLC
Viscosity of Oil handled : 80- 170 CST (Design)
Power required at design :
Point
Motor Rating : 46 KW
Type of strainers : Simplex
8.3 H.F.O. Storage Tank

No off : 2
Capacity : 4000 M3
Dia x Height : 22M x 10.8 M
8.4 Drain Tank

Nos : 2 (Two)
Size : 3 M x 1.5 M x 1.5 M
Heating syster : Coil heater (condensate)
8.5 Drain Pump
Nos : 2 (Two)
Type : Three spindle screw pump
Make : Bornemann
Discharge Pr : 25 MWC Flow 4 M3/hr
134
Speed : 1430 rpm
Motor : 2 KW
8.6 Flash Tank

Size : 2M x 2M
Insulation thickness : 50 MM
8.7 Vertical Sump Pump Type : Non-Clog
Rated flow : 30 M3/hr
Total Head : 7 MWC
Speed : 1450 rpm
Motor (KW) : 2.2 KW
No. Installed : 4
8.8 Fuel Oil Characteristics
Heavy Fuel Oil LSHS HPS
Specification : IS 1593 1971 -
Total Sulphur Content by wt : 1.0/ Max 4.5%
Max.
Gross cv. (Kcal/kg) : 10,700 (TYP) 1000 (TYP)
Flash point : 660C (Min) 660C (Min)
Water Content by (Vol) : 1.0% 1.0%
Sediment by-WT (Max) : 0.05% (TYP) 0.25%
Kinematic Viscosity in : 370 at 500C 500
(Max) at 500C
Centi stroke
Ash percentage by wt. (max) : 0.057 (TYP) 0.1%
135
COMPRESSED AIR SYSTEM
&
AUXILIARIES
136
9.0 COMPRESSED AIR SYSTEM
Manufacturer : Kirlosker Pneumatic

Model Number : T-BTD-BM
Type of compressor : Horizontal Balanced Opposed
Numbers : Eight Nos
: Instrument Air : 4 Nos.
: Plant Air : 4 Nos
Actual capacity of each compressor : 3
30.0Nm /min
Discharge pressure Kg/cm2 gauge : 8.0
Design ambient temperature : 50 deg C
Design ambient pressure : 0.99753 Kg/cm2 ab
Design ambient humidity : 100%
Exact capacity considering worst : 39.05(at45 deg.C&75%RH)
ambient condition as stated in data
specification sheet in M3/Min of
the air discharge (F.A.D.)
Air temperature after first stage : 159 deg. C
of compression
Air temperature after last stage of: 160 deg. C
compression (actual)
Outlet air temperature (After : 42 deg. C
cooler) 0C
Compressor efficiency at design condition : 75%
Mechanical efficiency at design : 90%
condition
Air pressure after L.P. stage : 1.9 Kg/cm2 g
KW input reuired at the compressor : 204.8
shaft in design rated condition
KW input required at the compressor : 212.00
shaft at design rated corresponding
to 103% of the rated speed.
Guaranteed power consumption : 224.56
137
(Maximum i.e. without any tolerance)
Crankshaft speed, r.p.m. : 591
Total cooling water requirement, : 240
M3/hr (For all compressors and its
accessories located in compressor house)
Number of stage : Two
Single acting or double acting : Double
Type of drive : Direct coupled thro flexible
coupling
Cylinder bore in mm : LP 530. HP 335
Stroke, mm : 200
Clearance in % of volume : LP - 11%, HP - 14.5%
Thickness,mm : LP - 16.5, HP - 14.50
Method of cylinder Lubrication : Non-Lubricated
Cooling media : Water
Cooling water pressure : 2.0 Kg/cm2 g
quantity 13.2 M3/hr
Type of Valves : Plate type
Intercooler specifications
Cooling medium : Water cooled
Cooling water presure and : 2.0 Kg/cm2 g
Quantity 13.8 M3/hr
Crank pin : Force feed
Cylinder wall : Non Lubricated
Cross head shoes : Force-feed
Gland : Self Lubricating teflon
Lub oil pressure : Maximum Kg/cm2g 4.0
Lub oil pressure : Maximum Kg/cm2g 4.0
: Normal Kg/cm2 g 3.0
: Minimum Kg/cm2 g 1.50
Lub oil temp. OC :(Max. allowable) 65 deg.C
138
EQUIPMENT COOLING WATER SYSTEM
&
AUXILIARIES
139
DMCW PUMP(TG Side)
Kind of pump Centrifugal pump

Number 03
Make WPIL ltd
Speed 1485 RPM
Capacity 1150 cum/hr
Discharge head 38Mtrs
PUMP MOTOR
pump motor type 3 ph, Sq. cage induction motor
Rating 180KW/ 241 HP
Voltage 415V, three phase a.c.
Duty S1
Insulation Class F
Frequency 50 Hz
Speed 1485RPM
Winding connection Delta
DE Bearing no 6319
NDE Bearing No 6319
DMCW PUMP(SG Side)
Kind of pump Centrifugal pump

Number 02
Make WPIL ltd
Speed 1485 RPM
Capacity 575 cum/hr
Discharge head 65 Mtrs
PUMP MOTOR
pump motor type 3 ph, Sq. cage induction motor
Rating 180KW/ 241 HP
Voltage 415V, three phase a.c.
Duty S1
Insulation Class F
Frequency 50 Hz
Speed 1485RPM
Winding connection Delta
140
DE Bearing no 6319
NDE Bearing No 6319
ACW Pumps
Kind of pump Centrifugal
No 03
Make WPIL Ltd
Pump size 14LN 19B
Discharge 1700 M3/Hr
Head 17 Mtrs
Motor Details.
Type 3 Ph. Sq.cage induction motor
Rating 125KW/168HP
Speed 987 RPM
Current 218 Amps
IP55, Insulation Class F,S1,winding Connection Delta, 94% Efficiency
DE/NDE bearing 6319/631
10.2 Plate Type Heat Exchanger
Nos : 5
Fluid : Primary - Secondary
: D.M. Water - Raw water
In/Out let temp 0C : 44.5/38 - 35/40.92
Flow rate (M3/hr) : 2140 - 2350
Design Pressure 10 10
Test pressure 15 15
Design temp 60degC 60 deg C
10.3 Equipment Cooling Water Sorage Tank

Elevation : 24.0M
Capacity : 60 M3 for unit No. 4
50 M3 for unit 5 & 6
141
10.4 Chemical Dosing System.
Injection at : Equipment cooling water
storage tank
Chemical : NAOH
Tank Size : 450 MM x 500 MM
10.5 ECW Booster Pump

No. : 3 (1 Standby)
Suction head : Normal - 0.6 - 3.8 MWC
Max. - 20 MWC
Discharge head : 24 MWC
MOTOR Rating : 240 KW
Speed :985 RPM
142
DIESEL GENERATOR SET
&
AUXILIARIES
143
11.0 DISEL GEN. SET
11.1 Manufacturer
Engine : Kirlosker Cummins
Alternator & Excitor : NGEF
Control panel : Control & Switchgear Co.
Pvt. Ltd.
Battery : Exide
Charge : Logicstat
11.2 Engine
Rating at site condition : 750 KVA
Engine type : KTA 3067 G
RPM : 1500 rpm
No. of Cylinders ^ arrangement : 16 cylinder 600 Vee.
Starting time : 30 Sec from Cold
Governor : PSG Motorised
Fuel Oil : HSD as per IS: 1460 grade
Lube Oil : MIL IS2104 C
Guaranteed fuel oil
Consumption at 100% : 150 gms/BHP/hr
Lub oil consumption : 0.62 lit/hr
Mech. Efficiency : 38%
Total Weight : 6 Tonnes
11.3 Alternator
KW : 600
KVA : 750
Pf : 0.8
Stator Current : 1043 A
Speed : 1500 rpm
Frequency : 50 HZ at 1500 rpm

Excitation Current : 2.5A at 47.0 V.
& Voltage
Efficiency
144
Load 110% : 93.7%
100 % : 94.6%
75% : 94%
50% : 93.5%
25% : 90.5%
Regulation - 30% Thru AVR voltage is maintanined within +/- 1%
11.4 Impedance
xd'' (Sat) 8.9% Xd - 15.5%
xd'' (unsat) 12.9% xd - 37.3%
Xo - 6.6%
Excitation type : Brush lessexcitation
3.4 KW DC
Insulation : Class – F
145
PLANT COMMUNICATION
SYSTEM
&
AUXILIARIES
146
12.0 PLANT COMMUNICATION SYSTEM
12.1 Public Address System Devices & Accessories

1. Manufacturer : PHILIPS
2. Manufacturer type & catalog : LBD 8612
3. Mounting : Cradle
12.2 Microphone
a) Type : Noise cancelling moving Coil

b) Impedance at : 230 ohms + 15%
c) Sensitivity 1000 HZ : 0.7 mv/Pa
d) Temperature Range : + 550C
e) Directional Characterstics : Noise Cancelling close talking
12.3 Reciever
a) Type : Moving Coil
b) Impedance at 100 HZ : 220 ohms (+/-20%)
c) Sound level at 1000 HZ in db : 116 dB
with respect to input
12.4 Amplifiers
A. Preamplifer/Line.Amplifier
(For each type & size)
Out put voltage : 2V

Frequency response : 200-8000 HZ +/-3db
Minimum load impedance : 240 ohms
Current Consumption
No Load : 35 MA
Full Load : 35 MA
147
Supply Voltage : 24 V
Working temp. range : 550C Max.
A/C operating Voltage : 240+/- 10%
and its premissible variation for
satisfactory operation
"B" Speaker Power Amplifier
Nominal out put power : 15 Watts

Sensitivity : 2V
Input impedance : 68 K. ohms
Load impedance : 8 to 16 ohms.
12.5 Current Consumption
Full load : 140 MA (16 ohms load)

No Load (IDLE) : 35 MA
Supply voltage : 240 VAC (Rectifier internally to 24
VDC)
12.6 Hand set Control Box
Dimension : 353 x 148 MM x MM (HxWxD)

Weight : 7.4 kgs
Type of circuit protection : Electronic, against function,
volu. control speech, filter,
Transmit, Reciever side
tone etc.
148
FIRE FIGHTING SYSTEM
&
AUXILIARIES
149
13.0 FIRE FIGHTING SYSTEM
13.1 Sprinkler system
Sprinkler pump : 2 nos( one motor driven,2nd DG set

driven)
Make Flowmore ltd
capacity : 410cum/hr
Head : 120meters
Pump Input : 134 KW
Speed 1488 RPM
PUMP MOTOR
Make Marathon Electric
Type 3Ph 415 V Sq Cage Induction Motor
Rating 200KW/268HP
Duty S1
Insulation Class F
Winding Connection Delta
Speed 1488 RPM
Bearing DE/NDE N321/6321
13.1.2 Sprinkler system DG set
Make : Greaves Cottons Ltd

Type : TBD3V6MK1
Rating : 253 HP
Speed : 1500 HP
13.2 Jockey Pump
Nos. : Two
Make : Flow More
Capacity : 75 M3/hr
Head : 105 MWC
Pump Input : 35.74KW
Speed : 2950 RPM
150
Motor Description:
Type; Three phase Sq. Cage induction motor

Rating: 55 KW/75 HP
Duty: S1
Voltage And Current raing: 415V &94 Amps
Insulation : Class F
Speed: 2955 RPM
Driving End bearing: 6314
NDE side: 6313
13.3 Hydrant System
Hydrant Pump
Make- Flowmore Ltd
Capacity 410 M3/Hr
TDH 105 meters
Pump input 150.31 KW
Speed 1488 RPM
Motor:
Make Marathon electric ltd
Type 3ph 415V Sq Cage induction motor
Insulation Class F
Duty S1
Winding Connection Delta
IP 55
Bearing DE/NDE 6321
Rating 200KW/ 268HP PF 0.85
13.3.1 Hydrant System DG Set
Make : Greaves Cottons Ltd

Type : TBD3V6MK1
Rating : 253 HP
Speed : 1500 HP
151
13.4 Booster Pumps in Hydrant Line
Nos. : Two (One diesel Engine Driven and
other is
motor Driven)
Capacity : 100 M3/hr
Head : 51 MWC
152
AIR CONDITION
SYSTEM
&
AUXILIARIES
153
14.0 AIR CONDITIONING SYSTEM
14.1Compressor
Main Control Room Esp Control Room
No. off Six (6) Six (6)
Make Kirlosker Pheumatic Co. Kirlosker
Pheumatic Co. Model AC - 1670 AC -
470
No. of Cylinders 16 4
Type Reciprocating Reciprocating
Refrigerant R-22 R-22
Type of Cooling Air Cooling Air Cooling
0
Condensing temp 2 C 4.440C
Operating RPM 1450. 1250 1000
Capacity (TR) 136.96,117.19 25.86
0
Drive KW at 50 C 128.99,111.18 23.27
14.2 Condenser
No. off Six (6) Six (6)

make Kirlosker Pneumatic Co. KirloskerPneumatic
Co.
Model 500-9, 500-8 250-70
Over all size OD 640X3419, 640x3114 340 x 2275
(MM) Min x Tube
Length (mm)
Shell Mat. MS MS
Shell Thickness mm 8 6.35
Tube Mat. Copper Copper
tube Size dia mm 19 19
Tube Thickness mm 1.41 1.41
No. of Tubes 278 64
154
Circulating Water Flow 130 25
m3/Hr
Water inlet temp 0C 31 31
Water Outlet temp 0C 34.80, 34.70 34.7
14.3Air Handling Units CT-IV. CT-IV. CT-V & Control Tower

Espcr
VI,CT-V & VI
Designation AHU-1 to 14 AHU-15 to 20
No. of fan motor 14 6
Capacity M3/hr 19813,32980,25730,30760 9062
Static Pr (MMWC) 50 40
Speed rpm 510, 614, 530, 614 550
BHP 7.8,10,8,10,8,10,8 4.2
Motor Rating KW at 800C 7.5,11,11,11, 3.7
14.4 Pumps
Ch. Water Cond. Water ESPCR WTPCS

Comp Room
No. off 5 5 6 2 6
Make Kirlosker make
Model DB80/32 DB100/32 KPD DB32/16
KPD50/32
50/32
Normal working 3 3 3 1 3
3
Design Capacity M /hr 80.70 130,115 25 10 20
Total Head at Design 33 30 30 30 30
Capacity - M
Full load RPM 1450 1450 1450 2900 2900
3
KW Miniumum flow M /hr 15 18.5 5.5 3.7 5.5
155
14.5 Cooling Towers
Control Tower EPCR WRPCR Comp.Room
Make Paharpur Induced Paharpur Paharpur IV, V,

VI
draft double flow Natural Natural
Type Double cell
Circulating Water 97.5 (per cell) 25 10 20,20

172.5 (Per Cell)
Make up water 0.20,0.20 0.75 0.75 0.75,0.75

Qty M3/hr
Inlet Water Temp.0C 34.8, 34.7 34.74 34.74,

34.7434.74
Out-let Water temp. 31,31 31 31 31,31
Design Wet Bulb 25.5 25.5 25.5 25.5

temp. 0C
Operating wt (kg) 6617&7787 1362 642 1090,1090
156
14.6 ESP
1. AC COMPRESOORS INSTALLED - 02
Normal 0 Running : 01
Make : Kirloskar Pneumatics Co Ltd.
Pune
Model : AC 470
Capacity of each compressor : 25 TR
Motor KW : 22
Refrigerant : Freon 22
2. COOLING WATER PUMPS INSTALLED : 02

Normal Running : 01
Make : Kirloskar Brothers Ltd.
Model : KPD 50/32
Capacity : 6.94 Letres per Seconds
Motor KW : 5.5
3. AIR HANDLING UNIT :

Nos Provided : 02
Normal Running : 02
Make : Neutech Mumbai for UT 5&6
and uniar Delhi for UT 4
Capacity : of each AHU 9062 Cubic
Metre per Hour
4. COOLING TOWER :
NOS Installed : 01
Make : Paharpur Cooling Towers Ltd.
Capacity : 60 Cubic Meter per Hour.
Model : Spratower 1225
157
INTER LOCK & PROTECTION
&
AUXILIARIES
158
15 INTERLOCK & PROTECTIONS
A. BOILER & AUXILIARIES

1.0 AIR PREHEATER INTERLOCKS :
AIR PREHEATER CAN BE STARTED IF THE FOLLOWING

PERMISSIVES ARE MET :-
Gude bearing lop bearing lop is not in off position support bearing
lop is not off position
- Air motor air supply available (air supply refore solenoid
valve/manual valve
- Local push button in released condition .
2.0 ID FAN INTERLOCKS :
ID FAN CAN BE STARTED IF THE FOLLOWING PERMISSIVE ARE

MET :-
a. ID Fan discharge gate in closed position.
b. Inlet guide vane minimum.
c. Scoop position minimum.
d. Inlet gate closed.
e. Bearing temp. normal, motor NDE/DE. Fan NDE/DE bearing
temp. normal (Omniguard < 80 Deg.C)
f. Hyd. Pump on. (any one) & Hydraulic coupling bearing
temperature Normal <80 Deg. C.
g. Hydaulic coupling oil pressure > 1.8 KSC.
h. Oil temp. after cooler adequate. < 60 Deg. C
I. Stack Path available. (any two ESP available)
j. Any APH to ESP available
- With local push button released, If ID fan is started, ID fan will take
start and inlet/out dampers will open.
- If the dampers fail to open within 180 seconds the running fan will
trip.
k. To run ID fan ''A'' ID fan ''B'' should not be running in bus A. no.
start command to run ID fan ''B'' on bus A/ID Fan ''C'' Can be started
if, ID fan ''B'' is not running in bus B, no start command to run ID
Fan ''B'' on bus B / To run ID Fan ''B'' on bus A.It is essential that, ID
fan
''B'' should neither be running in bus B nor should be getting a start
command & ID fan ''A'' should not be running nor it should be getting
a start command.
159
STACK PATH AVAILABLE CONDITION WILL BE SATISFIED WHEN : -
a. Secondary APHS are in sevice.
b. All gas dampers APH open. (Both APH regulating Dampers and.
isolating Dampers)
ID FAN PROTECTION :
2.1 RUNNING ID FAN WILL TRIP IN THE FOLOWING CONDITIONS -

1. Electrical Protection Trip.
2. Emergency push button pressed.
3. Stop command from UCB.
4. Bearing temp High-High. (MOTOR/FAN / Hydraulic coupling)
(80 Deg. C Annunciation, 90 Deg. C Trip).
5. Lub Oil pressure low.low set 0.5kg & reset 1.1 Kg/cm2
6. Fan Running & inlet/outlet gate close (Trip after 180 sec).
7. Hydra. coupling oil temp. at cooler outlet > 65 deg. C High-High.
8. Fan bearing vibration Hi-Hi > present value 80% of 25.4 microns/
Sec.
9. Corresponding FD fan trip (for ID fan-A, FD fan-B running and FD
fan-A tripped) (for ID fan-B, FD fan-A reunning and FD fan-B
tripped)
10. post purge fan trip (FSSS)
3.0 FD FAN INTERLOCKS :-
FA FAN CAN BE STARTED IF THE FOLLOWING

PERMISSIVES ARE MET -
1. Dishcharge Damper closed.
2. Blade pitch minimum.
3. Lub Oil pressure adequate > 0.5 Kg/Vq cm.
4. Oil tank level adequate.
5. Control oil pressure adequate. > 8 KSC
6. Any lub oil pump running.
7. Fan/ motor bearing temp. < 80 Deg. C
8. ID Fan permit.
ID FAN PERMIT WILL BE SATISFIED WHEN -

a. Both the ID Fans are in Service [OR]
b. Any ID Fan is running and FD fan is not running.
When given a start command fan will start and its discharge Damper
will open.
160
If the discharge Damper fails to open within 180 Sec the preset time.
Running fan will trip.
3.1 FD FAN PROTECTIONS :-

FD FANS WILL TRIP IN THE FOLLOWING CONDITIONS -
1. Electrical protections trip.
2. Emergeny push button pressed.
4. One ID Fan and one FD already in service & corresponding ID Fan
not running.
5. Fan motor bearing temp. High High.> 90 Deg. C
6. Outlet Damper fails to open within preset time/fan running and
discharge damper closed for more than. 180 seconds.
7, For vibration more than preset value.
8. All ID Fans stoped
9. Post Purge Fan trip
4.0 PA FAN INTER LOCKS :
PA FAN CAN BE STARTED IF THE FOLLOWING PERMISSIVES ARE

MET -
1. BIade pitch in minimum position.
2. Discharge Damper closed.
3. Lube Oil pressure adequate > 0.5 Kg/Cm2
4. Control Oil pressure adequate (Set 9 KSC. reset 11 KSC).
5. Lub oil tank level adeuate (not low).
6. BRG. TEMP Not high < 80 0C
7. Any one Oil Pump running.
8. Any one PAPH available air motor/ elelctric motor in service &
respective dampers are open.
9. FSSS Permit will be met if no MFT & all cold air dampers not
open more than 5%
10. Local push button in released condition. fan will take a start and
its desch. dampers fails to open within preset time. The fan
will trip.
4.1 DISCHARGE DAMPER :
A. When fan is in service and its discharge Damper is open. Command

goes to close the discharge damper of other non-runnings fan.
B. Both fans discharge damper will remain open if fans are not in
service.
161
C. Upon issue of start command for designated fan the respective
discharge damper closes.
4.2 PA FAN PROTECTIONS :
Running PA fan will trip in the following conditions :
1. Electrical protection trip.
3. Emergency push button pressed.
4. Fan/motor bearing temp. High-High > 90 Deg.C
(Omnigaurd+Temp. Sw in series)
5. M.F. T.
5. Fan Running & Outlet Damper fails to open After 180 Sec
time.
6. Fan Vibration Hi-Hi
5.0 SCANNER FAN LOGICS
AC FAN : -
Scanner fan can be started from FSSS console.

Start in the following conditions
a. Scanner duct to furnace DP is <152. 4mm of WCL
b. Loss of Critical power for > 2 sec
c. Start commond AC or DC persisting & neither fan start within
5 sec.
FAN CAN BE STOPPED WHEN
a. No Start command and stop command is given.

b. Scanner duct to furnace DP is > 152.4 mm WCL
or
c. Scanner duct to furnace DP High> 600mm WC for 10 secs.
5.1 DISCHARGE DAMPER
a. Opens automatically after fan is started

b. Opens automaticaly on loss of critical power for > 2 SECS.
c. Discharge damper (this condition holds for both AC & DC
fans)
Closes after 5 sec of Fan tripping and other fan running.
d. Discharge damper CIoses when DC fan is Started.
162
5.2 DC SCANNER FAN
a. It can he started from FSSS console
FAN STARTS AUTOMATICALY WHEN

a. DP between scanner header & furnace is<152.4 mm of WCL
after a time delay of 5 SECS
b. Loss up Critical power for > 2 secs.
c. Start command for AC or DC persisting neither fan taking
start within 5 SEC.
FAN CAN BE STOPPED WHEN

a. No start command present and stop command is given
b. DP between scanner header & furnace > 152.4 mm WCL
c. Scanner duct to furnace > 600 mm WCL
5.3 DISCHARGE DAMPER

a. Opens automatically when the fan is started
b. Opens automaticaly when loss of critical power for > 2 SECS.
c. Damper closes when fan is stopped after 5 SEC
d. Damper closes if AC fan is started.
5.4. EMERGENCY DAMPER
OPENING :
a. When both FD Fan are off
b. Loss of critical power for >2 SEC
CLOSING : WHEN ANY ONE FD FAN IS RUNNING
6.0 SEAL AIR FAN LOGICS :

a. Seal air fan can be started from FSSS console.
b. Seal air fan A or B start command persisting & neither of
them is starting within 5 SEC.
c. Seal air fan A trips after 15 sec if both PA fans trip
d. Seal air fan-A can he stopped manualy if fan - B is in service
and stop button is not operated.
6.1 SEAL AIR FAN - A
CAN BE STARTED FROM

1. Start push button
163
2. Start Command Given for any fan & neither of them is running
for more than 5 sec.
3. Either PA fan on
4. Either PA fan on & seal air header to cold air duct delta-p Less
than 101.6 mm WCL with a time delay of 10 sec & no stop
command
TRIP CONDITIONS
1. Push button
2. No PA fan is running for more than 15 sec.
3. Fan-B stop push button not pressed.
6.2 SEAL AIR FAN - B

1. Start push button.
2. Start command given for any fan & neither of these fan takes
start within 5 sec then start command goes to both fan.
3. Either PA fan ON & seal air header to cold air duct delta- P
<101.6mm WCL)
4. No stop command.
TRIP CONDITION
1. Neither of the fan discharge damper Open.
2. Stop push button.
3. Neither PA fan is on for more than 15 sec.
SEAL AIR FAN - B

a. It starts automatically when primary air fan is running & seal
air header to cold air duct DP is < 101. 6mm of wcl for more
than 10 sec.
b. Seal air fan-B trips after 15 sec of PA fan tripping.
c. Fan-B can be stopped only when fan-A is in sevice.
d. When start command for both fans are there and none of the
fans start one more command goes after 2 second for starting
the fans.
7.0 PULVERISERS
164
PULVERISER START PERMISSIVES :-
PULVERISER START PERMIT
a. No MFT & Any feeder Proven.

b. No MFT & Burner tilt Horizental & airflow less 40%
1. Pulveriser discharge V/V is open
2. Mill outlet temperature is < 93 Deg. C
3. Feeder in remote
4. Cold air gate open
5. No pulveriser auto unsuccessful start
6. Tramp iron gate open
7. Feeder inlet gate open
8. Primary air permit available
9. Lub oil temp > 320 F
10. Lub Oil sump level adequate
11. No pul veriser trip.
WHEN ABOVE CONDITIONS ARE FULFILLED PULVERISER READY
WILL APPEAR
PRIMARY AIR PERMIT
For mills A.B.C.D. - Either both PA and both FD on or any one PA and
one FD running and four or less no. of mills run
ning and PA header (A.B.C.D) duct pressure not
low or low low.
For mills E.F.G.H.J - Either both PA and both FD fans running or any
one FD and one PA running four or less pressure
not low or low-low
FOR PULVERISER START FOLLOWING ARE TO BE FUFILLED

1. Pulveriser ready.
2. Seal air to header under bowl DP > 200mm WCL.
3. Pulveriser not on.
4. Ignition permit available (3 out of 4 oil guns in service and
boiller load >30% and adjacent feeder running at>50%
loading).
5. Start command given.
7.1 IGNITION PERMITS FOR MILLS :-

MILL - A
(a) AB elevation 3 out of 4 guns in service.
(b) feeder B is proven and feeder speed > 50% and boiler
load > 30%
165
MILL - B
a. 3 Out of 4 AB guns in service
or
b. 3 Out of 4 CD guns in service and feeder C is proven with
feeder speed > 50%
or
c. Feeder A or C are proven with> 50% feeder speed & boiler
load > 30%
MILL - C
a. 3 out of a 4 CD elevation guns in service
or
b. 3 out of 4 AB elevation guns in service and feeder B
speed>50%
or
c. Feeder B or D proven with feeder speed > 50% and boiler
load > 30%
MILL - D
A. 3 Out of 4 CD Elevation guns in service

or
B. Feeder ''G'' or ''E'' proven with feeder speed>50% and boiler
load>30%
MILL - E
a. 3 out of 4 EF elevation guns in service

or
b. 3 out of 4 elevation guns in sevice with feeder ''D'' proven
and speed>50%
c. Feeder 'D' or 'F' in service with speed >50% and boiler
load>30%
MILL - F
[A] 3 out of 4 EF Elevation guns in service.

or
[B] FEEDER 'E' OR 'G' IN SERVICE WITH SPEED >50%
AND BOILER LOAD>30%
166
MILL - G
[A] 3 Out of 4 EF guns in service and feeder 'F' in service with

speed>50%
or
[B] Feeder 'F' or ' H' in service with feeder speed > 50% and
boiler load > 30%
MILL - H
[A] 3 out of 4 HJ guns in service.

or
[B] Feeder 'G' or 'J' in service with feeder speed > 50% and boiler
load > 30%
MILL - J
[A] 3 out of 4 HJ guns in service

or
[B] 3 feeder ' H' Is proven with speed > 50% and boiler load >
30%
7.2 COLD/HOT AIR DAMPERS & TEMPERATURE CONTROL :
[A] Cold and hot air dampers are released for auto operation when :-
1. Hot air gate is open.
2. No hot air gate close command.
3. Pulveriser is on.
[B] cold air damper will open 100% when pulveriser is on and hot air
gate is closed or hot air gate stop command is present.
or
Cold air damper opens 10 100% in case there is a master fueltrip
upon occurance of MFT after a delay of 5 minutes (300 secs)
cold air damper get an 100% open command from FSSS (refer line
55803, CE-FSSS drg no. 16382-2D-8558 in PA fans).
[C] Cold air damper closed to 5% open when pulveriser is tripped and
no cold air damper 100% open command
or
Not of the above case indicated in
Hot air damper closes when :
1. Pulveriser is off. or
167
2. loss of critical power or loss of the unit critical power & loss of
elevation critical power.
3. Hot air gate close command is present and hot air gate not
closed.or
4. Mill outlet temperature is high and gate is not closed.
7.3 COAL FEEDER STARTING
[A] Feeder can be started when the following are satisfied -

1. Pul veriser is in manual mode.
2. Feeder speed demand is at minimum.
3. Pulveriser in ready.
4. Pulveriser temp. is < 54 deg. & not morethan 93 deg.C
5. Ignition permit is rejected & ignitor permits available.
6. Pul veriser is on.
7. No boiller trip
8. No feeder stop command in manual mode.
[B] After feeder starting within 5 seconds, coal on belt should be estab-
lished. Otherwise feeder will trip. Ignition permit should be
available for 180 seconds from the moment start command to
feeder is given.
[C ] FEDDER TRIPS WHEN :-

1. Discharge chute is plugged.
2. Once Feeder trips, it can be restaried after 3 seconds
3. Feeder Can be stopped from the console when selected to
manual.
4. There is no coal in belt.
5. Trips in feed rate error of the demand and supply and Feeding
Mismatches By more than 20%.
7.4 PRIMARY AIR PERMIT

[A] Primary Air permit for pulverisers (A,B.C,D) & (E,F,G,.H & J) air
established when following conditions air satisfied.
1. Both PA fans and both FD fans are on
or
2. Any PA fan is ON and any FD fan is ON and less than 4 Millsl are
in service.
168
3. Hot PA header.Pressure Switche (ABCD) or (MGHS) and hot PA
heade Pressure Transmitter (ABCD) and hot PA header
pressure transmitter (EFGHJ) not Sensing low ( Unit PA header
Pressure is not Sensing low )
4. Hot PA header. Pressure Switches (ABCD) OR (EFGHJ) and
hot PA header Pressure Transmitter (ABCD) and hot PA header
Pressure Transmitter ( EFGHJ) not Sensing very low.
Unit PA header Pressure is not Sensing very low.
PA HDR Pressure is sensed currently with the help of header
(ABCD)& (EFGHJ) Switches in parallel and header pressure
(ABCD) and (EFGHJ) transmitters (LVM) in series.
Finally both switches and Transmitters are kept in series.
this concept is
Visualised to generate " Unit PA header Pressure low or
low- low .''' Absence of all the above cordition gives the PA
permit for ABCD & EFGHJ
[B] After the Associated pull veriser is ON, the primary air permit is
no longer required for the pul verser that is in service.
(C) When both PA fans are off or both FD fans are off all pulverisers
that are in service trip automatically.
[D] TRIP OF MILLS FPOM P A HEADER PRESSURE
1. The Sensing of PA Header pressure low & Lo Lo be taken from
both the header. pressure swiches & pressere Transmitters through
LVM's with any one sevitch (ABCD) or ( EF GHJ) & both the Trans
mitters Sensing a Lo or Lo Lo value respeclivelly.
2. Pulveriser A to J shall trip instantaniously in the event of PA header

pressure going LO LO or both of the PA or FD Fans are not on .
3. In the event of PA header Pressure going low it shall lead to

graded tripping of mills from J to E with a delay of 2 seconds.
4. In the event of tripping of one PA fan or 1 FD Fan mill J & E shall

trip
with a delay of 2 seconds from top to bottom till 4 mills Service.
Tripping command to J goes instantaniously and with a delay of 2
second & subsequent mills from H-E.
169
PULVERISERS STOP WHEN :-
1. Stop button is operated.
2. Pri. air trip command is present
3. Boiler Trip
4. Mill Discharge valve not open.
5. Ignition permit required and lost within 180 second.
6. Lub Oil pump trip(a) lub oil pump ON and pressure low with a
delay of 10 seconds. (b) pulveriser ON and lub oil pump
NOT ON for more than 10 seconds.
7. EPB trip.
8. Seal air header/minimum bowl dp< 128 mm of wcl with a delay
of I minute.
9. Elevation power not available for > 2 sec
10. Auto stop command is present
11. Pulveriser start command is persisting but pulveriser not on
within 10 seconds.
8.0 CC Pump Protections.
Running CC Pump will trip in the following conditions:-

1 Discharge valve 1 not fully open.
2. Discharge Valve 2 not fully open.
3 Motor cavity Temp. high T/C (I.V.M.) and local switch / indica
tor are in series with set value % 60o C and 57.2O C respectively.
4. Electrical trips/EPB trip
8.1 CC Pumps Permissives:
1. Motor cooling water flow adequate. ( > 32 Gallons/ Minute).

2. Casing diff temp. adequate. (>15 deg.c)
3. Motor cavity temp. adequate ( <57.2 deg.c).
4. Discharge valve -1 Open.
5. Discharge valve - 2 Open
6. EPB Released..
170
FSSS : LOGICS
9.0 MFT CONDITIONS:
Master fuel trip is iniitated if any one of the following occurs:

(a) All FD fans tripped.
(b) All ID fans Tripped.
(c) Inadequate water wall Circulation for more than 5 Secs.
(d) All CC pumps Tripped and (b) All CC pumps delta p across each
pump 10 psi and (c) any one discharge valve of each pump
not open
(e) Loss of Reheater Protection for More than 10 seconds ( incorpo
rated in ARP, However FSSS senses instantaniously.
(f) Both Secondary APHS Tripped.
(g) All Boiler Feed pump tripped ( this circuit has a delay at ARP
end)
h) Drum level low low for> 10 secs.
i) Furnace Pressure high - high (2/3 Logic) (> +325mm WCl )
j) Furnace pressure low-low 02/3 (LOGIC) (<-325mm wcl).
k) Loss of all fuel.
l) Flame Fallure
m) Loss of unit critical power for > 2 sec.
n) Emergency trip of Boiler.
o) Loss of 220 Volts DC supply for> 2 seconds.
p) Air flow < 30 % and Boiler Load < 30%
q) Loss of Combustion Control System C/C/S Power (110V
AC) for >2 Seconds . ( this is not connected in our
system ).
r) Simulate Trip (unit paneI in Simulate mode and any other
panel
in operate mode)
s) All Feeders off & Loss of power at any oil elevation in
service.
171
9.1 Purge cycle :
Purge Ready signal will Appear when:

a. HFO trip valve closed
b. All HFO Nozzle valves are closed
c. All Pulverisers off
d. All Feeders off
e. No Boiler trip
f. All scanners sense No Flame
( Fireball AB, BC, DE, FG, GH, HJ AND DISCRIMINATING AB,
CD,EF & H J)
g. Air Flow > 30%
h. All Hot Air Gates Closed
i. Drum level Satisfactory
j. All Aux air dampers modulating (AA to JJ).
k. Both PA fans off
l . Windbox/ Furnace delta `p' Adequate ( 25mm wcl ).
(When `push to purge' Button is Pressed, Purging will Start for
five Minutes.)
9.2 SECONDARY AIR CONTROL:
A. All Aux air Dampers AA, AB, BC, CD,DE EF, FG, GH, HJ,JJ
Modulate to Mainiain a preset Differential Pressure Between
windbox and Furnace Till 30% of Boiler Load.
B. When Boiler load crosses 30% the set point of windbox

Pressure is Increased automatically to another preset value and
all aux, air dampers except where there is oil firing,Start closing
from top to bottom in a sequential Manner to Maintain the new
delta p.
C. Aux . air dampers associated with oil elevations go to a fixed

opening of 35% the setting of 35 % Has been provided by BHEL
during Commisstoning.
D. All fuel air dampers A,B,C,D, E,F,G,H&J Modulate according

to Feeder speed after the feeder is proven UP TO 50% of feeder
speed the Designated Damper remaining closed and between
feeder speed variation for 50 to 100% fuel air damper modu
lates from 0 to 20 %
172
E. Aux. air dampers Assoctated with oil Elevations closes during
HEA Ignitor start and opens after oil Nozzle valves full open,
Elevation Started and start time has expired.
F. Al fuel air dampers close after 50 Seconds of respective Feeder
Trip.
G. When Boiler load falls down to < 30% all aux. air dampers
( except fuel air) Starts opening from Bottom to top in a se
quential Mnanner at a time interval of 10 secs, each.
9.3 HEAVY OIL RECIRCULATION VALVE :
9.3 A Opening: Valve can be opened from UCB from open push
button, when all HFO nozzle valves are closed.
9.3 B. Closing:- 1. Recirculation valve can be closed from close
push button from FSS console.
2 The valve closes automatically if any HFO Nozzle
valve is not closed.
9.4 (A) HFO Trip valve:
HFO Trip Valve can be opened from open push button if the
following conditions are satisfied :-
a. No Boiler Trip / No MFT.
b. HFO header temp.is Adequate> 120 deg.c.
c. HFO supply pr. is adequate> 8 KSC.
d. ALL HFO Nozzle Valves closed.
e. No close command.
f. IT can be opened when HFO Recirculation valve is opened and
All Nozzle valves Closed.
g. HFO Header pressure. atomising steam pressure and HFO
header Temperature are not Low low
9.4 (B) HFO TRIP VALVE CLOSES IN THE FOLLOWING CONDITIONS:

a. Loss of Critical power for>2 SEC.
b. Boiler Trip and any Nozzle valve is not Closed ( for time
being It has been Modified to only MFT )
c. Close PB Operated.
d. Atomising steam pressure is low for >2 Seconds when any
HFO Nozzle is not closed .
e. HFO Header pressure is low for >2 Seconds when any HFO
Nozzle is not closed.
f. HFO header temp. is low for >2 secs.
173
9.5.1 ON Elevation start Permissives:
The Following Conditions are to be fulfilled for Initiating start

command for oil Burners:-
A. Burner (TILT) : Horizontal
B. Air Flow : < 40%
C. No Boiler Trip
D. HFO Trip Valve is Open
If any Feeder Has Proven , Conditions (A) & (B) Are Bypassed
9.5.2 Elevation Trip.

Trip Command is Initiated when there is :
A. Boiler Trip
B. HFO Trip Valve not Open
9.6.0 OIL ELEVATION LOGICS:
9.6.1 START COMMAND: -

The elevation start command goes in any of the following
conditions :-
A. When start command is initiated from FSSS console
OR
B. When elevation support auto command is present from
pulverisers auto Looic
OR
C. When first run back system operates
D. And elevation start permit is present ( as described at 9.5.1

above)
9.6.2 When Start Commad is Given and there is no backup Trip

present, the Command goes to individual Corners as
folloows
Corner No. 1 Immediately
Corner No. 2 After 60 seconds.
Corner No. 3 After 30 seconds.
Corner No 4 After 90 seconds.
* In case of fast load cut back Initiation start command is issued
Simultaneously to all corners of an elevation.
9.6.3 If Flevation start time is expired I.e. 130 secs after Start
Command and 3/4 Oil Valves do not open and proove
174
UNSUCCESSFUL ELEVATION START "' ANNUNCIATION APPEARS.
9.6.4 IF elevation AC power is not Available for more than 2 secs.

" Loss of any Elevation power" Annunctition appears.
9.6.5 If Elevation stop time is expired z.e. 450 seconds (7.5 Min
utes) After Giving stop command, and any corner is not shut
down "Unsuccessful oil Elevation shut down' annunciation
appears.
9.6.6 If Elevation stop/start time is expired and any of the Ignitors

is not Retracted ''Unsuccessful spark rod Retraction'' Annun
ciation appears.
9.6.7. CORNER LOGIC:

When Start Command is Given to any corner the corner Proves
in the following Sequence, If the fullowing conditions are
Satisfied;
A. SCAVENGE VALVE IS CLOSED

B. Gun is in engaged condition
C. Nozzle Valve and Atomising steam Nozzle valve Manual
Isolating valves are open
D. Local selector Switch in remote Position
FOR ANY CORNER TO PROVE:

1. Spark rod advances
2. Gun Advances
3. Atomising steam valve opens
4. Spark Rod is Energised
5. HFO Nozzle valve opens
9.6.8 FOR HFO NOZZLE VALVE TO OPEN, FOLLOWING

CONDITIONS ARE TO BE FULFILLED:
a. No Corner trip command present

b. Flame is present or Ignitor spark is Energised
c. Atomising Valve full open
d. No scavange command is present
175
9.6.9. If the HFO Nozzle valve does not open within 25 secs. and
there is no flame a trip command goes to that corner
9.6.10 If the valve is fully opened and oil flow ( this condition is not
mandatory to keep an oil Gun in service however 3 out of 4
Oil nozzle valve proven would be satisfied only if all the guns
proven have Oil Flow adequate conditions ) is
established will Remain to be in Service.
9.6.11 CORNER STOP SEQUENCE
When a stop command is given to any corner, the Following

Sequence takes place.
a. A Scavenge Command will go to close HFO Nozzle valve
b. Atomising Nozzle valve will open
c. Simultanious command Goes to open Scavenge valve
and to advace Spark rod.
d. Spark is Energised after ignitor is advanced for 15 secs.
E. After 5 Minutes Scavenging Scavenge valve. will close.
F. Atomising valve will close on corner Trip
G. A Back -up trip will be initiated after 6 Minutes to close all
Nozzle valves if they are not closed.
9.6.12 CORNER TRIP

Corner trip is initiated in the following conditions :
a. Oil Gun Not Advanced
b. Guns not Clamped ( engaged )
c. Selector Switch is in off position and atomising manual valve
is Closed.
d. HFO Manual isotating valve or atomising steam isolating valves
are closed.
LOSS OF ALL FUEL TRIP PROTECTION
a. II Comes into Circuit when any of the Nozzle valves is not

closed.
b. Ii Gets reset 5 Seconds ofter MFT
this Protection trips the boiler when
I). The Protection is armed
and
176
All Elevation Tripped
Or
All Nozzle valves Closed
and
All Feeders off
or
Loss of power > 2sec.
II) All Feeders off
or
Loss of power >2 sec.
and
HFa Trip valves not closed
and
All HFO Nozzle valves not Closed
10.0 BOILER FLAME FAILURE PROTECTION
This protection comes into Picture after 2 sec of any Feeder

proving.
This protection acts when all Elevations i. e. AB,BC,DE,FG,GH,& HJ

are voting for no flame.
AB ELEVATION NO FLAME VOTE :
i) Feeder 'A' off and Feeder 'B' off for more than 2 sec.
or
ii) Elevation AB Scanner senses no Flame and elevation AB 2/4

HFO Nozzle not proven.
or
Loss of power Failure for > 2 sec.
or
iii) Elevation AB 2/4 Nozzle valves not proven
or
Power loss > 2 SEC
and
Elevation AB 2/4 nozzle valves not closed or Elevation
started
and
Power loss > 2 Sec.
177
ELEVATION BC FLAME FAILURE
a) Elevation BC 2/4 scanners senses no flame

or
b) Feeder 'B' off or loss of power > 2 sec
and Feeder 'C; off or loss of power > 2 sec
or
c) Feeder CD 2/4 nozzle valve not proven or power loss >2 sec and
Elevation CD any oil valve not closed or elevation started and
power loss >2 sec.
* Similar scheme for DE & FG elevation EF elevation oil guns sup

porting DE & FG elevation fire ball scanners.
10.1 DRUM LEVEL PROTECTION
Boiler will be tripped on drum level Protection if drum level goes

Hi- Hi > 10 sec or. drum level goes lo-lo for> 10 sec
and
i) Both Hydrasteps are voting
or
ii) Left Hydrasteps & RHS Transmitter are voting
or
iii) RHS Hydrastep & LHS transmitter are voting
10.2 INADEQUATE WATER WALL CIRCULATION FOR > 5 SECS
Inadequate water wall circulation tripping for boiler is to act as

follows:
All CC pumps tripped
or
All three pumps in service & dp <10 psi.
or
any one discharge valve of each of the pump is not open.
pump off is sensed From switch gear service contact ,DV- 1/

DV-2 discharge valve not open is sensed from valve limit
switches and low diff. Pressure transmitter. Boiler tripping would
occur only when all the 6 transmitters sense low dp together.
178
10.3.1 REHEATER PROTECTION LOGIC STAGE- II
01. Enabling when Boiler is working and main steam pressure

> 30 kg/sq. CM
02. Arming when HP bypass BP1 or HP bypass BP2 open >2%
and LP bypass V/V open.
03. On Reheater protection tripping for boiler is as follows.
i) Turbine is in tripped condition and boiler is working if BP1 &
BP2 are not open boiler will trip after 15 seconds.
OR
LP bypass Command is > 35% and both LP bypass v/v not
open for >35 seconds boiler will be tripped.
Once the protection is armed the protection will desarm only
after boiler Tripping.
10.3.2 RAHEATER PROTECTION STAGE -1
ARMING:
1. Boiler lighted up / no MFT
and
2. Boiler Pressure > 25 kg/cm2
and
3. Either BP1 or BP2 open 2% and LP bypass open > 2%
once only after that self Latching.
PROTECTION:
1. Protection arming
and
2. Turbine trip from CH-1 and CH-2
and
3. EitherLP bypass close or both HP bypass valves close
(<2% open) then boiler will trip after a time delay of
15 seconds.
B MAIN TURBINE PROTECTIONS

--------------------------------------------------------------------------------------
DESCRIPTION ALARM TRIP LOGIC
--------------------------------------------------------------------------------------
1.0 MECHANICAL
a. Local trip lever operated axial yes

b. Thrust. BRG Axial shift +/-1mm
179
c. Overspeed bolts 10%/11%
d. condnsr. vacuum low-low
2.1 ELECTRICAL:
a. Emergency trip from UCB Yes.

b. Remote trip during ATT ( Prot.progrm )
c. Fire Prot. I ( PB PUSH)
d. Fire prot II ( PB push)
e. MOT level low-low -100mm -150mm -50mm
f. Generator protn.
g. Boiler fire off or boiler trip
h. MCB trubine trip ATRS S/D Programme
I. Condsr. VAC .low-low 0.8 ksc / 140mm. 7 ksc/230
mm
2 out of 3
j. Extended turbine protns.
k. Lube oil pr. low- low 1.1 bar at brg end ( 2 out of 3 )
2.2 EXTENDED TURBINE PROTECTIONS:
a. Level Gen bushing casing top LvL> 75% ( 2 out of 2 )

b. Cold Gas temp. Behind cooler > 55 deg. c (2 out of 2 )
c. Warm air temp. main exciter > 80 deg. c (2 out of 2 )
d. Seal oil temp. behind cooler > 55 deg. c (2 out of 2 )
e. Primary water temp behind cooler >60 deg.c(2 out of 2)
f. Stator water flow low low < 13.3 kg/sec (2 out of 2)
g. Primary water flow main bushing ( U/V/W) <0.37 kg/ sec

(2out of 2 )
h. HP casing diff temp mid metal top/bottom >50 deg. k,
arming load > 20 % (2 out of 2)
i. IP casing -do- (Front) > 50 deg. k, arming load >20%
j. IP casing deltta Rear > 50 deg.k. arming. load >20%
k. HP Exhaust temp > 500 deg.c, ( 2 out of 2 )
180
2.3 FIRE PROTECTION 1 PB PUSH
Fire Potection 1 channel 1

Fire Protection 1 channel 2
Can be operated from UCB, MOT room near LP bypass, near HP
Turbine. when this is operated :-
1. Turbine Trip
2. SGC - CF pump off
3. SLC CF heater off
4. SLC CF pump off
5. CF Heater 1 & 2 off
6. HP C&F pump 1 & 2 off
7. HP CF Cir pump 1 & 2 off
8. Vacu. Breaker open
Fire Protection - II PB push FP2 channel 1 FP 2 channel 2 can be

operated from UCB, HP turbine, MOT room, and LP Bybass.
when this is operated :-
1. Same as 1 to 8 of fireprotection 1
2. SGC Oil supply off
3. SLC AOP 1 & 2 off
4. SLC EOP ON
5. SLC JOP -1 & 2 off
6. SLC JOP - III off
7. SLC Turning Gear off
8. AOP 1 & 2 off
9. JOP 1 & 2 off
10.JOP III ON
3.0 MOT LEVEL LOW-LOW - 15 0MM 2/3 LOGIC
1. Turbine trip
2. VACU Breaker Open
3. SGC Oil supply off
4. SLC AOP 1 & 2 off
5. SLC EOP on
6. SLC JOP 1 & 2 off
7. SLC JOP III off
8. SLC Turning gear off
9. AOP 1 & 2 off
181
10. JOP 1 & 2 off
11. JOP III on
4.0 CEP
CEP PERMISSIVES
1. Suction valve open 100 %
2. Discharge Valve Closed/Discharge header PR. > 28 kg/cm
Square
3. Recirculation valve open 100 %
4. Bearing temp < preset value
5. Discharge vent valve 100 % open
6. Hot well level Greater than Preset value
CEP TRIP:
1. Hot well level low low ( 2 out of 2 )
2. Suction valve close (o%)
3. Bearing temp high - high (100 deg celsius)
4. Discharge pressure low low ( 22 kg/ cm2 Falling and CEP
running) standby CEP comes in service at a discharge pres
sure of 26 ksc CEP discharge header pressure low alarm comes
at 27 KSC
PERMISSIVES FOR CEP AUTO START

1. Suction valve open 100 %
2. Discharge valve closed /discharge header pr. >28 kg /cm2
Square
3. Recirculation valve open 100%
4. Bearing temp. < preset value
5. CEP on auto
6. Other CEP trip
7. Any one CEP running and discharge header pressure < pre
set Value.
5.0 FRF LEVEL SONAR PROBES :

1. CL 001 -50 Lo alarm
2. CL 006,7, 8 - 150 Lo Lo alarm/trip
3. CL 011 level high alarm
4. CL 011 level LO - C.F. Circulation pp stop
AOP : 1 comes into service
Turbine speed greater then 15 RPM & less than 2850
RPM AOP 2 off or any discrepancy
182
Discharge header pressure less than 4.5 KSC
AOP: 2 Comes into service:
AOP 1 off or discrepancy
speed > 15 RPM < 2850 RPM
Discharge header Pressure < 4.5 KSC
6.0 TD BFP
START PERMISSIVES :-
1. Lube Oil pressure normal > 3.5 KSC at O` MTR near oil tank.
2. TD BFP control valve closed.
3. Position controller output 0 %
4. Disconnecting coupling engaged.
5. Pump Delta T low < 25 D.C.
6. Deareater level normal
7. pump discharge valve closed ( 80% Open)
8. Recirulation valve open (100%)
9. Suction valve open (100%)
10. Warm-up valve closed (0%)
TRIPS:
1. Suction valve not open (90 %)
2. Exhaust valve not open (90%)
3.Main pump bearing temp. high-high > 120 Deg. CEL

4.Turbine bearing temp. high- high > 120 degcel.
5.Trip oil pressure low-low <5 kcs ( 2/3 logic)
6.Lube oil pressure low- low < 2.9 ksc. (2/3 logic )
7.Vacuum low-low <0.2 KSC
8.Axial shift of main pump high - high + or - 0.75 mm (2/2
logic)
9. Axial shift of turbine high+or - 0.7 mm ( 2/2 logic )
10. Overspeed trip at 5930 (elec) 5920 (mech.)
11. Seal water temp high -high > 85 dec.cel . for main pump
DE/NDE. side.
12. Deareator level low- low
13. Local trip ( mech.) -1.
14. Local trip (Elect) (2/2)
15. UCB trip manual ( Elect. ) (2/2)
183
7.0 MD BFP:
START PERMISSIVES:
1. Seal water header pr. normal > 15 ksc.
2. Deaerator level normal.
3. Pump bearing temp. normal < 90O C
4. Motor DE/NDE bearing temp. normal < 90O C
5. Hydraulic Coupling bearing temp. normal <90O C
6. Discharge valve closed or header pressure not low.
7. Lube oil pressure normal > 1.2 KSC.
8. Recirculation valve open 100 %
9. Pump suction valve open 100 %
10. Warm-up valve closed O%
11. Main pump delta T Normal < 250 C
12. Hydraulic coupling scoop in min. position.
FOR AUTO START :

1. Seal water header pr. normal 15 ksc.
2. Deareator Level normal .
3. Pump bearing temp normal< 90O C
4. Motor DE/NDE bearing temp. Normal < 90O C
5. Hydraulic Coupling bearing temp. Normal< 90 deg. cel.
6. Discharge Valve closed or header pressure not low.
7. Lube Oil pressure normal > 1.2 ksc.
8. Recirculation valve open 100%
9. Pump suction valve open 100%
10. BEP "C" on auto
11. BFP ' A ' Tripped or BFP ` B tripped or BEP ` A `Running
and suction flow> one pump capacity or BFP `B` running
and suction flow > one pump capacity.
MDBFP TRIPS:
Any one condition :
1. Axial Displacement very high> 7 mm
2. Bearing temp very high > 100 O C.
3. Deaerator level low-low .
4. Lube oil pressure very low< 0. 8KSC.
5. Suction valve not open.
184
6. Seal water temp. (suction side) very high > 85O C.
7. Seal water temp. ( disch. side) very high >85O C
8. Push botton stop.
9. UCB manual stop.
C - GENERATOR PROTECTIONS
Generator & Aux. Data
Rated MW Capacity : 500 MW

Rated MVA Capacity : 588 MVA
Rated Terminal Voltage : 21 KV
Synchronous reactance : 193 %
Transient reactance : 24%
Sub-Transient reactance : 17%
Rated Power FActor : 0.85
NGT Details
Make : FRANCE TRANSFC France
: 18 kV/240V.3.3A/250A. 60kVA
: % Z - 7.5
: Secondary mid pt. eathed
: Secondary earting resist.
o.41 400A. 250 V
Generator I2t : 10
Continous Neg. Seq.
Withstand capacity : 8%
Generator Transformer
Rated MVA Capacity : 3 x 200 MVA

Voltage Ratio : 420/V3/21kV
Vector Group : Yd5
Cooling : OFAF
% Impedance : 12.59
Grounding : Solid
Unit Aux. Transformer
Rated MVA Capacity : 25 MVA

Voltage Ratio : 21 / 6.9 kV
Vector Group : Dy7
185
Cooling : OFAF
% Impedance : 8.5
Taps : OLTC : + 5% to- 10% on HV
Grounding Resistance : 12.7 , 300A, 10sec
PROTECTIONS
1. Generator Differential 87G

2. Generator & Generator Transformer
overall differential 87 GT
3. Generator loss of Excitation 40 G
Generator loss of Excitation 2A/40G
Generator loss of Excitation 2B/ 40g
Generator loss of Excitation 40 GX
4. GT over fluxing 99 GT, 2/99GT.
5. Low forward power interlock A 37 GA
Low Forward Power 2/ 37 GA
6. Low forward power interlock B 37 GB
Low forward power 2A/37 GB
Motoring Alarm AB/37 GB
7. Back up impedance 21/G
Back up impedance. 2/21G
8. Stator Earth Fault 1 64 G1
Stator earth fault 2 64 G2
Stator earth Fault Standby 64 G3
9. Inter turn fault 95 G
10. Rotor Earth Fault SIEMENS
11. GT HV Winding differ 87 HV
12. GT Standby E/F 51 NGT
13. Generator over voltage 59 G
Generator over voltage 2/59 G
14. O/H line differential 87 L
15. Negative Phase Seq. 46 G
16. Generator Overload 51 O/L, (51G)
17. Local Breaker Backup 50Z
Local Breaker Backup 2/50Z,2/50ZX
18. Pole Slipping 98 G
Resistive Finder Relay 98 GY
19. Generator under frequency (Alarm) 81 G
Generator Under frequency (Alarm) 2/81 G
20. UAT Differential 87 UTA
UAT Differential 87 UTB
186
21. UAT Backup over current 51 UTA
UAT Backup over current 51 UTB
22. GT Differential 87 T
23. UAT Back up E/F 51 NUTA, 51 NUTB
24. Gen. VT fuse fail 160/260/360X
GENERATOR PROTECTION 186 G OPERATES UNDER THE FOLOWING

CONDITIONS :-
01. Gen. Diff Protection 87 G

02. Gen Stator 100% E/F Protection 64 G1
03. Gen Under Frequency Alarm (Alarm Only) 81 G
04. Gen O/V Alarm (Alarm Only) 59 G
05. Gen Pole slipping protection 98G+98GY
06. Gen. Low forward power interlock 37GAX, 2/37GA
07. Generator Backup IMPEDENCE Protection 21G
08. GT HV Winding diff protection 87 HV
09. GT Standby E/F Protection 51 NGTX
10. GT WTI & OTI (Turbine Trip (TTR)) 30 B
11. UAT-A & R Backup Overcurrent Protection 51 UTA/UTB
12. GT BUCHHOLTZ 30 A
13. UAT A & B Buchholtz Flag Relay 30C/30D
14. LBB Protection Trip Flag Relay 30 F
16. UAT A & B Temperature high flag relay (only)
for tripping UAT in comer) 30L / 30N
17. Generator Stator 95% E/F Protection 64 G3
OPERATION OF 186G TRIP RELAY LEADS TO THE FOLLOWING -
01. Trip unit bus 'A' 6.6 KV Incomer

02. Trip unit bus 'B' 6.6 KV Incomer
03. Trip Generator Breaker / Transfer Coupler Breaker
04. Trip Field Breaker
05. Trip TTR - A
06. Trip TTR - B
07. TO Arm Main CB LBB Protection
08. To Auto Change Over Ckt of Unit/STN/TIE
187
GENERATOR OF PROTECTION 286G OPERATES
UNDER THE FOLOWING CONDITIONS -
01. Generator Transformer Block overall differential 87 GT

Protection.
02. Generator Negative Sequence Protection 46G
03. Generator Overload alarm (Alarm Only) 51 G
04. Generator Inter Turn Fault Protection 95 G
05. Generator Stator Standby Earith Fault Protection 64 G2
06. GT Over Fluxing 99 GT
07. Generator Field Fail Protection 40G
08. Generator low forward power protection 37GBX, 2A/37GB
09. Generator Transformer Diff Protection. 87T
10. L.B.B. Protection 2/50ZX
11. UAT A Differential Protection 87UTA
12. UAT B Differential Protection 87UTB
13. UATA Backup E/F Protection 51NUTA
14. UATB Backup E/F Protection 51NUTB
15. GT Pressure Relief Device Flag Relay 30 P
16. GT Fire Protection 30 J
17. UAT A& B Fire Protection Flag Relay 30H,30K
18. B/B Protection Trip Flag Relay 30M, 96X
19. UAT A&B UTI & OTI (Only for UAT Incomer Trip) 30L, 30N
OPERATING OF 286G TRIP RELAY LEADS TO THE FOLLOWING -
01. Trip Generator Breaker

02. Trip Field Breaker
03. Trip TTR- A
04. Trip TTR- B
05. To ARM Main CB LBB Protection
06. To Trip Circuit of 52 UTA, 52 UTB (6. 6KV UAT I/C)
07. To Auto Change Over CKT of Unit Bus A&B
08. To CC of Generator Field Circuit Breaker (Blocks Permissive)
09. To CC of Generator Circuit Breaker (Blocks Permissive)
BOILER - TURBINE - GENERATOR TRIPPING LOGIC
A. Boiller Problems Troubles Lead To

a. Boiler Trip MFR A
b. Boiler Trip MFR B
B. Operation of MFR A/B Lead to
a. Turbine Trip TTR A
188
b. Turbine Trip TTR B
C. Operation of Turbine Trip TTR A/B Leads To
a. ESV A/B, IV A/B Closed
D. Trip Oil Pressure <2 KG/CM2
AND
Operation of Low Forward Power Relay A/B 37A/B Lead to
a. Generator Trip Through 2/37GA, 2A/37GB & Then
186G/286G
b. Trip 400 KV Generator Breaker & 6.6 KV UAT I/C Breaker and
field Breaker
E. TURBINE GENERATOR TROUBLES LEAD TO
a. Operation of turbine trip relay TTR / A/B

b. Operation of low forward power relay A/B 37A/B
c. Generator trip through 2/37 GA, 2A/37GB, 186G, 286G
d. Trip 400 KV generator breakers & 6.6 KV UAT I/C breaker
and field breaker
F. ELECTRICAL FAULTS LEAD TO
a. Generator Trip 186G

b. Generator Trip 286G
c. 186G & 286G Trip all Gen. 400 KV & 6.6 KV breakers & field
breaker
d. Operate turbine trip TTR A/B
e. Change over of Unit to station supply at 6.6 KV.
500 MW GENERATOR TRANSFORMER
TRIP :
EACH PHASE GT HAS THE FOLLOWING PROTECTION -
01. Buchholtz trip
02. Pressure release device at a
pressure of 0.35 Kg/cm 2
03. Winding Temperature high
Alarm At 110 Deg. C
Trip at 120 Deg. C
04. Oll Temperature High Alarm
at 90 Deg. C
Trip at 100 Deg. C
189
GENERATOR TRANSFORMER COOLER CONTROL
Six numbers of cooler units. each unit consists of a fan and a pump.
1,3,5 Cooler units take start along with closing of field breaker & stop
with field breaker off.
2,4,6 Cooler units take start at 80O C. Winding temp & Stop at 70 deg C.
winding temp.
UATS
01. Buchholtz relay
02. On load tap changer buchholtz
03. winding temperature high Alarm at 90 Deg. C
Trip At 100 Deg. C.
o4. Oil Temperature High Alarm at 80 Deg. C
Trip at 90 Deg. C
on Temperature high of winding & oil it offloads the UAT.
FAN AUTO STARTING
There are four fans two auto & two standby. i.e. per radiator one
main & one reserve.
The main fan takes start at 65O C winding Temperature and
stops at 55 Deg. C. winding Temerature.
If the main fan trips due to any reason reserve fan takes start
automatically.
RECOMMENDED RELAY SETTINGS
Sl. Relay Desgn. Relay CTR. CT Core PTR PT Core

Recommended settings Remarks
No. type
1. Gen Differntial CAG 34 20000/5 A 1set=0.25A
87 G PhCT1, NCT4 Rstab=400
(ohm)
2. Gen & Gen Trafo DTH 32 21kV side 0.75 A
(fixed)
Overall Diff Gen 20,000/5A NCTI Bias=30%
190
87 GT UAT 20000/5 CT3,6 High Set =
1000%
400 kV side
1000/1A,CT5
ICT 0,823/2.38 A
3. Gen Loss of Exctation YCGF 20000/5A.CT2
40 G K2=K3+K4
=3.0 (offset)
k1=0.8
k2=3.0 Primary values
K3=1.0
K4=2.0 Dia = 1.03 ohm
K5 = 18.6
Offset= 0.176 ohm
2A/40G VTT 11 ttrip = 2.0
sec.
2B/40G VTT 11 trest = 10
sec.
40 GX VAA 11
4. GT Overfluxing 21kV/105V.VT1
99 GT GTT 11
2/99 GT VTT 11 trip = 2.0 sec
5. Low Forward Power 20.000/5 A.CT3

21kV/105V.VT1 p.u.< 0.5%at u.p.f.
Interiock A = 2.5
MW
37 GA WCD 13
2/37GA VTT 11 2.0
Sec
6. Low Forward Power 20.000/5A, CT3

21kV/105V. VT1 p.u.<0.5% at u.p.f.
Interiock B
=2.5MW
37 GB WCD 13
2A, 37 GB VTT 11 Trip =
2.0 sec
@B, 37GB VTT 11 Alarm =
15 sec.
191
7. Back up Impedance 20.000/5/ct2
21kV/105V.VT1 K1=12:K2=1.0 Secondary=9.0
21G YCG 15 IVT 11CV/63.5V K1*K2 =
12 ohm Primary =C 644
Relay Settng
2/21G VTT 11 t:1.5 sec
8. Stator Earth Fauilt NGT

Ratio RMV64: Vs = 5N = 3 =2
ST - 164 G1 PVMM 21kV/240 V RMM 61
: Dead band = 45%
Vrl =
80% time = 5 Sec.
ST - II 64 G2 VDG 14 21kV/105V VT2 PS : 5.4
V: TMs : 0.3 5.4V on open
Standby 64G3 VDG 14 IVT open
Across NGT PS : 5.4
V: TMS : 0.3
Connected across 64
9. Inter Turn Fault IVT 28.72V/110V

95.G PVMM
10. Rotor Earth Fault Siemens, Fld volt
= 300V at St-I : 80 K
W.G. rated output St-II :
5K
11. GT Differential by 1200/5A, BCT1A
87T DTH 31 12500/5A, BCT1C,3C hiset :
1000%
ICT : 8.87/4A
12. GT Standby E/F CDG 11 1000/1A, NBCT2B PS:0.2A
: TMS : 0.3
51 NGT
13. Gen Over voltage 21kV/105V, VT1
59 G VTIG 12 105%
(115.5V)
2/59 G VTT 11 3.0 secs.
14. 400 KV Diff. GT : 1000/1A, BCT1B PS : 0.1
: R stab = 685
192
87 HV CAG 34 Sw Yd 1000/1A, CT4
15. Neg. Phase Seq. 20,000/5A, CT2
46 G CTNM 31 ICT 4.04/5A
K1=3.9;K2 =2.25
(I2/In)2
*t=K1*K2
Alarm :
70% of I2s 5s.
2/46 G VTT 11 Alarm :
5.0 sec.
16. Gen Overload CTU 12 20,000/5A, CT2
51 G 4.4A;
5secs
17. Local Bkr. Backup 1000/1A. CT4
50 Z CTIG 39 0.05 A
2/50Z VTT 11 0.2 secs
203
18. Pole Slip ZTO 1 20.0005A, CT 2
21KV/105V VT1 =4.65 A Reverse offset = 3.05
98 G = 0.94
K2 = 0.82
=4 1=
2 = 75
= 50 ms
98 GY YTGM 14 20,000V5A, CT2
21KV/105/VT1 K1 = 1.6 K2 = 0.61
K3 = 4.0
K4 = 1 Forwardreach = 3.9
K5 = 1.2
=750 0
19. Gen. Under Freq. FTG 11 21KV/105V VT1

81 G VTT 11
p.u./d.o. diff : 0.2
2/81G 2.5 secs
20. UAT Differential DTH 31 (LT) 2500/1A, CT3 ICT so. curr
:0.75 A (Fixed)
87 UTA :0.84/2 89 A Blas :
30 %
193
87 UTB (HT) : 200/5A, CT2.5 High set
: 1000 %
ICT 286/5 A
21. UAT Backup O/C 1200/54
51 NUTA CTU 32 BCT1
51 UTB CTU 32 BCT4
22. UAT LV Backup E/F 100/1 A
51 UTA CTU 12 NBCT
51 UTB CTU 12
23. Seq. Iso Opening
102, 2/102 VTT 11 time:2.0
sec
24. Bus Sel. Incomplete VTT 11
2/89
D - OFF SITE EQUIPMENTS PROTECTIONS
COOLING TOWER / CIRCULATING WATER PUMPS
1.0 CW - Pumps permissives

01) Lub water pressure nurmal ( 2.2 kg cm2 )
02) Suction duct level normal ( 283 mtr from sea level )
03) Bearing Temperature not high ( high 95 O c)
04) Lub flow not lo-lo A&B (34 lpm, 30 lpm )
05) Discharge valve fully closed
06) CW inlet Butterfly valve open (A/B) at condensor
07) Hydraulic system O.K. (no trouble)
08) No Sequential stop command
09) No trip command persisting
10) Hydraulic system in remote operation mode.
Trippings:
01) Bearing Temperature Hi-Hi ( 95 deg. c rising)
02) Suction duct level low-low (283 m)
03) Pump running & discharge valve closed ( 5 deg. open
from full closed ) or 5 % open from fully closed
condition (Sequential Trip )
04) Pump Running & Lub Flow-low ( 45 sec ) 34 & 30 LPM
05) Hydraulic Emergnency trip ( push Button )
194
06) Push Button trip ( Local )
2.0 CT- PUMPS PERMISSIVES
01) Lub water pressure normal ( 2.2 kg cm2 )

02) Suction duct level normal ( 283 Mtr from sea level )
03) Bearing Temperature not high ( High 95 O C)
04) Lub Flow not Lo-Lo A&B (34 LPM, 30 LPM)
05) Discharge valve fully closed
06) Hydraulic system O.K. ( No. Trouble)
07) No Sequential stop command
08) No trip command Persisting
09) Hydraulic System in remote operation mode.
TRIPPINGS :
01) Bearing temperature Hi -Hi (95 Deg. C )
02) Suction Duct level low-low ( 283 M )
03) Pump Running & Discharge Valve closed ( 5 Deg. Open
From Full Closed Or 5.5% Open from fully closed
condition ( sequential trip )
04) Pump Running & lub flow low-low ( 45 sec) 34 & 30 LPM
05) Hydraulic Emergency trip ( push Button)
06) Push Button Trip ( Local )
3.0 ARCW PUMPS
PERMISSIVES :
01) Suction Pressure not low-low >0.11 kg/cm2
02) Bearing Temperature not High- high (<85O C
TRIPS :
01) Suction Pressure low-low < 0.11 kg/ cm2
02) Bearing Temperature High - High (> 85O C)
4.0 ECW PUMP PERMISSIVES

01) Suction Pressure not low-low > 1.1 kg/cm2
02) Bearing temperature high-high )<85O C )
Trips:
01) Suction Pressure not low-low <1.1 kg /cm2
195
02) Bearing Temperature high - high (> 85 O C
EQUIPMENT - WISE OIL RESERVOIR CAPACITY ST – II

Sl. Name of Equipment Oil Brand Tank/Reserva
No. Capacity (Lit)
1. Coal Mill Gear Box SMSP 320 3000
2. Coal Mill Roller assembly SMSP 680 90-240
3. Coal Feeder Gear Box S. Cyl. 680 05
4. PA Fan S. Prime 68 500
5. FD Fan S.Prime 68 600
6. ID Fan (DE/NDE Brg.) SS 150 90
7. ID Fan Fluid coupling ST - 10 2900
8. PAPH Guide Brg. Scyl C. 800 30
9. PAPH Support Brg. S. Cyl- C 800 30
10. PAPH M/D G/Box SS 220 50
11. SAPH Guide Brg. S.Cyl - C 800 50
12. SAPH Support Brg. S.Cyl. C 800 150
13. SAPH M/D Gear Box SS 220 150
14. HP Dozing Pump G/Box SS 150 10
15. Soot Blowers SMSP 320 01
16. Clinker Grinder G/Box SMSP 320 05
17. Clinker Grinder Fluid coupling SS 68 05
18. Scrapper Conveyor G/Box SMSP 680 180
19. Scrapper Conveyor Fluid coupling SS 68 05
20. Scrapper Conveyor PIV variator. SMSP 68 900
21. S/Conveyor VC Gate Hydraulic nit SS 68 80
22. LP Ash Water Pump SP 46 10
23. HP Ash Water Pump SP 46 10
24. Ash Slurry Pump Hydraulic Coupling ST 10 130
25. MOT SP 46 40,000
26. T.D.BFP SP 46 5750
27. M.D. BFP ST 10 80
28. AR CWPump SP46 05
29. CEP Motor (NDE) Top Brg. SP 46 15
30. CEP Motr. (DE) Bottom Brg. SP 32 20
31. ECW Pump SP 46 05
32. Primary water pump SP 46 02
33. Plant Air compressor (PAC) SS 68 70
34. Instrument Air Compressor (IAC) SS 68 70
35. LPDozing Pump G/Box SS150 05
36. LP Dozing Pump Hydraulic Chamber SP 12 01
37. Turbine Governing System FRF 20,000
196
38. CT Fan G/Box SMSP 320 70
39. CT Pump Motor Brg. (Tep/Bottom) SP 46 400
40. CW Pump Motor Brg. (Top/Bottom) SP AC 400
EQUIPEMENT - WISE OIL RESERV0IR CAPACITY ST-2 (WTP)

S. No. Brand of Oil Name of Equipments Quantity (Ltr.)
1. S. S. 68 Alum Metering Pump 25 Ltr.

Effluent Disposal 2 Ltr.
Degasser Water Pump 2 Ltr.
Acid Metering Pump 25 Ltr.
Alkali Metering Pump 25 Ltr.
2. S.P. - 68 DM Water Regeneration 1 ltr.

Alkali Transfer P/P 1 Ltr.
3. S.M.S.P. - 320 G/Box of lime prep. Tank - 5 Ltr.

Misxed Bed Blower 5 Ltr.
Gravity Filter Air Blower 5 Ltr.
G/ Box of Agitator of Clfr 5 Ltr.
G/Box of Alum Soln. Tank 5 Ltr.
G/Box of Hoist of Cl2 ///tonne 3 Ltr.
G/Box of Hoist of R/ Water 5 Ltr.
G/Box of Hoist of Comp. House 5 Ltr.
4. S. P. - 46 Raw Water Pump 25 ltr.
5. S. Cyl. C-800 G/Box of Bridge Drive 5 Ltr.
6. SAE - 10 Jockey Pump for Sprinkler 2 Ltr.
7. S. S. - 150 Compressor Inside DM Plant 30 Ltr.
8. Grease DM Water Transfer Pump (BCPP)

Servogem -3 Raw water Booster pump
Drinking Water Pump
Clarified Water pump
Filter water Pump
DM Water Transfer Pump
Clarified Water Pump (BCPP)
Sprinkler water Pump
Lime Transfer Pump
Chlorine Booster Pump
197
Sump p/p Clarified Water
Pump House
Degasser Blower
TURBINE STARTUP CURVES & CRITERIA
198
199
200
201
202
COOLANT TEMPERATURE CONTROL
Due to load variations during operation and the resulting termal

expansion and contractions, the generator is subjected to stresses.
In order to reduce these stresses, the hydrogen cooling circuit and the
primary water cooling circuit are each provided with a temperature
control system to control the cooling gas and primary water temperature
so that the active generator components are maintained at the proper
temperature level.
The requirements for the temperature control systems are described

below :
Cold = Cold gas temperature or cold primary water

temperature
hot = hot gas temperature or hot primary water temperature
mean = Mean temperature of hot and cold gas or of hot and
cold primary water
= hot - cold with generator carrying full load.
The temperature rise at full load is the temperature difference

between the hot and cold hydrogen gas as given in the hydrogen cooler
design data or between the hot and cold primary water as given in the
disign data of the primary water cooler.
After startup and runup to rated sped, the cooling water supply to the
hydrogen coolers should be opened only when the temperature of the
hydrogen gas has reached the preset cold gas reference. The temperature
difference between cold gas and hot gas is determind by the no-load
losses.
The cooling water supply to the primary water coolers should be

opened only when the generator is carrying load, since only then current-
dependent heat losses will have to be dissipated.
The temperature control systems are cold coolant temperature

control schemes with variable set point as a function of the stator
current. Set point adjustment is selectable between I and l2 or with an
exponent between one and two. With rising stator current, the set point
is reduced, so that the mean value (mean) of hot and cold coolant
temperatures assumes a nearly constant value, as shown in Fig. 1.
203
The difference between the setting values of the two set points
corresponds to half the temperature rise of the hydrogen cooling gas at
no-load, with 5-10K (9-180F) to be taken as a guiding value.
204
TABLE - I
Properties of dry saturated steam
205
TABLE - I
Properties of dry saturated steam
206
TABLE - II
Total heat or enthalpy of superheated steam
Kcal/kg
207
TABLE - II
Kcal/kg
208
TABLE - II
Kcal/kg
209
TABLE - II
Kcal/kg
210
TABLE - III
Specific volume of superheated steam
cu metre/kg
211
TABLE - III
cu metre/kg
212
TABLE - III
cu metre/kg
213
TABLE - III
cu metre/kg
214
TABLE - IV
Entropy of superheated steam
local kg ''K
215
TABLE - IV
local kg ''K
216
TABLE - IV
local kg ''K
217

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

INDIRA GANDHI SUPER THERMAL POWER PROJECT,

6. COAL HANDING PLANT

8.6 Flash Tank 146

11. DIESEL GENERATING SET

12. PLANT COMMUNICATION SYSTEM

D. OFF SITE EQUIPMENT PROTECTION

16 . GRAPHS, CURVES & TABLES

1.1 General Specification

Type of FIRING - Tilting TANGENTIAL

Minimum load at which steam generator can be - 2 adjacent,

Minimum load at which the steam generator can

Maximum load for which individual mill beyond- 50%

1.2 Furnace Specification

Side walls, Rear walls & Roof

Number 444 283 142

Water wall Headers

Lower Headr Outlet Header

Total circumferential/Modified 275/ (proj.) 6600/

1.8 Superheater Attemperator

1.9 Reheat Emergency temp. control attemperator

Type - Non Steaming

Lenght (MM) - 18.000

Location Valve Name and Value set Reset Pr. %

1. B1 Consol 204.00 195.8 4

SUPER 7. S129 Consol 187.0 181.3 3

Location S. No. Valve Name and Value set Reset Pr. %

9. s132 Consol 185.1 181.39 2

Location S. No. Valve Name and Value set Reset Pr. %

13. R1 Consol 54.84 53.2 3

17. R19 Consol 49.00 47.58 3

21. R130 Consol 48.07 45.15 4

Superheater Outlet t/h 1725 530.4 1221.9 924.5 1566

Feed Water t/h 1725 1507.9 1181.1 179.1 1434.5

Coal (HHV=3500 kcal/kg) t/h 367.0 327 266.3 206.2 382.1

AH (Outlet Primary) t/h 659.2 622.0 542.4 432.6 737.7

Sat Temp. in Drum oCC 361 359 356 354 360

Economiser Inlet 0C 256 253 243 229 174

SH Platen Inlet 0C 1116 1091 1037 972 1126

1.12.4 PRESSURES (DRAFTS (AIR&GAS)

The fuel data on which the guarantees given are as follows :

Fuel Design Coal

No. of mills in operation- 6 6 5 4 6

1.12.7 02, Co2 (DRY VOL) AND EXCESS AIR

1.12.8 HEAT BALANCE

EFFICIENCY% 86.60 86.69 87.13 87.56 87.72

Parameters 200 Mw (Stage I) 500MW (Stage II)

Sp. 30.0 20.0

Cation Cond. <0.3 <0.3 <0.3 <0.2 <0.2 <0.2

Res. Hydrazine .010- .010-

Ammoma as 0.5 0.5 1.0 1.0

Phosphate as 2-4 1-2

Total Iron as Fe 010 010 010 010 010 010

Total copper as .005 .005 .005 .003 .003 .003

Chloride as CI 1.0 0.5

D.O as 02 .040 .005 .040 .005

Sodium as Na 005 .005

pH at 250C 6.8-7.0 (6.5-7.0) 6.8-7.0 8.5-9.0

Cond. at 250C 5 <10 <2.2

D.O. (mg/!) >1.0 <0.1 <0.1