Performance Guarantee Tests on Khaperkheda Thermal Power Project

8/21/2019 Performance Guarantee Tests on Khaperkheda Thermal Power Project

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CONTENTS

1. OBJECTIVE

2. TEST CODE

3. TEST SCHEMATIC

4. SELECTION OF INSTRUMENTS

5. AGEING

6. TOLERANCES

7. FREQUENCY OF OBSERVATIONS

8. DURATION OF TESTS

9. ADVANCE PLANNING FOR THE TESTS

10. PREPARING THE TG CYCLE FOR THE TESTS

11. PRETEST SHUT DOWN ACTIVITIES

12. INSTALLATION OF TEST INSTRUMENTS

13. GENERAL GUIDE LINES

14. INSTRUMENTS CALIBRATION AND CORRECTIONS

15. ITEMS ESSENTIAL FOR AGREEMENT

16. PROGRAMME OF TESTING

17. PRESERVATION OF TEST FLOW ASSEMBLIES

18. CONDITION AND CYCLE ISOLATION OF THE PLANT

19. POST TEST ACTIVITIES

1.0 OBJECTIVE

The Performance Guarantee Tests on Khaperkheda Thermal Power Project, unit # 3 & 4 210 MW TGshall be carried out to prove the Guaranteed Heat Rate and Output of the TG Set.This Procedure has been prepared to carry out the tests at site as mentioned above for the followingconditions.

S.No. Guarantee Conditions Guarantee Values

A01.

TG PACKAGE

Gen. Output at rated throttle pressure & temp withcondenser backpressure of 67 mm of Hg (abs) atrated turbine parameters.

210 MW


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02. Heat rate at 210 MW load. 30.5 deg C cooling watertemp. with 67 mm of Hg (abs) condenser backpressure and 0% make up

1939 .3 Kcal/Kwh

03. Auxiliary power consumption

- Boiler feed pumps 2 x 50 % 5320 Kw

- Condensate pumps 1 x 100 % 440 Kw- excitation system

Vapour exhaust fan Vacuum pumps 190 Kw Lube oil system Generator seal oil system

Total Aux. Power

5950 Kw.

B. OTHER BHEL

MANUFACTURED PACKAGES

CW pump power (2 pumps)

1260.7 Kw. Per

Pump.

* Aux. Power Consumption of all aux. Mentioned above (sr. no. 3) will be measured during PG

test with 67 mm of Hg (abs) condenser backpressure and 0% make up. Excitation Power shall be

measured with plant instruments. HT Aux. Will be measured with DPM/Power Transducers and LT

Aux. Will be measured with clamp on meter.

2.0 TEST CODE

The HEAT RATE Tests shall be carried out in line with the recommendations of ASME PTC-6, 1976 Test

Code and in line with approved Document No. PE-4-183-100-211 Rev. 05 for method for computationof Heat Rate.

3.0 TEST SCHEMATIC

The approved test scheme titled PERFORMANCE GUARANTEE TEST INSTRUMENTATION SCHEME, NO.PE-3-183-100-210 REV. 02 shall be used.

4.0 SELECTION OF INSTRUMENTS

The instruments meeting accuracy requirements, as specified in ASME-PTC-6 1976 TEST CODE shallbe used.Instruments selected and proposed to be used shall be as per the TG PG TEST INSTRUMENTATIONSCHEME/LIST which specifies the type of instruments and their ranges etc.The brief details of the instruments to be used during the P.G. Test are

S.No. PARAMETER TO BE

MEASURED

RANGE MEASURING

INSTRUMENT

01. Differential pressure 0-2.5 Kg/Sq. Cm Transmitters

02. Pressure 0-250 Kg/Sq. Cm Transmitters

03. Cond. Back Pressure 0-780 mm Hg. Transmitters

03. Temperature 0-300 Deg. C PRT - 100


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04. Temperature 300-600 Deg. C K Type T.C.

05. Generator Power 0-1000 Watts.

0-5 Amps.

0-65 Volts.

Digital Power mete

06. Speed 0-1000 rpm Non contact type

Tachometer

5.0 AGEING

If the test is carried out after 4 months of the date of first commissioning, due to any reason what soever, the specific heat consumption shall be increased by following amounts for each month or part ofa month by which the period between the initial commissioning and the acceptance test exceeds 4months.0.01% for the following 8 months0.06% for the period there after.

6.0 TOLERANCES

The tolerances on results shall be computed based on uncertainty/inaccuracy of the measuringinstruments used during PG test.

7.0 FREQUENCY OF OBSERVATIONS

It will be carried out as per ASME-PTC-6 which is briefly given below.Heat rate and output test observations from indicating and differential measurement for primary flowshall be made at intervals not greater than 1 minute. Other important measurements shall also bemade at not greater than 1-minute interval. Hot well and D/A levels shall be read at intervals notexceeding 5 minutes.

8.0 DURATION OF TESTS

As per ASME-PTC-6, tests shall be carried out at a steady state run of minimum 2 hours duration.However duration will be mutually decided, depending upon the conditions prevailing duringconductance of P.G. Tests, Minimum two test for heat rate at 100% MCR and one for output test shallbe conducted.

9.0 ADVANCE PLANNING FOR THE TEST

9.01 During the pretest unit commissioning/erection period, every effort shall be made by BHEL toensure the provision of all test tapping points as per test scheme. BHEL shall inform to MSEB in

advance for any missing point measurement which is not possible to be used due to unavoidablereasons and mutually agreed upon. Minimum two tests for heat rate at 100% MCR and one for outputtest shall be conducted.

9.02 Welded type thermowells shall be used by BHEL for temperature measurement on all criticalhigh temperature lines. These thermowells shall remain permanently installed on the pipe lines.

9.03 Screwed type thermowells shall be used in low pressure lines (pressure less than 40 ata) fortemperature measurement and shall be installed in the unit, just prior to the test. For thesethermowells, matching stub with suitable plug will be provided in the engineering stage itself. In casethese thermowells are found missing then these are to be obtained from the respective unit andsupplied & installed during erection stage itself.

9.04 All the pressure test tappings as mentioned in PG Test Instrumentation Scheme No. PE-3-193-100-210 Rev. 02 are supplied with single or double root valves depending upon the pressure rating ofthe pipe lines. They are supplied by BHEL piping centre in line with the erection drawings released forconstruction. In case some of the pressure tappings are not available, the same shall be provided oralternatively, either a T-off shall be taken from the operational tapping point or operational point


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shall be used, as mutually agreed. Impulse pipe of suitable size shall be laid during pretestpreparations. The pressure lines will be strong enough to withstand any type of vibrations and willhave uniform gradient.

9.04a For Pressure and temperature tapping points in case not available/constraint in its use isobserved before the commencement, alternate operational points will be used after mutualagreement.

9.05 Test CTs and PTs (MSEB scope) of 0.2 accuracy class are to be provided by BUS DUCT

supplier. The installation and/or test data for ratio and phase angle errors at different VA burdens andpower factors shall be provided by. MSEB for accurate power calculations. Additionally test certificates giving the aboveinformation, as submitted by the generator bus duct supplier shall also be arranged by MSEB.

9.06 CT terminals should be provided with termination arrangement for shorting or opening links.Effects of connecting leads shall be neutralized in power calculations by measuring voltage dropacross PT terminals and measuring point.

9.07 It has to be checked during erection stage that no pipeline or installation etc. Fouls the testtapping. Test temperature element are 450 mm along. Enough space should be available for eachtapping point so that the test temperature elements can be inserted without any difficulty. In case of

any obstruction an alternate test stub is to be provided as per point No. 9.02 & 9.03 if possible.9.08 Test CTs & PTs terminals to be brought to UCB panel. CT terminals be provided with shortinglink.

10.0 PREPARING THE TG CYCLE FOR THE TEST

Efforts are to be made to ensure that all the TG systems/equipments are brought into service withinreasonable period of the first synchronisation and trial run should also be completed by this period.Normally with the increase in running hours, salt deposits take place and also turbine clearanceschange. This deteriorates the turbine performance and thus the test should be conducted preferablywithin four months after first synchronisation.

The unit readiness for conducting the PG Tests is to be ensured as per the checklist.

10.01 To ensure that all LP & HP heaters are in normal operation and drips of these heaters arecascaded properly as per the cycle. It is to be checked that there is no by passing of the drips eitherto condenser or to deaerator and this is to be ensured for sufficient time before actualcommencement of the test.

10.02 To check that there should not be any leakage in the tubes of HP & LP heaters tubes.

10.03 To ensure the cleanliness of condenser tubes and to get the same cleaned if required duringthe shut down prior to the tests.

10.04 To ensure that the machine is able to run on orie vacuum pump only. Further the vacuumobtained with this running pump should preferably be nearer to the design value.

10.05 To ensure that pressure of Main Steam First Stage, Cold Reheat. Hot Reheat Extractions tovarious heaters and condenser back pressure are near the design values at 210 MW load.

10.06 To ensure that the test flow assembly is available at site with all its matching flanges andfasteners.

10.07 To ensure that the CW pressure drop across the inlet and outlet of the condenser is within thedesign figure and there is no tube leakage in condenser. Conductivity and Oxygen content at

condenser hot well should also be within the prescribed limits.10.08 To ensure the cleanliness of the E.S.V. and I.V. strainers. In case of the excessive pressuredrop, same should be cleaned.

10.09 To ensure that the unit is capable of attaining and maintaining the full load design parameters


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i.e. Main Steam pressure and temperature, Hot Reheat temperature and Condenser Back Pressure.

10.10 To ensure that all the local gauge glasses of the condenser, hot well deaerator and HP & LPheaters are working and are clean and visible. There should not be any gauge glass leakage.

10.11 To ensure that there is adequate light to observe the levels at all places where the operatorswill log the test readings.

10.12 A system tightness check i.e. Deaerator Drop Test shall be done by keeping the

interconnection on steam and load side isolated and also by closing the make-up inlet and by keepingthe CBD, EBD, SOOT Blowing and steam supply to fuel oil heating, atomisation etc. shut off. Thedeaerator level is to be raised to the maximum permissible before this exercise. Fall in deaeratorlevel i.e. system losses are then to be observed and calculated. It is to be ensured that the unit isable to run in the above condition for at least three hours. The problem if any, is to be rectified andthe efforts shall be made to bring down the system unaccounted leakage.

10.13 To ensure the availability of coal in sufficient quantity so that the machine may be loaded tofull load for any desired interval of time and the constancy of test conditions may be attained as perASME-PTC-6 code.

10.14 To ensure the tightness of the system, steam/feed & condensate drain line valves connected to

turbine flash tank for non passing as per the designed heat and mass balance diagram.10.15 To ensure the availability of all tapping as per test scheme. This includes tapping points forindividual equipment performance which may not be required for contractual tests.

10.16 To ensure that the HP & LP Bypass valves to the condenser are not passing.

10.17 To ensure the availability of all the BFPs, CEPs, CWPs coal mills, ID, FDA PA fans etc. so thatthere is no constraints in achieving and maintaining full load for at least 8 hrs. a day.

10.18 To ensure tightness of the vales as per the design heat & mass balance. For this purpose aspecific list of isolation of valves & systems bearing valve numbers shall be prepared in advance oftest.

11.0 PRETEST SHUT DOWN ACTIVITIESAfter it is ensured that the unit is ready for the test, a suitable shut down shall have to be agreedbetween BHEL and MSEB. BHEL shall then supply the calibrated test instruments, prior to the start ofthe shut down. Major activities to be carried out during this shut down shall be as follows.

11.01 Mounting/installing missing screw type thermowells, test flow assembly, provision for T-offand laying ofimpulse pipe lines etc.

11.02 Providing any additional test tapping points if found necessary/applicable/missing.

11.03 Necessary arrangement/rectification for meeting the system requirements.

11.04 Necessary arrangement/rectification for meeting the requirement of system isolation i.e.attending the defective/passing valves identified during the joint inspection before shut down. To thiseffect, a list of valves to be kept closed during the test shall be jointly finalised with MSEB, prior tothe test and the system shall be isolated as per this list.

11.05 In case of prolonged operation, if necessary the internals of the turbine shall be checked forits cleanliness.

11.06 The demagnetisation of test PTs and CTs will be carried out.

11.07 Mounting of temperature elements in identified hot areas and laying their cables.

11.08 Laying impulse pipe line (if not already laid) from the root valves in hot zones and terminatingwith isolating valves. Their root valves to be kept open.


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11.09 Condenser tube cleaning and condenser air tightness checks to be done and leakages to be gotattended.

12.0 INSTALLATION OF TEST INSTRUMENTS (ASME-PTC-6)

12.01 FLOW MEASURING DEVICESIn most of the places spool pieces are not provided in the pipelines, location is only indicated on theisometric pipeline drawings. Spool pieces are to be made at site, in case the flow measuring

assemblies along with the matching flanges are supplied during erection stage itself. Otherwise, thepipeline is to be cut as per the marked location and flanges along with flow assemblies are bemounted during the shutdown. Flow measuring assembly device in any case is to be mounted duringthe shutdown prior to the test so that these are not in use for longer duration prior to the test.

Flow measuring devices are to be mounted during the shut down prior to the test so that the same isnot in use for longer duration prior to the test.

Correct installation of flow assembly as per requirement is to be ensured and installation arranged byBHEL in pretest shut down. It is preferable to check the impulse pipe line connections afterinstallation for any leakage/choking etc. by pressurising the flow measuring device to the extentpossible during the unit shut down itself. For flow orifice in the condensate line to deaerator, the

system can be checked by running the condensate pump. Problem noticed if any has to be attendedduring the shut down itself.

12.02 TEMPERATURE MEASURING INSTRUMENTSChromel Alumel thermocouples and Platinum Resistance Thermometers elements will be used fortemperature measurements. After connecting extension leads (Compensating cable for TCs and leadwires for PRTs), these elements will be mounted into thermowells as per the instrument allocationlist. Thermocouple wire is to be connected such that Chromel portion of the extension lead isconnected to Chromel part of the sensor. To identify this a positive sign has been marked on eachChromel terminal.

Thermocouples, PRTs and transmitter out put shall be measured with precision Data Logger ofaccuracy 0.03%.

12.03 PRESSURE MEASURING INSTRUMENTSImpulse pipe lines are to be laid for the Pressure Transmitters.

Impulse pipe lines for the vacuum (negative pressure) measurement points should be laid such

that transmitter is mounted above the tapping point. Thus the line should be laid upwards.

All the impulse lines should be rigid enough to avoid any vibration in the instrument.

For height correction in pressure measuring points the vertical distance from the center of the

transmitter to the tapping point is to be measured for each tag number and joint protocol to besigned. The distance above the tapping point is taken as positive whereas same below the tappingpoint is taken as negative for pressure correction.

The impulse pipe lines are to be flushed/purged sufficiently and steam to be allowed to condensebefore mounting the transmitters.

A transmitter/gauges will be charged only before use, otherwise it should be kept isolated to avoid itsexposure to vacuum in case the unit trips.

12.04 POWER MEASURING INSTRUMENTS

CTs and PTs for P.G. Test use should be identified well in advance and locations of their terminals inpanels checked for connection of the power meters refer the generator schematic drawings.

The CTs and the PTs should be damagnetised during the shut down and it should be ensured that noprotection relay is connected in their circuit during the P.G. Test.


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The lead resistance voltage drop in the circuit of PTs shall be measured along with MSEBrepresentative and protocol for the same made before starting the P.G. Test.

The digital power meter will be connected to the identified CTs and PTs terminals preferably in threephase four wire mode.

12.05 LEVEL MEASUREMENTLevel measurements of all the storage tanks shall be noted by means of local gauge glass level

indicators equipped with metric scales. It shall be ensured before carrying out the test, that the levelindicators are in good working condition. Readings are to be recorded on the Data Sheet sampleenclosed.

Apart from it, the Control Room readings for levels of all storage tanks shall also be additionallyrecorded for reference.

13.0 GENERAL GUIDE LIENS

13.01 All electrical instruments should be placed away from any magnetic field. Their proper levelingshould also be ensured.

13.02 If felt necessary, the mounting adjustable coupling can be removed and in that case T/Cs PRTsshould be properly tied and pressed downward with a piece of wire. Stub projections and sensorstems, which are protruding out of thermowells should be covered with asbestos rope for providingthermal insulation.

13.03 Demagnetisation of CTs.Any of the following two methods may be employed.

13.03a Short circuit the secondary through a 3C ohms resistor of sufficient current capacity andgradually increase the primary alternating current to full rated value. After this gradually reduce it tozero.

13.03b With the primary open circuit, gradually increase the alternating current through thesecondary to 5/1Amp. After this gradually reduce it to zero. In case of voltage transformer caseshould be taken to avoid short circuit of secondary.

13.04 All the instruments should be stored in a clean dry place nearer to unit under test, preferablyat Turbine Floor.

13.05 Tags giving Tag No., Serial No. and Service etc. should be provided at both tapping point endand the instrument end.

13.06 All the Pressure Transmitters gauges/differential manometer/kenometer/U tube manometershould bemounted in vertical position.

13.07 Depending upon the likelihood of completion of the above activities a date is finalised for theconductance of P.G. Tests. BHEL representative shall then commission all the instruments and conductthe tests jointly with MSEB under mutually agreed conditions.

14.0 INSTRUMENTS CALIBRATION AND CORRECTION

14.01 All the test instruments except Pressure Transmitters shall be duly calibrated at recognisedTest Houses.

14.02 The calibration certificates shall be furnished to MSEB before dispatching the instruments tosite.

14.03 Pressure Transmitters reading shall be additionally corrected for height corrections bymeasuring the difference in levels between center of the transmitter & center of pipeline.

14.04 Pressure Transmitters shall be calibrated at site by BHEL Engineer before the conductance ofthe tests in the presence of MSEB representative and the calibration certificates shall be jointly


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signed.

14.05 Correction due to actual mercury density and actual barometric pressure shall also be appliedwherever applicable.

15.0 ITEMS ESSENTIAL FOR AGREEMENT

15.01 Nomination of coordinating Test Engineers from MSEB and BHEL.

15.02 The programme and the dates of the series of tests. In accordance with this programme, allthe test instruments shall be transported to site.

15.03 Suitable shut down required prior to test to carry out the preparatory activities.

15.04 Means for obtaining steady operating parameters at their rated values.

15.05 Deputation of adequate qualified personnel by MSEB to note down the test readings for whichexact number will be intimated to them well in advance.

15.06 Submission of drawings/information, as required and intimated by BHEL in advance for the nonBHEL scope of equipment.

15.07 Provision of T & P by customer like compressed air, welding sets, power supply etc.15.08 Provision of il lumination at all measuring junctions and working places by MSEB.

16.0 PROGRAMME OF TESTING

16.01 The completion of test preparations, mounting of instruments and isolation of thermal cycleare to be checked before start of test.

16.02 The load is raised to rated capacity at rated parameters for taking a set of trial readings of allinstruments and for aquatinting the observers with the operation of instrument. All observers shall beallotted with their respective junctions and shall note down the readings on the prescribed logsheetsto be supplied by BHEL.

16.03 The readings of the trial test are analysed. If the results differ much from the design values,the case is to be investigated and rectification to be carried out wherever required. To this effect, it isessential that the load is maintained at rated values. The mock test can be repeated until the resultsare satisfactory. Then the time for test can be mutually decided.

16.04 During the trial test, it is checked that all the instruments are functioning/indicating properlyand verified wherever necessary. The pressure transmitters are isolated after the trial test.

16.05 The load is raised to rated capacity at rated parameters at least one hour before the start ofthe test and the parameters shall be maintained constant throughout the test.

16.06 The system is isolated so that no unaccounted flow goes out of comes into cycle. The makeupquantity shall be measured by noting down the various storage tanks levels at regular intervals of thetest.

16.07 Consistency of the load shall be accomplished by load limiter. Once the control valves havebeen set, they shall be left undisturbed throughout the test.

16.08 The operations which shall not be carried out during the test which are to be isolated are forthe following which the isolations are to be carried out.

Soot Blowing

Continuous Blow Down. Dusting of the Associated Boiler Unit. Steam Supply to fuel Atomisation. Fuel Heating and SCAPH Chemical dozing. Water and Steam Sampling etc.


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16.09 PRDS control valve spindle cooling water, atmospheric valve gland sealing water flow shall beadjusted for minimum flow.

16.10 Proper sealing water supply to vacuum system specially to atmospheric valve seals shall beensured.

16.11 All efforts shall be made to maintain the parameters constant throughout the test.

16.12 After the preparations have been completed, the test shall be started by synchronising thewatches of the observers with that of the control room.

16.13 The test readings shall be logged in the data logger and manual readings shall be noted downin the prescribed log sheets in triplicate, which shall be signed by the observers and countersigned byMSEB and BHEL at the end of the tests.

16.14 One set of the test readings shall be handed over to MSEB and two sets shall be retained byBHEL for their analysis at their works.

16.15 Sensitivity of the condenser hot well level control shall be reduced or preferably the level be

controlledmanually to avoid excessive fluctuation in the condensate flow to Dearator.17.0 PRESERVATION OF TEST FLOW ASSEMBLIESPG test low measuring assemblies for measurement of test flow are normally supplied directly tosite assembled condition in 2 halves. Flow measurement is an important measurement which effectsthe PG Test results appreciably.

A minor dent on the sharp edge of the orifice or on its plain surface or on the inside surface of theflow nozzle causes a large inaccuracy in flow measurement. Thus orifice plates/nozzles should neverbe hung with a wire or a rope passing through their inner bore which may cause dent on them. Eventhe adjoining pipe pieces encompassing the orifices/nozzles, which are normally machined frominside, should be carefully handled during installation. In all cases these assemblies should be storedin covered shed and protected from corrosion as any roughness on them may add to inaccuracy.

In view of above, it is needless to emphasize the importance of proper preservation of theseassemblies.Also flow measuring assemblies received in assembled condition, should not be dismantled as it iscalibrated before supply. Dismantling may affect its calibration.

18.0 CONDITION AND CYCLE ISOLATION OF THE PLANTBefore starting the performance test the plant has to be in a good state. To be familiar with the plantduring operation and for finding out deficiencies, if any and for checking of all the measuringinstruments, customer has to allow pretests with the plant.

It is sufficient that the whole plant cycle is provided as presumed in the guarantee agreement. Allcross connections to other units must be closed and all drainages must be ensured absolutely tight.Piping which are not utilized they have to be blanked off or it not possible they have to be checkedfor tightness.

A special care will be used in isolating test cycle from any connection extraneous to the test, whetherinside or outside the unit. These shall be attended in case founding passing.

The following is the general list of the lines and the unit component that will be isolated or put out ofservice during test. A specific list of isolation of valves & systems bearing valve numbers for eachvalve shall be prepared in advance of the test which shall be used during performance testing.

All the LP turbine by passMake up lineAuxiliary steam headerTurbine spraysDrain lines on stop intercept and control valves


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Common units header not fedAuxiliary boiler steam lineSteam to air PreheatersCondensate chemical injectionFeedwater chemical injectionSteam generator ventsSteam generator soot blowersCondensate and feed water flow by passing heatersHeater drain by pass

Heater shell drainsHeater water box ventsWater lines for water washing the turbineSteam Generator blowdownsEmergency blow down valveMain steam line to SSRDearator overflow line

The following lines will be throttled to a minimumDearator ventsThe water sampling equipment flows will be measured by Weighing if any.The water level in the feed water tank and in the condenser have to be watched and all changes to be

considered by making the quantity balance.Before starting the performance test all items which could influence the result of the test have to bebrought into steady state. This has to be kept for the whole test.

19.0 POST TEST ACTIVITIES

A shut down of the unit is to be arranged for removing flow measuring assembly.

TG-PG TEST INSTRUMENTATION LIST

PRESSURE POINTS

Sr. No. Tag

No.

Service Instrument Accuracy Range

1 P201 MS BEF. STRAINER (L) PR. TRANS. 0.1% 0-250Kg./Sq.Cm.

2 P202 HRH AFT. STRAINER (L) PR. TRANS. 0.1% 0-60Kg./Sq.Cm.

3 P203 MS BEF. STRAINER (R) PR. TRANS. 0.1% 0-250Kg./Sq.Cm.

4 P204 HRH AFT. STRAINER (R) PR. TRANS. 0.1% 0-60Kg./Sq.Cm.

5 P205 1stSTAGE PR. PR. TRANS. 0.1% 0-250Kg./Sq.Cm.

6 P206 FFW AT ECO. INLET PR. TRANS. 0.1% 0-250Kg./Sq.Cm.

7 P207 HP EXHAUST (TE) PR. TRANS. 0.1% 0-60Kg./Sq.Cm.

8 P208 HRH TO IPT BEF. STRAINER

(L).

PR. TRANS. 0.1% 0-60Kg./Sq.Cm.

9 P209 CRH AFT. RH SPRAY (R). PR. TRANS. 0.1% 0-60Kg./Sq.Cm.

10 P210 HRH TO IPT BEF. STRAINER

(R).

PR. TRANS. 0.1% 0-60Kg./Sq.Cm.

11 P211 CRH AFT. RH SPRAY (L). PR. TRANS. 0.1% 0-60Kg./Sq.Cm.12 P212 MS TO APRDS PR. TRANS. 0.1% 0-250Kg./Sq.Cm.

13 P213 APRDS SPRAY PR. TRANS. 0.1% 0-60Kg./Sq.Cm.

14 P214 EXTN. TO HPH-6 (HE) PR. TRANS. 0.1% 0-60Kg./Sq.Cm.


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15 P215 FW HPH-6 INLET PR. TRANS. 0.1% 0-250Kg./Sq.Cm.

16 P216 FW HPH-6 OUTLET PR. TRANS. 0.1% 0-250Kg./Sq.Cm.

17 P218 HPH-6 DRIP TO HPH-5 PR. TRANS. 0.1% 0-60Kg./Sq.Cm.

18 P219 EXTN. TO HPH-5 (TE) PR. TRANS. 0.1% 0-25Kg./Sq.Cm.

19 P220 EXTN. TO HPH-5 (HE) PR. TRANS. 0.1% 0-25Kg./Sq.Cm.

20 P221 FW HPH-5 INLET PR. TRANS. 0.1% 0-250Kg./Sq.Cm.21 P222 FW HPH-5 OUTLET PR. TRANS. 0.1% 0-250Kg./Sq.Cm.

22 P223 HPH-5 SHELL PR. PR. TRANS. 0.1% 0-60Kg./Sq.Cm.

23 P225 BFP-A DISCHARGE PR. TRANS. 0.1% 0-250Kg./Sq.Cm.

24 P226 BFP-B DISCHARGE PR. TRANS. 0.1% 0-250Kg./Sq.Cm.

25 P227 BFP-C DISCHARGE PR. TRANS. 0.1% 0-250Kg./Sq.Cm.

26 P229 SH SPRAY PR. PR. TRANS. 0.1% 0-250Kg./Sq.Cm.

27 P230 RH SPRAY PR. PR. TRANS. 0.1% 0-250Kg./Sq.Cm.

28 P231 CRH BEF. RH SPRAY (L) PR. TRANS. 0.1% 0-60Kg./Sq.Cm.29 P232 CRH BEF. RH SPRAY (R) PR. TRANS. 0.1% 0-60Kg./Sq.Cm.

PRESSURE POINTS

Sr. No. Tag No. Service Instrument Accuracy Range

1 P102 IPT EXHAUST (L) PR. TRANS. 0.1% 0-10Kg./Sq.Cm.

2 P104 IPT EXHAUST (R) PR. TRANS. 0.1% 0-10Kg./Sq.Cm.

3 P105 LPT INLET (L) PR. TRANS. 0.1% 0-10Kg./Sq.Cm.

4 P106 LPT INLET (R) PR. TRANS. 0.1% 0-10Kg./Sq.Cm.

5 P107 EXTN. TO D/A (TE) PR. TRANS. 0.1% 0-60Kg./Sq.Cm.

6 P108 EXTN. TO D/A (DE) PR. TRANS. 0.1% 0-60Kg./Sq.Cm.

7 P109 D/A SHELL PR. PR. TRANS. 0.1% 0-60Kg./Sq.Cm.

8 P110 BFP-A SUCTION PR. TRANS. 0.1% 0-60Kg./Sq.Cm.

9 P111 HPH-5 DRIP TO D/A (HE) PR. TRANS. 0.1% 0-60Kg./Sq.Cm.

10 P112 EXTN. TO LPH-3 (TE) PR. TRANS. 0.1% 0-10Kg./Sq.Cm.

11 P113 EXTN. TO LPH-3 (HE) PR. TRANS. 0.1% 0-10Kg./Sq.Cm.

12 P114 EXTN. TO LPH-2 (HE) PR. TRANS. 0.1% 0-10Kg./Sq.Cm.13 P115 EXTN. TO LPH-2 (HE) PR. TRANS. 0.1% 0-10Kg./Sq.Cm.

14 P116 EXTN. TO LPH-1 (TE) PR. TRANS. 0.1% 0-780mm. Hg.



17 P119 STEAM TO GSC PR. TRANS. 0.1% 0-10Kg./Sq. Cm.

18 P120 LP BYPASS (R) PR. TRANS. 0.1% 0-60Kg./Sq. Cm.

19 P121 LP BYPASS (L) PR. TRANS. 0.1% 0-60Kg./Sq. Cm.

20 P122 CEP SUCTION PR. TRANS. 0.1% 0-780mm. Hg.21 P123 CEP DISCHARGE PR. TRANS. 0.1% 0-25Kg./Sq. Cm.

22 P124 CONDENSATE NEAR FE. PR. TRANS. 0.1% 0-10Kg./Sq. Cm.

23 P125 APRDS AFT. PR. TRANS. 0.1% 0-25Kg./Sq. Cm.


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DESUPERHEATER

24 P126CW DIFF. PR. AT COND-A DP. TRANS. 0.1% 0-2.5Kg./Sq. Cm.

25 P127

26 P128CW DIFF. PR. AT COND-B DP. TRANS. 0.1% 0-2.5Kg./Sq. Cm.

27 P129

28 P130 CONDENSER VACUUM PR. TRANS. 0.1% 0-780mm. Hg.






34 P136 BFP-B SUCTION PR. TRANS. 0.1% 0-10Kg./Sq. Cm.

35 P139 CEP SUCTION PR. TRANS. 0.1% 0-780mm. Hg.

36 P140 BFP-C SUCTION PR. TRANS. 0.1% 0-10Kg./Sq. Cm.

37 P141 DC INLET PR. TRANS. 0.1% 0-25Kg./Sq. Cm.

FLOW POINTS


1 F101A MAIN CONDENSATE DP. TRANS. 0.1% 0-2.5Kg./Sq.Cm.

2 F101B MAIN CONDENSATE DP. TRANS. 0.1% 0-2.5Kg./Sq.Cm.

3 F102A RH SPRAY DP. TRANS. 0.1% 0-2.5Kg./Sq.Cm.

4 F102B RH SPRAY DP. TRANS. 0.1% 0-2.5Kg./Sq.Cm.

5 F103A SH SPRAY DP. TRANS. 0.1% 0-2.5Kg./Sq.Cm.6 F103B RH SPRAY DP. TRANS. 0.1% 0-2.5Kg./Sq.Cm.

TEMPERATURE POINTS


1 T101 MS BEF. STRAINER (L) T/C 1/2 DIN 250-550 Deg. C

2 T102 MS BEF. STRAINER (L) T/C 1/2 DIN 250-550 Deg. C

3 T103 MS BEF. STRAINER (R) T/C 1/2 DIN 250-550 Deg. C

4 T104 MS BEF. STRAINER (R) T/C 1/2 DIN 250-550 Deg. C5 T105 CRH AFTER SPRAY (L) T/C 1/2 DIN 250-550 Deg. C

6 T106 CRH AFTER SPRAY (R) T/C 1/2 DIN 250-550 Deg. C

7 T107 EXTN TO HPH-6 (TE) T/C 1/2 DIN 250-550 Deg. C

8 T108 EXTN TO HPH-6 (TE) T/C 1/2 DIN 250-550 Deg. C

9 T109 HRH BEF. STRAINER (L) T/C 1/2 DIN 250-550 Deg. C

10 T110 HRH BEF. STRAINER (L) T/C 1/2 DIN 250-550 Deg. C

11 T111 HRH BEF. STRAINER (R) T/C 1/2 DIN 250-550 Deg. C

12 T112 HRH BEF. STRAINER (R) T/C 1/2 DIN 250-550 Deg. C13 T114 IPT EXHAUST (L) T/C 1/2 DIN 250-550 Deg. C

14 T116 IPT EXHAUST (R) T/C 1/2 DIN 250-550 Deg. C

15 T117 LPT INLET (L) T/C 1/2 DIN 250-550 Deg. C


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16 T118 LPT INLET (L) T/C 1/2 DIN 250-550 Deg. C

17 T119 LPT INLET (R) T/C 1/2 DIN 250-550 Deg. C

18 T120 LPT INLET (R) T/C 1/2 DIN 250-550 Deg. C

19 T121 MS TO APRDS T/C 1/2 DIN 250-550 Deg. C

20 T122 SPRAY TO APRDS PRT Pt-100 1/2 DIN 250-550 Deg. C

21 T123 EXTN. TO HPH-6 (HE) T/C 1/2 DIN 250-550 Deg. C


23 T125 FW HPH-6 INLET PRT Pt-100 1/2 DIN 0-300 Deg. C

24 T126 FW HPH-6 INLET PRT Pt-100 1/2 DIN 0-300 Deg. C

25 T127 FW HPH-6 OUTLET PRT Pt-100 1/2 DIN 0-300 Deg. C


27 T131 HPH-6 DRIP TO HPH-5 PRT Pt-100 1/2 DIN 0-300 Deg. C

28 T132 HPH-6 DRIP TO HPH-5 PRT Pt-100 1/2 DIN 0-300 Deg. C





33 T137 FW INLET TO HPH-5 PRT Pt-100 1/2 DIN 0-300 Deg. C

34 T138 FW INLET TO HPH-5 PRT Pt-100 1/2 DIN 0-300 Deg. C



37 T141 EXTN. TO D/A (TE) T/C 1/2 DIN 250-550 Deg. C

38 T142 EXTN. TO D/A (TE) T/C 1/2 DIN 250-550 Deg. C39 T143 EXTN. TO D/A (DE) T/C 1/2 DIN 250-550 Deg. C

40 T144 EXTN. TO D/A (DE) T/C 1/2 DIN 250-550 Deg. C

41 T145 FFW AT ECO. INLET PRT Pt-100 1/2 DIN 0-300 Deg. C

TEMPERATURE POINTS


46 T146 FFW AT ECO. INLET PRT Pt-100 1/2 DIN 0-300 Deg. C

47 T147 SH SPRAY PRT Pt-100 1/2 DIN 0-300 Deg. C48 T148 RH SPRAY PRT Pt-100 1/2 DIN 0-300 Deg. C

49 T149 BFP-A DISCHARGE PRT Pt-100 1/2 DIN 0-300 Deg. C

50 T150 BFP-B DISCHARGE PRT Pt-100 1/2 DIN 0-300 Deg. C

51 T151 BFP-C DISCHARGE PRT Pt-100 1/2 DIN 0-300 Deg. C

52 T152 HP BYPASS AFT.HPB VAL. (R) T/C 1/2 DIN 250-550 Deg. C

53 T153 HP BYPASS AFT.HPB VAL. (L) T/C 1/2 DIN 250-550 Deg. C

54 T154 CRH BEF. SPRAY (R) T/C 1/2 DIN 250-550 Deg. C

55 T155 CRH BEF. SPRAY (R) T/C 1/2 DIN 250-550 Deg. C56 T156 CRH BEF. SPRAY (L) T/C 1/2 DIN 250-550 Deg. C

57 T157 CRH BEF. SPRAY (L) T/C 1/2 DIN 250-550 Deg. C

TEMPERATURE POINTS


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1 T201 LPT EXHAUST (R) (TE) PRT Pt-100 1/2 DIN 0-300 Deg. C

2 T202 LPT EXHAUST (L) (TE) PRT Pt-100 1/2 DIN 0-300 Deg. C

3 T203 LPT EXHAUST (R) (COND.E) PRT Pt-100 1/2 DIN 0-300 Deg. C

4 T204 LPT EXHAUST (L) (COND.E) PRT Pt-100 1/2 DIN 0-300 Deg. C

5 T205 EXTN. TO LPH-3 (TE) PRT Pt-100 1/2 DIN 0-300 Deg. C

6 T206 EXTN. TO LPH-3 (TE) PRT Pt-100 1/2 DIN 0-300 Deg. C

7 T207 EXTN. TO LPH-3 (HE) PRT Pt-100 1/2 DIN 0-300 Deg. C


9 T209 LPH-3 DRAIN TO LPH-2 PRT Pt-100 1/2 DIN 0-300 Deg. C


11 T211 LPH-3 INLET PRT Pt-100 1/2 DIN 0-300 Deg. C

12 T212 LPH-3 OUTLET PRT Pt-100 1/2 DIN 0-300 Deg. C

13 T213 LPH-3 O/L D/S OF BP VALVE PRT Pt-100 1/2 DIN 0-300 Deg. C

14 T214 EXTN. TO LPH-2 (TE) PRT Pt-100 1/2 DIN 0-300 Deg. C15 T216 EXTN. TO LPH-2 (HE) PRT Pt-100 1/2 DIN 0-300 Deg. C






21 T222 EXTN. TO LPH-1 PRT Pt-100 1/2 DIN 0-300 Deg. C

22 T223 LPH-1 DRAIN TO DC PRT Pt-100 1/2 DIN 0-300 Deg. C23 T224 LPH-1 DRAIN TO DC PRT Pt-100 1/2 DIN 0-300 Deg. C


25 T226 DC OUTLET PRT Pt-100 1/2 DIN 0-300 Deg. C


27 T228 DC DRAIN TO FLASH BOX-3 PRT Pt-100 1/2 DIN 0-300 Deg. C

28 T229 DC DRAIN TO FLASH BOX-3 PRT Pt-100 1/2 DIN 0-300 Deg. C

29 T230 DC INLET PRT Pt-100 1/2 DIN 0-300 Deg. C

30 T232 STEAM TO GSC PRT Pt-100 1/2 DIN 0-300 Deg. C

31 T233 GSC DRAIN TO FLASH BOX-

3

PRT Pt-100 1/2 DIN 0-300 Deg. C

32 T234 GSC INLET PRT Pt-100 1/2 DIN 0-300 Deg. C

33 T235 GSC OUTLET PRT Pt-100 1/2 DIN 0-300 Deg. C

34 T236 CW INLET-A PRT Pt-100 1/2 DIN 0-300 Deg. C

35 T237 CW INLET-A PRT Pt-100 1/2 DIN 0-300 Deg. C

36 T238 CW OUTLET-A PRT Pt-100 1/2 DIN 0-300 Deg. C






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42 T247 CW INLET-B PRT Pt-100 1/2 DIN 0-300 Deg. C

43 T248 CW INLET-B PRT Pt-100 1/2 DIN 0-300 Deg. C

44 T249 CW OUTLET-B PRT Pt-100 1/2 DIN 0-300 Deg. C






50 T258 CEP SUCTION PRT Pt-100 1/2 DIN 0-300 Deg. C

51 T259 CEP DISCHARGE PRT Pt-100 1/2 DIN 0-300 Deg. C

52 T260 COND. TO D/A NEAR FE PRT Pt-100 1/2 DIN 0-300 Deg. C

53 T261 COND. TO D/A NEAR FE PRT Pt-100 1/2 DIN 0-300 Deg. C

54 T262 COND. TO D/A (DE) PRT Pt-100 1/2 DIN 0-300 Deg. C

55 T263 COND. TO D/A (DE) PRT Pt-100 1/2 DIN 0-300 Deg. C56 T264 D/A SHELL TEMP. PRT Pt-100 1/2 DIN 0-300 Deg. C

57 T265 BFP-A SUCTION PRT Pt-100 1/2 DIN 0-300 Deg. C

58 T266 BFP-A SUCTION PRT Pt-100 1/2 DIN 0-300 Deg. C

59 T267 BFP-B SUCTION PRT Pt-100 1/2 DIN 0-300 Deg. C

60 T268 BFP-B SUCTION PRT Pt-100 1/2 DIN 0-300 Deg. C

61 T269 BFP-C SUCTION PRT Pt-100 1/2 DIN 0-300 Deg. C

62 T270 HPH-5 DRIP TO D/A PRT Pt-100 1/2 DIN 0-300 Deg. C

63 T271 HPH-5 DRIP TO D/A PRT Pt-100 1/2 DIN 0-300 Deg. C64 T272 APRDS AFT.

DESUPERHEATER

PRT Pt-100 1/2 DIN 0-300 Deg. C

65 T273 LP BYPASS (R) T/C 1/2 DIN 250-550 Deg. C

66 T274 LP BYPASS (L) T/C 1/2 DIN 250-550 Deg. C

67 T275 BFP-C SUCTION PRT Pt-100 1/2 DIN 0-300 Deg. C



AUXILIARY POWER MEASUREMENT

Sr.

No.

Tag No. Service Instrument Accuracy Range

1 PAX-1 CWP-A discharge Pr. PR. TRANS. 0.10% 0-10 Kg./Sq.Cm.

2 PAX-2 CWP-B discharge Pr. PR. TRANS. 0.10% 0-10 Kg./Sq.Cm.

3 PAX-3 Booster pump suction Pr. PR. TRANS. 0.10% 0-10 Kg./Sq.Cm.

4 PAX-4 BFP-A Suction Pr. PR. TRANS. 0.10% 0-25 Kg./Sq.Cm.

5 PAX-5 BFP-A discharge Pr. PR. TRANS. 0.10% 0-250 Kg./Sq.Cm.

6 PAX-6 BFP-A Suction flow DP.TRANS. 0.10% 0-2.5 Kg./Sq.Cm.

7 PAX-7 Booster pump-B Suction Pr. PR. TRANS. 0.10% 0-10 Kg./Sq.Cm.

8 PAX-8 BFP-B Suction Pr. PR. TRANS. 0.10% 0-25 Kg./Sq.Cm.


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9 PAX-9 BFP-B discharge Pr. PR. TRANS. 0.10% 0-250 Kg./Sq.Cm.

10 PAX-10 BFP-B Suction flow DP.TRANS. 0.10% 0-2.5 Kg./Sq.Cm.

11 PAX-11 CEP Suction Pressure PR. TRANS. 0.10% 0-780 mm. Hg.

12 PAX-12 CEP discharge Pressure PR. TRANS. 0.10% 0-60 Kg./Sq.Cm.

13 PAX-13 CEP discharge flow DP.TRANS. 0.10% 0-2.5 Kg./Sq.Cm.

1 TAX-1 BFP-A Suction temp RTD-100 1/2 DIN 0-300 Deg. C

2 TAX-2 BFP-B Suction temp RTD-100 1/2 DIN 0-300 Deg. C

3 TAX-3 CEP discharge temp RTD-100 1/2 DIN 0-300 Deg. C

1 P233 CW DISCH PR. PR. TRANS. 0.10% 0-10 Kg./Sq.Cm.

2 P234 CW DISCH PR. PR. TRANS. 0.10% 0-10 Kg./Sq.Cm.

1 F104 CONDENSATE FLOW (AUX.

POWER-PLANT ASSEMBLY)

DP. TRANS. 0.10% 0-2.5 Kg./Sq.Cm.

2 F105 FEED FLOW (AUX. POWER BFP

SUC-PLANT ASSEMBLY)

DP. TRANS. 0.10% 0-2.5 Kg./Sq.Cm.

ANNEXURES

1. CORRECTION CURVES

1.1 HEAT RATE CORRECTION CURVES

MAIN STEAM PRESSURE DRG No. PE-4-183-100-121

MAIN STEAM TEMP DRG No. PE-4-183-100-122

REHEAT CIRCUIT PR. DROP DRG No. PE-4-183-100-123

REHEAT STEAM TEMP. DRG No. PE-4-183-100-124

CONDENSER PRESSURE DRG No. PE-4-183-100-125

RH SPRAY DRG No. PE-4-183-100-136

FINAL FEED WATER TEMP. DRG No. PE-4-183-100-138

FREQUENCY DRG No. PE-4-183-100-140

POWER FACTOR DRG No. PE-4-183-100-142

SH SPRAY DRG No. PE-4-183-100-144

D/A LEVEL DROP DRG No. PE-4-183-100-137

1.2 OUTPUT CORRECTION CURVES

MAIN STEAM PRESSURE DRG No. PE-4-183-100-126

MAIN STEAM TEMP. DRG No. PE-4-183-100-127

REHEAT CIRCUIT PR. DROP DRG No. PE-4-183-100-128

REHEAT STEAM TEMP DRG No. PE-4-183-100-129

CONDENSER PRESSURE DRG No. PE-4-183-100-130

RH SPRAY DRG No. PE-4-183-100-135

FINAL FEED WATER TEMP. DRG No. PE-4-183-100-139

FREQUENCY DRG No. PE-4-183-100-141

POWER FACTOR DRG No. PE-4-183-100-143

SH SPRAY DRG No. PE-4-183-100-145

D/A LEVEL DROP (Ref. HRCC above) DRG No. PE-4-183-100-137

1.3 HOTWELL CURVE HXE/SK/1029


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1.4 D/A CURVE DRG No. 4-16310-00347

1.5 METHOD FOR COMPUTATION OF HEAT RATE

(DOCUMENT No. PE-4-183-100-211 REV 05)

2.0 CONNECTION BETWEEN PRESSURE SOURCE AND TRANSDUCER.

3.0 CONNECTION BETWEEN VACUUM SOURCE AND TRANSMITTER

4.0 TEMP. MEASUREMENT USING T/Cs AND PRTs

5.0 CONNECTION DIAGRAM FOR DIGITAL POWER METER

6.0 DATA SHEET

7.0 HEAT BALANCE

DRG No. PE-3-183-100-101

8.0 MS FLOW Vs FIRST STAGE PRESSURE

DRG No. PE-4-183-100-131(FOR INFORMATION CURVE)

DRG. NO. PE - 4 - 183 - 100 - 121


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DRG. NO. PE - 4 - 183 - 100 - 122


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DRG. NO. PE - 4 - 183 - 100 - 123


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DRG. NO. PE - 4 - 183 - 100 - 124


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DRG. NO. PE - 4 - 183 - 100 - 125


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DRG. NO. PE - 4 - 183 - 100 -136


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DRG. NO. PE - 4 - 183 - 100 - 138


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DRG. NO. PE - 4 - 183 - 100 - 140


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Drg. No. PE 4 - 183 - 100 - 142


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DRG. NO. PE - 4 - 183 - 100 - 144


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DRG. NO. PE - 4 - 183 - 100 - 137


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DRG. NO. PE - 4 - 183 - 100 - 126


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DRG. NO. PE - 4 - 183 - 100 - 127


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DRG. NO. PE - 4 - 183 - 100 - 128


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DRG. NO. PE - 4 - 183 - 100 - 129


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DRG. NO. PE - 4 - 183 - 100 - 130


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DRG. NO. PE - 4 - 183 - 100 - 135


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DRG. NO. PE - 4 - 183 - 100 - 139


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DRG. NO. PE - 4 - 183 - 100 - 141


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DRG. NO. PE - 4 - 183 - 100 - 143


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DRG. NO. PE - 4 - 183 - 100 - 145


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Drg. No. 4 - 16310 - 00347


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Doc. No. PE-4-183-100-211 REV 05


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METHOD FOR THE COMPUTATION OF HEAT RATE

The measurements which are directly connected with computation of Heat Rate are shown in sheet 1of this document. The other measurements required for the PG test are shown in the PG Test Scheme(Drg. No. PE-3-183-100-210 REV. 02). The procedure for the computation of heat rate from themeasurements envisaged is as given below.

1.0 EXTRACTION STEAM FLOWS TO HP-HEATERS AND DEAERATOR

Steam extraction to HP-Heater and deaerator is evaluated from thermal balance.

HP-HEATER NO. 6Z [H12 H7] = [M1+X+Y+Z-Mshs-MrhsMdea] (116-115) ............[A]

HP-HEATER NO. 5Y.[H11-H8] + Z [117-118] = [M1+X+Y+Z- Mshs-mrhsMdea].(114-113) .. [B]

DEAERATORX.111+M1.H10+[Y+Z].119 = [M1+X+Y+Z].112 .................................[C]Three unknown X, Y and Z can be calculated from equation [A], [B] & [C]Feed water flow Mfw = M1 + X + Y + Z Mshs-Mrhs Mdea ............[D]

NOTE: 1) When there is an increase in the level f deaerator, -ve sign shall be used for Mdea 2) When there is a decrease in the level of deaerator, +ve sign shall be used for Mdea Sum of storages [Msto] increases or decreased for the following tanks :-a) Hotwell storageb) Drum storage

c) Condensate make-up storage

d) Dearator storage

NOTE:For the above storages if there is a net increase in level, +ve sign is to be taken for Mstoand if there is a net decrease in level, -ve sign is to be taken for Msto to arrive at the unaccounted


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losses to be reflected in the main steam flow [Mms].

Mms = Mfw + MshsMstoMdrum .. [E]

NOTE :-

1. When there is increase in level of boiler drum, -ve sign shall be used for Mdrum2. When there is decrease in level of boiler drum, +ve sign shall be used for Mdrum

Reheat steam flow Mrh = Mms + Mrhs Z Md .. (F)M1 = Condensate flow to deaerator measured from flow measuring device F101 . Kg/hrMd = Gland leakages A, B and C from HP turbine to be computed (Mdi + Mdo) .kg/hrMdi = Gland leakages A, B and C from HPT inlet side .. kg/hrMdo = Gland leakages A, B and C from HPT outlet side .kg/hrMsto = Total increase/decrease of storage in system [from level gauges] during the test kg/hrMdea = Change in deaerator storage during the test .. kg/hrMdrum = Change in boiler drum level during the test ......kg/hrMshs = Super heater spray measured from flow measuring device F103 ...kg/hrMrhs = Reheater spray quantity measured by flow measuring device F102 kg/hr

X = Extraction steam flow to deaerator [calculated from thermal balances]....kg/hr Y = Extraction steam flow to HPH-5 [calculated from thermalbalance] ....kg/hr Z = Extraction steam flow to HPH-6 [calculated from

thermal balance] ....kg/hr

H1 = Enthalpy of steam entering deaerator based on measurements P108 & T143, T144...kcal/kg

H2 = Enthalpy of feed water at deaerator outlet based on measurements P110, T265, T266 & P136, T267, T268 & P140, T269, T275...........................kcal/kg

H3 = Enthalpy of feed water at HPH5 inlet based on measurements P221 & T137, T138 .kcal/kg

H4 = Enthalpy of feed water at HPH-5 outlet based on measurements P222 & T139, T140 kcal/kg

H5 = Enthalpy of feed water at HPH-6 inlet based on measurements P215 & T125, T126.kcal/kg

H6 = Enthalpy of feed water at HPH-6 outlet based on measurements P216 & T127, T128.kcal/kg

H7 = Enthalpy of HPH-6 drain based on measurements P218 & T131, T132

....................kcal/kg

H8 = Enthalpy of HPH-5 drain near heater based on measurements P111 & T270, T271...kcal/kg

H10 = Enthalpy of condensate entering deaerator Based on measurements P124 & T262, T263 ...............kcal/kg

H11 = Enthalpy of extraction steam entering HPH-5 Based on measurements P220 & T135, T136 ...............kcal/kg

H12 = Enthalpy of extraction steam entering HPH-6 Based on measurements P214 & T123, T124 ...............kcal/kg

2.0 HEAT RATE :-

HR = Mms[HmsHffw]+Mrh[Hrho-Hrhi]+Mshs[Hffw-Hshs]+Mrhs[Hrhi-Hrhs]


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---------------------------------------------------------------------------------------------------------------------

-- ............ [G]

Pnet.

HR = Heat Rate kcal/kwh Mms = Main steam flow at HPT inlet[as calculated] .. kg/hr Mrh = Reheat steam flow [ascalculated] ......kg/hr Hms = Enthalpy of

steam before ESV based on measurements P201, P203 & T101 to T104 kcal/kg

Hffw = Enthalpy of final feed water after HP-heaters based on measurements P206 & T145, T146.. Kcal/kgHrho = Enthalpy of hot reheat steam before IV based on measurements P208, P210 & T109 toT112 kcal/kgHrhi = Enthalpy of cold reheat steam based on measurements P207 & T107 to T108 . Kcal/kgHshs = Enthalpy of superheater spray based on any two of the measurements {P227, T151},{P226, T150} and {P225, T149} depending upon working BFPs.Hrhsi = Enthalpy of CRH after mixing of RH spray based on measurements P209, T106 & P211,T105 .. kcal/kgPnet = Pgen 63 (Towards integral auxiliaries) ..kw

Pgen = Power measured at Generator terminals .. kw

3.0 COMPUTATION OF TOTAL GLAND LEAKAGES :-

Steam leakage through the glands A, B and C is calculated using the formula given below

G = Steam leakage through the glands...............T/H.

P1= Pressure before the glands.......................ata

P2= Pressure after the glands......................ata

V1= Specific volume at inlet conditions to the glands..........cum/kg.

Data for design case is given below [Refer HBD No. PE-3-183-100-101 REV 02]

PARAMETER HPT INLET END HPT OUTLET ENDG 3.051 3.199

P1 41.27 41.27P2 6.835 6.835V1 *0.0838 **0.0655* Based on 41.27 ata & 816.0 kcal/kg.** Based on 41.27 ata & 349.6 DEG C.

For design case P1, P2, V1 and G are known and hence K can be evaluated.

K values calculated for the design case are as given below :a) For gland leakage from HPT inlet end K = 0.1394b) For gland leakage from HPT outlet end K = 0.1292

For test case, by putting this value of K and the test values of P1, P2 and V1 and computation of Gcan be done.

For the test case, the values of P1, P2 and V1 are determined as given below :


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For HPT inlet end : P1 is based on measurements P207

P2 is based on measurements P105 & P106

V1 is based on measurements P207 & TA

TA is calculated on the basis of P207 and enthalpy corresponding to P201 and203 & T101 to T104.

For HPT outlet end : P1 is based on measurements P207

P2 is based on measurements P105 to P108

V1 is based on measurements P207 & T107 to T108

4.0 NOTE :

1. The heat rate is guaranteed with 0% make-up and hence no make-up will be supplied to thecondenser during the performance guarantee test. Under these conditions the storage in the

deaerator feed storage tank is utilised towards the leakage losses and the measured heat rate shallbe corrected using the correction curve viz. Change in heat rate vs. change in storage of feed waterstorage tank.

2. In case the temperature measured at the HP turbine exhaust (measurements T107 to T108) isless than the temperature of extraction steam at HP Heater No. 6 inlet (measurements T123, T124)then leakage through the HP bypass valve is suspected. The leakage shall be estimated as givenbelow :

[Mms Md] [H12 Hrhi]Mhpb = _______________________

[Hms Hrhi]

where Mhpb = Quantity of steam leakage through the HP bypass valve . T/HR

The quantity of steam entering the HP turbine [Mms1] shall be corrected for the leakage through theHP bypass as given below and shall be used in the equation (G) instead of Mms.

Mms1 = Mms Mhpbp

5.0 GUARANTEE CONDITIONS.

1. Guaranteed Heat Rate at 100% load = 1939.3 Kcal/Kwhr.

(Ref HBD No. PE-3-183-100-101 REV 01 titled 210 MW 0% MU 0.0911 ata Back Pr).

2. Instrument uncertainly shall be computed with accuracy classes of various instruments to beused during the P.G. test in accordance with the document titled Guidance for evaluation ofmeasuring uncertainly in performance test of steam turbine A report by ASME Performance testcode committee G

3. If the test is carried out after four months of the date of first commissioning, due to anyreason whatsoever, the specific heat consumption shall be increased by following amounts for eachmonth or part of a month by which the period between the initial commissioning and the acceptance

test exceeds 4 months. 0.10% for the following 8 months 0.06% for the period thereafter

4. The pressure drop between MS strainer and ESV & between ESV and HPT in the MS line and


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between HRH strainer and IV & between IV & IPT in HRH line have not been considered in the heatbalance calculations since same is to be accounted in the respective system piping pressure drops.The actual pressure drops shall be estimated during the PG test based on layout envisaged and thecalculated steam flows and necessary corrections applied on the measured pressures.6.0 LIST OF CORRECTION CURVES

A. HEAT RATE CORRECTION CURVES FOR :

i. Main steam pressure.

ii. Main steam temperature.

iii. Reheat steam temperature.

iv. Reheat circuit pressure drop.

v. Back pressure.

vi. Reheat Spray/Superheater Spray.

vii. Change in feed water storage in Deaerator FW storage tank.

viii. Final feed water Temperature.

ix. Power factor.

x. Frequency.

B. OUTPUT CORRECTION CURVES FOR :

i. Main steam pressure.ii. Main steam temperature.iii. Reheat steam temperature.iv. Reheat circuit pressure drop.v. Back pressure.vi. Reheat Spray/Superheater Spray.vii. Change in feed water storage in Deaerator FW storage tank.viii. Final feed water temperature.ix. Power factor.x. Frequency.

CONNECTION BETWEEN PRESSURE SOURCE AND TRANSDUCER.


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CONNECTION BETWEEN VACUUM SOURCE AND TRANSMITTER.

TEMPERATURE MEASUREMENT USING T/Cs & PRTs.


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CONNECTION DIAGRAM FOR DIGITAL POWER METER

HEAT BALANCE Drg. No. PE-3-183-100-101


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Drg. No.: PE-4-183-100-131


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PROCEDURE FOR SITE PERFORMANCE GUARANTEE TEST OF BFP

PROJECT : 2 x 210 KHAPERKHEDA TPSUNITS3&4

CUSTOMER : MSEB

1.0 INTENT :

The intent of the site test is to prove the auxiliary power consumption of the Boiler Feed Pumpset measured at the input terminals of the BFP drive motor at guaranteed parameters.


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2.0 GUARANTEE PARAMETERS :

The guaranteed parameters of the pump are given at cl.no. 9.0

3.0 TEST SET UP :

The schematic arrangement for the test is illustrated in page no. 6.

4.0 MEASURING POINTS :

a) FLOW :

The Feed water flow of the Boiler Feed Pump is measured using the plant flow nozzleand test differential pressure transmitter.

b) HEAD :

The head measurement is done by test pressure transmitters in Booster pump suctions,BFP suction and BFP discharge.

c) TEMPERATURE :

The temperature measurement is done by test RTD.

d) SPEED :

The speed measurement is carried out by non-contact type digital tachometer.

c) POWER :

The power input at the motor terminals shall be measured by test watt transducerswhich shall be connected to C.T's and P.Ts provided in the switchgear.

5.0 PERFORMANCE TOLERANCES :

An overall tolerance of 3.5% will be used while comparing measured power with theguarantee power due to measurement uncertainties on flow, head and power. This is as per

Table-7 of BS-5316, Class C.

6.0 TEST METHODOLOGY :

6.1 The test instruments listed at cl.no. 10.0 will be connected as per the test scheme. All

transducers will be connected to a data logger.

6.2 Preliminary test shall be conducted for checking up of instruments.

6.3 After stabilisation, the test will be conducted for about 1 hour and readings will be recorded at

5 minute intervals in the data logger. The data logger print out of the readings thus recorded

shall be signed by Customer and BHEL Representatives. During the test, the customer shall try

to maintain the flow through the BFP within 3% of the flow at guarantee point, for recording

the various parameters.

6.4 Two tests will be conducted on each pump set.

7.0 CALCULATION PROCEDURE :

The auxiliary power consumption for BFP set is valid for a given set of guarantee parameters

of BFP suction flow and the feed water temperature. In case the BFP is operated at a pointdifferent from the guaranteed parameters, the input power would be computed using the

standard formulae relating Q, H and Efficiency, and the auxiliary power consumed at motor

terminals is derived after considering the motor efficiency, pump efficiency and hydraulic


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coupling losses corresponding to test flow, with reference to design curves of BFP and Booster

pump. Evaluation is done by averaging the test results of the two test carried out on each

pump.

8.0 AUXILIARY POWER GUARANTEE :

BFP parameters corresponding to Auxiliary Power guarantee :

(MRC Flow, 0% MU, 0.0911 ata back pr.)

Suction Flow (m3/hr) : 343.9 (per BFP)

Dynamic head (mlc) : 1890 (BFP + BP)

Temperature (C) : 159.50

Specific Wt. (kg/m3) : 907.77

Motor input power (kW) : 2660 (per BFP)

Total Auxiliary Power (kW) : 5320

NOTE :Auxiliary power is guaranteed with ZERO interstage flow i.e. interstage valve in

closed condition.

9.0 LIST OF INSTRUMENTS :

------------------------------------------------------------------------------------

PARAMETER TYPE AND RANGE OF TAG NO. ACCURACY REMARKS

Booster

PumpSuction Pr.

Pressure Transmitter 0-

10kg/sq.cm.PT1 0.1%

BFP suction

Pressure


30kg/sq.cm.PT2 0.1%

BFP

discharge

Pressure


300kg/sq.cm.PT3 0.1%

BFP suction

Flow

Diffl. Pr. Transmitter(Range will be selected

based on flow nozzledata)

DPT 0.1%

BFP SuctionTemperature

RTD 0 - 200C TE 1/3 DIN

BFP speedOptical non-contact

Digital Tachometer.N 1 RPM

Booster

Pump Speed

Optical non-contact

Digital Tachometer.N 1 RPM

Motor input

Power.Watt transducer W 0.25%

------------------------------------------------------------------------------------


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10.0 SAMPLE CALCULATIONS :

During the site test, pump parameters like flow, head and speed may be different from those

guaranteed. The following illustrates sample calculation for new auxiliary power based on site

test parameters.

A. Site tested data :

Feed water temp. = 150 C

Sp. wt. of feed water = 916.9 kg/m3from standards

Flow = 345 t/hr

Booster pump suction pressure = p1 kg/cm2

BFP suction pressure = p2 kg/cm2

BFP discharge pressure = p3 kg/cm2

Booster pump speed = 1510 rpm

BFP speed = 4800 rpm

Power input to motor terminals = 2770 kW

From the above data :

Flow = 345/0.9169 = 376.27 m3/hr

Booster pump head = {(p2 - p1) x 10} / 0.9169 = say 105 mlc

BFP head = {(p3 p2) x 10} / 0.9169 = say 1952 mlc

B. Estimated auxiliary power based on tested data :

i. Booster Pump :

Tested flow corrected to design speed = (1485/1510)x376.27=370 m3/hrEfficiency at corrected flow from design curve = 77%

916.9 x 376.27 x 105

Power input to pump = ------------------------ = 128 kW

102 x 3600 x 0.77

ii. Boiler Feed Pump:

Tested flow corrected to design speed = (5075/4800)x376.27=398m3/hrEfficiency at corrected flow from design curve = 81%

916.9 x 376.27 x 1952

Power input to pump = -------------------------- = 2264 kW

102 x 3600 x 0.81

iii. Hydraulic Coupling :


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Mechanical losses = 100 kW (Approximate)

HC Prim. speed BFP Test speed

Slip losses = ---------------------------------------- x Input power

(speed dependent) BFP Test speed

5998 4800

= ------------------- x 2264 = 188 kW.

4800

Total losses in Hydraulic Coupling = 100 + 188 = 288 kW

iv. Total input power = (i) + (ii) + (iii) = 128+2264+288 = 2680 kW

Motor efficiency from motor design curve = 95 %

Power input at Motor terminals = 2680/0.95

= 2821 kW

C. Auxiliary Power measured at site :

Auxiliary power measured at test speed = 2770 kW

D. Auxiliary power at motor terminals measured at site (C) will be compared to the estimated

auxiliary power (B-iv).

In case the measured power is higher than the calculated power, the difference of the two will

be treated as excess auxiliary power consumption.

RECORD OF REVISIONS

Rev.No.

Date Revision DetailsRevised

ByApproved

By


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01 26.12.2000 Revised as per MSEB ltr. No. 3084 dt.21.10.2000

02 12.01.2001Parameters revised to 0% MU as per

PEM ltr. dt. 11.01.2001

PROCEDURE FOR SITE PERFORMANCE GUARANTEE TEST OF CEP

Project : KHAPERKHEDA TPS, UNIT III & IV

Customer : MSEB

1.0 INTENT :

The intent of the site test is to prove the auxiliary power consumption of the CondensateExtraction Pump set measured at the input terminals of the CEP drive motor at guaranteeparameters.

2.0 GUARANTEE PARAMETERS : The guarantee parameters of BFP set are given at cl. No. 8.0

3.0 TEST SET UP : The schematic arrangement for the test is illustrated at page no. 5


a. FLOW :

The condensate water flow of the Condensate Extraction Pump is measured using test Differential Pressure Transmitter across orifice in down stream ofgland steam condenser.

b. HEAD : The head measurement is done by test pressure transmitters in Pump suction anddischarge

branches.c. TEMPERATURE :

The temperature measurement is done by test RTD.d. SPEED :

The speed measurement is carried out by tachometer.e. POWER :

The power input at the motor terminals shall be measured by test Wattmeter/transducers by

connecting these wattmeter/transducers to C.Ts and P.Ts provided in the switchgear.


0.1 An overall tolerance of 3.5% will be used while comparing measured power with the guaranteepower due to measurement uncertainties on flow, head and power. This is as per Table-7 of BS-5316,Class C.

6.0 TEST METHODOLOGY :

6.1 The test instruments listed at cl.no. 9.0 will be connected as per the test scheme. Transducerswill


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be connected to a data logger.

6.2 Preliminary test shall be conducted for checking the instruments.

6.3 After stabilisation, the test will be conducted for about 1 hour and readings will be recorded at(5) five

minute intervals in the data logger. The data logger print out of the readings thus recordedshall be

signed by Customer and BHEL Representatives. During the test, the customer shall try tomaintain the

flow through the BFP within 3% of the flow at guarantee point, for recording the various parameters.

6.4 Two tests will be conducted on each pump set.


The auxiliary power consumption for CEP set is valid for a given set of guaranteeparameters of CEP discharge flow and the temperature. In case the CEP is operated at apoint different from the guaranteed parameters, the input power would be computedusing the standard formulae relating Q, H and Efficiency, and the auxiliary powerconsumed at motor terminals is derived after considering the pump efficiency and motorefficiency corresponding to test flow from the design curves. Evaluation is done byaveraging the test results of the two tests carried out on each pump. Sample calculationsare given at cl.no. 10.0.

8.0 AUXILIARY POWER GUARANTEE :

Condensate Extraction Pump parameters for Auxiliary Power Guarantee : (MRC Flow, 0% MU, 0.0911 ata back pr.)

Flow (m3/hr) : 498.5 Dynamic head (mlc) : 219 (From Test Curve) Temperature (C) : 43.6

Specific Wt. (kg/m3) : 990 Motor input power (kW) : 440 Pump speed (rpm) : 1485

9.0 LIST OF INSTRUMENTS :-------------------------------------------------------------------------------------------------

Parameter Type & range of Tag No.Accuracy

-------------------------------------------------------------------------------------------------

Suction PressurePressure transducer -1 to +1

kg/sq.cm.PT1 0.1%

Discharge Pressure Pressure transducer 0 - 40kg/sq.cm.

PT2 0.1%

FlowDiffl. Pr. transmitter (Range will beselected before the test based on

the flow orifice data sheet).

DPT 0.1%


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Temperature RTD TE 1/3 DIN

SpeedOptical non-contact digitaltachometer.

N 1 rpm

Power Watt transducer W 0.25%

------------------------------------------------------------------------------------------------

10.0 SAMPLE CALCULATIONS :

During the site test, pump parameters like flow, head and speed may be different fromthose guaranteed. The following illustrates sample calculation for correcting the sitetested parameters to the design speed.

A. Site test data :

Speed : 1513 rpm.

Discharge temp. : 43C (sp. wt. to be taken from standard)

Flow : 540 m3/hr(TPH / sp. wt. at 43C)

Pump dynamic head :{(Disch. pr.- Suction pr.) x 10} / sp. wt. = say

227 mlc

Power input at motor

terminals: 456 kW.

B. Estimated auxiliary power based on tested data :

1. Flow corrected to design speed = 148/1513) X 540 = 530m3/hr.

2. Dynamic head corrected to design speed = (1485/1513)2

3. Pump efficiency at 530 m3/hr from design curve = 76%

530 x 218.68 x 990

4. Power input to pump = ------------------------ = 411.15 kW 3600 x 102 x 0.76

Pump input power 411.15

5. Power input to motor = ------------------------ = ---------- = 435 kW Motor efficiency 0.945

C. Auxiliary power measured at site :

1. Aux. power at tested speed of 1513 rpm = 456kW.

2. Aux. power corrected to design speed = (1485/1513)3 x 456 = 431.149kW.

D. Evaluation:

Site measured auxiliary power at motor terminals, corrected to pump designspeed (C2) will be compared to the estimated auxiliary power (B5).

In case the measured power corrected to design speed is higher than thecalculated power, the difference of the two will be treated as excess auxiliary


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power consumption.


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RECORD OF REVISIONS

Rev.

No.Date Revision Details

Revised

By

Approved

By

01 26.12.2000 Revised as per MSEB ltr. No. 3084

dt. 21.10.2000.

02 12.01.2001 Parameters revised to 0% MU as per

PEM ltr. dt. 11.01.2001.

PROCEDURE FOR SITE PERFORMANCE GUARANTEE TEST OF CWP

PROJECT : 2 X 210 MW KHAPERKHEDA TPS UNIT III &

IV

CUSTOMER : MSEB

1.0 INTENT :

The intent of the site test is to prove the auxiliary power consumption of the Cooling water

Pump set measured at the input terminals of the CWP drive motor at guarantee points.

2.0 GUARANTEE PARAMETERS :

The guaranteed parameters shall be as per Annexure-I.

3.0 TEST SET UP :

The schematic arrangement for the test shall be as per Annexure- III for CWP Set.


a) DISCHARGE PRESSURE:

Discharge Pressure measurement is done by a calibrated pressure gauge.

b) STATIC HEIGHT:

Static height of the pump discharge pressure gauge from the surface of the water linein the sump shall be measured as below.

1. Measure the height of pump discharge pressure gauge centre line fromthe

operating floor level, Say "Z1".

2. Measure the depth of water surface from the operating floor level, say"Z2".

Static Height = (Z1 + Z2).

c) SPEED :

The speed measurement is carried out by non-contact type digital tachometer.


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c) POWER :

The power input at the motor terminals shall be measured by test Watt Meters.


An overall tolerance of 1.5% will be used while comparing measured power with the

guaranteed power due to measurement uncertainties on head and power.


The auxiliary power consumption for CWP Set is valid for a given set of guaranteed

parameters of CWP Discharge flow and bowl head.

In case the CWP is operated at a point different from the guaranteed parameters, the input

power would be computed using the standard formula relating Q,H and Efficiency. And the

auxiliary power consumed at motor terminals is derived after considering pump efficiency and

motor efficiency corresponding todesigned flow, with reference to tested curves of CWP.

Refer Annexure IV for sample calculations.

ANNEXURE 1

AUXILIARY POWER GUARANTEE

Project : 2 x 210 MW Khaperkheda units 3 & 4

Customer : MSEB

CWP parameters corresponding to Auxiliary Power guarantee

Flow (cum/hr) : 13600

Bowl head (m) : 28.5

Motor input power (kw) : 1260.7

ANNEXURE II

LIST OF INSTRUMENTS

Parameter Type and rangeTag

No.Accuracy Remarks

Static height Measuring Tape MT -- -

Discharge

pressure

Pressure gauge 0-

7kg/sq.cm PG 0.1% -

SpeedOptical non-contact

Digital tachometerN 1 RPM -

Power Watt Meter W 0.25% -


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ANNEXURE IV

COMPUTATION OF POWER INPUT TO CWP MOTOR

(SAMPLE CALCULATIONS)


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1. Pump discharge pressure (P1) = 2.2 Kg/sq.cm (g)

2. Height of discharge pr. Gauge

center line from operating floor (Z1) = 1.0 m

3. Depth of water surface in the sump

from operating floor (Z2) = 5.0 m

4. Bowl Head (Hb) = (P1x10)+Z1+Z2+(V2/2g)+hr

Where, V = Velocity of water in discharge pipe.

V2/2g = 0.18 m (for a flow of 13600 m3/hr)

hf = Friction loss in pump column pipe

hf = 0.5 m (committed value)

HL = 22.0 + 1.0 + 5.0 + 0.18 + 0.5

= 28.68 m

5. Flow corresponding to Hb (28.68 m) = 13600m3/hr (refer tested curve)

6. Bowl efficiency = 89%

7. Power input to pump bowl = 1000 x 13600 x 28.68

---------------------

102 x 3600 x 0.89

= 1193.5 kW

8. a Thrust bearing loss = 9 KW

b Transmission loss = 3

KW Total loss (a + b)

= 12 kW

9. Pump shaft input power = 1193.5 + 12

= 1205.5 kW

10 Motor efficiency = 96 0%

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