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BADARPUR THERMAL POWER

SATATION

TECHNICAL DIARY

210MW

NTPC

NATIONAL THERMAL POWER STATION


INDEX
Sr. No. Contents Page No.
1.0 BOLIER & AUXLIARIES 4-29
1.1 Specifications
1.2 Performance data
1.3 F.S.S.S
1.4 Fans (ID, FD, PA,Ignitor & Scanner)
1.5 Air Heater
1.6 Soot blower
1.7 Electrostatic Precipitator
1.8 Coal burners & oil guns
1.9 Coal mill
1.10 Raw coal feeder
1.11 Fuel oil transfer pump
1.12 Dosing system
1.13 Ash handling system
1.14 D.M. Make up system
1.15 Coal Mill Reject System
2.0 TURBINE & AUXILIARIES 30-46
2.1 Specifications
2.2 Governing system
2.3 Turbine lubrication system
2.4 Condensate system
2.5 L.P.Heaters & air ejection system
2.6 Feed water sytem
2.7 H.P. Heaters
2.8 C.W. pump & C.W. booster pump
2.9 HP & LP Bypass system
3.0 GENERATOR & AUXILIARIES 47-57
3.1 Generator Specification
3.2 Specification Of Static Excitation System Unit
IV & V
3.3 Generator Seal Oil System
3.4 Stator Water Cooling System
3.5 Generator & UAT Transformers
4.0 PROTECTION & INTERLOCK 58-72
4.1 Unit protections
4.2 Partial load conditions
4.3 Protection & interlock of unit auxiliaries
4.4 Electrical protection for unit auxiliaries
5.0 PROTECTION RELAYS SETTINGS 73-86
5.1 Recommended Settings of Generator, GT &
UATs
5.2 Recommended Settings Of 6.6 KV Sections
5.3 Recommended Setting Of MCB Relays
6.0 NEW C&I SYSTEM COMMISSIONED 87-89
7.0 OFF-SITE AUXILIARIES 90-132
7.1 Switchyard
7.2 Air compressors
7.3 Control structure pump house
7.4 Ash Handling Plant
7.5 Cooling Tower
7.6 Diesel generator
7.7 Water Treatment Plant
7.8 Old Coal Handling Plant
7.9 New Coal Handling Plant
7.10 Fuel Oil System
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 Volatile Moistur Ash Grindibility (HGI ) High Heating


Carbon Matter e Value
38 % 26 % 8% 28 % 55 4860 Kcal / Kg

1.1.3 FURNACE Fusion Welded Type

Width Depth Height Volume


13.86 m 10.59 m 42.79 m 5210 cu. m.

1.1.4 SUPERHEATER , REHEATER & ECOMOMISER

S. Description Heating No. of Size (mm) Material


No. Surface Coils / Tube
( sq. m )

1. Low Temp. 8209.5 Upper Bank – 44.5 x 5 1 Cr , ½ Mo


S/H 67 ( SA 213
T11 )
Lower Bank – 44.5 x 4.5 SA210CrAl
67 44.5 x 4.5 SA209T1
Terminal 44.5 x 4.5 SA213T11
Tubes 67 x 6 =
402
2. Platen S/H 944.5 29 a) 51 x 1 Cr , ½ Mo
4.5/5.6/ ( SA
7.1/8.8 213T11 ) &
SA213T22
3. Final S/H 1036 119 a) 47.6 x 2¼ Cr , 1
7.1 Mo
b) 47.6 x ( SA
6.6 213T22 )
c) 47.6 x
8.6
4. Ceiling & 540 Roof Panels – 54 x 4.5 Carbon Mo
Enclosures 120 (SA209T1)
Front Wall – 51x 4.5 Carbon
181 Steel
Rear Wall – (SA210GrA
136 1)
Side Wall – 66 51 x 4.5 Carbon
x2 Steel
(SA210GrA
1

5. Reheater 2650 Front assembly 54 x 3.6 Carbon Mo


–59 47.6 x 3.4 (SA209T)
Rear assembly 2¼ Cr , 1
- 89 Mo
( SA
213T22 )
1 Cr , ½ Mo
( SA
213T11 )
SA213T22
SA213Tp34
7A
6. Economiser 5440 67 44.5 x 4.5 Carbon
Steel
(SA210A)

1.1.5 ATTEMPERATOR

Type No. of Stages Location Medium of Spray


Spray One Between Horizontal Feed Water
& Platen S/H

1.1.6 FUEL SPECIFICATIONS

A) COAL

i. Fixed Carbon 38.%


ii. Volatile Matter 26%
iii. Moisture 8.0%
iv. Ash 28%
v. Grindability 55HGI
vi. High Heat 4860 Kcal/Kg
vii. Coal size to Mill 20 mm
B) OIL

i. Low Heat value 10000 kcal/kg


ii. Sulpher 4.5% w/w
iii. Moisture 1% w/w
iv. Flash point 660 C.
v. Viscosity 1500 redwood at 37.80 C .
vi. Sp. Weight 0.98 at 380 C.

1.1.7 SAFETY VALVES

Location Make & No. Size Set pressure Relieving


type per (kg/cm2) capacity
boiler (t/hr.)
Drum a)dresser 1 3” 158.2 190.04
1749wa
b)dresser 2 3” 161 162.08
1749wa 162.41 195.08
Super – dresser 1 2½“ 144 86.73
Heater 1739wd
SH-electro dresser 1 2½“ 142 88.06
magnetic 1538-vx
Relief valve
Reheater a)dresser 1 4” 33.4 94.7
inlet 1775wa
b)dresser 3 6” 33.75 136.01
1785 34 137.38
34.45 138.76
Reheater dresser 1 6” 30.58 114.93
outlet 1705 rwd

1.2 PERFORMANCE DATA

1.2.1 DESIGNED PARAMETERS

Description Flow (t/hr) Load Temperature ( C0.) Pressure (kg/ cm2)


MCR NCR 60%MCR MCR NCR 60%MCR MCR NCR 60%MCR
210mw 210mw 210mw
Steam
Steam at 700 662 420 540 540 540 137 136 13.2
final SH
Outlet
Steam at 580 575 375 540 540 540 24.5 24.7 14.9
Reheater
Outlet
Steam at - - 332 331 293 26.4 26.5 16.0
Reheater
Steam - - 342 340 334 150.7 148 137.4
from Drum
Steam - - 430 433 452 146 144 135.5
leaving
Horizontal
SH
Steam - - 514 514 512 - -
leaving
Platen SH
Water
Feed water 700 643 371 247 246 220 153 150 139.2
entering
economiser
Feed water - - 278 277 262 - -
leaving
Economiser
Flue gas
Flue gas - - 1125 1135 1118 - -
leaving
Furnace
Flue gas - - 1020 1017 981 - -
entering
Reheater
Flue gas - - 697 690 670
entering
Horizontal
SH
Flue gas 463 459 433
entering
Eco.
Flue gas 364 366 336
entering
APH
Flue gas 146 143 129
leaving
APH
Air
PA flow at 96.7 77.8 70.3 338 336 316
APH Outlet
SA flow at 678.3 624.5 481.5 330 329 311
APH Outlet
Tempering 120.8 85.5 92.9 38 38 38
air
Total 919.3 869.3 668.2
combustion
air
Fuel 110.1 105.1 71.5
Coal(HHV
=5000Kcal/
Kg.)

1.2.2 PRESSURE AND DRAFT (AIR &GAS)

PRIMARY AIR

Description Units MCR NCR Control load


60% MCR
P.A. Fan Outlet mmwc 740 734 700
A.H. Inlet mmwc 727 723 691
A.H.Outlet mmwc 672 672 661
Mill Inlet mmwc 634 634 634
Mill Outlet mmwc 228 228 228

SECONDARY AIR

Description Units MCR NCR Control load


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

FLUE GAS

Description Units MCR NCR Control load


60% MCR
SH Platen Inlet mmwc -5 -5 -5
RH Inlet mmwc -6 -6 -6
Finish SH Inlet mmwc -14 -13 -9
LTSH Inlet mmwc -20 -19 -12
Economiser mmwc -37 -35 -20
Inlet
A.H. Inlet mmwc -54 -49 -31
E.P. Inlet mmwc -184 -165 -84
I.D. Fan Inlet( mmwc -242 -222 -128
Including Static
Head)

1.2.3 MILL AND BURNER PERFORMANCE

Description Units MCR NCR Control load


60% MCR
No. of Burner - 16 16 12
in operation
Burner Tilt Degree 0 +10 +30
No. of mills in - 4 4 3
operation
Mill Loading % 80 79 70
Air flow per T/hr 52.3 52.3 52.3
Mill
0
Air Temp. at C 172 171 160
Mill Inlet
0
Mill Outlet C 77 77 77
Temp.
Fineness % Thru’ 200 70 70 70
Mesh

1.2.4 O2, CO2 ( BY VOLUME ) AND EXCESS AIR

Description Units MCR NCR Control load


60% MCR
O2 in Gas at % 4.3 4.3 5.5
Economiser
Outlet
CO2 in Gas at % 14.9 14.8 13.7
Economiser
Outlet
Excess air in % 25 25 36
Gas at
Economiser
Outlet
1.2.5 DESIGNED PRESSURE DROPS

Description Units MCR NCR Control load


60% MCR
SH System Kg/cm2 13.7 12.0 5.4
RH System Kg/cm2 1.9 1.8 1.1
Economiser Kg/cm2 2.1 2.0 1.8
System

A. Air mmwc
Wind-box 115
APH 94
Air-duct 63
Aero-foil 25

B Across Pulv. 305


Fuel Piping 308

C. Flue Gas mmwc


Furnace 4
S/H & R/H 48
Eco 19
Flue gas Duct & Dampers 52
Regenerative APH 110
Static Head 20
Velocity Head & Exit Loss 20
ESPS 22
Total Loss 295

1.2.6 HEAT BALANCE

Dry gas loss 4.63%


Carbon loss 2%
Radiation loss 0.26%
Unaccounted loss 1.5%
H2 in air and H2O in fuel 4.9%
Total loss 13.3%
Efficiency 86.7%

1.2.7 RECOMMENDED FEED WATER LIMITS

Drum operating Pr. in kg/cm2 61-100 101 & above


1. Hardness Nil Nil
2. ph at 250 C.(Copper alloy pre-boiler syms.) 8.8-9.2 8.8-9.2
3. ph at 250 C.(Copper free pre-boiler syms.) 9.0-9.4 9.0-9.4
4. Dissolved Oxygen(max) ppm 0.007 0.007
5. Total Iron(max)ppm 0.01 0.01
6. Total Silica(max)ppm 0.02 0.02
7. After Cation Column Conductivity at 0.5 0.3
250 C( micro-mhos/cm),online
8. Hydrazine residual(ppm) 0.02-0.04 0.02 - 0.04
9. Permanganate consumption(ppm) Nil Nil
10.Oil Not allowed Not allowed
11 Chlorides not allowed Not allowed Not allowed
12.Copper(max)ppm 0.005 0.005

1.2.8 RECOMMENDED BOILER WATER LIMITS

Drum operating Pr. (kg/ cm2) 61-100 101 & above


1. Total dissolved solids (max)ppm 100 50
2. Conductivity at 250Cmicro-mhos/cm 200 100
3. Phosphate residual(ppm) <20 2-4 #
4. ph at 250C. 9.0-10.0 9.0-9.5
5. Silica(max)ppm 2.0 0.4 *
6. Chlorides(max.)ppb <4000 <2000
7. Total hardness Nil 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. DESCRI PERMISSIVE INTERLOCK PROTECTION


NO. PTION
1. Ignitor 1. Ignitor Oil Pressing one pair (lo or a. ignitor oil
trip v/v Supply Pr. Is ho) of oil gun start push header pr. Falls
Adequate (>13kg button gives a starting below 9kg for >
/Sq.Cm) impulse to all the four 2sec. And
ignitors of that elev. The ignitor V/v not
2. All Ignitor spark is applied for 10 closed.
V/Vs are sec. Only for every b. Boiler trip
closed(cr12 on) pressing of ignitor start command
push button. present(icrl 61
off)
c. When ignitor
trip v/v is closed
“v/v closed” green
signal comes on
(cr63 on)
2. Heavy Oil 1. Boiler trip 1. HO header
Trip circuit (MFR) pressure is low for
Valve is reset. (2 more than 2 secs
CRL 61 is (TDR 281 is ON)
ON) 2. Steam and
2. All HO nozzle heavy oil
valves of AB, differential pressure
CD & EF oil is low (less than 0.3
guns are Kg/Sq.Cm) for
proven fully more than 2 secs
closed. (1 and provided no
CRL 107 AB, guns are being
CD, EF are started or stopped
ON) (TDR 287 is ON)
3. HO supply 3. Boiler trip
pressure is occurs (2 CRL 61 is
adequate OFF)
(more than 7
Kg/Sq.Cm)
4. HO pressure
not low (less
than 1.5
Kg/Sq.Cm for
more than 2
sec. ) TDR
281 is OFF.
3. Heavy Oil 1. DC power
Elevation available
start (TDR 51 is
ON)
2. Ignitor trip
valve proven
fully open (1
CRL 259 is
ON)
3. No boiler trip
command
persists
4. Heavy oil
temp above
100 deg C
5. Air flow
adjusted
between 30 to
40% of full
load air flow
6. Burner tilt
placed in
horizontal
position
4 Heavy Oil 1. The main oil 1. In first 10 secs of
corner gun is inserted pair start time trial
start in guide pipe the associated
& coupled elevation ignitors are
2. The local started. When
maintenance ignitors are proven
control switch ignitor ON signal
is placed in comes (CR 29 AB 1,
remote 2, 3, 4 are ON) If the
3. HO manual flame is not provend
isolation spark will cease and
valve is open jamesbury valve will
4. Atomising close after 10 secs.
steam manual 1 When minimum 3 out
isolation of 4 ignitors at the
valve is open associated elevation
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)
5 HO Depressing the associated
elevation elevation pair button will
shut down 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 SPECIFICATIONS

Sr. Descri Type No Of Capaci Press. Temp KW Motor RPM


No. ption Boiler ty mmwc 0C Voltage
m3/sec KV/V
A ID Fan Axial 2 230.9 387 150 1300 6.6 990
Impulse
Type
B FD Fan Axial 2 103.8 520.5 50 800 6.6 490
Reaction
Type
C PA Fan Radial 2 65.3 1345.5 50 1250 6.6 1485
Backward
Curved
D Ignitor Centrifu 2 400 4’’WG - 11 415v 1460
Air Fan Gal Sefm
E Scanner -do- 2 1100 160 50 1.1 415v 3000
Air Fan M3
F Seal -do- 2 11000 150 50 10 440V 2850
Air Fan M3

1.4.2 FAN LUBE SYSTEM AND CONTROL

A: ID FAN LUBE OIL SYSTEM

S.N. PUMP MOTOR FAN

I TYPE-Gear type Power-0.5HP

II Capacity-5LPM Voltage-415v
Frequency-50C/S,3 Inlet vane control
Ph.
III Operating Press-2Kg/cm2 Speed-1380 RPM

IV Relief Pr-7 Kg/cm2 Rated current-


-1.08 Amps

B: FD FAN LUB OIL SYSTEM:

Pump Motor Fan control


I Type-Gear type Power-4KW

II Capacity-79.2 LPM Voltage-415V, Variable pitch blade


Frequency-50c/s,3Ph control
III Lub oil Pr. 0.8 to3ata (g) Speed-1400 rpm
Rated Current-11
Amp

C: PA FAN LUBE OIL SYSTEM

Sr.N PUMP MOTOR FAN

I TYPE-Gear type Power-0.5HP

II Capacity-5LPM Voltage-415v
Frequency-50C/S,3 Inlet Guide vane
Ph.
III Operating Press-2Kg/cm2 Speed-1425 RPM contol

IV Relief Pr-7 Kg/cm2 Rated current


1.2 Amps
1.5 AIR HEATER

1.5.1 STEAM COIL AIR PRE-HEATER

TYPE Steam Coil R2-10


No.Of Boiler 2
Medium Secondary Air
H.S. IN M2 770 per Air Heater

1.5.2 RE- GENERATIVE AIR PRE-HEATER

Type Tri Sector Regenerative 27 vi 72 (T)


No. Boiler 2
Medium i)Primary Air
ii) Secondary Air
iii) Flue gas
H.S. IN M2 19000 per Air Heater

HEATING ELEMENT ROTOR DRIVE CLEANING


DEVICE
i) Hot layer-864 mm i) Motor-GE 15 HP i) Motor-0.25 HP
Open hearth steel
ii) Intermediate ii) Voltage-415v ii) Speed reducer
Layer-864mm 4800:1
Open hearth steel iii) Speed-960 rpm
iii) Cold layer-305mm iv) Speed-110:1 reducer
corten –A steel v) Oil Capacity-13G

SUPPORTING BEARING GUIDE BEARING AUX.AIR MOTOR

i) Type- Spherical Thurst Double roller Motor-4 BHP


Bearing bearing
ii) Lubrication-Oil Oil Bath Air Pr.-5.6 Kg/cm2
bath type
iii) 18 Gallons Oil capacity-4 Speed-255 rpm
Gallons
iv) Motor rating-3/4 HP 1 to 0.5 HP
1.5.3 PERFORMANCE OF AIR PREHEATER

500 PA 500 PA 720 PA REVERSE


NORMAL REVERSE ROTATION
ROTATION ROTATION
FLOW t/hr mmWC mmWC NORMA 20% 20%
L MORE LESS
PRI Air In 180 165 163 182 144
SEC Air In 681 697 699 837 561
GAS Gas In 999 999 999 1199 799

PRI Air Out 97 97 97 116 78


SEC Air Out 680 680 680 816 544
GAS Gas Out 1084 1085 1085 1286 884
0 0 0 0 0
TEMPERATURE C C C C C
PRI Air In 38 38 38 38 38
SEC Air In 41 41 41 41 41
GAS Gas In 369 369 369 369 369

PRI Air Out 337 325 326 321 331


SEC Air Out 329 333 334 332 338
GAS Gas Out 146 146 146 149 142
PRESSUR DROP mmWC C mmWC mmWC mmWC mmWC
PRI Air 44 44 22 29 14
SEC Air 90 90 124 159 107
GAS 112 112 112 146 75

1.6 SOOT BLOWER

Location Header Pr Type Qty./Boiler Medium


(Kg/cm2)

i) Furnace 30 Wall 56 Super


blowers heated
RWSE steam
ii) Platen,Convention 30 Long 20 Super
Super heater & retractable heated
Re-heater
ii) Air Heater 30 Swiveling 2 Super
heated
steam
1.7 ELECTOSTATIC PRECIPITATORS

1.7.1 DESIGN CONDITIONS UNIT # 4 UNIT # 5

i) Gas flow rate 1333709 m3/hr. 133380 m3/hr


ii) Temprature 1500 C 1460 C
iii) Dust concentraion 31.8 gm/m3 28.3 gm/Nm3
iv) Inlet pressure 2000mmwc 2000mmwc
v) Type 2 FAAX .5x36-9590-2 2FAA. 5x32-11190-2
vi) NO. of boilers 2 2
vii) No. off fields in series 5 5
in each gas path
viii) No. of parallel pass per 4 4
boiler
ix) Design pressure drop 99% 99%
across precipitator
x) Design pressure drop 15MMWC 15MMWC
across precipitator
xi) Gas velocity at electrode 1.08 m/sec. 0.93 m/sec
Zone
xii) Treatment time 16.62 sec. 17.243 sec

1.7.2 COLLECTING PLATES EMITTING ELECTRODES

i) No. of rows per field 38 No of electrodes in each rows 32

ii) No. of collecting plates 384 No of electrodes in each field 1184


per field (8plates in each row)
iii) Total no. of plates/boiler 6080 No .of electrodes / boiler 23680
iv) Nominal height of 9M Total length of electrodes 6829M
Collecting plates per field
v) Nominal length of 400 MM Size 2.5 mm
Collecting plates
vi) Specific collecting area 132.88 m2 Plate/wire spacing 150mm
Type Spiral with hooks

1.7.3 RAPERS FOR COLLECTING RAPERS FOR EMITTING


PLATES ELECTRODES

i) No. & type of One drop hammer Type & no. Spiral hooks
rappers Per row for collecting approx one
Surface area of 57.6m2 dropHammer/
Two rows
ii) Rapper weight 4.9 kg. Rapper wt. 3 kg.

iii) Frequency varies from 6 raps/hr.at Frequency 10 raps/hr


Inlet field to 1 rap/hr. at
Exit field
iv) Drive ` Geared electric motor Drive Geared elec
controlled by synchronous tric motor
programmer with synch
ronous programmer

1.7.4 HOPPERS

i) Type & quality Pyramidal


ii) No. of hoppers 40 (2 per field)
iii) Capacity 8 hrs. storage
iv) Heating Electrical heating at hopper bottom

1.7.5 GAS DISTRIBUTION SYSTEM

i) Type & quality Perforated plate 25 sets


ii) Location Inlet of precipitator

1.7.6 ELECTRICAL SYSTEM

A) RECTIFIER UNIT # 4 UNIT # 5

i) Rating 60kv (peak/800 m.a.) 70 kv (peak/1000 m.a.)


ii)Number 20 20
iii) Type Silicon diode full wave bridge connection
iv) Location Mounted on precipitator top

B) RECTIFIER CONTROL PANEL

i) Type & control Thyristor/microprocessor based)


on controller(PRECICON
ii)Number 20
iii) Location In the control room at ground level

C) AUX.CONTROL PANEL

i)Number 4
ii)Equipment controlled Geared motors for rapping mechanism, heating
elements om hoppers & shaft insulators.
iii) Location 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) For 20 insulators at the rate of 1 kw = 20 kw


ii) Support insulators for 80 insulators at the rate of 1 kw = 80 kw

1.8 COAL BURNERS,IGNITORS & OIL GUNS

A) COAL BURNERS

i) Type Titling tangential fired corner


ii) No. of boiler 24 (4 each in 6 elevation)
iii) Titling limit +/- 30 deg. Cent.

B) IGNITORS
i) Type 6 eddy plate oil side ignitors air atomised
ii) NO. off 12 (4 per elevation)
iii) Location Elevation AB,CD,EF
iv) Capacity 0.5 millions k.cal./hour
v) Turn down ratio Nil
vi) Oil pr. At control cabinet 12.5 to 14 kg/cm2
vii) Oil firing rate 50 kg/hr/ignitor
viii) Atomising air quality Water free service
ix) Atomising air pr. 5.5 to 7 kg/cm2
x) Atomising air consumptio 14.5 Nm3 / hr/ ignitor-when off
xi) Combustion air quality 560 Nm3 / hr / ignitor
xii) Combustion air pr. At wind box 75 MMWC

C LIGHT OIL (W.U.) GUNS

i) Type Tilting, tangential, air atomized internal mix


ii) No. off 4
iii) Location Elevation AB corners
iv) Capacity 10% of boiler MCR
v)Turn down ratio 2.5 :1
vi) Oil firing rate 1265 kg / hr / gun
vii) Atomising air quality Service air water free
viii) Atomising air consumption 190 Nm3 hr / gun
ix) Atomising air pr. 5.36 kg/cm2
x)Differencial pr. Between oil & air 1 kg/cm2

C) FUEL (LDO) OIL GUNS

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 XRP 783 Bowl Mills


ii) No. of boiler 6
iii) System pressurised
iv) Capacity 39.7 mt / hr
v) Coal grindibility 55 HGI
vi) Max. moisture content 12%
vii)Finness through 200 mesh 70%

MOTORS

i) Rating 340 kw
ii) Voltage 6.6 kv 3 phase
iii) Frequency 50 c/s
iv) RPM 990
v) Rated current 41.7 Amps
vi) No load current 15-16 Amps

1.10 RAW COAL FEEDER

i) Type chain type


ii) Width 600 mm
iii) Length 12400 mm
iv) Speed variation 1:6
v) Depth of coal bed 120-200 mm
vi) Capacity max. 45 mt / hr.

MOTORS

i) Rating 7.5 kw
ii) Voltage 415v
iii) Current 15.5 Amps
iv) Speed 975 rpm

1.11 FUEL OIL TRANSFER PUMPS

DESCRIPTION TRANSFERPUMP DRAIN PUMPS

i) Capacity 120 m3 /hr 5 m3 / hr


ii) Discharge 80 MMWC 40 MMWC
iii) Suction 5 MMWC 5 MMWC
iv) Max. temp. of oil handle 600 C 600 C
By the pump

1.12 DOSING SYSTEM

DESCRIPTION PHOSPHATE HYDRAZINE

i) Soln. preparation tank 1 no. 600 ltr. 1 no. 500 ltr.


ii) Metering tank 1 no. 600 ltr. 1 no. 500 ltr.

A) PUMP

I) No. of boiler 2 2
ii) Capacity 0-100 ltr./hr. 0-30 ltr./hr
iii) Type Horizontal Horizontal
reciprocating reciprocating

iv) Head 195 kg / cm2 110 MMWC

MOTOR

i) Rating 2.2 kw
ii) Voltage 415 v,50 c/s
iii) Speed 1430 rpm
iv) Current rating 4.8 amps.
1.13 ASH HANDLING SYSTEM

A) MAX.ASH COLLECTION RATE

i) Bottom ash hopper: (1 No.) 12 ton/hr.


ii) Air heater hopper (4 No.) 2.08 ton/hr.
iii) Economiser hopper (4 No.) 1.74ton/hr
iv) EP hopper (4 No.) 52.36 ton hr/
v) Stack hopper (2 No.) 0.79 ton/hr
vi) Bottom ash 12 ton/hr.
vii) Fly ash 56.97 ton/hr.
viii) Total ash 66.97 ton / hr.
ix) Gross storage volume 33 M3
of BA Hopper
x) HP Water pressure 9.5 kg/cm2
xi) LP Water pressure 5.5 kg/cm2

B) ASH PUMP:

i) Quantity of sealing water 15 m3/hr.

ii) Pressure of sealing water 8 kg/cm2


iii) Pump capacity 1000 m3 / hr
iv) Head developed 23-33 MMWC
v) Speed 800 rpm

C) ASH ANALYSIS

i) Silica 55.09-68.8 %
ii) Alumina 19.8-29.8 %
iii) Iron oxide 3.05-18.3 %
iv) Titanium oxide 10.0-2.05 %
v) Lime 1.1-2.1 %
vi) Magnesia 0.26-1.2 %
vii) Sulfuric acid hydrous 0.4-1.8 %
viii) Phosphoric Anhydride 0.19-0.28 %
ix) Alkalis 0.16-3.04 %

1.14 MAKE UP SYSTEM

No .of DM Water storage tank 5

1.14.1 MAKE UP PUMP MOTORS


i) No. 2 Make-Crompton greaves
ii) Make: Mather & platt
iii) Type: 4/5,two stage MEDI Type-Induction motor
Voltage-415v,3 phase
iv) Discharge-100 m3/hr. Current-49 amps
v) Head-50 MMc Speed-1475 rpm
vi) Speed-1480 rpm

Connected to hot well, unit drain tank & deaerator.

1.14.2 FILL PUMPS MOTORS

i) No.-2 nos Make-Crompton greaves


ii) Make : IIIplurovane,5 CHR Type-AC induction motor
iii) Discharge-200 m3/hr. KW/HP- 187/250,voltage-6000v
21 amps.
iv) Head – 200 mwc
v) Speed – 1480 rpm Speed – 1483 rpm
Connected to-boiler drum & deaerator.

1.14.3 QUANTITY OF WATER REQUIRED FOR BOILER FILLING:

SYSTEM UNIT ENTIRELY UNIT FILLED TO


FILLED (M3) OPERATING LEVEL (M3)

1676 internal dia drum 37.20 11.53


Water walls 126.3 126.30
Super heater 97.18 ----
Reheater 48.10 ----
Economiser 25.17 25.17
Main steam piping 12.05 ----
------------- -------------
TOTAL 345.00 163.00
------------- -------------

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 equipment’s Erection, Testing &
Commissioning of complete system. A/T No.BTPS/PUR/P3/IMP/86-87/2428 dt. 31-12-
86

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 : 2


Capacity each : 5 m3

SECONDARY SYSTEM:

From storage bins to stage-I mills 2C & 3C


Air receiver capacity for secondary system: 10 m3

1.15.6 DENSEVEYOR

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

1.15.7 AIR COMPRESSORS

Type Screw
Model & Type SES-520 single stage
Capacity 520 cfm +/- 5%
Make Khosla Indair
Drive Motors NGEF
Discharge Pressure 7 kg/cm2
Speed 4500 RPM
Actual Quantity of free air compressed FAD 520 +/- 5% cfm
Volumetric efficiency 91%
Brake HP required at Comp.shaft at 105.0 HP
rated load
Motor Rating 130.0 HP
Type of bearings for rotors Cylindrical roller and 4 point
Bearings
Details of lubrication Oil flooded (forced feed)
Materials of construction:
Rotors EN-8
Gears EN-41B
Bearings Mfd.Std.
Frame and running gear (coupling) forged steel,
rubber – flexible
Shaft EN-8
Base plate MS
Type and size of suction and Butterfly suction valves -
discharge valve MS (CI body) DK-100 (4")
Details of special features After cooler and oil coolers
Total cooling water quantity 150 LPM
required at 360C
Cooling water out let temp. 100 C above inlet temp. Oil
cooler and after cooler.

1.15.8 AIR FILTER CUM SILENCER

Type Dry filter type


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

Equipment & Model Electromagnetic vibratory feeder - Model F-33


Duty For handling coal mill rejects
Manufacturer Internal Combustion
Quantity 2
Maximum capacity 25 T/Hr
Particle size 30 - 35 mm (Max.)
Bulk density of material 1600 kg/ m3
Inclination to horizontal 6/8 deg
Power supply 400/440 V
Power consumption 525 Watts
Feeders through size 450 mm x 1100 mm
Material of trough MS
Type of suspension Suitable for suspension type arrangement
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

i) H.P. CYLINDER 12 stages (1st is governing stage) each stage


Consists of a diaphragm & a set of moving
Blades connected on a disc
BODY In two valves made of Creep Resistance
(Cr-Mo-V) steel
STUDS & NUTS High Creep Resistance (Cr-Mo-V) steel
Forgings
NOZZLE & STEAM 4 Nos (2 on Top & 2 on sides) made
CHEST of High Creep resisting (Cr-Mo-V)
Steel casting
ii) I .P. CYLINDER 11 stages
BODY 2 parts (a ) Pressure part made of
Creep Resisting (Cr-Mo-V) steel
Casting in 2 halves (b ) exhaust part
Made of fabricated steel structure
In 2 halves.
STUDS & NUTS Creep Resisting (Cr-Mo-V)
steel Forgings
NOZZLE BOXES Cast integral with the casing.

iii) L.P.CYLINDER Stages 4( double flow) last but


one stage on each sides are
Baumanns satg
BODY In 3 parts (1 middle & 2 exhaust
parts) All fabricated from weldable
quality mild steel & divided in two
halves horizontally.
iv) H.P.ROTOR All the discs integrally forged
with the shaft of single (Cr-Mo-V)
steel forging. H.P./I.P rotor coupling
is rigid coupling.
v) I.P.ROTOR 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.
vi) L.P. ROTOR 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.
vii) ROTOR BLADES High temp zone blades are of high
(Cr-Mo-V) steel & rest are
of stainless steel.
2.1.3 STEAM EXTRACTIONS

No of Steam Connected Ext, steam Ext.steam Steam flow


extractions extraction to press in Kg/ temp.in 0C T/hr.
stages cm2 in
Ist (HPT) 9th HPH-7 39.06 337 400
Iind (CRH 12th HPH-6/D/A 26.2 314 77
IIIrd (IPT 15th HPH-5/D/A 11.96 433 16.2
IV (IPT) 18th LPH4 6.47 3680C 26
V (IPT) 21st LPH3 2.78 252 23
VI (IPT) 23rd LPH2 1.28 172 28
VII (LPT) 25th LPH1 0.28 - 12.6
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.

ix) 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.

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 EVENT


4.6mm IV begins to open
5.5 mm ESV begins to open
5.9 mm IV fully open
6.65 mm ESV fully open
9.6 mm 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 MOB DTE oil medium


system and bearing) or
Turbine oil -14
Or
Servo prime -14
Or
Turbinol-47
Specific gravity at 500C 0.852
Kinematic viscosity at 500C 28 Centistokes
Neutralization number 0.2
Flash point 2010C(min)
Pour point 66.600C(max)
Ash percentage by weight 0.01%
Mechanical impurities Nil
Oil pressure in governing system 20 Kg/cm2 (Guage)
Oil pressure for lubrication of bearings 1 Kg/cm2 (Guage)

2.3.2 MAIN OIL TANK

Capacity 28000 Lts


Oil capacity in systems 4000 Lts
Main oil centrifuge capacity 6000 Lts/Hr
Oil transfer pumps capacity for purifier unit 6000 Lts/Hr
Polishing filter capacity 6000 Lts/Hr
Impure and pure oil storage tank capacity 40 m3 each
Impure and pure transfer oil pump capacity & head 45 m3 /Hr, 18 MWC

2.3.3 MAIN OIL PUMP

Pressure corresponding to discharge of 4000lits/min 20 Atg


Pressure corresponding to discharge of 7000lits/min 16 Atg
Suction pressure 1Atg
Power consumption 250 Kw
Type of coupling with rotor Flexible gear type
No. of injectors 2 Nos.
Oil pressure developed by Ist injector 1 Kg/cm2
Oil pressure developed by IInd injector 3 Kg/cm2
Speed 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 200 Kw
Speed 1000 rpm
Voltage 6.6 KV,3 Ph, 50 C/s
Arrangement Horizontal

2.3.5 A.C.STANDBY OIL PUMP

PUMP MOTOR
Type 150COAV ,BHEL Type 22F Q UE/O
(multistage, centrifugal oil
Pump, driven by motor) Power 25 Kw
Capacity 150 m3 /Hr,(2500 L/Min) Speed 960 rpm
Head 30 MWC Current 52 amps
No. of stages 2 Voltage 415 volts,3 Ph, 50
C/S
Arrangement Vertical
Impeller material Bronze
Min. oil pressure 0.6 Kg/cm2 For auto starting

BEARING

Type Single Row Deep Grove Ball Bearing


( Thrust anti friction bearing)
Number S.K.F. 6306
Lubricant Mobile D.T.E. medium IOC

2.3.6 D.C. EMEGENCY OIL PUMP

PUMP MOTOR

Type 100 NCU centrifugal pump Power 13 Kw


driven by D.C. motor Voltage 220 volts D.C.
Min. oil pressure 0.5 Kg/cm2 Current 67.6 amps
for starting Speed 1500 rpm
interlock Type D-62
Capacity 108 m3 /Hr
(1800 L/min)
Head 22 MWC

BEARING

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 MAIN CENTRIFUGE (OIL PURIFIER)

PUMP MOTOR

Type of oil purifier MAB-206-S-20 KW(HP) 7.5(10)


Capacity of purifier 6000 Lts/hr Frequency 50 Hz
Capacity of transfer pumps 6000 Lts/ hr Voltage 440 Volt
Oil pressure at inlet of separator 2.35 Kg/cm2 Current 13.6 amps
Speed 1500 rpm (max) Speed 1440 rpm

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 WH
KW 120
Voltage 440 volts

2.3.8 MAIN OIL COOLERS

No. of coolers 5 nos.(4 nos. at a time in service)


Cooling surface area of oil coolers 63 m2
Quantity of oil cooled 1500 Lit/min or 90 m3 /Hr
Water consumption 130 m3 /Hr
No. of water paths 4
Designed oil pressure 5 Kg/cm2
Designed water pressure 5 Kg/cm2
Working pressure of oil 3 Kg/cm2
Working pressure of water 2.5 Kg/cm2
Inlet oil temperature 550C
Outlet oil temperature 450C
Inlet water temperature 330C(max360C)
Outlet water temperature 35.640C
Rated oil velocity 1.1 M/sec
Rated water velocity in tubes 1.25 M/sec
Frictional drop for the bank of operative 1.6 MWC
oil coolers on the cooling water side
Dia. of tubes 19/17 mm
Heat transfer coefficient 400 Kcal/m2 Hr 0C
Hydraulic resistance on oil side 1.48 Kg/cm2
No. of oil circulation passes 22
No. of partitions 21
Hydraulic test pressure of oil coolers 8 Kg/cm2

2.4 CONDENSATE SYSTEM

2.4.1 CONDENSER

2 (Nos, 50% capacity of 2 pass/condenser)


Design pressure (steam space) 0.1 Kg/cm2
Cooling water consumption 2*13500 m3/hr
No. of cooling tubes 2*7810=15620
Length of cooling tubes 10 mts
Dia of cooling tubes 30/28 mm
Weight of condenser without water 305 tonnes
Tube material Cooling Zone Cupronickel 190/10
Air zone Cupronickel 70/30
Water boxes material Rolled steel plates
Max. permissible design pressure of cooling tubes 5 Kg/cm2 Gauge

2.4.2 CONDENSATE PUMP

PUMP MOTOR

3 nos (50% capacity each) Type AVM450M4


Type 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 75 0C
Max motor bearing temperature 75 0C
Max vibration of gland housing 40 microns
& thrust bearing
Max condensate temperature 180 0C

2.5 LP HEATERS & AIR EECTION SYSTEM

2.5.1 L.P.HEATERS

LPH Type Location Tube Shell Tube plate No. of relief


No. material Material material valve
1 Inside upper Horizontal U. shape Fabricated Mild Steel 2 Nos.(1 for
part of each surface type brass from MS steam side&
condenser( in 16*10 plates 1 for cond.
two halves) side
2 Mezzine floor Vertical --DO-- --DO-- --DO-- --DO--
surface type
3 --DO-- --DO-- --DO-- --DO-- --DO-- --DO--
4 --DO-- --DO-- --DO-- --DO-- --DO-- --DO--

2.5.2 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 DRIP PUMP

PUMP MOTOR

Nos. 2(100% capacity) Output 90 KW


Type 100 CJH, multistage centrifugal Voltage 415 V
Horizontal pump
No. of stages 9 Current 148 amp
Delivery quantity 1416 L/min Speed 1475 rpm
Manometric head 195 MWC Frequency 50C/S
Speed 1475 rpm
Temp. of liquid 1000C max

2.5.5 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

Type of Nos. Range Aux. Steam Steam Steam


ejector source of pressure temp. in consumption
0
steam in C in kg/hr
kg/cm2
A) 1 Up to 450 mm D/A or 16 4.5 250 1100 kg/hr
Starting Hg column in ATA
ejector condenser header
B) Main 2 Up to 760 mm --Do-- 4.5 250 750 each
ejector Hg column in
condenser
C) 1 Up to 200 mm --Do-- 4.5 250 1100
Priming Hg column in
ejector condenser
D) Gland 1 Eject steam --Do-- 4.5 250
steam and air mixture
cooler from end gland
No.1 seals of main
turbine
2.6 FEED WATER SYSTEM

2.6.1 BOILER FEED PUMP

A) PUMP

No. of pumps 3 Nos. (50% capacity)


Type Multi stage , Horizontal high pressure,
Barrel type pump 200 KHI
Nos. of stages 6
Max. rated suction pressure 12.3 ata
Discharge capacity 430T/hr
Head 1830MWC
Feed water temp. 164.20C
Speed 4320 rpm
Lubrication Forced
Stuffing box Mech seal
Quantity of water for 100 T/hr
minimum take off
Min. suction pressure of BFP 6 Kg/cm2
Quantity of water for 8 T/hr
Heating take off
Cooling water consumption 280 T/min.(Approx)
Net weight of pump 5850 Kg
Drive Electric motor through hydraulic coupling

B) MOTOR

Manufacturers M/S BHEL Hardwar


Type ATD-4000
Output 4000 KW
Rated Voltage 6.6 KV
Current 421 amp
Speed 1483 rpm
Frequency/ power factor 50 C/S, 0.914

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 415 V, 3 Ph, 50 C/S
Type of Aux. oil pump Gear type
Type of main oil pump Gear type
Oil pressure in radial bearing 0.8 to 1.00 Atg
Bearing temperature 650C(max)
Oil pressure for thrust bearing 0.5 Atg
Min. discharge pressure of BFP 120 kg/cm2
Max feed water temperature at BFP discharge 1750C
Max BFP flow 475 T/hr
Max motor bearing temperature 800C
Max temperature difference of 30 0C
feed water and BFP body
Max motor hot air/ temp. 80 0C (600C normal)
Normal BFP discharge pressure 170 kg/cm2
Seal water temp. 650C-700C

2.6.3 BOOSTER PUMP

No. of pump one for each BFP


Use 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 H.P.HEATER No.5 H.P.HEATER No6 H.P.HEATER No7


Feed water inlet 166.76 184.92 220.90
temp. in 0C
Enthalpy of F.W. 170.70 189.51 227.48
inlet in Kcal/kg
F.W. outlet temp in 184.92 220.90 242.78
0
C
Enthalpy of F.W. at 189.51 229.48 251.41
outlet in Kcal/kg
F.W. flow (kg/hr) 643165 643165 643165
Ext. stem inlet 11.96 26.20 39.06
pressure in kg/cm2
Ext. stem inlet temp. 433 314 377
in 0C
Enthalpy of Ext. 796 727 754
steam in Kcal/kg
Steam flow (kg/hr) 16271 44777 29880
No. of coils 292 288 288

Load at which H.P. Heaters are taken into service 60 to 70 Mw


Without H.P. Heaters ma. Curtis wheel pressure 89 kg/cm2
Full load Curtis wheel pressure with H.P. Heaters 102 kg/cm2

2.8 CW PUMPS & CW BOOSTER PUMP

2.8.1 CIRCULATING WATER PUMP

No. of pumps 2 Nos.(100% capacity)


Make FLOWMORE
Number of stage One
Capacity of pump 15000 m3 /hr
Total dynamic head 11.5 MWC
Efficiency 86%
Speed 420 rpm
B.H.P. 740 HP
Motor BHEL, 950HP,6.6 KV splash proof type
Type of pump lubrication Self water lubricated
Direction of rotation Anti clock wise (from top)
Coupling of motor & pump Rigid type
CW water is used in Condenser, Main oil coolers& H2 gas
coolers

2.8.2 C.W. BOOSTER PUMPS

PUMP

No. of pump 2 Nos.(100% capacity)


Lubrication in board & Mobilux grease No.2
Outboard bearing
Speed 1487 rpm
Make Mather Greaves Pvt. Ltd.
Discharge pressure 2.5 kg/cm2
Normal bearing temperature 600C
Normal pump vibration 40 microns

MOTOR

Output 55 KW
Speed 1487 rpm
Amps 96
Voltage 415 V
Make NGEF

2.9 H.P.& L.P. BYPASS SYSTEM

(i) 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)
(ii) All the HP & LP BYPASS valves are hydraulically operated for which oilat
about 50 kg/cm2 is supplied by a separate oil supply unit.

2.9.1 DESIGN CAPACITY OF H.P. BYPASS STATION

Injector water Boiler feed water


Nos. of H.P. Bypass valve 1 for each MS line
Total capacity 200T/hr steam flow
Capacity of each bypass valve 100T/hr steam flow
Max. MS temp. 5400C
Max MS pressure 140 ATA
Down stream temp 3800C

2.9.2 DESIGN CAPACITY OF LP BYPASS STATION

Injector water Condensate water


Nos. of LP Bypass valve 1 for each HRH line
Capacity of each LP bypass valve 112T/hr steam flow
Total capacity 224T/hr steam flow
Design temp. 5400C
Down stream temp 2000C (max)
Steam pressure at upstream side 6 kg/cm2

2.10 TURBINE ROLLING & LOADING GUIDE LINES

2.10.1 TURBINE ROLLING GUIDE LINES

S. No. If max metal temp of HPT If max metal temp is less than If max metal temp
casing is less than 1500C 1500C-3500C is more than 3500C
1 Speed from 0-500 rpm Speed from 0-500 rpm Speed from 0-1200
= 5 mts = 5 mts rpm
= 5 mts
2 Hold at 500 rpm =10 mts Hold at 500 rpm =5 mts for Hold at 1200 rpm
checking differential expansion, =5 mts for checking
bearing vib etc. differential
expansion, bearing
vib etc.
3 Speed from 500 rpm to From 1200 rpm to
1200 rpm @ 50 rpm = 14 3000 rpm = 5 mts
mts without any pause
4 Hold at 1200 rpm Raise the speed from 500 rpm
(Soaking)= 20 mts to 1200 rpm = 5 mts
5 Speed from 1200 rpm to
Hold for 3 mts for checking
3000 rpm =5 mts differential expansion, bearing
vib etc.
6 Hold at 3000 rpm Raise the speed from 1200 rpm
(Soaking)= 20-25 mts to 3000 rpm = 3 mts without
any pause
7 Hold the turbine at this speed
(3000 rpm) for checkings.
8 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


If the max. casing If the max. casing
less than 1500C metal temp. is less metal temp. is
than 1500C-3500C more than 3500C
1 Load up to 5 to 7 Mw after Load after synch. = Load after synch.
synchronization 20 to 30 Mw 20 to 30 Mw. After
Steam pr =30 Kg/cm2 Steam pr. =70 taking mills ( one
0 2
Steam temp. =350 C Kg/cm by one) in service
Steam temp. before IV=3200C Steam temp = 3500C load can
Soaking time =30 mts Soaking accordingly be
time=10mts. raised to 210 Mw
depending upon
other conditions.
2 5 Mw to 30 Mw @ 3 Mw/10 mts From 30 Mw to 65
in 70 mts. Mw in 35 mts.
Steam pr before ESV =65 Kg/cm2 Soaking time =35
Steam Temp =4300C mts.
Steam temp before IV =4200C Steam pr =90
2
Soaking time = 20 mts Kg/cm
( All the drain valves in extraction Steam temp =4500C
lines of LP heaters to be closed.)
3 Raise from 30 Mw to 70 Mw @ 1 From 60 Mw to 210
Mw/ min in 50 mts. Mw = 45 mts
Steam pr before ESV =105 Depending upon
Kg/cm2 other conditions
Steam temp before ESV=4900C
Steam temp before IV=4800C
Soaking time= 30 mts

4 Raise from 70 Mw to 210 Mw in


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 247000 KVA


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

3.1.2 MAIN PARAMETERS OF THE COOLING MEDIUM

A. HYDROGEN IN STATOR CASING

i) Nominal hydrogen pressure 3. 5 Kg/cm2


ii) Permissible variation +/- 0.2 Kg/cm2 (G)
iii) Nominal cold gas temperature 440C
iv) Hydrogen purity 97%
v) Relative humidity hydrogen at normal pressure 60%
vi) Oxygen content 1.2%

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 370C
ii) Minimum allowable water temperature 150C
iii) nominal water flow 350 m3/Hr
iv) Maximum permissible cooling water 4 Kg/cm2 (G)
pressure in the gas cooler

D. WATER TO STATOR WINDING WATER COOLER

i) Nominal consumption of cooling water at temp. of 350C 95 m3/Hr


ii) Nominal consumption of cooling water at temp. of 370C 110 m3/Hr
iii) ) Nominal consumption of cooling water at temp. of400C 130 m3/Hr

3.1.3 ELECTRICAL DATA

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

i) Ratio of ceiling voltage to the rated excitation voltage 2.0


ii) Ratio of thre field forcing current to the nominal current 1.6
iii) Duration of field forcing 10 Secs
iv) Response Time 100 milisecs

3.1.5 SHORT CIRCUIT CURRENTS

i) Sub transient current on three phase short circuit 10 Pu


ii) Transient current on three phase short circuit 3.3 Pu
iii) Steady state current on three phase short circuit 1.4 Pu

3.1.6 REACTANCES

i) Direct axis sub transient reactance ( x”d) 0.214 Pu


ii) Direct axis transient reactance (x’d) 0.305 Pu
iii) Direct axis synchronous reactance (xd) 2.22 Pu
iv) Negative phase sequence reactance (xd2 ) 0.26 Pu
v) Zero sequence reactance (xo) 0.105

3.1.7 PERMISSIBLE TEMPERATURE RATINGS

i) Maximum temperature of stator core 1050 C


ii) Maximum temperature of stator winding 1050 C
iii) Max temp of rotor wdg. 1150 C
iv) Permissible temperature rise of rotor winding 710 C
over cold gas temperature
v) Maximum temperature of hot gas 750 C
vi) Maximum distillate temperature at stator winding outlet 850 C
vii) Maximum stator winding temperature 750 C

3.1.8 TIME CONSTANTS

i) Field time constants with open circulated stator winding (Tdo) 7 secs
ii) Field time constants with three phase sort circuit 0.96 secs
current of stator winding(T’d3)
iii) ) Field time constants with two phase sort circuit 1.5 secs
current of stator winding(T’d2)
iv) Field time constants with one phase sort circuit
current of stator winding 1.73secs
v) Time constant of the aperiodic component for 3 phase short circuit(Ta3) 0.29 secs
vi) Time constant of the aperiodic component for 2 phase short circuit(Ta2) 0.24 secs
vii) Time constant of the aperiodic component for one phase short circuit(Ta1) 0.25 secs
viii) Time constant of the periodic component of the sub transient
current for 3 phase : 2 phase and 1 phase short circuit(T”d) 0.121 secs

3.1.9 GENERATOR VOLUME AND FILLING QUANTITIES

i) Total gas volume of the generator 56 M3


ii) CO2 for expelling hydrogen with unit at standstill 120 M3
iii) CO2 for expelling hydrogen with unit under rolling 168 M3
iv) H2 filling quantity with unit at standstill 300 M3
v) H2 filling quantity with unit rolling 340 M3
vi) Make up Hydrogen required per day 15 M3
(max)
3.1.10 TORQUE, CRITICAL SPEED ETC

i) Torque under normal working condition 76.32 Tons


ii) Ratio short circuit torque to full load torque 8
iii) Flywheel moment of the rotor 21.1 T.M2
iv) Ist critical speed of the rotor( calculated) 1370 rpm
v)2nd Critical speed of the rotor (calculated) 3400 rpm

3.1.11 OIL CONSUMPTION

i) Consumption of oil per generator bearing (Excluding shaft seals) 300lit/min


ii) Oil pressure at bearing inlet 0.3to 0.5
Kg/cm2
iii) Consumption of oil in both the shaft seals 160 lit/min
3.1.12 OVERALL DIMENSION AND WEIGHTS

i) Overall stator diameter 3960 mm


ii) Length of the stator 6580 mm
iii) Length of the rotor 9770 mm
iv) Diameter of the rotor barrel 1075 mm
v) Weight of the heaviest lift (Stator with gas coolers and turnions) 175,000 Kg
vi) Weight of gas cooler 1415 Kg
vii) weight of rotor 42,000 Kg
viii) Weight of bearings with brush gear along with foundation plates 49,500 Kg
ix) Weight of end terminals 85 Kg
x) Weight of end shield 2000 Kg
xi) Total weight of generator 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) Direct axis transient reactance


i) Saturated x’d p.u. 0.234
ii) Unsaturated x’du p.u. 0.266

c) Direct axis sub-transient reactance


i) Saturated x’d p.u. 0.179
ii) Unsaturated x’du p.u. 0.214

8. Machine Time Constants:


i) Direct axis transient open ckt T’do sec. 7
ii) Direct axis transient close ckt T’do sec. 0.84
iii) Sub-transient T”d sec 0.03
iv) Armature Ta sec. 0.29

9. Field winding resistance at 20 oC Rf 20 ohm 0.0878

10 Field excitation requirement


i) No load field voltage ufo VDC 102
ii) No load field current Ifo ADC 917
iii) Nominal field voltage Ufn VDC 310
iv) Nominal field current Ifn ADC 2600
v) Max. cont. rated field voltage Ufmax VDC 338
vi) Max. cont. rated field current Ifmax ADC 2830
vii) Ceiling voltage Ud VDC 620
viii) Ceiling current Id ADC 4500
ix) Duration of field forcing -- Sec. 10

11. Field test voltage - Kvrms -


12. Synchronising slip - % -
13. AVR CT Ratio - AAC/AAC
10,000/5
14. AVR PT ratio - VAC/VAC 15750/110
15. Ambient - oC 50
16. Altitude - meters 1000

B) SPECIFICATION OF STATIC EXCITATION EQUIPMENT

1. Accuracy of excitation control - % + 0.5


2. Range of voltage control in auto - % 90 Ugn -110 Ugn
3. Range of voltage control man. - % 70 Ufo-110 Ifn
4. Range reactive current compensation - % upto +
15
5. Frequency range of operation - Hz 47.5-52
6. Total No of parallel THY. Bridges - No 4*
7. No of redundant THY bridges - No 1*
8. Protection class IP 31
9 Excitation equipment rating
a) Voltage - VDC 338 *
b) Current - ADC 2830 *

10 Range of MAVR regulation -MAX. LEAD-O-MAX-LAG


11 Station battery supply - VDC 220

• Equipment not part of DVR supply


3.3 GENERATOR SEAL OIL SYSTEM

3.3.1 SPECIFICATION

i) Type of shaft seals Radial flow, double


chamber, thrust type
ii) Hydrogen pressure 3.5 Kg/cm2
iii) seal oil pressure 4.1 to 4.4 Kg/cm2
iv) Inlet seal oil temperature 40 0 C
v) Quantity of seal oil/seal 80 lit/min
vi) Thrust oil pressure 1 to 2.2 Kg/cm2
vii) Oil required to fill the system 4000 liters

3.3.2 OIL INJECTION

i) Pressure of oil at inlet to injector from 20 Kg/cm2


governing oil system
ii) Lub. Oil system 1 to 1.5 Kg/cm2
iii) Injector nozzle size 8 mm
iv) Oil pressure at injector outlet 10 Kg/cm2

3.3.3 SEAL OIL PUMPS

A.C. SEAL OIL PUMPS D.C. SEAL OIL PUMPS

i) Type : Multistage vertical split i) Type : Multistage vertical split


centrifugal type centrifugal type
ii) Discharge: 3.34 lit/sec ii) Discharge: 4.16 lit/sec
iii) Head: 120 MWC iii) Head: 194 MWC
iv) Speed: 1465 or 2900 rpm iv) Shut off head: Not more than
12% of rated head
v) Shut off Head: Not more than 12% v) Min seal oil pressure : 5.5 Kg/cm2
of the rated head below which DC
pump will start
vi) Minimum governing : 6.5 Kg/cm2
oil pressure below which
AC pump will start

MOTOR MOTOR

i) Type: Squirrel cage induction i) Type: Compound wound self excited type
ii) Voltage: 415V+/- 10% ii) Rating: 26 KW
iii) Frequency: 3 Phase, 50c/s iii) Voltage: 220VDC+10% & -20%
iv) Rating: 15 KW/20 HP iv) Speed: 1800 or 2900 rpm
v) Speed: 1465 or 290 rpm v) Rated current: 139 Amp.
vi) Rated Current: 27 Amp. vi) Operation Speed: 70-80% of rated speed
3.3.4 SEAL OIL COOLER

i) No. of coolers 2 Nos.


ii) Inlet temperature of oil 500C
iii) Temperaure of oil at cooler outlet 400C
iv) Quantity of oil to be cooled 160 lit/min
v) Inlet pressure of oil to cooler 10 Kg/cm2
vi) No of cooling tubes 420
vii) Material & size of cooling tubes 15*1 mm, copper
viii) Pressure drop in the oil cooler 5 mwc
ix) Inlet cooling water temperature 330C
x) Outlet cooling water temperature 37.500C
xi) Cooling water designed pressure 5 Kg/cm2 (Max)
xii) Cooling water quantity required 95 m3/Hr
xiii) Cooling water quality Clarified water

3.3.5 PRESSURE REGULATOR

Differential pressure regulator Thrust oil regulator


i) Type: Plunger type Plunger type
ii) Inlet oil pressure: 6 to 9 Kg/cm2 6 to 9 Kg/cm2
iii) Differential pressure maintained: 0.6 to 0.9 Kg/cm2 1.0 to 2.2 kg/cm2
iv) Clearance between plunger and body : 0.03 mm 0.03 to 0.05 mm

3.4 STATOR WATER COOLING SYSTEM

A. STATOR WATER COOLING PUMP

PUMP

i) Type: Horizontal spindle, end suction directly driven, centrifugal type


ii) Discharge: 40 m3/Hr
iii) Head: 45 mwc
iv) Make: Kirloskar Brothers Limited

MOTOR

i) Type: Squirrel cage induction type


ii) Rating: 9.3 Kw
iii) Rated voltage: 415V+/-10V, 3 phase,50 c/s
iv) Rated current: 17 amp.
v) Speed: 2900rpm
vi) Make: Kirloskar Electric
B. STATOR WATER COOLERS

i) Nominal temperature of primary water to be cooled 650C


ii) Nominal temperature of cooled primary water 400C
iii)Nominal tempearure of cooling D.M.water 330C
at inlet on the secondary side
iv)Nominal temperature of cooling water 36.50C
at the outlet on the secondary side
v) Quantity of D.M. Water on the secondary side 95m3/Hr
vi) Secondary side D.M.water inlet pressure 5 Kg/cm2(max)
vii) Tube dimensions 15*1mm
viii) Length of cooling tubes 1720mm
ix) No. of tubes per cooler 420
x)Tube material Copper

C. EXPANSION TANK

i) Material: Stainless Steel


ii) Tank volume 2.1 m3
iii) Volume inside the tank 250 to 300 mmof Hg
iv) Water level under normal operating 850 mm
conditions( from the bottom of the tank)
v) High water level which gives signal 1200mm
( from the bottom of the tank)
vi) Low/ emergency water level requiring tripping of TG 500mm
( from the bottom of the tank)

D. WATER JET EJECTOR

i) Quality of water Clarified


ii) Quantity of water required 7 to 10m3/Hr
iii) Pressure 2 Kg/cm2
iv) Temperature 330C

3.5 GENERTATOR & UAT TRANSFORMERS

3.5.1 GENERTATOR TRANSFORMER (T4)

TRANSFORMER RATING

Make M/S TELK, Kerala


Type of cooling OFB/OB/ON
MVA 240/168/120 MVA
Voltage (HV) 236 KV
Voltage (LV) 15.75 KV
Current (HV) 587/411/293 A
Current (LV) 8798/6158/4399 A
Phase HV/LV 3/3
Impedance 15.55 %
Frequency 50 Hz
Vector Group Yd1
Connection HV/LV Star / Delta
Max temp rise in oil 45 Deg C
Temp rise in winding 55 / 60 Deg C
Weight of core and winding 133000 Kg
Weight of oil 43100 Kg
Total weight 238900 Kg
Quantity of oil 42500 liter
Tap Off load

BUSHING CT

Ratio 600 / 1 Amp


Continuous current 800 Amp
Accuracy class P.S.
Minimum knee point voltage 1000 Volt
Max exciting current at knee point voltage 0.14 Amp.
Max secondary wdg. Resistance at 75 Deg C 3 Ohm

3.5.2 GENERTATOR TRANSFORMER (T5)

TRANSFORMER RATING

Make M/S BHEL, Bhopal


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

BUSHING CT

Ratio 600 / 1 Amp


Continuous current 800 Amp
Accuracy class P.S.
Minimum knee point voltage 1000 Volt
Max exciting current at knee point voltage 0.14 Amp.
Max secondary wdg. Resistance at 75 Deg C 3 Ohm

3.5.3 UNIT AUXLIARY TRANSFORMERS (Unit 4 & 5)

RATING

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

PROTECTION
AND
INTERLOCK
4.1 UNIT PROTECTIONS

Sl.No. DESCRIPTION ANNUNCIAT TRIPPING TIME DELAY


ION VALUE
1 Drum level low -100 mm -175 mm -
2 Drum level high +100 mm +175 mm -
3 Furnace pressure high +25 mmwcl +175 mmwcl -
4 Furnace vacuum high -25 mmwcl -175 mmwcl -
5 Loss of 220 V More than 2
D.C.supply of FSSS secs
6 Less thanfire ball and
loss of 110V D.C.
Supply
7 Loss of all fuel trip
8 On flame failure
9 Air flow less than 30%
10 Both ID fan tripped
11 Both FD fans tripped
12 Both PBS on FSSS
pressed
13 Reheater protection(
This protection will act
when there is no flow
through R.H. & furnace
outlet temperature more
than 5380C)
14 Condenser vacuum 650 mm Hg 540 mm Hg
15 H.P. heater level very 750 mm 4250 mm
high
16 All BFPs tripped - - 15 secs
17 T.G.babbit metal 750C 800C
temperature
18 Turbine rotor axial shift +1.2 mm -
-1.7 mm
19 Loss of voltage on unit 50% of rated 5 to 10 secs
auxiliary bus bar value
20 Emergency governor 11% and 12%
overspeed tripping overspeed
21 Emergency governor 14% overspeed
backup
22 Turbine lub oil pressure A.C. lub oil 0.3 kg/cm2
pump starts at
0.6 kg/cm2,
D.C. lub oil
pump starts at
0.5 kg/cm2
23 M.S. Temperature low 5200C 4500C
24 Turbine shut down - -
switch
25 Manual tripping(UCB)
through push buttons

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. Descripti Permissives Ineterlocks Protections


No. on
1 ID Fans a. Regulating a. Opening of a. Bearing temperature
vane FG-10 in outlet damper too high
minimum FG-12 after a b. Motor bearing
position time delay of 60 temperature too high
b. Outlet damper secs. c. Lub. Oil pressure for
FG-12 closed b. Connecting the motor bearing low
c. Fan/fan motor regulating vane with T.D. of 0-3 mts.
bearing (FG-10) to d. Both A.H. A&B off (
temperature is regulator Provided de-
not very high c. Opening the interlocking in inter
interconnecting locked position)
damper FG-5&
FG-18
d. Closing the
inlet damper
FG-17& outlet
damper FG-13
of other fan
e. Bringing the
other fan inlet
vane to
minimum
position
f. Permiisive to
start selected
FD fan
2 FD fans a. ID fan is a. Opening the a. Bearing temp. too
started outlet damper high
b. Control oil BA-3 with T.D. b. Motor bearing temp.
pressure is of 60 secs. too high
adequate(8 b. Connecting the c. Both ID fans trips
kg/cm2) impellar blade d. If lub oil pressure
c. Fan impellar (BA-1) control continues to be below
blades are in drive to a preset value for 30
min. regulator. mts.
position.(BA- c. Opening the e. If ID fan A or B trips
1) inter connecting and FD is selected in
d. Outlet damper damper BA-2. combination with ID
(BA-3) is in d. Closing the fan.
closed outlet damper
position. of other fan.
e. FD fan e. Bringing the
bearing temp. impeller blades
is not high. of other fan to
f. FD fan motor min. position.
bearing temp.
is not high.

3 Air Establish electric Wherever A.H. Temp. of support and


Heater supply to A.H. trips impulse is guide bearing 700C.
motor. given for starting
Take out the push air motor provided Air motor also trips if
button of the guide/support- temp. of support/guide
motor. bearing temp. is bearing 700C.
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
BA-12, 14,22&24.
Tripping of
corresponding ID
fans.
4 Ignitor At least one ID Discharge damper
fan and one FD fan will open & damper
must be in of standby fan
service. closes.
When start push The fan will start
button is pressed. automatically when
any ignitor or oil
elevation is
initiated.
5 Scanner a. The scanner Discharge damper Scanner air fan
fan duct to will open & damper emergency damper opens
furnace of standby fan automatically when both
differential closes with T.D. of FD fans are off.
pressure is 5 secs.
less than 115
mmwcl.
b. When start
push button is
pressed.
6 Primary a. Purge a. Fan discharge a. Fan bearing temp. too
air fan complete & damper BA-19 high.
NO boiler trip opens with T.D. b. PA fan motor bearing
condition is of 60 secs. temp. too high.
present. b. Fan inlet c. Lub oil pressure to
b. Regulating regulating inlet motor bearing low
vanes BA-17 vane BA-17 is after a time delay of
in min. connected to 0-5mts.
position. regulator. d. P.A. fan shall trip
c. Outlet damper c. Inter connecting when one of the two
BA-19 in damper BA-21 FD fans trip and this
closed opens. fan is selected.
position. d. Regulating vane e. Motor protection
d. Lub oil of other PA fan operated.
pressure is closes to min.
adequate position(BA-
around 2 18)
kg/cm2 e. Outlet damper
e. PA fan of other PA fan
bearing temp closes.(BA-20)
not very high. f. Load is reduced
by tripping
bottom mills
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.
7 Seal air One PA fan is Manually fan can Running seal air fan will
fan running be tripped only if trip automatically after 60
all the mills are secs time delay when
stopped. both PA fan trips.
Only one seal air
fan can be started at
time.
8 Pulverise a. Discharge a. Permissive to a. Boiler trip condition
r valve are open the hot air is present.
open. gate. b. Discharge valve are
b. Seal air valve b. Permissive to closed.
is open. start R.C.feeder. c. Loss of elevation
c. Cold air shut c. Permissive for A.C. for more than 2
off gate is regulators secs.
open. impulse to act d. Support ignition
d. Feeder inlet on hot air energy is removed
gates are dampers. within 3 mts of feeder
open(Check starting.
only) e. PA fan tripping.
e. Tram iron f. Low primary air
hopper valve pressure for more
is open than 5 secs.
f. Primary air g. Motor protection
pressure is operates.
aduquate. h. PA pressure very low
g. D.C.power to will trip all mill
FSSS is instantaneously.
available.
h. Pulveriser
outlet temp. is
less than
940C.
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.
Pulverise a) A min of 3
r A* 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.
9 Raw coal 1) No boiler trip 1) To release R.C.Feeder will trip if:
feeder condition speed control to 1) Boiler trips
persists auto after 50 2) Elevation D.C. fails
2) Elevation secs. after2 secs time dealy
D.C. is 2) To modulate 3) Elevation A.C. fails
available fuel air dampers 4) Ignition energy
3) Elevation according to disappears beforev
A.C. is feeder speed 180 secs from the
available after 50 secs. start of the feeder.
4) Ignition 5) Pulverisers trips
energy is 6) Loss of coal flow and
available. pulveriser amp. Low(
5) Pulverisor is this impulse will act
on only after 5 secs from
6) Hot air gate is feeder start.
open When R.C. Feeders trip
7) No stop signal A) To close hot air gate
8) Fuel damper when either the
closed 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 Pump A will start 3)
motor automatically if
lubricatio pump B trips
n oil provided A/M
system 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.

FD fan Pump A will start 4)


lub oil automatically if
system 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
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.
12 Furnace Furnace temp If furnace temp
temp probe shall be probe is inside the
probe prohibited from furnace and temp.
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. Description Permissive Interlock Protections


No.
1 Boiler feed 1. Lubricating 1. If lub oil pressure is 1.Main BFP will trip if
2
pump oil pressure at below 1 kg/cm A.O.P. will lub oil pressure is
bearing come. below 0.5 kg/cm2
should be 1 2. If BFP tripped it’s 2.Pump will trip if its
kg/cm2 A.O.P. will come in auto as motor bearing
2. Suction soon as lub oil pressure temperature is more
pressure at drops 1 kg/cm2 . than 800C
suction of When any BFP put on 3.Pump will trip if
booster pump “standby” it’s A.O.P. will discharge flow is more
should be come. than 500 T/hr.
more than 3 3. A.O.P.will trip after 10 4. Pump will trip if
kg/cm2 in hot secs when BFP lub oil water temperature at
start up. pressure goes to 4 kg/cm2. delivery of BFP is
3. If suction 4. At 200T/hr discharge more than1750C
pressure at flow pump recirculation 5.Pump will trip if
suction at valve should open & at 220 discharge pressure is
booster pump T/hr it should get closed. less than kg/cm2 for 12
is less than 3 5. Standby BFP will come secs.
kg/cm2 for on auto as soon as either 6.Pump will trip if
more than 20 working BFP trips or suction pressure of
secs. Pump common header pressure at main BFP is below 6
will trip. discharge side is low. kg/cm2
4. Suction for 20secs, though it
valve will start.
(BF1/2/3) is 7.On turbine trip one
fully open. BFP will trip if two are
5. in operation.
Recirculation
valve (BF-
22/23/24) is
fully closed.
2 Circulating 1. 1. When any CW pump is 1. On closing of
water pump Correspondin started its corresponding discharge valve
g condenser valve (CW3/4) on CW line CW-1&2 pump
outlet valve to unit oil coolers shall will trip.
(CW1&2) is open. 2. CW pump will
fully open. 2.when one CW pump trips trip if its motor
the corresponding valve bearing
CW1& CW3 or temperature is
CW2&CW4 shall close more than 800C
and partial load relay will 3. When both CW
operate. pumps trip CW
booster pump
trips.
3 CW 1. At least one 1. If both CW pumps trip 1. CW booster pump
boosr\ter CW pump booster pump will trip. will trip if both CW
pump(Gas should be 2.When running pump trip pump trip.
cooler inservice. reserve pump will start 2. Pump will trip if
booster immediately motor current goes
pump) 3.If discharge pressure falls beyond 100 Amp.
below 2 kg/cm2 standby
pump will start.
4 Condensate 1. Reserve pump will start 1. Working pump will
pump as soon as running pump trip if discharge
trips. pressure before its
2. Reserve pump will start NRV becomes low(10
when common discharge kg/cm2) after 30 secs of
header pressure falls below pump starting.
10 kg/cm2.
3. If all condensate pump
trips solenoid valve DM-
105 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.
5 A.C. Lube A.C lube oil pump will
oil pump come in auto if bearing oil
pressure goes down to 0.6
kg/cm2

6 D.C. lube oil pump will


come in auto if bearing oil
pressure goes down to 0.5
kg/cm2

7 Barring gear Barring gear B/G will trip if lube oil


will start only pressure goes to 0.3
if lub oil kg/cm2
pressure is
more than 0.3
kg/cm2
Barring gear
will engage
only if rotor is
in engage
condition.
8 Drip pump Pump will 1. HD-3 discharge valve Working drip pump
start only if will be fully closed if no will trip if LPH-2 drip
HD-3( drip is running but will level falls to 200 mm
discharge start opening as soon as for 20 secs or HD-2 &
valve) is drip pump starts. HD-3are in closed
closed & 2. Reserve drip pump will position.
opening of start as soon as running
regulating drip pump trips or
valve HD-3 is discharge pressure of
more than a working pump falls below
preset value. a preset value for 10 secs.
9 Heater 6 1.If HPH-6 extraction
pressure falls tp preset
value its drip valve cascade
to deaerator & HD-29(to
HPH-5) will close & HD-
30 will open.
2.If HPH-6 extraction
steam pressure is above the
preset value HD-29 (to
HPH-5) will open & HD-
30 will close.

10 HP Heater 5 1.If HPH-5 extraction 1.HPH will be


steam pressure falls below bypassed through
a preset value its drain will group bypass
cascade to LPH-4 i.e.HD- protection valve at 750
21(to LPH-4) will open & mm drip level.
HD-31(to D/A) will close. 2.Turbine will trip at
2. if HPH-5 extraction HPH level 4250 mm.
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
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.
11 Deaerator Deaerator drain valve DW-
136 will open & close
when D/a level goes higher
& lower than preset value
respectively.
12 H.P.& L.P. 1. “Generator 1. When turbine is running
Bypass circuit breaker or not running & HP
system close” signal bypass control is on
should not be manual the memory 1.05
there. will get closing signal
2.Condenser through AND logic, if
vacuum too valve position is less than
low (600 mm 2%.
of Hg 2. If turbine is not running
column) and control is on Auto the
signal should memory 1.05 will get
not be there. closing signal through
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
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.
13 Extraction 1. When extraction steam
Auxiliary pressure build up to the
steam to preset value (9 kg/cm2) for
D/A through 3rd extraction (Es-7) will
ES-7,ES- open & Es-6 & AS-57 will
6&As-57 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 & ES-
7 & 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.
14 Chamber 1. If As-43 is open then
heating As-47 will close.
valve As- 2. If As-44 is open then
43& 44 As-48 will close.
verses
spindle leak
off valve
15 I.S.P.U.G.(I M/C load reduced when
nitial steam steam pressure drops to
pressure 117 kg/cm2 & fully
unloading unloaded at 91 ata.
gear)
16 Extraction NRV closes when ESV
NRV on closes i.e. solenoid valve
extraction MC-53&54 will open.
lines
17 Load limiter Prevent further opening of
C.V. Beyond set point but
does not prevent closing of
C.V.
18 A.C. Seal When seal oil pressure
oil pump drops to 6.5 kg/cm2 A.C.
seal oil pump will start.
19 D.C. Seal When seal oil header
oil pump 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 Relay CTR / Range Setting


No. Type PTR
1. Generator Differential CAG 34 10000/5 Amp 0.25 - 1 A 0.25 Amp
(87 G)
2. Generator Inter Turn CAG 14 3000 / 5 Amp 1- 4A 4.0 Amp
Fault (87 TG)
3. Over All Differential DTH32 GEN &UAT- 15% of 5 A 15 % of 5
(87 GT). 10000/5 Amp.
Bushing & Bias – 15,30 30 %
Switchyard - & 45 %
600/1 High set – 1000 %
ICT – 1.0 / 1000 % Fixed
2.6 A Fixed
4. GT Back up Earth CDG 11 600/1 0.1-0.4 A PS-0.2 A,
fault (51 NT) TMS-0.4
5. GT Restricted E/F CAG 14 600/1 0.2-0.4 A 0.2 Amp.
(87 NT)
6. Gen Over Voltage VAGM 15750/110 V 110 – 140 % 121 Volt
(59 G) 22
VTT 11 1.0 to 10 sec 2.0 Sec.

7. Gen Over Load Alarm CTU 12 10000/5 A 50 – 200 % 102 %


(51 G1) 05 – 5 Sec 2.5 Sec
8. Gen Back up YCG 15 10000/5 A, K1=6 K2 = 1
Impedance VTT11 15750/110 V 0.5 – 5 Sec St-I– 2.5 Sec
(21 G) VTT11 1 – 10 Sec St-II- 3Sec
9. UAT Over load alarm CAG 19 600/5A 2.5-5 A 4.375 A
(51 T4A & T4B) VTT 11 1 – 10 Sec 4.0 Sec
10. Generator Negative CTN 31 10000/5A A - 70%
Phase Sequence (46) T – 15%
VTT 11 6 – 60 Sec 60 Sec
11. UAT B/U O/C CAG 37 600/5 A 10-40A 12 A
(50 T4A & 50 T4B) VAT 11 0.5 – 3 Sec 0.5 Sec
VTT 11 0.5 – 3 Sec 0.5 Sec
12. UAT Differential DTH31 HV=600/5 A Current -15% Current -
(87 T4A & T4B) LV=1250/5A of 5A 15%
Bias Bias=30%
15,30,45% High Set =
High Set = 1000 %
1000 % Fixed
Sr. Relay Relay CTR / Range Setting
No. Type PTR
13. Stator Earth Fault VDG14 15750/110 V V=5.4-20 V PS=12.5V
(64G) TMS=0.3
14. 1ST Rotor E/F (64F1) VME - 4 mA 4 mA
VTT 11 0.5 – 5 Sec 2.0 Sec
15. 2ND Rotor E/F (64 F2) CAEM - 1.1 mA 1.1 mA
16. Generator GTT21 15750/110 V K=1-1.25 K=1.125
Transformer Over T=12-120
Fluxing (99) Sec T=15 Sec
17. Low Forward Power WCD 11 15750/110 V 0.5 % 0.5%
( 37) 10000/5A
VTT 11 1 - 10 Sec 2 Sec
18. Reverse Power 15750/110 V
( 32) WCD 11 10000/5A 0.5 % 0.5%
2/ 32 A VTT 11 1 – 10 Sec 2 Sec
2/32 B VTT 11 12 - 120 Sec 120 Sec
19. Anti Motoring VAT11 0.5 – 5 Sec 5 Sec
Protection VTT 11 6 – 60 Sec 10 Sec
(2/32 YA & 2/32YT)
20. Generator Loss of YCGF 15750/110 V K1=0.845,
Field (40) 11 10000/5A K2=3.5,
K3=0.5,
K4=3,
K5=18.6
VTT 11 1-10 Sec 2Sec
VTT 11 5-25 Sec 10Sec
21. Generator Under VAGM 15750/110 V 44 – 88 Volt PS-80.5 V
Voltage (27) 22
22. Generator Pole ZTO 11 15750/110 V 5.2 Amp
Slipping (98) 10000/5A 75 Deg elect
Offset=
3.156 Ohm,
T=52.5mSec
23. Check Synchronizing SKE 11 Phase
Relay (25) Angle=10%,
Voltge=6%,
F=0.11%
5.1.2 RECOMMENDED RELAY SETTING OF GENERATOR, GENERATOR
TRANSFORMER AND UAT (UNIT 5)

Sr. Relay Relay CTR / Range Setting


No. Type PTR
1. Generator Differential CAG 34 10000/5 Amp 0.25 - 1 A 0.25 Amp
(87 G)
2. Generator Inter Turn CAG 14 3000 / 5 Amp 1- 4A 4.0 Amp
Fault (87 TG)
3. Over All Differential DTH32 GEN &UAT- 15% of 5 A 15 % of 5
(87 GT). 10000/5 Amp.
Bushing & Bias – 15,30 30 %
Switchyard - & 45 %
600/1 High set – 1000 %
ICT – 1.0 / 1000 % Fixed
2.6 A Fixed
4. GT Back up Earth CDG 11 600/1 0.1-0.4 A PS-0.2 A,
fault (51 NT) TMS-0.4
5. GT Restricted E/F CAG 14 600/1 0.2-0.4 A 0.2 Amp.
(87 NT)
6. Gen Over Voltage VTU 21 15750/110 V 105 – 110 % V=110 %
(59 G) 0.5-5 Sec 2 Sec

7. Gen Over Load Alarm CTU 12 10000/5 A 50 – 200 % 4.75 A


(51 G1) 05 – 5 Sec 5 Sec
8. Gen Back up YCG 15 10000/5 A, K1=6 K2 = 1
Impedance VTT11 15750/110 V 0.5 – 5 Sec St-I– 2.5 Sec
(21 G) VTT11 1 – 10 Sec St-II- 3Sec
9. UAT Over load alarm CTU12 600/5A 2.5-10 A 4A
(51 T5A & T5B) 1 – 10 Sec 5 Sec
10. Generator Negative CTN 31 10000/5A A - 70%
Phase Sequence (46) T – 15%
VTT 11 6 – 60 Sec 60 Sec
11. UAT B/U O/C CAG 37 600/5 A 10-40A 12 A
(50 T5A & 50 T5B) VAT 11 0.5 – 3 Sec 0.3 Sec
VTT 11 0.5 – 3 Sec 0.3 Sec
12. UAT Differential DTH31 HV=600/5 A Current -15% Current -
(87 T5A & T5B) LV=1250/5A of 5A 15%
Bias Bias=30%
15,30,45% High Set =
High Set = 1000 %
1000 % Fixed
Sr. Relay Relay CTR / Range Setting
No. Type PTR
13. Stator Earth Fault VDG14 15750/110 V V=5.4-20 V PS=5.4V
(64G 1) TMS=0.3
14. 100 % Stator E/F RAGEA T(119)-1
(64 G2) Sec, T(149)-
5 Sec
15. 1ST Rotor E/F (64F1) VAEM - 1.1 mA 1.1 mA
VTT 11 0.5 – 5 Sec 2.0 Sec
16. 2ND Rotor E/F (64 F2) CAEM - 1.1 mA 1.1 mA
17. Generator GTT21 15750/110 V K=1-1.25 K=1.1
Transformer Over T=12-120
Fluxing (99) Sec T=12 Sec
18. Low Forward Power WCD 11 15750/110 V 0.5 % 0.5%
( 37) 10000/5A
VTT 11 1 - 10 Sec 2 Sec
19. Reverse Power 15750/110 V
( 32) WCD 11 10000/5A 0.5 % 0.5%
2/ 32 VTT 11 1 – 10 Sec 2 Sec

20. Anti Motoring VAT11 1-10 Sec 5 Sec


Protection VTT 11 12-120 Sec 60 Sec
(2/32 YA & 2/32YT)
21. Generator Loss of YCGF 15750/110 V K1=0.845,
Field (40) 11 10000/5A K2=3.5,
K3=0.5,
K4=3,
K5=18.6
VTT 11 1-10 Sec 2Sec
VTT 11 5-25 Sec 10Sec
22. Generator Under VAGM 15750/110 V 44 – 88 Volt PS-80.5 V
Voltage (27) 22
23. Generator Pole ZTO 11 15750/110 V 5.2 Amp
Slipping (98) 10000/5A 75 Deg elect
Offset=
3.156 Ohm,
T=52.5mSec
24. Check Synchronizing SKE 11 Phase
Relay (25) Angle=10%,
Voltge=6%,
F=0.11%
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 Setting
No.
1. Main Incoming Supply from CAG 37 2000 / 5 10 – 40 Amp 13.7 A
Station T/R – 3 (3SA1 & VTT 11 A 0.5 – 5 Sec 1.1 Sec
3SB1) U/V 20%,1.5
Sec
2. Main Supply to CSA from CAG 37 800/5 A 10 – 40 A 10 Amp
3SA at 3SA VTT 11 0.5 – 5 sec 0.8 Sec
U/V No Trip
3. Reserve Supply to CSA from CAG 37 800/5 A 10 – 40 A 10 Amp
3SB at 3SB VTT 11 0.5 – 5 sec 0.8 Sec
U/V No Trip
4. Main Supply to CT3 (Cooling CAG 37 800/5 A 10 – 40 A 10.8 A
Tower) from 3SA at 3SA VTT 11 0.5 – 5 sec 0.8 Sec
U/V No Trip
5. Main Supply to CT3 at CT3 CAG 37 800/5 A 10 – 40 A 10.8 A
VTT 11 0.5 – 5 sec 0.5 Sec
U/V 20%,1.5
Sec
6. Main Supply to CSA at CSA CAG 37 400/5 A 10 – 40 A 12 A
VTT 11 0.5 – 5 sec 0.5 Sec
U/V 20%,1.5
Sec
7. Reserve Supply to CSA at CAG 37 400/5 A 10 – 40 A 12 A
CSA VTT 11 0.5 – 5 sec 0.5 Sec
U/V 20%,1.5
Sec
8. Main Supply to WCA from CAG 37 400/5 A 10 – 40 A 10 A
CSA at WCA VTT 11 0.5 – 5 sec 0.5 Sec
U/V 20%,1.5
Sec
9. Reserve Supply to WCA from CAG 37 400/5 A 10 – 40 A 10 A
CSA at WCA VTT 11 0.5 – 5 sec 0.5 Sec
U/V 20%,1.5
Sec
10. Reserve Supply feeder for CAG 37 1250/5 A 10 – 40 A 22 A
Unit bus 4A,4B,5A & 5B VTT 11 0.5 – 5 sec 0.8 Sec
from 3SA & 3SB (3SA2 &
3SB2)
11. Interconnecting feeder CAG 37 1250/5 A 10 – 40 A 10 A
between Stage – I & Stage – VTT 11 0.5 – 5 sec 0.8 Sec
II (4A01 & 4B01)
Sr. Name of Feeder Relay Type CTR Range Setting
No.
12. Station Auxiliary T/R 1 &2 CAG 37 200 / 5 A 10 – 40 Amp 18.7 A
(TS3 & TS4 / 1600 KVA) VTT 11 0.5 – 5 Sec 0.5 Sec
CAG 37 25 – 100 A 75 A
13. Stand By T/R 1 &2 (TR3 & CAG 37 200 / 5 A 10 – 40 Amp 18.7 A
TR4 / 1600 KVA) VTT 11 0.5 – 5 Sec 0.5 Sec
CAG 37 25 – 100 A 75.7 A
14. Stand By T/R CAG 37 150 / 5 A 10 – 40 Amp 15.5 A
(TR5 / 1000 KVA) VTT 11 0.5 – 5 Sec 0.5 Sec
CAG 37 25 – 100 A 66.7 A
15. Control Structure Transformer CAG 37 150 / 5 A 10 – 40 Amp 15.5 A
(1000 KVA) VTT 11 0.5 – 5 Sec 0.5 Sec
CAG 37 25 – 100 A 67.4 A
16. Lighting Transformer CAG 37 150 / 5 A 10 – 40 Amp 15.5 A
(TL3 / 1000 KVA) VTT 11 0.5 – 5 Sec 0.5 Sec
CAG 37 25 – 100 A 68 A
17. Cooling Tower Transformer CAG 37 200 / 5 A 10 – 40 Amp 18.7 A
(1600 KVA) VTT 11 0.5 – 5 Sec 0.5 Sec
CAG 37 25 – 100 A 77 A
18. Coal Handling Transformer CAG 37 150 / 5 A 10 – 40 Amp 15.5 A
(TC3 / 1000 KVA) VTT 11 0.5 – 5 Sec 0.5 Sec
CAG 37 25 – 100 A 66.7 A
19. Water Treatment Plant T/R CAG 37 150 / 5 A 10 – 40 Amp 15.5 A
(1000 KVA) VTT 11 0.5 – 5 Sec 0.5 Sec
CAG 37 25 – 100 A 66.7 A
20. Clarifier Water Transformer CAG 37 100 / 5 A 10 – 40 Amp 14.7 A
(630 KVA) VTT 11 0.5 – 5 Sec 0.5 Sec
CAG 37 25 – 100 A 65 A
21. CT Pumps (930 KW) CDGM 62 150/5 A 3.6 – 6.2 A PS = 3.95
Full load current = 111 A TMS=0.2
Starting current = 577.2 A 25 – 100 A 30 A
Starting time = 1.67/4.76 Sec U/V 70%, 0.5
Sec
22. HP Flush Water Pumps CDGM 62 30/5 A 3.6 – 6.2 A PS = 3.95
(187 KW) TMS =
Full load current = 23 A 25 – 100 A 0.25
Starting current = 115 A U/V 30 A
Starting time = 2.66/5.25 Sec 70%, 0.5
Sec
23. Clarified Water Pumps CDGM 62 40/5 A 3.6 – 6.2 A PS = 4.35
(280 KW) TMS=0.5
Full load current = 111 A 25 – 100 A 30 A
Starting current = 577.2 A U/V 70%, 0.5
Starting time = 1.67/4.76 Sec Sec
Sr. Name of Feeder Relay Type CTR Range Setting
No.
24. Clarified Raw Water Pumps CDGM 62 40/5 A 3.6 – 6.2 A PS =3.95
(280 KW) TMS=0.2
Full load current = 31.5 A 25 – 100 A 37.5 A
Starting current = 173.5 A U/V 70%, 0.5
Starting time = 2.0 Sec Sec
25. Boiler Fill Pumps (250 HP) CDGM 62 30/5 A 3.6 – 6.2 A PS =4.35
Full load current = 20.4 A TMS=0.2
Starting current = 133 A 25 – 100 A 42.5 A
Starting time = 2.2 Sec U/V 70%, 0.5
Sec

5.2.2 RECOMMENDED RELAY SETTING OF 6.6 KV UNIT SECTION


STAGE - II (Unit - 4)

Sr. Name of Feeder Relay CTR Range Setting


No. Type
1. Unit Auxiliary T/R CAG 37 150 / 5 A 10 – 40 A 18.7 A
(T4C & T4D / 1000 KVA) VTT 11 0.5 – 5 sec 0.5 Sec
CAG 37 25 – 100 A 68 Amp
2. EP Transformer CAG 37 200 / 5 A 10 – 40 A 18.7 A
(1600 KVA) VTT 11 0.5 – 5 sec 0.5 Sec
CAG 37 25 – 100 A 75.7 A
3. Reserve Incomer from CAG 37 1250 / 5 A 10 – 40 Amp 22 Amp
( For Bus 4A & 4B) VTT 11 0.5 – 5 Sec 05 Sec
4. ID FAN A & B (1300 KW) CDGM 200 / 5 A 3.6 to 6.2 A PS = 3.6
Full Load Current = 138 A 62 TMS=0.35
Starting Current = 717.6 A 25 – 100 A 30 Amp
Starting Time = 7/10 Sec U/V No Trip
5. Bowl Mills A,B,C,D,E & F CDGM 50 / 5 A 3.6 – 6.2 PS = 3.95
(335 KW) 62 TMS=0.2
Full Load Current = 41.7 A 25 – 100 A 40 Amp
Starting Current =270 A U/V 70%,0.5
Starting Time = 4.76 Sec Sec
6. PA Fans A & B (1250 KW) CDGM 150 / 5 A a. – 6.2 PS = 4.35
Full Load Current = 132.5 A 62 TMS=1.0
Starting Current =795 A 25 – 100 A 40 A
Starting Time = 24.5/33 Sec CTU 12 9A,15 Sec
U/V 50%,9 Sec
7. SOP (200 KW) CDGM 30 / 5 A 3.6 – 6.2 PS = 4.35
Full Load Current = 21.8 A 62 TMS=0.25
Starting Current = 128.4 A 25 – 100 A 34 A
Starting Time = 3/5 Sec U/V 70%,0.5
Sec
Sr. Name of Feeder Relay CTR Range Setting
No. Type
8. FD Fans A & B (800 KW) CDGM 100 / 5 A 3.6 – 6.2 PS = 4.35
Full Load Current = 84.9 A 62 TMS=0.35
Starting Current = 509.4 A 25 – 100 A 40 A
Starting Time = 5.5/8 Sec U/V 50%,9 Sec
9. C W Pumps A & B (950 HP) CDGM 100 / 5 A 3.6 – 6.2 PS = 3.95
Full Load Current = 82.8 A 62 TMS=0.2
Starting Current = 422 A 25 – 100 A 33 A
Starting Time = 1.45/2.1 Sec U/V No Trip
10. CEP Pumps A,B,C (220 KW) CDGM 30 / 5 A 3.6 – 6.2 PS = 4.35
Full Load Current = 25 A 62 TMS=0.2
Starting Current = 135 A 25 – 100 A 42.5 A
Starting Time = 2.5 Sec U/V 50%,9Sec
11. BFP A,B & C (4000 KW) CDGM 500 / 5 A 3.6 – 6.2 PS = 3.95
Full Load Current = 421 A 62 TMS=0.2
Starting Current = 2020 A 25 – 100 A 33 A
Starting Time = 5/9 Sec CAG 34 0.1 – 1 A 0.1 A
U/V 50%,9 Sec

5.2.3 RECOMMENDED RELAY SETTING OF 6.6 KV


STATION SECTION STAGE - III

Sr. Name of Feeder Relay Type CTR Range Setting


No.
1. Main Incomer to CT4 CAG 37 800/5 A 10 – 40 A 10 A
(Cooling Tower) from 3SB at VTT 11 0.5 – 5 sec 0.8 Sec
3SB U/V No Trip
2. Main Incomer for CT4 at CT4 CAG 37 800/5 A 10 – 40 A 10 A
Bus VTT 11 0.5 – 5 sec 0.5 Sec
U/V 20%,1.5
Sec
3. Bus coupler between CT3 & CAG 37 800/5 A 10 – 40 A 10 A
CT 4 Bus VTT 11 0.5 – 5 sec 0.5 Sec

4. Station Auxiliary T/R CAG 37 200 / 5 A 10 – 40 Amp 10 A


(TS5 / 1600 KVA) VTT 11 0.5 – 5 Sec 0.5 Sec
CAG 37 25 – 100 A 66 A
5. Stand By T/R CAG 37 200 / 5 A 10 – 40 Amp 10 A
(TR6 / 1600 KVA) VTT 11 0.5 – 5 Sec 0.5 Sec
CAG 37 25 – 100 A 66 A
6. Lighting Transformer CAG 37 150 / 5 A 10 – 40 Amp 10 A
(TL4 / 1000 KVA) VTT 11 0.5 – 5 Sec 0.5 Sec
CAG 37 25 – 100 A 65 A
Sr. Name of Feeder Relay Type CTR Range Setting
No.
7. Cooling Tower Transformer CAG 37 200 / 5 A 10 – 40 Amp 10 A
(1600 KVA) VTT 11 0.5 – 5 Sec 0.5 Sec
CAG 37 25 – 100 A 66 A
8. CT Pumps (960 KW) CDGM 32 150/5 A 3.6 – 6.2 A PS = 3.6
Full load current = 115 A TMS=0.2
Starting current = 632.5 A CAG 37 25 – 100 A 34 A
Starting time = ¾.5 Sec 70%, 0.5
U/V Sec

5.2.4 RECOMMENDED RELAY SETTING OF 6.6 KV UNIT SECTION


STAGE - II (Unit - 5)

Sr. Name of Feeder Relay CTR Range Setting


No. Type
1. Unit Auxiliary T/R CAG 37 150 / 5 A 10 – 40 A 10 A
(T5C & T5D / 1000 KVA) VTT 11 0.5 – 5 sec 0.5 Sec
CAG 37 25 – 100 A 65 Amp
2. EP Transformer CAG 37 200 / 5 A 10 – 40 A 10 A
(1600 KVA) VTT 11 0.5 – 5 sec 0.5 Sec
CAG 37 25 – 100 A 66 A
3. Reserve Incomer from CAG 37 1250 / 5 A 10 – 40 Amp 22 Amp
( For Bus 5A & 5B) VTT 11 0.5 – 5 Sec 0.3 Sec
4. ID FAN A & B (1100 KW) CDGM 150 / 5 A 3.6 to 6.2 A PS = 4.35
Full Load Current = 116.5 A 32 TMS=0.4
Starting Current = 855 A CAG 37 25 – 100 A 43 Amp
Starting Time = 7/10 Sec U/V No Trip
5. Bowl Mills A,B,C,D,E & F CDGM 50 / 5 A 3.6 – 6.2 PS = 3.95
(340 KW) 32 TMS=0.2
Full Load Current = 41.7 A CAG 37 25 – 100 A 40 Amp
Starting Current =250.2 A CTU 12 8.1A,3 Sec
Starting Time = 2.9/6.1 Sec U/V 70%,0.5 S
6. PA Fans A & B (1250 KW) CDGM 150 / 5 A b. – 6.2 PS = 4.35
Full Load Current = 135.3.A 32 TMS=0.8
Starting Current =811.8 A CAG 37 25 – 100 A 40 A
Starting Time = 19/28 Sec CTU 12 9A,10 Sec
U/V 50%,9 Sec
7. SOP (200 KW) CDGM 30 / 5 A 3.6 – 6.2 PS = 3.6
Full Load Current = 22 A 32 TMS=0.2
Starting Current = 132 A CAG 37 25 – 100 A 34 A
Starting Time = 3.5/5 Sec U/V 70%,0.5
Sec
Sr. Name of Feeder Relay CTR Range Setting
No. Type
8. FD Fans A & B (750 KW) CDGM 100 / 5 A 3.6 – 6.2 PS = 3.6
Full Load Current = 79.5 A 32 TMS=0.5
Starting Current = 477 A CAG 37 25 – 100 A 38 A
Starting Time = 6.5/10 Sec U/V 50%,9 Sec

9. CEP Pumps A,B,C (220 KW) CDGM 30 / 5 A 3.6 – 6.2 PS = 3.95


Full Load Current = 25 A 32 TMS=0.3
Starting Current = 135 A CAG 37 25 – 100 A 36 A
Starting Time = 2.5 Sec U/V 50%,9Sec
10. BFP A,B & C (4000 KW) CDGM 500 / 5 A 3.6 – 6.2 PS = 3.95
Full Load Current = 421 A 32 TMS=0.3
Starting Current = 2020.8 A CAG 37 25 – 100 A 32 A
Starting Time = 5/9 Sec CAG 34 0.1 – 1 A 0.1 A
U/V 50%,9 Sec

5.3 RECOMMENDED SETTING OF MCB RELAYS

Sr. Name of Feeder Type of Relay Type CTR/PTR Range Setting


No. Protection
1 IP1&IP2 Distance Quadro mho 600/1 A - Z1=1.792 Ohm
Protection 220KV/110V Z2=2.24 Ohm
(t2=350 ms)
Z3=2.56Ohm
(t3=1.05ms)
Z3’=0.4 Ohm
Backup CDD21 O/C E/F Comp.=130%
Protection (Directional) 50-200% (R-Ph)O/C=150%
E/F (B-Ph)O/C=150%
20-80% E/F =20%
TMS=0.3 sec

2 Mehrauli 1&2 Distance RR3V 600/1 A - Z1=1.68 Ohm


Protection Scheme Z2=3.15 Ohm
220KV/110V (t2=350 ms)
Z3=5.76Ohm
(t3=1.0 sec)
Backup IDMT O/C (R-Ph)O/C=150%
Protection (Directional) 50-200% (B-Ph)O/C=150%
E/F E/F =20%
20-80% TMS=0.2 sec
Sr. Name of Feeder Relay CTR Range Setting Sr. No.
No. Type
3 Ballbhagarh 1&2 Distance MM3V 600/1 A - Z1=2.396 Ohm
Protection Scheme Z2=3.355 Ohm
220KV/110V (t2=350 ms)
Z3=9.1Ohm
(t3=1.0 sec)

Backup IDMT O/C (R-Ph)O/C=125%


Protection (Directional) 50-200% (B-Ph)O/C=125%
E/F E/F =20%
20-80% TMS=0.3 sec
4 Okhala – 1 Distance RR3V 600/1 A - Z1=1.63 Ohm
Protection 220KV/110V Z2=2.44 Ohm
(t2=350 ms)
Z3=4.89Ohm
(t3=1.0 sec)

Backup IDMT O/C (R-Ph)O/C=125%


Protection (Directional) 50-200% (B-Ph)O/C=125%
E/F E/F =20%
20-80% TMS=0.3 sec
5 Okhala – 2 Distance RR3V 600/1 A - Z1=0.834 Ohm
Protection 220KV/110V Z2=1.44 Ohm
(t2=200 ms)
Z3=2.952Ohm
(t3=1.0 sec)
Backup IDMT O/C (R-Ph)O/C=125%
Protection (Directional) 50-200% (B-Ph)O/C=125%
E/F E/F =20%
20-80% TMS=0.3 sec
6 NOIDA Distance - 600/1 A - Z1=2.65 Ohm
Protection 220KV/110V Z2=4.51 Ohm
(t2=220 ms)
Z3=8.29Ohm
(t3=1.0 sec)
Backup IDMT 20-80% E/F =20%
Protection (Directional) TMS=0.3 sec
Sr. Name of Feeder Relay CTR Range Setting Sr. No.
No. Type
7 Alwar Distance MM3V 600/1 A - Z1=13.44 Ohm
Protection Scheme 220KV/110V Z2=20.16 Ohm
(t2=450 ms)
Z3=26.88Ohm
(t3=1.0 sec)
Backup IDMT O/C (R-Ph)O/C=125%
Protection (Directional) 50-200% (Y-Ph)O/C=125%
E/F (B-Ph)O/C=125%
20-80% E/F =20%
TMS=0.3 sec
8 Bypass Distance Quadro mho 600/1 A - Reqired setting
Protection 220KV/110V can be set
Backup IDMT O/C Reqired setting
Protection (Directional) 50-200% can be set
E/F
20-80%
9 Bus Coupler Instantant CAG33 1200/2 A 4 – 16 4A
O/C 220KV/110V Amp. 50A(R-Ph)
50C(B-Ph)
E/F 2 – 8 Amp 2A
50N

Instantant CAG39 0.5-2Amp 1.8 A


Dead time (51A,51C)
O/C
E/F
0.5-2Amp 0.5 A
(64)
10 Station Tr. 1&2 Backup IDMT 600/1 A O/C (R-Ph)O/C=50%
Protection 220KV/110V 50-200% (B-Ph)O/C=50%
E/F E/F =20%
20-80%
Biased DMH 15-50% 30%
Diff.
Protection
11 Station Tr. 3 Backup IDMT 600/1 A E/F (R,Y,B-Ph) O/C
Protection 220KV/110V 10-40% 20%
Differential DTH-31 - 15%
Protection
Rest. E/F CAG-14 5-20% 10%
12 Bus Bar Bus Bar CAG-34 600/1 A 50-200% 125%
Differential Differential
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 :Levelstart
Total no. of probes : 14
Range : 0-500 mmWCI
Drum Pressure :200 kg/cm2
Temperature : 4000 C
Power supply : Dual for odd & even set of
electrodes
Indication local and UCB for left & right side.

6.1.2 VARIABLE FREQUENCY DRIVE IN RC FEEDERS:(#4,5)

Make : L&T
Rating : 7.5 KW,415V 3Ph
Feeders :6 nos.
Features : Remote speed indication & facility
for auto control

6.1.3 RC FEEDER SPEED INDICATION AND STOPPAGE ALARM : ( # 4,5)

Make : Masibus
Sensor : Inductive proximity switches
Indication : Digital speed indication in UCB for
each feeder
Alarm : 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 : Fuji Tosdic


Output : 24 V pulsating

6.1.5 ANNUNCIATION SYSTEM :(#4,5)

Make : ILK Mark –II (CMOSbased)


I/P supply : 230V AC
6.1.6 DISTRIBUTED CONTROL SYSTEM (DCS): (#5)

Make : Siemens Teleperm ME Plus.

1. Closed loop controls including:


a) PA header pressure
b) Furnace draft
c) SH attemperation
d) RH attemperation

2. Analog & Digital Measurements

6.1.7 SEQUENCE OF EVENTS LOGGER (#5)

Make : Siemens
Mode : Sieser
No. of points : 256
Time stamping : 1 msec
SECTION –VII

OFF-SITE

AUXLIARIES
7.1 SWITCHYARD

7.1.1 STATION TRANSFORMER (#1)

TRANSFORMER RATING

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

7.1.2 STATION TRANSFORMER (#2)

TRANSFORMER RATING

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

7.1.3 STATION TRANSFORMER (#3)

TRANSFORMER RATING

Make BHEL
MVA 25
Date Of First Charging 15-06-1977
Voltage Ratio HV/LV (kV) 220/7
Current HV/LV (Amps.) 65.6/2062
Phases 3
Frequency (Hz) 50
Vector Group Yd1
Type Of Cooling ON/AB
Tap Changer Type OLTC
Impedance % 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 INTERLOCKS

1 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)
2 Bus and line isolators can not be operated electrically if breaker of that Bay is in
closed position.
3 2nd Bus isolator of any Bay can only be closed (electrically) when Bus coupler
breaker and its both isolators are in closed position.
4 By Pass Isolator of any Bay can be operated (electrically) only when By Pass Bay
Breaker is in open position.
5 Earthling switches have electrical/mechanical interlocks with isolators.
6 Electrical interlock provided for closing only one by pass isolator at a time.

7.1.10 UNDER FREQUENCY PROTECTION (Islanding)

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 IMPORTANT ANNUNCIATIONS (required immediate attention)

1 Control Circuit faulty


2 Breaker Air Pressure Low
3 V.T. fuse faulty
4 Line V.T.fuse faulty
5 Bus Protection Bus wire faulty
6 Bus connection disturbed
7 Bus Differential protection DC faulty
8 Bus protection zones combined
9 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 IP-I
2 Station I, III
3 Okhla-I
4 Ballabhgarh-I
5 Units-I, III, V
6 Jaipur
7 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 AIR COMPRESSORS

7.2.1 STATION AIR COMPRESSOR

Total Nos. 3
Jacket water pressure 4.2 kg/cm2 (Max.)
H.P. Cylinder outlet 1100 F to 1200 F
Water Temp

7.2.2 COMPRESSOR NO. 1 & 2

Make Pneumatic Tool company


(India)Ltd., Mumbai.
Type Slow speed, Horizontal straight
Line & Double Acting Type
Speed 300 RPM
Nos. of Cylinder 2
Pressure 100 Psig
Max. working pressure 120 Psig
No. 2
Capacity 21m3/hr

MOTOR

Motor capacity 126 KW


Voltage 415V
RPM 1500
Amps 221
Make Siemens

RECEIVER

Capacity 250C.F.
Working pressure 125 Psig
Test pressure 185 Psig

7.2.3 COMPRESSOR NO 3

Make Consolidated Pneumatic


Tool company(India)Ltd.,
Mumbai.
Type Slow speed, Two cylinders
Horizontal & double
acting type.
Speed 300 RPM
Capacity 741 CFM at 100Psig
( 20.926M3/min)
Working pressure 100 Psig ( 7 kg/cm2)
Max. Unloading Pressure 100 Psig ( 7 kg/cm2)
No. One

RECEIVER
Capacity 10 M3.
Design pressure 9.2 kg/cm2
Test pressure 13.8 Kg/cm2

MOTOR
Capacity 132 KW
Voltage 415V+ 10%
RPM 1500
Amps 227
Make Siemens
7.2.4 PLANT AIR COMPRESSORS(ST-II & III)

No 2
Capacity 30 m3/min
Pressure 70 MWC
Make Kirlosker Pneumatic

MOTOR
Capacity 200 KW
Voltage 6.6 KV
RPM 988
Amps 23
Make Kirlosker

7.2.5 INSTRUMENTAIR COMPRESSOR (U#4)

Make K.G.Khosla Compressor Ltd.


Type KHOSLA – CRPELLE
Double acting, Horizontal/cross
heads two opposite cylinders.

Speed 750 RPM


Free air Delivery 14.6 m3/min.
Working/cut-off 8.0 kg/cm2
Pressure
Re-starting Pressure 7 kg/cm2
No. of compressor 2
Lubrication oil 1.5 to 2 kg/cm2
Pressure
Jacket water pressure 8 kg/cm2
HPC outlet water 1100 F to 1200 F
Temperature

MOTOR

Capacity 100 KW
Voltage 415 Volts
Amps 173/177
Make Kirlosker Electric
Speed 1500 RPM

RECEIVER

Capacity 5 M3
Hydraulic Test Pressure 16.19 kg/cm2
Working Pressure 10.15 kg/cm2

AIR DRYING UNIT

1) Type Purge Reactivation


2) Flow Rate 14.6 kg/cm2
3) Inlet Pressure 8 kg/cm2
4) Outlet pressure 7.6 kg/cm2
5) Inlet Temp. 440 C
6) Outlet Temp. 540 C
7) Outlet Moisture 22 ppm
content
8) Cycle Time
a) For absorption 6 Hrs
b) For regeneration 2 ½ Hrs
c) For cooling 3 ½ Hrs
9) Service Continuous
10) Drying Agent Silica
11) Design Pressure 10 kg/cm2

7.2.6 INSTRUMENT AIR COMPRESSORS (U#5)

7.2.7 COMPRESSURE 1&2

Make Kirlosker Pneumatic


Capacity 18 m3./min
(2 Nos)
Pressure 7 kg/cm2

MOTOR
Capacity 120 KW
Voltage 415 V
RPM 1000
Amps 212
Make Kirlosker

7.2.8 COMPRESSURE 3

Make K.G.Khosla Compressor Ltd.


Type KHOSLA – CRPELLE
Double acting, Horizontal/cross
heads two opposite cylinders.

Speed 750 RPM


Free air Delivery 14.6 m3/min.
Working/cut-off 8.0 kg/cm2
Pressure
Re-starting Pressure 7 kg/cm2
Lubrication oil 1.5 to 2 kg/cm2
Pressure
Jacket water pressure 8 kg/cm2
HPC outlet water 1100 F to 1200 F
Temperature

MOTOR

Capacity 100KW
Voltage 415 V
RPM 1500
Amps 173
Make Kirlosker

AIR DRYING UNIT

1) Type Purge Reactivation


2) Flow Rate 14.6 kg/cm2
3) Inlet Pressure 8 kg/cm2
4) Outlet pressure 7.6 kg/cm2
5) Inlet Temp. 440 C
6) Outlet Temp. 540 C
7) Outlet Moisture 22 ppm
content
8) Cycle Time
a) For absorption 6 Hrs
b) For regeneration 2 ½ Hrs
c) For cooling 3 ½ Hrs
9) Service Continuous
10) Drying Agent Silica
11) Design Pressure 10 kg/cm2

7.3 CONTROL STRUCTURE PUMP HOUSE

7.3.1 HP FLUSH WATER PUMP

No -I, II, III, IV 4


Make Worthigton
Type Multistage Vertical Turbine Pump
Capacity 500 m3/Hr
Head 94.5 MWC
Speed 1500 RPM
MOTOR

Make Kirloskar
Type Induction Motor
Rating 6.6 KV,187 KW ,22Amp.
RPM 1485

7.3.2 H.P. WATER PUMPS

No-V, VI 2
Make Kirloskar
Type Multistage Vertical Turbine Pump
Capacity 400 m3/Hr
Head 94.5 MWC

MOTOR

Make Kirloskar
Type Induction Motor (IP23/IC01)
Rating 6.6 KV,150 KW
RPM 1485

7.3.3 FIRE & SCREEN PUMP

Make Worthigton
No 2
Type Multistage Vertical Turbine Pump
Capacity 500 m3/Hr
Head 94.5 MWC

MOTOR

Make Kirloskar
Type Induction Motor
Rating 6.6 KV,185 KW
RPM 1485

7.3.4 DEISEL FIRE PUMP

Make Kirloskar
Type DHR-35 Three Stage
Capacity 500 m3/Hr
Pressure 10 Kg/cm2
Engine Model Model NTA-855-F
Rating 132 Kw
7.3.5 LP FLUSH WATER PUMPS

No 3
Make Jyoti
Type B400 D3F 300, Multistage vertical turbine pump
Capacity 600 m3/Hr
Head 55 MWC
Speed 1440 RPM

MOTOR

Make Jyoti Limited, Baroda


Type Induction Motor (IP23/IC01)
Rating 415 V,132 KW ,230Amp
RPM 1470

7.3.6 CLARIFIED RAW WATER PUMP(CRW)

Make Kirloskar,(CRW1)/Flowmore(CRW2,3)
No 3
Capacity 3500 m3/Hr
Head 20.5 MWC

MOTOR

Make Kirloskar.
Type Induction Motor
Rating 6.6 KV,280 KW
RPM 985

7.3.7 TRAVELLING WATER SCREENS

Make BSBK
Total no of screens 7 nos
Capacity 20000 cu mt /hr

7.3.8 SCREEN WASH PUMPS

Make Mather and Platt.


Capacity 300 cu mt/hr
Pressure 6.0 kg/cm2
Motor 75KW/1485RPM/131Amp

7.3.9 CHLORINATION PUMP


No 1
Type Vertical
Capacity 200 m3/Hr
Head 66.75 MWC
Drive Motor 55KW/85HP, 415V, 1500RPM, 93Amp

7.3.10 MAKE-UP PUMP AT AGRA CANAL

Drive Motor 1425RPM, 14.1Amp, 415V

7.3.11 DEDS PUMPS


No. 3
Type Vertical Turbine Pump
Capacity 200 m3/Hr
Head 120MWC
Speed 1480
Motor 110KW/1485RPM/197Amp/Kirlosker

7.4 ASH HANDLING PLANT

7.4.1 ASH PUMP (OLD)

Make Flowmore
Model D85
Capacity 1000 m3/hr
Pressure : 3.3 kg/cm2
Quantity 1.
Speed 800 RPM
Motor 194 KW

MOTOR

Capacity 194 KW
Voltage 415 V
RPM 1000
Amps 331
Make Siemens

7.4.2 ASH SLURRY PUMPS ( NEW)

Make Indure
Model D85D
Capacity: 1300 m3./hr
Pressure 5.0 kg/cm2
Quantity 3
MOTOR

Capacity 322 KW
Voltage 6.6 KV
RPM 991
Amps 35
Make Kirlosker

7.4.3 BOTTOM ASH PUMPS

Quantity 2 nos.
Make Beacon Weir
Model SDC 200/200
Capacity 410 m3/hr
Pressure 8.0 kg/cm2
Motor 160KW/1485RPM/220Amp/NGEF

7.5 COOLING TOWER

Intake Channel Level (Normal) 202 mtrs

7.5.1 C.T PUMP

Nos 2 for each 210 MW unit


Dischrge 4160 L/sec or 15000 m3 /hr
Head 17.855 mwc
Speed 405 rpm
Make FLOWMORE(U4)
KIRLOSKAR BROTHERS LTD. (U5)

MOTOR

Type Induction motor


Speed 421 rpm
KW 930
Current 108.5 amps
Volts 6600 volts, 3 Ph. 50 C/S
Make BHEL

7.5.2 COOLING TOWER


Make Gammon(U4)/ Paharpur(U5)
Number 1 for each unit of 210 MW
No. of cells/tower 16
Rate of flow /unit 27000 m3 /hr/Tower
Cooling Range 100C
Max. operating inlet water temp. 500C

7.5.3 COOLING TOWER FANS

Fan Type Axial Induced Draft


No. off fans/Tower 16
No. off blades/fan 9
No. off row of fan 2 (8 in each row )
Dia. 7315 mm
Reduction gear Ratio 10:1 L.X.
Fan speed 151 rpm
Type V-1400C.T.
Make Radicon worm Reducer
Lub oil Enklo-120 or Servo-40

MOTORS

Make N.G.E.F.
Volts 415V
Current 130 amps
K.W. 75
Speed 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 2
Make Jyoti Ltd.
Rated output 250KVA
Power Factor/ Voltage 0.8/415
Frequency 50 Hz , 3 ph.
Insulation Class B
Speed 1500rpm
Current 348 Amps
Ratings CR Excitation 85V 50 Amp.
No. of space heaters One
Rated KW 200W
Rated Voltage 230V

7.7 WATER TREATMENT PLANT

7.7.1 WATER ANALYSIS as CaCo3 p.p.m.

COMPONENTS RAW WATER MODIFIED FOR DESIGN


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

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 0.2 ppm (max.)


Conductivity at 20 C 10 micro-mhos/cm
Total dissolved solids 2ppm as such
7.7.3 PRETREATMENT SECTION

Description Alum Prep. Const. Head tank Lime Const. Head tank
Cum storage for Alum solution tank for lime
tank
Nos. off 2 1 1 1
Dimensions 12300x1200D 765Lx380Wx380H 16200 765Lx380Wx380H
x1480D
Concentratio 10% 10% 10% 10%
n of solution
High Speed 2 Nos. Nil 1 Nos. Nil
Mixture

7.7.4 CLARIFLOCULATOR

Nos. One
Size 168000 x 4000D
Capacity 400 m3/Hr.

7.7.5 FLASH MIXER MECHANISM

Nos. One set


Make Hindustan Door Oliver

7.7.6 CHLORINATOR

Nos. 2
Capacity 0.1 to 5.5 kg/cm2 (Max.)
Model Banaco Mark II
Type Press Gaseous Chlorinator
Capacity (0.1 – 5.5 ) kg/Hr
Operating Pressure/ 2.0 kg/cm2
Unit
Operating water 3m3/Hr.
Qty/Unit

7.7.7 TANKS

LOCATION MODEL HP/RPM MAKE/FRAM QTY.


E SIZE
Alum Prepn. PH 5 0.5/1440 Kirloskar/N80 3
Cum. Storage
Tank
Lime Soln.Tank PM 1 1.0/1000 Kirloskar/N90L 1
for
clarifloculator
Sodium sulphite PM 5 0.5/1440 Kirloskar/N80 2
Soln. Tank
Alkali dilution PM 10 1.0/1000 Kirloskar/NPOL 2
tank
Lime prepn. PH 5 0.5/1440 Kirloskar/N80 1
Tank for
neutraliasation

7.7.8

DESCRIPTION CLARIFIED WATER SLUDGE DISPOSAL


PUMP PUMP
Nos. 2
Capacity 250M3/hr. 250M3/hr.
Discharge Head 36 MWC 15 MWC
Model No. 6 DC 124 3x2x10 BPO
Make Best & Crompton Best & Crompton
Motor 2 2
HP/RPM 60/1440 5/1440
Make Kirloskar Kirloskar
D.P. 2.5 kg/cm2

7.7.9 DEMINERALISATING SECTION

DESCRIPTION PRESSURE ALKALI CARBON


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

DESCRIPTION BACKWASH AIR BLOWER SODIUM


WATER PUMP SULPHATE
DOSING PUMP
Nos. 2 2 2
Capacity 170 M3/Hr. 4.65 m3/min 227 Lit/Hr.
Discharge Head 20 MWC 0.21 kg/cm2 7 kg/cm2
Medium Water Air Sodium sulphite
soution
Motors HP/RPM 25/1440 7.5/1440 0.5/1440

DESCRIPTION BACKWASH WATER SODIUM SULPHATE


PUMP SOUTION TANKS
Nos. 1 2
Size 1000Lx6000Wx2580H 12200 x 1200D
Concentration of Soln. - 10 %
High speed Mixture - 2

DESCRIPTION CATION UNIT ANION UNIT MIXED BED UNIT


Nos. 4 4 4
Type Strongly Acidic Strongly basic Strongly Acidic &
Basic
Shell Design 4.0 5.3 5.3
Pressure(kg/cm2)
Max./Min. Treatment 80/28 70/28 47/28
flow (m3/Hr.)
Average Treatment 35 35 35
flow (m3/Hr.)
Capacity between 850 706 700
Regeneration M3
“ GROSS”
Wastw water / 110 80 25
Regeneration M3
Time per 55 mints. 115 mints. 115 mints.
Regeneration
Type of Chemical Hcl NaOH Hcl & NaOH
100% chemical 880 500 38.5
Regeneration per
unit(kg)
Type of Resin 2K 225 DANIP ZK225/DAFFIP
Resin qty. M3/unit 12.5 6.695 0.77/2.10

7.7.10 REGENERATION FLOW

UNIT OPERATION FLOW-M3/HR. TIME-MIN


3K Back wash (once in a 55.4 5
week)
Acid Injection 5% 52.8 20
w/v
Down flow 79.8 20
Acid Rinse 52.8 25
Down flow 79.2 25
Final Rinse 35.0 5
D.A. Back wash 13.6 5
Alkali Injection 22.2 30
Alkali Transfer 22.2 5
Alkali Rinse 67.0 60
M.B. Middle Collector 14.0 1
wash
Back wash 14.0 6
Alkali Injection 15.3 30
Up flow 6.9 30
Alkali Transfer 14.9 5
Up flow 6.9 5
Alkali Rinse 25.2 20
Acid Injection 5% 7.5 6
W/V
Down Flow 3.5 6
Acid Rinse 7.4 10
Drain Down - 5
Air Min. 3.0 M3/Min. 10
Final Rinse 3.5 10

7.7.11

DESCRIPTION DEGASSER TOWER DEGASSED WATER-


SUMP
Nos. 2 2
Size 2000Lx2000Wx3400H 7500Lx7500Wx2750H

DESCRIPTION DEGASSER AIR- MIXED BED AIR DEGASSED


BLOWER BLOWER WATER PUMP
Nos 4 2 3
Capacity 75 m3/min. 3m3/min. 120 m3/min.
Discharge Head 100MWC 0.4 kg/cm2 45 MWC
Medium Air Air Acidic water
MOTOR HP/RPM 5/1440 7.5/1440 40/1440
MOTOR-Make Kirloskar Kirloskar Kirloskar
DESCRIP ALKALI BULK ALKALI BULK ACID ACID
TION PREPAR ALKALI DILUTIO ACID MEASUR MEASUR
ATION STORAG N TANK STORAG ING ING
TANK E TANK FOR E TANK TANK TRANSF
DA/MB FOR ZK ER MB
Nos. Two One Two Five Two Two
Size 12000 16000 x 16000 34000 18000 4570
x1200D 4500L x1500D x6200L x1500D x762D
Solution - - 20% 30% 30% 30%
Concentrat
ion in
Tank

DESCRIPTIO ACID EFFLUENT ALKALI ALKALI


N TRANSFER DISCHARGE TRANSFER INJECTION
PUMP PUMP PUMP PUMP
Nos. 1 2 2 2
Capacity 25 150 15 5
Discharge Head 17.5 18 20 25
MWC
Media 32% Hcl Acid/Alkali 20% NaOH Alkali
MOTOR- 5/1440 20/1440 5/1440 7.5/1440
HP/RPM
Motor make Kirloskar Kirloskar Kirloskar Kirloskar

DESCRIPTIO PRIMING LIME PREPN. NEUTRALISING PIT


N CHAMBER TANK
Nos One One One
Size mm. 6000 x900D 12000 x1200D 10000Lx10000Wx3000H

DESCRIPTION STRONGLY STRONGLY MIXED BED UNIT


ACIDIC CATION BASIC ANION
UNIT UNIT
Nos. Four Four Four
Type Strongly Acidic Strongly Basic -
Size(mm) 2800 x3600H 2400 x2600H 1400 x3000H
Max.Working 3.6 4.6 4.6
Pr.(kg/cm2)
Min.Treatment 28 28 28
flow(M3/Hr.)
Max. Treatment 80 70 47
flow(M3/Hr.)
Average Treatment 35 35 35
flow(M3/Hr.)
Capacity between 850 706 700
regeneration(M3)
Period between 20 20 20
regeneration(Hrs.)
Waste Water per 110 80 25
regeneration (M3)
Type per 55 115 115
regeneration(Mints)

RESINTYPE INDIAN 225 INDIAN NIP ANION CATION


INDIAN FFIP INDIAN 225
Resin Quantity 12500 6695 2100 770
(Lts.)
Regenerant Hcl NaOH NaOH Hcl
Chemical
100% 880 544 Through fan 38.5
Chemical/Regen with 5BA
eration(kgs)

7.7.12 REGENERATION FLOWS

UNIT OPERATION FLOW(M3/Hr.) TIME(Min.)


Strong Acidic cation Middle collector 55.4 1
unit flushing
Down Flow 79.2 20
Back wash 55.4 5
Acid Injection @ 5% 52.8 20
Down Flow 79.2 25
Acid Rinse 52.8 25
Final Rinse 35.0 5
Strong basic Anion Back wash 13.6 5
Unit
Caustic Injection @ 22.2 30
5%
Caustic Transfer 22.2 5
Caustic Rinse 67.0 60
Mixed Bed Flushing/ Back wash 14.0 6
Up flow 6.9 30
Caustic Injection 7.2 15.3 30
%
Up flow 6.9 20
Caustic Rinse 25.2 20
Up flow 6.9 5
Caustic Transfer 6.9 5
Down flow 3.5 10
Acid Injection @ 7.4 10
5%
Drain Down - 5
Air Mix. 180 10
Final Rinse 35 10

7.7.13 GEO-MILLER CLARIFLOCULATOR

Nos. 2
Type Radial flow clarifloculator
Capacity 3200 m3/Hr./unit
Overload 20 % (Max.)
Size 54300 Dia x4915 Deep.

7.7.14 FLASH MIXER MECHANISM

Nos. 2(one/unit)
Make Geo-Miller Private Ltd.
Detension Time 60 Secs.
Dia. 3.7 mts.
Gate 2/unit
Draining Service valve 150 DA.

7.7.15 ALUM DOSING UNIT

Nos. 3/unit
Capacity/Tank Soln. (10 % strength ) to last for 8 Hrs.
operation while flow of 3200 m3/hr.

Size Alum dosing basket – 3.2x1.09x0.75mts.


Alum dosing Tank- 3.33x3.2x3.4 mts.
Total No. – 3

7.7.16 DRIVING PADDLE

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

7.7.17 OPERATING HOIST FOR ALUM

Nos 2 .
Capacity 1 Ton each
Type Gear operated travelling trolley are
fitted on monorails.

7.7.18 LIME DOSING UNIT

TANK 2/Unit
Type Semi Circular
Size 3.35(Dia.)x3.600L
Capacity 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 M.S.
Type Rotation about horizontal axis
Motor 2 H.P., 1500r.p.m., gear ratio 1:

7.7.19 DESLUDGING PUMP

Capcity 300 m3 /hr


Total Head 15 M.
BHP absorbed 23.4

MOTOR
HP 30
Speed 1450 rpm

7.7.20 ECHNICAL SPECIFICATION OF ACTIVATED CARBON


FILTERS (ACF)

SR NO. FEATURES
1. Quantity (No.) Four
2. Type Vertical down flow.
3. Normal operating flow 55.00 m3/Hr
4. Operating Pressure 3.5 – 4.00 (kg/cm2)
5. Dimensions Dia x HOS 2200mm x 2650mm
6. Material of construction M.S.
7. Back wash Time 15-20 min. or till the effluent is
clear.
8. Max. allowable Pressure drop. 0.8-1.0 kg/cm2
9. Type of operation Manual.
7.7.21 DETAILS OF FILTER MEDIA IN ACF

SR. MATERIAL SIZE QUANTITY


NO.

1. Pebble 2”x 1½” 2164.00 x 4 kgs


1½” x 1” 541.00 x 4 kgs
1” x ¾” 541.00 x 4 kgs
¾” x ¼” 541.00 x 4 kgs

2. Quartz cylex ½” x ¼” 513 x 4 kgs


3. Mixed sand - 93500 x 4 kgs
4. Activated Carbon - 2508 x 4 kgs

7.8 OLD COAL HANDLING PLANT

7.8.1 COAL CHARACTERISTICS AT BTPS

Description At relative humidity 60 % & air


temp. 400 C
Moisture 6-9%
Ash 24-33%
Volatile Matter 24-28%
Gross calorific value 4778-4944 kcal/kg
Hard grove grindability Index 45-50
Bulk density 0.8 Tonne/m3
Size 250 mm

7.8.2 DESIGN CAPACITY OF COAL HANDLING PLANT

( 3X100MW + 2X210MW UNITS)

DESCRIPTION UNIT 3X100MW 3X100+2X210MW

Coal consumption Tonnes/Hr 187.5 450


Max.daily Tonnes 4500 10800
Consumption
Average daily Tonnes 3600 8000
Coal consumption
Annual Coal Tonnes 1312500 315,00,00

7.8.3 WAGON TIPPLER

Nos. 2
Make Tata Robins-Fraser Ltd.
Type Weighing Type with recording,
Side discharge
Total Time for Tripping 4 minutes (For 1 wagon)
Max.angle of rotation 1350 C (giving 450 angle at
Side of wagon )
Total Weight 125 tonnes
Capacity 85 tonnes

MOTOR

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

7.8.4 STEEL WIRE ROPES

a) Counter weight Rope Dia-40mm


Nos. –2
Length – 123 ft.(3
b) Hoisting Rope Dia – 38mm
Nos. –4
Length – 24.28 mts
Construction-6X41
7.8.5 CAR PULLER

Rope Size 1-3/8” (35mm)


Braking Electro Magnetic
Coupling Clutch Type
Speed Reducer V-1400 Worm reducer

MOTOR

Capacity 30KW/40 HP
Amps 52.5
RPM 960

7.8.6 COAL CRUSHERS


Make TRF
Type Non-reversible ring granulator type
Coal size input 250 mm
Coal size output 20mm
Capacity 600 MT/Hr. per crusher
Nos. 2
Working oil temp. 500C-850C
Limit
Rotor Speed 720 rpm
Rotor dia 360 mm
Rotor length 3875 mm

MOTOR

Voltage 6.6KV
Amps 33.5
RPM 1490
Capacity 300KW

7.8.7 BELT CONVEYERS

Carrying Capacity 600 Tons/Hr


Speed 2.3 mts/sec
Width 1 mt.(For all)
Material Nylon Fabric with Dead WT.

7.8.8

CONVEYER LENGTH & MM PLY RAISE OF


NO. INCLINATION
1A & 1B 171548 4 150
2A & 2B 164345 4 140
3A & 3B 156371 4 11698 mm at 150C &
rest is horizontal
4 92087 4 130
5 100262 4 120
6 223778 4 10562 mm at 150C &
rest is horizontal
7 177000 4 Horizontal
8 153832 4 150
9 20900 4 180
10A&10B 4 Horizontal

MOTOR SPECIFICATIONS
Speed 1440 rpm
Voltage 415 V

CONVEYOR NO. CAPACITY REDUCTION RATIO


1A & 1B 150 HP 35.5:1
2A & 2B 150 HP 35.5:1
3A & 3B 100HP 20:1
4 60 HP 25:1
5 75 HP 25:1
6 60 HP 20:1
7 50 HP 20:1
8 100 HP 25:1
9 30 HP 20:1
10A & 10B 75 HP 20:1

7.8.9 TRIPPER

Type Motor Propelled Tripper


Quantity 5 Nos.
Belt width 1mt.
Drum Dia 600 mm
Speed 30 to 35 ft/min

MOTOR
Type 3 ph.Squirrel cage Induction Motor
Capacity 7.5 H.P.
(Traverse Drive)
Speed 1500rpm
Voltage 415 V
Telescopic Chute 5 H.P.
drive capacity

7.8.10 ROTORY PLOUGH FEEDER

Quantity 2
Overall Length 11700 mm
Height 3500 mm
Width 1980 mm

MOTOR TRAVERSE MOTOR PLOUGH MOTOR

Type Induction Motor Induction Motor


Capacity 7.5 H.P. 40 H.P.
Speed 720 rpm 1430 rpm
Voltage 415 V 425V
Speed 20 to 30 ft/minute -

7.8.11 BELT WEIGHER


SR. NO. DESCRIPTION SPECIFICATION
1.0 Location Belt conveyor 2 A,2B
2.0 Quantity 2
3.0 Type Mechanical
4.0 Make Gillanders Arbuthnot & Co. Ltd.
5.0 Type of speed sensor Mechanical
6.0 Type of load sensor Mechanical
7.0 No. of load cell per weigher
8.0 Capacity
8.1 Rated 600 MTPH
8.2 Maximum(Designed) 750 MTPH
8.3 Minimum 120 MTPH
9.0 Accuracy 10.50%
10.0 Calibration By test chain
10.1 Weight per unit length of chain 46.85 Kg / m
11.0 Remote Panel
11.1 Type of flow indicator Moving coil meter
12.0 Type of totalising counter EM counter
13.0 No. of Digits 6
14.0 Whether zero reset button provided Yes
15.0 Local
15.1 Type of flow indicator NA
15.2 Type of totalising counter Mechanical

15.3 Power supply 230V AC +/- 10%, 50 Hz

7.8.12 MAGNETIC SEPERATOR


Make Electro ZAVOD
Type Suspended
Nos. 2
Size 1500mm x 1350mm x 800 mm
Power Required 8.5 KW/11.0 KW (Hot/Cold)
Operating Voltage 220 VDC

7.8.13 METAL DETECTOR

Metal detector specification for OCHP is same as NCHP.

7.8.14 LIST OF FLUID COUPLINGS

S.NO. TYPE OF COUPLINGS

1 STD – 08 ]
2 STD – 07 ]
3 STD – 06 ] M/s Fludomate make
4 STD - -5A ] (Conveyors)

5 FCU – 17.75 ]
6 FCU – 16.5 ] M/s Pembril Greaves make
7 FCU – 14.5 ] (Conveyors)
8 FCU – 12.75 ]

9 HFD – 10 B ] M/s Fludomate make (Crushers).


10 HFD – 14B ]

11 SCR – 41 R ] M/s Pembril make (Crushers)

7.8.15 ROTECTION & INTERLOCKS

DESC PERMISSIVE INTERLOCK PROTECTION


RIPTIO
N
Belt i)No Conveyor i) If any belt trips the i) If one belt runs out
belt can be whole system behind it of alignment more
Conveyor started before will trip. than limit,the
the belt ahead ii) No second belt of same swaying switch will
of it is kept pair can run with other trip the belt & whole
running. belt in service(But for system behind it.
ii) No. belt will 1A & 1B this interlock ii) Belts are provided
run if its can be by passed when with emergency trip
delivery gate is yard & BKR feeding belt sway switch to
opened to the both are in service.) avoid eccentric
belt not in iii) If any belt trip the movement
service. feeders to ,centrifugal switch
corresponding 1st belt for excessive
will trip. slipping,skewing &
iv) If any belt trip the breaking of belt.
feeders to iii) Any conveyor loaded
corresponding 1st belt beyond 600T/hr will
will trip. trip.
v) If conveyor after iv) If the belt is cut or
crusher trips the screen the belt speed
& conveyor before reduces below a
crusher will trip along certain limit belt
with feeder. trips.
Screens If screen trips the system after
screen will trip.
Tripper Respective
conveyor
should be in
operation.
Plough Respective The traverses can not be
Feeder conveyor effected unless the blade cutter
should be in is previously started.
service.
Car Wagon trippler
Puller & should not be in
Beetle operation.
Charger
Wagon Car puller or
Trippler Beetle charger
should not be in
operation.
Motors Provided with over load
protection ,short circuit
protection, single phase
protection.

7.9 NEW COAL HANDLING PLANT

7.9.1 WAGON TIPPLER

SR. NO. DESCRIPTION SPECIFICATION


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

7.9.2 RING GRANULATOR (CRUSHER)

SR. NO. DESCRIPTION SPECIFICATION


1.0 Type Ring Type Granulator
2.0 Make Mcnally Bharat Engineering Co. Ltd.
3.0 Model No. RG-729
4.0 Quantity 2
5.0 Capacity- Rated 600 MT/hr
-Design 750Mt/hr
6.0 Material to be handled R.O.M.Coal
7.0 Maximum RPM 750
8.0 Hard Grove Index 50-70
9.0 Maximum lump size (-) 100 mm
10.0 Maximum moisture content 20%
11.0 Bulk density of coal O.B.T./m
12.0 Guaranteed output of lump 100%
size at specified input size and (-) 20 mm
moisture
13.0 Material of Parts
13.1 Material of rotor shaft EN-19
13.2 Material of upper breaker Tiscral
plate
13.3 Material of breaker plate Cast MN steel IS-276, Gr.III
13.4 Material of suspension bars EN-19
13.5 Material of side liners Tiscral
13.6 Material of ring hammers IS-276 Grade-III
14.0 Bearing No. Torrington “22238”
15.0 Method of lubrication of Manual grease lubrication and 40,000
crusher bearing and life working hours
16.0 Specification of motor
16.1 Power rating 550 KW
16.2 Speed(RPM) 750
16.3 Duty cycle Continous, 24 Hours/Day operation
16.4 Method of mounting Coupled through fluid coupling with the
crusher
17.0 Granulator weight 28 T

7.9.3 VIBRATORY FEEDER

Sr.No. Description Specification Specification Specification


1 Location Below wagon Below Above coal
tippler hopper reclaim crusher
hopper
2 Type Mechanical turflo Mechanical Mechanical
type turflo type turflo type
3 Manufacture Tata Robins Fraser Tata Robins Tata Robins
Ltd. Fraser Ltd. Fraser Ltd.
4 Model No. & size TE-9 TE-9 TE-11
3’X8’ 4’X8’ 5’X10’
5 Numbers 6 Nos. 4 Nos. 2 Nos.
6 Guaranteed capacity 200 TPH 300TPH 600 TPH
7 Designed capacity 250 TPH 375 TPH 750 TPH
8 Length of tray 2438 mm 2438 mm 3038 mm
9 With of tray 915 mm 1219 mm 1524 mm
10 Slope of tray 100 down hill 100 down hill 100 down
hill
11 Operating Speed 800 rpm 800 rpm 800 rpm
12 Feeder stroke ½” ½” ½”
13 Material of
construction
Tray M.S. IS-226 M.S. IS-226 M.S. IS-226
Liner 10 mm thick tiscral 10 mm thick 10 mm thick
tiscral tiscral
14 Type of feed By changing the By changing By changing
rate controller rpm of feeder the rpm of the rpm of
feeder feeder
15 HP rating of each 10 15 20
feeder
16 Approximate weight 1960 Kg 2520 Kg 3750 Kg
17 Recommended 51 mm 51 mm 51 mm
clearance between
feeder and stationary
chute

7.9.4 BELT WEIGHER

SR. DESCRIPTION SPECIFICATION


NO.
1.0 Location On conveyor 12 A,12B,15A &15B
2.0 Quantity 4
3.0 Type Electronic load cell single idler sensing
system with rate indicator and integrator
(Totalizer)
4.0 Make Integrated process automation
5.0 Type of speed sensor AC Digital Tacho
6.0 Type of load sensor Strain gauge
7.0 No. of load cell per weigher 1
8.0 Capacity
8.1 Rated 600 MTPH
8.2 Maximum(Designed) 750 MTPH
8.3 Minimum 120 MTPH
9.0 Accuracy
9.1 At rated ty(Guaranteed) +/-0.5% F.S.
9.2 At maximum +/-0.5% F.S.
capacity(Guaranteed)
9.3 At minimum pacity(Guaranteed) +/-0.5% F.S.
10.0 Calibration By test chain
10.1 Weight per unit length of chain 49.5 Kg / m
11.0 Type of flow indicator Moving coil meter
12.0 Type of totalising counter EM counter
13.0 No. of Digits 6
14.0 Whether zero reset button Yes
provided
15.0 Remote Panel
15.1 Type of flow indicator Moving core type indicator
15.2 Type of totalising counter EM counter
16.0 Power supply required 230V+/- 10%, 50 Hz, +/- 2% Single phase
17 .0 Power Demand 100 VA

7.9.5 METAL DETECTOR

SR. NO. DESCRIPTION SPECIFICATION


1.0 Type Electronic
2.0 Make Unique Electromag, Mumbai
3.0 Model No. Type SCTA
4.0 Location 15A, 15B
5.0 Quantity 2 nos in each conveyor
6.0 Sensitivity at normal working 25 mm dia MS/AL sphere
condition
6.1 At maximum capacity with 25 mm dia MS/AL sphere
maximum moisture content
6.2 Particular to sensitivity Depends on conductivity properties and
to other electrical characteristic of materials.
non ferrous material Sensitivity is adjustable.
6.3 Power requirement (Watt) 150 VA
6.4 Power supply required 230 V +/- 10% C/S +/- 5%(Combine
+/- 10%)
6.5 Enclosure material and Search coil 3 mm, Pane 2 mm
thickness
6.6 Degree of protection IP-54
6.7 Hooter Provided

7.9.6 MAGNETIC SEPARATOR

SR. NO. DESCRIPTION SPECIFICATION


1.0 Type Overband, inline magnetic separator
2.0 Manufacturer Electrometike
3.0 Number & Location 2 Nos, for 14A, 14B
4.0 Tramp iron size & weight Max weight upto 50 Kg of tramp iron to MS rod
(both maximum & or L/D ratio upto5 with min. weight of 100 grams
minimum ) or MS cubes of 2 cm weighing around 62 gms
to be separated shall be lifted from anywhere of coal bed at a
distance of 400 mm from the face of the magnet.
5.0 Type of drive system Chain drive
6.0 Details of cross belt
6.1 Make Dunlop
6.2 With 1200 mm
6.3 Number of plies 4
6.4 Top/ Bottom cover 3/1.5 mm
thickness
6.5 Material specification 32 OZ fabric
7.0 Weight of equipment Total 9 Tons approx,
8.0 Type of rectifier Silicon
9.0 Magnetic core material Mild Steel (High permeability type)
10.0 Field density 800 gauss at distance of 400 mm from the face
plate of the magnet
11.0 Magnet coil material Aluminum with class –H insulation
12.0 Total power requirement 15 KW for magnet
5.5 KW for motor
13.0 Details of drive
13.1 Rating Motor- 5.5 KW TEFC, 3 Ph AC motor
Gear Box- 15:1 Reduction ratios, Warm gear box
13.2 Make Motor- GEC make
Gear Box- NAW make
14.0 Operating voltage 190 V DC
Of magnet

7.9.7 CONVEYER BELT

Sr.No. Description Specification


1.01 Designation 11A/B 12A/B 13A/B 14A/B 15A/B 16 17A/B 18A/B
1.02 Capacity
Rated 600 TPH
Design 750 TPH
1.03 Width 1000 mm
1.04 Belt position A A
length C/C (M) 210.29 210.3 51.25 248.25 170.9 124.45 128.09 116.7
B B
209.98 108.82
1.04.02 Total lift (M) 23.35 21.05 6.0 29.8 28.4 15.7 14.75 14.966
1.04.03 Type of fabric Nylon
1.04.04 Is belt flat or Troughed
troughed
1.04.05 Trughing angle 35
(Deg)
1.04.06 Belt joints Vulcanised
1.05.05 Cover grade Fire resistance
1.06.00 Belt type/ No. 800/4 800/4 80/4 800/4 800/4 800/4 800/4 800/4
of plies
1.09 Thickness of
covers (M)
1.09.01 Top (mm) 5 5 5 5 5 5 5 5
1.09.02 Bottom (mm) 2 2 2 2 2 2 2 2
1.10.00 Belt 2.9 2.9 2.5 2.5 2.5 2.5 2.5 1.0
speed(m/sec)
1.11.00 Allowable 48 44.64 24.72 64.8 56.76 40.68 38.04 26.04
working tension
(KN)
1.12.00 Supplier data of 50 50 40.1 70 50 50 40 40
working tension
(KN/m)

7.9.8 FLUID COUPLING (SCOOP TYPE)

Sr. No. Description Specification


1 Location Ring granulator (Crusher)
2 Type Scoop type
3 Nos. 2
4 Manufacturer PEMBRIL FLUIDRIVE LTD,
Auranagabad
5 Model No. 41 SWGR 25W Scaled version
6 Rating of motor 550 KW
7 Rated KW transmitted 500 KW
8 Rated torque transmitting capacity with 150 to 275% of full load torque
torque
9 Rated input speed 750 rpm
10 Rated Slip 3%
11 Temperature at which plug fuses 1800 C+/-50 C
12 Weight of the coupling unfilled (Kg) 1654 Kg
13 Type of bearing and life Spherical roller bearing Approx.
Life-3000 working hours
14 Quantity of oil for coupling 184 Lits of SHELL TELLOS
OIL-29
15 MATERIAL OF CONSTRUCTION
a. Impeller Aluminum alloy
b. Runner Aluminum alloy
c. Casing Aluminum alloy
d. Shaft EN-8
e. Flanges for input and output coupling Forged Steel

16. Coupling shall be capable of rotating in both directions.


17. Equipment should be dynamically balanced.

7.9.9 FLUID COUPLING (TRACTION TYPE)

Sr. No. Description Specification


1 Manufacturer Fluidomat
2 Type Traction type
3 Type of prime mover Direct on squirrel cage
induction motor
4 Input rpm 1470 Approx
5 Max. no. of starts per hour 2 consecutive starts or 3
starts/hr spaced

6 Whether Acceleration torque limitation No


desired
7 Whether fusible plug to be provided Yes
8 Maximum slip 3%
9 Max .torque transmitting Adjustable in the range of
150% to 275 % of full
required torque
10 Direction of rotation Should be capable of
rotation in both direction
11 Bearing lubrication Lubrication of bearing
should preferably be done
with the fluid itself
12 Output coupling Flexible/Semiflexible
13 Balancing Dynamically balanced
14 Material of construction
a. Impellar High tensile aluminum
alloy
b. Runner High tensile aluminum
alloy
c. Casing High tensile aluminum
alloy
d. Shaft EN-8
e. Flanges for input and output couplings Forged steel
7.9.10 SCHEDULE OF FLUID COUPLING (TRACTION TYPE)

Sr.No. Location Quantity Motor RPM Coupling Gear Model No.


Conveyor rating(KW) input box
rating input
(KW) rating
(KW)
1 11A/B 2 125 1470 116.8 113.3 STD/E/08
2 12A/B 2 125 1470 109.0 105.7 STD/E/08
3 13A/B 2 55 1470 44.0 42.7 STD/E/06
4 14A/B 2 150 1470 135.6 131.5 STD/E/08
5 15A/B 2 150 1470 119.1 115.5 STD/E/08
6 16 1 110 1470 85.1 82.9 STD/E/07
7 17A/B 2 110 1470 79.0 76.6 STD/E/07
8 18A/B 2 37 1470 22.0 21.3 STD/E/05A

7.9.11 BELT FEEDER

Sr.No. Description Specification


1.0 Location Crusher house Breaker house
2.0 Capacity
2.1 Rated capacity (TPH) 600 750
2.2 Designed capacity (TPH) 750 750
3.0 Quantity & Type 2 (Unidirectional) 2(reveesible)
4.0 Manufacturer M/S McNally Bharat engineering Co. Ltd.
5.0 Feeder Length (M) 6.0 11.0
6.0 Material handled 100 mm crushed coal 20 mm crushed coal
7.0 Bulk density (T/m3) 0.8
8.0 Design ambient temperature 50
(0C)
9.0 Moisture content of coal (%) 20 (max)
10.0 Hours of operation per day 24
11.0 Belt
11.1 Belt width 1200 mm
11.2 Belt Speed (m/min) approx 24.0
11.3 Type of fabric Nylon
11.3.1 Cover thickness (mm/min) 9/2
Top/Bottom
11.4 Cover grade Fire resistant
11.5 Type of loading & Discharging Through chutes
12.0 Idlers
12.1 Carrying idlers
12.1.1 Type 152.4 mm dia rubber disc single roll, impact
type
12.1.2 Configuration Flat
12.1.3 Spacing 400 mm at loading points & 500 mm at other
portion
12.1.4 Disc material Special resilient rubber having greater shock
absorbing capacity
12.1.5 Type of fixing arrangements Mounting on slotted pipe sleeves on shaft to
for discs provide friction grip by spring action &
located by collars
12.1.6 Lubrication & seal Antifriction bearing with labyrinth type seal.
All grease fitting shall be rutton head type
having plastic caps.
12.2 Return idlers
12.2.1 Type 152.4 mm dia steel tube flat idler
12.2.2 Spacing 2000 mm
12.3 Type of idler seal Double labyrinth seal
12.4 Min. tube thickness )mm) 4
12.5 Applicable standard IS-4776 latest edition
12.6 Shaft material EN-8 or Equivalent
13.0 Pulleys
13.1 Pulleys construction Heavy duty welded steel as per IS-8531
13.2 Pulley shaft material Forged steel to IS-1875 Class-V
13.3 Type of bearing & plummer Antifriction double row self aligning
block spherical roller bearing in split type plummer
block with labyrinth seal. 4000 hours
working life.
13.4 Type of lubrication Grease
13.5 Quantity & type of pulleys 1 no. drive, 1 no. tail pulley per feeder
13.6 Pulley dia & width (mm) 630 drive & tail pulley per feeder
13.7 Type of lagging on drive 12 mm thick vulcanized natural rubber
pulley herringbone type lagging
13.8 Type of lagging on other 12 mm thick vulcanized plain natural rubber
pulley lagging
13.9 Height of USOB from 1200 mm
supporting floor
14.0 Skirt Board
14.1 Length Continuous
14.2 Material
a. Main plate 16 mm thick MS plate
b. Liner 10 mm thick MS scral
c. Cover plate 4 mm thick MS plate
15.0 Gear Box
15.1 Type Worm
15.2 Type of enclosure Totally enclosed dust proof
15.3 Type of lubrication Splash
15.4 Additional requirements Draining plug & oil level guage
16.0 Coupling
16.1 Type Flexible pin-bush type
16.2 Location Between drive pulley & gear box and motors
16.3 Coupling guard Provided
17.0 Tail pulley guard Standard wire mesh guard for all the feeders
18.0 Take up unit
18.1 Type Screw type
18.2 Location Tail end of feeder
18.3 Travel To suit
19.0 Scrappers
19.1.0 External
19.1.1 Location Inside head end chutes
19.2.0 Internal Rubber edge V- type
19.2.1 Location Near tail pulley
20.0 Belt protection Drive
20.1.0 Zero Speed switch
20.1.1 Quantity 1 no. at each conveyor
20.2.0 Quantity
20.2.1 Belt Sway switch 2 pair at suitable location of feeder per feeder

7.9.12 LOCO WDS-4


No. 4
Type 6M 282 A(k)
Model 01/21
Working method 4 stroke, single acting
Fuel injection Direct injection
Weight of engine without water & oil 7150 Kg
Maximum length 2876 mm
Maximum Width 2035 mm
Total Height 2035 mm with oil sump
1550 mm without oil sump
Number of cylinder 6
Cylinder bore 240 mm
Piston stroke 280 mm
Total swept volume 76 Lit
Swept volume per cylinder 12.7 Lit
Compression ratio 12:2:1
Nominal output 650 HP
Rotating speed at nominal load 1000 rpm
Idling speed 440 rpm
Torque at nominal load 541 Mkg
Mean effective pressure 8.6 Kg/cm2
Sense of rotation viewed at flywheel Anticlockwise
Engine cooling water circulation
Cooling water temp- Engine inlet 800C
Engine outlet 85 to 900
Lub oil pressure Lowest under load 1.8 to 2.1 Kg/cm2
Rated engine speed 2.4 to 3.0 kg/cm2
At idling speed 0.75 Kg/cm2
Suction Height 1.5 m

7.9.13 ELECTRIACL STARTER


Type TF-24 V1595 Bosch
Voltage 24 V
Output 1000 watts

7.9.14 DOZER (D155A-1)

Total 6 Nos.
Make BEMLD155A-1

No. 2
Model KOMATSU S6D 155-4D
Diesel Engine
Rated RPM 2000
Rated Horse Power 320 HP
Maximum torque ( at about 1400 rpm) 144 KgM
Start system- starting motor 24 V, 11 KW
Equipment weight 5780 Kg
Maximum tilt 1000 mm

7.9.15 CUMMINS DIESEL ENGINE – KT(A)1150


No. 4
No. of cylinder 6
Bore stroke (mm) 159 x 159
Displacement CID/Lit 1150/18.9
Maximum HP 525
Rim 2100
Peak torque (Ft-Lb) 1550

7.10 FUEL OIL SYSTEM

7.10.1 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

No. of pumps available 3


Type of model no. Rotary Gear
Liquid to be pumped L.D.O.
Capacity m3/hr 120
Suction pressure MWC 5
Discharge pressure MWC 80
Total Dynamic head MWC 85
Efficiency 45.50%
Pump speed 975 rpm
Maximum Temp. Of liquid to 600 C
be pumped
Setting pressure in kg/cm2 9

MOTORS

Type/Make TEFC/Crompton
RPM 1000
Voltage 415 V, 3PH, 50 c/s
H.P. 100
Temp. rise over an ambient temp. of 650 C
450 C

FILTERS

No. Of coarse filters 3


Type/Manufacturer Duplex/Technique
Design Pressure 1 kg/cm2
Maximum pressure drop at 75 % 35 kg/cm2
Cleanliness

7.10.4 FUEL (LDO) PRESSURE PUMP

No. off 4
Type Multi screw positive
displacement
Discharge pressure 25 kg/cm2
Capacity 250 lit/min.

MOTOR

Manufacturer M/s Kirloskar


Type 3ph. Induction motor.
Rating 37 KW, 1500 rpm.

7.10.5 LIGHT OIL (HSD) UNLOADING PUMP (STAGE II &III)

No. off 1
Make AROTA
Capacity 40 m3/hr

MOTOR

Type 3ph. Induction motor.


Rating 18.5KW, 1500 rpm

7.10.6 LIGHT OIL (HSD) PRESSURE PUMP (STAGE II &III)

No. off 2
Model No. PDE-45-4 GR-22 AU2
Capacity 250 Lit/min at 2 CST
Pressure 25 Kg/cm2

MOTOR

Type 3ph. Induction motor.


Rating 18.5KW, 1500 rpm

7.10.7 FUEL OIL (LDO) PRESSURE PUMP (UNIT #4)

No. off 2
Type Multi screw positive
displacement , Horizontal
Make TUSHACO
Model No. PDHU-5-4
Capacity 250 lit/min.
Discharge pressure 25 kg/cm2

MOTOR

Manufacturer M/s Siemens


Type 3ph. Induction motor.
Rating 18.5KW, 3000
7.10.8 FUEL OIL (LDO) PRESSURE PUMP (UNIT #5)

No. off 2
Type Multi screw positive
Displacement, Vertical
Make TUSHACO
Model No. PDH-60-SDEF
Capacity 250 lit/min.
Discharge pressure 25 kg/cm2

MOTOR

Manufacturer M/s Siemens


Type 3ph. Induction motor.
Rating 18.5KW, 3000

7.10.9 LIGHT OIL CHARACTERISTICS

1. Flash point 660 C minimum


2. Pour point maximum 120 C for winter
3. Kinematic Viscosity in Cent. 2.5 to 15.7
Stocks at 380 C
4. Ash content 0.02 max. by wt.
5. Carbon residue content 1.5 by wt.
6. Sediment content 0.10 by wt.
7. Sulpher content 1.8 by wt.
8. Moisture content 0.25 maximum by volume
9. Acidity Nil.