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NEWS TECH
TECHNICAL MAGAZINE
ENGINEERS’WELFARE FORUM
SgTPP ZONE
MESSAGE
Welcome to our Technical Magazine ‘NEWS-TECH’ publication in the eve
of Engineers’ Day. It gives me immense pleasure that our Engineers’
Welfare Forum, SgTPP Zone is going to publish a technical magazine
which is securing latest, optimal technical knowledge for the employees
in the field of Sagardighi Thermal Power Plant and is going to play a vital
role among us.
Technical Magazine ‘NEWS-TECH’ focuses on various issues related to
Sagardighi Thermal Power Plant. The mission is to educate, inform by
producing a unique and latest technical magazine to further create
awareness about our plant. It will help to create a platform for knowledge
sharing, learning and engaging best practices among our communities. So
an effort to contribute with this cause on our part and with the support of
my EWF members, we have launched this magazine to gather resources,
educate, inform and collaborate to help our fellow engineers.
I convey my best wishes on all the members of EWF, SgTPP Zone and
expect that the publication ‘NEWS-TECH’ will be able to attain its desired
goal and wish it’s a grand success.
Sincerely,
(SANDIP KUMAR JANA)
Secretary,EWF-SgTPPZone
Content
Erection of condenser 500mw by sibnath ray, ex senior manager
Write up on governing system by sibnath ray, ex senior manager
Erection of turbine 500 mw by sibnath ray, ex senior manager
Introduction of bcw pumps in sgtpp 2X500mw by atanu maity
Difference between Stage# I and Stage # II Coal Handling Plant
at Sagardighi Thermal Power Plant by suvro sen and avijit
masanta
Earthquake by Pinaki Mukherjee Ten interesting facts about power scenario in india by sourav
Chatterje
Modification work at coal handling plant stage# 1by subhajit
paul
Technical dairy stage#2 by soumitra Banerjee
BRIEF NOTES ON VARIABLE FREQUENCY DRIVE INSTALLED AT ID FAN #
500MW
WRITE UP ON TURBINE DRIVEN BOILER FEED PUMP BY TRIDIP DEBNATH
Write up on sas integration by Narayan mohan dhar and Kaushik
dasgupta
ERECTION OF CONDENSER 500 MW
Prepared by: Sibnath Ray, Ex Senior Manager (Construction)
Condenser base plates are placed on the condenser concreted pedestals after marking the
locations. Located positions are properly chipped for grouting them on the pedestals. GP- 1
Grouting Cement is used for fixing the packers over the Condenser Column.
Size of the packers: 140 mm x 200 mm x 32 mm. Total Nos. of packers on each pedestal: 64
Nos.
Condenser column width = 1200 mm. Transverse center distance between two column =
3575 mm + 3575 mm = 7150 mm.
Center line from Longitudinal direction of column = 6435 mm. Hence length of each column
= 6435 + 6435 = 12870 mm
Elevation of spring bottom plate (column top surface) = - 0. 67 Meter. Zero level consider
from 34.5 Meter MSL.
Free length of spring = 645 mm: Pre compressed length = 565 mm from works. Under
loaded condition = 492 mm. At site all spring assembly sets are pre compressed at 492 mm
with the help of hydraulic jack.
Each spring set is placed over 4 Nos. packers. Each side column has 16 Nos. springs. Hence
total Nos. of packers 16x4 = 64 Nos.
From Longitudinal center line of column, packers are placed as per dimensions. Front side
packers are placed 60 mm away from longitudinal center line. Hence there is a 60 mm
distance between turbine center line & condenser center line in longitudinal direction. From
turbine center line in longitudinal direction front side (switchyard end) condenser length is 60
mm less than rear side (boiler end).
[This type of arrangement has been made for two purposes. I) Condenser rear end lifted by
139 mm & front end lifted by 37 mm by inserting packer plates. Hence rear end is higher
than by front end by 102 mm. Initially 37 mm thick shims are placed over all packers before
placement of condenser base plate, to lift front & rear end of condenser by 37 mm.
Thickness of packers under spring sets in between front & rear spring sets will be calculated
by the principle of symmetrical triangles. Here 16 Nos. spring assemblies are provided at
each condenser concreted pedestal. Extreme front side spring assembly needs not to lift. Rest
15 Nos. spring assemblies are to be lifted. Lifting value will be gradually increased & amount
will be as mentioned below. [ 102 / 15 = 6.8: 2nd spring assembly to be lifted by 6.8 mm, 3rd
spring assembly to be lifted by 6.8 x 2 = 13.6 mm, 4th spring assembly to be lifted by 6.8 x 3
= 20.4 mm ………. 15th spring assembly to be lifted by 6.8 x 15 = 102 mm] All packers are
to be placed below the spring bottom plate. After final alignment all packers are welded
together along with base plate (32 mm thick) but top packer (5 mm thick) is kept free for
movement during condenser expansion. Now check the center line of condenser through
turbine longitudinal center line. Both turbine & condenser center line will coincide. 2) There
will not be any accumulated cooling water at rear water box after stopping the CW pump as
water will flow from rear water box to front water box due to downward slope towards front
end. During running condition weight of water at rear end will be more than front end. To
compensate the above load rear end spring coils capacity has been enhanced as per
requirement.]
Distance between two sets of packers is 780 mm (390 mm + 390 mm) in longitudinal
direction. Gap (in transverse direction) between two packers is 200 mm.
Fabrication of Bottom plates, dome wall, side wall plates etc. are done as per drawing.
Bottom plates, dome wall side, wall plates are checked for dimensions as per log sheet at 17
Meter Turbine Floor.
Bottom plates are in two segments. These two bottom plates are placed on prepared bed at 17
Meter TG floor for joining them by welding process. Surface ovality is checked by water tube
gauge. Tolerance will be with in ± 12 mm. Proper stiffener are welded over two bottom plates
to arrest bending during joining of two bottom plates by welding process. Stiffeners are
removed after placement in positions. After completion of welding turn up the bottom surface
at top. Hot Well part is welded on the bottom plate surface. Fixed all 32 Nos. spring
assemblies at their proper positions by tag welding process. Placed 37 mm thick shims over
all the packers of concreted condenser pedestals to lift front & rear end of condenser by 37
mm. Now total assembly is placed on the packers of concreted condenser pedestals by EOT
crane through switchyard end. Again check the ovality & should be with in ± 12 mm.
MTP (Main Tube Plate) front & rear end are in two segments. At 17 meter TG floor each
end MTP two segments are joined on the fabrication bed. Checked for ovality & straightness
at 16 points. Tolerance will be with in ± 12 mm for ovality. Placed front & rear end MTP
assemblies in position. Aligned the MTPs w.r.t. longitudinal & transverse direction of
condenser. Straightness also checked with the help of plumber. Proper fixers are arranged for
holding them in their positions. 3 Nos. wedge type keys are provided at both end of MTP for
micro shifting of MTP towards sidewise, front or rear side of MTP as the case may be for
alignment with other side MTP. Check the length between the two MTP at top, middle &
bottom at identical tube holes at twelve positions at each side as per log sheet. Again checked
the dimensions at diagonally top, bottom & diagonally bottom to top for proper alignment of
MTP. Again check the straightness by the plumber at convenient places.
Condenser side walls (Turbine side & Generator side) are in six segments. [Height of side
wall gradually decreases from front end (switchyard end) to rear end (boiler end). Front end
is 102 mm higher than by rear end. After lifting of condenser towards boiler end by 102 mm,
elevation of side wall will be same at front & rear end of side wall.]
Front side (towards switchyard side) three segments are placed on prepared bed at 17 Meter
TG floor for joining by welding process. Proper stiffener are tag welded over three side wall
plates to arrest bending during joining of two bottom plates by welding process. Rear side
(towards boiler side) end two segments are placed on prepared bed at 17 Meter TG floor for
joining by welding process. Proper stiffener are tag welded over two side wall plates to arrest
bending during joining of two bottom plates by welding process.
Front (3 pieces) & rear (2 pieces) welded side walls of one side (either turbine end or
generator end) are placed on the bottom plate in their positions. These side walls are aligned
along the longitudinal & transverse direction of condenser. Any ovality found over side plate
then pull that part through rope & locked with the bottom plate. In this process side wall
straightness can be corrected. Check the space for middle part of side wall. This space is in-
between front & rear welded side walls. Straightness of side wall is checked by plumber.
After proper alignment tag welded the front & rear side walls with bottom plate. Proper fixers
are arranged for holding them in their positions. Top of the above side walls are also properly
supported. Middle part of side wall is having cutting allowance. After final measurement cut
the middle part of side wall. Now placed middle part of side wall in between front & rear side
walls. After proper alignment with front & rear side walls, middle part of side wall is tag
welded with bottom plate, front & rear side walls. This condenser side wall is aligned along
the longitudinal & transverse direction of condenser. Straightness of side wall is checked by
plumber. Now middle part of side wall is welded with front & rear side walls after arranging
proper stiffeners.
In the same process other side wall of condenser is welded with bottom plate. Distance
between two side walls are to be checked at 3 to 4 positions (Top, Middle & Lower part of
condenser) for better alignment. Angle stiffeners are tag welded & pulled through ropes to
make straightness of side wall. After proper alignment, four corners of side wall plates &
Main Tube Support Plates are tag welded.
Mark the positions of Tube Support Plates (Turbine end & Generator end) on the I - Section
beams of bottom plates as per drawing. Thickness of TSP is 16 mm. Prepare 17 mm slots
with the help of two Nos. flat over I beam by tag welding process. Similar way prepare 17
mm slots over both side walls. Placed T S Plates one by one on the respective slots through
boiler side end. In this manner placed the 4 nos. TSP in slots. Hold the 4 Nos. T S Plates by
tie rods as per log sheet. Next placed the 5 nos. TSP in slots & hold them by another tie rods
as per log sheet. Centering of TSP tube holes is done by piano wire. Take the readings at top,
bottom, left & right of piano wire. Bottom reading should be less than 0.5 mm than top
reading as during welding of TSP with condenser I section of bottom plate TSP will be pulled
towards bottom by 0.5 mm. In this manner TSP tube will centered w.r.t piano wire. . Both
end condenser side wall reading of piano wire should be -0.5 mm than the other side reading.
During welding of TSP with condenser side wall TSP will be pulled towards side wall by 0.5
mm. In this manner TSP tube will centered w.r.t piano wire. During centering of tube holes
TSP may be lifted up or lower down as the case may be. Lowering can be done by cutting the
lower part of TSP. Lifting up can be done by a wedge key. Sidewise shifting can be done by
pulling or pushing the TSP as the case may be.
In this manner centering of 9 Nos. TSP from boiler end of condenser are to be completed.
Vacuum pipes are in three segments. Placed the boiler end vacuum pipe through Tube
Support Plates in positions. Tag welded the vacuum pipe with T S Plates by argon welding to
avoid deposition of welding materials inside the tube. Middle part of vacuum pipe is kept in
a convenient place on the bottom plate. Now positioned front end vacuum pipe (switchyard
side) in position. Extreme end TSP rear end flat is tag welded over I - beam of bottom plate &
two side walls in positions for placement of extreme end TSP. Placed extreme end TSP in
position through front end vacuum pipe. After placement of extreme end TSP, its front end
flat is tag welded for holding TSP in position. Centering of TSP through piano wire is done.
Method is same as mentioned above.
For placement of next TSP adopt the process as above. In this manner placed 4 Nos. TS
Plates over front end vacuum pipe (switchyard side).
Hold these 4 Nos. T S Plates by tie rods as per log sheet. Tie rods of next 3 Nos. TSP also
placed in the front end of TSP & kept them very close to previous 4 Nos. tie rods. This
method is adopted as there is not enough space for inserting tie rods of next 3 Nos. TSP.
Next placed the 3 nos. TSP in slots through front end vacuum pipe. Now tie rods marked for
next 3 Nos. tie rods are pulled out from previous 4 Nos. TSP & placed them in their proper
positions in the next 3 Nos. TSP.
In between 9th & 10th TSP (counting from boiler end) gap between tie rods are arc welded by
a short piece of tie rods. Other end of tie rods are also arc welded. Tie rods & TSP are welded
by argon welding. Main tube plate & tie rods are arc welded.
Total Nos. of tie rods 32 x 2 (Turbine side & Generator side) = 64 Nos. 4 + 1(small) = 5 Nos.
pieces are welded in position to form one tie rod.
In between 9th & 10th TSP (counting from boiler end) gap between front & rear vacuum pipe
is argon welded by the Middle part of vacuum pipe.
Insert two Nos. tubes at top & bottom of TSP (each Turbine side & Generator side) & rotate
tubes through hands during welding of TSP with bottom plate & side walls. First weld TSP
holding down flat with bottom plate & side plate is done. Afterwards welding is done with
flat with TSP. During welding process if pulling of TSP is more than the desired value then
tubes through TSP cannot be rotated. At this situation stopped welding & do the welding in
opposite direction. By this operation pulling of TSP will be in opposite direction & tubes can
be rotated through TSP.
Wall side welding to be done from top to bottom. For proper welding, welding starts 6’’
below from top of TSP & gradually goes up of TSP. Next welding process will be similar as
above. In this way complete the side wall welding with TSP. Four corners of MTP &
condenser side walls are welded. Side walls are also properly welded.
Rear end (Boiler side) is to be lifted by 102 mm than the front end. Thickness of packers
over spring sets in between front & rear spring sets will be calculated by the principle of
symmetrical triangles. Size of packers at each spring assembly is mentioned earlier. All
packers are to be placed below the spring bottom plate after lifting by hydraulic jacks. After
final alignment all packers are welded together along with the base plates (32 mm thick) but
top packer (5 mm thick) is kept free for movement during condenser expansion. Now check
the center line of condenser through turbine longitudinal center line. Both turbine &
condenser center line will coincide.
At middle part of condenser all the Tube Support Plates of each end are first welded by
anchor rods from top end to bottom end. Two Nos. each from turbine end & generator end ie
total 4 Nos. anchor rods are clubbed together & welded by anchor plate for rigidity.
Total Nos. of anchor rod: [TSP side 10 Nos. + TSP top 5 Nos]. x 2 (Turbine side & Generator
side) = 30 Nos. Each piece is formed by welding 5 piecess (4 + 1 small) in position.
Baffle plates are properly placed top the vacuum pipe over TSP & welded by argon welding.
In this zone presence of water vapor is almost nil as almost all steam has been condensed to
steam. Residue part will contain air & non-condensable gas only.
Now ready for condenser tube insertion. For easy passing of condenser cleaning ball through
condenser tubes, tubes are not cut towards entry point of ball. Hence lower parts of condenser
tubes are cut towards boiler end & for upper part tubes are cut towards switchyard end.
Condenser tubes are expanded at both ends Main Tube Plate by tube expander.
Dome wall is to be erected between condenser top 4 side walls with LP 4 side walls through a
neck piece. MTP side two dome walls are placed in positions over MTP. Top of dome walls
are aligned with the bottom of the LP side walls in vertical plane. In this position dome walls
is fixed by proper fixtures. MTP side neck joint is at top end (near to LP girder). LP side
walls (Turbine end & Generator end) are hanging through LP girder & radially locked by the
guide pin. Positions of guide pins are in pedestals No. 3 & 4. Neck joint of these two side is
done below the guide pin. Hence these two side dome wall height is small compare to MTP
sides. Condenser side wall end dome walls are placed in positions & aligned with the bottom
of the LP side walls in vertical plane. . Dome wall stiffeners are welded as per drawing. LP
Heater – 1 is also placed in position & erected as per drawings.
Condenser fill test is done by filling the water above 6” of top of condenser tube & hold it for
72 hrs. Checked for any leakage through any condenser tube, etc. If any leakage found then
rectify & again hold for 72 hrs.
Condenser water box test: Fill the condenser tube side with water & raised pressure at 7.5
kg/cm2 & hold it for 30 minutes. Test is completed if no pressure drop occurs.
Before condenser spring floating all pipes & any types of supports are to be disconnected
from condenser. Now condenser springs are floated. Checked the gap between condenser
dome wall neck & LP side wall neck. According to the gap prepare neck pieces. After
adjustment dome walls are properly arc welded. Now neck pieces are placed & welded 1st
with the LP side walls as per welding schedule & then with dome walls after maintain 3 to 5
mm welding gap. Hence condenser springs are loaded with the weight of empty of condenser
& LPH – 1. During turbine running condition weight of all pipes, water & steam are taken by
the LP Girders through LP side walls.
Important:
Before emptying cooling water through condenser, all condenser springs are to be locked to
avoid any type of lifting of condenser (It happens very rarely).
WRITE UP ON GOVERNING SYSTEM 500 MW KWU
TURBINE Prepared by: Sibnath Ray, Ex Senior Manager (Construction)
Please refer the Governing System Drawing for easy
understanding.
Starts Control Fluid Pump. It creates two type of control fluid.
1) 8 kg/cm2 & 2) 32 kg/cm2 (only for the actuator of control valves)
8 kg/cm2 control fluid flows to
i) Main Trip Gear & blocked.
ii) Reset solenoid valve & blocked.
iii) Cold Reheat NRV & hydraulically closed the valve.
iv) Starting & load limiting device & blocked.
v) Hydraulic Governor & Electronic Hydraulic Governor & blocked.
vi) Solenoid valve of Trim valve & Trim Valve switched on.
vii) Over speed trip test device & blocked.
viii) Change over solenoid valve No. 1 & blocked. Change over solenoid valve No. 2
& flows under the piston of change over valve & lifts the piston
32 kg/cm2 control fluid (filtered) flows under the pilot piston through auxiliary pilot valve.
Unfiltered flows under the piston of main pilot.
Resetting of system by Start Up Fluid & Aux. Start Up Fluid
Bring Starting & Load Limiting Device to closed position (0%) from 100% open position. It
will push the bellow of Speeder gear through lever. This action will open the drain port of
auxiliary follow up piston in maximum condition.
8 kg/cm2 control fluid will create start up fluid & auxiliary start up fluid through Starting &
Load Limiting Device.
Startup fluid will flow to top of Test Valve of stop valve through test solenoid valve No. 1 &
push down the piston of test valve.
Auxiliary start up fluid will flow under the piston of Hand Trip Gear & Main Trip Gear
through Reset Solenoid Valve. This action will lift the pistons of Hand Trip Gear & Main
Trip Gear. Auxiliary start up fluid will also flow to Over Speed Actuator through Over Speed
Trip Test Device & reset the system if required. Auxiliary start up Fluid will reset Hand Trip
Gear, Main Trip Gear & Over Speed Actuator.
Control fluid will create Trip Fluid & Auxiliary Trip Fluid through Main Trip Gear.
Auxiliary Trip Fluid will flow to Hand Trip Gear, Remote Trip Solenoid Valve (RTS) &
Over Speed Actuator through Over Speed Trip Test Device & blocked.
Trip Fluid will flow 1st to Change Over Valve.
From Change Over Valve trip fluid flows to:-
1) Test Solenoid Valve 1 & 2 and blocked.
2) Top of actuator of ESV & IV through Test Valve. This action will lower down the
piston against spring force.
3) Auxiliary follow up piston & follow up piston create auxiliary secondary fluid
& secondary fluid respectively. Initially draining through theses pistons is
maximum, pressure of auxiliary secondary fluid & secondary fluid is minimum.
Secondary fluid flows to the Auxiliary Pilot of HP & IV Control Valves & just
lower down their piston of Auxiliary Pilot.
4) Trim device switched on.
During fly out of nut of emergency governor when turbine speed increases beyond its limit,
fly out nut will push the piston of Over Speed Trip actuator & release the auxiliary trip fluid
to drain. This action will also drain the trip fluid & closed the ESV, IV & Control Valves.
Whenever RTS energized for tripping of TG set through boiler, turbine, generator relay etc.,
auxiliary trip fluid will drain through RTS. This action will also drain the trip fluid & closed
the ESV, IV & Control Valves.
If Hand Trip Gear pressed downwards during any emergency condition arises, auxiliary trip
fluid will drain through Hand Trip Gear drain port. This action will also drain the trip fluid &
closed the ESV, IV & Control Valves.
Opening of ESV & IV:-
Slowly open the Starting & Load Limiting Device (SLLD) up to 50%. This action will open
the drain port of startup fluid & auxiliary start up fluid through SLLD.
Auxiliary start up fluid will drain through SLLD & pistons of Hand Trip Gear, Main Trip
Gear & Over Speed Actuator retained their position as they are in equilibrium condition.
Test valve main piston will be lifted up by spring force. This action will allow draining of trip
fluid from top of ESV & IV actuator & flow of trip fluid under the bottom of ESV & IV
actuator piston. Actuator piston of ESV & IV lifted up & lifts the ESV & IV piston for full
opening of ESV & IV.
Opening of Control Valves of HP & IV to reach turbine speed 2850 rpm:-
Open the SLLD 50% to 100%. This action will release the linkage from bellow & bellow will
come down. Speeder gear spring will lower down the leaver. This lever will lower down the
linkage of aux. follow up piston & decrease the draining port of auxiliary follow up piston.
Auxiliary secondary fluid pressure increases. Increased auxiliary secondary fluid pressure
lowers down the pilot piston of Hydraulic Governor. Control fluid flows on the top of the
main piston of Hydraulic Governor. This action lowers down the piston & lowered the
linkage of follow up piston of Hydraulic Governor. Draining through follow up piston
decreases. Secondary fluid pressure (for HP & IP) through Hydraulic Governor increases.
Feedback linkage lifted the piston & blocked the incoming port of control fluid of Hydraulic
Governor. In this condition secondary fluid pressure will be fixed till any change in auxiliary
secondary fluid pressure occurred.
As the secondary oil pressure increased it lowers further the piston of aux. pilot of
servomotor of control valve. Filtered 32 kg/cm2 oil will flow to the upper of pilot piston of
servomotor of control valve. As pilot piston moves down, main pilot will lift up. Unfiltered
32 kg/cm2 oil will flow under the main piston of servomotor of CV. Control valve lifted up.
As main piston lifted up it will lower down the main pilot through cam arrangement till it
blocked further entry of unfiltered 32 kg/cm2 oil under the main piston. Steam flows through
HP & IP control valves & turbine speed increases. When speed increases 2850 rpm primary
oil (lubricating oil) flows under the bellow of speeder gear. Speeder gear linkage lifted up &
decreases the auxiliary secondary fluid pressure. This action lowers the pressure of
secondary oil & restrict further opening of control valves. Over speed testing trip oil
(lubricating oil) also flows to over speed test device under blocked condition. Increased HP
secondary oil pressure lifted the piston of servomotor of CRH NRV. Control fluid flows in
reverse direction to the actuator of CRH NRV & opens the CRH NRV.
Speeder Gear raised to 100% for reaching 3000 rpm, synchronization & full loading of
machine:
As speeder gear raised 0% to 100% gradually, rotor speed will reach from 2850 rpm to 3000
rpm. Machine will be synchronize. After synchronization gradually open the speeder gear.
Load will increased gradually. When load increases above 50 MW, trim device solenoid
valve de-energized & trimming action withdrawn as hydraulic fluid drained through this
valve. Gradually machine will achieved full load.
LOAD REDUCING BY EHG:
As proportionate valve of EHG energized, its piston will be lower down & control fluid will
lifted up the follow-up piston lever & secondary fluid of HP & IP will reduce. Control valve
of HP & IP will be closed till load reduces to 300 MW. Load can be increased or decreased
with the help of EHG.
Controlling Mode:
If control is hydraulic governor then speeder gear is minimum position & electric controller is
in maximum position. If control is electro-hydraulic governor then speeder gear is at
maximum position & electric control is in minimum position.
AUTAMATIC TURBINE TESTER (ATT): PROTECTION DEVICE:-
Main Trip Valve & Remote Trip Solenoid:
First energized change over solenoid valve No. 1 & 2. Solenoid valve No. 1 lowers its piston
& control fluid will flows on the top of the piston of change over valve. 2nd solenoid valve
lowers its piston & control fluid from bottom of change over valve drained. Change over
valve piston will lowers down. Now control fluid from solenoid valve No.1 flows to the
system via change over valve & act as trip fluid.
Energized remote trip solenoid (RTS), aux. trip fluid will drain through RTS. Piston of Main
Trip Gear & Hand Trip Gear will lower down & blocked trip fluid from MTG & CH. OV.
V/V will also drain.
Resetting of MTG & HTG:
Now 1st de-energized RTS, its piston will lifted up & closed the drain port. Energized Reset
Solenoid Valve, its piston will lift up & control fluid will flow to the path of aux. startup
fluid. This fluid will lifted up the piston of HTG & MTG like aux. startup fluid. Control fluid
will re-established Trip & Aux. Trip Fluid through MTG. Resetting is going on. After
resetting of MTG & HTG de-energized reset solenoid valve & C F fluid under MTG & HTG
which act as aux. startup fluid will drain through SLLD.
De-energized change over solenoid valve No. 1 & 2. This action will drain control fluid from
top of change over valve through solenoid valve No. 1 & control fluid flows under the piston
of change over valve through solenoid valve No. 2 & repositioned its piston. Trip & aux. trip
will create through MTG as usual.
OVER SPEED TRIP TEST DEVICE:
1st operate the valve in closed direction of over speed trip test device manually through which
aux. trip fluid flows to over speed actuator. This action stopped draining of aux. trip fluid
when over speed trip test conducted manually. Now operate motor operated valve of over
speed trip test device in downward direction, test oil will flow to emergency governor & nut
will fly out. This action will hit the lever of actuator of emergency governor & pull its piston.
Blocked aux. trip fluid will be drained. Oil injection is going on & test is completed. Now
operate the motor operated valve in upward direction & test oil will be blocked.
Resetting of emergency governor actuator is done by operating the valve of over speed trip
test device (which blocks the control fluid) manually in downward direction. Control fluid
will flow & act as startup fluid & reset the emergency governor actuator. Now lifted the
above valve manually & resetting fluid will be drained through SLLD.
Next operate the valve in open direction of over speed trip test device manually through
which aux. trip fluid flows to over speed actuator. This action re-established the aux. trip
fluid in the emergency governor actuator.
HAND TRIP DEVICE:
Trip Fluid changeover action is to be started first. Activated change over solenoid No. 1 & 2.
Control fluid under the piston of change over valve will be drained through solenoid valve
No. 2 and control fluid will flow on the top of change over valve through solenoid valve No.
1. Now this control fluid will act as Trip Fluid. Operate Hand Trip Gear in downward
direction. This action will drain the auxiliary trip fluid from the system. Hand Trip Gear &
Main Trip Gear pistons will be lowered by spring force. Blocked trip fluid from Main Trip
Gear also drained.
Next energized reset solenoid valve. Control fluid will flow through this solenoid valve &
act as Aux. Startup Fluid. This fluid will lifted up the pistons of HTG & MTG. Resetting of
HTG & MTG is done. Control Fluid will create trip fluid & auxiliary trip fluid through MTG.
Now de-energized reset solenoid valve. This action will drain Aux. Startup Fluid under the
piston of HTG, MTG & Over Speed actuator. Next de-energized change over solenoid No. 1
& 2. This action will lifted up the piston of Change Over Valve as control fluid will flow
under the piston of Change Over Valve through solenoid valve No.2 & darning of control
fluid from top of Change Over Valve occurred through solenoid valve No.1.
Below the tests can be conducted by reducing load to 300 MW.
HP Stop Valve & Control Valve:
Motor of Control Valve Actuator energized in closed direction. This action will close the HP
control valve. Next ESV closing is started by energized test solenoid valve No. 2. Trip Fluid
will flow under the pilot piston of Test Valve & lifted its piston. This action will drain trip
fluid under the actuator of ESV & ESV will be closed.
Next releasing of ESV will be started 1st by de-energized test solenoid valve No. 2 & then
energizing test solenoid valve No.1. As de-energized test solenoid valve No. 2, trip fluid
under pilot piston will be drained & trip fluid will flow under the bottom of ESV piston. In
the meantime solenoid valve No.1 has been energized & trip fluid will flow through test
solenoid valve No.1 & act as startup fluid & flows on the top of test valve. Piston of Test
valve lowers & trip fluid flows on the top of ESV actuator & trip fluid under the bottom of
ESV actuator drained. ESV actuator piston will be lowered down against spring force.
Now de-energized test solenoid No. 1 & startup fluid will be drained. Test valve piston will
be lifted up. This action will drain trip fluid from top of ESV actuator & trip fluid from other
part of test valve flows under the bottom of ESV actuator piston. This action will open the
ESV.
Motor of Control Valve Actuator energized in opened direction & control valve will be
opened.
COLD REHEAT NRV:
Energized solenoid valve of cold reheat NRV. This action will drain HP secondary fluid from
the pilot piston of CRH NRV actuator. CRH NRV will be closed. Now de-energized solenoid
valve of cold reheat NRV. This action will again flows HP secondary fluid under the bottom
of pilot piston of NRV actuator & NRV will be opened.
WRITE UP ON TURBINE ERECTION (500 MW) BHEL MAKE
Prepared by: Sibnath Ray, Ex Senior Manager (Construction)
Civil department will hand over the TG top deck to Mechanical erection department.
They will give the elevation of concreted pedestals (1, 2, 3 & 4). They also marked the
Center line of TG in longitudinal direction & Center line of LP in transverse direction.
These two center lines are transferred to concreted pedestals of condenser. Civil
department handed over one Master Elevation Level Plate near pedestal No. 4 whose
elevation is 18 Meter as per site drawing. This is the elevation of #4 pedestal parting
plane. Mechanical erection department will cross check the all concreted pedestals
elevation & center lines & sleeves center line distances.
Now all concreted pedestals top will be chipped by chisel for better gripping during
concreting. Blue matching of all four pedestals anchor plates w.r.t sole plates
(located at pedestal bottom) was done. More than 80% blue matching achieved & 0.05
mm filler gauge not passed. Each pedestal has 4 Nos. sole plate & anchor plate for
tightening pedestal by foundation anchor bolts.
Blue matching of LP Base Plate (Front Right, Front Left & Rear Right, Rear Left) anchor
plates w.r.t sole plates (located at pedestal bottom) was done. More than 80% blue
matching achieved & 0.05 mm filler gauge not passed. Each LP Base Plate has 3 Nos.
sole plate & anchor plate for tightening LP Base Plate by foundation anchor bolts.
Before placing 4 Nos. pedestals over concreted pedestals following activities are done at
turbine floor. Clean all pedestals, remove all bearing assembly. Dimension of bearings are
checked. Shims under bearing pads are recorded. 0.03 mm shims should not pass through
top & bottom halves of bearing parting plane after tightening the bolts. Pedestals ½ bore
& full bore readings are also recorded.
Now placed 4 Nos. pedestals over concreted pedestals. Foundation anchor bolts are
placed through foundation pipe sleeves. With respect to turbine center line piano wire, 4
Nos. pedestals are centered. LP Base Plates (Front 2 Nos. & Rear 2 Nos.) are placed in
position & foundation anchor bolts are placed through foundation pipe sleeves. With
respect to turbine center line piano wire in longitudinal direction & Center line of LP
piano wire in transverse direction LP Base Plates are centered. With the help of pedestals
jack bolts elevation of 4 Nos. pedestals are adjusted. Temporary packers are placed under
pedestals for centering & leveling. Preliminary elevation is checked by water tube gauge.
Accurate elevation is checked by water pot depth micrometer. Placed water pot over
Master Elevation Level Plate, parting plane of pedestals Nos. 1, 2, 3 & 4. 1st measured
the depth of water level at Master Elevation Level Plate by depth micrometer. Then take
the readings of other water pot placed over pedestals 1, 2, 3 & 4. Elevation of Master
Elevation Level Plate & pedestals Nos. 4 is same. During the above test proper cover to
be arranged to arrest wind flow & noise also. Preferable time to conduct the test is early
in the morning (4:30 hrs. to 6 hrs.).
Elevation of # 4 pedestal elevation is 18 Mtr. as per drawing & this reading is consider as
00 reference with respect to other pedestals. Elevation of pedestal parting planes as per
drawing value is #4 → 0.00 mm: #3 → 3.38 mm: #2 → 5.02 mm: #1 → 6.53 mm.
With the help of base plate jack bolts elevation (sitting area of plum key on LP Base Plate
& its elevation is 17.200 Meter as per site drawing) of LP Base Plates are adjusted with
the help of water pot depth micrometer. Now distance between bearing pedestals, LP
Base Plates & other dimensions are adjusted as per log sheet.
Final ½ bore readings & center line of pedestals bores are checked. If half bore error
reading value is more than ± 0.2 mm, then correction is required, otherwise ignore the
reading.
HALF BORE ERROR
Half bore readings are taken at pedestals No. 1 (only rear end), 2 (front & rear end),
3(front & rear end), 4(front & rear end).
Pedestal top half is placed over bottom half. By inside micrometer bore reading is
recorded in vertical position. Half bore reading is the half of the above reading. This
reading is known as calculated reading. Now take the bottom half reading in vertical
position. This reading is known as actual reading. Difference of the above two reading
should be zero. If readings are different, then this difference reading value is known as
Half Bore Error. If actual reading is less than calculated reading then rotor will be lifted
up when rotor will be placed on bearing as bearing base is prepared as per calculated half
bore reading. For centering, pedestal of this end is required to be lowered by screwing
jack bolts. In other case action will be just reversed. If difference reading value is more
than ± 0.2 mm, then correction is required, otherwise ignore the reading.
Now tightening pedestals by foundation anchor bolts. Small size gravels are places inside
the all pipe sleeves which dampens the vibrations.
Now bearing pedestals are ready for grouting. Prepared proper shuttering arrangement
around pedestals & LP base plates so that liquid concrete material should not leaked.
Material used for grouting is PIDILITE PAGEL V1 ratio →pagel v1 (1) : water
(0.125). Poured prepared concrete mixture on the pedestals & LP base plates one by one.
At top surface of concreting small gravels are placed so that surface crack should not
occur. Curing time 20 days (minimum) to 28 days (maximum).
After completion of grouting, elongation of the foundation anchor bolts of bearing
pedestals & LP base plates are done as per design value. Again checked all the
dimensions & elevations of bearing pedestals & LP base plates. Half bore error readings
of four pedestals are also checked. All the readings should be with in drawing value.
Bearing
No.
Pedestal Elevation For Unit # 3
Before Grouting After Grouting
1 6.55 mm 6.56 mm
2 5.00 mm 5.02 mm
3 3.45 mm 3.48 mm
4 0.00 mm 0.06mm
Checked HPT rear coupling holes diameter (16 Nos.), IPT front coupling holes diameter
(16 Nos.), IPT rear coupling holes diameter (18 Nos.) & LPT front and rear coupling
holes diameter (18 Nos. each).
Face Run Out of HP, IP, LP Front & Rear are recorded across coupling holes (outer left,
inner left & outer right, inner right). Difference of reading should be 0.02 mm.
HP front & rear side journal diameter, recess diameter & depth are measured.
IP front & rear side journal diameter, IP rear recess, depth and IP front spigot, height are
measured. LP front & rear side journal diameter, LP rear recess, depth and LP front
spigot, height are measured.
Shaft Front
Journal
Dia
Rear
Journal
Dia
Front Side Rear Side Remarks
Spigot
dia.
Depth Recess Dia. Depth
HP 250,
( (- 0.029
mm)
380,( –
0.036
mm)
Recess
dia. 180
(+ 0.01 to
+ 0.03)
18
mm
450 (+ 0.01
to + 0.03)
12
mm
For HP
Recess at
both end.
Drg.
Value
IP ----- 450 (-
0.04)
450 (-
0.02)
7 mm 450 (+ 0.01
to + 0.03)
12
mm
Drg.
Value
LP ----- 500 (+
0.01 to +
0.03)
450 (-
0.02)
7 mm 450 (+ 0.01
to + 0.03)
10
mm
Drg.
Value
GEN. 450, (-
0.04)
450,
(0.04)
449.96
(actual)
7 mm 299.96
(actual)
7 mm Drg.
Value
EXT. 260, (-
0.032)
260, (-
0.032)
299.92 (
“ )
7 mm Drg.
Value
After coupling bolt full tightening there will be minimum 2 to 3 mm gap between spigot
& recess of each coupling. After placing bearing bottom halves, centering & elevation
checking of rotors are to done one by one. Placed bearing No. 1 & 2 on their bottom
supports & centered them w.r.t piano wire.
Now ready for turbine erection.
Placed HP module on pedestals No. 1 & 2. Four side horns of bottom cylinder are
supported on their respective plum packers. Release HP rotor locks. Now HP rotor is
supported on bearings & HP cylinder assembly is supported on plum packers.
Centering of HP Cylinder w.r.t Rotor:
Bearings (1 & 2) are already centered. Centering of HP casing (front & rear side) is done
w.r.t rotor by dial gauge. Rotate the HP shaft & record the dial gauge readings.
Adjustment if required is done by adding shims or removing shims under the lubro-right
plum packer as the case may be with the help of hydraulic jacks. Suppose front top dial
gauge reading is more than bottom. Then front bottom is more open than top. Suppose
difference reading is 0.5 mm. Then 0.25 mm shim is to be added under front two side
plum packer for adjustment.
Roll Check of HP Cylinder for minimum radial clearance:
Placed 4 Nos. hydraulic jacks under the 4 horns of HP cylinder in vertical position for
lifting up & down of cylinder & kept 4 Nos. dial gauge at 4 corner of HP cylinder in
vertical position for watching the movement of cylinder. Rotate the rotor with the help of
EOT crane/ by manual. Lift all the four hydraulic jacks till they touch the cylinder horns.
This will be sense when hydraulic jacks are loaded. Now lift all the four jacks in equal
amount until force requirement to rotate the rotor increases. Stopped shaft rotation
immediately. This reading should be 0.03 to 0.045 mm. The dial gauge reading is the
minimum bottom radial clearance. Now remove shims under 4 Nos. plum keys. Lower
down all 4 Nos. hydraulic jacks in equal amount until force requirement to rotate the
rotor increases. Stopped shaft rotation immediately. This reading should be 0.03 to 0.045
mm. The dial gauge reading is the minimum top radial clearance. Top & bottom radial
clearance should be 0.70 to 0.80 mm. Now lifted all the four jacks by 0.2 mm above the
cylinder original position. Placed shims in position & lower down the jacks to shift the
cylinder load on the palm packers. All the four dial gauge readings should show zero.
Placed 4 Nos. hydraulic jacks at 4 sides of cylinder in horizontal position for shifting of
cylinder left & right side & kept 4 Nos. dial gauge at 4 sides of HP cylinder in horizontal
position for watching the movement of cylinder. 1st release RH side 2 Nos. hydraulic
jacks & operate 2 Nos. LH side hydraulic jacks to shift HP turbine module from LH side
to RH side. Operate hydraulic jacks until force requirement to rotate the rotor increases.
Stopped shaft rotation immediately. This reading should be 0.03 to 0.045 mm. The dial
gauge reading is the minimum left side radial clearance. Similar away Shift HP cylinder
from RH side to LH side until force requirement to rotate the rotor increases. Stopped
shaft rotation immediately. This reading should be 0.03 to 0.045 mm. The dial gauge
reading is the minimum right side radial clearance. LH & RH side radial clearance
should be 0.70 to 0.80 mm. Now return back the HP cylinder in original position.
For adjustment at top & bottom radial clearance shims under 4 Nos. plum packers to be
added or removed as the case may be.
After adjustment of LH & RH side radial clearance prepare 2 Nos. radial keys each for
front & rear end as per available gap. Both side key clearances will be maintained 0.02
to 0.04 mm.
Bump Check of HP Rotor:
Before bump check rotor is to be fixed at bearing No. 2. This can be achieved by
maintaining equal gap at both end thrust bearing pad spaces. HP cylinder is also to be
fixed by maintaining distance between coupling face & cylinder face as per log sheet.
Rotate individual HP rotor by manual & shift rotor towards front pedestal with the help
of jack bolt. Then bring the rotor in original position & again shift rotor in opposite
direction with the help of jack bolt. As soon as requirement of force to shift rotor
increases then stopped shifting. The summation of the above two dial gauge reading is
the minimum clearance between the moving blade & static blade. This test is known as
Bump Check. Reading towards front pedestal is positive & away from front pedestal is
negative. Positive reading should be 2.5 mm & negative reading should be 1.9 mm.
Summation of both reading should be 4.4 to 4.5 mm.
HORN DROP TEST for HP
This test is conducted for checking the loading of all four corners of bottom outer
cylinder.
Placed 4 Nos. dial gauge at four corners of the cylinder in vertical position. Now operate
hydraulic jack at one corner & lift 0.3 to 0.35 mm, so that shim over plum packer can be
removed. Now lowered down the above jack. Hence this corner will be lowered a little
bit from its previous position. Now record the diagonally opposed dial gauge reading
also. This corner may be lifted to some extent. This reading will be positive. This dial
gauge reading should be deducted from the previous dial gauge reading. This reading is
the final reading for this corner. In this manner take the other three corners of bottom
cylinder reading. Correction is done for LH & RH readings of front and rear cylinder.
Suppose cylinder front LH & RH reading is - 0.8 & - 0.6 mm respectively. Then cylinder
front LH is more loaded than front RH cylinder. For correction add shim at front RH
side after taking out from front LH side of cylinder. Thickness of shim will be 0.8 – 0.6
= 0.2 mm/4 = 0.05 mm. Hence 0.05 mm shims to be withdrawn from front LH side of
cylinder & add this to front RH side cylinder. If difference of reading is below 0.1 mm
then correction is not required.
Centering of IP Cylinder:
Placed IP bottom outer cylinder on pedestals No. 2 & 3 with the help of 4 Nos. jack bolts
fitted at four corners of IP bottom cylinder. During boxed up of IP cylinder these jack
bolts are removed after placing required shims under plum packers. Elevation of parting
plane of IP bottom outer cylinder towards both the pedestals is checked with the help of
dial gauge. Pedestals & IP bottom outer cylinder elevation will be same. Hence IP front
end parting plane elevation & # 2 pedestal elevation and IP rear end parting plane
elevation & # 3 pedestal elevations is same. Adjustment of elevation is done with the
help of jack bolts fitted at four corners of cylinder. Centering of IP bottom cylinder is
done w.r.t piano wire. 1st towards both side seal bore & afterwards middle part of
cylinder. Placed outer top cylinder over outer bottom cylinder. Alternate cylinder flange
bolts are tightened & checked the parting plane joint with 0.05 mm filler gauge & it
should not pass. Checked the ovality at front & rear ends of IP outer cylinder where rotor
passes through them. Dis-assembled the top outer cylinder from bottom one.
Now placed bottom inner cylinder over bottom outer cylinder on their respective
keyways with the help of 4 Nos. jack bolts. Elevation of bottom inner & outer cylinder
will be same & adjustment is done by four Nos. jack bolts. These jack bolts are screwed
with IP bottom inner cylinder lugs & placed on the keyways of outer cylinder & by
screwing or unscrewing IP inner bottom cylinder can be flushed with the IP outer bottom
cylinder. At the time of IP cylinder boxed up 4 Nos. packers are prepared as per gap
between IP bottom outer cylinder & IP inner top cylinder horns. Placed these packers in
positions & remove these 4 Nos. jack bolts. Placed inner top cylinder over inner bottom
cylinder. Alternate cylinder flange bolts are tightened & checked the parting plane joint
with 0.05 mm filler gauge & it should not pass. Checked the ovality at front & rear ends
of IP inner cylinder where rotor passes through them. If ovality persists then remove 4
Nos. dowel pins from outer top bottom or inner top bottom cylinder as the case may be
& correction is done after loosening the cylinder parting plane fasteners. In general at the
time of final boxed up these dowel pins are removed after heat tightening of IP cylinder
parting plane fasteners. Remove IP inner top cylinder. Placed bearing No. 3 at pedestal
No. 3. Centered bearing w.r.t piano wire. IP rotor is placed on bearing No. 3 at rear end
& front end is coupled with HP rotor by loose bolts as IP front end has no bearing.
Axial alignment of HP – IP Rotor:
HP & IP coupling are coupled by 4 Nos. loose bolts. Nuts are also loose fitted. HP
coupling recess & IP coupling spigot are in their position. Now checked the axial gap at
top, bottom, left & right position at zero degree & recorded the readings. Now rotate the
HP – IP rotor at 90 degree by an Iron Rod through IP rear end & checked the axial gap at
top, bottom, left, right position & recorded the readings. Similar way rotates the HP – IP
rotor at 180 & 270 degree & recorded all the readings. Then take average of the above
readings. Difference between Top, Bottom & Left, Right reading should be within 0.03
mm.
Adjustment: If reading is more, then adjustment can be done by changing the shims
under bearing bottom pads as the case may be.
Centering of IP cylinder w.r.t rotor:
Both inner & outer top cylinders are properly placed in positions. Centering of IP casing
(front & rear side) is done w.r.t rotor by dial gauge. Rotate the HP – IP shaft together &
record the dial gauge readings. Adjustment if required is done by adding shims or
removing shims under the lub-wright plum packer as the case may be with the help of
hydraulic jacks. Suppose front top dial gauge reading is more than bottom. Then front
bottom is more open than top. Suppose difference reading is 0.5 mm. Then 0.25 mm
shim is to be added under front two side plum packer for adjustment. Difference of
reading is maintained within 0.05 mm.
Roll Check of IP Cylinder for minimum radial clearance:
Both inner & outer top cylinders are properly placed in positions. HP & IP rotor are
coupled & fasteners are loose fitted. Placed 4 Nos. hydraulic jacks under the 4 horns of
IP cylinder & kept 4 Nos. dial gauge at 4 corner of IP cylinder in vertical position for
watching the movement of cylinder. Rotate the rotor with the help of an iron rod through
IP rear end. Lift all the four hydraulic jacks till they touch the cylinder horns. This will
be sense when hydraulic jacks are loaded. Now lift all the four jacks in equal amount
until force requirement to rotate the rotor increases. Stopped shaft rotation immediately.
This reading should be 0.03 to 0.045 mm. The dial gauge reading is the minimum
bottom radial clearance. Now remove shims under 4 Nos. plum keys. Lower down all 4
Nos. hydraulic jacks in equal amount until force requirement to rotate the rotor
increases. Stopped shaft rotation immediately. This reading should be 0.03 to 0.045 mm.
The dial gauge reading is the minimum top radial clearance. Top & bottom radial
clearance should be 0.70 to 0.80 mm. Now lifted all the four jacks by 0.2 mm above the
cylinder original position. Placed shims in position & lower down the jacks to shift the
cylinder load on the palm packers. All the four dial gauge readings should show zero.
Placed 4 Nos. hydraulic jacks at 4 sides of cylinder in horizontal position & kept 4 Nos.
dial gauge at 4 sides of IP cylinder in horizontal position for watching the movement of
cylinder. 1st release RH side 2 Nos. hydraulic jacks & operate 2 Nos. LH side hydraulic
jacks to shift IP turbine cylinder from LH side to RH side. Operate hydraulic jacks until
force requirement to rotate the rotor increases. Stopped shaft rotation immediately. This
reading should be 0.03 to 0.045 mm. The dial gauge reading is the minimum left side
radial clearance. Similar away Shift IP cylinder from RH side to LH side until force
requirement to rotate the rotor increases. Stopped shaft rotation immediately. This
reading should be 0.03 to 0.045 mm. The dial gauge reading is the minimum right side
radial clearance. LH & RH side radial clearance should be 0.70 to 0.80 mm. Now return
back the IP cylinder in original position.
For adjustment at top & bottom radial clearance shims under 4 Nos. plum packers to be
added or removed as the case may be.
After adjustment of LH & RH side radial clearance prepare 2 Nos. radial keys each for
front & rear end as per available gap. Both side key clearances will be 0.02 to 0.04 mm.
Bump Check for IP:
Before conducting bump check 1st bring the rotor in original position. This can be
achieved by adjusting thrust bearing pad gap equal at both side. Again fixed IP cylinder
by maintaining distance between IP coupling face & IP cylinder face as per log sheet. By
the above process cylinder & rotor are kept in original position. HP – IP coupling fitted
by 4 Nos. loose bolts & coupling nuts are properly tightened. Now placed 4 Nos. dial
gauge at four corner of the IP cylinder for watching the movement of cylinder. Placed 4
Nos. hydraulic jacks at four corners in horizontal direction for shifting cylinder. Rotate
the HP – IP rotor by an Iron Rod through IP rear end. Release 2 Nos. hydraulic jacks
towards HP end & operate 2 Nos. hydraulic jacks towards LP end. As soon as
requirement of force to rotate rotor increases then stopped shifting of cylinder. The dial
gauge reading is the minimum positive reading. Next release 2 Nos. hydraulic jacks
towards LP end & operate HP end hydraulic jack. Shift the cylinder from HP end to LP
end till dial gauge reading shows zero. Then further shift cylinder towards HP end by
hydraulic jacks till force requirement to rotate rotor increases. This is the minimum
negative reading. This test is known as Bump Check. Reading towards HP side is +ve &
towards LP side is –ve. Positive reading should be 2.5 mm & negative reading should be
1.5 mm . Summation of both reading should be 4.0 to 4.1 mm.
Steam Path Clearance for IP:
1st fixed the rotor at bearing No. 2. This is the zero – zero position of rotor. Now bring
the
IP cylinder at zero – zero position ie maintain the distance between IP coupling face &
IP
cylinder face as per log sheet. Now record radial & axial clearance as per log sheets.
LP Cylinder Centering:
Placed LH & RH side girder in position over respective LP base plate & leveled by
water pot gauge. Turbine side LP girder elevation will flush with 3rd pedestal elevation
& generator side LP girder elevation will flush with generator front side pedestal
elevation (18 Mts). Placed front & rear side Wall & fixed them with girders until girder
elevation flush with the Side Walls. Checking will be done with dial gauge. After proper
alignment necessary bolting & welding are carried out for proper rigidity.
After proper centering of girders & side walls, prepare keys for front & rear guide pin.
Clearance to be maintained within 0.06 to 0.08 mm. Keys are radial keys of side wall.
These two guide pins are fixed at pedestal No. 3 & 4 during concreting of pedestal No. 3
& 4.
Bottom inner – inner cylinder & outer cylinder together are supplied as assembled
condition. Bottom inner – inner cylinder & bottom outer cylinder is fixed by 4 Nos. pins
at middle of LP bottom cylinder. Now total assembly is placed on the axial keyways of
girders. Elevation of girder & LP bottom cylinder assembly will be same. Total 8 Nos.
jack bolts fitted at four sides of LP bottom cylinder. During boxed up of LP cylinder
these jack bolts are removed after placing required shims under girder packers.
Elevation of parting plane of LP bottom cylinder towards both the pedestals is checked
with the help of dial gauge. Pedestals & LP bottom cylinder elevation will be same.
Hence LP front end parting plane elevation & # 3 pedestal elevation and LP rear end
parting plane elevation & # 4 pedestal elevations is same. Adjustment of elevation is
done with the help of jack bolts fitted at four sides of LP bottom cylinder. Elevation of
bottom cylinder assembly, girder & side wall should be same. Elevation of bottom inner
& outer cylinder will be same & adjustment is done by four Nos. jack bolts. These jack
bolts are screwed with LP bottom inner cylinder horns & placed on the keyways of outer
cylinder & by screwing or unscrewing LP inner bottom cylinder can be flushed with the
LP outer bottom cylinder. At the time of LP cylinder boxed up 4 Nos. packers are
prepared as per gap between LP bottom outer cylinder & LP top inner cylinder horns.
Placed these packers in positions & remove these 4 Nos. jack bolts. Centering of LP
bottom inner cylinder is done w.r.t piano wire, 1st towards both end & afterwards middle
part of cylinder. Placed safety platforms at all openings over parting plane of bottom LP
cylinder.
Placed LP top outer cylinder over bottom cylinder & checked with 0.05 mm filler gauge
after tightening alternate flange bolts. 0.05 mm Filler should not pass. Remove LP top
outer cylinder assembly. Placed inner – inner top cylinder over inner – inner bottom
cylinder & checked with 0.05 mm filler gauge after tightening alternate flange bolts.
Filler should not pass. Again placed LP outer top cylinder over LP bottom outer cylinder
& tighten flange by fasteners. Top inner – inner LP cylinder & LP top outer cylinder is
now fixed by 4 Nos. pins at middle part of LP top cylinder. Remove LP top cylinder
assembly. Placed bearing No. 4 at pedestal No. 4. LP rotor is placed on bearing No. 4 at
rear end & front end coupled with IP rotor by loose bolts as LP front end has no bearing.
Check the radial clearance of LP rotor last stage blade with last stage diffuser at front &
rear end by filler gauge. Clearance will be 13 to 15 mm towards IP end & 6 to 8 mm
towards generator end. If clearance is less then adjustment is done by grinding/scrapping
process as the case may be. In case of Last but one diffuser, reading to be taken in
similar way ie front reading is more than rear one.
Bearing Clearance:
Checked the bearing clearance for brg. No. 1,2,3,4 & recorded their values. Top
clearance is taken by lead wire & side clearance is taken by filler gauge. Bearing bottom
half has one pad. Shims at three sides (at two sides & top of pad) of bearing bottom pad
is provided for micro shifting sidewise & lifting or lowering of journal shaft during final
alignment after floating TG top deck. Generator side bottom half bearing have two side
pads & one bottom pad for micro shifting of generator shaft by adjustment of shims
during alignment.
Bearing No. Top oil clearance Side oil
clearance
1 0.31 to 0.42 mm 0.30 to 0.35 mm
2 0.34 to 0.46 mm 0.40 to 0.42 mm
3 & 4 0.50 to 0.56 mm 0.35 to 0.45 mm
5 & 6 0.55 to 0.68 mm 0.65 to 0.75 mm
7 0.43 to 0.53 mm 0.35 to 0.43 mm
Thrust bearing checking: Clearance is maintained between 0.25 mm to 0.30 mm. Limit is
0.20 mm to 0.40 mm.
Locking of bearings:
Bearing No. 1, 2, 3 & 4 are radially locked by side pad at both LH & RH side. Locking
key Clearance for brg. No. 1 & 2 is 0.02 mm to 0.04 mm & for brg. No. 3 & 4 is 0.08
mm to 0.10 mm.
In case of brg. No. 2 at both side bearing is also axially locked by 2 Nos. axial pad at
each LH & RH side.
Axial alignment of IP – LP Rotor:
IP & LP coupling are coupled by 4 Nos. loose bolts. Nuts are also loose fitted. IP
coupling recess & LP coupling spigot are in their position. Now checked the axial gap at
top, bottom, left, right position at zero degree & recorded the readings. Now rotate the
HP – IP – LP rotor together at 90 degree by LP rear end through EOT crane sling &
checked the axial gap at top, bottom, left, right position & recorded the readings. Similar
way rotates the HP – IP – LP rotor at 180 & 270 degree & recorded all the readings.
Then take average of the above readings. Difference between Top, Bottom & Left, Right
reading should be within 0.03 mm.
Run out Checking of HP – IP rotor couplings & Rotor Journals:
HP –IP coupling are coupled by alternate bolts (lower diameter) & nuts are properly
tightened. Placed Dial gauge at the coupling outer radius (2 Nos. for HP & 2 Nos. for IP
rotor) and at rotor journal No. 1, 2 & 3. Now rotate the HP – IP rotor by an Iron Rod
through IP rear end & checked the dial gauge reading at HP, IP coupling radius and at
rotor journal No. 1, 2 & 3 at each coupling hole. Recorded all the dial gauge readings at
each coupling hole. Difference between the maximum & minimum dial gauge reading is
the run out of rotor at that position. Suppose max. & min. dial gauge reading of a dial
gauge is + 0.01 mm & - 0.015 mm. Then run out at that particular point is 0.01 mm – (-
0.015) = 0.025 mm. After final tighten of coupling bolts, additional + 0.015mm reading
is allowed for run out reading.
Run out Checking of IP – LP rotor couplings & Rotor Journals:
IP –LP coupling are coupled by alternate bolts (lower diameter) & nuts are properly
tightened. Placed Dial gauge at the coupling outer radius (2 Nos. for IP & 2 Nos. for LP
rotor) and at rotor journal No. 3 & 4. Now rotate the HP – IP – LP rotor by LP rear end
through EOT crane sling & checked the dial gauge reading at IP, LP coupling radius and
at rotor journal No. 3 & 4 at each coupling hole. Recorded all the readings at each
coupling hole. Difference between the maximum & minimum dial gauge reading is the
run out of rotor at that position. Suppose max. & min. dial gauge reading of a dial gauge
is + 0.025 mm & - 0.015 mm. Then run out at that particular point is 0.025 mm – (-
0.015) = 0.04 mm. After final tighten of coupling bolts, additional + 0.015 mm reading
is allowed for run out reading.
SWING CHECK AT FRONT END (BRG. No.1):
Swing check is to be done without top outer & inner of IP & LP cylinders. As correction
if required to be done by adjusting the HP – IP coupling bolts or skin cutting the IP
coupling face at pedestal No.2. During Swing check at brg. No. 1, bearing is withdrawn
from brg. No.1 & hang through EOT crane after placing the journal over dummy bearing
which is hanging through sling and maintained the same elevation of journal No.1. LP –
Generator should be de-coupled condition. Place dial gauges at LH, RH & top of journal
No.1. LH & RH dial gauge will show the swing of rotor at LH & RH side during rotation
of rotor at pedestal No. 4. While top dial gauge will show whether rotor is maintaining
the same elevation or not while rotor is rotating. Rotor to be rotated through #4 pedestal
with the help of EOT crane. Rotor swing limit is 0.22 mm at each side. This reading is
achieved by subtracting from Max. reading to Min. reading of each side (LH & RH).
Roll Check of LP Cylinder for minimum radial clearance:
HP – IP – LP couplings are coupled by 4 Nos. loose bolts & nuts also loose fitted. Now
rotate the HP – IP – LP rotor by LP rear end through EOT crane sling at pedestal # 4.
Lift LP cylinder assembly by jack bolts (jack bolts are provided for lifting & lowering
the LP cylinder assembly) at four sides (8 Nos. jack bolts) in equal amount until force
requirement to rotate the rotor increases. Stopped shaft rotation immediately. This
reading should be 1.3 mm. This is the minimum bottom radial clearance. Now remove
shims under the four LP cylinder legs sited on the girder keyway. Lowering the LP
cylinder assembly by jack bolts at four sides in equal amount until force requirement to
rotate the rotor increases. Stopped shaft rotation immediately. This reading should be 1.3
mm. This is the minimum top radial clearance. Now lifted all the four jacks by 0.2 mm
above the cylinder original position. Placed shims in position & lower down the jacks to
shift the cylinder load on the palm packers. All the four dial gauge readings should show
zero.
Adjustment if required can be done by adding or removing shims under the four LP
cylinder horns sited on the girder keyway as the case may be.
For checking LH & RH side minimum radial clearance, placed 4 Nos. hydraulic jacks in
horizontal direction & kept 4 Nos. dial gauge at 4 side of LP cylinder in horizontal
position for watching the movement of cylinder. 1st release RH side 2 Nos. hydraulic
jacks & operate 2 Nos. LH side hydraulic jacks to shift LP turbine cylinder from LH side
to RH side. Operate hydraulic jacks until force requirement to rotate the rotor increases.
Stopped shaft rotation immediately. This reading should be 1.3 mm. The dial gauge
reading is the minimum left side radial clearance. Similar away Shift LP cylinder from
RH side to LH side until force requirement to rotate the rotor increases. Stopped shaft
rotation immediately. This reading should be 1.3 mm. The dial gauge reading is the
minimum right side radial clearance.
After final adjustment of side radial clearance prepare radial keys at front & rear side.
Both side clearances will be 0.06 to 0.08 mm. This is situated at LP outer casing bottom
side.
Girder for both sides is locked by axial key at IP cylinder end. Clearance is maintained
for each key is 0.15 mm.
Horn Drop Test for LP cylinder:
As volume & weight of LP cylinder is huge Horn Drop Test is done on individual corner
& correction is done for individual corner only. At each corner there are two Nos. plum
packers. At each corner one by one shim over plum packer is removed with the help of
hydraulic jack. After releasing hydraulic jack record the dial gauge reading. Correction
method for individual corner is same as in the case of HP & IP cylinder. Correction will
be done if difference of reading is above 0.1 mm.
Bump check for LP cylinder:
Rotor is to be fixed at bearing No. 2 by maintain equal gap at both side of thrust bearing
pad. Cylinder is fixed by axial locking keys (Prepare equal thickness of keys & maintain 0.15
mm clearance). Now remove axial keys. Placed 2 Nos. hydraulic jacks each at LH & RH of
front & rear end of LP cylinder for shifting cylinder axially. Placed 4 Nos. dial gauge at 4
ends for recording movement of cylinder. HP – IP – LP couplings are coupled by 4 Nos.
loose bolts & nuts are properly tightened. Now rotate the HP – IP – LP rotor by LP rear end
through EOTcrane sling at pedestal # 4. Release two Nos. hydraulic jack at front end &
operate other 2 Nos. hydraulic jacks from rear end. As soon as requirement of force to rotate
rotor increases then stopped shifting of cylinder. The dial gauge reading is the minimum
positive reading.Next release 2 Nos. hydraulic jacks at rear end & operate front end hydraulic
jack. Shift the cylinder from IP end to Generator end till dial gauge reading shows zero. Then
further shift cylinder towards Generator end by hydraulic jacks till force requirement to
rotate rotor increases. This is the minimum negative reading. This test is known as Bump
Check. Reading towards IP side is +ve & towards Generator side is –ve. Positive reading
should be 32 mm & negative reading should be 5.2 mm . Summation of both reading should
be 37.5 mm.
Steam Path Clearance for LP:
1st fixed the rotor at bearing No. 2. This is the zero – zero position of rotor. In case of
LP cylinder, Cylinder is fixed by maintaining equal gap on both sides at axial keyways. Now
record radial & axial clearance as per log sheets.
Rotor is locked at Brg. No. 2. (Combined journal cum thrust bearing)
HP outer cylinder is locked axially at pedestal # 2 by two Nos. keys each at LH & RH
end of pedestal. Clearance is maintained for each key is 0.15 mm.
HP outer cylinder is locked radially by 2 Nos. radial keys each for front & rear end of
HP cylinder. Each side key clearances will be maintained 0.02 to 0.04 mm.
IP outer cylinder is locked axially at pedestal # 2 by two Nos. keys each at LH & RH end
of pedestal. Clearance is maintained for each key is 0.15 mm.
IP outer cylinder is locked radially by 2 Nos. radial keys each for front & rear end IP
cylinder. Each side key clearances will be maintained 0.02 to 0.04 mm.
IP inner cylinder is locked axially at outer cylinder keyways (towards HP end). Each
side key clearances will be maintained 0.02 to 0.04 mm.
LP outer cylinder is locked axially at IP end girder keyways where LP lugs rest.
Clearance is maintained for each key is 0.15 mm.
LP outer cylinder is locked radially by radial keys at front & rear side. Both side
clearances will be 0.06 to 0.08 mm. This is situated at LP outer casing bottom side.
LP inner cylinder is locked axially at outer cylinder keyways (towards IP end). Each side
key clearances will be maintained 0.06 to 0.08 mm.
LP side wall (Turbine side & Generator side) are radially locked by guide pins.
Clearance is
maintained 0.06 to 0.08 mm.
Casing locking blocks are provided for HP & IP cylinder at 4 corner of cylinder. These
plates are fixed with respective pedestals. Clearance is maintained 0.2 mm.
Girder for LH & RH sides is locked by axial key at IP cylinder end. Clearance is
maintained for each key is 0.15 mm.
HP cylinder & HP rotor expands towards front pedestal. Hence HP front glands have
labyrinth type seal ring & front pedestal end have see through type gland seal rings. IP
cylinder & IP rotor expands towards Generator end. Hence IP glands towards No. 2
bearing have labyrinth type seal ring & LP end have see through type gland rings. LP
cylinder & LP rotor expands towards Generator end. At LP, rotor expansion is the
summation of expansion of IP rotor & expansion of LP rotor. Hence here at both end
gland type is see through type.
LP shaft seal Thermal Clearance:
This seals are provided at front & rear of LP cylinder. Thermal expansion of shaft seal
assembly is 0.02 mm. These seals are fixed from # 3 & # 4 pedestals. Clearance between
LP gland box & shaft is 21.5 mm (after removing seal holders). Clearance between LP
gland box seal segments & shaft seal is 0.8 mm (after fitting of seals on seal holders).
Fixing of rotor during rotation of rotor at the time of checking:
Rotor position is to be locked during conducting roll check, bump check etc. Rotor
locking is done at two positions. One at HP – IP coupling end & other is at the rear end
of LP rotor coupling flange. In both the cases locking screws placed opposite over the
projected collar. Locking screw tips touch the collar in both direction & fixed the rotor
position during rotation of rotor.
Boxed up of IP Cylinder:
Again take the swing check at bearing No.1 as mentioned earlier. If found ok then
proceed further. Now remove IP rotor assembly. Thoroughly cleaned IP bottom cylinder.
Then positioned IP rotor assembly in position & coupled with HP & LP couplings.
Parting plane jointing paste applied on bottom IP inner cylinder & placed top inner
cylinder over bottom cylinder. Parting plane jointing bolts are fitted as per schedule &
elongated the coupling bolts after heat tightening. Similarly placed top outer cylinder &
Parting plane jointing bolts are fitted as per schedule & elongated the coupling bolts after
heat tightening. Now record the readings of IP rotor centering with IP cylinder at both
ends, horn drop test & bump check.
Boxed up of LP Cylinder:
Now remove LP rotor assembly. Thoroughly cleaned LP bottom cylinder. Then
positioned LP rotor assembly in position & coupled with IP couplings. Parting plane
jointing paste applied on bottom IP inner cylinder & placed top inner cylinder over
bottom cylinder. Parting plane jointing bolts are fitted as per schedule & elongated the
coupling bolts after heat tightening. Similarly placed top outer cylinder & Parting plane
jointing bolts are fitted as per schedule & coupling bolts are hammer tightened. Now
record the readings of LP rotor centering with LP cylinder at both ends, horn drop test &
bump check.
Preparation of coupling bolts:
HP – IP Coupling:
After final axial alignment of HP – IP coupling, coupled all the 16 Nos. paired coupling
holes by loose bolts & tighten properly. 1st open one coupling bolt & enlarge coupling
hole diameter of both the HP & IP coupling half together by honing process so that both
the HP & IP coupling half hole diameter flushed with each other. Now prepare coupling
bolt as per hole diameter & measured its weight. Bolt diameter should be less than by
hole diameter by 0.02 to 03 mm. Placed the coupling bolt in position & tighten properly.
Next open the diagonally opposed coupling bolt & do the same operation as above. In
this way prepare the other coupling bolt & tighten them in position. Difference of weight
of each coupling bolt should be within 2 grams to avoid unbalance. This is done by
grinding process.
Coupling procedure of IP – LP & LP – Gen. is same as above.
Elongation of coupling bolts:
After pipe connection of HP – IP cylinder coupling bolts are elongated to 0.31 mm to
0.34 mm after tightened by special tools with the help of EOT crane.
Elongation of IP – LP coupling bolts is 0.46 to 0.49 mm & for LP – Gen. is 0.51 to 0.54
Direction concept:
Stand in front of Front Pedestal → LH side is Switchyard & it is named as LH side.
RH side is Boiler & it is named as RH side. Again stand in front of HP – IP Turbine &
face front is
towards Boiler. Generator side will be consider as LH side & Turbine side will be
consider as
RH side.
Connection of combined ESV & CV with HP cylinder:
Measured the thickness of U Seal ring. Side by side measured the projected part of ESV
collar which will press the U Seal ring and also the depth at HP cylinder steam admission
pipe where
U Seal ring sits.
ESV collar will sits over HP cylinder steam admission pipe & press the U seal ring.
Difference between the above two reading should be the thickness of U Seal ring – 0.68
mm. When breech nut will be tighten fully U Seal ring will be pressed by 0.68mm.
Placed U Seal ring over HP cylinder steam admission pipe sitting area. Breech nut fitted
over ESV connecting end & tightened properly. After heating breech nut at
recommended temperature rotate the breech by 42 mm.
Connection of HP cylinder exhaust pipe:
Measured the depth where U Seal ring sits on HP cylinder exhaust pipe. Measure the
thickness of U Seal ring. Thickness of U Seal ring should be higher than 1.02 mm. U
Seal ring will be pressed by 1.02 mm. Pull HP exhaust pipe nearer to HP cylinder
exhaust pipe. Placed U Seal ring in position & tighten HP cylinder exhaust pipe & HP
cylinder exhaust pipe coupling flange by fasteners. The above two pipes sits on metal to
metal contact (top surfaces of spigot & bottom surface of recess). After full tightening of
flange there will be 3 mm gap between the Coupling outer flanges.
Connection of IP steam inlet pipe: IP Outer cylinder & IP inner cylinder is connected by L
type seal ring. L type seal ring is fixed inside the IP outer casing by sleeve joint. This sleeve
has outer threaded zone at bottom length & one collar at top end. There is a inner threaded
zone around the steam entry hole of inner side of outer cylinder. Placed L type seal ring over
the outer periphery of steam entry hole of IP inner side of outer casing. Positioned sleeve
collar over L type seal ring. Now screwed the sleeve for holding the L type seal ring by
maintaining 0.05 mm clearance. L type seal ring will be slightly loose fitted over outer
casing. This system allows free expansion of outer cylinder. Placed inner casing over outer
casing. IP inner casing bottom in case of lower cylinder & inner top casing in case of top
cylinder have V shaped groove where projected part of L type seal ring sits. There will be
0.05 mm clearance all around the L type seal ring & V shaped grooves of IP inner casing
bottom & top halves. After steam heating of IP cylinder L type seal ring will sealed due to
expansion. The above arrangement also allows free expansion of inner cylinder.
Connection of Actuator with Stop & Control Valves:
When hydraulic actuators & stop valves cum control valves bonnets are joined by
fasteners,
actuator piston will be compressed against spring force by 12 to 15 mm as the case may
be.
Stop valves or control valves disc will be closed rigidly against spring force.
Generator:
Generator is placed over 4 Nos. base plates (locatedk at LH side two Nos. & RH side
two Nos.). Elevation of base plate is 17.020 Meter. In between two plates axial block is
provided for axially fixing the generator. Fixing is done by both side two Nos. key. Keys
are press fitted.
There are 4 Nos. (LH side two Nos. & RH side two Nos.) base plate for generator front
bearing pedestal & 2 Nos. (LH side one No. & RH side one No.) base plate for generator
rear bearing pedestal. Elevation of these base plates is also 17.020 mm.
During checking of Generator keep axial gap between LP & Generator coupling by 27
mm as expansion of rotor is 27 mm towards generator end.
Radial clearance of generator front side blower is 2.5 to 3 mm. Axial clearance of blower
is 27 mm.
Generator can be lifted up or lowered down by hydraulic jacks at appropriate position.
Sidewise shifting is also done by hydraulic jacks. Generator is fixed by 16 Nos.
foundation bolts (8 Nos. each side). Generator front pedestal fixed by 4 Nos. foundation
bolts (2Nos. each side). Generator rear pedestal fixed by 2 Nos. foundation bolts (1No.
each side).
Exciter: Method of Exciter erection is similar to generator. Exciter is locked by 8 Nos.
foundation bolts (4 Nos. each side).
Swing check at exciter end:
During Swing check at brg. No. 7, bearing is withdrawn from brg. No.7 & hang through
EOT crane after placing the journal at dummy bearing which is hanging through sling
and maintained the same elevation of journal No.7. LP – Generator should be de-
coupled condition. Place dial gauges at LH, RH & bottom of journal No.7. LH & RH
dial gauge will show the swing of rotor at LH & RH side. While bottom dial gauge will
show whether rotor is maintaining the same elevation or not while rotor is rotating.
Rotor to be rotated through #4 pedestal with the help of EOT crane. Rotor swing limit is
0.32 mm at each end. This reading is achieved by subtracting from Max. reading to Min.
reading of each side (LH & RH).
Followings readings are taken before pipe connection, after pipe connection &
after TG deck floating.
1) Alignment of HP – IP, IP – LP, LP – Gen. & Gen. – Exciter coupling
2) Roll Check, Bump Check, Horn Drop Test of HP, IP, LP (Bump check of LP is done
before pipe
connection only. After IP to LP pipe connection Shifting of LP cylinder is not
possible).
3) Bearing clearances of 1, 2, 3, 4, 5, 6 & 7
Introduction of BCW pump in SgTPP 2X500 MW
Prepared By: Atanu Maity, Manager (PS), Commissioning
With Higher Steam Pressures, the Circulation in the Boiler comes down due to reduction in
the Density Difference between Steam and Water ( the main driving force of water through
the water wall tubes ) and hence to drive the water through the Water Walls , a Pump is to be
provided between the Boiler Drum and the Water Wall Bottom header .The Pump which is
used to drive Water through the Water walls at Higher Boiler pressures is known as BOILER
WATER CIRCULATING PUMP ( CC PUMP ).
BCW pump placed in
down comer between
drum and bottom ring
header
Two leading manufacturer and supplier of BCW pump are Torishima/Japan and Hayward
tailor/UK. Sagardighi sage-II(2X500MW) is provided with Torishima Made three BCW
pump/unit with single suction double discharge.
FEATURES:
• Glandless design eliminates leakage completely
• The use of high durability water lubricant bearing eliminates the need for other
lubricants
• By adopting an effective motor cooling circuit no injection of high pressure water
from outside is required( only cooling water at low pressure is needed)
• Maintenance free and highly reliable design of simple mechanism
• Wetted coil motor ensures high efficiency and reliability compared to conventional
motor
• Pull out system facilitates installation , overhaul and inspection
• Vertical suspension types saves plant space
• Pump can follow freely the thermal expansion of pipe line
• Direct connection to the pipe line eradicates the necessity of other foundation
• Easy shut down and starting operation
Design:
Casing: Pressure tight motor casing is flanged onto the pump casing. Both the pump
and motor are designed to withstand full system design pressure.
Bearings:
The shaft is guided in two water lubricated plain bearing. The axial thrust developed
within the pump is nominally hydraulically balanced with a small axial thrust being
supported by a water lubricated segmental thrust bearing.
Nozzle Orientation:
Suction nozzle is arranged axially and discharge nozzle radially.
Driving motor:
The driving motor and the pump form an integral unit. The stator and rotor are
surrounded and flushed through by the fluid pumped within controlled temperature
limit. The water content of the motor is circulated by an auxiliary impeller in the
motor through a heat exchanger mounted outside the pump
Heat barrier:
A heat barrier is provided between pump and the motor so as to prevent heat transfer
from the hot pump to the cold motor thereby protecting the motor’s insulation of
windings.
The associated systems of boiler circulating pumps consists of the following:
A) Fill and purge line system
This system consists of supply lines from High Pressure water source from BFP
discharge & SG fill pump and also low
pressure water source, removable strainer basket, HP fill and Purge cooler, filter,
orifice and all connected lines
both inlet and outlet circuits. The removable strainer basket and HP fill and purge
cooler are common for all the
three circulating pumps.
B)Auxiliary cooling water system
This system is supplied with LP coolant from DMCW cooling water system and also
from a separate emergency
cooling water from over head tank source. The system supplies cooling water to
I) LP Cooler for Pump Motor and
II) HP fill and Purge cooler.
III) Heat barrier
Discharge valve of BCW PUMP:
Two nos discharge cum check valves are provided on two discharge limbs with no
valves in suction line
Cooling system of BCW pump
Technical Data of Boiler Circulating Water (BCW) Pump (2W +1S):
Pump:
Make Torishima Pump Mfg. Co. Ltd., Osaka, Japan
Type & Size HLAV2X300 – 460/1C
Total head 31.26 M
Capacity 2987 m3/Hr.
Design temperature 3700C
Design pressure 214 Kg/cm2
Test pressure 321 Kg/cm2
Motor:
Make Torishima Pump Mfg. Co. Ltd., Osaka, Japan
Type HLV5/4GV35 – 335 (Wet stator squirrel cage 3
phase induction motor)
Specification code JEC-37
Rated output 350 KW
Nos. of poles 4
Voltage 3300 ± 10% V
Frequency 50 Hz (Variation: + 3%, - 5%)
Full Load Current 89.7 Amps
No Load Current Approx. 35 Amps
Starting Current 500% of FLC with IS tolerance
Full load speed 1470 rpm
Duty Continuous
Ambient temperature 500C
Type of enclosure & ventilation Totally enclosed – No ventilation (wet)
Degree of protection IP 68 (Terminal Box IP 55)
Insulation Class “Y” (900C)
Material & treatment of insulation XLPE extruded insulation on winding wire & lead
cable with taped internal joints
Efficiency at 100%, 50%, 25% load 91%, 88%, 81.2%
Power factor at 100%, 50%, 25%
load
0.75, 0.56, 0.337
Winding connection Star
Permissible starting duty cycle Cold: 3 starts/Hr.; Hot: 2 starts/hr.
Method of cooling IC8W1W7
Motor GD2 13 Kg.M2
Bearings:
Nos. of bearing 2
Type Tilting Pad
Lubrication system Self (boiler water)
Life at rated speed 30,000 Hrs.
Bearing end play 1 mm
Max. permissible temperature of brg. 900C
Motor Cooler:
Water requirement 150 LPM
Losses removed by cooler 41 KW (at cooler design condition)
Max. cooling water inlet temperature 390C
Max. cooling water outlet
temperature
430C
Temperature rise through cooler 40C
Permissible cooler outlet water
pressure
28 bar
Pressure drop through cooler Approx.. 0.5 bar
Arrangement to ensure water flow Auxiliary impeller on motor shaft
Weight:
Weight of stator (wound) Approx.. 700 Kg without pressure casing
Weight of rotor (wound) Approx.. 200 Kg without shaft
Weight of copper Approx.. 150 Kg
Net weight of motor Approx.. 7300 Kg with heat barrier & terminal box
Important Interlocks:
HP cooling water outlet temperature
High Alarm
630C
HP cooling water outlet temperature
V. High Alarm & Pump tripped
660C
Difference between Stage# I and Stage # II Coal Handling
Plant at Sagardighi Thermal Power Plant
Prepared By: Subhro Sen, Manager (PS), Electrical Construction, SgTPP &
Avijit Masanta, Asst. Mgr (PS), Commissioning (BOP), SgTPP
Sl
no
Description Stage# I Stage# II
1 Rated Capacity 800TPH 2000TPH
2 Main Components
Single Track Hopper with
Single Crusher House, Single
Stacker Cum Reclaimer with
Two(02) nos of stack yard
Single Track Hopper, Single wagon
tippler with single Crusher house,
Double Stacker cum Reclaimer
with 4 nos stack yard.
3 Track Hopper
Length of Track Hopper :
210Mtr
Nos of division throughout the
length : 70
Nos ofWagon Placement: 19
Gratings are placed in line with
Track Hopper Top Surface
Length of Track Hopper: 265Mtr
Nos of division throughout the
length: 84
Nos of Wagon Placement: 23
Gratings are placed 300mm down
in respect to Track Hopper Top
Surface
4 Wagon Tippler
No Provision for Wagon
Tippler
Name of Manufacturer: M/s
MBECL
Name of Collaborator:
Type of Wagon Tippler: Rotaside
Gear Driven with Hydraulic Drive
and Hydraulic Clamping (TOP,
SIDE WALL and WHEEL
GRIPPING Arrangement). Tippling
Angle Maximum 160 degree,
Wagon can be handled as per
RDSO G-33 (Rev-1)
5 Paddle Feeders
Make: Elecon
04 nos of Paddle Feeders (Each
of 800TPH Rated Capacity)
placed at the bottom of Track
Hopper. Plough Drive:
Hydraulic Type with Gear Box
in between Plough Blade and
Hydraulic Motor.
Long Travel: Hydraulic Type.
For reeling of Power Cable
and Control Cable, PCRD
(Power Cable reeling Drum)
and CCRD (Control Cable
Reeling drum) placed at
Paddle Feeder Table.
Make: MSEL
04 nos Paddle Feeders (Each of
1200TPH Rated Capacity) placed at
the bottom of Track Hopper.
Plough Drive: Hydraulic Type,
Plough Blades are directly coupled
with Hydraulic Motor.
Long Travel: Different Rack
installed throughout the length of
Paddle Feeder Rail Structure,
travelling done with a rack and
pinion mechanism.
Power Transmission and
communication done through E-
Chain System instead of PCRD
and CCRD.
6 Crusher House
RBF: 02 (two) nos RBF (Belt
Speed: 1mtr/sec, Width: 1600
mm) installed at the top of
crusher house which are used
for dividing the feeding into 03
(three) nos Roller Screens and
Crushers.
Roller Screens: Make:
ELECON
03 (three) nos Roller
Screens(800TPH rated
capacity) are installed where
32 sets of Roll Bodies and 02
nos of Electrical Drives are
installed for Coal transfer.
Crushers: Make: MSEL
03 (three) nos ring granulators
(124 nos of ring hammer) are
installed of 800TPH capacity.
Electrical Motor : 750 Kw and
700 rpm
Belt Feeders: 03 nos of belt
feeders are installed at the
bottom of each crusher for
feeding coal to both of the
route finally at the outlet of
Crusher house.
Roller Screens: Make: MSEL
04 (Four) nos Roller Screens (02
nos for each route [Capacity:
1200TPH each]) are installed where
24 sets of Roll Bodies and 02 nos
of Electrical Drives are installed.
Crushers: Make: MSEL
04 (four) nos ring granulators (124
nos of ring hammer) are installed of
1200TPH capacity. Electrical
Motor: 850 Kw and 750 rpm.
RBF: In stage# II RBFs are
installed at the Crusher discharge.
Each of the RBF carries the coal
from 02 nos crushers.
Belt Speed maintained:
1.8mtr/sec. Width of Belt is
2000mm. On one side RBF
discharges to the Stack Yard and on
another side it discharges towards
bunker as well as to Stage I
7 Stacker Cum
Reclaimer
Make: ELECON Capacity:
800TPH
Long Travel: 06 nos Electrical
Motor and gear box mounted
for travelling of Boggies.
Boom Luffing: 02 nos
Hydraulic Power Cylinders
actuators are used for boom
luffing.
Slew Mechanism: 02 sets of
Electric Motor and Gearbox
mounted for slewing.
Boom Conveyor: Electrical
Motor and Gearbox mounted.
Intermediate Conveyor:
Electrical Motor and Gear Box
mounted.
Operator Cabin: Adjustment
of cabin height done by means
of hydraulic cylinder and
actuator.
Bucket Wheel: Electric Motor
Make: MSEL Capacity: 2000TPH
Long Travel: 12 nos Electrical
Motor and gear box mounted for
travelling of Boggies.
Boom Luffing: 02 nos Hydraulic
Power Cylinders actuators are used
for boom luffing.
Slew Mechanism: 02 sets of
Hydraulic Motors and single
Hydraulic Power Pack mounted for
slewing.
Boom Conveyor: Hydraulic Motor
and Hydraulic Power Pack mounted
Intermediate Conveyor:
Hydraulic Motor and Hydraulic
Power Pack mounted
Operator Cabin: Adjustment of
cabin height done by means of
hydraulic cylinder and actuator.
Bucket Wheel: Hydraulic Motor
and Hydraulic Power Pack
mounted.
and Gear Box mounted for
rotating Bucket wheel.
Transfer of Coal from Yard
Conveyer to Intermediate
Conveyor done by means of
vibrating feeder.
Yard Conveyor: Having
Electric motor and gearbox on
both of its sides for reversible
movements
Power Transmission and
Communication: PCRD and
CCRD Installed.
Transfer of Coal from Yard
Conveyer to Intermediate Conveyor
done by means of cross conveyor
(driven by electric motor and
gearbox).
Yard Conveyor: Having hydraulic
motor and HPP on both of its sides
for reversible movements
Power Transmission and
Communication: Power
Transmission Through E Chain
System. And Communication is
Wireless Fidelity
8 Travelling Tripper
Make: MSEL Capacity:
800TPH
02 nos Travelling Trippers
installed for Bunkering of 02 X
300MW Units
Make: MSEL Capacity: 2000TPH
04 nos Travelling Trippers installed
for Bunkering of 02 X 500MW
Units
9 Conveyors
Make: MBECL Capacity:
800TPH
Belt Width: 1200mm
Belt Speed: 2.8mtr/sec
Drive Type: Electric Motor
with Gear Box and Fluid
Coupling.
Hold Backs in Gear Boxes are
used for braking of conveyors
Make: MBECL Capacity:
2000TPH
Belt Width: 1600 mm
Belt Speed: 3.1 mtr/sec
Drive Type: Radial Piston type
Hydraulic Motors are directly
coupled with the drive pulley which
are taking pressure from the Axial
Piston Type hydraulic pumps in
hydraulic power pack. Hydraulic
pumps are driven by Electric
Motors mounted on top of HPP.
Braking mechanism is incorporated
at hydraulic motor, acts by means
of hydraulic system
10 Electrical System
Voltage Grade Used: 6.6 KV
and 415 V. All the Electric
Motors are horizontally
mounted at Conveyor and
Equipment drives.
HT Switchgear make: M/s
AREVA
LT Switchgear make: M/s
Schneider Electric
Motor Make: Alstom
PLC: Rockwell Automation.
Voltage Grade Used: 11 KV, 3.3
KV and 415 V. All the Electric
Motors are vertically mounted at
Conveyor drives.
HT Switchgear make: M/s
MEGAWIN
LT Switchgear make: M/s L&T
Motor Make: Marathon
PLC: Honeywell.
11
Other Systems
DE, DS, Ventilation System,
Compressed Air System for
BOBR Unloading as well as
In Stage# II CHP, Dry Fog Dust
Suppression System, Suspended
Magnet and 02 nos Coal Sampling
Flap Gate Operation, ILMS,
Belt Weighing System, Metal
Detector, 01 no Coal Sampling
Unit before bunker conveyor
installed at Stage# I CHP.
Unit (Crusher House and TP-14)
are installed along with all the other
systems at Stage# I
Earthquake Prepared by Pinaki mukherjee, Manager(PS), IPH (E), SgTPP
The word earthquake is a fear full word to all of us. The division of science related to
research and analysis of earthquake is called seismology and broadly it is in under Geology.
The word earth quake (also known as a quake, tremor or temblor) is the perceptible shaking
of the surface of the Earth, resulting from the sudden release of energy in
the Earth's crust that creates seismic waves. Till date no firm forecasting is possible regarding
the earthquake. Earthquakes are measured using observations from seismometers . The
moment and magnitude as the standard measuring quantity of the earth quake. Normally in
this scale the more numerous earthquakes smaller than magnitude 5 reported by national
seismological observatories are measured mostly on the local magnitude scale, also referred
to as the Richter magnitude scale. Both the two type of scale are more or less similar in their
physical significance. Magnitude of this scale 3 is lower and 7 or more is called devastating.
The largest earthquakes in historic times have been of magnitude slightly over 9, although
there is no limit to the possible magnitude. Intensity of shaking is measured on the
modified Mercalli scale. The shallower an earthquake, the more damage to structures it
causes, all else being equal.
In every earthquake having an epicenter, means the point where an earthquake or
underground explosion originates the earth has four major layers: the inner core, outer core,
mantle and crust. The crust and the top of the mantle make up a thin skin on the surface of
our planet. But this skin is not all in one piece – it is made up of many pieces like a puzzle
covering the surface of the earth. Not only that, but these puzzle pieces keep slowly moving
around, sliding past one another and bumping into each other. We call these puzzle
piecestectonic plates, and the edges of the plates are called the plate boundaries. The plate
boundaries are made up of many faults, and most of the earthquakes around the world occur
on these faults. Since the edges of the plates are rough, they get stuck while the rest of the
plate keeps moving. Finally, when the plate has moved far enough, the edges unstick on one
of the faults and there is an earthquake
Among the different theory behind the earthquake the most acceptable theory is plate tectonic
theory. As per this theory The plates consist of an outer layer of the Earth, the lithosphere,
which is cool enough to behave as a more or less rigid shell. Occasionally the
hot asthenosphere of the Earth finds a weak place in the lithosphere to rise buoyantly as a
plume, or hotspot. In bellow mentioned fig showing the different plate.
The earth release its internal heat by convecting or boiling the hot asthenospheric mantle
rises to the surface and spreads laterally, transporting oceans and continents as on a slow
conveyor belt. The speed of this motion is a few centimeters per year, about as fast as your
fingernails grow. The earthquake generate between the collisions of any of the two plates.
Effects of earth quake.
1. Landslides and avalanches
2. Fires.
3. Soil liquefaction
4. Tsunami
5. Floods
6. Human impacts.
Major Earthquake:-
Earthquakes of magnitude 8.0 and greater since 1900. The apparent 3D volumes of the
bubbles are linearly proportional to their respective fatalities. One of the most devastating
earthquakes in recorded history was the 1556 Shaanxi earthquake, which occurred on 23
January 1556 in Shaanxi province, China. More than 830,000 people died. Most houses in the
area were yaodongs—dwellings carved out of loess hillsides—and many victims were killed
when these structures collapsed. The1976 Tangshan earthquake, which killed between
240,000 and 655,000 people, was the deadliest of the 20th century.
The 1960 Chilean earthquake is the largest earthquake that has been measured on a
seismograph, reaching 9.5 magnitudes on 22 May 1960. Its epicenter was near Cañete, Chile.
The energy released was approximately twice that of the next most powerful earthquake,
the Good Friday earthquake (March 27, 1964) which was centered in Prince William Sound,
Alaska. The ten largest recorded earthquakes have all been mega thrust earthquakes;
however, of these ten, only the2004 Indian Ocean earthquake is simultaneously one of the
deadliest earthquakes in history.
Earthquakes that caused the greatest loss of life, while powerful, were deadly because of their
proximity to either heavily populated areas or the ocean, where earthquakes often
create tsunamis that can devastate communities thousands of kilometers away. Regions most
at risk for great loss of life include those where earthquakes are relatively rare but powerful,
and poor regions with lax, unenforced, or nonexistent seismic building
Center for Seismology, Ministry of Earth Sciences is nodal agency of Government of
India dealing with various activities in the field of seismology and allied disciplines. The
major activities currently being pursued by the Center for Seismology include, a) earthquake
monitoring on 24X7 basis, including real time seismic monitoring for early warning of
tsunamis, b) Operation and maintenance of national seismological network and local
networks c) Seismological data center and information services, d) Seismic hazard and risk
related studies e) Field studies for aftershock / swarm monitoring, site response studies f)
earthquake processes and modeling, etc. The MSK (Medvedev-Sponheuer-Karnik) intensity
broadly associated with the various seismic zones is VI (or less), VII, VIII and IX (and
above) for Zones 2, 3, 4 and 5, respectively, corresponding to Maximum Considered
Earthquake (MCE).
In Zone-5- The region of Kashmir, the western and central Himalayas, North and Middle
Bihar, the North-East Indian region and the Rann of Kutch fall in this zone.
In Zone-4 - The Indo-Gangetic basin and the capital of the country (Delhi), Jammu and
Kashmir fall in Zone 4. In Maharashtra, the Patan area (Koyananager) is also in zone no-4.
In Bihar the northern part of the state like- Raksaul, Near the border of India and Nepal, is
also in zone no-4.
In Zone- 3- The Andaman and Nicobar Islands, parts of Kashmir, Western Himalayas fall
under this zone. This zone is classified as Moderate Damage Risk Zone which is liable to
MSK VII. and also 7.8 The IS code assigns zone factor of 0.16 for Zone 3. In Zone-2-This
region is liable to MSK VI or less and is classified as the Low Damage Risk Zone.
Zone-1- Since the current division of India into earthquake hazard zones does not use Zone 1,
no area of India is classed as Zone 1.Future changes in the classification system may or may
not return this zone to use.
TEN INTERESTING FACTS ABOUT POWER SCENARIO IN INDIA
Prepared By: Sourav Chatterjee, AM(PS), AHP Electrical Maintenance, SgTPP
Some interesting facts about the country's power situation to chew on:
India has an installed capacity of more than 170,000 megawatts, up from a mere 1,362
megawatts at the time of Independence in 1947.
The majority (around 60%) is generated from coal and lignite, while just under a
quarter (about 22%) is hydro-electric
Despite its soaring energy needs, India has one of the lowest per capita rates of
consumption of power in the world - 734 units as compared to a world average of
2,429 units. This is nothing compared with say, Canada, (18,347 units) and the US
(13,647 units). China's per capita consumption (2,456 units) is more than three times
that of India.
The low per capita consumption is despite the fact that the power sector has been
growing at more than 7% every year.
Homes and farms are consuming more power today than industries and businesses.
Industrial consumption has actually dropped from 61.6% in 1970-71 to 38% in 2008-
2009.
India has suffered consistent power shortages since Independence in 1947. Peak
demand shortage is more than 10%, whereas the overall energy shortage is more than
7%.
Sixty-five years after Independence, only nine states - Andhra Pradesh, Gujarat,
Karnataka, Goa, Delhi, Haryana, Kerala, Punjab and Tamil Nadu - of 28 have been
officially declared totally electrified.
India remains perennially energy starved despite 15% or more of federal funds being
allocated to the power sector. Bankrupt state-run electricity boards, an acute shortage
of coal, skewed subsidizes which end up benefiting rich farmers, power theft, and
under-performing private distribution agencies are to blame, say experts. There is no
shortage of money, and the problem, as the Planning Commission admits, is more "in
the delivery process [than] in the system".
Transmission and distribution losses have leapt from 22% in 1995-96 to about 25.6%
in 2009-2010. The states with the worst losses are Indian-administered Kashmir,
Bihar, Chhattisgarh, Jharkhand and Madhya Pradesh. The best performers: Punjab,
Himachal Pradesh, Andhra Pradesh and Tamil Nadu.
India's first power generation company was the private Calcutta Electric Supply
Corporation (CESC) started in 1899. The first diesel power plant was set up in Delhi
in 1905. The first hydro-electric power station was set up in Mysore in 1902. At the
time of Independence, about 60% of India's power sector was privately owned.
Today, about 80% of the installed capacity is in the hands of the government. Private
companies own 12% of the capacity.
BIBLIOGRAPHY: BBC NEWS INDIA
The CARAVAN MAGAZINE
MODIFICATION WORK AT COAL HANDLING PLANT STAGE# 1 PREPARED BY : SUBHAJIT PAUL, AM(PS) CHP (MM)
PROJECT: FIXING OF RAIL AT TP-1, TP-1A & Crusher house
Problem:
In CHP uncrushed coal from trackhopper passes through TP-1, TP-1A & crusher house
(Conv 3A/B & RBF- 1&2) before entering into crusher. At TP-1 & 1A because of fall
height every now and then, the impact idlers at the intake of C-2A/B & C-3A/B are getting
damaged causing belt sway, skirt coming out, coal spillage etc. The chutes were also
extensively damaged.
Impact of the problem:
As a result, of above every now and then gates are to be changed, frequent outage of
conveyor 2A/B & 3A/B and interruption in coal evacuation was taking place.
Objective
To reduce the downtime of C-2A/B & C-3A/B and to improve evacuation from track
hopper.
Measures taken
A rail has been inserted across the intake chute of conv 2A/B, conv 3A/B & RBF just
above coffin box to reduce the impact of coal lumps falling from greater height. Thus, the
conveyor & the impact rollers & chutes at loading zone are protected from frequent damage.
Result:
Outage of C-2A/B, C-3A/B & RBF due to damaged impact idler, skirt problem or
chute leakage has been comprehensively reduced.
RAIL INSERT AT TP
PROJECT: Removal of impact table (garland idlers) of Paddle Feeder - 4
Problem
Garland idler system is very maintenance prone. Replacement of garland idlers requires
lifting of conveyor belt, cutting of impact table, removal of damage roll, reaffixing of new
roll, reaffixing of impact table and finally release of conveyor belt. Frequency of
replacement of garland idlers is at least thrice a year per plough feeder.
Secondly, a span of conveyor belt remains hanging hence has a tendency of belt sway at
load condition. Moreover, weight of garlanding system is approx. 2 MT, which is
practically an unnecessary weight. Plough feeder travels with this weight. This is an
unnecessary weight on the travel wheels & hence causes travelling problem
As the space between the skirt rubber & the belt is very small, with slightest pressure of
coal skirt was coming out of belt causing coal spillage and creating unclean working
atmosphere at the passages along the conveyor belt.
SOLUTION
To avoid the above discussed problems, our motivated team of Engineers carried out brain
storming session and found following solutions as most suitable one.
Initially it was tried by reducing the plough feeder’s discharge chute so that gap between
chute and belt becomes 800mm.This solution sustained for some time. Hence, again
through brain storming it was decided to remove the impact table so that coal will directly
fall from chute to conveyor belt on idlers over deck plate as was done in NTPC &
suggested by Mr. Gopal Krishna (AGM; NTPC, Kahalgaon). In this case as coal will
directly fall on idlers on deck plate & damage of idlers may take place hence the deflector
plate has been extended to minimize the fall height to 400mm. accordingly, our
technicians carried out the job. First, they removed the old impact table and skirt board.
Then discharge chute has been made tapered and extended up to the conveyor. Skirt board
has been made inclined accordingly for the entire length of discharge area. The system
was successfully commissioned and handed over to operation.
Technical Datasheet for 500 MW
Prepared By : Soumitra Banerjee, Sr. Manager (Commissioning)
IMPORTANT RATED PARAMETERS AT 500 MW GENERATION (At 100%
TMCR):
Generation 500 MW
Main steam flow 1457.1 TPH
Reheated steam flow 1301.2 TPH
Feed water flow 1434.1 TPH
Superheater spray water flow 23 TPH
Reheater spray water flow Nil
MS pressure at SH outlet 176.6 Kg/Cm2(g)
MS temperature at SH outlet 5400C
MS pressure at HPT inlet 166.7 bar
MS temperature at HPT inlet 5370C
CRH pressure & temperature at HPT
outlet
44 bar, 336.10C
HRH pressure at IPT inlet 39.6 bar, 5650C
HRH temperature at IPT inlet 5650C
CAP pressure & temperature
Condenser pressure 0.1027 bar (abs)
Total coal flow 353 TPH at 100% TMCR & 387 TPH at 100%
BMCR
Coal rate 0.706 Kg/KWH at 100% TMCR
Total combustion air 1901 TPH
O2 in flue gas at EM outlet 3.59%
CO2 in flue gas at EM outlet 14.41%
Excess air in gas at EM outlet 20%
FW temperature at EM inlet 253.40C
FW temperature at EM outlet 3240C
Boiler drum pressure 191.2 Kg/Cm2(g)
Saturation temperature in drum 3610C
Furnace pressure - 5 mmwc
Wind box pressure 70 mmwc
Technical Data of Boiler:
Make BHEL
Type Controlled Circulation with Rifled Tubing, (CC+), Radiant
Reheat, Dry Bottom, Top supported, Tangential Fired,
Balanced Draft boiler
Designation 19177 301-51 CC+
16115 235-51
Furnace type Balanced draft furnace with fusion welded water walls
Furnace width 19.177 M
Furnace depth 16.115 M
Furnace volume 17112 m3
Boiler steaming capacity 1590 TPH superheated steam at 100% BMCR
1358 TPH reheated steam at 100% BMCR
Design drum pressure 209 Kg/cm2(g) at 100% BMCR
Working drum pressure 195.1 Kg/cm2(g) at 100% BMCR with HP heaters; 187.6
Kg/cm2(g) at 100% BMCR without HP heaters
Super heater outlet pressure 178 Kg/cm2(g) at 100% BMCR
Total combustion air 2080 TPH at 100% BMCR
1901 TPH at 100% TMCR
Fuel heat input 1276.2 x 106 Kcal/hr. @ BMCR
Total heat output of system 1051.4 MKcal/hr
Boiler efficiency 83.12% at 100% BMCR
83.20% at 100% TMCR
83.24 at 50% TMCR
Total coal flow for 500 MW
generation
353 TPH at 100% TMCR
387 TPH at 100% BMCR
Feed water temperature at
Economizer inlet
253.40C
O2 in flue gas at E/M outlet 3.59%
CO2 in flue gas at E/M outlet 14.41%
Excess air in flue gas at E/M
outlet
20%
Temperature of flue gas at
APH outlet
1270C at BMCR
1250C at TMCR
Super Heater:
Stage: 1 Type: LTSH Horizontal & Pendant
Heating Surface Area: 8661 m2
Stage: 2 Type: SH Division Panellette (Tube Projected)
Heating Surface Area: 1415 m2
Stage: 3 Type: SH Finish Platen (Tube Projected)
Heating Surface Area: 1485 m2
Reheater:
Stage: 1 Type: Pendant Platen
Stage: 2 Type: Pendant Spaced
Total Heating Surface area 8620 m2
Economizer:
Type Plain Tube Type
Total Heating Surface Area 19000 m2
No. of blocks Three (03)
Air Pre Heater:
Type Bisector (Primary APH Type: 27.5 VI 2000; Secondary
APH Type: 30.0 VI 2000)
Nos. Of air heater Primary: 02 Nos. & Secondary: 02 Nos.
Total Heating Surface Area Primary APH: 40070 m2 & Secondary APH: 62742 m2
Motor power Primary AH: 11.0 KW & Secondary AH: 18.5 KW
Water Holding Capacity:
Drum (full) 60 m3
Water Wall 160 m3
Economizer 135 m3
Superheater 145 m3
Reheater 220 m3
Total 720 m3
Fuel Data for Design Coal:
Type: Sub Bituminous Coal
Proximate Analysis:
Fixed Carbon (FC) 26%
Volatile Matter (VM) 19%
Moisture 15%
Ash 40%
Grindability Index 55 HGI
Higher Heating Value (HHV) 3300 Kcal/Kg
Ash fusion temperature 14000C
Ultimate Analysis:
Carbon 29.73%
Hydrogen 3.7%
Sulphur 0.5%
Nitrogen 1.8%
Oxygen 8.66%
Carbonates 0.58%
Phosphorous 0.03%
Moisture 15%
Ash 40%
Heavy Fuel Oil Specification (HFO):
Service Oil burners
Standard HFO, GHV TO IS-1593
Pumping temperature 550C
Flash point minimum (Pen sky-martens closed
cup)
660C
Firing temperature 1200C
Kinematic viscosity at 550C (Max.) 370 cst
Total sulphur (max) 4.5% by weight
Specific gravity 0.980 @ 550C
Gross Heating Value (GCV) 10,000 Kcal/Kg
Light Diesel Oil Specification (LDO):
Service Oil burners
Standard IS-1460
Pumping temperature 350C
Firing temperature 350C
Viscosity 2 – 15.7 cst @ firing temperature
Total sulphur (max) 1.8% by weight
Density at 350C 0.830 Kg/liter
High Heating Value 10,000 Kcal/Kg (approx..)
FANS
Technical Data of F.D. Fan (2x50%):
Fan:
Make BHEL
Type Axial flow fan
Model No. FAF 24.5/11.8-1
Capacity 267 m3/sec
Pressure 410 mmwc
Control Blade pitch control
Design inlet temperature 500C
Motor:
Make BHEL, Bhopal
Frame size 1LA7802-6
Type SCIM
Enclosure type TETV
Application standard IS 325/1996
Motor Power 1450 KW
Rated Speed 994 rpm
Voltage 3300 ± 10% V
Full Load Current 312.5 Amps
No Load Current 85 Amps
Starting Current 600% of FLC (max)
Frequency 50 + 3%, - 5% Hz
Degree of protection IP 55
Insulation class F, Temperature rise limited to Class B
Duty Continuous (S1)
Method of cooling IC 511
Efficiency at 100%, 75% & 50% load 95.5 / 95.2 / 94.5%
Power factor at 100%, 75% & 50%
load
0.85/0.83/0.77
Starting requirement No. of equally spread starts per hour: 03; No. of
cold starts per hour: 02; No. of hot starts per hour:
01
Vibration level 75 µ (peak to peak) / IS-12075
Stator winding connection Star
Bearings Make: NSK/SKF/FAG; Type: Antifriction;
Lubrication: Grease; DE: NU 232M + 6232C3;
NDE: NU228M; Life: 40,000 Hrs.
Weights:
Stator 6700 Kg
Rotor 2300 Kg
Total weight 9500 Kg
Technical Data of I.D. Fan (2 x 50%):
Fan:
Make BHEL, Bhopal
Type Radial flow fan
Model No. NDZV 47 SIDOR
Capacity 587 m3/sec
Pressure 490 mmwc
Design inlet temperature 1500C
Control Inlet damper control + VFD
Motor:
Make BHEL, Bhopal
Frame size 1DQ4344
Type Three Phase Synchronous Motor
Motor Power 3950 KW
Speed 546 rpm
Stator Voltage 2x 2300 V
Excitation Voltage (field voltage) 96 V DC
Stator Current 2 x 576 Amps
Excitation current (field current) 311 Amps
Phase 2 x 3 Phase
Frequency 45.5 Hz
No. of pole 10
Insulation Class F
Degree of protection IP 55
Power factor 0.90
Duty Continuous (S1)
Connection Double Star
Type of cooling ICW37A81 Self Cooling
Motor Weight 31000 Kg
Brushless Exciter:
Power 30 KW
Excitation current 59 Amps (AC)
Excitation voltage 316 V (AC)
Connection Star
DC Voltage 96 V
DC Current 311 Amps
Speed 546 rpm
Technical Data of P.A. Fan (2 x 50%):
Fan:
Make BHEL
Type Axial flow fan
Model No. PAF 19/10.6-2
Capacity 185 m3/sec
Pressure 1275 mmwc
Design inlet temperature 500C
Control Blade pitch control
Motor:
Make BHEL, Bhopal
Frame size 1LA7924-4
Type SCIM
Motor Power 3100 KW
Speed 1496 rpm
Voltage 11000± 10% V
Full load Current 187 Amps
No load current 35 Amps
Frequency 50 ± 5%
Duty S1
No. of poles 4 (Four)
Enclosure type TETV
Ambient temperature 500C
Power factor at 100%, 75% & 50% load 0.90/0.89/0.86
Efficiency at 100%, 75% & 50% load 96.5/ 96.2/ 95.2%
Motor vibration level 2.8 m/s (rms)
Degree of protection IP 55
Insulation Class F/ Micalastic (VPI)
Winding connection Star
Bearings Type: Sleeve; Lubricant: ISO VG68, 5.5
LPM for each bearing; Life: Unlimited
Technical Data of Scanner Air Fan (1 AC + 1 DC):
(1W + 1S)
Fan:
Make Airochem Engineering Company
Type Radial, Backward Curved Blade, Single Suction Centrifugal
Fan
Medium to be handled Dust laden air
Duty Continuous
Max. dust concentration 300 mg/m3
Ambient condition 760 mm Hg, 500C, Air density: 1.09
Capacity 8000 m3/hr
Suction pressure 0 to 272 mmwc
Pressure developed 250 mmwc
Fan speed 2900 rpm
Fan Bearing Type: Spherical Roller Brg.; Brg. No. 22211 K; Make:
FAG/SKF
Efficiency 78.8%
Power consumption 7 KW
AC Motor:
Make Crompton Greaves / Kirloskar Electric
Type TEFC/SQI
Frame size 160M
Power 9.3 KW
Voltage 415 ± 10% V
Frequency 50 ± 5% Hz
Speed 2900 rpm
Full load current 7 Amps
Starting current 600% of FLC
Full load efficiency & P.F. 87% & 0.88
Duty cycle S1
Stator winding connection Star / Delta
Insulation Class F
Degree of protection IP 55
Bearings Type: Seated Ball Bearings; DE: Brg. No. 6309 2RS;
NDE: Brg. No. 6309 2RS; Brg. Life: 40,000 Hrs.
(anticipated)
DC Motor:
Make Crompton Greaves
Type Solid type
Frame size AFS 225S
Applicable standard IS-4722
Rated output 10 kW
Rated speed 3000 rpm
Armature rated voltage 220 V, DC
Allowable variation of
voltage range
+10% to – 15%
Type of excitation Shunt, Self Excited
Full load armature current 52 Amps, DC
Full load shunt field current 0.55 Amps, DC
Starting current Limited to 200% of FLC
Full load efficiency 85%
Duty cycle Continuous (S1)
Insulation Class F
Degree of protection IP 55
Bearings DE: 6213 – 2RS; NDE: 6213-2RS; Life: > 30,000 Hrs.
Technical Data of Seal Air Fan (1W + 1S):
Motor:
Make Kirloskar Electric
Type 3 Phase Induction Motor
Frame size 1F 12615
Rated power 55 KW
Voltage 415 ± 10% V
Frequency 50 ± 5% Hz
Current 94 Amps
Speed 1480 rpm
Ambient temperature 500C
Duty S1
Efficiency 93.6%
Stator connection Delta
Degree of protection IP 55
Insulation Class F
Power factor 0.87
Application standard IS 325
Bearings DE: 6314C3; NDE: 6314C3
Technical Data of Coal Mill (7 W + 2S):
Mill:
Make BHEL
Type XRP 1003 (Bowl Mill)
Capacity 65.67 TPH
Normal coal quantity per mill at design coal
data
55.26 TPH
Grindability of design coal 55 HGI
HHV of design coal 3300 Kcal/Kg
Total moisture 15%
Pulverized Coal fineness 70% through 200 mesh (75 micron) & 98%
through 50 mesh (300 micron)
Mill outlet temperature range 66 to 1000C
Motor:
Make BHEL, Bhopal
Type SCIM
Enclosure TETV
Frame size 1LA7636-6
Application standard IS 325/1996
Duty Continuous (S1)
Rated continuous output 525 KW
Rated voltage 3300 ± 10% V
Rated frequency 50 + 3% , -5% Hz
Full load current 129 Amps
No load current 54.5 Amps
Starting current 600% of FLC (max)
Rated speed 984 rpm
Ambient temperature 500C
Degree of protection IP 55
Insulation class F, Temperature rise limited to Class B
Method of cooling IC 511
Efficiency at 100%,75% & 50% load 93.8/93.5/92.6
Power factor at 100%, 75% & 50% load 0.76/0.71/0.61
Vibration level 50 µ (peak to peak)/IS 12075
Stator winding connection Star
Bearings Make: NSK/SKF/FAG; Type: Antifriction;
DE: NU228M + 6228C3; NDE: NU224M;
Lubrication: Grease; Life: 40,000 Hrs.
Starting requirements:
No. of equally spread starts per hour 03
No. of cold starts per hour 02
No. of hot starts 01
Weights:
Stator 4050 Kg
Rotor 1200 Kg
Total weight 5750
Technical Data of Coal Feeder (7W + 2S):
Make Stock Redler India Pvt. Ltd.
Type Gravimetric Feeder with electronic weighing
Model EG 3651
Size 36″ Inlet, 7 ft. Centre distance
Maximum Capacity 87000 Kg/hr
Weighing accuracy ± 0.5%
Feeder speed 0.1620 m/s
Type of control Micro Processor (DT- 9)
Belt Drive Motor:
Make Marathon
Type of drive VFD
Frame size (IEC) SE 132M
Applicable code IS 325
No. of pole 4 pole
Drive motor rating 7.5 KW
Voltage 415 ± 10% V
Frequency 50 ± 5% Hz
Full load current 13.4 Amps
Insulation Class H
Ambient temperature /
temperature rise
500C/700C
Full Load Motor speed 1450 rpm
Duty S1
Efficiency at 100%, 75% ,
50% load
90.5 /90.5/ 88
Power factor at 100%, 75% ,
50% load
0.86 /0.84/0.75
Cooling arrangement IC 411 (TEFC)
Weight (approx.) 96 Kg
Clean Out Conveyor Motor:
Make Marathon
Frame size (IEC) DA 71
Applicable code IS 325
Insulation Class H
Ambient temperature /
temperature rise
500C/700C
Duty S1
Drive motor rating 0.25 KW
Voltage 415 ± 10% V
Frequency 50 ± 5% Hz
Full load current 0.8 Amps
Starting current 4 x FLC
Full Load Motor speed 1340 rpm
Efficiency at 100%, 75% ,
50% load
60 /59/ 54
Power factor at 100%, 75% ,
50% load
0.72 /0.68/0.54
Cooling arrangement IC 411 (TEFC)
Weight (approx.) 13.3 Kg
M.O.C:
Feeder body Carbon Steel
Inlet Chute Stainless Steel
Belt Nylon – Nylon fabric impregnated with natural rubber compound
All coal contact parts Stainless Steel
Coal Flow Monitor (CFM):
Make Merrick Industries, Inc.
Type Ultrasonic Acoustic Flow Monitor
Sensitivity 40 dB – 80 dB (adjustable)
Size Detector: 7.5″ (191 mm) diameter (flange) x 9″ (229 mm) long.
Control Unit: 8″ x 11″ x 4″ (w x h x d) [203 mm x 279 mm x 102
mm]
Power requirement 110 – 240 V AC, 50/60 Hz, 1Phase, 0.4 A @ 110 V AC Typical
Ambient requirement Detector: - 200C to 600C ; Control Unit: - 200C to 550C
Output NO/NC relay; For no flow rated at 220 V A, 2A; Door mounted
light indication of relay status; Adjustable time delay: 5 to 60 Sec.
Technical Data of Boiler Circulating Water (BCW) Pump (2W +1S):
Pump:
Make Torishima Pump Mfg. Co. Ltd., Osaka, Japan
Type & Size HLAV2X300 – 460/1C
Total head 31.26 M
Capacity 2987 m3/Hr.
Design temperature 3700C
Design pressure 214 Kg/cm2
Test pressure 321 Kg/cm2
Motor:
Make Torishima Pump Mfg. Co. Ltd., Osaka, Japan
Type HLV5/4GV35 – 335 (Wet stator squirrel cage 3
phase induction motor)
Specification code JEC-37
Rated output 350 KW
Nos. of poles 4
Voltage 3300 ± 10% V
Frequency 50 Hz (Variation: + 3%, - 5%)
Full Load Current 89.7 Amps
No Load Current Approx. 35 Amps
Starting Current 500% of FLC with IS tolerance
Full load speed 1470 rpm
Duty Continuous
Ambient temperature 500C
Type of enclosure & ventilation Totally enclosed – No ventilation (wet)
Degree of protection IP 68 (Terminal Box IP 55)
Insulation Class “Y” (900C)
Material & treatment of insulation XLPE extruded insulation on winding wire & lead
cable with taped internal joints
Efficiency at 100%, 50%, 25% load 91%, 88%, 81.2%
Power factor at 100%, 50%, 25%
load
0.75, 0.56, 0.337
Winding connection Star
Permissible starting duty cycle Cold: 3 starts/Hr.; Hot: 2 starts/hr.
Method of cooling IC8W1W7
Motor GD2 13 Kg.M2
Bearings:
Nos. of bearing 2
Type Tilting Pad
Lubrication system Self (boiler water)
Life at rated speed 30,000 Hrs.
Bearing end play 1 mm
Max. permissible temperature of brg. 900C
Motor Cooler:
Water requirement 150 LPM
Losses removed by cooler 41 KW (at cooler design condition)
Max. cooling water inlet temperature 390C
Max. cooling water outlet
temperature
430C
Temperature rise through cooler 40C
Permissible cooler outlet water
pressure
28 bar
Pressure drop through cooler Approx.. 0.5 bar
Arrangement to ensure water flow Auxiliary impeller on motor shaft
Weight:
Weight of stator (wound) Approx.. 700 Kg without pressure casing
Weight of rotor (wound) Approx.. 200 Kg without shaft
Weight of copper Approx.. 150 Kg
Net weight of motor Approx.. 7300 Kg with heat barrier & terminal box
Important Interlocks:
HP cooling water outlet temperature
High Alarm
630C
HP cooling water outlet temperature
V. High Alarm & Pump tripped
660C
Technical Specification of E.C.W. Pump (1W + 1S):
Pump:
Make Kirloskar Brothers Ltd.
Model No. KPD 32/20A
Total head 45 M
Discharge 10 m3/hr
Pump input power 2.22 KW
Recommended prime mover rating 3.7 KW
Impeller diameter CF8M/186
Size 32 x 50 mm
Speed 2875 rpm
Motor:
Make Crompton Greaves Pvt. Ltd.
Frame size NG100L
Model No. 3.70KNG2
Rated power 3.7 KW / 5 HP
Voltage 415 ± 10% V
Frequency 50 ± 5%
Rated current 6.7 Amps
Speed 2875 rpm
Duty S1
Bearings DE: 6206 ZZ; NDE: 6205 ZZ
Ambient temperature 500C
Efficiency 87.5%
Degree of protection IP 55
Insulation Class F/ Temperature rise limited to Class ‘B’
Technical Data of E.C.W. Tank:
Capacity
Low level
High level
Technical Data of L.D.O. Pressuring Pump (1W + 1S):
Pump:
Make UT Pumps & Systems Pvt. Ltd.
Model PDHU CL-370.R22.A42.B5
Type Triple Screw Pump
Liquid LDO
Viscosity of liquid 2 – 15.2 cst
Operating temperature 350C
Capacity at minimum viscosity 525 LPM @ 2 cst
Capacity at maximum viscosity 540 LPM @ 15.2 cst
Suction pressure (-) 0.5 Kg/cm2(g)
Discharge pressure 25 Kg/cm2(g)
NPSH required 4.5 MWC @ 15.2 cst
Speed 2920 rpm
BHP at minimum viscosity 36 KW
BHP at maximum viscosity 36 KW
Pump efficiency 61% @ minimum viscosity
Pump Bearing Type: Radial Ball Bearing; Brg. No. 6308; Lubrication:
Lithium based grease; Filling quantity of grease: 250
gms.
Pump Coupling Type: 3 piece pin push coupling; Make: Love Joy;
Model No. RC58
Pump safety relief valve Make: UTPSL; Set pressure: 30 Kg/cm2(g); Over
pressure: 33 Kg/cm2(g)
Motor:
Make Kirloskar Electric Co. Ltd.
Applicable standard IS-325, IS-2148
Type FLP Cage
Frame size LE 250M
Degree of protection IP 55
Rated power 55 KW
Rated Speed 2945 rpm
Permissible voltage 415 ± 10% V
Permissible frequency 50 ± 5% Hz
Full load current 91 Amps
No load current 22 Amps
Starting current 600% of FLC
Efficiency At 100% load: 93%
At 75% load : 93%
At 50% load : 90%
Power factor At 100% load: 0.90
At 75% load : 0.88
At 50% load : 0.80
Duty cycle S1
Insulation Class F ,Temperature rise limited to class B
Motor Bearing (DE & NDE) Type: Anti friction; Make: SKF/NTN/FAG;
Lubrication: Lithium soap based grease; Bearing Life:
40,000 Hrs.(approx.)
Major tripping interlocks:
Pump discharge pressure “High”
& pump trip
At 4.2 MPa with 5 Sec TD
LDO tank level “Low” & Pump
trip
0.8 M
Technical Data of H.F.O Pressuring Pump (1 W + 2S):
Pump:
Make UT Pumps & Systems Pvt. Ltd.
Model PDHU -90.4N.R22.A42.B51
Type Triple Screw Pump
Liquid HFO
Viscosity of liquid 180 – 370 cst
Operating temperature 550C
Capacity at minimum viscosity 855 LPM @ 180 cst
Capacity at maximum viscosity 870 LPM @ 370 cst
Suction pressure (-) 0.5 Kg/cm2(g)
Discharge pressure 30 Kg/cm2(g)
NPSH required 4.5 MWC @ 370 cst
Speed 1450 rpm
BHP at minimum viscosity 60 KW
BHP at maximum viscosity 65 KW
Pump efficiency 72% @ minimum viscosity
Pump Bearing Type: Radial Ball Bearing; Brg. No. 6314; Lubrication:
Lithium based grease; Filling quantity of grease: 250
gms.
Pump Coupling Type: 3 piece pin push coupling; Make: Love Joy;
Model No. RC70
Pump safety relief valve Make: UTPSL; Set pressure: 35 Kg/cm2(g); Over
pressure: 38.5 Kg/cm2(g)
Motor:
Make Kirloskar Electric Co. Ltd.
Applicable standard IS-325, IS-2148
Type FLP Cage
Frame size LE 280M
Degree of protection IP 55
Rated power 90 KW
Rated Speed 1482 rpm
Permissible voltage 415 ± 10% V
Permissible frequency 50 ± 5% Hz
Full load current 153 Amps
No load current 43 Amps
Starting current 600% of FLC
Efficiency At 100% load: 94.2%
At 75% load : 94.2%
At 50% load : 92.5%
Power factor At 100% load: 0..87
At 75% load : 0.84
At 50% load : 0.76
Duty cycle S1
Insulation Class F ,Temperature rise limited to class B
Motor Bearing (DE & NDE) Type: Anti friction; Make: SKF/NTN/FAG;
Lubrication: Lithium soap based grease; Bearing Life:
40,000 Hrs.(approx.)
Major tripping interlocks:
Pump discharge pressure “High”
& pump trip
At 4.2 MPa with 5 Sec TD
LDO tank level “Low” & Pump
trip
0.8 M
Technical Data of Drain Oil Pump (1 No.):
Pump:
Make TUSHACO PUMPS PVT. LTD.(DAMAN)
Type Internal Gear Pump
Model R-20-DG
Liquid handled LDO/HFO/LSHS
Liquid viscosity 180-370 cst
Speed 1450 rpm
Capacity 70 LPM @ 180 cst & 71 LPM @ 370 cst
Suction pressure (-) 0.5 Kg/cm2(g)
Discharge pressure 10 Kg/cm2(g)
Discharge pressure ‘Low’ alarm 0.3 MPa
NPSH required < 5.0 MWC @ 370 cst
BHP at minimum viscosity 2.6 KW
BHP at maximum viscosity 4.0 KW
Pump efficiency 40% @ minimum viscosity
Pump Bearing Type: Ball Bearing; Brg. No. RLS-6ZZ, C3-R1;
Lubrication: Grease
Pump Coupling Type: 3 piece pin push coupling; Make: Love Joy;
Model No. RC042
Pump safety relief valve Make: Fainger Lesser Valves; Set pressure: 15
Kg/cm2(g); Over pressure: 17 Kg/cm2(g)
Motor:
Make Crompton Greaves Ltd.
Type 3 Phase, AC Squirrel Cage Induction Motor
Frame size E 132M
Motor output power 5.5 KW
No. of poles 4
Voltage 415 ± 10% V
Permissible frequency 50 ± 5% Hz
Full load current 10.59 Amps
Full load speed 1450 rpm
Duty cycle S1
Insulation Class F ,Temperature rise limited to class B
Degree of protection IP 55
Efficiency At 100% load: 86%
At 75% load : 85%
At 50% load : 84%
Power factor At 100% load: 0..84
At 75% load : 0.81
At 50% load : 0.73
Motor Bearing DE: 6308ZZ; NDE: 6208ZZ; Lubrication: Grease
Technical Data of Drain Oil Tank:
Capacity 10 m3
Elevation (-) 2.5 M
Location Inside FO P/P House
Drain oil sump level “High” alarm: 1.1 M
Drain oil sump level “Low” alarm: 0.5 M
Technical Data of HFO Tank:
Total no. of tank Two (02) for Phase-II
Each tank capacity 2000 KL
Tank level ‘High’ 12.2 M
Tank level ‘Low’ 0.8 M
Tank area sump level”HH” 1.4 M
Tank area sump level”High” 1.1 M
Tank area sump level”Low” 0.5 M
Technical Data of L.D.O Burners:
Service Initial startup & warm up
Atomizer External mixed, constant pressure, compressed air atomised
Fuel LFO to IS 1460
Maximum Capacity Total 7.5% MCR heat input
No. of oil guns 04 (in one elevation)`
Location of oil guns In auxiliary air nozzle – AB elevation
Oil Gun Performance Data:
Max. Rating Minimum Rating Scavenging
LFO flow / gun 2500 Kg /Hr. 850 Kg/hr.
LFO pressure 10.8 Kg/cm2(g) 3.2 Kg/cm2(g)
Atomizing air flow /
gun
207 Nm3/hr 155 Nm3/hr 241 Nm3/hr
Atomizing air pressure 5.25 Kg/cm2(g) 5.25 Kg/cm2(g) 5.25 Kg/cm2(g)
Technical Data of H.F.O. Burners:
Service Warming up boiler at controlled rate; Ignition of pulverized
coal fuel; Stabilization of coal flame at lower loads; Turbine
synchronization; Safe shut down of boiler
Burner Tilting tangential; Corner fired
Oil gun Parallel pipe design, steam atomized, external mixed,
constant pressure atomizer
Air nozzle Rectangular
Diffuser 190 mm, 10 off 450 vanes with leading edge with scanner
and igniter cutting
Oil gun assembly dimension KF = 2689 mm ± 3 mm
Atomizer designation Spray plate 90 J 24
Atomizer spray angle 900
Fuel HFO
Maximum Capacity 30% MCR total in five elevations
No. of oil guns 20 (4 per elevation)
Location of oil guns Aux. air nozzles – AB, CD, EF, FG & HJ
Oil Gun Performance Data:
Max. Rating Minimum Rating Scavenging
HFO flow / gun 2000 Kg /Hr. 850 Kg/hr.
HFO pressure 8.2 Kg/cm2(g) 3.2 Kg/cm2(g)
Atomizing steam flow /
gun
214 Kg/hr 267 Kg/hr 325 Kg/hr
Atomizing steam
pressure
5.25 Kg/cm2(g) 5.25 Kg/cm2(g) 5.25 Kg/cm2(g)
Note:
Oil viscosity at the gun : 15 to 30 cst
Steam quality: 10 to 150C superheat
Same HFO gun is used for LFO fuel also without changing the atomizer. Operating of
the respective burner valves in the burner section does not changeover of fuel
Technical Specification of HEA Igniter:
Make Fives Combustion System Pvt. Ltd.
Service Oil burner light up
Type High Energy Arc Igniter
Location Burner mounting panel
Input 110 Volt AC, 50 Hz
Output Minimum 4 sparks/sec, 12 Joules/spark
Retractor stroke 8″
Flexible Spark Rod A = 115 inches (without tip)
Flexible Guide Pipe L = 900 ± 10 mm
Technical Data of E.S.P.
Make
Size 4 X FAA-9 X 45M – 2 X 100150 - 2
No. of ESP per boiler Four (04)
Design gas flow rate to ESP 741.4 m3/Sec
Gas temperature at ESP inlet 1250C
Inlet dust concentration 70.5 gm/Nm3
Outlet dust concentration with one field out
of service
50 mg/ Nm3
Velocity of gas inside ESP 0.61 m/sec
No. of fields per ESP 18 Nos.
No. of ESP hoppers per field 02 Nos.
No. of ESP hoppers per ESP 36 Nos.
STEAM TURBINE TECHNICAL DATA:
Manufacturer BHEL - Haridwar
Type Subcritical, three cylinder, tandem compounding,
reheat , condensing steam turbine
Rated Load 500 MW
Maximum load under valve wide
open condition (VWO)
525 MW
Turbine Stages HPT: Single flow 17 nos. reaction stages ; IPT:
Double flow, 12 nos. reaction stages per flow; LPT:
Double flow, 6 nos. reaction stages per flow
Rated Speed 3000 RPM
Maximum / Minimum operating
speed
3090 RPM / 2850 RPM
Speed exclusion range at operation
without load (This speed range
should be passed through in one
smooth operation to avoid
endangering the turbine blades due
to resonance)
420 RPM to 2850 RPM
Standard over speed setting 3330 RPM
Turbine start-up mode Slow, Normal & Fast mode
Turbine soaking speed during steam
rolling at any mode
First barring speed to 360 RPM. Soaking at this speed
till fulfillment of all criteria of rated speed, then speed
rise to 3000 RPM
Critical speed of turbo generator First critical speed near 800 rpm, 2nd & 3rd critical
speed in between 1100 – 2000 rpm (approx. near 1300
rpm & near 1900 rpm)
Direction of rotation CCW viewed from front pedestal towards the
Generator
Fixed point of HP & IP casing (axial
position)
HP-IP pedestal
Fixed point of LP casing Front point of support on the longitudinal girder by
means of fitted keys
Fixed point of turbine rotor Thrust bearing in the HP turbine rear bearing pedestal
(No.2 bearing)
Total nos. of extraction for heaters Six (06)
Rated MS pressure at HP stop valve
inlet
166.7 bar
Rated MS temperature at HP stop
valve inlet
5370C
Rated steam pressure before 1st HP
drum stage
154.2 bar
Rated HP cylinder exhaust pressure 44 bar
Rated HP cylinder exhaust
temperature
336.1 0C
Rated steam pressure at IP cylinder
stop valve inlet
39.6 bar
Rated steam temperature at IP
cylinder stop valve inlet
565 0C
Rated steam pressure at LP cylinder
exhaust
0.1027 bar
Rated steam temperature at LP
cylinder exhaust
46.4 0C
Extraction 1 steam pressure /
temperature (rated)
0.339 bar / 72 0C
Extraction 2 steam pressure /
temperature (rated)
1.437 bar / 147.3 0C
Extraction 3 steam pressure /
temperature (rated)
2.745 bar / 208.2 0C
Extraction 4 steam pressure /
temperature (rated)
6.93 bar / 309.4 0C
Extraction 5 steam pressure /
temperature (rated)
17.9 bar / 444.8 0C
Extraction 6 steam pressure /
temperature (rated)
44.0 bar / 336.1 0C
Condenser pressure 0.1027 bar (abs)
Condenser low vacuum trip value 0.3 bar (abs)
Gland steam supply header pressure 35 mbar (g)
HPT casing exhaust metal
temperature Alarm / Trip value
485 0C / 500 0C
LPT casing exhaust metal
temperature Alarm / Trip value
90 0C / 110 0C (LPT hood spray valve should be
opened at 90 0C)
Alarm & Tripping value of “Casing
Metal Temperature Difference”
between upper & lower casing
halves of HPT, middle
+ 90 0C & + 100 0C
Alarm & Tripping value of “Casing
Metal Temperature Difference”
between upper & lower casing
halves of IPT, front
+ 30 0C & + 45 0C
Alarm & Tripping value of “Casing
Metal Temperature Difference”
between upper & lower casing
halves of IPT, rear
+ 30 0C & + 45 0C
Alarm & tripping value of “Axial
Shift”
+ 0.5 mm & + 1.0 mm
Alarm & tripping value of bearing
pedestal vibration
84 µm & 106 µm
Alarm & tripping value of shaft 200 µm & 320 µm
vibration
Alarm & tripping value of bearing
metal temperature (operating
temperature below 75 0C)
900C & 1300C
Alarm & tripping value of bearing
metal temperature (operating
temperature 75 0C to 850C)
1000C & 1300C
Weight of HP turbine, completely
assembled
95 T
Weight of IP turbine, top half outer
casing
26 T
Weight of IP turbine, top half inner
casing, complete with blading
16 T
Weight of LP turbine, top half outer
casing complete
43 T
Weight of LP turbine, top half inner
outer casing, complete with blading,
guide blade carriers & diffusers
37 T
Weight of HP turbine rotor,
complete with blading
16 T
Weight of IP turbine rotor, complete
with blading
23 T
Weight of LP turbine rotor,
complete with blading
100 T
Weight of Main Stop valve and
Control Valve, complete with
servomotors, without bend & pipe
section
27 T
Weight of Reheat Stop valve and
Control Valve, complete with
servomotors, without bend & pipe
section
34 T
TURNING GEAR SYSTEM:
Type of Drive Hydraulic Turbine
Method of engagement Hydraulic
Location of HTG Between the MOP & the journal bearing in the HPT
front bearing pedestal
Turning speed 70 – 120 RPM
Turning gear cut in / cut out speed Cut in when turbine speed < 210 RPM during shut
down & cut out when turbine speed is > 240 RPM
during start up
Criteria to stop turning gear
during shut down of turbine
HP turbine casing metal temperature & shaft
temperature should be < 1000C
N.B: A manual turning gear is provided in addition to the hydraulic turning gear to
enable the combined shaft system to be rotated manually. It is located at IP-LP
pedestal.
TURBINE LUBE OIL SYSTEM TECHNICAL DATA:
A) Main Oil Tank (M.O.T):
Rated capacity 25/40 m3
First oil filling (estimated) 53 m3
Flushing oil quantity 32 m3
Normal oil level 0 mm
Low oil level (-) 50 mm
V. Low oil level (-) 100 mm
B) Turbine lube oil specification:
Oil class ISO VG 46
Kinematic viscosity at 400C 41.4 – 50.6 cst
Kinematic viscosity at 500C 28 cst
Neutralization No. (Total acidity) < 0.20 mg KOH/g
Total acidity after 2500 hrs. oxidation < 0.20 mg KOH/g
Specific gravity at 500C 0.85
Specific gravity at 150C 0.90
Flash point (Cleveland open cup) >2000C
Pour point < (-) 60C
Emulsion characteristics < 20 minute
Foaming tendency at 250C < 400 cm3
Foaming stability at 250C < 450 sec
Deaeration capacity at 500C < 4 minute
Ash content (by weight) < 0.01%
Water content (by weight)
< 0.01%
Solid particles (by weight) < 0.05%
Particle distribution Class 8 (minimum)
Water release capacity < 300 sec
Recommended turbine lube oil i) Servo Prime 46 (Supplier: M/S IOCL
ii) Gulf Crest 46 ( Supplier: M/S Gulf Oil India
Ltd)
iii) Power- Turbo 46 (Supplier: M/S Apar Ltd.)
iv) Regal R&O 46 (Supplier: M/S Caltex)
v) Turbinol 46 (Supplier: M/S HPCL)
vi) Total Preslia 46 (Supplier: M/S
TOTALFINAELF)
vii) Castrol Perfecto T-46 Superclean (Supplier:
M/S Castrol India Ltd.)
viii) Turbol 46 (Supplier: M/S Bharat
Petroleum)
ix) Mobil DTE Medium/ DTE798 (Supplier: M/S
Indo Mobil Ltd.)
x) Daphne Super Turbine Oil 46 (Supplier: M/S
Savita Chemicals)
xi) Shell Turbo Oil T46 (Supplier: M/S Bharat
Shell Ltd.)
C) A.C. Aux. Oil Pump (1W + 1S) Specification:
Pump:
Make Kirloskar Brothers Ltd.
Type KPDS 250/52M
Delivery nozzle size of pump
casing
250 mm
Nominal diameter of impeller 52 cm
Total head (H) 78.4 M
Discharge (Q) 360.96 m3/hr.
Transmission bearing lub. Self
Pump input power 89.61
Speed 1480 rpm
Delivery pipe size 200 mm
Column length 1500 mm
Impeller diameter C1/500 mm
Recommended prime mover
rating
110 KW
Motor:
Make Bharat Bijlee
Type 3 Phase SQIM
Motor rating 110/150 KW/HP
Voltage range 373 – 456 V
Voltage 415 V
Current 188 Amps
Frequency 50 + 5% Hz
Efficiency 84.5%
P.F 0.86
Speed 1484 rpm
Regressing Hrs. 4000
Duty S1
Protection IP 55
Insulation class F/B Rise
D) D.C. Emergency Oil Pump Specification:
Pump:
Make Kirloskar Brothers
Type KPDS - 80/32 L
Delivery nozzle size of pump
casing
80 mm
Nominal diameter of impeller 32 cm
Total head (H) 27.63 M
Discharge (Q) 108 m3/hr
Transmission bearing lub. Self
Pump input power 10.335
Speed 1425 rpm
Delivery pipe size 150 mm
Impeller diameter C1/329 mm
Recommended prime mover
rating
13 KW
Motor:
Make Crompton Greaves
Motor power 13 KW
Insulation Class F
Duty S1
Ambient temperature 500C
Field voltage 220 V
Field current 0.85 amp
Armature voltage 155 V
Armature current 97 Amps
Moment of inertia (GD2) 1.65 kg. m2
Speed 1425 rpm
Protection IP 55
E) Main Oil Pump (MOP) Specification:
Make BHEL
Discharge (Q) 350 m3/hr.
Discharge pressure 9.1 bar
Speed 3000 rpm
Drive Turbine
F) A.C. Jacking Oil Pump Specification:
Pump:
Make TUSHACO Pumps Pvt. Ltd.
Type T3SA /46
Discharge pressure 178 Bar
Speed 2955 rpm
Power 60 KW
Motor:
Make Crompton Greaves
Type 3 Phase SCIM
Frame ND250MX
Machine No. NADTX100353DV
Motor power 60/80.46 KW/HP
Voltage 415 + 10% V
Current 75 Amps
Efficiency 93.2%
P.F 0.94
Frequency 50 + 5% Hz
Duty S1
Protection IP 55
DE Brg. 6314-C4
NDE Brg. 6314-C4
Grease Lithium soap based grade-2
RELUB Hrs. 2500
Ambient temperature 500C
G) D.C. Jacking Oil Pump Specification:
Pump:
Make TUSHACO Pumps Pvt. Ltd.
Type T3SA 38/46
Discharge pressure 176 Bar
Speed 2900 rpm
Power 60 KW
Motor:
Make Crompton Greaves
Frame AUS280M
Machine No. DASH6301
Motor power 60 KW
Armature Voltage 220 V
Armature Current 310 Amps
Efficiency 85%
Insulation Class F
Frequency 50 + 5% Hz
Duty S1
Protection IP 55
DE Brg. 63162
NDE Brg. 63162
Speed 2900 rpm
Field voltage 220 V
Field current 1.44 Amps
Ambient temperature 500C
N.B. Jacking oil pump must be in operation at turbine speed below 510 rpm to avoid
damage to bearings. Jacking oil pump should be cut out at turbine speeds above 540
rpm.
Pressure limiting valve (Relief Valve) setting in jacking oil system: 178 bar
Safety valve setting in jacking oil system: 200 bar
H) M.O.T Vapor Extractor (1W + 1S):
Fan:
Make SK System Pvt. Ltd. Delhi
Motor:
Make Bharat Bijlee
Motor power 0.75/100 KW/HP
Voltage Range 373/456 V
Working voltage 415 V
Frequency 50 + 5% Hz
Duty S1
P.F. 0.82
Speed 2650 rpm
Ambient temperature 500C
I) Estimated oil requirement of different bearings:
Bearing No. Oil Requirement(Litre/Sec)
Brg. No.1 0.8
Brg. No.2 15.4
Brg. No.3 4.55
Brg. No.4 9.29
Generator front brg. (i.e. Brg. No.5) 7.92
Generator rear brg. (i.e. Brg. No.6) 7.92
Exciter brg. (i.e. Brg. No.7) 0.70
Oil requirement for Hydraulic Barring
at 4.5 – 5.0 bar oil pressure
57.4
TURBINE CONTROL FLUID SYSTEM TECHNICAL DATA:
(A) Control Fluid Tank (C.F.T):
Rated capacity 10/16 m3
First fill quantity 15 m3
Flushing fluid quantity (estimated) 12 m3
Tank material SS
Normal oil level
High oil level
Low oil level
(B) Control Fluid Specification:
Type Fire Resistant Fluid (FRF)
Kinematic viscosity at 400C 41.4 – 50.6 cst
Air release capacity at 500C
< 3 minutes
Neutralization No. < 0.1 mg KOH/g
Water content < 1000 mg/kg
Water seperability < 300 sec
Demulsification < 20 minutes
Density at 150C 1250 kg/m3
Flash point (Cleveland open cup) > 2350C
Ignition temperature > 5500C
Pour point ≤ - 180C
Wick flame persistence time ≤ 5 Sec
Chlorine content < 50mg/kg
Oxidation stability < 2.0 mg KOH/g
Hydrolytic stability change of
neutralization number
< 2.0 mg KOH/g
Electrical resistivity >50 MΩm
Recommended FRF i) Reolube Turbofluid 46XC ( Supplier: M/S
Chemture, UK)
ii) Fryquel EHC-N (Supplier: M/S Supresta, USA)
(C) Control Fluid Pump Specification (1W + 1S):
Pump:
Make KSB
Type
Operating temperature 550C
Fluid density at operating temperature 1100 Kg/m3
Capacity 74 m3/hr
Head 248 m
Pump speed 2982 RPM
Motor:
Make Siemens
Motor power 132 KW
Voltage 415 ± 10% V
Frequency 50 ± 5%
Current 215 Amps
Power factor 0.91
Speed 2982 RPM
Connection Delta
Efficiency 94.6%
Degree of protection IP 55
(D) Control Fluid Tank Vapour Extractor Fan Specification (1W + 1S):
Fan:
Make Air Link Engineers Pvt. Ltd.
Air delivery capacity 0.017 m3/sec
Pressure 50 mmWG
Fan speed 2820 RPM
Motor power 0.75 HP
(E) Control Fluid Purification Unit:
Water Drying Filter (Absorbing Filter):
Make Bilfinger Rotring Engineering GmbH
Type S-1800-4-WA
Cartridge type VELCON Aquacon water absorbing, Type: AC-
71801
Mesh size 1 µm
Pressure drop at clean condition 0.1 to 0.3 bar
Design pressure 3 bar
Design temperature 800C
Operating temperature Maximum 800C
Operating pressure 0 to 3 bar
Test pressure 4.5 bar
Material Carbon Steel
Fullers Earth Filter:
Make Bilfinger Rotring Engineering GmbH
Type PYG-12-900
Media NAF Attapulgite 30/60 mesh, LVM Clay Type:
F1020-60
Quantity per element 17.2 Kg
Amount of elements 12 Pcs
Pressure drop Maximum 0.8 bar
Design pressure 3 bar
Design temperature 800C
Operating temperature Maximum 800C
Operating pressure 0 to 3 bar
Test pressure 4.5 bar
Material Carbon Steel
Finest Filter (Polishing Filter):
Make Bilfinger Rotring Engineering GmbH
Type S-1800-14-TUY
Cartridge type ROTRING PR-180-TUY
Mesh size < 1 µm
Pressure drop at clean condition 0.1 to 0.3 bar
Design pressure 3 bar
Design temperature 800C
Operating temperature Maximum 800C
Operating pressure 0 to 3 bar
Test pressure 4.5 bar
Material Carbon Steel
Safety Valve:
Make Niezgodka GmbH
Type 1.1
Head C
Connection G ½”
Seat 12.5 mm
Disk Metal / Viton (FKM)
Set pressure 3.2 bar
Material Steel
Automatic Vent Valve:
Make Mankenberg
Type EB 1.12
Material Stainless Steel
Connection 3/4” / 1/2””
Pressure Indicator:
Make Armaturenbau
Type RChG 100-3 glycerine filled
Case diameter 100 mm
Pressure range 0 to 4 bar
Material Stainless Steel
Connection 1/2”
Pressure Differential Indicator Switch:
Make Boll & Kirch
Type 4.36.2
Protection class IP 65
Electrical data Max. 250V / Max. 60 Hz
Pressure range 0 to 0.8 bar
Material GD – Aluminum
Connection 1/4”
Flow Indicator:
Make Honsberg
Type Optiflux WR20KI Sight Glass
Material Stainless Steel
Connection 3/4”
TECHNICAL DATA OF C.E.P (2W + 1S):
Pump:
Make BHEL, Hyderabad
Model No. EN6J40/500
Type Vertical, canister
No. of stages 6 (Six)
Design flow rate 695 m3/hr
Inlet temperature 46.40C
Specific gravity of liquid handled 0.9896
NPSH required at pump mounting flange 2.8 M for 3% head breakdown
3.95 M for 1% head breakdown
4.15 M for 0% head breakdown
4.55 for 40,000 hrs. erosion life of first stage
impeller
Suction pressure 0.757 Kg/cm2
Discharge pressure 24.83 Kg/cm2
Total dynamic head 255 MLC
Shut off head 360 M
Pump speed 1485 rpm
Overall efficiency of pump set 77.08%
External seal water requirement (when no 6 m3/hr
pumps are running)
Minimum flow requirement for continuous
stable operation
300 m3/hr
Peripheral speed at the eye of 1st stage
impeller
19.21 m/s
Type of 1st stage impeller Double suction, radial discharge
Impeller O.D. 388 mm for 1st stage & 418 mm for other stages
Canister Minimum wall thickness: 12 mm
Design pressure: 2.0 Kg/cm2
Depth below pump mounting flange: 5.892 M
Canister losses: 0.4 mwc
Critical speed First critical speed in water: 3380 rpm
2nd critical speed in water : 5798 rpm
GD2 of rotor including coupling 32 Kg-m2
Top Shaft Length: 3606 mm
Diameter: 100 mm (max)
Span between bearings: 1350 mm
Intermediate Shaft Length: 3167 mm
Diameter: 87 mm
Span between bearings: 1350 mm
Bottom Shaft Length: 2607 mm
Diameter: 88 mm
Span between bearings: 1350 mm
Method of coupling with adjacent shafting Muff coupling
Radial Bearings Type: Cutless Rubber Bearing
Total No. 10
Size: 100 mm
Pump Thrust Bearing Type: Tilting pad thrust bearing
Design load: 2732 Kg
Maximum load: 6038 Kg
Suction Strainer:
Type Simplex basket type
Recommended hole size 315 microns
Perforated sheet SS 304
Wire mesh SS 316
Element support plate IS 2062 Gr.B
Shell SA 516 Gr.60/70
Motor:
Make BHEL, Bhopal
Type SCIM
Frame size 1LA 7636-4
Application standard IS 325/1996
Duty Continuous (S1)
Rated power 900 KW
Rated voltage & variation 3300 ± 10% Volts
Rated frequency & variation 50 ± 5% Hz
Full load current 195 Amps
No load current 57 Amps
Starting current 600% of full load current (max.)
Speed 1489 RPM
Enclosure TETV
Degree of protection IP 55
Insulation Class F, Temperature rise limited to Class B
Power factor (at 100%, 75% & 50% load) 0.85 / 0.83/ 0.76
Efficiency (at 100%, 75% & 50% load) 95%, 94.5%, 94%
Vibration level 2.24 mm/s (rms)
Stator winding connection Star
DE Bearing Type: 6226 C3; Make: NSK/SKF/FAG
NDE Bearing Type: 7322 B; Make: NSK/SKF/FAG
Bearing life 40,000 Hrs.
Bearing lubrication Grease
Weight Stator: 3850 Kg; Rotor: 1100 Kg; Total: 5450 Kg
Moment of inertia (GD2) Load to motor speed: 32 Kg-m2
Motor: 124 Kg-m2
Space heater Total No. 04
Power: 630 Watts each
Power supply: 240 V AC, 1 Phase
TECHNICAL DATA OF MDBFP:
Booster Pump:
Make BHEL/ Hyderabad
Model No. FA1B75
Type Single stage centrifugal pump
Casing type Split
Capacity 1030 m3/hr
Minimum flow through BP 400 m3/hr
Suction pressure at design capacity 9.14 Kg/cm2
Head (H) 203 M
Maximum shut off head 236 mlc
NPSH required 4.7 mlc
Efficiency at design point 81.6%
Design temperature of feed water handled 161.70C
Power required by pump 632 KW
Speed 1495 rpm
DE Bearing Journal bearing
NDE Bearing Tilting pad double thrust bearing
(Manufacturer: Michell Bearing/ Glacier)
Bearing housing vibration Normal: 7 mm/s; High: 11 mm/s ; V. High:
18 mm/s
Boiler Feed Pump:
Make BHEL/ Hyderabad
Model No. FK4E36
Type Four stage centrifugal pump
Casing type Barrel
Design capacity 1030 m3/hr
Minimum flow through BFP 400 m3/hr
Design temperature of feed water handled 161.70C
Pump speed 5485 rpm
Suction pressure at design capacity 27.52 Kg/cm2
Discharge pressure at design capacity 212.11 Kg/cm2
Design temperature at pump outlet 166.70C
Head (H) 2047 M
Total dynamic head at design speed &
capacity
2250 mlc
Maximum shut off head 3280 mlc
Power required by pump 6412 KW
Balance leak-off flow 30 m3/hr
Efficiency at design point 81.1%
Bearing housing vibration Normal: 7 mm/s; High: 11 mm/s ; V. High:
18 mm/s
Motor:
Make BHEL, Bhopal
Type 3 Phase Squirrel Cage Induction motor
Specification IS325
Frame 1TF7642
Sl. No. 41088P421-51-01
Power 10000 KW
Year of manufacturing 2013
Stator voltage 11000 KV
Stator current 605 Amps
Speed 1495 rpm
Ambient temperature 500C
Temperature rise 700C
Frequency 50 Hz
Insulation class F
Connection Star
Degree of protection IP-55
D.E. Bearing 220 x 140
N.D.E. Bearing 220 x 140
Weight 23000 Kg
Hydraulic Coupling (Voith Coupling):
Make Voith Turbo Pvt. Ltd. Hydrabad
Type R18KGS 14APICCW
Sl. No. 114-00439
Year of manufacturing 2013
Power input 6800 KW
Input motor speed 1495 rpm
Gear ratio Primary circuit: 101/30 ; Secondary circuit:
53/45
Primary start up speed 5033 rpm
Full load slip 2.13%
Secondary speed (maximum) 5710 rpm
No. of bearings Total: 10 [Journal Brg: 8 & Thrust Brg: 2]
Minimum position to start the unit Zero (0)
Recommended oil ISO VG 32
Oil tank storage capacity 2500 Ltrs.
Hydraulic coupling scoop tube actuator Make: ABB; Type: Electro Mechanical
(A) TECHNICAL DATA OF LUBE OIL MOTOR:
Make Siemens
Type 3 phase induction motor
Sl No. 64604385
Frame 2004
Efficiency 92.5%
Duty S1
Insulation class F
Degree of protection IP-55
Frequency 50 Hz
Voltage 415 ± 10% Volts
Power 30 KW
Current 51 Amps
Speed 2950 rpm
Ambient temperature 500C
Weight 250 Kg
(B) TECHNICAL DATA OF WORKING OIL COOLER:
Make Voith Turbo Pvt. Ltd.
Heat transfer capacity 1442 KW
Weight (empty) 2915 Kg
Test pressure 13 kg/cm2 (hydraulic)
Shell side (oil side):
Design pressure 10 kg/cm2
Design temperature 1200C
Pressure drop 0.745/0.800 kg/cm2
Flow rate 77.53 m3/hrs
Outlet temperature 550C
Inlet temperature 93.350C
Working fluid ISO VG 32
Tube side (water side):
Design pressure 10 kg/cm2
Design temperature 700C
Pressure drop 0.599/0.600 kg/cm2
Flow rate 124.01 m3/hrs
Outlet temperature 48.020C
Inlet temperature 380C
Working fluid Water
TECHNICAL DATA OF TDBFP:
Turbine:
Turbine type K 1401-2
Maximum output power 7.383 MW
Design rating (economical rating) 6.198 MW
Inlet steam pressure before stop valve 6.13 ata
Inlet steam temperature before stop valve 308.40C
Exhaust pressure 0.1064 ata
Rated speed 5435 rpm
Speed range 1093 – 5690 rpm
Turbine Governing System EHG
Turbine soaking speed 1500 rpm
Turbine over speed setting 5650 rpm
Booster Pump:
Make BHEL/ Hyderabad
Model No. FA1B75
Type Single stage centrifugal pump
Casing type Split
Capacity 1030 m3/hr
Minimum flow through BP 400 m3/hr
Suction pressure at design capacity 9.14 Kg/cm2
Head (H) 203 M
Maximum shut off head 269 mlc
NPSH required 4.7 mlc
Efficiency at design point 81.6%
Design temperature of feed water handled 161.70C
Power required by pump 632 KW
Speed 1495 rpm
DE Bearing Journal bearing
NDE Bearing Tilting pad double thrust bearing
(Manufacturer: Michell Bearing/ Glacier)
Bearing housing vibration Normal: 7 mm/s; High: 11 mm/s ; V.
High: 18 mm/s
Boiler Feed Pump:
Make BHEL/ Hyderabad
Model No. FK4E36
Type Four stage centrifugal pump
Casing type Barrel
Design capacity 1030 m3/hr
Minimum flow through BFP 400 m3/hr
Design temperature of feed water handled 161.70C
Pump speed 5485 rpm
Suction pressure at design capacity 27.52 Kg/cm2
Discharge pressure at design capacity 212.11 Kg/cm2
Design temperature at pump outlet 166.70C
Head (H) 2047 M
Total dynamic head at design speed & capacity 2250 mlc
Maximum shut off head 3280 mlc
Power required by pump 6411 KW
Balance leak-off flow 30 m3/hr
Bearing housing vibration Normal: 7 mm/s; High: 11 mm/s ; V.
High: 18 mm/s
Gear Box:
Make Triveni Engineering & Industries Ltd.
Mysore, India
Model No. N1000C
Gear Box Sl. No. 1000 X 000168NCLF
Rated power 670 KW/898 hp
Gear Ratio 3.674
Service factor 2
No. of teeth Gear/Pinion 158/43
Output speed 1495 rpm
Input speed (nominal/actual) 5485 /5493 rpm
Gear box lube oil grade ISO VG-46
Lube oil flow 30 LPM
Lube oil pressure 1.0 to 1.5 Kg/cm2
Vibration limit Alarm: 46 micron; Trip: 70 micron
Maximum allowable bearing temperature 900C
Heat load 7382.232 Kcal/hr.
TDBFP LUBE OIL SYSTEM:
Technical Specification of A.C. Lube Oil Pump (1W + 1S):
Pump:
Make TUSHACO Pump Pvt. Ltd.
Type 13S140/40 (Three Screw pump)
Sl. No. 1379506/7385 & 1379506/7386
Discharge pressure 11.6 Kg/cm2
Speed 1450 rpm
Capacity 150 m3/hr
Motor:
Make Bharat Bijlee
Type 3 phase SQIM
Sl. No. 1301831 & 1301832
Rated power 80 KW/120 HP
Voltage range 373 – 456 V
Rated voltage 415 V
Rated current 149 Amps
Connection Delta
Duty S1
Power factor 0.89
Frequency 50 ± 5% Hz
Ambient temperature 500C
Efficiency 94.7%
Grease SKFLGMT3K3K-3D
Regreasing time 4000 Hrs.
Technical Specification of D.C. Lube Oil Pump:
Pump:
Make
Type
Discharge pressure 4.5 Kg/cm2
Capacity 25 m3/hr
Pumping head 51.14 m
Speed 2900 rpm
Radial bearing type SKF or EQ 6309
Thrust bearing type SKF of EQ 2X 7310
Motor:
Make
Type Shunt
Frame AFS225M
Power 11 KW
Armature Voltage 220 V DC
Armature Current 59 Amps
Field Voltage 220 V DC
Field Current 0.44 amp
Insulation Class F
Degree of protection IP 55
DE Bearing 62132 RS
NDE Bearing 62132 RS
Oil Tank:
Capacity 10 M3
Oil type ISO VG 46
Function Storing the oil volume required for governing & lubricating system
Normal oil level
Low oil level
V. Low oil level
Standby AC driven lube oil pump will cut in when pump discharge pressure ≤ 6.5
kg/cm2 (g) OR lube oil header pressure ≤ 1.1 kg/cm2 (g)
Turbine tripped at lube oil header pressure ≤ 0.8 kg/cm2 (g)
DC EOP will cut in at lube oil header pressure ≤ 0.8 kg/cm2 (g) to ensure positive
supply of oil to bearings after tripping of turbine
Technical Data of Oil Tank Vapor Exhaust Fan (1W +1S):
Fan:
Make I.M.M. Pvt. Ltd.
Type Centrifugal fan
Capacity 396 m3/hr
Static pressure 100 mm of WC
Speed 2830 rpm
Drive Impeller directly mounted on motor shaft
BHP 0.38
Vibration limit Maximum 60 micron or 4.5mm/s
Motor:
Make I.M.M. Pvt. Ltd.
Type 3 phase SQIM flange mounted
Frame size E 90 L
Mounting B3
Rating 0.5 HP 2 Pole
Speed 2800 rpm
Voltage 415± 10% Volts
Frequency 50 ± 5% Hz
Insulation class F with temperature rise limited to class B
Degree of protection IP 55
Enclosure TEFC – flame proof
Oil Cooler (1W + 1S):
Make BHEL
Type Shell & Tube twin oil cooler
Shell side:
ID x Thickness 489 x 9.5 mm
Surface area 85 m2
Design pressure 13.5 Kg/cm2
Design temperature 1000C
Tube Side:
Design pressure 10 Kg/cm2
Design temperature 1000C
Oil cooler outlet temperature ‘Low’ alarm: 400C
Oil cooler outlet temperature ‘High’ alarm: 550C
Oil Filter (1W + 1S):
Make EPE Process Filters & Accumulators Pvt. LTD.
Type Disposable cartridge type duplex filter
Filtration capacity 10 micron
DP across filter ‘High’
alarm
1.5 kg/cm2
Technical Specification of A.C. Jacking Oil Pump (1 x 100% Capacity):
Pump:
Make Delta PD Pumps Pvt. Ltd.
Type Positive displacement Gear Pump
Capacity 9 litre/min
Discharge pressure 100 bar
Set pressure of safety relief valve 110 Kg/cm2(g)
Set pressure of pressure relief valve 100 Kg/cm2(g)
Speed 1440 rpm
Motor:
Make Crompton Greaves
Type 3 phase induction motor
Frame ND112N
Power 3.7 KW
Voltage 415± 10% Volts
Current 7.4 amps
Connection Delta
Speed 1430 rpm
Insulation class F
Degree of protection IP 55
Duty S1
Efficiency 85%
Frequency 50±5%
Ambient temperature 500C
DE Bearing 6C067 ZZ
NDE Bearing 6205 ZZ
Technical Specification of Barring Gear / Turning Gear:
Type Hydraulic Turning Gear (HTG) [Hydraulic turbine with a single row of
blades]
Baring speed 80 to 120 rpm
N.B. A manual turning device (ratchet wheel assembly) is provided for redundancy
Technical Specification of Drain Oil Pump (1 x 100% Capacity):
Pump:
Make Delta PD Pumps Pvt. Ltd.
Size DRT-80
Capacity 50 LPM
Discharge pressure 3.0 Kg/cm2 (g)
Speed 1415 rpm
Motor:
Make Crompton Greaves
Type 3 phase Induction Motor
Frame ND 90 L
Power 1.5 KW
Voltage 415± 10% Volts
Current 3.3 amps
Frequency 50±5%
Speed 1415 rpm
Insulation Class F
Degree of protection IP 55
Ambient temperature 500C
Duty S1
DE Bearing 6205 ZZ
NDE Bearing 6205 ZZ
Technical Data of Lube Oil Purifier (Centrifuge):
Separator:
Make GEA Westfalia Separator Group GmbH, Germany
Model OTC59067
Maximum admissible rated bowl speed 12000 rpm
Maximum admissible density of the
feed product
Nil Kg/dm3
Heavy liquid density 1.0 Kg/dm3
Solid density (centrifugally dry) 2.0 Kg/dm3
Starting time 2-4 min.
Maximum allowable time to run the
bowl without liquid
15-30 Minutes
Run down time (after switching off the
motor with drive belt)
20 min.
Run down time (without drive belts, i.e.
in the case of torn, jumped off or
defective drive belt)
40 min.
Suction height of feed pump Max. 0.4 bar
Pressure head of double centripetal
pump (feed pump)
1 – 2 bar
Output of the feed pump 3000 lph
Rotation of the bowl Clock Wise when viewed from top
Motor:
Power rating 4 KW
Frequency 50 Hz
Speed 3000 rpm
Enclosure IP 55
Weights:
Separator (with motor, without bowl) 110 Kg
Bowl 30 Kg
Motor 47 Kg
AUXILIARY COOLING WATER PUMP (A.C.W PUMP) TECHNICAL DATA:
(2W + 1S for 2x500MW)
Pump:
Make WPIL Ltd.
Type Vertical wet pit, non-pull out type with above floor
discharge single stage centrifugal pump
Model C 30 TC
Discharge capacity (Q) 3650 m3/hr
Range of operation of the
pump
30% to 130% of the rated flow [Minimum Flow: 1095
m3/hr; Maximum Flow: 4745 m3/hr]
Head (H) 43.30 Mtr.
Shut off head 85.5 MWC
NPSH required at rated
capacity
8.3 MWC
Minimum submergence
required above suction bell tip
2000 mm
Pump input power 497 KW
Speed (N) 1488 rpm
Bowl efficiency 86.83%
Pump efficiency 86%
Pump thrust bearing Type: Antifriction type thrust bearing; Make: SKF/ FAG/
Equivalent; Lubrication: Oil lubricated; Design life:
40,000 Hrs
Motor:
Make BHEL
Frame No. ILA 7564-4P
Motor rated power 580 KW
Stator voltage 3300 V
Stator current 126 Amps
Duty Continuous
Stator connection Star
Degree of protection IP55
Insulation class F
Phase Three
Frequency 50 Hz
Ambient temperature 500C
Motor DE bearing 6224C3
Motor NDE bearing 7322 B
COOLING WATER PUMP (C.W. PUMP) TECHNICAL DATA (3W +1 S):
Pump:
Make BHEL Hyderabad
Model No. CW10
Type Mixed flow single stage closed type impeller
centrifugal pump
Rated capacity (Q) 20500 m3/hr.
Bowl head at rated capacity (H) 28.5 MLC
Total dynamic head at rated capacity &
at minimum water level
28.0 MLC
Total head loss from suction bell inlet
to pump discharge flange at rated
capacity
0.5 MLC
Shut off head 50 MLC
Satisfactory range of operation 75 to 120% of rated capacity
Rated speed 420 rpm
Bowl efficiency at rated capacity 85%
NPSH required at rated capacity 10.8 MLC
Minimum submergence required
(above suction bell mouth tip)
6.9 MLC
Pump thrust bearing Type: Tilting pad thrust bearing; Make: Michell
Bearings Ltd. ; Design life: 40,000 Hrs.; Coolant:
Oil sump lubricated, tube cooled
Vibration value on pump thrust bearing Operating value: 6.1 mm/s; Alarm value: 7.6
mm/s; Trip value: 11.9 mm/s
Motor:
Make BHEL
Frame No. IRQ7907-7
Duty Continuous
Rated power 2400 KW
Rated voltage 11 KV
Current 160 Amps
Speed 420 rpm
Phase 3
Frequency 50 Hz
Insulation class F
Degree of protection IP 55
Specification IS325
Stator connection Star
Power factor 0.82
Efficiency 96.1%
Ambient temperature 500C
FEED POOL (CW/ACW SUMP):
Capacity at normal water level
High level 10.0 M (local)
Normal level 9.5 M (local)
Adequate level to run CW & ACW
Pump
(-) 2.0 M in CRT[i.e. 9.0 M local]
Low level (-) 2.15 M in CRT [i.e. 8.85 M local] for CW Pump
& (-) 2.2 M in CRT [i.e. 8.8 M local] for ACW
Pump
Very Low level (-) 2.4 M in CRT [i.e. 8.6 M local] for both CW
Pump & ACW Pump
COOLING TOWER:
Make Paharpur Cooling Tower Ltd. (PCTL)
Type Natural Draft Cooling Tower (NDCT)
Rated cooling water flow 65000 m3/hr.
Maximum permissible drift loss 0.007% of design cooling water flow (i.e. 4.55 m3/hr)
Hot water inlet temperature 42.50C
Design ambient W.B.T 270C
Design cooling range 10.50C
Design approach to inlet air
W.B.T
5.00C
Cooled water temperature at CT
basin
320C
Design R.H 60%
Bottom diameter of hyperbolic
section cooling tower
105.5 M
Top diameter of hyperbolic
section cooling tower
72 M
Total height of cooling tower
from the top of CT hot basin
135.089 M
Total height of cooling tower
from the top of CT basin wall (EL
34.5 M above MSL)
144.649 M
TECHNICAL DATA OF CONDENSER:
Make BHEL
Type Surface type two pass, water cooled & spring
mounted
Tube material & tube plate SS 304 & Carbon Steel
Design cooling water (CW) inlet
temperature
330C
Maximum cooling water inlet temperature 360C
Design CW outlet temperature 42.40C at 100% TMCR
Design CW flow 58350 m3/hr
Pressure drop through water tubes at design
CW flow
4.5 mwc
Condensate outlet temperature 46.10C
Cleanliness factor 90% with 5% tube plugged condition
Design condenser pressure 77 mm Hg(abs)
Maximum condenser pressure 89 mm Hg(abs)
Water box design pressure 5 kg/cm2(g)
Steam side design pressure Full vacuum to 1.08 kg/cm2(abs)
Hotwell storage capacity Minimum 03 (three) minutes between
‘Normal’ & ‘Low’ level with maximum steam
condensed corresponding VWO operation
Velocity of water in tubes 1.8 m/s
Cooling water temperature differential Not more than 9.50C (during maximum thermal
across condenser legs load)
T.T.D Not less than 2.80C
Dissolved O2 in Hotwell < 0.015 cc/litre
Total Nos. of condenser tubes 24398
Tube O.D. x thickness 31.75 mm x 0.71 mm
Tube O.D. x thickness for top two rows 31.75 mm x 0.889 mm
Effective tube length 13300 mm
Effective tube surface area required 26907 m2
Tube surface area provided 32367 m2
Shell overall length 18560 mm
Shell overall width 8920 mm
Plugging margin at 100% TMCR condition 5%
Condenser Hotwell level Normal: (+) 0.590 M; Low: (+) 0.030 M; V.
Low: (-) 0.130 M; High: (+) 0.690 M; V.
High: (+) 0.740 M
Condenser thermal load 546039921 Kcal/Hr (at 500 MW, 3% MU,
0.1047 ata condenser pressure)
Technical Data of Service & Instrument Air Compressor [ S.A: (1W +1S); I.A: (2W
+ 1S)]:
Compressor:
Make Atlas Copco (India) Ltd.
Model ZR 275-8.5
Type Oil free screw compressor
Discharge pressure at after cooler outlet at rated
condition
8.0 Kg/Cm2(g)
Normal working pressure 7.5 Kg/Cm2(g)
Capacity (FAD) at design ambient condition [i.e.
450C & RH:100%]
46.53 m3/min
Design temperature 450C
Outlet air temperature after high pressure stage of
compressor at design capacity
160 - 1900C
Compressed air after-cooler outlet temperature 450C
Input power required at compressor shaft at rated
condition
291 KW
Input power required at compressor shaft at
unloaded condition
59 KW
Total cooling water requirement considering ∆T as
100C at rated condition
28 m3/hr
Nos. of screw & screw arrangement 02 [1 male + 1 female] per stage
Number of lobes in male rotor 04
Number of flutes in female rotor 06
Main bearings Type: Anti friction type; Make: SKF;
Lubrication: Forced feed
Drive Motor:
Make Marathon Electric Motors (India) Ltd.
Frame DC400F3
Motor speed at full load 2980 RPM
Motor rating 345 KW
Service factor 1
Pole 2 Pole
Voltage 3.3 KV ± 10%
Frequency 50 Hz ± 5%
Ambient temperature 500C
Insulation Class F
Degree of protection IP 55
Cooling IC 411 (TEFC)
Duty S1
Type of construction Sq. Cage
Full load current 70.5 Amps
Starting current 600% of FLC
Efficiency at 100%, 75%, 50% load 95 / 94/ 92.5%
Power factor at 100%, 75%, 50% load 0.90/0.88/0.78
GD2 40 Kgm2
No. of consecutive starts per hour Cold Start: 2; Hot Start: 3
Air Intake Filter:
Type Dry type filter cartridge
Filtering media Paper
Particle removing efficiency 99.9% up to particle size of 3 micron
Intercooler:
Type Shell & tube
Compressed air inlet / outlet temperature 160 – 1800C / 480C
Cooling water inlet / outlet temperature 390C / 490C
Aftercooler:
Type Shell & tube
Compressed air inlet / outlet temperature 160 – 1900C / 480C
Cooling water inlet / outlet temperature 390C / 490C
Oil Cooler:
Type Plate type heat exchanger (PHE)
Air Receiver:
Total number of air receiver 05 (IA:03 nos & SA: 02 nos)
Capacity of each receiver 10 m3
Technical Data of Air Dryer (4W + 1S):
Make Atlas Copco Airpower, Belgium
Model No. MD 600W
Type Rotary Drum Type Dryer
Desiccant Silica Gel
Type of operation Continuous
Rated flow 36 Nm3/min
Dew point temperature at air dryer outlet (at
atmospheric pressure)
(-) 400C
Air pressure drop 0.3 bar
Maximum electric power input 0.12 KW
Cooling water consumption corresponding to
water temperature rise of 50C
2.5 LPS
Net weight 180 Kg
Technical Data Of S.G. Fill Pump (CTP): [1W +1S]
Pump:
Make WPIL
Pump size 4U13
Discharge capacity 120 m3/hr
Head 50 M
Motor
Make ABB
Type M2BA315MLA4K
Duty S1
Volt 415 ± 10% V
Current
Power
Duty
Technical Data Of D.M.S.W. Pump [ 1Working for each unit & 1 is Common
Standby]:
Pump:
Make
Discharge Capacity 120 m3/hr
Head 50 M
Motor:
Make ABB
Type EHDC200WLCA, 3 Phase SCIM
Duty S1
Power 30 KW / 4 HP
Voltage 415 ± 10% V
Current 54 Amps
Power factor 0.83
Ambient temperature 600C
Efficiency 93.2%
Insulation Class F
Degree of protection IP 55
Frequency 50 Hz
Speed 1470 RPM
Connection Delta
DE Bearing 6312 ZZ C3
NDE Bearing 6311 ZZ C3
Technical Data of C.S.T.
Make Thermosystems Pvt. Ltd. Hyderabad
Total No. of tank 02 (Two)
Material of construction IS 2062 Gr.B for plate & IS 2062 Gr.A for structural steel
Capacity of each tank 750 m3
Tank diameter 10.8 M
Tank height 9.5 M
Shell thickness 8 mm
Bottom plate thickness 8 mm
Roof plate thickness 8 mm
Tank level High 9.0 m
Tank level Low adequate to run
pump
3.5 m for DMSW Pump & 4.0 m for SG Fill Pump
Tank level Low 2.0 m for both DMSW & SG Fill Pump
Tank level V. Low 1.6 m for both DMSW Pump & SG Fill Pump
Technical Data of Deaerator:
Design pressure 9.0 Kg/cm2(g) & Full vacuum
Hydro test pressure 11.7 Kg/cm2(g)
Operating pressure 6.41 Kg/cm2(g)
Feed Storage Tank (FST) capacity 192 m3 (for 6 minutes storage capacity)
Operating temperature 160.70C
Storage tank design temperature (Max. /
Min.)
3600C/00C
Nos. of trays 576
Nos. of spray nozzles 108
M.O.C.
Shell (Storage tank & header) SA 516 Gr.70 with S1, S5, S8
Dished Ends SA 516 Gr.70 with S1, S5, S8
Nozzle Stubs SA 106 Gr.B
Trays SA 240 TP 430
Cover for manhole SA 105
Tray removal openings SA 106 Gr.B
Spray valves SS TP 304
Weights:
Dry condition 104360 Kg
Operating condition 312360 Kg
Flooded condition 484360 Kg
Water Level:
Normal Level 0 mm
High Level + 480 mm
Overflow Valve Open: + 500 mm ; Close: + 250 mm
Low Level - 580 mm
V. Low Level - 1900 mm
Dimension:
FST shell I.D. 3600 mm
FST shell thickness 18 mm
Deaeration Chamber I.D. 3000 mm
Deaeration Chamber shell thickness 16 mm
D.M.C.W. (TG) PUMP SPECIFICATION (2W + 1S):
Pump:
Make WPIL
Type M2BA315ML A4K
Size 12 LN14A
Capacity (Q) 1150 m3/hr.
Head (H) 35 M
NPSH required at rated capacity 5 MWC
Motor:
Make ABB
Type M-2-BA-315MLA4K-IP-50 (Squirrel cage induction
motor)
Voltage 415 ± 10%
Current 253 Amps
Power 50 KW/200 HP
Connection type Delta
Frequency 50 Hz
Speed 1485 rpm
Efficiency 95.8%
Duty S1
DE bearing 6319C3
NDE bearing 6316C3
Ambient temperature 500C
D.M.C.W. (SG) PUMP SPECIFICATION (1W + 1S):
Pump:
Make WPIL
Size 10 LN22A
Discharge capacity(Q) 1100 m3/hr.
Head (H) 61 M
Stage Single
NPSH required at rated capacity 4.4 MWC
Motor:
Make BHEL
Frame size 11A7560-4
Type SCIM
Type of enclosure TETV
Application standard IS 325/1996
Rated power 315 KW
Stator voltage 3300 ± 10% V
Frequency 50 ± 3% & - 5% Hz
Full load current 70 Amps
No load current 22 Amps
Starting current 600% of FLC (max)
Speed 1482 rpm
Connection Star
Insulation class F
Ambient temperature 500C
Degree of protection IP-55
Duty Continuous
Efficiency at 100%, 75% & 50% load 93.5 /93/13.5%
Power factor at 100%, 75% & 50% load 0.84/0.82/0.74
Starting requirement No. of equally spread starts per hour: 03; No. of
cold starts per hour: 02; No. of hot starts: 01
Vibration level 50 µ (peak to peak)/ IS 12075
Method of cooling IC 511
Bearings Make: NSK/SKF/FAG; Type: Antifriction; DE:
NU222M + 6222C3; NDE: NU219M;
Lubrication: Grease; Life: 40,000 Hrs.
Weights:
Stator weight 2500 Kg
Rotor weight 650 Kg
Total weight 3650 Kg
DMCW OVERHEAD TANK (for TG & SG Aux):
Capacity 10 M3
Tank Material CS (Minimum thickness 6 mm)
Normal level
Low level
V. low level
Overflow level
Normal MU to DMCW O/H tank From DMSW pump discharge
Emergency MU to DMCW O/H tank From CEP discharge
Technical Specification of G.S.C Vapor Exhauster (1W + 1S):
Fan:
Motor:
Make Bharat Bijlee
Type 3 Phase SQIM
Power 3.1 KW
Voltage Range 373 to 456 V
Working voltage 415 V
Current 7.05 Amps
Connection Delta
Duty S1
Efficiency 85%
Ambient temperature 500C
Insulation Class FB
Frequency 50 ± 5% Hz
Speed 2900 RPM
Degree of protection IP 55
Weight 24 Kg
Technical Data of Drain Cooler:
Type Shell & Tube
Design Standard ASME Sec.VIII Div-1 2007 up to & incl. Addenda. Nil &
HEI 6th Edition
Shell Side:
Design pressure 3 Kg/cm2(g) & full vacuum
Test pressure 3.9 Kg/cm2(g)
Design temperature 1200C
No. of zone One
Corrosion allowance 3.2 mm
Tube Side:
Design pressure 40 Kg/cm2(g) & full vacuum
Test pressure 52 Kg/cm2(g)
Design temperature 1440C
No. of pass One
Corrosion allowance 3.2 mm
Tube size OD: 19.05 mm; Length: 4000 mm
Total number of tubes 675 (Note: 666 nos. tubes are required to get design thermal
performance)
Weight:
Dry weight 2400 Kg
Operating weight 3600 Kg
Flooded weight 3600 Kg
Technical Data of LP Heater-2:
Type U Tube horizontal condensing , Shell & Tube (Double Pass)
Design Standard ASME Sec.VIII Div-1 2007 up to & incl. Addenda. Nil &
HEI 6th Edition
Heat duty Condensing zone: 41.34 x 106 Kcal/hr
Sub -cooling zone: 4.3 x 106 Kcal/hr
Heat Transfer co-efficient Condensing zone: 2827 Kcal/hr.m2.0C
Sub -cooling zone: 1870 Kcal/hr.m2.0C
LMTD Condensing zone: 11.440C
Sub -cooling zone: 15.940C
Heat transfer area required Condensing zone: 1084 m2
Sub -cooling zone: 145 m2
Total heat transfer area
provided
1337 m2
Extraction steam parameter Pressure: 1.412 Ata
Temperature: 147.70C
Quantity: 71.96 TPH
Drain /Drip parameter Drain I/L temperature: 1110C
Drain I/L quantity: 40.72 TPH
Drain O/L temperature: 73.10C
Drain O/L quantity: 112.68 TPH
Feed water parameter FW I/L temperature: 68.30C
FW I/L quantity: 1152.981 TPH
FW O/L temperature: 106.20C
FW O/L quantity: 1152.981 TPH
T.T.D 2.80C
D.C.A 4.80C
Shell Side:
Design pressure 3.0 Kg/cm2(g) & Full Vacuum
Test pressure 3.9 Kg/cm2(g)
Corrosion allowance 3.2 mm
Shell O.D. x Thickness φ 1532 x 16 mm
Design temperature 1550C
Tube Side:
Design pressure 40 Kg/cm2(g) & Full Vacuum
Test pressure 52 Kg/cm2(g)
Number of tubes 917 ‘U’ type
Corrosion allowance 3.2 mm
Tube O.D. 19.05 mm
Tube thickness 20 BWG
Leg length 11940 mm
Material SA 688 TP304
Feed water velocity 1.58 m/s
Pressure drop in tubes 0.6 Kg/cm2
Design temperature 1520C
Safety Relief Valve (Shell Side):
Set pressure 3.0 bar
Relieving capacity 296588 Kg/hr
Weight:
Empty 26000 Kg
Operating 33000 Kg
Flooded 43000 Kg
Tube bundle 18500 Kg
Technical Data of L.P Heater-3:
Type U Tube horizontal condensing , Shell & Tube (Double Pass)
Design Standard ASME Sec.VIII Div-1 2007 up to & incl. Addenda. Nil &
HEI 6th Edition
Heat duty Condensing zone: 22.71 x 106 Kcal/hr
Sub -cooling zone: 0.74 x 106 Kcal/hr
Heat Transfer co-efficient Condensing zone: 3252 Kcal/hr.m2.0C
Sub -cooling zone: 1680 Kcal/hr.m2.0C
LMTD Condensing zone: 21.350C
Sub -cooling zone: 11.220C
Heat transfer area required Condensing zone: 751 m2
Sub -cooling zone: 39.3 m2
Total heat transfer area
provided
847 m2
Extraction steam parameter Pressure: 2.687 Ata
Temperature: 208.40C
Quantity: 40.72 TPH
Drain /Drip parameter Drain O/L temperature: 1110C
Drain O/L quantity: 40.72 TPH
Feed water parameter FW I/L temperature: 106.20C
FW I/L quantity: 1152.981 TPH
FW O/L temperature: 126.40C
FW O/L quantity: 1152.981 TPH
T.T.D 2.80C
D.C.A 4.80C
Shell Side:
Design pressure 4.0 Kg/cm2(g) & Full Vacuum
Test pressure 5.2 Kg/cm2(g)
Corrosion allowance 3.2 mm
Shell O.D. x Thickness φ 1332 x 16 mm
Design temperature 2160C
Tube Side:
Design pressure 40 Kg/cm2(g) & Full Vacuum
Test pressure 52 Kg/cm2(g)
Number of tubes 925 ‘U’ type
Corrosion allowance 3.2 mm
Tube O.D. 19.05 mm
Tube thickness 20 BWG
Leg length 9560 mm
Material SA 688 TP304
Feed water velocity 2.0 m/s
Pressure drop in tubes 0.7 Kg/cm2
Design temperature 1520C
Safety Relief Valve (Shell Side):
Set pressure 4.0 bar
Relieving capacity 296588 Kg/hr
Weight:
Empty 18000 Kg
Operating 24000 Kg
Flooded 31500 Kg
Tube bundle 12500 Kg
Technical Data of H.P. Heater-5A & 5B:
Type U Tube horizontal condensing , Shell & Tube (Double Pass)
Design Standard ASME Sec.VIII Div-1 2007 up to & incl. Addenda. Nil &
HEI 6th Edition
Heat duty Desuperheating zone: 4.24 x 106 Kcal/hr.
Condensing zone: 20.84 x 106 Kcal/hr
Sub -cooling zone: 4.22 x 106 Kcal/hr
Heat Transfer co-efficient Desuperheating zone: 410 Kcal/hr.m2.0C
Condensing zone: 2260 Kcal/hr.m2.0C
Sub -cooling zone: 1684 Kcal/hr.m2.0C
LMTD Desuperheating zone: 95.830C
Condensing zone: 14.330C
Sub -cooling zone: 14.320C
Heat transfer area required Desuperheating zone: 108 m2
Condensing zone: 643 m2
Sub -cooling zone: 176 m2
Total heat transfer area
provided
1018 m2
Extraction steam parameter Pressure: 17.40 Ata
Temperature: 444.50C
Quantity: 43.709 TPH
Drain /Drip parameter Drain I/L temperature: 209.60C
Drain I/L quantity: 74.822 TPH
Drain O/L temperature: 1690C
Drain O/L quantity: 118.531 TPH
Feed water parameter FW I/L temperature: 164.10C
FW I/L quantity: 728.5045 TPH
FW O/L temperature: 204.80C
FW O/L quantity: 728.5045 TPH
T.T.D (-) 0.30C
D.C.A 4.80C
Shell Side:
Design pressure 24.0 Kg/cm2(g) & Full Vacuum
Test pressure 36 Kg/cm2(g)
Corrosion allowance 3.2 mm
Shell O.D. x Thickness φ 1540 x 20 mm
Design temperature 2240C
Tube Side:
Design pressure 330 Kg/cm2(g) & Full Vacuum
Test pressure 495 Kg/cm2(g)
Number of tubes 1181 ‘U’ type
Corrosion allowance 3.2 mm
Tube O.D. 15.875 mm
Tube thickness 12/13 BWG
Leg length 8650 mm
Material SA 688 TP304
Feed water velocity 2.01 m/s
Pressure drop in tubes 1.0 Kg/cm2
Design temperature 2440C
Safety Relief Valve (Shell Side):
Set pressure 24.0 bar
Relieving capacity 461807 Kg/hr
Weight:
Empty 44500 Kg
Operating 49000 Kg
Flooded 59080 Kg
Tube bundle 31000 Kg
Technical Data of H.P.Heater-6A & 6B:
Type U Tube horizontal condensing , Shell & Tube (Double Pass)
Design Standard ASME Sec.VIII Div-1 2007 up to & incl. Addenda. Nil &
HEI 6th Edition
Heat duty Desuperheating zone: 3.8 x 106 Kcal/hr.
Condensing zone: 32.96 x 106 Kcal/hr
Sub -cooling zone: 4.02 x 106 Kcal/hr
Heat Transfer co-efficient Desuperheating zone: 610 Kcal/hr.m2.0C
Condensing zone: 2334 Kcal/hr.m2.0C
Sub -cooling zone: 1640 Kcal/hr.m2.0C
LMTD Desuperheating zone: 43.910C
Condensing zone: 16.940C
Sub -cooling zone: 19.970C
Heat transfer area required Desuperheating zone: 142 m2
Condensing zone: 834 m2
Sub -cooling zone: 137 m2
Total heat transfer area
provided
1200 m2
Extraction steam parameter Pressure: 42.75 Ata
Temperature: 334.80C
Quantity: 74.822 TPH
Drain /Drip parameter Drain O/L temperature: 209.60C
Drain O/L quantity: 74.822 TPH
Feed water parameter FW I/L temperature: 204.80C
FW I/L quantity: 728.5045 TPH
FW O/L temperature: 253.40C
FW O/L quantity: 728.5045 TPH
T.T.D (-) 0.30C
D.C.A 4.80C
Shell Side:
Design pressure 57.0 Kg/cm2(g) & Full Vacuum
Test pressure 85.5 Kg/cm2(g)
Corrosion allowance 3.2 mm
Shell O.D. x Thickness φ 1580 x 40 mm
Design temperature 2730C
Tube Side:
Design pressure 330 Kg/cm2(g) & Full Vacuum
Test pressure 495 Kg/cm2(g)
Number of tubes 1181 ‘U’ type
Corrosion allowance 3.2 mm
Tube O.D. 15.875 mm
Tube thickness 12/13 BWG
Leg length 10200 mm
Material SA 688 TP304
Feed water velocity 2.01 m/s
Pressure drop in tubes 1.2 Kg/cm2
Design temperature 2930C
Safety Relief Valve (Shell Side):
Set pressure 57.0 bar
Relieving capacity 461807 Kg/hr
Weight:
Empty 54000 Kg
Operating 59300 Kg
Flooded 70700 Kg
Tube bundle 37000 Kg
Technical Data of Turbine Oil Purifier (T.O.P):
Purifier:
Make GEA
Model No. OCT20-91-067
Speed 10000 RPM
Separator Motor:
Make Bharat Bijlee
Type MD 13M255
Power 7.5 KW
Voltage 415 V
Voltage range 373 to 456 V
Rated current 13.7 Amps
Connection Delta
Power factor 0.87
Frequency 50 ± 5% Hz
Ambient temperature (-) 200C to 450C
Duty S1
Speed 2920 RPM
Feed Pump Motor:
Make Bharat Bijlee
Type MD 11M435
Power 3.7 KW
Voltage 415 V
Current 7.3 Amps
Connection Delta
Power Factor 0.83
Efficiency 85%
Duty S1
Ambient temperature (-) 200C to 450C
Speed 1430 RPM
Heater interlocks:
Low oil temperature alarm < 450C
Heater - I cut out temperature Oil temperature > 550C
Heater - II cut out temperature Oil temperature > 600C
Heater - III cut out temperature Oil temperature > 650C
Heater - IV cut out temperature Oil temperature > 700C
Heaters start permissive Water level in heater is NOT LOW
Tripping Interlocks: Any motor overload
Liquid seal broken
Emergency PB operated
Oil charging valve solenoid will be de-
energies due to low oil temperature (<450C)
Technical Specification of Condenser Vacuum Pump (1W + 1S):
Pump:
Make EDWARDS Ltd.
Model No. SHR 22500
Item No. NR7112000
Seal fluid Water
Ring fluid Water
Capacity 4510 m3/hr
Speed 585 RPM
Weight 2655 Kg
Motor:
Make WEG
Frame W21-355M/L-10
Voltage 415 V
Power 132 KW
Current 285 Amps
Speed 595 RPM
Efficiency 94%
Phase 3 (Three)
Duty S1
Insulation Class F
Degree of protection IP 55
Ambient temperature 500C
Frequency 50 Hz
SF 1.0
P.F 0.69
Weight 1771 Kg
Technical Specification of Vacuum Pump Seal water cooler:
Make Funke Heat Exchanger System Company Ltd.
Net weight 560 Kg
Heat transfer surface 22.7 M
Baffle space 150 mm
Shell Side:
Design pressure 1.0 Mpa
Test pressure 1.5 Mpa
Working pressure 0.11 Mpa
Design temperature 800C
Medium Service liquid
Tube Side:
Design pressure 1.0 Mpa
Test pressure 1.5 Mpa
Working pressure 0.09 Mpa
Design temperature 800C
Medium Cooling water
TECHNICAL DATA OF TURBO GENERATOR:
Make BHEL, Haridwar
Type THDF 115/59
Specification IS 5422 IEC:34
KW Rating 500,000
KVA Rating 588,000
Power Factor 0.85 Lag
Frequency 50 Hz
Speed 3000 RPM
Insulation Class F
Stator Phase 3 Phase
Stator Connection YY
Stator Voltage 21 kV
Stator Current 16.166 kA
Rotor Voltage 340 V
Rotor Current 4040 Amps
Terminal voltage variation ± 5%
Frequency variation -5% to +3%
Stator winding cooling Direct water cooled
Stator core cooling Direct H2 cooled
Rotor cooling Direct radial H2 cooled
H2 Gas Pressure 3.5 Kg/cm2 (g)
Minimum H2 Gas Pressure &
corresponding MW
2.5 bar (g) & 470 MW
Rated cold gas temperature 450C
Maximum hot gas temperature 750C
Efficiency 98.65% (at 100% load); 98.64% (at 75% load); 98.43%
(at 50% load); 97.47% (at 25% load)
Critical speeds 1st Critical Speed: 864 RPM; 2nd Critical Speed: 2388
RPM; 3rd Critical Speed: 4680 RPM
Stator water inlet temperature 500C
Stator water outlet temperature 900C
Volume of H2 space in Generator 80 m3 at rated gas pressure of 3.5 Kg/cm2(g)
Recommended H2 purity Normal: 98%; Minimum: 96%
Allowable H2 leakage at rated gas
pressure
12 m3/day
Volume of H2 required to purge
the CO2 to bring the casing at rated
pressure (at NTP & standstill
condition)
480 m3
Volume of CO2 required to purge
H2 at NTP & standstill condition
160 m3
Volume of CO2 required to purge
air at NTP
160 m3
Volume of air required to purge
CO2 at NTP
240 m3
Total Generator losses 6.838 MW
TECHNICAL DATA OF GENERATOR EXCITATION SYSTEM (Brushless
Excitation):
(A) Technical Data of Pilot Exciter [P.M.G (Permanent Magnet Generator)]:
Make BHEL
Type ELP 50/42 – 30/16
Reference standard IEC 34
Type of drive Direct
Nos. of pole 16
Rated output 65 KVA
Rated power factor 0.6
Rated voltage 220 V (no load) AC
Rated current 195 Amps
Rated speed 3000 RPM
No. of phases & frequency 3 Phase, 400 Hz
Insulation class & type Class F & Enameled Glass taped
Stator winding resistance per phase at
250C
0.00275 Ohm
(B) Technical Data of Main Exciter:
Make BHEL
Type ELR 70/90 – 30/6 – 20
Reference standard IEC 34
Type of drive Direct
Rated output 3780 KVA
No. of phases & frequency 3 Phase, 150 Hz (DC output after rotating
rectifier)
Rated voltage at generator rated output & P.F. 340 Volts AC
Rated current at generator rated output & P.F. 4040 Amps
Field current at generator rated output & P.F. 86 Amps
Exciter rectified field voltage with manual
control
TECHNICAL SPECIFICATION OF H2 GAS DRIER (1W + 1S):
Make Mellcon Engineers Pvt. Ltd.
Model No. CSB-188 (Refrigerant type)
Dryer Capacity 40 m3/hr
Inlet pressure 5 Kg/cm2 (g)
Inlet temperature (Max.) 600C
Outlet dew point temperature at line pressure (+) 3 to 50C at line pressure
Purge loss Nil
Supply voltage 415 V AC, 3 Phase, 50 Hz
Operation Automatic
Base frame size 900 mm x 850 mm
Height from base 2000 mm (approx.)
Refrigerant R-134a
Compressor rating 3225 K.Cal/hr.
Compressor anti-freeze temperature protection
setting value
Compressor trips at refrigerant temperature
00C & Compressor starts at refrigerant
temperature 60C
Compressor interlocks for H2 dew point
temperature
Compressor trips at H2 dew point
temperature (dryer outlet) 00C & starts at
50C
Compressor protection tripping value through
refrigerant pressure
Compressor trips at 220 psi compressor
discharge pressure through HP protection &
Compressor trips at 20 psi of compressor
suction pressure through LP protection
Condenser fan auto start / stop set value Fan starts at 170 psi refrigerant pressure at
compressor discharge & stops at 130 psi
Dryer running cycle time setting 10 hrs running with 90 sec time delay for
next cycle start with auto mode operation
GENERATOR PRIMARY WATER SYSTEM:Primary Water Pump (1W +1S):
Pump:
Make Sulzer Pumps
Kind of pump Single stage Centrifugal with spiral casing & overhung
impeller
Type C7 65-250
Discharge capacity 70 m3/hr.
Head 90 M
NPSH 2 M
DE Bearing 6308
NDE Bearing 6308
Speed 2955 rpm
Motor:
Make Bharat Bijlee
Type 3 Phase SQIM
Voltage range 373 – 456 V
Power 37 KW
Voltage 415 V
Current 62.9 Amps
DE Bearing 6312 2ZC3
NDE Bearing 6212 2ZC3
Insulation class F
Degree of protection IP-55
Duty S1 (Continuous)
Power factor 0.88
Efficiency 93%
Speed 2955 rpm
Frequency 50 ± 5% Hz
Ambient temperature 500C
A) Primary Water NaOH Dosing System (Alkalizer Unit):
Alkalizer Unit Components: NaOH tank, NaoH tank cap, Diaphragm Pump, NaOH tank
vent with lime filter, spring loaded feed valve/check valve
NaOH dosing system is provided to maintain the PW conductivity 1.0 to 3.0 µs/cm & pH
8-9.
NaOH dosing pump will auto start when conductivity after ION exchanger < 1.0 µs/cm.
NaOH dosing pump will auto cut out when conductivity after ION exchanger > 3.0 µs/cm
or conductivity after main filter after PHE become high > 2.5 µs/cm
NaOH solution concentration: 10 – 20 g of NaOH per dm3
Lime filter: Consists of equal parts of NaOH & Ca(OH)2 . This mixture is commercially
known as Soda Lime. Lime filter is used to prevent the formation of carbonates in NaOH
solution.
Technical Specification of Alkalizer Pump-Motor set:
Make ProMInent; DOSER PCHNIK; Germany
Type BT4A160 INPB200 AA000000
Sl. No. PN-20121298-38
Power supply 200 – 230 V
Power 17 Watt
Current 0.3 Amp
Frequency 50-60 Hz
Dosing rate 1.1 litre/hr. or 0.29 gmph
Pressure 16 bar/232 psi
Ion Exchanger (1 x 100% capacity):
Type Mixed Bed
Volume 83 litres
Resin Lewatit S 100KR/H/Chloride free & Lewatit 500
KR/OH/Chloride free
Resin volume 56 litres (45 Kg)
Function Remove all copper, iron, chlorine, CO2 ions
B) Primary Water Tank:
Capacity
Normal level
Low level
V. Low level
Make up From DMSW pump discharge when tank level low
C) Primary Water Heat Exchanger (P.H.E) [1W+1S]:
Make Tranter India Pvt. Ltd.
Type Plate type heat exchanger (PHE)
Design temperature 800C (Hot) & 800C (Cold)
Design pressure 16 kg/cm2 (Hot) & 16 kg/cm2 (Cold)
Test pressure 24 kg/cm2 (Hot) & 24 kg/cm2 (Cold)
Weight 480 Kg(empty) ; 533 Kg (full)
D) Main Filter (1W + 1S):
Make M/S Boll & Kirch
Kind of filter Strainer type filter with magnet bars
Type 1.53.1
Volumetric flow rate 25 dm3/sec (max)
Degree of filtration 150 mm
Pressure drop across filter 0.1 bar with clean filter & 1.2 bar with 100% fouling
E) Fine Filter (1x 100% capacity):
Make M/S Boll & Kirch
Kind of filter 1 plug. 1 cartridge
Type 1.55.1
Volumetric flow rate 0.42 dm3/sec (max)
Degree of filtration 5 mm (0.2 mils)
Pressure drop across filter 0.15 bar with clean filter & 1.2 bar with 100% fouling
A) Technical Specification of A.C. Seal Oil Pump (1W + 1S):
Pump:
Make UT Pumps & Systems Pvt. Ltd.
Model No. PDHU-CL-275
Type
Capacity 258 LPM
Discharge pressure 12 Kg/cm2
Speed 1450 RPM
Motor:
Make Crompton Greaves Ltd.
Type 3 Phase Induction Motor
Frame ND 132M
Power 7.5 KW / 10 HP
Voltage 415 ± 10% Volts
Frequency 50 ± 5% Hz
Current 14.63 Amps
Speed 1455 RPM
Duty S1
Insulation Class F
Degree of protection IP 55
Ambient temperature 500C
Efficiency 87%
DE Bearing 6308 2Z
NDE Bearing 6208 2Z
Stator winding connection Delta
B) Technical Specification of DC Seal Oil Pump (1No. SB):
Pump:
Make UT Pumps & Systems Pvt. Ltd.
Model No. PDHU-CL-575B6
Type
Capacity 258 LPM
Discharge pressure 12 Kg/cm2
Motor:
Make Crompton Greaves Ltd.
Type Shunt
Frame Size AF 5225L
Excitation Self
Power 8.5 KW
Armature voltage 150V
Armature current 67 Amps
Field voltage 220 V
Field current 1.5 Amps
Speed 1450 rpm
Duty S1
Insulation Class F
Degree of protection IP 55
Ambient temperature 500C
DE Bearing 62132 RS
NDE Bearing 62132 RS
Weight 400 Kg
GD2 1.5 Kg-m2
C) Technical Specification of Seal Oil Vacuum Pump (1W +1S):
Pump:
Make Acme Vacuum Pump & Engg. Pvt. Ltd.
Model No. SSP70D
Discharge capacity 7.0 LPM
Vacuum 0.20
Speed 1410 RPM
Power required 0.5 HP
Temperature 850C
Motor:
Make Crompton Greaves Ltd.
Frame GD 718
Type 3 Phase Induction Motor
Power 0.37 KW
Voltage 415 ± 10% Volts
Frequency 50 Hz
Current 2.7 Amps
Duty S1
Ambient temperature 450C
Speed 1410 RPM
Insulation Class F
DE / NDE Bearing 6003 2Z/ 6003 2Z
Connection Delta
Technical Specification of Heat Exchanger (1W + 1S):
Make GEA Ecofiex Fadia Pvt. Ltd.
Type Plate type – VT40CDL25
Design pressure 16 bar
Test pressure 28 bar
Design temperature 1000C
BRIEF NOTES ON VARIABLE FREQUENCY DRIVES
INSTALLED AT ID FAN# 500MW
Prepared By: Wasim Ahmed, Manager (PS), Electrical Construction,
SgTPP
VFD drives are widely used in thermal power plants mainly due to precise speed control &
promise of improved efficiency. A brief account of such technical superiority of VFD drives
over fluid coupling is being summarized in this ensuing section with principle of operation &
other features.
Schematic Diagram of an Ideal Coal-fired Boiler--- highlighting Steam and Flue
Gas path:
ADVANTAGES OF USING VARIABLE FREQUENCY DRIVES
UNLIMITED STARTS / STOPS
SOFT START
INCREASE IN MECHANICAL LIFE
INCREASE IN MOTOR LIFE
WIDE FLOW CONTROL
PRECISE SPEED CONTROL
ROUTINE MAINTENANCE FREE
HIGHLY EFFICIENT
**Variable frequency system can be used for Synchronous Motors, Super Synchronous
Motors and Squirrel Cage Induction Motors. Here in (2*500) MW Sagardighi Thermal
Power Plant , it is being applied for Synchronous Motor and Load Commuted Inverter has
been come into action as the motor is rated around 3950 KW which is in between ideal range
(1000 KW to 15000 KW) for application of LCI.
Load Commutated Inverter (LCI) Scheme for Synchronous Motor
The basic components of an Ideal LCI can broadly be listed as follows:
CONVERTER DUTY TRANSFORMER
DC LINK REACTOR
RECTIFIER BRIDGE
INVERTER BRIDGE
SYNCHRONOUS MOTOR WITH BRUSHLESS EXCITER
ELECTRONIC CONTROL
Pic: Typical SLD of 2.3 kV LC
Design features of LCI:
MICROPROCESSOR BASED DIGITAL CONTROL
FUSELESS POWER CIRCUIT
REDUNDANT COOLING FAN/PUMP
THYRISTORS WITH N+1 OPTION
IMOK INDICATION FOR EACH THYRISTOR
TUNABLE ACCELERATION/ DECELERATION RATES
EMERGENCY DECELERATION
IN BUILT MOTOR AND INVERTER PROTECTIONS
COMPARISON OF ID FAN ARRANGEMENT FOR VFD & HYDRAULIC
COUPLING
In thermal Power Plants mostly four types of Flow Control Devices are used,viz., Load
Commutated Inverter, Hydraulic Coupling, Inlet Guide Vane and Output Damper or
Throttling.
Let’s watch a comparison curve regarding efficiency of all four flow control devices:
So it is quite clear that LCI is the most effective flow control devices among all.
OPERATIONAL WRITE UP ON TURBINE DRIVEN
BOILER FEED PUMP AT 500MW UNIT
PREPARED BY: TRIDIP DEBNATH, AM (PS), COMMISSIONING,
SgTPP
At the era of techno-commercial, Turbine Driven Boiler Feed Pump is one of the power -
saving equipment to fill feed water into the boiler with comparing of Motor Driven Boiler
Feed Pump. At 500 MW unit of SgTPP Thermal Power Plant, power consumption of
MDBFP is approx. 10 MW whereas TDBFP consumes 6.2-7.4 MW. In 500MW unit there are
two similar TDBFPs located on turbine floor.
Basic pumps (feed pumps) are same of MDBFP and TDBFP, but main difference is
drivenpower, one is Motor and another is steam turbine.
Boiler Feed
PUMP
Booster
Pump
Gear Box Steam Driven
Turbine
Arrangement of TDBFP
Booster
Pump Boiler Feed
Pump
Motor Hydraulic
Coupling
Arrangement of MDBFP
There are three sources of steam for TDBFP turbine such as APRDS, CRH and main turbine
extraction -4 at Sagardighi Thermal Power Project. Initially steam is consumed from APRDS
and pressure is set approx. 11 kg/cm2(g) and it was observed that above 300 MW load,
TDBFP run smoothly from Extraction -4 steam but CRH steam pressure very much
fluctuating. That is why it is tough to control TDBFP operation from CRH steam. APRDS
and CRH steam is controlled with Auxiliary Control Valve and if pressure is increased more
than 12kg/cm2 then a safety valve popped. TDBFP run smoothly with pressure 4-6 kg/cm2
STEAM SOURCE
APRDS. Pr.
10kg/cm2
STEAM SOURCE
CRH, Max. Pr.
44kg/cm2
STEAM SOURCE EXT-4/CAP,
Max. pr. 6.9kg/cm2
MAIN CONTROL VALVE
AUXILIARY CONTROL VALVE
ESV
TURBINE OF TDBFP
EXHAUST STEAM GOING TO
CONDENSER DIRECT
STEAM FLOW DIAGRAM
Safety
valve
Auxiliary Equipment and systems of TDBFP:
a) Lube Oil system: - 2 nos. AOP (AC), (one stand by and one working), One no. AC
JOP(Jacking Oil Pump), One DC EOP, Two nos. vapor extraction Fan(one standby
and one working), One lube oil tank (10M3), 2 nos .Lube oil cooler, 2 nos. Lube oil
filter, one centrifuge.
b) Governing system: - One Auxiliary Control valve, One Stop Valve, one Main Control
valve, Governing rack.
Operation of above valves: - First control oil comes from discharge header of AOP
and its pressure approx. 8-9kg/cm2. Control oil goes to hand trip valve (22250)
through trip solenoid valve 2222A and 2222B. Hand trip valve can be reset by
energized the remote engagement solenoid valve (1050). After resetting trip liver, a
trip oil (Pr.>5 kg/cm2) generated and goes to solenoid valves 2220, 2221 and electro
hydraulic converter (EHC) 1800A and 1800B. After energized solenoid valve 2221,
startup oil built up and compresses the spring at above piston of the emergency stop
valve. After that de-energized the solenoid valve 2220 and trip oil pressure opened the
ESV.
Electrohydraulic controller 1800A generated secondary oil and controls the main
control valve. Similarly 1800B controls the auxiliary control valve.
Drawing insert
c) Feed Water System: - Water from deaerator flows through the booster pump and its
discharge is fed to Boiler Feed Pump suction. From the discharge of BFP the feed
water passes through two parallel paths of two nos. HP Heater each path (5A, 6A &
5B, 6B), economizer, and finally reaches the boiler drum.
d) Gland sealing of turbine: - Before opening of exhaust valve gland sealing should be
done as this line connected to condenser. Initially gland sealing steam comes from
APRDS line and a CRH line. After speed of turbine reaches more than 4000rpm it
goes to automatic self-sealing mode.
Following line up should be checked before steam rolling of TDBFP:-
a) Pump side: -Suction valve of booster pump should be opened and proper venting
should be done through basket strainer, booster pump casing and BFP casing
vents. All DMCW lines should be opened for jacket and seal cooling for both
pumps. Recirculation manual as well as pneumatic operated valve should be
opened.
b) Lube oil: - Oil level of MOT should be checked and it will be more than 1380
mm. All pumps breaker will be service position and LOS will be release
condition. DMCW water line should be opened for cooler.
c) Gland sealing: All drain valves should be opened before charging of gland
sealing steam. Warm up line drain will be also opened condition.
d) DCS logic should be checked. Following logics should be checked.
1. Lube oil pump A interlock:-
Start permissive:- Lube oil tank level > 1380mm.
Stop permissive:-a. LOP-B on lube oil discharge pr. >7.5 kg/cm2 or lube oil
common header pr.>1.5 kg/cm2.
b. TDBFP not working.
c. TDBFP speed Zero and speed<10rpm.
Auto start condition: a. LOP-B tripped (2 sec pulse).
b.TDBFP working or LOP-B on (90sec delay) and lube oil
discharge pr. Low <7.5 kg/cm2 or lube oil common
header pr.<1.5.
2. Lube oil pump -A interlock:-
Start permissive:- Lube oil tank level > 1380mm.
Stop permissive:-a. LOP-A on lube oil discharge pr. >7.5 kg/cm2 or lube oil
common header pr.>1.5 kg/cm2.
b. TDBFP not working.
c. TDBFP speed Zero and speed<10rpm.
Auto start condition: a. LOP-A tripped (2 sec pulse).
b.TDBFP working or LOP-B on (90sec delay) and lube oil
discharge pr. Low <7.5 kg/cm2 or lube oil common
header pr.<1.5.
3. JOP Interlock:-
Stop permissive: a. TDBFP Speed zero and Speed<10rpm.
b. TDBFP Speed >540rpm.
Auto start condition: TDBFP speed <510 rpm(10 sec pulse)
Auto stop condition: TDBFP Speed >540 rpm.
4. DC EOP interlock:-
Auto start condition:- a. Lube oil common header pr.2v3 very low
<0.7kg/cm2 or lube oil common hdr pr. Switch
low <0.75kg/cm2. and TDBFP speed >10
rpm or 100% casing tem.>85deg c.
Start permissive: EOP dc starter ready to start.
stop permissive:- auto start CMD not presetting or AOP A on or AOP-B on or
TDBFP speed zero.
5. Turning Gear Valve Interlock:-
Auto open condition:- speed<=510rpm
Auto close condition:- Speed >540 rpm
Close permissive: - TDBFP speed >540 and 100% casing temp <=85 deg.
C.
Start up Procedure of TDBFP:-
a) Lube oil charging:- First charge DC EOP for oil filling at all lube oil line after that
charge any AOP. AOP Discharge pressure set with in pressure 9-10 kg/cm2.
b) TDBFP put in Barring:- JOP start and set pressure 100 kg/cm2 at discharge point (0
mtr). Open turning gear valve and if turbine not running then hand barring require and
set JOP two line valves( Two valve first full closed then open slightly approx 1/8th
turn). Lube oil Pressure of after barring valve will be within 3.5 to 4 kg/cm2 and
barring speed reaches 260-280 rpm.
c) Gland Sealing charging:- First open the APRDS main isolating valve at PRDS floor
then ensure the steam temperature more than 300 deg. Centigrade. Open the
individual manual individual isolatingvalve of PRDS. During charging of gland
sealing, open all casing and line drain valves (MTL08,MTL06,MTL07,MTL09) .
Initially gland steam header pr. controller take in manual mode and increase control
valve command more than 55%. After increasing gland steam header pressure, set
header pressure 300mmwc and put the controller auto mode. During charging of
gland sealing, motorized bypass valve (MTW71A) may be opened 6-10 %. After
established the gland sealing, opened the exhaust valve.
d. ESV opening:- First reset the governing system and wait some times for reaching the
trip oil pressure as well as above piston pressure more than 5kg/cm2 then open the
ESV with manual mode. During ESV opening, Drain valve CRHV 153 will be opened
condition.
e. Rolling and loading the turbine:- Increase the demand of the auxiliary control valve
and maintain the live steam pressure up to 4 kg/cm2 .Then set 1600 rpm at speed reference
because a on feedback given for running of TDBFP(If MDBFP tripped at that time but MFT
will not be taken place because TDBFP running feedback on condition at that time) .
Soaking will be continued till the temperature reaching 150degree centigrade at BFP casing
100%. Speed of the TDBFP may be increased as per requirement of discharge pressure of
BFP. Maintain the live steam temperature above 300 degree centigrade. Steam from
Extraction -4 may be charged at 300 MW load and above because at that time steam pressure
is 4kg/cm2 and more. TDBFP may be put in auto mode and speed reference will be varied as
per requirement of system in auto mode. Live Steam pressure may be put in auto mode with a
set point and Auxiliary control valve demand also varies as per requirement of set point.
TDBFP run smoothly with steam of extraction -4. A safety valve has been installed at after
auxiliary control valve and it popped above 12 kg/cm2 steam pressure. So it is very difficult
at CRH pressure because CRH valve (EXV15) open at pressure 12.7 kg/cm2 and above 287
degree centigrade temperature.
Shut down procedure of TDBFP:-
Reduce the speed up to 1500 rpm corresponding reduce the live steam pressure with
help of auxiliary control valve.
Then Tripped the turbine and speed will be reduced gradually and JOP will be started
at below speed 510 rpm.
Isolate the all steam valves.
Barring valve will be opened at below speed 510 rpm and finally it will be run with
barring speed (250-280 RPM)
If the 100% BFP casing temperature reduced at below 85 degree centigrade the
barring gear valve may be closed.
Steam turbine and Gear box of the TDBFP
SAS INTEGRATION AT SAGARDIGHI
Er. Narayan Mohan Dhar, HOD (TEC-IT), SgTPP, WBPDCL
Er. Kaushik Dasgupta, AM (TEC-IT), SgTPP, WBPDCL
With the advent of SgTPP Phase I (2*300) MW, WBPDCL has step into a new era of
modernization in the field of Power System Engineering. Phase I of SgTPP has been
equipped with state of art fully numerical relays, IEDs and SCADA (Supervisory control and
data acquisition) system which have change the concept of Electrical Protection and Control
System. The Nari Electric RCS-9700 SCADA system compromises of Bay Control Units
(BCU) for individual bays of switchyard. These bays are used for real time and continuous
monitoring and supervision of analog (Current, Voltage etc) and binary (CB state, Isolator
feedback etc) data. Raw data are collected from switchyard at these BCUs and processed
therein. The SCADA system used GOOSE (Generic Object Oriented Substation Events) for
communication. GOOSE is a controlled model mechanism in which any format of data
(status, value) is clubbed into a data set and communicated within a time period of few
milliseconds. Actually GOOSE is a subdivision of Generic Substation Events (GSE), which
is a control model of IEC 61850 helps to provides a fast and reliable mechanism of
transferring event data over entire switchyard network. All BCUs here are function through
GOOSE technology. Individual BCUs are unique networking ID and are communicated with
sub-station layer through NR developed IEC 103 Transmission Protocols. The sub-station
layers compromises of all data of individuals BCU and communicated to station layer/server
of SCADA. The server processed, stores, back-up, all such data and provides SLD, report,
alarms SOE, graphs and other features to HMI for real-time monitoring and control of the
switchyard equipment.
Numerical relays are like IEDs (Intelligent Electronic Devices) also communicate with field
protection instruments (CT, CVT, CB etc) and provide protection of all electrical equipment
installed at switchyard. These are very compact models and can be configured for several
protection functions at a single device. There is an Interposing Relay for every protection
function which used to communicate the fault details and tripping elements with the SCADA
system. These IEDs used RS-485 for communication and hence communicate with SCADA
system via a protocol convertor. The protocol convertor can convert the RS-485 to IEC 103
protocol and thus all SOE and fault details can be viewed and analyzed with a single click
from control room HMI.
With commissioning of Stage II (2*500) MW and extension of 400KV switchyard (inclusion
of International feeders for power trading to Bangladesh), the Power System Engineering at
SgTPP has step further ahead. Stage II has come with concept of Bay Control Rooms (BCR)
at switchyard premises which includes BCU and Relays of one diameter of Bays. These
reduce huge cost of power cable laying for CT PT and other control cables from switchyard
to control room. The data of BCU and Relays are converted into optical fiber and transmitted
to control room. In control room data are revert back to IEC 104 protocol for communication
with new SCADA server. The new SCADA is Alstom make DS-AGILE.
Among all these technology advancement there arise a challenge for SAS Integration
(Substation Automation System). The existing (NARI) and new (Alstom) SAS has used
different communication protocol for data supervision and control. The existing SAS used
IEC 103 protocol whereas the new SAS used IEC 104 protocol. The IEC 103 protocol is not
an open protocol and hence the control room seems to maintain two SCADA HMIs for
separate portions of the same switchyard. This is a real concerned part from operation aspect.
After lots of brainstorming and efforts Alstom SAS seems to fail fetching data from NARI
SAS as NARI use their proprietary protocol which is not interoperability. With help of
knowledge of NARI SAS of SgTPP concerned department and NARI electric hardware
support, at last this major problem has been sorted out. Phase-I NARI system has RTU
(Remote Terminal Unit) which used to communicate between SCADA and DCS system. The
detailed study and discussion with NARI engineers help to find a way-out that the existing
RTU can be used to change over IEC 103 protocol to IEC 104 for providing existing SAS
data to Alstom make new SAS. For this an extra programmable CPU has been installed by
NARI engineer to the existing RTU. This CPU helps to convert IEC 103 protocol to IEC 104
but not vice versa is possible. Once this conversion is achieved SgTPP concerned department
studied and help to provide all networking ID address and all data structure of individual bays
(Telecontrol, Telecommunication etc) to Alstom engineers for their integration. On receiving
such existing SAS data-structure Alstom then was able to configure all these data to the new
SAS. The existing SAS data converted to 104 protocols by NARI- RTU’s new CPU and
forwarded to Alstom system. At Alstom end a new Gateway was installed which receive the
104 protocol based existing SAS data and communicated with the Alstom DS AGILE
servers. Thus supervision and control of the existing SAS can be done through the new SAS.
At last, the much desire SAS integration becomes successful.
104
