BADARPUR THERMAL POWER SATATION

TECHNICAL DIARY 210MW

NTPC
NATIONAL THERMAL POWER STATION

INDEX
Sr. No. 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 1.15 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4 3.5 4.0 4.1 4.2 4.3 4.4 5.0 5.1 Contents BOLIER & AUXLIARIES Specifications Performance data F.S.S.S Fans (ID, FD, PA,Ignitor & Scanner) Air Heater Soot blower Electrostatic Precipitator Coal burners & oil guns Coal mill Raw coal feeder Fuel oil transfer pump Dosing system Ash handling system D.M. Make up system Coal Mill Reject System TURBINE & AUXILIARIES Specifications Governing system Turbine lubrication system Condensate system L.P.Heaters & air ejection system Feed water sytem H.P. Heaters C.W. pump & C.W. booster pump HP & LP Bypass system GENERATOR & AUXILIARIES Generator Specification Specification Of Static Excitation System Unit IV & V Generator Seal Oil System Stator Water Cooling System Generator & UAT Transformers PROTECTION & INTERLOCK Unit protections Partial load conditions Protection & interlock of unit auxiliaries Electrical protection for unit auxiliaries PROTECTION RELAYS SETTINGS Recommended Settings of Generator, GT & Page No. 4-29

30-46

47-57

58-72

73-86

5.2 5.3 6.0 7.0 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.9 7.10

UATs Recommended Settings Of 6.6 KV Sections Recommended Setting Of MCB Relays NEW C&I SYSTEM COMMISSIONED OFF-SITE AUXILIARIES Switchyard Air compressors Control structure pump house Ash Handling Plant Cooling Tower Diesel generator Water Treatment Plant Old Coal Handling Plant New Coal Handling Plant Fuel Oil System

87-89 90-132

SECTION-I

BOILER AND AUXILIARY

1.1 SPECIFICATIONS 1.1.1 TYPE Natural circulation , Dry Bottom , Tangentially fired , Balanced Draft , Radiant Reheat type with direct fired pulverised coal system. 1.1.2 DESIGNED FUEL Indian Bituminous Coal

Fixed Carbon 38 %

Volatile Matter 26 %

Moistur e 8%

Ash 28 %

Grindibility (HGI ) 55

High Heating Value 4860 Kcal / Kg

1.1.3 FURNACE

Fusion Welded Type

Width 13.86 m 1.1.4

Depth 10.59 m

Height 42.79 m

Volume 5210 cu. m.

SUPERHEATER , REHEATER & ECOMOMISER S. No. Description Heating Surface ( sq. m ) 8209.5 No. of Coils / Tube Size (mm) Material

1.

Low Temp. S/H

Upper Bank 67 Lower Bank 67 Terminal Tubes 67 x 6 = 402 29

44.5 x 5

44.5 x 4.5 44.5 x 4.5 44.5 x 4.5

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

2.

Platen S/H

944.5

a) 51 x 4.5/5.6/ 7.1/8.8 a) 47.6 x 7.1 b) 47.6 x 6.6 c) 47.6 x 8.6 54 x 4.5 51x 4.5

3.

Final S/H

1036

119

1 Cr , Mo ( SA 213T11 ) & SA213T22 2 Cr , 1 Mo ( SA 213T22 )

4.

Ceiling & Enclosures

540

Roof Panels 120 Front Wall

Carbon Mo (SA209T1) Carbon

181 Rear Wall 136 Side Wall 66 x2

51 x 4.5

Steel (SA210GrA 1) Carbon Steel (SA210GrA 1 Carbon Mo (SA209T) 2 Cr , 1 Mo ( SA 213T22 ) 1 Cr , Mo ( SA 213T11 ) SA213T22 SA213Tp34 7A Carbon Steel (SA210A)

5.

Reheater

2650

Front assembly 59 Rear assembly - 89

54 x 3.6 47.6 x 3.4

6.

Economiser

5440

67

44.5 x 4.5

1.1.5

ATTEMPERATOR Type Spray No. of Stages One Location Medium of Spray Between Horizontal Feed Water & Platen S/H

1.1.6 A) i. ii. iii. iv. v. vi. vii.

FUEL SPECIFICATIONS COAL Fixed Carbon Volatile Matter Moisture Ash Grindability High Heat Coal size to Mill 38.% 26% 8.0% 28% 55HGI 4860 Kcal/Kg 20 mm

B) i. ii. iii. iv. v. vi.

OIL Low Heat value Sulpher Moisture Flash point Viscosity Sp. Weight 10000 kcal/kg 4.5% w/w 1% w/w 660 C. 1500 redwood at 37.80 C . 0.98 at 380 C.

1.1.7

SAFETY VALVES Make & type a)dresser 1749wa b)dresser 1749wa dresser 1739wd dresser 1538-vx a)dresser 1775wa b)dresser 1785 dresser 1705 rwd 1.2 No. per boiler 1 2 1 1 Size Set pressure (kg/cm2) 158.2 161 162.41 144 142 Relieving capacity (t/hr.) 190.04 162.08 195.08 86.73 88.06

Location

Drum

3 3 2 2

Super Heater SH-electro magnetic Relief valve Reheater inlet

1 3

4 6

33.4 33.75 34 34.45 30.58

94.7 136.01 137.38 138.76 114.93

Reheater outlet

PERFORMANCE DATA

1.2.1 DESIGNED PARAMETERS Temperature ( C0.) Flow (t/hr) Load MCR NCR 60%MCR MCR NCR 60%MCR 210mw 210mw 700 662 420 540 540 540 Pressure (kg/ cm2) MCR NCR 60%MCR 210mw 137 136 13.2

Description

Steam Steam at final SH Outlet Steam at

580

575

375

540

540

540

24.5

24.7

14.9

Reheater Outlet Steam at Reheater Steam from Drum Steam leaving Horizontal SH Steam leaving Platen SH Water Feed water entering economiser Feed water leaving Economiser Flue gas Flue gas leaving Furnace Flue gas entering Reheater Flue gas entering Horizontal SH Flue gas entering Eco. Flue gas entering APH Flue gas leaving APH Air PA flow at APH Outlet SA flow at APH Outlet Tempering

- - - -

332 342 430

331 340 433

293 334 452

26.4 150.7 146

26.5 148 144

16.0 137.4 135.5

- -

514

514

512

- -

700

643

371

247

246

220

153

150

139.2

- -

278

277

262

- -

- -

1125

1135

1118

- -

- -

1020

1017

981

- -

- -

697

690

670

463

459

433

364

366

336

146

143

129

96.7 678.3 120.8

77.8 624.5 85.5

70.3 481.5 92.9

338 330 38

336 329 38

316 311 38

air 919.3 Total combustion air 110.1 Fuel Coal(HHV =5000Kcal/ Kg.)

869.3

668.2

105.1

71.5

1.2.2

PRESSURE AND DRAFT (AIR &GAS)

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

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

FLUE GAS Description SH Platen Inlet RH Inlet Finish SH Inlet Units mmwc mmwc mmwc MCR -5 -6 -14 NCR -5 -6 -13 Control load 60% MCR -5 -6 -9

LTSH Inlet Economiser Inlet A.H. Inlet E.P. Inlet I.D. Fan Inlet( Including Static Head) 1.2.3

mmwc mmwc mmwc mmwc mmwc

-20 -37 -54 -184 -242

-19 -35 -49 -165 -222

-12 -20 -31 -84 -128

MILL AND BURNER PERFORMANCE

Description No. of Burner in operation Burner Tilt No. of mills in operation Mill Loading Air flow per Mill Air Temp. at Mill Inlet Mill Outlet Temp. Fineness

Units Degree % T/hr

0

MCR 16 0 4 80 52.3 172 77 70

NCR 16 +10 4 79 52.3 171 77 70

Control load 60% MCR 12 +30 3 70 52.3 160 77 70

C C

% Thru 200 Mesh

1.2.4

O2, CO2 ( BY VOLUME ) AND EXCESS AIR

Description O2 in Gas at Economiser Outlet CO2 in Gas at Economiser Outlet Excess air in Gas at Economiser Outlet

Units %

MCR 4.3

NCR 4.3

Control load 60% MCR 5.5

14.9

14.8

13.7

25

25

36

1.2.5

DESIGNED PRESSURE DROPS

Description SH System RH System Economiser System

Units Kg/cm2 Kg/cm2 Kg/cm2

MCR 13.7 1.9 2.1

NCR 12.0 1.8 2.0

Control load 60% MCR 5.4 1.1 1.8

A.

Air Wind-box APH Air-duct Aero-foil Across Pulv. Fuel Piping

mmwc 115 94 63 25 305 308

C.

Flue Gas Furnace S/H & R/H Eco Flue gas Duct & Dampers Regenerative APH Static Head Velocity Head & Exit Loss ESPS Total Loss

mmwc 4 48 19 52 110 20 20 22 295

1.2.6 HEAT BALANCE Dry gas loss Carbon loss Radiation loss Unaccounted loss H2 in air and H2O in fuel Total loss Efficiency 1.2.7 4.63% 2% 0.26% 1.5% 4.9% 13.3% 86.7%

RECOMMENDED FEED WATER LIMITS 61-100 Nil 101 & above Nil

Drum operating Pr. in kg/cm2 1. Hardness

2. ph at 250 C.(Copper alloy pre-boiler syms.) 3. ph at 250 C.(Copper free pre-boiler syms.) 4. Dissolved Oxygen(max) ppm 5. Total Iron(max)ppm 6. Total Silica(max)ppm 7. After Cation Column Conductivity at 250 C( micro-mhos/cm),online 8. Hydrazine residual(ppm) 9. Permanganate consumption(ppm) 10.Oil 11 Chlorides not allowed 12.Copper(max)ppm

8.8-9.2 9.0-9.4 0.007 0.01 0.02 0.5 0.02-0.04 Nil Not allowed Not allowed 0.005

8.8-9.2 9.0-9.4 0.007 0.01 0.02 0.3 0.02 - 0.04 Nil Not allowed Not allowed 0.005

1.2.8 RECOMMENDED BOILER WATER LIMITS Drum operating Pr. (kg/ cm2) 1. Total dissolved solids (max)ppm 2. Conductivity at 250Cmicro-mhos/cm 3. Phosphate residual(ppm) 4. ph at 250C. 5. Silica(max)ppm 6. Chlorides(max.)ppb 7. Total hardness 61-100 100 200 <20 9.0-10.0 2.0 <4000 Nil 101 & above 50 100 2-4 # 9.0-9.5 0.4 * <2000 Nil

Note: # If the Boiler water pH is not maintained in the prescribed limit, residual Phosphate may be increased but upto 10 ppm only. Silica value in Boiler water should commensurate with the drum pressure. 1.3 FURNACE SAFEGUARD SUPERVISORY SYSTEM (FSSS) FSSS facilitates remote manual/automatic control of fuel firing equipment through mechanized system and suitable interlocks/logics. The system provides protection against malfunctions of fuel firing equipment and associated air systems. 1.3.1 FSSS INTERLOCKS AND PROTECTION 1. PURGE READY CONDITIONS

i) 220vDC and 110vAC supply to FSSS panel estd.(crl 53 and tdr 10 are both on) ii) Boiler Drum level normal(CR 169 is off) iii) At least one ID and one FD fan running(CR 151 is off) iv) Ignitor trip v/v proven closed(CR 263 is on) v) Warm-up trip v/v proven closed(CR 279 is on) vi) All Ignitors oil/air v/vs proven closed(CR12 is on) vii) All WO and HO nozzle hydromotor v/vs proven closed(CR16 is on)

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

SR. NO. 1.

DESCRI PTION Ignitor trip v/v

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

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

PROTECTION a. ignitor oil header pr. Falls below 9kg for > 2sec. And ignitor V/v not closed. b. Boiler trip command present(icrl 61 off) c. When ignitor trip v/v is closed v/v closed green signal comes on (cr63 on) 1. HO header pressure is low for more than 2 secs (TDR 281 is ON) 2. Steam and heavy oil differential pressure is low (less than 0.3 Kg/Sq.Cm) for more than 2 secs and provided no guns are being started or stopped (TDR 287 is ON) 3. Boiler trip occurs (2 CRL 61 is OFF)

2.

Heavy Oil Trip Valve

1. Boiler trip circuit (MFR) is reset. (2 CRL 61 is ON) 2. All HO nozzle valves of AB, CD & EF oil guns are proven fully closed. (1 CRL 107 AB, CD, EF are ON) 3. HO supply pressure is adequate (more than 7 Kg/Sq.Cm) 4. HO pressure

3.

Heavy Oil Elevation start

1.

2.

3.

4.

5.

6.

Heavy Oil corner start

1.

2.

3.

4.

not low (less than 1.5 Kg/Sq.Cm for more than 2 sec. ) TDR 281 is OFF. DC power available (TDR 51 is ON) Ignitor trip valve proven fully open (1 CRL 259 is ON) No boiler trip command persists Heavy oil temp above 100 deg C Air flow adjusted between 30 to 40% of full load air flow Burner tilt placed in horizontal position 1. In first 10 secs of The main oil pair start time trial gun is inserted the associated in guide pipe elevation ignitors are & coupled started. When The local ignitors are proven maintenance ignitor ON signal control switch comes (CR 29 AB 1, is placed in 2, 3, 4 are ON) If the remote flame is not provend HO manual spark will cease and isolation jamesbury valve will valve is open close after 10 secs. Atomising steam manual 1 When minimum 3 out of 4 ignitors at the isolation associated elevation valve is open

HO elevation shut down

are proven ON (1 CR131 AB is ON) 2 25 secs later a start command is sent to corner 3 (when pair 1&3 are started) or 4 (when 2&4 is started) 3 When the gun is fully advanced the atimising steam nozzle valve opens. 4 When the atomising steam valve is proven fully open the heavy oil nozzle valve opens placing HO gun in service. (Total time taken for proving the pair of guns is 90 secs) Depressing the associated elevation pair button will initiate a 375 secs stop time trial to shut down the scavenge the associated pair of LO guns as follows.

1.4 FANS 1.4.1 Sr. No. A Descri ption ID Fan SPECIFICATIONS Type No Of Boiler 2 Capaci ty m3/sec 230.9 Press. Temp mmwc 0C 387 150 KW Motor Voltage KV/V 6.6 RPM

FD Fan

PA Fan

Ignitor Air Fan

Axial Impulse Type Axial Reaction Type Radial Backward Curved Centrifu Gal

1300

990

103.8

520.5

50

800

6.6

490

65.3

1345.5

50

1250

6.6

1485

400 Sefm

4WG -

11

415v

1460

E F

Scanner -doAir Fan Seal -doAir Fan

2 2

1100 M3 11000 M3

160 150

50 50

1.1 10

415v 440V

3000 2850

1.4.2 A: S.N. I II

FAN LUBE SYSTEM AND CONTROL ID FAN LUBE OIL SYSTEM PUMP TYPE-Gear type Capacity-5LPM MOTOR Power-0.5HP Voltage-415v Frequency-50C/S,3 Ph. Speed-1380 RPM Rated current-1.08 Amps FAN

Inlet vane control

III IV

Operating Press-2Kg/cm2 Relief Pr-7 Kg/cm2

B:

FD FAN LUB OIL SYSTEM: Pump Type-Gear type Capacity-79.2 LPM Lub oil Pr. 0.8 to3ata (g) Motor Power-4KW Voltage-415V, Frequency-50c/s,3Ph Speed-1400 rpm Rated Current-11 Amp Fan control

I II III

Variable pitch blade control

C: Sr.N I II

PA FAN LUBE OIL SYSTEM PUMP TYPE-Gear type Capacity-5LPM MOTOR Power-0.5HP Voltage-415v Frequency-50C/S,3 Ph. Speed-1425 RPM Rated current 1.2 Amps FAN

Inlet Guide vane contol

III IV

Operating Press-2Kg/cm2 Relief Pr-7 Kg/cm2

1.5 1.5.1

AIR HEATER

STEAM COIL AIR PRE-HEATER TYPE No.Of Boiler Medium H.S. IN M2 Steam Coil R2-10 2 Secondary Air 770 per Air Heater

1.5.2 RE- GENERATIVE AIR PRE-HEATER Type No. Boiler Medium Tri Sector Regenerative 27 vi 72 (T) 2 i)Primary Air ii) Secondary Air iii) Flue gas 19000 per Air Heater

H.S. IN M2

HEATING ELEMENT i) Hot layer-864 mm Open hearth steel ii) Intermediate Layer-864mm Open hearth steel iii) Cold layer-305mm corten A steel i) ii)

ROTOR DRIVE Motor-GE 15 HP Voltage-415v

CLEANING DEVICE i) Motor-0.25 HP ii) Speed reducer 4800:1

iii) Speed-960 rpm iv) Speed-110:1 reducer v) Oil Capacity-13G

SUPPORTING BEARING i) Type- Spherical Thurst Bearing ii) Lubrication-Oil bath type iii) 18 Gallons iv) Motor rating-3/4 HP

GUIDE BEARING Double roller bearing Oil Bath Oil capacity-4 Gallons 1 to 0.5 HP

AUX.AIR MOTOR Motor-4 BHP Air Pr.-5.6 Kg/cm2 Speed-255 rpm

1.5.3

PERFORMANCE OF AIR PREHEATER 500 PA NORMAL ROTATION mmWC 180 681 999 97 680 1084 0 C 38 41 369 337 329 146 mmWC C 44 90 112 1.6 Location 500 PA 720 PA REVERSE REVERSE ROTATION ROTATION mmWC NORMA 20% L MORE 165 163 182 697 699 837 999 999 1199 97 680 1085 0 C 38 41 369 325 333 146 mmWC 44 90 112 97 680 1085 0 C 38 41 369 326 334 146 mmWC 22 124 112 116 816 1286 0 C 38 41 369 321 332 149 mmWC 29 159 146

FLOW t/hr PRI SEC GAS Air In Air In Gas In

20% LESS 144 561 799 78 544 884 0 C 38 41 369 331 338 142 mmWC 14 107 75

PRI Air Out SEC Air Out GAS Gas Out TEMPERATURE PRI Air In SEC Air In GAS Gas In PRI Air Out SEC Air Out GAS Gas Out PRESSUR DROP PRI Air SEC Air GAS

SOOT BLOWER Type Qty./Boiler Medium

Header Pr (Kg/cm2) 30

i)

Furnace

ii)

ii)

Platen,Convention Super heater & Re-heater Air Heater

30

Wall blowers RWSE Long retractable Swiveling

56

20

Super heated steam Super heated Super heated steam

30

1.7 ELECTOSTATIC PRECIPITATORS 1.7.1 DESIGN CONDITIONS UNIT # 4 1333709 m3/hr. 1500 C 31.8 gm/m3 2000mmwc 2 FAAX .5x36-9590-2 2 5 4 99% 15MMWC 1.08 m/sec. 16.62 sec. UNIT # 5 133380 m3/hr 1460 C 28.3 gm/Nm3 2000mmwc 2FAA. 5x32-11190-2 2 5 4 99% 15MMWC 0.93 m/sec 17.243 sec

i) Gas flow rate ii) Temprature iii) Dust concentraion iv) Inlet pressure v) Type vi) NO. of boilers vii) No. off fields in series in each gas path viii) No. of parallel pass per boiler ix) Design pressure drop across precipitator x) Design pressure drop across precipitator xi) Gas velocity at electrode Zone xii) Treatment time

1.7.2

COLLECTING PLATES 38

EMITTING ELECTRODES No of electrodes in each rows 32

i) No. of rows per field

ii) No. of collecting plates 384 per field (8plates in each row) iii) Total no. of plates/boiler 6080 iv) Nominal height of 9M Collecting plates v) Nominal length of 400 MM Collecting plates vi) Specific collecting area 132.88 m2

No of electrodes in each field 1184 No .of electrodes / boiler Total length of electrodes per field Size 23680 6829M 2.5 mm

Plate/wire spacing 150mm Type Spiral with hooks

1.7.3

RAPERS FOR COLLECTING PLATES One drop hammer Per row for collecting Surface area of 57.6m2

RAPERS FOR EMITTING ELECTRODES Type & no. Spiral hooks approx one dropHammer/ Two rows

i) No. & type of rappers

ii) Rapper weight iii) Frequency

4.9 kg.

Rapper wt.

3 kg. 10 raps/hr

iv) Drive

varies from 6 raps/hr.at Frequency Inlet field to 1 rap/hr. at Exit field Geared electric motor Drive controlled by synchronous programmer

Geared elec tric motor with synch ronous programmer

1.7.4

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

1.7.5

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

1.7.6 A)

ELECTRICAL SYSTEM RECTIFIER UNIT # 4 UNIT # 5

i) Rating ii)Number iii) Type iv) Location B)

60kv (peak/800 m.a.) 70 kv (peak/1000 m.a.) 20 20 Silicon diode full wave bridge connection Mounted on precipitator top

RECTIFIER CONTROL PANEL i) Type & control ii)Number iii) Location Thyristor/microprocessor based) on controller(PRECICON 20 In the control room at ground level

C)

AUX.CONTROL PANEL i)Number ii)Equipment controlled iii) Location 4 Geared motors for rapping mechanism, heating elements om hoppers & shaft insulators. In the control room at ground level

D)

MOTORS For both emitting electrodes i) Quantity 20 Nos. ii) Rating 0.5 HP,1.1 rpm at 3 ph,50 c/s , 415v iii) Location on the casing side panel

E)

HEATING ELEMENTS i) HOPPERS For forty hoppers at the rate of 6 kw /hopper = 240 kw ii) SHAFT INSULATORS i) ii) For 20 insulators at the rate of 1 kw = 20 kw Support insulators for 80 insulators at the rate of 1 kw = 80 kw

1.8 COAL BURNERS,IGNITORS & OIL GUNS A) COAL BURNERS Titling tangential fired corner 24 (4 each in 6 elevation) +/- 30 deg. Cent.

i) Type ii) No. of boiler iii) Titling limit B) IGNITORS i) Type ii) NO. off iii) Location iv) Capacity v) Turn down ratio vi) Oil pr. At control cabinet vii) Oil firing rate viii) Atomising air quality ix) Atomising air pr. x) Atomising air consumptio xi) Combustion air quality xii) Combustion air pr. At wind box C LIGHT OIL (W.U.) GUNS i) Type ii) No. off iii) Location

6 eddy plate oil side ignitors air atomised 12 (4 per elevation) Elevation AB,CD,EF 0.5 millions k.cal./hour Nil 12.5 to 14 kg/cm2 50 kg/hr/ignitor Water free service 5.5 to 7 kg/cm2 14.5 Nm3 / hr/ ignitor-when off 560 Nm3 / hr / ignitor 75 MMWC

Tilting, tangential, air atomized internal mix 4 Elevation AB corners

iv) Capacity v)Turn down ratio vi) Oil firing rate vii) Atomising air quality viii) Atomising air consumption ix) Atomising air pr. x)Differencial pr. Between oil & air C) FUEL (LDO) OIL GUNS

10% of boiler MCR 2.5 :1 1265 kg / hr / gun Service air water free 190 Nm3 hr / gun 5.36 kg/cm2 1 kg/cm2

i) Type Tilting,tangential steam atomised internal mix ii) No. off 12 (4 per elevation) iii) Location Elevation AB,CD,EF corners iv) Capacity 20% of boiler MCR in total v)Turn down ratio 4:1 vi) Oil firing rate 1320 kg / hr / gun vii) Oil pr. At gun 8.5 kg / cm2 viii) Atomising steam quality Super heated by 10-15 deg.cent. ix) Steam consumption 150 kg / hr / gun x) Steam pressure at gun 9.5 kg / cm2 xi)Differential pressure 1 kg / cm2 between oil & steam 1.9 COAL MILL i) Type ii) No. of boiler iii) System iv) Capacity v) Coal grindibility vi) Max. moisture content vii)Finness through 200 mesh MOTORS i) Rating ii) Voltage iii) Frequency iv) RPM v) Rated current vi) No load current 1.10 RAW COAL FEEDER i) Type ii) Width chain type 600 mm 340 kw 6.6 kv 3 phase 50 c/s 990 41.7 Amps 15-16 Amps XRP 783 Bowl Mills 6 pressurised 39.7 mt / hr 55 HGI 12% 70%

iii) Length iv) Speed variation v) Depth of coal bed vi) Capacity max. MOTORS i) Rating ii) Voltage iii) Current iv) Speed

12400 mm 1:6 120-200 mm 45 mt / hr.

7.5 kw 415v 15.5 Amps 975 rpm

1.11 FUEL OIL TRANSFER PUMPS DESCRIPTION i) ii) iii) iv) Capacity Discharge Suction Max. temp. of oil handle By the pump TRANSFERPUMP 120 m3 /hr 80 MMWC 5 MMWC 600 C DRAIN PUMPS 5 m3 / hr 40 MMWC 5 MMWC 600 C

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

iv)

Head MOTOR

i) Rating ii) Voltage iii) Speed iv) Current rating

2.2 kw 415 v,50 c/s 1430 rpm 4.8 amps.

1.13 ASH HANDLING SYSTEM A) MAX.ASH COLLECTION RATE 12 ton/hr. 2.08 ton/hr. 1.74ton/hr 52.36 ton hr/ 0.79 ton/hr 12 ton/hr. 56.97 ton/hr. 66.97 ton / hr. 33 M3 9.5 kg/cm2 5.5 kg/cm2

i) Bottom ash hopper: (1 No.) ii) Air heater hopper (4 No.) iii) Economiser hopper (4 No.) iv) EP hopper (4 No.) v) Stack hopper (2 No.) vi) Bottom ash vii) Fly ash viii) Total ash ix) Gross storage volume of BA Hopper x) HP Water pressure xi) LP Water pressure B) ASH PUMP:

i) Quantity of sealing water ii) Pressure of sealing water iii) Pump capacity iv) Head developed v) Speed C) ASH ANALYSIS

15 m3/hr. 8 kg/cm2 1000 m3 / hr 23-33 MMWC 800 rpm

i) Silica ii) Alumina iii) Iron oxide iv) Titanium oxide v) Lime vi) Magnesia vii) Sulfuric acid hydrous viii) Phosphoric Anhydride ix) Alkalis

55.09-68.8 % 19.8-29.8 % 3.05-18.3 % 10.0-2.05 % 1.1-2.1 % 0.26-1.2 % 0.4-1.8 % 0.19-0.28 % 0.16-3.04 %

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

i) No. 2 ii) Make: Mather & platt iii) Type: 4/5,two stage MEDI iv) Discharge-100 m3/hr. v) Head-50 MMc vi) Speed-1480 rpm Connected to hot well, unit drain tank & deaerator. 1.14.2 FILL PUMPS i) No.-2 nos ii) Make : IIIplurovane,5 CHR iii) Discharge-200 m3/hr. iv) Head 200 mwc v) Speed 1480 rpm Connected to-boiler drum & deaerator.

Make-Crompton greaves Type-Induction motor Voltage-415v,3 phase Current-49 amps Speed-1475 rpm

MOTORS Make-Crompton greaves Type-AC induction motor KW/HP- 187/250,voltage-6000v 21 amps. Speed 1483 rpm

1.14.3 QUANTITY OF WATER REQUIRED FOR BOILER FILLING: SYSTEM UNIT ENTIRELY FILLED (M3) 37.20 126.3 97.18 48.10 25.17 12.05 ------------345.00 ------------UNIT FILLED TO OPERATING LEVEL (M3) 11.53 126.30 ------25.17 ---------------163.00 -------------

1676 internal dia drum Water walls Super heater Reheater Economiser Main steam piping TOTAL 1.15

COAL MILL REJECT HANDLING SYSTEM

1.15.1 CLIENTS ORDER REFERENCE: For Design, Manufacture & supply of imported equipments- A/T No. BTPS/PUR/P3/IMP/86-87/2427 dated 31-12-86. For Design, manufacturer & supply of indigenous equipments Erection, Testing & Commissioning of complete system. A/T No.BTPS/PUR/P3/IMP/86-87/2428 dt. 31-1286 SUPPLIERS: FOREIGN: Simon-Macawber Limited,

Shawlane Industrial Estate Doncaster South Yorkshire DN2 4SE, UK INDIGENOUS: Bakhtawar Singh Balkrishan & Co "Beekay House" L-8, Green Park extension New Delhi - 110016. 1.15.2 DESIGN BASIS & DATA BASIS Normal Reject rate of mills < 5% Reject rate considered for design is 10%

DESIGN DATA: Maximum Quantity of rejects per mill 3 TPH Normal Quantity of reject per mill 1.7 TPH Average Mean Reject rate per unit of 210 M 9.8 TPH Average quantity of rejects per day for 470 Tones 2 x 210 MW units Density of mill rejects is taken as 1.6 T/m3 for volumetric computations and 2.2 T/ m3 for load/strength computations. 1.15.3 DESIGN CAPACITY PROVIDED IN THE SYSTEM: Removal capacity at each mill 3 TPH Removal from storage bunker to tube mill of 100 MW unit 5 TPH Storage bunker capacity 80 m3

1.15.4 COMPRESSED AIR REQUIREMENTS: Compressed air is required in the system for conveying and controls as below: For primary system at 9.8 TPH per unit of 210 MW 8.82 m3/min For Secondary system at 5.0 TPH per unit 10 m3/min Total Air required for the complete system (8.82x2)+(10x2)=37.64 m3/min Provided 4 Nos compressors with maximum 3 Nos working and 1 No as standby, each of 14.7 m3 capacity (FAD) delivering at 7 kg/cm2 (g)

1.15.5 AIR RECEIVERS: Nos per Boiler : Capacity each : SECONDARY SYSTEM: From storage bins to stage-I mills 2C & 3C Air receiver capacity for secondary system: 10 m3 2 5 m3

1.15.6 DENSEVEYOR Model System : batch conveying Vessel capacity: Pipe size Design Code Safe working pressure Hydraulic test pressure 12/8 12 Ft3 150 mm BS5500 Class III 110 lb/in2 (7 kg/cm2) 150 lb/in2 (10 kg/cm2 )

1.15.7 AIR COMPRESSORS Type Model & Type Capacity Make Drive Motors NGEF Discharge Pressure Speed Actual Quantity of free air compressed Volumetric efficiency Brake HP required at Comp.shaft at rated load Motor Rating Type of bearings for rotors Details of lubrication Materials of construction: Rotors Gears Bearings Frame and running gear Shaft Screw SES-520 single stage 520 cfm +/- 5% Khosla Indair 7 kg/cm2 4500 RPM FAD 520 +/- 5% cfm 91% 105.0 HP 130.0 HP Cylindrical roller and 4 point Bearings Oil flooded (forced feed) EN-8 EN-41B Mfd.Std. (coupling) forged steel, rubber flexible EN-8

Base plate Type and size of suction and discharge valve Details of special features Total cooling water quantity required at 360C Cooling water out let temp.

MS Butterfly suction valves MS (CI body) DK-100 (4") After cooler and oil coolers 150 LPM 100 C above inlet temp. Oil cooler and after cooler.

1.15.8 AIR FILTER CUM SILENCER Type Max. particle size removed after cooler and Inter cooler Type Material of construction Shell Tubes Tube sheets Tube support plates No of passes Cooling surface Oil Cooler After Cooler Dry filter type 10 Microns Shell and tube type (water through tube) IS-226 Copper 3/8" MS MS 2 passes 9.6 m2 5.5 m2

Air Pressure drop through the after cooler/oil cooler 2-3 psi Cooling water inlet/outlet size 1" & 3/4" BSP Cooling water quantity required at 360 C 150 LPM Air outlet temp. 100 C above cooling water temp. 1.15.9 VIBRATORY FEEDER Electromagnetic vibratory feeder - Model F-33 For handling coal mill rejects Internal Combustion 2 25 T/Hr 30 - 35 mm (Max.) 1600 kg/ m3 6/8 deg 400/440 V 525 Watts 450 mm x 1100 mm MS Suitable for suspension type arrangement

Equipment & Model Duty Manufacturer Quantity Maximum capacity Particle size Bulk density of material Inclination to horizontal Power supply Power consumption Feeders through size Material of trough Type of suspension

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

SECTION - II

TURBINE AND AUXILIARIES

2.1 SPECIFICATION 2.1.1 TURBINE MAIN DATA Rated Power 210MW Rated Speed 3000 rpm Rated Steam(Pressure) before ESV 130 Kg/cm2 abs Rated Steam Temp. before ESV 5350 C Rated Steam pressure Before IV 27 Kg/cm2 abs Rated Steam temp. Before IV 5350 C Rated Steam Flow 670 T/Hr HPT Exhaust Pressure 27 Kg/cm2 HPT Exhaust Temperature 3270 C Rated circulating water quantity 27000 M3 through condenser Condenser back pressure 0.09 Kg/cm2 Critical Speed 1585,1881,2017&2489 Rated condenser cooling water inlet 240 C to 330 C temperature Rated condenser cooling water 1.0 to 1 Kg/cm2 pressure Type of governing Hydro mechanical Nozzle type governing Type of turbine condensing, Tandom compound Three cylinder, Horizontal Nos. of bearing 5 Nos.( for turbine side only & HPC front bearing is combined thrust & journal bearing Barring gear 3.4rpm, ac motor of 30kw, 730rpm, 50c/s, 415v, 220:1 Ratio Location of anchor point of At the middle foundation frame of front the turbine exhaust part of the L.P. Cylinder 2.1.2 CONSTRUCTIONAL DETAILS 12 stages (1st is governing stage) each stage Consists of a diaphragm & a set of moving Blades connected on a disc In two valves made of Creep Resistance (Cr-Mo-V) steel High Creep Resistance (Cr-Mo-V) steel Forgings 4 Nos (2 on Top & 2 on sides) made of High Creep resisting (Cr-Mo-V) Steel casting 11 stages 2 parts (a ) Pressure part made of Creep Resisting (Cr-Mo-V) steel

i) H.P. CYLINDER

BODY STUDS & NUTS NOZZLE & STEAM CHEST ii) I .P. CYLINDER BODY

STUDS & NUTS NOZZLE BOXES iii) L.P.CYLINDER

Casting in 2 halves (b ) exhaust part Made of fabricated steel structure In 2 halves. Creep Resisting (Cr-Mo-V) steel Forgings Cast integral with the casing. Stages 4( double flow) last but one stage on each sides are Baumanns satg In 3 parts (1 middle & 2 exhaust parts) All fabricated from weldable quality mild steel & divided in two halves horizontally. All the discs integrally forged with the shaft of single (Cr-Mo-V) steel forging. H.P./I.P rotor coupling is rigid coupling. Seven discs integrally forged with rotor & remaining four discs are shrank fit . shaft is (Cr-Mo-V) steel forging. & discs are high strength Ni- steel forging. IP/LP rotor coupling is (semi) flexible lens type coupling. All the discs are shrunk fit on the shaft. Shaft is (Cr-Mo-V) steel& discs are of high strength Ni steel forgings LP/Generator coupling is rigid coupling. High temp zone blades are of high (Cr-Mo-V) steel & rest are of stainless steel.

BODY

iv) H.P.ROTOR

v) I.P.ROTOR

vi) L.P. ROTOR

vii) ROTOR BLADES

2.1.3

STEAM EXTRACTIONS Steam extraction stages 9th 12th 15th 18th 21st 23rd 25th Connected to HPH-7 HPH-6/D/A HPH-5/D/A LPH4 LPH3 LPH2 LPH1 Ext, steam press in Kg/ cm2 39.06 26.2 11.96 6.47 2.78 1.28 0.28 Ext.steam temp.in 0C in 337 314 433 3680C 252 172 Steam flow T/hr. 400 77 16.2 26 23 28 12.6

No of extractions Ist (HPT) Iind (CRH IIIrd (IPT IV (IPT) V (IPT) VI (IPT) VII (LPT)

2.2

GOVERNING SYSTEM TYPE: Hydro mechanical automatic governing. i) SPEED GOVERNOR: Directly coupled to turbine rotor through coupling & hydraulically coupled to speed governor pilot block located front pedestal. PUPPOSE: Sensing of any speed due to difference between power generated by turbine & load on it. For this governor sleeve moves proportional to speed change. ( Range is 4+1% speed change.) ii) FOLLOW PILOT VALVE: FUNCTION: It follows the governor sleeve in case of change of speed & maintains the gap between governor sleeve & nozzle tip to move summation pilot valve accordingly. iii) LOAD SPEED CONTROL PILOT VALVE: PURPOSE: For initial charging of protections oil in governing system through emergency governor pilot valve & to open ESV, IV & control valve. iv) SUMMATION PILOT VALVE: PURPOSE: To receive movement signals from follow pilot valve & gives command to intermediate pilot valve to open or close the control valves. v) INTERMEDIATE PILOT VALVE: PURPOSE: To amplify the hydraulic signal form summation pilot valve, differentiator, electro hydraulic transducer and emergency governor pilot valve & transmit to control valve servomotor. vi) CONTROL VALVE SERVO MOTOR: PURPOSE: It receives hydraulic signal from intermediate pilot valve & actuates HPT and IPT control valves. vii) LOAD LIMITER: PURPOSE: To limit the load raising beyond set point by limiting the opening the control valve by speed governor.( its continuos operation is not recommended.)

viii)

DIFFERENTIATOR: PURPOSE: It prevents undue speed rise in case of more than 50% load through off which causes anticipatory closure of control valve of HPT and IPT. ELECTRO HYDRAULIC TRANSDUCER: PURPOSE: It converts electric signals of 2 seconds diverted from generator circuit breaker (when opens) into hydraulic signal & momentarily closes the control valve for 2 seconds to avoid overspeed.

ix)

x)

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

xi)

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

xii)

TURBINE SHUT DOWN SWITCH: PURPOSE: TO manually trip the turbine locally or from UCB.

xiii)

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

xiv)

BACK UP PROTECTION(SPEED GOVERNOR PIOLT BLOCK): PURPOSE: It trips the turbine at 14 to 15% over speed if emergency governor fails to operate.

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

12.8 mm

All control valves fully open

2.3

TURBINE LUBRICATION SYSTEM

2.3.1 LUBRICATING OIL SPECIFICATION: Type (Recommended oil for governing system and bearing) MOB DTE oil medium or Turbine oil -14 Or Servo prime -14 Or Turbinol-47 0.852 28 Centistokes 0.2 2010C(min) 66.600C(max) 0.01% Nil 20 Kg/cm2 (Guage) 1 Kg/cm2 (Guage)

Specific gravity at 500C Kinematic viscosity at 500C Neutralization number Flash point Pour point Ash percentage by weight Mechanical impurities Oil pressure in governing system Oil pressure for lubrication of bearings 2.3.2 MAIN OIL TANK Capacity Oil capacity in systems Main oil centrifuge capacity Oil transfer pumps capacity for purifier unit Polishing filter capacity Impure and pure oil storage tank capacity Impure and pure transfer oil pump capacity & head 2.3.3 MAIN OIL PUMP Pressure corresponding to discharge of 4000lits/min Pressure corresponding to discharge of 7000lits/min Suction pressure Power consumption Type of coupling with rotor No. of injectors Oil pressure developed by Ist injector Oil pressure developed by IInd injector Speed

28000 Lts 4000 Lts 6000 Lts/Hr 6000 Lts/Hr 6000 Lts/Hr 40 m3 each 45 m3 /Hr, 18 MWC

20 Atg 16 Atg 1Atg 250 Kw Flexible gear type 2 Nos. 1 Kg/cm2 3 Kg/cm2 3000 rpm

2.3.4 STARTING OIL PUMP FOR NORMAL OPERATION Type Plurovane III(Unit4) Plurovane III A(Unit 5) ( Multi stage centrifugal pump),Mather& Platt Capacity 200 m3 /Hr Head 200 MWC(20 Kg/cm2 ) A.C.MOTOR Capacity Speed Voltage Arrangement 2.3.5 PUMP Type 200 Kw 1000 rpm 6.6 KV,3 Ph, 50 C/s Horizontal

A.C.STANDBY OIL PUMP MOTOR Type 22F Q UE/O Power 25 Kw Speed 960 rpm Current 52 amps Voltage 415 volts,3 Ph, 50

Capacity Head No. of stages C/S Arrangement Vertical Impeller material Bronze Min. oil pressure 0.6 Kg/cm2 For auto starting BEARING Type Number Lubricant 2.3.6 PUMP Type 100 NCU centrifugal pump driven by D.C. motor Min. oil pressure 0.5 Kg/cm2 for starting interlock Single Row Deep Grove Ball Bearing ( Thrust anti friction bearing) S.K.F. 6306 Mobile D.T.E. medium IOC

150COAV ,BHEL (multistage, centrifugal oil Pump, driven by motor) 150 m3 /Hr,(2500 L/Min) 30 MWC 2

D.C. EMEGENCY OIL PUMP MOTOR Power 13 Kw Voltage 220 volts D.C. Current 67.6 amps Speed 1500 rpm Type D-62

Capacity Head BEARING

108 m3 /Hr (1800 L/min) 22 MWC

1. 1 no double row self aligning ball bearing for free end. 2. 1 no. double row self aligning spherical roller bearing. 2.3.7 PUMP Type of oil purifier Capacity of purifier Capacity of transfer pumps Oil pressure at inlet of separator Speed LUBRICANTS Lubrication points: (1) Worm gear housing (2) bowl (2) Bowl spindle(4) bearing of coupling (3) Gears of lifting devices (60 motor HEATER Type KW Voltage 2.3.8 WH 120 440 volts MAB-206-S-20 6000 Lts/hr 6000 Lts/ hr 2.35 Kg/cm2 1500 rpm (max) MAIN CENTRIFUGE (OIL PURIFIER) MOTOR KW(HP) 7.5(10) Frequency 50 Hz Voltage 440 Volt Current 13.6 amps Speed 1440 rpm

MAIN OIL COOLERS 5 nos.(4 nos. at a time in service) 63 m2 1500 Lit/min or 90 m3 /Hr 130 m3 /Hr 4 5 Kg/cm2 5 Kg/cm2 3 Kg/cm2 2.5 Kg/cm2 550C 450C 330C(max360C) 35.640C 1.1 M/sec

No. of coolers Cooling surface area of oil coolers Quantity of oil cooled Water consumption No. of water paths Designed oil pressure Designed water pressure Working pressure of oil Working pressure of water Inlet oil temperature Outlet oil temperature Inlet water temperature Outlet water temperature Rated oil velocity

Rated water velocity in tubes Frictional drop for the bank of operative oil coolers on the cooling water side Dia. of tubes Heat transfer coefficient Hydraulic resistance on oil side No. of oil circulation passes No. of partitions Hydraulic test pressure of oil coolers

1.25 M/sec 1.6 MWC 19/17 mm 400 Kcal/m2 Hr 0C 1.48 Kg/cm2 22 21 8 Kg/cm2

2.4 CONDENSATE SYSTEM 2.4.1 CONDENSER 0.1 Kg/cm2 2*13500 m3/hr 2*7810=15620 10 mts 30/28 mm 305 tonnes 190/10 70/30 Rolled steel plates 5 Kg/cm2 Gauge

2 (Nos, 50% capacity of 2 pass/condenser) Design pressure (steam space) Cooling water consumption No. of cooling tubes Length of cooling tubes Dia of cooling tubes Weight of condenser without water Tube material Cooling Zone Cupronickel Air zone Cupronickel Water boxes material Max. permissible design pressure of cooling tubes 2.4.2 CONDENSATE PUMP PUMP 3 nos Type

MOTOR

(50% capacity each) Type AVM450M4 Multistage, vertical turbine type, 3 ph, 50 C/S, cos0 0.84 Centrifugal pump, Voltage 6.6 KV low specific speed, Insulation Class B medium head, medium capacity Current 25 amp DHRC 28, size300*250 Power 220Kw, HP-300 Stages 8 RPM 1489 Direction Clockwise viewed Space heater 2 nos. of 250w,240w of rotation from motor end Discharge 281 tones/hr Ambient temperature 500C Manometric head 201 mts Weight of motor 3000 Kg RPM 1489 B.H.P. 256 Caution Not to run below 193 mt manometric head Normal discharge 20 Kg/cm2 header pressure

Max thrust bearing oil temperature Max motor bearing temperature Max vibration of gland housing & thrust bearing Max condensate temperature

75 0C 75 0C 40 microns 180 0C

2.5 LP HEATERS & AIR EECTION SYSTEM 2.5.1 L.P.HEATERS Tube material Horizontal U. shape surface type brass 16*10 Vertical --DO-surface type --DO---DO---DO---DO-Location Shell Tube plate No. of relief Material material valve Fabricated Mild Steel 2 Nos.(1 for steam side& from MS 1 for cond. plates side --DO---DO---DO---DO---DO---DO---DO---DO---DO--

LPH Type No. 1 Inside upper part of each condenser( in two halves) 2 Mezzine floor 3 4 2.5.2 --DO---DO--

GLAND STEAM COOLER I

FUNCTION a. Eject steam and air mixture from turbine seals b. Eject spindle leak off from ESV, IV & control valves Gland sealing steam pressure 1.03 to 1.05 Kg/cm2 Source of gland sealing steam 16 ATA header or D/A Temperature of sealing steam 1300C to 1500C Type of seals Labyrinth glands of radial clearance type 2.5.3 GLAND STEAM COOLER NO II

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

Delivery quantity Manometric head Speed Temp. of liquid 2.5.5

1416 L/min 195 MWC 1475 rpm 1000C max

Speed Frequency

1475 rpm 50C/S

DEAERATOR

Deaerator pressure 7 Kg/cm2 Deaerator temp. 1700C Quantity of limiting 0.005 cc/Lit gases (mainly O2) in feed water Steam source Aux source( In starting)/2nd or 3rd Extraction of turbine Design Direct contact type heater in two parts (a) Deaerating Coulmn: Horizontal spray cum tray type fabricated from boiler quality steel plates, meant for deaeration of gases(O2) from water (b) Feed storage tank : Horizontal, fabricated from boiler quality steel plates. Means for water storage and heating Source tank capacity 87.5 m3 Deaerating capacity 759.110 kg/hr Test 200 Psig. (14 kg/cm2) 2.5.6 AIR EJECTOR SYSTEM Nos. Range Aux. source of steam D/A or 16 ATA header --Do-Steam pressure in kg/cm2 4.5 Steam temp. in 0 C 250 Steam consumption in kg/hr 1100 kg/hr

Type of ejector

A) Starting ejector B) Main ejector C) Priming ejector D) Gland steam cooler No.1

Up to 450 mm Hg column in condenser Up to 760 mm Hg column in condenser Up to 200 mm Hg column in condenser Eject steam and air mixture from end gland seals of main turbine

4.5

250

750 each

--Do--

4.5

250

1100

--Do--

4.5

250

2.6 FEED WATER SYSTEM 2.6.1 BOILER FEED PUMP

A) PUMP No. of pumps Type Nos. of stages Max. rated suction pressure Discharge capacity Head Feed water temp. Speed Lubrication Stuffing box Quantity of water for minimum take off Min. suction pressure of BFP Quantity of water for Heating take off Cooling water consumption Net weight of pump Drive B) MOTOR M/S BHEL Hardwar ATD-4000 4000 KW 6.6 KV 421 amp 1483 rpm 50 C/S, 0.914 3 Nos. (50% capacity) Multi stage , Horizontal high pressure, Barrel type pump 200 KHI 6 12.3 ata 430T/hr 1830MWC 164.20C 4320 rpm Forced Mech seal 100 T/hr 6 Kg/cm2 8 T/hr 280 T/min.(Approx) 5850 Kg Electric motor through hydraulic coupling

Manufacturers Type Output Rated Voltage Current Speed Frequency/ power factor 2.6.2 OPERATING DETAILS

Water pressure in equalizing pipe of balancing Disc 3 to 4 kg/cm2 more than suction branch pressure ( but not ore than 5 kg/cm2) No. of bearings 2 Radial sleeve bearing and 1 thrust bearing Motor bearing 2 Radial sleeve bearing Hydraulic coupling bearing 4 Radial bearings and 2 tilting pad bearings No. of oil coolers 2 nos.( one for hydraulic coupling working oil and one for lubricating oil of bearings)

Auxiliary oil pump Type of Aux. oil pump Type of main oil pump Oil pressure in radial bearing Bearing temperature Oil pressure for thrust bearing Min. discharge pressure of BFP Max feed water temperature at BFP Max BFP flow Max motor bearing temperature Max temperature difference of feed water and BFP body Max motor hot air/ temp. Normal BFP discharge pressure Seal water temp. 2.6.3 BOOSTER PUMP

415 V, 3 Ph, 50 C/S Gear type Gear type 0.8 to 1.00 Atg 650C(max) 0.5 Atg 120 kg/cm2 discharge 1750C 475 T/hr 800C 30 0C 80 0C (600C normal) 170 kg/cm2 650C-700C

No. of pump Use

one for each BFP 1. To provide a positive suction pressure to BFP & to avoid possibility of cavitations 2.To reduce the BFP stages Make M/S Mather & Platt. Type 8/10 Delivery quantity 460 T/hr Speed 1475 rpm Drive Main motor Min. booster pump suction pressure 3.5 kg/cm2 Delivery head 31 MWC 2.7 H.P.HEATERS (DESIGN SPECIFICATION) Description Feed water inlet temp. in 0C Enthalpy of F.W. inlet in Kcal/kg F.W. outlet temp in 0 C Enthalpy of F.W. at outlet in Kcal/kg F.W. flow (kg/hr) Ext. stem inlet pressure in kg/cm2 Ext. stem inlet temp. in 0C H.P.HEATER No.5 166.76 170.70 184.92 189.51 643165 11.96 433 H.P.HEATER No6 184.92 189.51 220.90 229.48 643165 26.20 314 H.P.HEATER No7 220.90 227.48 242.78 251.41 643165 39.06 377

Enthalpy of Ext. steam in Kcal/kg Steam flow (kg/hr) No. of coils

796 16271 292

727 44777 288

754 29880 288 60 to 70 Mw 89 kg/cm2 102 kg/cm2

Load at which H.P. Heaters are taken into service Without H.P. Heaters ma. Curtis wheel pressure Full load Curtis wheel pressure with H.P. Heaters 2.8 2.8.1 CW PUMPS & CW BOOSTER PUMP

CIRCULATING WATER PUMP 2 Nos.(100% capacity) FLOWMORE One 15000 m3 /hr 11.5 MWC 86% 420 rpm 740 HP BHEL, 950HP,6.6 KV splash proof type Self water lubricated Anti clock wise (from top) Rigid type Condenser, Main oil coolers& H2 gas coolers

No. of pumps Make Number of stage Capacity of pump Total dynamic head Efficiency Speed B.H.P. Motor Type of pump lubrication Direction of rotation Coupling of motor & pump CW water is used in

2.8.2 PUMP

C.W. BOOSTER PUMPS

No. of pump Lubrication in board & Outboard bearing Speed Make Discharge pressure Normal bearing temperature Normal pump vibration MOTOR Output Speed Amps

2 Nos.(100% capacity) Mobilux grease No.2 1487 rpm Mather Greaves Pvt. Ltd. 2.5 kg/cm2 600C 40 microns

55 KW 1487 rpm 96

Voltage Make 2.9 H.P.& L.P. BYPASS SYSTEM (i)

415 V NGEF

(ii)

Provided to increase the rate of steam temperature rise and warm up the HRH,CRH, IPT & transfer pipe lines ( at 60% MCR full pressure & temp. can be obtained i.e. 60% capacity) All the HP & LP BYPASS valves are hydraulically operated for which oilat about 50 kg/cm2 is supplied by a separate oil supply unit. DESIGN CAPACITY OF H.P. BYPASS STATION Boiler feed water 1 for each MS line 200T/hr steam flow 100T/hr steam flow 5400C 140 ATA 3800C

2.9.1

Injector water Nos. of H.P. Bypass valve Total capacity Capacity of each bypass valve Max. MS temp. Max MS pressure Down stream temp

2.9.2

DESIGN CAPACITY OF LP BYPASS STATION Condensate water 1 for each HRH line 112T/hr steam flow 224T/hr steam flow 5400C 2000C (max) 6 kg/cm2

Injector water Nos. of LP Bypass valve Capacity of each LP bypass valve Total capacity Design temp. Down stream temp Steam pressure at upstream side 2.10

TURBINE ROLLING & LOADING GUIDE LINES

2.10.1 TURBINE ROLLING GUIDE LINES S. No. 1 If max metal temp of HPT casing is less than 1500C Speed from 0-500 rpm = 5 mts Hold at 500 rpm =10 mts If max metal temp is less than If max metal temp 1500C-3500C is more than 3500C Speed from 0-500 rpm Speed from 0-1200 rpm = 5 mts = 5 mts Hold at 500 rpm =5 mts for Hold at 1200 rpm checking differential expansion, =5 mts for checking differential bearing vib etc. expansion, bearing vib etc.

4 5

Speed from 500 rpm to 1200 rpm @ 50 rpm = 14 mts Hold at 1200 rpm (Soaking)= 20 mts Speed from 1200 rpm to 3000 rpm =5 mts

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

7 8

Raise the speed from 500 rpm to 1200 rpm = 5 mts Hold for 3 mts for checking differential expansion, bearing vib etc. Hold at 3000 rpm Raise the speed from 1200 rpm (Soaking)= 20-25 mts to 3000 rpm = 3 mts without any pause Hold the turbine at this speed (3000 rpm) for checkings. Total = 75 mts Toatl = 26 mts Total = 15 mts

2.10.2 TURBINE LOADING GUIDE LINES S. No. If the max. casing metal temp. is less than 1500C-3500C Load up to 5 to 7 Mw after Load after synch. = 20 to 30 Mw synchronization Steam pr. =70 Steam pr =30 Kg/cm2 0 2 Kg/cm Steam temp. =350 C Steam temp. before IV=3200C Steam temp = 3500C Soaking time =30 mts Soaking time=10mts. If the max. casing metal temp. is less than 1500C If the max. casing metal temp. is more than 3500C Load after synch. 20 to 30 Mw. After taking mills ( one by one) in service load can accordingly be raised to 210 Mw depending upon other conditions.

5 Mw to 30 Mw @ 3 Mw/10 mts in 70 mts. Steam pr before ESV =65 Kg/cm2 Steam Temp =4300C Steam temp before IV =4200C Soaking time = 20 mts ( All the drain valves in extraction lines of LP heaters to be closed.) Raise from 30 Mw to 70 Mw @ 1 Mw/ min in 50 mts. Steam pr before ESV =105 Kg/cm2 Steam temp before ESV=4900C Steam temp before IV=4800C Soaking time= 30 mts Raise from 70 Mw to 210 Mw in

From 30 Mw to 65 Mw in 35 mts. Soaking time =35 mts. Steam pr =90 2 Kg/cm Steam temp =4500C From 60 Mw to 210 Mw = 45 mts Depending upon other conditions

70 mts. @ 2 Mw/ min Pr before ESV= 130 Kg/cm2 Temp before ESV= 5350C Temp before IV= 5350C

SECTION-III

GENERATOR AND AUXLIARIES

3.1 GENERATOR SPECIFICATION 3.1.1 GENERATOR MAIN DATA (at rated H2 pressure and cooling water temperature) i) Maximum continuous KVA Rating ii) Maximum continous KW rating iii) Rated terminal voltage iv) Rated stator current v) Rated Power factor vi) Excitation current at MCR condition vii) Slip ring voltage at MCR condition viii) Rated speed ix) Rated frequency x) Short circuit Ratio xi) Efficiency at MCR condition xii) Negative sequence current capability xiii) Direction of rotation viewed from slip ring end xiv) Phase connection xv) No. of terminals brought out xvi) Type 3.1.2 A. 247000 KVA 210000 KW 15750 V 9050 A 0.85 lag 2600 A 310 V 3000 rpm 50 Hz 0.49 98.49% 122t nots Anticlockwise Double star 9(6neutral & 3 phase) THW-210-2

MAIN PARAMETERS OF THE COOLING MEDIUM HYDROGEN IN STATOR CASING 3. 5 Kg/cm2 +/- 0.2 Kg/cm2 (G) 440C 97% 60% 1.2%

i) Nominal hydrogen pressure ii) Permissible variation iii) Nominal cold gas temperature iv) Hydrogen purity v) Relative humidity hydrogen at normal pressure vi) Oxygen content B. DISTILLATE TO STATOR WINDING

i) Nominal pressure at stator winding inlet 3.5 Kg/cm2 ii) Permissive variation +/- 0.5 Kg/cm2 iii) Cold distillate nominal temperature at stator winding inlet 450C iv) Permissible variation +30C (-100 C with unloading) v) Rated distillate flow 27 m3/Hr vi) Permissible variation +/- 3 m3/Hr vii) Nominal specific resistivity of distillate 200 Kohm-cm viii) Minimum permissible specific resistivity 75 Kohm- cm C. WATER TO GAS COOLER

i) Nominak inlet cooling water temperature ii) Minimum allowable water temperature iii) nominal water flow iv) Maximum permissible cooling water pressure in the gas cooler D. WATER TO STATOR WINDING WATER COOLER

370C 150C 350 m3/Hr 4 Kg/cm2 (G)

i) Nominal consumption of cooling water at temp. of 350C ii) Nominal consumption of cooling water at temp. of 370C iii) ) Nominal consumption of cooling water at temp. of400C 3.1.3 ELECTRICAL DATA

95 m3/Hr 110 m3/Hr 130 m3/Hr

i) Resistance of stator winding per phase at 200C 0.00155 ohm ii) Resistance of rotor winding per phase at 200C 0.0896 ohm iii)Capacitance of the stator winding in hot condition (Calculated value) 0.69 microfarad iv) Line charging capacity 75 MVAR v) Basic impulse insulation level between turns 49,000 (Peak) vi) Basic impulse insulation level with respect to body 49,000(peak) 3.1.4 GENERATOR EXCITATION DATA 2.0 1.6 10 Secs 100 milisecs

i) Ratio of ceiling voltage to the rated excitation voltage ii) Ratio of thre field forcing current to the nominal current iii) Duration of field forcing iv) Response Time 3.1.5 SHORT CIRCUIT CURRENTS

i) Sub transient current on three phase short circuit ii) Transient current on three phase short circuit iii) Steady state current on three phase short circuit 3.1.6 REACTANCES

10 Pu 3.3 Pu 1.4 Pu

i) Direct axis sub transient reactance ( xd) ii) Direct axis transient reactance (xd) iii) Direct axis synchronous reactance (xd) iv) Negative phase sequence reactance (xd2 ) v) Zero sequence reactance (xo) 3.1.7 PERMISSIBLE TEMPERATURE RATINGS

0.214 Pu 0.305 Pu 2.22 Pu 0.26 Pu 0.105

i) Maximum temperature of stator core

1050 C

ii) Maximum temperature of stator winding iii) Max temp of rotor wdg. iv) Permissible temperature rise of rotor winding over cold gas temperature v) Maximum temperature of hot gas vi) Maximum distillate temperature at stator winding outlet vii) Maximum stator winding temperature 3.1.8 TIME CONSTANTS

1050 C 1150 C 710 C 750 C 850 C 750 C

i) Field time constants with open circulated stator winding (Tdo) ii) Field time constants with three phase sort circuit current of stator winding(Td3) iii) ) Field time constants with two phase sort circuit current of stator winding(Td2) iv) Field time constants with one phase sort circuit current of stator winding v) Time constant of the aperiodic component for 3 phase short circuit(Ta3) vi) Time constant of the aperiodic component for 2 phase short circuit(Ta2) vii) Time constant of the aperiodic component for one phase short circuit(Ta1) viii) Time constant of the periodic component of the sub transient current for 3 phase : 2 phase and 1 phase short circuit(Td) 3.1.9 GENERATOR VOLUME AND FILLING QUANTITIES

7 secs 0.96 secs 1.5 secs

1.73secs 0.29 secs 0.24 secs 0.25 secs 0.121 secs

i) Total gas volume of the generator ii) CO2 for expelling hydrogen with unit at standstill iii) CO2 for expelling hydrogen with unit under rolling iv) H2 filling quantity with unit at standstill v) H2 filling quantity with unit rolling vi) Make up Hydrogen required per day 3.1.10 TORQUE, CRITICAL SPEED ETC i) Torque under normal working condition ii) Ratio short circuit torque to full load torque iii) Flywheel moment of the rotor iv) Ist critical speed of the rotor( calculated) v)2nd Critical speed of the rotor (calculated) 3.1.11 OIL CONSUMPTION i) Consumption of oil per generator bearing (Excluding shaft seals) ii) Oil pressure at bearing inlet iii) Consumption of oil in both the shaft seals

56 M3 120 M3 168 M3 300 M3 340 M3 15 M3 (max)

76.32 Tons 8 21.1 T.M2 1370 rpm 3400 rpm

300lit/min 0.3to 0.5 Kg/cm2 160 lit/min

3.1.12 OVERALL DIMENSION AND WEIGHTS i) Overall stator diameter ii) Length of the stator iii) Length of the rotor iv) Diameter of the rotor barrel v) Weight of the heaviest lift (Stator with gas coolers and turnions) vi) Weight of gas cooler vii) weight of rotor viii) Weight of bearings with brush gear along with foundation plates ix) Weight of end terminals x) Weight of end shield xi) Total weight of generator 3960 mm 6580 mm 9770 mm 1075 mm 175,000 Kg 1415 Kg 42,000 Kg 49,500 Kg 85 Kg 2000 Kg 239,000 Kg

3.2 SPECIFICATION OF STATIC EXCITATION SYSTEM UNIT IV & V The Static Excitation Equipment has been designed and manufactured for machine having following technical details A) TYPE OF MACHINE TURBO ___________________________________________________________________________ Sl.No Description Abbreviation Unit Value 1. Rated OUTPUT MW/MVA 210/247 2. Stator voltage Un VAC 15750 3. Stator Current IN AAC 9094 4. Synchronous speed Ns rpm 3000 5. Power factor Cos 0.85LAG 6. System frequency Hz c/s 50 7. Machine reactance: a) Synchronous reactance i) Direct acxis unsaturated xd p.u. 2.225 ii) Quadrature xq p.u. 2.11 b) i) ii) c) i) ii) 8. i) Direct axis transient reactance Saturated xd Unsaturated xdu Direct axis sub-transient reactance Saturated xd Unsaturated xdu Machine Time Constants: Direct axis transient open ckt Tdo

p.u. p.u.

0.234 0.266

p.u. p.u.

0.179 0.214

sec.

ii) iii) iv) 9. 10 i) ii) iii) iv) v) vi) vii) viii) ix) 11. 12. 13. 14. 15. 16. B) 1. 2. 3. 4. 15 5. 6. 7. 8. 9

Direct axis transient close ckt Tdo Sub-transient Td Armature Ta Field winding resistance at 20 oC Field excitation requirement No load field voltage ufo No load field current Ifo Nominal field voltage Ufn Nominal field current Ifn Max. cont. rated field voltage Ufmax Max. cont. rated field current Ifmax Ceiling voltage Ud Ceiling current Id Duration of field forcing -Field test voltage Synchronising slip AVR CT Ratio 10,000/5 AVR PT ratio Ambient Altitude -

sec. sec sec. Rf 20 ohm

0.84 0.03 0.29 0.0878

VDC ADC VDC ADC VDC ADC VDC ADC Sec. Kvrms % AAC/AAC VAC/VAC oC meters -

102 917 310 2600 338 2830 620 4500 10

15750/110 50 1000

SPECIFICATION OF STATIC EXCITATION EQUIPMENT Accuracy of excitation control Range of voltage control in auto Range of voltage control man. Range reactive current compensation Frequency range of operation Total No of parallel THY. Bridges No of redundant THY bridges Protection class Excitation equipment rating a) Voltage b) Current Range of MAVR regulation Station battery supply Equipment not part of DVR supply % + 0.5 % 90 Ugn -110 Ugn % 70 Ufo-110 Ifn % upto + Hz No No IP VDC ADC 47.5-52 4* 1* 31 338 * 2830 *

10 11

-MAX. LEAD-O-MAX-LAG VDC 220

3.3

GENERATOR SEAL OIL SYSTEM

3.3.1 SPECIFICATION i) Type of shaft seals ii) Hydrogen pressure iii) seal oil pressure iv) Inlet seal oil temperature v) Quantity of seal oil/seal vi) Thrust oil pressure vii) Oil required to fill the system 3.3.2 OIL INJECTION i) Pressure of oil at inlet to injector from governing oil system ii) Lub. Oil system iii) Injector nozzle size iv) Oil pressure at injector outlet 3.3.3 SEAL OIL PUMPS 20 Kg/cm2 1 to 1.5 Kg/cm2 8 mm 10 Kg/cm2 Radial flow, double chamber, thrust type 3.5 Kg/cm2 4.1 to 4.4 Kg/cm2 40 0 C 80 lit/min 1 to 2.2 Kg/cm2 4000 liters

A.C. SEAL OIL PUMPS i) Type : ii) Discharge: iii) Head: iv) Speed: Multistage vertical split centrifugal type 3.34 lit/sec 120 MWC 1465 or 2900 rpm

D.C. SEAL OIL PUMPS i) Type : Multistage vertical split centrifugal type ii) Discharge: 4.16 lit/sec iii) Head: 194 MWC iv) Shut off head: Not more than 12% of rated head v) Min seal oil pressure : 5.5 Kg/cm2 below which DC pump will start

v) Shut off Head: Not more than 12% of the rated head vi) Minimum governing : 6.5 Kg/cm2 oil pressure below which AC pump will start MOTOR i) Type: Squirrel cage induction ii) Voltage: 415V+/- 10% iii) Frequency: 3 Phase, 50c/s iv) Rating: 15 KW/20 HP v) Speed: 1465 or 290 rpm vi) Rated Current: 27 Amp.

MOTOR i) Type: Compound wound self excited type ii) Rating: 26 KW iii) Voltage: 220VDC+10% & -20% iv) Speed: 1800 or 2900 rpm v) Rated current: 139 Amp. vi) Operation Speed: 70-80% of rated speed

3.3.4 SEAL OIL COOLER i) No. of coolers ii) Inlet temperature of oil iii) Temperaure of oil at cooler outlet iv) Quantity of oil to be cooled v) Inlet pressure of oil to cooler vi) No of cooling tubes vii) Material & size of cooling tubes viii) Pressure drop in the oil cooler ix) Inlet cooling water temperature x) Outlet cooling water temperature xi) Cooling water designed pressure xii) Cooling water quantity required xiii) Cooling water quality 3.3.5 PRESSURE REGULATOR Thrust oil regulator Plunger type 6 to 9 Kg/cm2 1.0 to 2.2 kg/cm2 0.03 to 0.05 mm 2 Nos. 500C 400C 160 lit/min 10 Kg/cm2 420 15*1 mm, copper 5 mwc 330C 37.500C 5 Kg/cm2 (Max) 95 m3/Hr Clarified water

Differential pressure regulator i) Type: Plunger type ii) Inlet oil pressure: 6 to 9 Kg/cm2 iii) Differential pressure maintained: 0.6 to 0.9 Kg/cm2 iv) Clearance between plunger and body : 0.03 mm 3.4

STATOR WATER COOLING SYSTEM

A. STATOR WATER COOLING PUMP PUMP i) ii) iii) iv) Type: Horizontal spindle, end suction directly driven, centrifugal type Discharge: 40 m3/Hr Head: 45 mwc Make: Kirloskar Brothers Limited

MOTOR i) ii) iii) iv) v) vi) Type: Squirrel cage induction type Rating: 9.3 Kw Rated voltage: 415V+/-10V, 3 phase,50 c/s Rated current: 17 amp. Speed: 2900rpm Make: Kirloskar Electric

B. STATOR WATER COOLERS i) Nominal temperature of primary water to be cooled ii) Nominal temperature of cooled primary water iii)Nominal tempearure of cooling D.M.water at inlet on the secondary side iv)Nominal temperature of cooling water at the outlet on the secondary side v) Quantity of D.M. Water on the secondary side vi) Secondary side D.M.water inlet pressure vii) Tube dimensions viii) Length of cooling tubes ix) No. of tubes per cooler x)Tube material C. EXPANSION TANK i) Material: ii) Tank volume iii) Volume inside the tank iv) Water level under normal operating conditions( from the bottom of the tank) v) High water level which gives signal ( from the bottom of the tank) vi) Low/ emergency water level requiring tripping of TG ( from the bottom of the tank) D. WATER JET EJECTOR i) Quality of water ii) Quantity of water required iii) Pressure iv) Temperature 3.5 3.5.1 Clarified 7 to 10m3/Hr 2 Kg/cm2 330C Stainless Steel 2.1 m3 250 to 300 mmof Hg 850 mm 1200mm 500mm 650C 400C 330C 36.50C 95m3/Hr 5 Kg/cm2(max) 15*1mm 1720mm 420 Copper

GENERTATOR & UAT TRANSFORMERS

GENERTATOR TRANSFORMER (T4)

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

Current (HV) Current (LV) Phase HV/LV Impedance Frequency Vector Group Connection HV/LV Max temp rise in oil Temp rise in winding Weight of core and winding Weight of oil Total weight Quantity of oil Tap BUSHING CT Ratio Continuous current Accuracy class Minimum knee point voltage Max exciting current at knee point voltage Max secondary wdg. Resistance at 75 Deg C 3.5.2 GENERTATOR TRANSFORMER (T5)

587/411/293 A 8798/6158/4399 A 3/3 15.55 % 50 Hz Yd1 Star / Delta 45 Deg C 55 / 60 Deg C 133000 Kg 43100 Kg 238900 Kg 42500 liter Off load

600 / 1 Amp 800 Amp P.S. 1000 Volt 0.14 Amp. 3 Ohm

TRANSFORMER RATING Make Type of cooling MVA Voltage (HV) Voltage (LV) Current (HV) Current (LV) Phase HV/LV Impedance Frequency Vector Group Connection HV/LV Max temp rise in oil Temp rise in winding Weight of core and winding Weight of oil Total weight Quantity of oil M/S BHEL, Bhopal OFB/OB/ON 240/168/120 MVA 236 KV 15.75 KV 587/411/293 A 8798/6158/4399 A 3/3 14.75 % 50 Hz Yd1 Star / Delta 45 Deg C 55 / 60 Deg C 138800 Kg 37850 Kg 234000 Kg 49540 liter

Tap BUSHING CT Ratio Continuous current Accuracy class Minimum knee point voltage Max exciting current at knee point voltage Max secondary wdg. Resistance at 75 Deg C

Off load

600 / 1 Amp 800 Amp P.S. 1000 Volt 0.14 Amp. 3 Ohm

3.5.3 UNIT AUXLIARY TRANSFORMERS (Unit 4 & 5) RATING No. Make Capacity Voltage HV / LV Current HV / LV No. of phases HV / LV Type of cooling Vector Group Impedance Impedance Frequency Tap Changer Max rise in oil temp above ambient Weight of core and winding Weight of Oil Total weight 2 / Unit EMCO, Mumbai 12500 KVA 15.75 / 6,9 KV 458.2 / 1045.8 Amp 3/3 ON Dd0 7.877/7.57 (UAT4A/4B) 7.762/7.725 (UAT 5A/5B) 50 Hz. On Load 45 Deg C 12000 Kg 6430 Kg 27100 Kg

SECTION IV

PROTECTION AND INTERLOCK

4.1 Sl.No. 1 2 3 4 5 6 DESCRIPTION Drum level low Drum level high Furnace pressure high Furnace vacuum high Loss of 220 V D.C.supply of FSSS Less thanfire ball and loss of 110V D.C. Supply Loss of all fuel trip On flame failure Air flow less than 30% Both ID fan tripped Both FD fans tripped Both PBS on FSSS pressed Reheater protection( This protection will act when there is no flow through R.H. & furnace outlet temperature more than 5380C) Condenser vacuum H.P. heater level very high All BFPs tripped T.G.babbit metal temperature Turbine rotor axial shift Loss of voltage on unit auxiliary bus bar Emergency governor overspeed tripping Emergency governor backup Turbine lub oil pressure

UNIT PROTECTIONS ANNUNCIAT ION -100 mm +100 mm +25 mmwcl -25 mmwcl TRIPPING VALUE -175 mm +175 mm +175 mmwcl -175 mmwcl TIME DELAY More than 2 secs

7 8 9 10 11 12 13

14 15 16 17 18 19 20 21 22

650 mm Hg 750 mm 750C

540 mm Hg 4250 mm 800C +1.2 mm -1.7 mm 50% of rated value 11% and 12% overspeed 14% overspeed 15 secs

5 to 10 secs

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

0.3 kg/cm2

23 24 25

M.S. Temperature low Turbine shut down switch Manual tripping(UCB) through push buttons

5200C -

4500C -

4.2

PARTIAL LOAD CONDITION

1. One if two ID fans trips. 2. One if two FD fans trips. 3. One if two PA fans trips 4. One of the two BFPs trips and standby does not come up in more than 60 secs. 5. One of the two CW pump trips. 6. One of the two condensate pump trips and standby does not come up in more than 60 secs. When this relay acts following sequential actions take place: (a) Turbine load is reduced. (b) One of the PA fans trips (c) FSSS reduce boiler output

4.3

PROTECTION & INTERLOCK OF THE UNIT AUXLIARIES

4.3.1 BOILER AUXLIARIES Sl. No. 1 Descripti on ID Fans Permissives Ineterlocks Protections

a. Bearing temperature a. Opening of a. Regulating too high outlet damper vane FG-10 in b. Motor bearing FG-12 after a minimum temperature too high time delay of 60 position c. Lub. Oil pressure for secs. b. Outlet damper motor bearing low FG-12 closed b. Connecting the with T.D. of 0-3 mts. regulating vane c. Fan/fan motor d. Both A.H. A&B off ( (FG-10) to bearing Provided deregulator temperature is interlocking in inter not very high c. Opening the locked position) interconnecting damper FG-5& FG-18 d. Closing the inlet damper FG-17& outlet

e.

f.

FD fans

a. ID fan is started b. Control oil pressure is adequate(8 kg/cm2) c. Fan impellar blades are in min. position.(BA1) d. Outlet damper (BA-3) is in closed position. e. FD fan bearing temp. is not high. f. FD fan motor bearing temp. is not high. Establish electric supply to A.H. motor. Take out the push button of the motor.

a.

b.

c.

d.

e.

damper FG-13 of other fan Bringing the other fan inlet vane to minimum position Permiisive to start selected FD fan Opening the outlet damper BA-3 with T.D. of 60 secs. Connecting the impellar blade (BA-1) control drive to regulator. Opening the inter connecting damper BA-2. Closing the outlet damper of other fan. Bringing the impeller blades of other fan to min. position.

a. Bearing temp. too high b. Motor bearing temp. too high c. Both ID fans trips d. If lub oil pressure continues to be below a preset value for 30 mts. e. If ID fan A or B trips and FD is selected in combination with ID fan.

Air Heater

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

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

Ignitor fan

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

Scanner fan

Primary air fan

a. The scanner duct to furnace differential pressure is less than 115 mmwcl. b. When start push button is pressed. a. Purge complete & NO boiler trip condition is present. b. Regulating vanes BA-17 in min. position. c. Outlet damper BA-19 in closed position. d. Lub oil pressure is adequate around 2 kg/cm2 e. PA fan bearing temp not very high.

BA-12, 14,22&24. Tripping of corresponding ID fans. Discharge damper will open & damper of standby fan closes. The fan will start automatically when any ignitor or oil elevation is initiated. Discharge damper will open & damper of standby fan closes with T.D. of 5 secs.

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

a. Fan discharge damper BA-19 opens with T.D. of 60 secs. b. Fan inlet regulating inlet vane BA-17 is connected to regulator. c. Inter connecting damper BA-21 opens. d. Regulating vane of other PA fan closes to min. position(BA18) e. Outlet damper of other PA fan closes.(BA-20) f. Load is reduced by tripping bottom mills

a. Fan bearing temp. too high. b. PA fan motor bearing temp. too high. c. Lub oil pressure to motor bearing low after a time delay of 0-5mts. d. P.A. fan shall trip when one of the two FD fans trip and this fan is selected. e. Motor protection operated.

Seal air fan

One PA fan is running

Pulverise r

a. Discharge valve are open. b. Seal air valve is open. c. Cold air shut off gate is open. d. Feeder inlet gates are open(Check only) e. Tram iron hopper valve is open f. Primary air pressure is aduquate. g. D.C.power to FSSS is available. h. Pulveriser outlet temp. is less than 940C.

leaving top three mills in service when one PA fan is running. g. When both PA fan trips all running mills will trip. h. When one PA fan is running partial load relay is energised. Manually fan can be tripped only if all the mills are stopped. Only one seal air fan can be started at time. a. Permissive to open the hot air gate. b. Permissive to start R.C.feeder. c. Permissive for regulators impulse to act on hot air dampers.

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

a. Boiler trip condition is present. b. Discharge valve are closed. c. Loss of elevation A.C. for more than 2 secs. d. Support ignition energy is removed within 3 mts of feeder starting. e. PA fan tripping. f. Low primary air pressure for more than 5 secs. g. Motor protection operates. h. PA pressure very low will trip all mill instantaneously.

Pulverise r A*

Raw coal feeder

i. Burner tilt is horizontal and air flow is less than 40%.( This is applicable only to the first mill to be started.) j. Pulveriser ignition energy is available. a) A min of 3 out of 4 elevation AB light oil(or heavy oil) noozle valve proven open. b) Boiler loading is greater than 30% and pulveriser B is in service at greater than 50% loading. 1) No boiler trip 1) To release speed control to condition auto after 50 persists secs. 2) Elevation 2) To modulate D.C. is fuel air dampers available according to 3) Elevation feeder speed A.C. is after 50 secs. available 4) Ignition energy is available. 5) Pulverisor is on 6) Hot air gate is open 7) No stop signal 8) Fuel damper closed

R.C.Feeder will trip if: 1) Boiler trips 2) Elevation D.C. fails after2 secs time dealy 3) Elevation A.C. fails 4) Ignition energy disappears beforev 180 secs from the start of the feeder. 5) Pulverisers trips 6) Loss of coal flow and pulveriser amp. Low( this impulse will act only after 5 secs from feeder start. When R.C. Feeders trip A) To close hot air gate when either the pulverisar amps is

above maximum set point. B) Pulveriser bowl differnencial pressure is high an impulse will be given to bring R.C. Feeders speed to minimum. ID fan motor lubricatio n oil system Pump A will start automatically if pump B trips provided A/M switch is in auto position. Pump A will start automatically with a time delay of 60 secs if oil pressure falls below a set value and pump B is worki9ng provided A/M switch in auto position. Whenever the lub oil pressure at entry to ID fan motor bearing falls below a set value impulse shall be given after a time of 0-3 mts to trip the ID fan. Pump A will start automatically if pump B trips provided A/M switch is in auto position. Pump A will start automatically with a time delay of 0-60 secs if oil 3)

FD fan lub oil system

4)

pressure below a set value and pump B is working provided A/M switch is in auto position. Pump B will start automatically after 1 secs if pump A trips provided A/M switch is in auto position. 11 PA fan Pump A will start automatically if pump B trips provided A/M switch is in auto position . Pump B will start on auto with time a delay of 1 secs if pump A trips provided A/M switch is in auto position. Furnace temp If furnace temp 12 Furnace probe shall be probe is inside the temp prohibited from furnace and temp. probe being advanced exceeds 5400C it further into the will be retracted furnace if furnace back automatically temp sensed by it is more than 5400C *For pulveriser B to F all conditions regarding their permissive to start, interlock and protection will be similar as for pulveriser A., except the adjacent elevation nozzle valves proven open or adjacent pulveriser should have loading more than 50%. 4.3.2 TURBINE AUXLIARIES Sl. No. 1 Description Boiler feed pump Permissive 1. Lubricating oil pressure at bearing Interlock Protections

1. If lub oil pressure is 1.Main BFP will trip if 2 below 1 kg/cm A.O.P. will lub oil pressure is below 0.5 kg/cm2 come.

Circulating water pump

should be 1 kg/cm2 2. Suction pressure at suction of booster pump should be more than 3 kg/cm2 in hot start up. 3. If suction pressure at suction at booster pump is less than 3 kg/cm2 for more than 20 secs. Pump will trip. 4. Suction valve (BF1/2/3) is fully open. 5. Recirculation valve (BF22/23/24) is fully closed. 1. Correspondin g condenser outlet valve (CW1&2) is fully open.

2. If BFP tripped its A.O.P. will come in auto as soon as lub oil pressure drops 1 kg/cm2 . When any BFP put on standby its A.O.P. will come. 3. A.O.P.will trip after 10 secs when BFP lub oil pressure goes to 4 kg/cm2. 4. At 200T/hr discharge flow pump recirculation valve should open & at 220 T/hr it should get closed. 5. Standby BFP will come on auto as soon as either working BFP trips or common header pressure at discharge side is low.

2.Pump will trip if its motor bearing temperature is more than 800C 3.Pump will trip if discharge flow is more than 500 T/hr. 4. Pump will trip if water temperature at delivery of BFP is more than1750C 5.Pump will trip if discharge pressure is less than kg/cm2 for 12 secs. 6.Pump will trip if suction pressure of main BFP is below 6 kg/cm2 for 20secs, though it will start. 7.On turbine trip one BFP will trip if two are in operation.

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

CW boosr\ter pump(Gas cooler booster

1. At least one CW pump should be inservice.

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

1. On closing of discharge valve CW-1&2 pump will trip. 2. CW pump will trip if its motor bearing temperature is more than 800C 3. When both CW pumps trip CW booster pump trips. 1. CW booster pump will trip if both CW pump trip. 2. Pump will trip if motor current goes

pump)

Condensate pump

A.C. Lube oil pump

3.If discharge pressure falls below 2 kg/cm2 standby pump will start. 1. Reserve pump will start as soon as running pump trips. 2. Reserve pump will start when common discharge header pressure falls below 10 kg/cm2. 3. If all condensate pump trips solenoid valve DM105 on DM water sealing line will open for providing condensate pump sealing by DM water. 4. As soon as any one condensate pumps starts DM-105 gets closed. 5.If one of the two condensate pump trips & standby does not come in auto within 60 secs, partial load relay should be energized. A.C lube oil pump will come in auto if bearing oil pressure goes down to 0.6 kg/cm2 D.C. lube oil pump will come in auto if bearing oil pressure goes down to 0.5 kg/cm2

beyond 100 Amp.

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

Barring gear Barring gear will start only if lub oil pressure is more than 0.3 kg/cm2 Barring gear will engage only if rotor is in engage condition.

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

Drip pump

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

Heater 6

1. HD-3 discharge valve will be fully closed if no drip is running but will start opening as soon as drip pump starts. 2. Reserve drip pump will start as soon as running drip pump trips or discharge pressure of working pump falls below a preset value for 10 secs. 1.If HPH-6 extraction pressure falls tp preset value its drip valve cascade to deaerator & HD-29(to HPH-5) will close & HD30 will open. 2.If HPH-6 extraction steam pressure is above the preset value HD-29 (to HPH-5) will open & HD30 will close. 1.If HPH-5 extraction steam pressure falls below a preset value its drain will cascade to LPH-4 i.e.HD21(to LPH-4) will open & HD-31(to D/A) will close. 2. if HPH-5 extraction steam pressure is above the preset value its drain cascade to deaerator i.e. HD-31(to D/A) will open & HD-21(to LPH-4) will close. 3.If drip level in any HPH rises up to 750 mm solenoid valve (MC101&MC102) for NRV of extraction lines will open. 4. Back up feed water bypass valve (BF-40) will open. 5. After full opening of

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

10

HP Heater 5

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

11

Deaerator

12

H.P.& L.P. Bypass system

BF-40, inlet and outlet valve BF-38 & BF39 will close. 6. Steam extraction valve Es-3, ES-4, ES-5 to HPH will close. Deaerator drain valve DW136 will open & close when D/a level goes higher & lower than preset value respectively. 1. Generator 1. When turbine is running circuit breaker or not running & HP bypass control is on close signal should not be manual the memory 1.05 will get closing signal there. through AND logic, if 2.Condenser valve position is less than vacuum too low (600 mm 2%. 2. If turbine is not running of Hg and control is on Auto the column) signal should memory 1.05 will get closing signal through not be there. AND logic if valve position is less than 2%. 2. If turbine is not running and control is on Auto then is no closing signal to memory 1.05 independent of valve position. 4. If temp. After outlet of HP&LP bypass station becomes too high the closing signal to HP bypass valve forwarded &pressure loop changes from auto to manual. 5.If any of the bypass valve are open more than 2% a signal is available through OR logic to indicate that valve is open & same signal is used to change the control of valve from manual to Auto if previously it was on

13

Extraction Auxiliary steam to D/A through ES-7,ES6&As-57

14

15

16

17

Chamber heating valve As43& 44 verses spindle leak off valve I.S.P.U.G.(I nitial steam pressure unloading gear) Extraction NRV on extraction lines Load limiter

manual. 6.When HP bypass valve is less than 2% open a tight closure signal is given to valve 03.01 when it is not in operation so that spray water temp valve02.01 is not subjected to high water pressure. 1. When extraction steam pressure build up to the preset value (9 kg/cm2) for 3rd extraction (Es-7) will open & Es-6 & AS-57 will close. 2.When set value of extraction pressure is more than 3rd extraction set value but less than 2nd extraction then ES-6 will open & ES7 & AS-57 will close. 3. When extraction pressure of 3rd & 2nd extraction is less than the set value ES-6 & ES-7 will close & AS-57 will open. 4. On turbine tripEs-6 & ES-7 will close &AS-57 will open. 1. If As-43 is open then As-47 will close. 2. If As-44 is open then As-48 will close.

M/C load reduced when steam pressure drops to 117 kg/cm2 & fully unloaded at 91 ata. NRV closes when ESV closes i.e. solenoid valve MC-53&54 will open. Prevent further opening of

18

A.C. Seal oil pump D.C. Seal oil pump

19

C.V. Beyond set point but does not prevent closing of C.V. When seal oil pressure drops to 6.5 kg/cm2 A.C. seal oil pump will start. When seal oil header pressure drops to 5.5 kg/cm2 D.C. seal oil pump will start.

SECTION V

PROTECTION RELAYS SETTINGS

5.1

RECOMMENDED SETTINS OF GENERATOR, GT & UATs

5.1.1 RECOMMENDED RELAY SETTING OF GENERATOR, GENERATOR TRANSFORMER AND UAT (UNIT 4)

Sr. Relay No. 1. Generator Differential (87 G) 2. Generator Inter Turn Fault (87 TG) 3. Over All Differential (87 GT).

Relay Type CAG 34 CAG 14 DTH32

CTR / PTR 10000/5 Amp 3000 / 5 Amp GEN &UAT10000/5 Bushing & Switchyard 600/1 ICT 1.0 / 2.6 A 600/1 600/1 15750/110 V

Range 0.25 - 1 A 1- 4A 15% of 5 A Bias 15,30 & 45 % High set 1000 % Fixed 0.1-0.4 A 0.2-0.4 A 110 140 % 1.0 to 10 sec

Setting 0.25 Amp 4.0 Amp 15 % of 5 Amp. 30 % 1000 % Fixed PS-0.2 A, TMS-0.4 0.2 Amp. 121 Volt 2.0 Sec.

4. GT Back up Earth fault (51 NT) 5. GT Restricted E/F (87 NT) 6. Gen Over Voltage (59 G)

CDG 11 CAG 14 VAGM 22 VTT 11 CTU 12 YCG 15 VTT11 VTT11 CAG 19 VTT 11 CTN 31 VTT 11 CAG 37 VAT 11 VTT 11 DTH31

7. Gen Over Load Alarm (51 G1) 8. Gen Back up Impedance (21 G) 9. UAT Over load alarm (51 T4A & T4B) 10. Generator Negative Phase Sequence (46) 11. UAT B/U O/C (50 T4A & 50 T4B) 12. UAT Differential (87 T4A & T4B)

10000/5 A 10000/5 A, 15750/110 V 600/5A 10000/5A

600/5 A

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

102 % 2.5 Sec K1=6 K2 = 1 0.5 5 Sec St-I 2.5 Sec St-II- 3Sec 1 10 Sec 2.5-5 A 4.375 A 1 10 Sec 4.0 Sec A - 70% T 15% 60 Sec 6 60 Sec 12 A 10-40A 0.5 Sec 0.5 3 Sec 0.5 Sec 0.5 3 Sec Current Current -15% 15% of 5A Bias=30% Bias High Set = 15,30,45% 1000 % High Set = Fixed 1000 %

50 200 % 05 5 Sec

Sr. Relay No. 13. Stator Earth Fault (64G) 14. 1ST Rotor E/F (64F1) 15. 2ND Rotor E/F (64 F2) 16. Generator Transformer Over Fluxing (99) 17. Low Forward Power ( 37) 18. Reverse Power ( 32) 2/ 32 A 2/32 B 19. Anti Motoring Protection (2/32 YA & 2/32YT) 20. Generator Loss of Field (40)

Relay Type VDG14 VME VTT 11 CAEM GTT21

CTR / PTR 15750/110 V 15750/110 V

Range V=5.4-20 V 4 mA 0.5 5 Sec 1.1 mA K=1-1.25 T=12-120 Sec 0.5 % 1 - 10 Sec 0.5 % 1 10 Sec 12 - 120 Sec 0.5 5 Sec 6 60 Sec

Setting PS=12.5V TMS=0.3 4 mA 2.0 Sec 1.1 mA K=1.125 T=15 Sec 0.5% 2 Sec 0.5% 2 Sec 120 Sec 5 Sec 10 Sec K1=0.845, K2=3.5, K3=0.5, K4=3, K5=18.6 2Sec 10Sec PS-80.5 V 5.2 Amp 75 Deg elect Offset= 3.156 Ohm, T=52.5mSec Phase Angle=10%, Voltge=6%, F=0.11%

WCD 11 15750/110 V 10000/5A VTT 11 15750/110 V WCD 11 10000/5A VTT 11 VTT 11 VAT11 VTT 11 YCGF 11 15750/110 V 10000/5A

21. Generator Under Voltage (27) 22. Generator Pole Slipping (98)

VTT 11 VTT 11 VAGM 22 ZTO 11

15750/110 V 15750/110 V 10000/5A

1-10 Sec 5-25 Sec 44 88 Volt

23. Check Synchronizing Relay (25)

SKE 11

5.1.2 RECOMMENDED RELAY SETTING OF GENERATOR, GENERATOR TRANSFORMER AND UAT (UNIT 5)

Sr. Relay No. 1. Generator Differential (87 G) 2. Generator Inter Turn Fault (87 TG) 3. Over All Differential (87 GT).

Relay Type CAG 34 CAG 14 DTH32

CTR / PTR 10000/5 Amp 3000 / 5 Amp GEN &UAT10000/5 Bushing & Switchyard 600/1 ICT 1.0 / 2.6 A 600/1 600/1 15750/110 V

Range 0.25 - 1 A 1- 4A 15% of 5 A Bias 15,30 & 45 % High set 1000 % Fixed 0.1-0.4 A 0.2-0.4 A 105 110 % 0.5-5 Sec

Setting 0.25 Amp 4.0 Amp 15 % of 5 Amp. 30 % 1000 % Fixed PS-0.2 A, TMS-0.4 0.2 Amp. V=110 % 2 Sec

4. GT Back up Earth fault (51 NT) 5. GT Restricted E/F (87 NT) 6. Gen Over Voltage (59 G)

CDG 11 CAG 14 VTU 21

7. Gen Over Load Alarm (51 G1) 8. Gen Back up Impedance (21 G) 9. UAT Over load alarm (51 T5A & T5B) 10. Generator Negative Phase Sequence (46) 11. UAT B/U O/C (50 T5A & 50 T5B) 12. UAT Differential (87 T5A & T5B)

CTU 12 YCG 15 VTT11 VTT11 CTU12 CTN 31 VTT 11 CAG 37 VAT 11 VTT 11 DTH31

10000/5 A 10000/5 A, 15750/110 V 600/5A 10000/5A

600/5 A

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

4.75 A 5 Sec K1=6 K2 = 1 0.5 5 Sec St-I 2.5 Sec St-II- 3Sec 1 10 Sec 2.5-10 A 4A 1 10 Sec 5 Sec A - 70% T 15% 60 Sec 6 60 Sec 12 A 10-40A 0.3 Sec 0.5 3 Sec 0.3 Sec 0.5 3 Sec Current Current -15% 15% of 5A Bias=30% Bias High Set = 15,30,45% 1000 % High Set = Fixed 1000 %

50 200 % 05 5 Sec

Sr. Relay No. 13. Stator Earth Fault (64G 1) 14. 100 % Stator E/F (64 G2) 15. 1ST Rotor E/F (64F1) 16. 2ND Rotor E/F (64 F2) 17. Generator Transformer Over Fluxing (99) 18. Low Forward Power ( 37) 19. Reverse Power ( 32) 2/ 32 20. Anti Motoring Protection (2/32 YA & 2/32YT) 21. Generator Loss of Field (40)

Relay Type VDG14 RAGEA

CTR / PTR 15750/110 V

Range V=5.4-20 V

Setting PS=5.4V TMS=0.3 T(119)-1 Sec, T(149)5 Sec 1.1 mA 2.0 Sec 1.1 mA K=1.1 T=12 Sec 0.5% 2 Sec 0.5% 2 Sec 5 Sec 60 Sec K1=0.845, K2=3.5, K3=0.5, K4=3, K5=18.6 2Sec 10Sec PS-80.5 V 5.2 Amp 75 Deg elect Offset= 3.156 Ohm, T=52.5mSec Phase Angle=10%, Voltge=6%, F=0.11%

VAEM VTT 11 CAEM GTT21

15750/110 V

WCD 11 15750/110 V 10000/5A VTT 11 15750/110 V WCD 11 10000/5A VTT 11 VAT11 VTT 11 YCGF 11 15750/110 V 10000/5A

1.1 mA 0.5 5 Sec 1.1 mA K=1-1.25 T=12-120 Sec 0.5 % 1 - 10 Sec 0.5 % 1 10 Sec 1-10 Sec 12-120 Sec

22. Generator Under Voltage (27) 23. Generator Pole Slipping (98)

VTT 11 VTT 11 VAGM 22 ZTO 11

15750/110 V 15750/110 V 10000/5A

1-10 Sec 5-25 Sec 44 88 Volt

24. Check Synchronizing Relay (25)

SKE 11

5.2

RECOMMENDED SETTINGS OF 6.6 KV SECTIONS

5.2.1 RECOMMENDED RELAY SETTING OF 6.6 KV STATION SECTION STAGE - II Sr. Name of Feeder Relay Type CTR Range No. 2000 / 5 10 40 Amp CAG 37 1. Main Incoming Supply from A 0.5 5 Sec VTT 11 Station T/R 3 (3SA1 & U/V 3SB1) 2. Main Supply to CSA from 3SA at 3SA 3. Reserve Supply to CSA from 3SB at 3SB 4. Main Supply to CT3 (Cooling Tower) from 3SA at 3SA 5. Main Supply to CT3 at CT3 CAG 37 VTT 11 U/V CAG 37 VTT 11 U/V CAG 37 VTT 11 U/V CAG 37 VTT 11 U/V CAG 37 VTT 11 U/V CAG 37 VTT 11 U/V CAG 37 VTT 11 U/V CAG 37 VTT 11 U/V CAG 37 VTT 11 800/5 A 10 40 A 0.5 5 sec 10 40 A 0.5 5 sec 10 40 A 0.5 5 sec 10 40 A 0.5 5 sec

Setting 13.7 A 1.1 Sec 20%,1.5 Sec 10 Amp 0.8 Sec No Trip 10 Amp 0.8 Sec No Trip 10.8 A 0.8 Sec No Trip 10.8 A 0.5 Sec 20%,1.5 Sec 12 A 0.5 Sec 20%,1.5 Sec 12 A 0.5 Sec 20%,1.5 Sec 10 A 0.5 Sec 20%,1.5 Sec 10 A 0.5 Sec 20%,1.5 Sec 22 A 0.8 Sec

800/5 A

800/5 A

800/5 A

6. Main Supply to CSA at CSA

400/5 A

10 40 A 0.5 5 sec

7. Reserve Supply to CSA at CSA

400/5 A

10 40 A 0.5 5 sec

8. Main Supply to WCA from CSA at WCA

400/5 A

10 40 A 0.5 5 sec

9. Reserve Supply to WCA from CSA at WCA

400/5 A

10 40 A 0.5 5 sec

10. Reserve Supply feeder for Unit bus 4A,4B,5A & 5B from 3SA & 3SB (3SA2 & 3SB2) 11. Interconnecting feeder between Stage I & Stage II (4A01 & 4B01)

1250/5 A

10 40 A 0.5 5 sec

CAG 37 VTT 11

1250/5 A

10 40 A 0.5 5 sec

10 A 0.8 Sec

Sr. Name of Feeder No. 12. Station Auxiliary T/R 1 &2 (TS3 & TS4 / 1600 KVA) 13. Stand By T/R 1 &2 (TR3 & TR4 / 1600 KVA) 14. Stand By T/R (TR5 / 1000 KVA) 15. Control Structure Transformer (1000 KVA) 16. Lighting Transformer (TL3 / 1000 KVA) 17. Cooling Tower Transformer (1600 KVA) 18. Coal Handling Transformer (TC3 / 1000 KVA) 19. Water Treatment Plant T/R (1000 KVA) 20. Clarifier Water Transformer (630 KVA) 21. CT Pumps (930 KW) Full load current = 111 A Starting current = 577.2 A Starting time = 1.67/4.76 Sec 22. HP Flush Water Pumps (187 KW) Full load current = 23 A Starting current = 115 A Starting time = 2.66/5.25 Sec 23. Clarified Water Pumps (280 KW) Full load current = 111 A Starting current = 577.2 A Starting time = 1.67/4.76 Sec

Relay Type CAG 37 VTT 11 CAG 37 CAG 37 VTT 11 CAG 37 CAG 37 VTT 11 CAG 37 CAG 37 VTT 11 CAG 37 CAG 37 VTT 11 CAG 37 CAG 37 VTT 11 CAG 37 CAG 37 VTT 11 CAG 37 CAG 37 VTT 11 CAG 37 CAG 37 VTT 11 CAG 37 CDGM 62

CTR 200 / 5 A

Range 10 40 Amp 0.5 5 Sec 25 100 A 10 40 Amp 0.5 5 Sec 25 100 A 10 40 Amp 0.5 5 Sec 25 100 A 10 40 Amp 0.5 5 Sec 25 100 A 10 40 Amp 0.5 5 Sec 25 100 A 10 40 Amp 0.5 5 Sec 25 100 A 10 40 Amp 0.5 5 Sec 25 100 A 10 40 Amp 0.5 5 Sec 25 100 A 10 40 Amp 0.5 5 Sec 25 100 A 3.6 6.2 A 25 100 A

Setting 18.7 A 0.5 Sec 75 A 18.7 A 0.5 Sec 75.7 A 15.5 A 0.5 Sec 66.7 A 15.5 A 0.5 Sec 67.4 A 15.5 A 0.5 Sec 68 A 18.7 A 0.5 Sec 77 A 15.5 A 0.5 Sec 66.7 A 15.5 A 0.5 Sec 66.7 A 14.7 A 0.5 Sec 65 A PS = 3.95 TMS=0.2 30 A 70%, 0.5 Sec PS = 3.95 TMS = 0.25 30 A 70%, 0.5 Sec PS = 4.35 TMS=0.5 30 A 70%, 0.5 Sec

200 / 5 A

150 / 5 A

150 / 5 A

150 / 5 A

200 / 5 A

150 / 5 A

150 / 5 A

100 / 5 A

150/5 A

U/V CDGM 62 30/5 A 3.6 6.2 A 25 100 A U/V

CDGM 62

40/5 A

3.6 6.2 A 25 100 A

U/V

Sr. Name of Feeder No. 24. Clarified Raw Water Pumps (280 KW) Full load current = 31.5 A Starting current = 173.5 A Starting time = 2.0 Sec 25. Boiler Fill Pumps (250 HP) Full load current = 20.4 A Starting current = 133 A Starting time = 2.2 Sec

Relay Type CDGM 62

CTR 40/5 A

Range 3.6 6.2 A 25 100 A

Setting PS =3.95 TMS=0.2 37.5 A 70%, 0.5 Sec PS =4.35 TMS=0.2 42.5 A 70%, 0.5 Sec

U/V CDGM 62 30/5 A 3.6 6.2 A 25 100 A U/V

5.2.2

RECOMMENDED RELAY SETTING OF 6.6 KV UNIT SECTION STAGE - II (Unit - 4) Relay Type CAG 37 VTT 11 CAG 37 CAG 37 VTT 11 CAG 37 CAG 37 VTT 11 CDGM 62 U/V CDGM 62 U/V CDGM 62 CTU 12 U/V CDGM 62 U/V 150 / 5 A a. 6.2 25 100 A CTR 150 / 5 A Range Setting 18.7 A 0.5 Sec 68 Amp 18.7 A 0.5 Sec 75.7 A 22 Amp 05 Sec PS = 3.6 TMS=0.35 30 Amp No Trip PS = 3.95 TMS=0.2 40 Amp 70%,0.5 Sec PS = 4.35 TMS=1.0 40 A 9A,15 Sec 50%,9 Sec PS = 4.35 TMS=0.25 34 A 70%,0.5 Sec

Sr. Name of Feeder No. 1. Unit Auxiliary T/R (T4C & T4D / 1000 KVA) 2. EP Transformer (1600 KVA) 3. Reserve Incomer from ( For Bus 4A & 4B) 4. ID FAN A & B (1300 KW) Full Load Current = 138 A Starting Current = 717.6 A Starting Time = 7/10 Sec 5. Bowl Mills A,B,C,D,E & F (335 KW) Full Load Current = 41.7 A Starting Current =270 A Starting Time = 4.76 Sec 6. PA Fans A & B (1250 KW) Full Load Current = 132.5 A Starting Current =795 A Starting Time = 24.5/33 Sec 7. SOP (200 KW) Full Load Current = 21.8 A Starting Current = 128.4 A Starting Time = 3/5 Sec

10 40 A 0.5 5 sec 25 100 A 200 / 5 A 10 40 A 0.5 5 sec 25 100 A 1250 / 5 A 10 40 Amp 0.5 5 Sec 200 / 5 A 3.6 to 6.2 A 25 100 A 50 / 5 A 3.6 6.2 25 100 A

30 / 5 A

3.6 6.2 25 100 A

Sr. Name of Feeder No. 8. FD Fans A & B (800 KW) Full Load Current = 84.9 A Starting Current = 509.4 A Starting Time = 5.5/8 Sec 9. C W Pumps A & B (950 HP) Full Load Current = 82.8 A Starting Current = 422 A Starting Time = 1.45/2.1 Sec 10. CEP Pumps A,B,C (220 KW) Full Load Current = 25 A Starting Current = 135 A Starting Time = 2.5 Sec 11. BFP A,B & C (4000 KW) Full Load Current = 421 A Starting Current = 2020 A Starting Time = 5/9 Sec

Relay Type CDGM 62 U/V CDGM 62 U/V CDGM 62 U/V CDGM 62 CAG 34 U/V

CTR 100 / 5 A

Range 3.6 6.2 25 100 A

Setting PS = 4.35 TMS=0.35 40 A 50%,9 Sec PS = 3.95 TMS=0.2 33 A No Trip PS = 4.35 TMS=0.2 42.5 A 50%,9Sec PS = 3.95 TMS=0.2 33 A 0.1 A 50%,9 Sec

100 / 5 A

3.6 6.2 25 100 A

30 / 5 A

3.6 6.2 25 100 A

500 / 5 A

3.6 6.2 25 100 A 0.1 1 A

5.2.3

RECOMMENDED RELAY SETTING OF 6.6 KV STATION SECTION STAGE - III

Sr. Name of Feeder No. 1. Main Incomer to CT4 (Cooling Tower) from 3SB at 3SB 2. Main Incomer for CT4 at CT4 Bus

Relay Type CAG 37 VTT 11 U/V CAG 37 VTT 11 U/V CAG 37 VTT 11 CAG 37 VTT 11 CAG 37 CAG 37 VTT 11 CAG 37 CAG 37 VTT 11 CAG 37

CTR 800/5 A

Range 10 40 A 0.5 5 sec 10 40 A 0.5 5 sec

Setting 10 A 0.8 Sec No Trip 10 A 0.5 Sec 20%,1.5 Sec 10 A 0.5 Sec 10 A 0.5 Sec 66 A 10 A 0.5 Sec 66 A 10 A 0.5 Sec 65 A

800/5 A

3. Bus coupler between CT3 & CT 4 Bus 4. Station Auxiliary T/R (TS5 / 1600 KVA) 5. Stand By T/R (TR6 / 1600 KVA) 6. Lighting Transformer (TL4 / 1000 KVA)

800/5 A

10 40 A 0.5 5 sec 10 40 Amp 0.5 5 Sec 25 100 A 10 40 Amp 0.5 5 Sec 25 100 A 10 40 Amp 0.5 5 Sec 25 100 A

200 / 5 A

200 / 5 A

150 / 5 A

Sr. Name of Feeder No. 7. Cooling Tower Transformer (1600 KVA) 8. CT Pumps (960 KW) Full load current = 115 A Starting current = 632.5 A Starting time = .5 Sec

Relay Type CAG 37 VTT 11 CAG 37 CDGM 32 CAG 37 U/V

CTR 200 / 5 A

Range 10 40 Amp 0.5 5 Sec 25 100 A 3.6 6.2 A 25 100 A

Setting 10 A 0.5 Sec 66 A PS = 3.6 TMS=0.2 34 A 70%, 0.5 Sec

150/5 A

5.2.4

RECOMMENDED RELAY SETTING OF 6.6 KV UNIT SECTION STAGE - II (Unit - 5) Relay Type CAG 37 VTT 11 CAG 37 CAG 37 VTT 11 CAG 37 CAG 37 VTT 11 CDGM 32 CAG 37 U/V CDGM 32 CAG 37 CTU 12 U/V CDGM 32 CAG 37 CTU 12 U/V CDGM 32 CAG 37 U/V CTR 150 / 5 A Range Setting 10 A 0.5 Sec 65 Amp 10 A 0.5 Sec 66 A 22 Amp 0.3 Sec PS = 4.35 TMS=0.4 43 Amp No Trip PS = 3.95 TMS=0.2 40 Amp 8.1A,3 Sec 70%,0.5 S PS = 4.35 TMS=0.8 40 A 9A,10 Sec 50%,9 Sec PS = 3.6 TMS=0.2 34 A 70%,0.5 Sec

Sr. Name of Feeder No. 1. Unit Auxiliary T/R (T5C & T5D / 1000 KVA) 2. EP Transformer (1600 KVA) 3. Reserve Incomer from ( For Bus 5A & 5B) 4. ID FAN A & B (1100 KW) Full Load Current = 116.5 A Starting Current = 855 A Starting Time = 7/10 Sec 5. Bowl Mills A,B,C,D,E & F (340 KW) Full Load Current = 41.7 A Starting Current =250.2 A Starting Time = 2.9/6.1 Sec 6. PA Fans A & B (1250 KW) Full Load Current = 135.3.A Starting Current =811.8 A Starting Time = 19/28 Sec 7. SOP (200 KW) Full Load Current = 22 A Starting Current = 132 A Starting Time = 3.5/5 Sec

10 40 A 0.5 5 sec 25 100 A 200 / 5 A 10 40 A 0.5 5 sec 25 100 A 1250 / 5 A 10 40 Amp 0.5 5 Sec 150 / 5 A 3.6 to 6.2 A 25 100 A 50 / 5 A 3.6 6.2 25 100 A

150 / 5 A

b. 6.2 25 100 A

30 / 5 A

3.6 6.2 25 100 A

Sr. Name of Feeder No. 8. FD Fans A & B (750 KW) Full Load Current = 79.5 A Starting Current = 477 A Starting Time = 6.5/10 Sec

Relay Type CDGM 32 CAG 37 U/V

CTR 100 / 5 A

Range 3.6 6.2 25 100 A

Setting PS = 3.6 TMS=0.5 38 A 50%,9 Sec

9. CEP Pumps A,B,C (220 KW) Full Load Current = 25 A Starting Current = 135 A Starting Time = 2.5 Sec 10. BFP A,B & C (4000 KW) Full Load Current = 421 A Starting Current = 2020.8 A Starting Time = 5/9 Sec

CDGM 32 CAG 37 U/V CDGM 32 CAG 37 CAG 34 U/V

30 / 5 A

3.6 6.2 25 100 A

500 / 5 A

3.6 6.2 25 100 A 0.1 1 A

PS = 3.95 TMS=0.3 36 A 50%,9Sec PS = 3.95 TMS=0.3 32 A 0.1 A 50%,9 Sec

5.3 RECOMMENDED SETTING OF MCB RELAYS Sr. No. 1 Name of Feeder IP1&IP2 Type of Protection Distance Protection Relay Type Quadro mho CTR/PTR 600/1 A 220KV/110V Range Setting Z1=1.792 Ohm Z2=2.24 Ohm (t2=350 ms) Z3=2.56Ohm (t3=1.05ms) Z3=0.4 Ohm E/F Comp.=130% (R-Ph)O/C=150% (B-Ph)O/C=150% E/F =20% TMS=0.3 sec Z1=1.68 Ohm Z2=3.15 Ohm (t2=350 ms) Z3=5.76Ohm (t3=1.0 sec) (R-Ph)O/C=150% (B-Ph)O/C=150% E/F =20% TMS=0.2 sec

Backup Protection

CDD21 (Directional)

O/C 50-200% E/F 20-80%

Mehrauli 1&2

Distance Protection

RR3V Scheme

600/1 A 220KV/110V

Backup Protection

IDMT (Directional)

O/C 50-200% E/F 20-80%

Sr. No. 3

Name of Feeder Ballbhagarh 1&2

Relay Type Distance Protection

CTR MM3V Scheme

Range 600/1 A 220KV/110V -

Setting

Sr. No. Z1=2.396 Ohm Z2=3.355 Ohm (t2=350 ms) Z3=9.1Ohm (t3=1.0 sec)

Backup Protection

IDMT (Directional)

Okhala 1

Distance Protection

RR3V

600/1 A 220KV/110V

O/C 50-200% E/F 20-80% -

(R-Ph)O/C=125% (B-Ph)O/C=125% E/F =20% TMS=0.3 sec Z1=1.63 Ohm Z2=2.44 Ohm (t2=350 ms) Z3=4.89Ohm (t3=1.0 sec) (R-Ph)O/C=125% (B-Ph)O/C=125% E/F =20% TMS=0.3 sec Z1=0.834 Ohm Z2=1.44 Ohm (t2=200 ms) Z3=2.952Ohm (t3=1.0 sec) (R-Ph)O/C=125% (B-Ph)O/C=125% E/F =20% TMS=0.3 sec Z1=2.65 Ohm Z2=4.51 Ohm (t2=220 ms) Z3=8.29Ohm (t3=1.0 sec) E/F =20% TMS=0.3 sec

Backup Protection

IDMT (Directional)

Okhala 2

Distance Protection

RR3V

600/1 A 220KV/110V

O/C 50-200% E/F 20-80% -

Backup Protection

IDMT (Directional)

NOIDA

Distance Protection

600/1 A 220KV/110V

O/C 50-200% E/F 20-80% -

Backup Protection

IDMT (Directional)

20-80%

Sr. No. 7

Name of Feeder Alwar

Relay Type Distance Protection

CTR MM3V Scheme

Range 600/1 A 220KV/110V

Setting -

Sr. No. Z1=13.44 Ohm Z2=20.16 Ohm (t2=450 ms) Z3=26.88Ohm (t3=1.0 sec) (R-Ph)O/C=125% (Y-Ph)O/C=125% (B-Ph)O/C=125% E/F =20% TMS=0.3 sec Reqired setting can be set Reqired setting can be set

Backup Protection

IDMT (Directional)

O/C 50-200% E/F 20-80% 600/1 A 220KV/110V O/C 50-200% E/F 20-80% 4 16 Amp. 2 8 Amp

Bypass

Distance Protection Backup Protection

Quadro mho IDMT (Directional)

Bus Coupler

Instantant O/C E/F

CAG33

1200/2 A 220KV/110V

4A 50A(R-Ph) 50C(B-Ph) 2A 50N 1.8 A (51A,51C)

Instantant Dead time O/C E/F

CAG39

0.5-2Amp

0.5-2Amp 10 Station Tr. 1&2 Backup Protection IDMT 600/1 A 220KV/110V O/C 50-200% E/F 20-80% 15-50%

0.5 A (64) (R-Ph)O/C=50% (B-Ph)O/C=50% E/F =20% 30%

11

Station Tr. 3

12

Bus Bar Differential

Biased Diff. Protection Backup Protection Differential Protection Rest. E/F Bus Bar Differential

DMH

IDMT DTH-31 CAG-14 CAG-34

600/1 A 220KV/110V

E/F 10-40% 5-20% 50-200%

(R,Y,B-Ph) O/C 20% 15% 10% 125%

600/1 A

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

SECTION VI

NEW C&I SYSTEM COMMISSIONED

6.1

NEW SYSTEMS COMMISSIONED IN STAGE II UNITS

6.1.1 ELECTRONIC DRUM LEVEL INDICATORS: (#4,5) Make Total no. of probes Range Drum Pressure Temperature Power supply Indication local and UCB for left & right side. 6.1.2 VARIABLE FREQUENCY DRIVE IN RC FEEDERS:(#4,5) Make Rating Feeders Features : L&T : 7.5 KW,415V 3Ph :6 nos. : Remote speed indication & facility for auto control :Levelstart : 14 : 0-500 mmWCI :200 kg/cm2 : 4000 C : Dual for odd & even set of electrodes

6.1.3 RC FEEDER SPEED INDICATION AND STOPPAGE ALARM : ( # 4,5) Make Sensor Indication Alarm : Masibus : Inductive proximity switches : Digital speed indication in UCB for each feeder : An immediate alarm is given in case of stoppage of the feeder in UCB

6.1.4 LP/HP HEATER DRIP LEVEL CONTROLLERS (#4) (Single loop PID controller) Make Output 6.1.5 ANNUNCIATION SYSTEM :(#4,5) Make I/P supply : ILK Mark II (CMOSbased) : 230V AC : Fuji Tosdic : 24 V pulsating

6.1.6 DISTRIBUTED CONTROL SYSTEM (DCS): (#5) Make 1. a) b) c) d) 2. Closed loop controls including: PA header pressure Furnace draft SH attemperation RH attemperation Analog & Digital Measurements : Siemens Teleperm ME Plus.

6.1.7 SEQUENCE OF EVENTS LOGGER (#5) Make Mode No. of points Time stamping : Siemens : Sieser : 256 : 1 msec

SECTION VII

OFF-SITE AUXLIARIES

7.1

SWITCHYARD

7.1.1

STATION TRANSFORMER (#1)

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

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

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

Vector Group Type Of Cooling Tap Changer Type Impedance %

Yd1 ON/AB OLTC 12.62

7.1.4

BUS BARS SCHEME

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

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

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

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

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

In case of feeders, distance scheme covers phase to ground, phase to phase protection with zone indications. In case of failure of main (distance protection), back up IDMT

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

7.1.9 1

INTERLOCKS ABCB can not be closed from remote, if 1 Lockout relay (186) is not resetted 2 Low Air Pressure 3 Control Circuit faulty (DC not available) Bus and line isolators can not be operated electrically if breaker of that Bay is in closed position. 2nd Bus isolator of any Bay can only be closed (electrically) when Bus coupler breaker and its both isolators are in closed position. By Pass Isolator of any Bay can be operated (electrically) only when By Pass Bay Breaker is in open position. Earthling switches have electrical/mechanical interlocks with isolators. Electrical interlock provided for closing only one by pass isolator at a time. UNDER FREQUENCY PROTECTION (Islanding)

2 3 4 5 6 7.1.10

At 47.8 c/s - 220KV Badarpur / Sahibabad feeder will trip At 47.6 c/s - 220 KV Badarpur / Ballabhgarh I, II and Alwar feeders will trip.

220KV BUS-I AND II (as the case may be) may become dead if any of the five unit breakers is under trip position and its Bus and line Isolators are in closed position and the air pressure drops to 16 kg/ cm2 (approx.) 7.1.11 1 2 3 4 5 6 7 8 IMPORTANT ANNUNCIATIONS (required immediate attention) Control Circuit faulty Breaker Air Pressure Low V.T. fuse faulty Line V.T.fuse faulty Bus Protection Bus wire faulty Bus connection disturbed Bus Differential protection DC faulty Bus protection zones combined

Bus bars paralleled by isolators.

There are 20 Bays in 220KV switchyard connected to 220KV Bus-I and Bus-II as per following description:BUS-I 1 2 3 4 5 6 7 IP-I Station I, III Okhla-I Ballabhgarh-I Units-I, III, V Jaipur Mehrauli-I

BUS-II 1 IP-II 2 Station-II 3 Okhla-II 4 Ballabhgarh-II 5 Units-II, IV 6 Sahbabad 7 Mehrauli-II By Pass Bay can be connected to either of these buses and bus coupler is used for coupling both the buses.

7.2 7.2.1

AIR COMPRESSORS

STATION AIR COMPRESSOR 3 4.2 kg/cm2 (Max.) 1100 F to 1200 F

Total Nos. Jacket water pressure H.P. Cylinder outlet Water Temp 7.2.2 Make Type Speed Nos. of Cylinder Pressure COMPRESSOR NO. 1 & 2

Pneumatic Tool company (India)Ltd., Mumbai. Slow speed, Horizontal straight Line & Double Acting Type 300 RPM 2 100 Psig

Max. working pressure No. Capacity MOTOR Motor capacity Voltage RPM Amps Make RECEIVER Capacity Working pressure Test pressure 7.2.3 Make COMPRESSOR NO 3

120 Psig 2 21m3/hr

126 KW 415V 1500 221 Siemens

250C.F. 125 Psig 185 Psig

Type

Speed Capacity Working pressure Max. Unloading Pressure No. RECEIVER Capacity Design pressure Test pressure MOTOR Capacity Voltage RPM Amps Make

Consolidated Pneumatic Tool company(India)Ltd., Mumbai. Slow speed, Two cylinders Horizontal & double acting type. 300 RPM 741 CFM at 100Psig ( 20.926M3/min) 100 Psig ( 7 kg/cm2) 100 Psig ( 7 kg/cm2) One 10 M3. 9.2 kg/cm2 13.8 Kg/cm2

132 KW 415V+ 10% 1500 227 Siemens

7.2.4 No Capacity Pressure Make MOTOR Capacity Voltage RPM Amps Make

PLANT AIR COMPRESSORS(ST-II & III) 2 30 m3/min 70 MWC Kirlosker Pneumatic

200 KW 6.6 KV 988 23 Kirlosker

7.2.5 Make Type

INSTRUMENTAIR COMPRESSOR (U#4) K.G.Khosla Compressor Ltd. KHOSLA CRPELLE Double acting, Horizontal/cross heads two opposite cylinders. 750 RPM 14.6 m3/min. 8.0 kg/cm2 7 kg/cm2 2 1.5 to 2 kg/cm2 8 kg/cm2 1100 F to 1200 F

Speed Free air Delivery Working/cut-off Pressure Re-starting Pressure No. of compressor Lubrication oil Pressure Jacket water pressure HPC outlet water Temperature MOTOR Capacity Voltage Amps Make Speed RECEIVER Capacity

100 KW 415 Volts 173/177 Kirlosker Electric 1500 RPM

5 M3

Hydraulic Test Pressure Working Pressure AIR DRYING UNIT 1) Type 2) Flow Rate 3) Inlet Pressure 4) Outlet pressure 5) Inlet Temp. 6) Outlet Temp. 7) Outlet Moisture content 8) Cycle Time a) For absorption b) For regeneration c) For cooling 9) Service 10) Drying Agent 11) Design Pressure 7.2.6 7.2.7 Make Capacity Pressure MOTOR Capacity Voltage RPM Amps Make 7.2.8 Make Type COMPRESSURE 3

16.19 kg/cm2 10.15 kg/cm2

Purge Reactivation 14.6 kg/cm2 8 kg/cm2 7.6 kg/cm2 440 C 540 C 22 ppm

6 Hrs 2 Hrs 3 Hrs Continuous Silica 10 kg/cm2

INSTRUMENT AIR COMPRESSORS (U#5) COMPRESSURE 1&2 Kirlosker Pneumatic 18 m3./min (2 Nos) 7 kg/cm2

120 KW 415 V 1000 212 Kirlosker

K.G.Khosla Compressor Ltd. KHOSLA CRPELLE Double acting, Horizontal/cross heads two opposite cylinders. 750 RPM 14.6 m3/min.

Speed Free air Delivery

Working/cut-off Pressure Re-starting Pressure Lubrication oil Pressure Jacket water pressure HPC outlet water Temperature MOTOR Capacity Voltage RPM Amps Make AIR DRYING UNIT 1) Type 2) Flow Rate 3) Inlet Pressure 4) Outlet pressure 5) Inlet Temp. 6) Outlet Temp. 7) Outlet Moisture content 8) Cycle Time a) For absorption b) For regeneration c) For cooling 9) Service 10) Drying Agent 11) Design Pressure

8.0 kg/cm2 7 kg/cm2 1.5 to 2 kg/cm2 8 kg/cm2 1100 F to 1200 F

100KW 415 V 1500 173 Kirlosker

Purge Reactivation 14.6 kg/cm2 8 kg/cm2 7.6 kg/cm2 440 C 540 C 22 ppm

6 Hrs 2 Hrs 3 Hrs Continuous Silica 10 kg/cm2

7.3 7.3.1

CONTROL STRUCTURE PUMP HOUSE

HP FLUSH WATER PUMP 4 Worthigton Multistage Vertical Turbine Pump 500 m3/Hr 94.5 MWC 1500 RPM

No -I, II, III, IV Make Type Capacity Head Speed

MOTOR Make Type Rating RPM 7.3.2 No-V, VI Make Type Capacity Head MOTOR Make Type Rating RPM 7.3.3 FIRE & SCREEN PUMP Worthigton 2 Multistage Vertical Turbine Pump 500 m3/Hr 94.5 MWC Kirloskar Induction Motor (IP23/IC01) 6.6 KV,150 KW 1485 H.P. WATER PUMPS 2 Kirloskar Multistage Vertical Turbine Pump 400 m3/Hr 94.5 MWC Kirloskar Induction Motor 6.6 KV,187 KW ,22Amp. 1485

Make No Type Capacity Head MOTOR Make Type Rating RPM 7.3.4 DEISEL FIRE PUMP Make Type Capacity Pressure Engine Model Rating

Kirloskar Induction Motor 6.6 KV,185 KW 1485

Kirloskar DHR-35 Three Stage 500 m3/Hr 10 Kg/cm2 Model NTA-855-F 132 Kw

7.3.5 No Make Type Capacity Head Speed MOTOR Make Type Rating RPM 7.3.6 Make No Capacity Head MOTOR Make Type Rating RPM 7.3.7

LP FLUSH WATER PUMPS 3 Jyoti B400 D3F 300, Multistage vertical turbine pump 600 m3/Hr 55 MWC 1440 RPM

Jyoti Limited, Baroda Induction Motor (IP23/IC01) 415 V,132 KW ,230Amp 1470 CLARIFIED RAW WATER PUMP(CRW) Kirloskar,(CRW1)/Flowmore(CRW2,3) 3 3500 m3/Hr 20.5 MWC

Kirloskar. Induction Motor 6.6 KV,280 KW 985 TRAVELLING WATER SCREENS BSBK 7 nos 20000 cu mt /hr

Make Total no of screens Capacity 7.3.8 Make Capacity Pressure Motor 7.3.9 No

SCREEN WASH PUMPS Mather and Platt. 300 cu mt/hr 6.0 kg/cm2 75KW/1485RPM/131Amp CHLORINATION PUMP 1

Type Capacity Head Drive Motor

Vertical 200 m3/Hr 66.75 MWC 55KW/85HP, 415V, 1500RPM, 93Amp .

7.3.10 Drive Motor 7.3.11 No. Type Capacity Head Speed Motor

MAKE-UP PUMP AT AGRA CANAL 1425RPM, 14.1Amp, 415V DEDS PUMPS 3 Vertical Turbine Pump 200 m3/Hr 120MWC 1480 110KW/1485RPM/197Amp/Kirlosker 7.4 ASH HANDLING PLANT

7.4.1 Make Model Capacity Pressure : Quantity Speed Motor MOTOR Capacity Voltage RPM Amps Make 7.4.2 Make Model Capacity: Pressure Quantity

ASH PUMP (OLD) Flowmore D85 1000 m3/hr 3.3 kg/cm2 1. 800 RPM 194 KW

194 KW 415 V 1000 331 Siemens ASH SLURRY PUMPS ( NEW) Indure D85D 1300 m3./hr 5.0 kg/cm2 3

MOTOR Capacity Voltage RPM Amps Make 7.4.3 Quantity Make Model Capacity Pressure Motor 7.5 Intake Channel Level (Normal) 7.5.1 C.T PUMP Nos Dischrge Head Speed Make 2 for each 210 MW unit 4160 L/sec or 15000 m3 /hr 17.855 mwc 405 rpm FLOWMORE(U4) KIRLOSKAR BROTHERS LTD. (U5) 322 KW 6.6 KV 991 35 Kirlosker BOTTOM ASH PUMPS 2 nos. Beacon Weir SDC 200/200 410 m3/hr 8.0 kg/cm2 160KW/1485RPM/220Amp/NGEF COOLING TOWER 202 mtrs

MOTOR Type Speed KW Current Volts Make 7.5.2 COOLING TOWER Make Number No. of cells/tower Rate of flow /unit Induction motor 421 rpm 930 108.5 amps 6600 volts, 3 Ph. 50 C/S BHEL

Gammon(U4)/ Paharpur(U5) 1 for each unit of 210 MW 16 27000 m3 /hr/Tower

Cooling Range Max. operating inlet water temp. 7.5.3 COOLING TOWER FANS

100C 500C

Fan Type No. off fans/Tower No. off blades/fan No. off row of fan Dia. Reduction gear Ratio Fan speed Type Make Lub oil MOTORS Make Volts Current K.W. Speed

Axial Induced Draft 16 9 2 (8 in each row ) 7315 mm 10:1 L.X. 151 rpm V-1400C.T. Radicon worm Reducer Enklo-120 or Servo-40

N.G.E.F. 415V 130 amps 75 1475 rpm

7.6

DIESEL GENERATOR

One Diesel Engine is directly coupled with generator for producing power. Diesel generator set is capable of supplying power to Barring gear motors of unit I,II,III,& IV A.C. standby lub. oil pump & Hydrogen seal oil pump of unit IV.There are 10 numbers of outgoing feeders panels for supplying power of different motors and emergency lighting Boards when supply to any of feeder panels fails signal impulse starts the diesel generator set automatically & it supplies power through solenoid operated air circuit breaker provided in M.C.C. The control circuit is such that the set can be stopped only manually and also this can be achieved only when the set is not supplying load to any of the feeder. A provision is there to start the set manually. However, supplying of load to the feeders will be automatic through the solenoid operated breakers.

10.6.1 SPECIFICATION 10.6.2 GENERATOR No Make Rated output

2 Jyoti Ltd. 250KVA

Power Factor/ Voltage Frequency Insulation Speed Current Ratings No. of space heaters Rated KW Rated Voltage

0.8/415 50 Hz , 3 ph. Class B 1500rpm 348 Amps CR Excitation 85V 50 Amp. One 200W 230V

7.7 WATER TREATMENT PLANT 7.7.1 WATER ANALYSIS as CaCo3 p.p.m. COMPONENTS Calcium Magnesium Sodium & Potassium Total Cations Total Hardness M.C. Alkalinity Sulphate Chlorides Total Anions Iron as Fe Silica ( Reactive) as SiO2 Turbidity J.T.U. Permanganate No or B.O.D. Conductivity at 25 C RAW WATER 240 64 306 612 304 326 72 214 612 0.1 13.0 3500 72 1300 MODIFIED FOR DESIGN 300 64 312 676 265 363 97 216 676 0.1 13.0 -

Note: Modified analysis is after 50 ppm Alum, 37ppm lime & 2ppm sodium sulphite done. 7.7.2 TREATED WATER QUALITY

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

7.7.3

PRETREATMENT SECTION Alum Prep. Cum storage tank 2 12300x1200D 10% 2 Nos. Const. Head tank for Alum 1 765Lx380Wx380H 10% Nil Lime solution tank 1 16200 x1480D 10% 1 Nos. Const. Head tank for lime 1 765Lx380Wx380H 10% Nil

Description

Nos. off Dimensions Concentratio n of solution High Speed Mixture

7.7.4

CLARIFLOCULATOR One 168000 x 4000D 400 m3/Hr.

Nos. Size Capacity 7.7.5 Nos. Make 7.7.6 CHLORINATOR FLASH MIXER MECHANISM

One set Hindustan Door Oliver

Nos. Capacity Model Type Capacity Operating Pressure/ Unit Operating water Qty/Unit 7.7.7 TANKS MODEL PH 5 HP/RPM 0.5/1440

2 0.1 to 5.5 kg/cm2 (Max.) Banaco Mark II Press Gaseous Chlorinator (0.1 5.5 ) kg/Hr 2.0 kg/cm2 3m3/Hr.

LOCATION Alum Prepn. Cum. Storage Tank Lime Soln.Tank for

MAKE/FRAM E SIZE Kirloskar/N80

QTY. 3

PM 1

1.0/1000

Kirloskar/N90L

clarifloculator Sodium sulphite Soln. Tank Alkali dilution tank Lime prepn. Tank for neutraliasation 7.7.8 DESCRIPTION Nos. Capacity Discharge Head Model No. Make Motor HP/RPM Make D.P.

PM 5 PM 10 PH 5

0.5/1440 1.0/1000 0.5/1440

Kirloskar/N80 Kirloskar/NPOL Kirloskar/N80

2 2 1

CLARIFIED WATER PUMP 2 250M3/hr. 36 MWC 6 DC 124 Best & Crompton 2 60/1440 Kirloskar 2.5 kg/cm2

SLUDGE DISPOSAL PUMP 250M3/hr. 15 MWC 3x2x10 BPO Best & Crompton 2 5/1440 Kirloskar

7.7.9 DEMINERALISATING SECTION DESCRIPTION Nos. Size Filtering Media Max/min. Treatment flow m3/Hr. Back wash flow rate m3/Hr. Duration of back wash Air scour flow rate m3/Hr. PRESSURE FILTER(DUEL MEDIA) 4 30000 x 1350H Sand+Anthracite 55/28 170 5 mints 4.65 ALKALI CARBON FILTER 1 8000 x 2300H Active Carbon 10 5 mints -

DESCRIPTION

BACKWASH WATER PUMP 2 170 M3/Hr. 20 MWC Water

AIR BLOWER

Nos. Capacity Discharge Head Medium

2 4.65 m3/min 0.21 kg/cm2 Air

SODIUM SULPHATE DOSING PUMP 2 227 Lit/Hr. 7 kg/cm2 Sodium sulphite

Motors HP/RPM

25/1440

7.5/1440

soution 0.5/1440

DESCRIPTION Nos. Size Concentration of Soln. High speed Mixture

BACKWASH WATER PUMP 1 1000Lx6000Wx2580H -

SODIUM SULPHATE SOUTION TANKS 2 12200 x 1200D 10 % 2

DESCRIPTION Nos. Type Shell Design Pressure(kg/cm2) Max./Min. Treatment flow (m3/Hr.) Average Treatment flow (m3/Hr.) Capacity between Regeneration M3 GROSS Wastw water / Regeneration M3 Time per Regeneration Type of Chemical 100% chemical Regeneration per unit(kg) Type of Resin Resin qty. M3/unit

CATION UNIT 4 Strongly Acidic 4.0 80/28 35 850

ANION UNIT 4 Strongly basic 5.3 70/28 35 706

MIXED BED UNIT 4 Strongly Acidic & Basic 5.3 47/28 35 700

110 55 mints. Hcl 880

80 115 mints. NaOH 500

25 115 mints. Hcl & NaOH 38.5

2K 225 12.5

DANIP 6.695

ZK225/DAFFIP 0.77/2.10

7.7.10 REGENERATION FLOW UNIT 3K OPERATION Back wash (once in a week) Acid Injection 5% w/v FLOW-M3/HR. 55.4 52.8 TIME-MIN 5 20

D.A.

M.B.

Down flow Acid Rinse Down flow Final Rinse Back wash Alkali Injection Alkali Transfer Alkali Rinse Middle Collector wash Back wash Alkali Injection Up flow Alkali Transfer Up flow Alkali Rinse Acid Injection 5% W/V Down Flow Acid Rinse Drain Down Air Min. Final Rinse

79.8 52.8 79.2 35.0 13.6 22.2 22.2 67.0 14.0 14.0 15.3 6.9 14.9 6.9 25.2 7.5 3.5 7.4 3.0 M3/Min. 3.5

20 25 25 5 5 30 5 60 1 6 30 30 5 5 20 6 6 10 5 10 10

7.7.11 DESCRIPTION Nos. Size DEGASSER TOWER 2 2000Lx2000Wx3400H DEGASSED WATERSUMP 2 7500Lx7500Wx2750H

DESCRIPTION Nos Capacity Discharge Head Medium MOTOR HP/RPM MOTOR-Make

DEGASSER AIRBLOWER 4 75 m3/min. 100MWC Air 5/1440 Kirloskar

MIXED BED AIR BLOWER 2 3m3/min. 0.4 kg/cm2 Air 7.5/1440 Kirloskar

DEGASSED WATER PUMP 3 120 m3/min. 45 MWC Acidic water 40/1440 Kirloskar

DESCRIP TION

ALKALI PREPAR ATION TANK Two 12000 x1200D -

BULK ALKALI STORAG E TANK One 16000 x 4500L -

Nos. Size Solution Concentrat ion in Tank

ALKALI DILUTIO N TANK FOR DA/MB Two 16000 x1500D 20%

BULK ACID STORAG E TANK Five 34000 x6200L 30%

ACID MEASUR ING TANK FOR ZK Two 18000 x1500D 30%

ACID MEASUR ING TRANSF ER MB Two 4570 x762D 30%

DESCRIPTIO N Nos. Capacity Discharge Head MWC Media MOTORHP/RPM Motor make

ACID TRANSFER PUMP 1 25 17.5 32% Hcl 5/1440 Kirloskar

EFFLUENT DISCHARGE PUMP 2 150 18 Acid/Alkali 20/1440 Kirloskar

ALKALI TRANSFER PUMP 2 15 20 20% NaOH 5/1440 Kirloskar

ALKALI INJECTION PUMP 2 5 25 Alkali 7.5/1440 Kirloskar

DESCRIPTIO N Nos Size mm.

PRIMING CHAMBER One 6000 x900D

LIME PREPN. TANK One 12000 x1200D

NEUTRALISING PIT One 10000Lx10000Wx3000H

DESCRIPTION

Nos. Type Size(mm) Max.Working Pr.(kg/cm2) Min.Treatment flow(M3/Hr.) Max. Treatment flow(M3/Hr.)

STRONGLY ACIDIC CATION UNIT Four Strongly Acidic 2800 x3600H 3.6 28 80

STRONGLY BASIC ANION UNIT Four Strongly Basic 2400 x2600H 4.6 28 70

MIXED BED UNIT

Four 1400 x3000H 4.6 28 47

Average Treatment flow(M3/Hr.) Capacity between regeneration(M3) Period between regeneration(Hrs.) Waste Water per regeneration (M3) Type per regeneration(Mints)

35 850 20 110 55

35 706 20 80 115

35 700 20 25 115

RESINTYPE Resin Quantity (Lts.) Regenerant Chemical 100% Chemical/Regen eration(kgs)

INDIAN 225 12500 Hcl 880

INDIAN NIP 6695 NaOH 544

ANION INDIAN FFIP 2100 NaOH Through fan with 5BA

CATION INDIAN 225 770 Hcl 38.5

7.7.12 REGENERATION FLOWS UNIT Strong Acidic cation unit OPERATION Middle collector flushing Down Flow Back wash Acid Injection @ 5% Down Flow Acid Rinse Final Rinse Back wash Caustic Injection @ 5% Caustic Transfer Caustic Rinse Flushing/ Back wash Up flow Caustic Injection 7.2 % Up flow FLOW(M3/Hr.) 55.4 79.2 55.4 52.8 79.2 52.8 35.0 13.6 22.2 22.2 67.0 14.0 6.9 15.3 6.9 TIME(Min.) 1 20 5 20 25 25 5 5 30 5 60 6 30 30 20

Strong basic Anion Unit

Mixed Bed

Caustic Rinse Up flow Caustic Transfer Down flow Acid Injection @ 5% Drain Down Air Mix. Final Rinse

25.2 6.9 6.9 3.5 7.4 180 35

20 5 5 10 10 5 10 10

7.7.13 GEO-MILLER CLARIFLOCULATOR Nos. Type Capacity Overload Size 7.7.14 FLASH MIXER MECHANISM Nos. Make Detension Time Dia. Gate Draining 7.7.15 ALUM DOSING UNIT Nos. Capacity/Tank 3/unit Soln. (10 % strength ) to last for 8 Hrs. operation while flow of 3200 m3/hr. Alum dosing basket 3.2x1.09x0.75mts. Alum dosing Tank- 3.33x3.2x3.4 mts. Total No. 3 2(one/unit) Geo-Miller Private Ltd. 60 Secs. 3.7 mts. 2/unit Service valve 150 DA. 2 Radial flow clarifloculator 3200 m3/Hr./unit 20 % (Max.) 54300 Dia x4915 Deep.

Size

7.7.16 DRIVING PADDLE Motor R.P.M. Gear base ratio 2 H.P 1550 1:50

7.7.17 OPERATING HOIST FOR ALUM Nos 2 .

Capacity Type

1 Ton each Gear operated travelling trolley are fitted on monorails.

7.7.18 LIME DOSING UNIT TANK Type Size Capacity 2/Unit Semi Circular 3.35(Dia.)x3.600L 12 hrs. to dose 80% pure hydrated lime slurry Of 10% strength at the rate of 35 ppm to a normal flow of 3200 m3/hr.

PADDLES Material Type Motor 7.7.19 DESLUDGING PUMP Capcity Total Head BHP absorbed MOTOR HP Speed 300 m3 /hr 15 M. 23.4 M.S. Rotation about horizontal axis 2 H.P., 1500r.p.m., gear ratio 1:

30 1450 rpm

7.7.20 ECHNICAL SPECIFICATION OF ACTIVATED CARBON FILTERS (ACF) SR NO. 1. 2. 3. 4. 5. 6. 7. 8. 9. FEATURES Quantity (No.) Type Normal operating flow Operating Pressure Dimensions Dia x HOS Material of construction Back wash Time Max. allowable Pressure drop. Type of operation

Four Vertical down flow. 55.00 m3/Hr 3.5 4.00 (kg/cm2) 2200mm x 2650mm M.S. 15-20 min. or till the effluent is clear. 0.8-1.0 kg/cm2 Manual.

7.7.21 SR. NO. 1.

DETAILS OF FILTER MEDIA IN ACF MATERIAL SIZE QUANTITY

Pebble

2x 1 1 x 1 1 x x x -

2164.00 x 4 kgs 541.00 x 4 kgs 541.00 x 4 kgs 541.00 x 4 kgs 513 x 4 kgs 93500 x 4 kgs 2508 x 4 kgs

2. 3. 4.

Quartz cylex Mixed sand Activated Carbon

7.8 7.8.1

OLD COAL HANDLING PLANT

COAL CHARACTERISTICS AT BTPS Description At relative humidity 60 % & air temp. 400 C 6-9% 24-33% 24-28% 4778-4944 kcal/kg 45-50 0.8 Tonne/m3 250 mm

Moisture Ash Volatile Matter Gross calorific value Hard grove grindability Index Bulk density Size 7.8.2

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

7.8.3 Nos.

WAGON TIPPLER 2

Make Type Total Time for Tripping Max.angle of rotation Total Weight Capacity MOTOR R.P.M. Amps H.P. Voltage

Tata Robins-Fraser Ltd. Weighing Type with recording, Side discharge 4 minutes (For 1 wagon) 1350 C (giving 450 angle at Side of wagon ) 125 tonnes 85 tonnes

1480 100 75 415V,50c/s, 3 Phase Induction Motor. (Power is transmitted through Traction type fluid coupling.)

7.8.4

STEEL WIRE ROPES Dia-40mm Nos. 2 Length 123 ft.(3 Dia 38mm Nos. 4 Length 24.28 mts Construction-6X41

a) Counter weight Rope

b) Hoisting Rope

7.8.5

CAR PULLER 1-3/8 (35mm) Electro Magnetic Clutch Type V-1400 Worm reducer

Rope Size Braking Coupling Speed Reducer MOTOR Capacity Amps RPM 7.8.6 COAL CRUSHERS Make Type Coal size input Coal size output

30KW/40 HP 52.5 960

TRF Non-reversible ring granulator type 250 mm 20mm

Capacity Nos. Working oil temp. Limit Rotor Speed Rotor dia Rotor length MOTOR Voltage Amps RPM Capacity 7.8.7 BELT CONVEYERS

600 MT/Hr. per crusher 2 500C-850C 720 rpm 360 mm 3875 mm

6.6KV 33.5 1490 300KW

Carrying Capacity Speed Width Material 7.8.8 CONVEYER NO. 1A & 1B 2A & 2B 3A & 3B 4 5 6 7 8 9 10A&10B LENGTH & MM 171548 164345 156371 92087 100262 223778 177000 153832 20900 PLY 4 4 4 4 4 4 4 4 4 4

600 Tons/Hr 2.3 mts/sec 1 mt.(For all) Nylon Fabric with Dead WT.

RAISE OF INCLINATION 150 140 11698 mm at 150C & rest is horizontal 130 120 10562 mm at 150C & rest is horizontal Horizontal 150 180 Horizontal

MOTOR SPECIFICATIONS Speed Voltage CONVEYOR NO. 1A & 1B CAPACITY 150 HP

1440 rpm 415 V REDUCTION RATIO 35.5:1

2A & 2B 3A & 3B 4 5 6 7 8 9 10A & 10B 7.8.9 Type Quantity Belt width Drum Dia Speed MOTOR Type Capacity (Traverse Drive) Speed Voltage Telescopic Chute drive capacity TRIPPER

150 HP 100HP 60 HP 75 HP 60 HP 50 HP 100 HP 30 HP 75 HP

35.5:1 20:1 25:1 25:1 20:1 20:1 25:1 20:1 20:1

Motor Propelled Tripper 5 Nos. 1mt. 600 mm 30 to 35 ft/min

3 ph.Squirrel cage Induction Motor 7.5 H.P. 1500rpm 415 V 5 H.P.

7.8.10 ROTORY PLOUGH FEEDER Quantity Overall Length Height Width MOTOR Type Capacity Speed Voltage Speed 7.8.11 SR. NO. 1.0 2.0 TRAVERSE MOTOR Induction Motor 7.5 H.P. 720 rpm 415 V 20 to 30 ft/minute BELT WEIGHER DESCRIPTION Location Quantity 2 11700 mm 3500 mm 1980 mm PLOUGH MOTOR Induction Motor 40 H.P. 1430 rpm 425V -

SPECIFICATION Belt conveyor 2 A,2B 2

3.0 4.0 5.0 6.0 7.0 8.0 8.1 8.2 8.3 9.0 10.0 10.1 11.0 11.1 12.0 13.0 14.0 15.0 15.1 15.2 15.3

Type Make Type of speed sensor Type of load sensor No. of load cell per weigher Capacity Rated Maximum(Designed) Minimum Accuracy Calibration Weight per unit length of chain Remote Panel Type of flow indicator Type of totalising counter No. of Digits Whether zero reset button provided Local Type of flow indicator Type of totalising counter Power supply

Mechanical Gillanders Arbuthnot & Co. Ltd. Mechanical Mechanical

600 MTPH 750 MTPH 120 MTPH 10.50% By test chain 46.85 Kg / m Moving coil meter EM counter 6 Yes NA Mechanical 230V AC +/- 10%, 50 Hz

7.8.12 MAGNETIC SEPERATOR Make Type Nos. Size Power Required Operating Voltage 7.8.13 METAL DETECTOR

Electro ZAVOD Suspended 2 1500mm x 1350mm x 800 mm 8.5 KW/11.0 KW (Hot/Cold) 220 VDC

Metal detector specification for OCHP is same as NCHP. 7.8.14 LIST OF FLUID COUPLINGS

S.NO. 1 2 3 STD 08 STD 07 STD 06

TYPE OF COUPLINGS ] ] ] M/s Fludomate make

4 5 6 7 8 9 10 11

STD - -5A FCU 17.75 FCU 16.5 FCU 14.5 FCU 12.75 HFD 10 B HFD 14B SCR 41 R

] (Conveyors) ] ] M/s Pembril Greaves make ] (Conveyors) ] ] M/s Fludomate make (Crushers). ] ] M/s Pembril make (Crushers)

7.8.15 DESC RIPTIO N Belt Conveyor

ROTECTION & INTERLOCKS PERMISSIVE INTERLOCK PROTECTION

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

i)

Screens Tripper Respective conveyor

If any belt trips the whole system behind it will trip. ii) No second belt of same pair can run with other belt in service(But for 1A & 1B this interlock can be by passed when yard & BKR feeding both are in service.) iii) If any belt trip the feeders to corresponding 1st belt will trip. iv) If any belt trip the feeders to corresponding 1st belt will trip. v) If conveyor after crusher trips the screen & conveyor before crusher will trip along with feeder. If screen trips the system after screen will trip.

i)

ii)

iii)

iv)

If one belt runs out of alignment more than limit,the swaying switch will trip the belt & whole system behind it. Belts are provided with emergency trip belt sway switch to avoid eccentric movement ,centrifugal switch for excessive slipping,skewing & breaking of belt. Any conveyor loaded beyond 600T/hr will trip. If the belt is cut or the belt speed reduces below a certain limit belt trips.

Plough Feeder

Car Puller & Beetle Charger Wagon Trippler

should be in operation. Respective conveyor should be in service. Wagon trippler should not be in operation. Car puller or Beetle charger should not be in operation.

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

Motors

Provided with over load protection ,short circuit protection, single phase protection. 7.9 NEW COAL HANDLING PLANT

7.9.1 SR. NO. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0

WAGON TIPPLER DESCRIPTION Manufacturer Type & Model No. Gross Load Capacity Minimum nos. of tippling/hr Maximum angle of rotation Type of brakes Type of Inhaul Machine Type of Outhaul Machine Type of Reduction Unit Dust Suppression System provided Wagon Tippler Drive system SPECIFICATION Elecon Engineering Company Ltd. Rota side 90T 17 150 Degree Automatic Electro Hydraulic Thrust Operated Beetle Charger Beetle Charger Helical Gear Box Yes Through 98KW slip ring motor, reduction gear unit, fluid coupling, flexible brake coupling, spur and pinion gears From control desk provided in the wagon tippler control room.

12.0

Control system

7.9.2 SR. NO. 1.0

RING GRANULATOR (CRUSHER) DESCRIPTION Type SPECIFICATION Ring Type Granulator

2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0

Make Model No. Quantity Capacity- Rated -Design Material to be handled Maximum RPM Hard Grove Index Maximum lump size Maximum moisture content Bulk density of coal Guaranteed output of lump size at specified input size and moisture Material of Parts Material of rotor shaft Material of upper breaker plate Material of breaker plate Material of suspension bars Material of side liners Material of ring hammers Bearing No. Method of lubrication of crusher bearing and life Specification of motor Power rating Speed(RPM) Duty cycle Method of mounting Granulator weight VIBRATORY FEEDER Description Location

Mcnally Bharat Engineering Co. Ltd. RG-729 2 600 MT/hr 750Mt/hr R.O.M.Coal 750 50-70 (-) 100 mm 20% O.B.T./m 100% (-) 20 mm

13.0 13.1 13.2 13.3 13.4 13.5 13.6 14.0 15.0 16.0 16.1 16.2 16.3 16.4 17.0 7.9.3 Sr.No. 1

EN-19 Tiscral Cast MN steel IS-276, Gr.III EN-19 Tiscral IS-276 Grade-III Torrington 22238 Manual grease lubrication and 40,000 working hours 550 KW 750 Continous, 24 Hours/Day operation Coupled through fluid coupling with the crusher 28 T

Specification Below wagon tippler hopper Mechanical turflo type Tata Robins Fraser Ltd. TE-9 3X8

2 3 4

Type Manufacture Model No. & size

Specification Below reclaim hopper Mechanical turflo type Tata Robins Fraser Ltd. TE-9 4X8

Specification Above coal crusher Mechanical turflo type Tata Robins Fraser Ltd. TE-11 5X10

5 6 7 8 9 10 11 12 13

Numbers Guaranteed capacity Designed capacity Length of tray With of tray Slope of tray Operating Speed Feeder stroke Material of construction Tray Liner Type of feed rate controller HP rating of each feeder Approximate weight Recommended clearance between feeder and stationary chute

6 Nos. 200 TPH 250 TPH 2438 mm 915 mm 100 down hill 800 rpm

4 Nos. 300TPH 375 TPH 2438 mm 1219 mm 100 down hill 800 rpm

2 Nos. 600 TPH 750 TPH 3038 mm 1524 mm 100 down hill 800 rpm

M.S. IS-226 10 mm thick tiscral By changing the rpm of feeder 10 1960 Kg 51 mm

14

15 16 17

M.S. IS-226 10 mm thick tiscral By changing the rpm of feeder 15 2520 Kg 51 mm

M.S. IS-226 10 mm thick tiscral By changing the rpm of feeder 20 3750 Kg 51 mm

7.9.4 SR. NO. 1.0 2.0 3.0

BELT WEIGHER DESCRIPTION Location Quantity Type SPECIFICATION On conveyor 12 A,12B,15A &15B 4 Electronic load cell single idler sensing system with rate indicator and integrator (Totalizer) Integrated process automation AC Digital Tacho Strain gauge 1 600 MTPH 750 MTPH 120 MTPH

4.0 5.0 6.0 7.0 8.0 8.1 8.2 8.3 9.0

Make Type of speed sensor Type of load sensor No. of load cell per weigher Capacity Rated Maximum(Designed) Minimum Accuracy

9.1 9.2 9.3 10.0 10.1 11.0 12.0 13.0 14.0 15.0 15.1 15.2 16.0 17 .0 7.9.5 SR. NO. 1.0 2.0 3.0 4.0 5.0 6.0 6.1 6.2

At rated ty(Guaranteed) At maximum capacity(Guaranteed) At minimum pacity(Guaranteed) Calibration Weight per unit length of chain Type of flow indicator Type of totalising counter No. of Digits Whether zero reset button provided Remote Panel Type of flow indicator Type of totalising counter Power supply required Power Demand METAL DETECTOR DESCRIPTION Type Make Model No. Location Quantity Sensitivity at normal working condition At maximum capacity with maximum moisture content Particular to sensitivity to other non ferrous material Power requirement (Watt) Power supply required Enclosure material and thickness Degree of protection Hooter MAGNETIC SEPARATOR DESCRIPTION Type Manufacturer

+/-0.5% F.S. +/-0.5% F.S. +/-0.5% F.S. By test chain 49.5 Kg / m Moving coil meter EM counter 6 Yes

Moving core type indicator EM counter 230V+/- 10%, 50 Hz, +/- 2% Single phase 100 VA

SPECIFICATION Electronic Unique Electromag, Mumbai Type SCTA 15A, 15B 2 nos in each conveyor 25 mm dia MS/AL sphere 25 mm dia MS/AL sphere Depends on conductivity properties and electrical characteristic of materials. Sensitivity is adjustable. 150 VA 230 V +/- 10% C/S +/- 5%(Combine +/- 10%) Search coil 3 mm, Pane 2 mm IP-54 Provided

6.3 6.4 6.5 6.6 6.7 7.9.6 SR. NO. 1.0 2.0

SPECIFICATION Overband, inline magnetic separator Electrometike

3.0 4.0

Number & Location Tramp iron size & weight (both maximum & minimum ) to be separated Type of drive system Details of cross belt Make With Number of plies Top/ Bottom cover thickness Material specification Weight of equipment Type of rectifier Magnetic core material Field density Magnet coil material Total power requirement Details of drive Rating Make Operating voltage Of magnet CONVEYER BELT

5.0 6.0 6.1 6.2 6.3 6.4 6.5 7.0 8.0 9.0 10.0 11.0 12.0 13.0 13.1 13.2 14.0

2 Nos, for 14A, 14B Max weight upto 50 Kg of tramp iron to MS rod or L/D ratio upto5 with min. weight of 100 grams or MS cubes of 2 cm weighing around 62 gms shall be lifted from anywhere of coal bed at a distance of 400 mm from the face of the magnet. Chain drive Dunlop 1200 mm 4 3/1.5 mm 32 OZ fabric Total 9 Tons approx, Silicon Mild Steel (High permeability type) 800 gauss at distance of 400 mm from the face plate of the magnet Aluminum with class H insulation 15 KW for magnet 5.5 KW for motor Motor- 5.5 KW TEFC, 3 Ph AC motor Gear Box- 15:1 Reduction ratios, Warm gear box Motor- GEC make Gear Box- NAW make 190 V DC

7.9.7 Sr.No. 1.01 1.02

1.03 1.04

Description Designation Capacity Rated Design Width Belt position length C/C (M)

11A/B

12A/B

13A/B

Specification 14A/B 15A/B 600 TPH 750 TPH 1000 mm

16

17A/B

18A/B

1.04.02 1.04.03 1.04.04

Total lift (M) Type of fabric Is belt flat or

A 210.29 B 209.98 23.35

210.3

51.25

248.25

170.9

124.45

21.05

6.0

29.8 28.4 Nylon Troughed

15.7

A 128.09 B 108.82 14.75

116.7

14.966

1.04.05 1.04.06 1.05.05 1.06.00 1.09 1.09.01 1.09.02 1.10.00 1.11.00

1.12.00

troughed Trughing angle (Deg) Belt joints Cover grade Belt type/ No. of plies Thickness of covers (M) Top (mm) Bottom (mm) Belt speed(m/sec) Allowable working tension (KN) Supplier data of working tension (KN/m) 7.9.8 Sr. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

35 Vulcanised Fire resistance 800/4 800/4

800/4

800/4

80/4

800/4

800/4

800/4

5 2 2.9 48

5 2 2.9 44.64

5 2 2.5 24.72

5 2 2.5 64.8

5 2 2.5 56.76

5 2 2.5 40.68

5 2 2.5 38.04

5 2 1.0 26.04

50

50

40.1

70

50

50

40

40

FLUID COUPLING (SCOOP TYPE) Description Location Type Nos. Manufacturer Model No. Rating of motor Rated KW transmitted Rated torque transmitting capacity with torque Rated input speed Rated Slip Temperature at which plug fuses Weight of the coupling unfilled (Kg) Type of bearing and life Quantity of oil for coupling MATERIAL OF CONSTRUCTION a. Impeller b. Runner c. Casing Specification Ring granulator (Crusher) Scoop type 2 PEMBRIL FLUIDRIVE LTD, Auranagabad 41 SWGR 25W Scaled version 550 KW 500 KW 150 to 275% of full load torque 750 rpm 3% 1800 C+/-50 C 1654 Kg Spherical roller bearing Approx. Life-3000 working hours 184 Lits of SHELL TELLOS OIL-29 Aluminum alloy Aluminum alloy Aluminum alloy

d. Shaft e. Flanges for input and output coupling

EN-8 Forged Steel

16. Coupling shall be capable of rotating in both directions. 17. Equipment should be dynamically balanced. 7.9.9 Sr. No. 1 2 3 4 5 FLUID COUPLING (TRACTION TYPE) Description Manufacturer Type Type of prime mover Input rpm Max. no. of starts per hour Specification Fluidomat Traction type Direct on squirrel cage induction motor 1470 Approx 2 consecutive starts or 3 starts/hr spaced No Yes 3% Adjustable in the range of 150% to 275 % of full required torque Should be capable of rotation in both direction Lubrication of bearing should preferably be done with the fluid itself Flexible/Semiflexible Dynamically balanced High tensile aluminum alloy High tensile aluminum alloy High tensile aluminum alloy EN-8 Forged steel

6 7 8 9

Whether Acceleration torque limitation desired Whether fusible plug to be provided Maximum slip Max .torque transmitting

10 11

Direction of rotation Bearing lubrication

12 13 14

Output coupling Balancing Material of construction a. Impellar b. Runner c. Casing d. Shaft e. Flanges for input and output couplings

7.9.10

SCHEDULE OF FLUID COUPLING (TRACTION TYPE)

Sr.No.

Location Quantity Motor Conveyor rating(KW)

RPM

Coupling input rating (KW) 116.8 109.0 44.0 135.6 119.1 85.1 79.0 22.0

1 2 3 4 5 6 7 8 7.9.11 Sr.No. 1.0 2.0 2.1 2.2 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 11.1 11.2 11.3 11.3.1 11.4 11.5 12.0 12.1 12.1.1

11A/B 12A/B 13A/B 14A/B 15A/B 16 17A/B 18A/B

2 2 2 2 2 1 2 2

125 125 55 150 150 110 110 37

1470 1470 1470 1470 1470 1470 1470 1470

Gear box input rating (KW) 113.3 105.7 42.7 131.5 115.5 82.9 76.6 21.3

Model No.

STD/E/08 STD/E/08 STD/E/06 STD/E/08 STD/E/08 STD/E/07 STD/E/07 STD/E/05A

BELT FEEDER Description Location Capacity Rated capacity (TPH) Designed capacity (TPH) Quantity & Type Manufacturer Feeder Length (M) Material handled Bulk density (T/m3) Design ambient temperature (0C) Moisture content of coal (%) Hours of operation per day Belt Belt width Belt Speed (m/min) approx Type of fabric Cover thickness (mm/min) Top/Bottom Cover grade Type of loading & Discharging Idlers Carrying idlers Type Specification Crusher house Breaker house 600 750 750 750 2 (Unidirectional) 2(reveesible) M/S McNally Bharat engineering Co. Ltd. 6.0 11.0 100 mm crushed coal 20 mm crushed coal 0.8 50 20 (max) 24 1200 mm 24.0 Nylon 9/2 Fire resistant Through chutes

152.4 mm dia rubber disc single roll, impact type

12.1.2 12.1.3 12.1.4 12.1.5

Configuration Spacing Disc material Type of fixing arrangements for discs Lubrication & seal

12.1.6

Flat 400 mm at loading points & 500 mm at other portion Special resilient rubber having greater shock absorbing capacity Mounting on slotted pipe sleeves on shaft to provide friction grip by spring action & located by collars Antifriction bearing with labyrinth type seal. All grease fitting shall be rutton head type having plastic caps. 152.4 mm dia steel tube flat idler 2000 mm Double labyrinth seal 4 IS-4776 latest edition EN-8 or Equivalent Heavy duty welded steel as per IS-8531 Forged steel to IS-1875 Class-V Antifriction double row self aligning spherical roller bearing in split type plummer block with labyrinth seal. 4000 hours working life. Grease 1 no. drive, 1 no. tail pulley per feeder 630 drive & tail pulley per feeder 12 mm thick vulcanized natural rubber herringbone type lagging 12 mm thick vulcanized plain natural rubber lagging 1200 mm

12.2 12.2.1 12.2.2 12.3 12.4 12.5 12.6 13.0 13.1 13.2 13.3

Return idlers Type Spacing Type of idler seal Min. tube thickness )mm) Applicable standard Shaft material Pulleys Pulleys construction Pulley shaft material Type of bearing & plummer block

13.4 13.5 13.6 13.7

Type of lubrication Quantity & type of pulleys Pulley dia & width (mm) Type of lagging on drive pulley 13.8 Type of lagging on other pulley 13.9 Height of USOB from supporting floor 14.0 Skirt Board 14.1 Length 14.2 Material a. Main plate b. Liner c. Cover plate 15.0 Gear Box 15.1 Type 15.2 Type of enclosure 15.3 Type of lubrication 15.4 Additional requirements

Continuous 16 mm thick MS plate 10 mm thick MS scral 4 mm thick MS plate Worm Totally enclosed dust proof Splash Draining plug & oil level guage

16.0 16.1 16.2 16.3 17.0 18.0 18.1 18.2 18.3 19.0 19.1.0 19.1.1 19.2.0 19.2.1 20.0 20.1.0 20.1.1 20.2.0 20.2.1

Coupling Type Location Coupling guard Tail pulley guard Take up unit Type Location Travel Scrappers External Location Internal Location Belt protection Drive Zero Speed switch Quantity Quantity Belt Sway switch

Flexible pin-bush type Between drive pulley & gear box and motors Provided Standard wire mesh guard for all the feeders Screw type Tail end of feeder To suit

Inside head end chutes Rubber edge V- type Near tail pulley

1 no. at each conveyor 2 pair at suitable location of feeder per feeder

7.9.12 LOCO WDS-4 No. Type Model Working method Fuel injection Weight of engine without water & oil Maximum length Maximum Width Total Height Number of cylinder Cylinder bore Piston stroke Total swept volume Swept volume per cylinder Compression ratio Nominal output Rotating speed at nominal load Idling speed Torque at nominal load Mean effective pressure Sense of rotation viewed at flywheel Engine cooling

4 6M 282 A(k) 01/21 4 stroke, single acting Direct injection 7150 Kg 2876 mm 2035 mm 2035 mm with oil sump 1550 mm without oil sump 6 240 mm 280 mm 76 Lit 12.7 Lit 12:2:1 650 HP 1000 rpm 440 rpm 541 Mkg 8.6 Kg/cm2 Anticlockwise water circulation

Cooling water temp- Engine inlet Engine outlet Lub oil pressure Lowest under load Rated engine speed At idling speed Suction Height 7.9.13 Type Voltage Output 7.9.14 Total Make No. Model Rated RPM Rated Horse Power Maximum torque ( at about 1400 rpm) Start system- starting motor Equipment weight Maximum tilt 7.9.15 CUMMINS DIESEL ENGINE No. No. of cylinder Bore stroke (mm) Displacement CID/Lit Maximum HP Rim Peak torque (Ft-Lb) 7.10 7.10.1 ELECTRIACL STARTER TF-24 V1595 Bosch 24 V 1000 watts DOZER (D155A-1)

800C 85 to 900 1.8 to 2.1 Kg/cm2 2.4 to 3.0 kg/cm2 0.75 Kg/cm2 1.5 m

6 Nos. BEMLD155A-1 2 KOMATSU S6D 155-4D Diesel Engine 2000 320 HP 144 KgM 24 V, 11 KW 5780 Kg 1000 mm KT(A)1150 4 6 159 x 159 1150/18.9 525 2100 1550

FUEL OIL SYSTEM

FUEL OIL UNLOADING SYSTEM

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

7.10.2

STORAGE FACILITIES

Three light oil storage tanks of 2,000 m3 capacity each have been installed at the back of the fuel oil pump house. Each tank is provided with immersion type steam heater to keep the oil temp. at around 500 C in case of HFO unloading. SPECIFICATION OF EQUIPMENT 7.10.3 FUEL (L.D.O.) TRANSFER PUMPS 3 Rotary Gear L.D.O. 120 5 80 85 45.50% 975 rpm 600 C 9

No. of pumps available Type of model no. Liquid to be pumped Capacity m3/hr Suction pressure MWC Discharge pressure MWC Total Dynamic head MWC Efficiency Pump speed Maximum Temp. Of liquid to be pumped Setting pressure in kg/cm2 MOTORS Type/Make RPM Voltage H.P. Temp. rise over an ambient temp. of 450 C FILTERS No. Of coarse filters Type/Manufacturer Design Pressure Maximum pressure drop at 75 % Cleanliness 7.10.4 No. off Type Discharge pressure FUEL (LDO) PRESSURE PUMP

TEFC/Crompton 1000 415 V, 3PH, 50 c/s 100 650 C

3 Duplex/Technique 1 kg/cm2 35 kg/cm2

4 Multi screw positive displacement 25 kg/cm2

Capacity MOTOR Manufacturer Type Rating 7.10.5 No. off Make Capacity MOTOR Type Rating 7.10.6 No. off Model No. Capacity Pressure MOTOR Type Rating 7.10.7 No. off Type Make Model No. Capacity Discharge pressure MOTOR Manufacturer Type Rating

250 lit/min.

M/s Kirloskar 3ph. Induction motor. 37 KW, 1500 rpm. LIGHT OIL (HSD) UNLOADING PUMP (STAGE II &III) 1 AROTA 40 m3/hr

3ph. Induction motor. 18.5KW, 1500 rpm LIGHT OIL (HSD) PRESSURE PUMP (STAGE II &III) 2 PDE-45-4 GR-22 AU2 250 Lit/min at 2 CST 25 Kg/cm2

3ph. Induction motor. 18.5KW, 1500 rpm FUEL OIL (LDO) PRESSURE PUMP (UNIT #4) 2 Multi screw positive displacement , Horizontal TUSHACO PDHU-5-4 250 lit/min. 25 kg/cm2

M/s Siemens 3ph. Induction motor. 18.5KW, 3000

7.10.8 No. off Type

FUEL OIL (LDO) PRESSURE PUMP (UNIT #5) 2 Multi screw positive Displacement, Vertical TUSHACO PDH-60-SDEF 250 lit/min. 25 kg/cm2

Make Model No. Capacity Discharge pressure MOTOR Manufacturer Type Rating 7.10.9 LIGHT OIL CHARACTERISTICS

M/s Siemens 3ph. Induction motor. 18.5KW, 3000

1. Flash point 2. Pour point maximum 3. Kinematic Viscosity in Cent. 4. Ash content 5. Carbon residue content 6. Sediment content 7. Sulpher content 8. Moisture content 9. Acidity

660 C minimum 120 C for winter 2.5 to 15.7 Stocks at 380 C 0.02 max. by wt. 1.5 by wt. 0.10 by wt. 1.8 by wt. 0.25 maximum by volume Nil.