BADARPUR THERMAL POWER

SATATION

TECHNICAL DIARY
210MW

NTPC
NATIONAL THERMAL POWER STATION

INDEX
Sr. No.
1.0
1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
2.0
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
3.0
3.1
3.2
3.3
3.4
3.5
4.0
4.1
4.2
4.3
4.4
5.0
5.1

Contents
BOLIER & AUXLIARIES
Specifications
Performance data
F.S.S.S
Fans (ID, FD, PA,Ignitor & Scanner)
Air Heater
Soot blower
Electrostatic Precipitator
Coal burners & oil guns
Coal mill
Raw coal feeder
Fuel oil transfer pump
Dosing system
Ash handling system
D.M. Make up system
Coal Mill Reject System
TURBINE & AUXILIARIES
Specifications
Governing system
Turbine lubrication system
Condensate system
L.P.Heaters & air ejection system
Feed water sytem
H.P. Heaters
C.W. pump & C.W. booster pump
HP & LP Bypass system
GENERATOR & AUXILIARIES
Generator Specification
Specification Of Static Excitation System Unit
IV & V
Generator Seal Oil System
Stator Water Cooling System
Generator & UAT Transformers
PROTECTION & INTERLOCK
Unit protections
Partial load conditions
Protection & interlock of unit auxiliaries
Electrical protection for unit auxiliaries
PROTECTION RELAYS SETTINGS
Recommended Settings of Generator, GT &

Page No.
4-29

30-46

47-57

58-72

73-86

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

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

87-89
90-132

SECTION-I

BOILER
AND
AUXILIARY

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

Fixed
Carbon
38 %

Volatile
Matter
26 %

1.1.3 FURNACE

Moistur
e
8%

Ash

Grindibility (HGI )

28 %

55

High Heating
Value
4860 Kcal / Kg

Fusion Welded Type

Width
13.86 m
1.1.4

Indian Bituminous Coal

Depth
10.59 m

Height
42.79 m

Volume
5210 cu. m.

SUPERHEATER , REHEATER & ECOMOMISER

S.
No.

Description

Heating
Surface
( sq. m )

No. of
Coils / Tube

Size (mm)

Material

1.

Low Temp.
S/H

8209.5

Upper Bank
67

44.5 x 5

44.5 x 4.5
44.5 x 4.5
44.5 x 4.5

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

2.

Platen S/H

944.5

Lower Bank
67
Terminal
Tubes 67 x 6 =
402
29

3.

Final S/H

1036

119

4.

Ceiling &
Enclosures

540

Roof Panels
120
Front Wall

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

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

Carbon Mo
(SA209T1)
Carbon

181
Rear Wall
136
Side Wall 66
x2

1.1.5

51 x 4.5

5.

Reheater

2650

Front assembly
59
Rear assembly
- 89

54 x 3.6
47.6 x 3.4

6.

Economiser

5440

67

44.5 x 4.5

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

ATTEMPERATOR
Type
Spray

No. of Stages
One

1.1.6

FUEL SPECIFICATIONS

A)

COAL

i.
ii.
iii.
iv.
v.
vi.
vii.

Fixed Carbon
Volatile Matter
Moisture
Ash
Grindability
High Heat
Coal size to Mill

Location
Medium of Spray
Between Horizontal Feed Water
& Platen S/H

38.%
26%
8.0%
28%
55HGI
4860 Kcal/Kg
20 mm

B)

OIL

i.
ii.
iii.
iv.
v.
vi.

Low Heat value

Sulpher
Moisture
Flash point
Viscosity
Sp. Weight

1.1.7

SAFETY VALVES
No.
per
boiler
1

Size

Set pressure
(kg/cm2)

158.2

Relieving
capacity
(t/hr.)
190.04

161
162.41
144

162.08
195.08
86.73

142

88.06

a)dresser
1775wa
b)dresser
1785

33.4

94.7

dresser
1705 rwd

33.75
34
34.45
30.58

136.01
137.38
138.76
114.93

Location

Make &
type

Drum

a)dresser
1749wa
b)dresser
1749wa
dresser
1739wd
dresser
1538-vx

Super
Heater
SH-electro
magnetic
Relief valve
Reheater
inlet

Reheater
outlet

10000 kcal/kg
4.5% w/w
1% w/w
660 C.
1500 redwood at 37.80 C .
0.98 at 380 C.

1.2

PERFORMANCE DATA

1.2.1 DESIGNED PARAMETERS

Description

Steam
Steam at
final SH
Outlet
Steam at

Temperature ( C0.)
Flow (t/hr) Load
MCR NCR 60%MCR MCR NCR 60%MCR
210mw
210mw

Pressure (kg/ cm2)

MCR NCR 60%MCR
210mw

700

662

420

540

540

540

137

136

13.2

580

575

375

540

540

540

24.5

24.7

14.9

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

- -

332

331

293

26.4

26.5

16.0

- -

342

340

334

150.7

148

137.4

- -

430

433

452

146

144

135.5

- -

514

514

512

- -

247

246

220

153

150

139.2

- -

278

277

262

- -

- -

1125

1135

1118

- -

- -

1020

1017

981

- -

- -

697

690

670

463

459

433

364

366

336

146

143

129

700

643

371

96.7

77.8

70.3

338

336

316

678.3

624.5

481.5

330

329

311

120.8

85.5

92.9

38

38

38

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

1.2.2

869.3

668.2

105.1

71.5

PRESSURE AND DRAFT (AIR &GAS)

PRIMARY AIR
Description

Units

MCR

NCR

P.A. Fan Outlet

A.H. Inlet
A.H.Outlet
Mill Inlet
Mill Outlet

mmwc
mmwc
mmwc
mmwc
mmwc

740
727
672
634
228

734
723
672
634
228

Control load
60% MCR
700
691
661
634
228

SECONDARY AIR
Description

Units

MCR

NCR

F.D.FanOutlet
SCAH Inlet
SCAH Outlet
AH Inlet
AH Outlet
Aerofoil Inlet
Windbox Pr.
Windbox to
Furnace Diff.

mmwc
mmwc
mmwc
mmwc
mmwc
mmwc
mmwc
mmwc

317
312
287
282
193
180
140
140

291
286
265
261
185
174
140
140

Description

Units

MCR

NCR

SH Platen Inlet
RH Inlet
Finish SH Inlet

mmwc
mmwc
mmwc

-5
-6
-14

-5
-6
-13

Control load
60% MCR
213
211
201
198
162
157
140
140

FLUE GAS
Control load
60% MCR
-5
-6
-9

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

mmwc
mmwc

-20
-37

-19
-35

-12
-20

mmwc
mmwc
mmwc

-54
-184
-242

-49
-165
-222

-31
-84
-128

MILL AND BURNER PERFORMANCE

Description

Units

MCR

NCR

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

16

16

Control load
60% MCR
12

Degree
-

0
4

+10
4

+30
3

%
T/hr

80
52.3

79
52.3

70
52.3

172

171

160

77

77

77

70

70

70

1.2.4

% Thru 200
Mesh

O2, CO2 ( BY VOLUME ) AND EXCESS AIR

Description

Units

MCR

NCR

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

4.3

4.3

Control load
60% MCR
5.5

14.9

14.8

13.7

25

25

36

1.2.5

DESIGNED PRESSURE DROPS

Description

Units

MCR

NCR

SH System
RH System
Economiser
System

Kg/cm2
Kg/cm2
Kg/cm2

13.7
1.9
2.1

12.0
1.8
2.0

A.

Air
Wind-box
APH
Air-duct
Aero-foil

mmwc
115
94
63
25

Across Pulv.
Fuel Piping

305
308

C.

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

mmwc
4
48
19
52
110
20
20
22
295

Control load
60% MCR
5.4
1.1
1.8

1.2.6 HEAT BALANCE

Dry gas loss
Carbon loss
Radiation loss
Unaccounted loss
H2 in air and H2O in fuel
Total loss
Efficiency
1.2.7

4.63%
2%
0.26%
1.5%
4.9%
13.3%
86.7%

RECOMMENDED FEED WATER LIMITS

Drum operating Pr. in kg/cm2

1. Hardness

61-100
Nil

101 & above

Nil

2. ph at 250 C.(Copper alloy pre-boiler syms.)

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

8.8-9.2
9.0-9.4
0.007
0.01
0.02
0.5

8.8-9.2
9.0-9.4
0.007
0.01
0.02
0.3

0.02-0.04
Nil
Not allowed
Not allowed
0.005

0.02 - 0.04
Nil
Not allowed
Not allowed
0.005

1.2.8 RECOMMENDED BOILER WATER LIMITS

Drum operating Pr. (kg/ cm2)
1. Total dissolved solids (max)ppm
2. Conductivity at 250Cmicro-mhos/cm
3. Phosphate residual(ppm)
4. ph at 250C.
5. Silica(max)ppm
6. Chlorides(max.)ppb
7. Total hardness

61-100
100
200
<20
9.0-10.0
2.0
<4000
Nil

101 & above

50
100
2-4 #
9.0-9.5
0.4 *
<2000
Nil

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

PURGE READY CONDITIONS

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

viii)All Pulv. are off(CR 26 is on)

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

SR.
NO.
1.

DESCRI
PTION
Ignitor
trip v/v

PERMISSIVE

INTERLOCK

PROTECTION

1. Ignitor Oil
Supply Pr. Is
Adequate (>13kg
/Sq.Cm)

Pressing one pair (lo or

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

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

2. All Ignitor
V/Vs are
closed(cr12 on)

2.

Heavy Oil
Trip
Valve

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

3.

Heavy Oil
Elevation
start

1.

2.

3.

4.

5.

6.

Heavy Oil
corner
start

1.

2.

3.

4.

not low (less

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

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

HO
elevation
shut down

1.4 FANS
1.4.1

SPECIFICATIONS
RPM

1300

Motor
Voltage
KV/V
6.6

50

800

6.6

490

50

1250

6.6

1485

11

415v

1460

Press. Temp
mmwc 0C

KW

Capaci
ty
m3/sec
230.9

387

150

103.8

520.5

65.3

1345.5

400
Sefm

4WG -

Sr.
No.

Descri
ption

Type

No Of
Boiler

ID Fan

FD Fan

PA Fan

Ignitor
Air Fan

Axial
Impulse
Type
Axial
Reaction
Type
Radial
Backward
Curved
Centrifu
Gal

990

Scanner -doAir Fan

Seal
-doAir Fan

1.4.2
A:

2
2

1100
M3
11000
M3

160

50

1.1

415v

3000

150

50

10

440V

2850

FAN LUBE SYSTEM AND CONTROL

ID FAN LUBE OIL SYSTEM

S.N.

PUMP

MOTOR

TYPE-Gear type

Power-0.5HP

II

Capacity-5LPM

Voltage-415v
Frequency-50C/S,3
Ph.
Speed-1380 RPM

III

Operating Press-2Kg/cm2

IV

Relief Pr-7 Kg/cm2

B:

FAN

Inlet vane control

Rated current-1.08 Amps

FD FAN LUB OIL SYSTEM:

Motor
Power-4KW

Fan control

Pump
Type-Gear type

II

Capacity-79.2 LPM

Variable pitch blade

control

III

Lub oil Pr. 0.8 to3ata (g)

Voltage-415V,
Frequency-50c/s,3Ph
Speed-1400 rpm
Rated Current-11
Amp

C:

PA FAN LUBE OIL SYSTEM

FAN

Sr.N

PUMP

MOTOR

TYPE-Gear type

Power-0.5HP

II

Capacity-5LPM

Voltage-415v
Frequency-50C/S,3
Ph.
Speed-1425 RPM

III

Operating Press-2Kg/cm2

IV

Relief Pr-7 Kg/cm2

Rated current
1.2 Amps

Inlet Guide vane

contol

1.5
1.5.1

AIR HEATER

STEAM COIL AIR PRE-HEATER

TYPE
No.Of Boiler
Medium
H.S. IN M2

Steam Coil R2-10

2
Secondary Air
770 per Air Heater

1.5.2 RE- GENERATIVE AIR PRE-HEATER

Type
No. Boiler
Medium

Tri Sector Regenerative 27 vi 72 (T)

2
i)Primary Air
ii) Secondary Air
iii) Flue gas
19000 per Air Heater

H.S. IN M2

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

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

ROTOR DRIVE
i)

Motor-GE 15 HP

ii)

Voltage-415v

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

iii) Speed-960 rpm

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

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

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

1.5.3

PERFORMANCE OF AIR PREHEATER

FLOW t/hr

500 PA
NORMAL
ROTATION
mmWC

PRI
SEC
GAS

180
681
999

500 PA
720 PA REVERSE
REVERSE
ROTATION
ROTATION
mmWC
NORMA 20%
L
MORE
165
163
182
697
699
837
999
999
1199

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

97
680
1084
0
C
38
41
369

97
680
1085
0
C
38
41
369

97
680
1085
0
C
38
41
369

116
816
1286
0
C
38
41
369

78
544
884
0
C
38
41
369

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

337
329
146
mmWC C
44
90
112

325
333
146
mmWC
44
90
112

326
334
146
mmWC
22
124
112

321
332
149
mmWC
29
159
146

331
338
142
mmWC
14
107
75

Air In
Air In
Gas In

1.6
Location

i)

ii)

ii)

Furnace

Platen,Convention
Super heater &
Re-heater
Air Heater

20%
LESS
144
561
799

SOOT BLOWER

Header Pr
(Kg/cm2)
30

30

30

Type

Qty./Boiler

Wall
blowers
RWSE
Long
retractable

56

Swiveling

20

Medium

Super
heated
steam
Super
heated
Super
heated
steam

1.7 ELECTOSTATIC PRECIPITATORS

1.7.1

DESIGN CONDITIONS UNIT # 4

i) Gas flow rate

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

1.7.2

1333709 m3/hr.
1500 C
31.8 gm/m3
2000mmwc
2 FAAX .5x36-9590-2
2
5

133380 m3/hr
1460 C
28.3 gm/Nm3
2000mmwc
2FAA. 5x32-11190-2
2
5

99%

99%

15MMWC

15MMWC

1.08 m/sec.

0.93 m/sec

16.62 sec.

17.243 sec

COLLECTING PLATES

i) No. of rows per field

38

ii) No. of collecting plates

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

1.7.3

RAPERS FOR COLLECTING

PLATES

i) No. & type of

rappers

UNIT # 5

One drop hammer

Per row for collecting
Surface area of 57.6m2

EMITTING ELECTRODES
No of electrodes in each rows

32

No of electrodes in each field 1184

No .of electrodes / boiler
Total length of electrodes
per field
Size

23680
6829M
2.5 mm

Plate/wire spacing
150mm
Type
Spiral with hooks

RAPERS FOR EMITTING

ELECTRODES
Type & no.

Spiral hooks
approx one
dropHammer/
Two rows

ii) Rapper weight

4.9 kg.

iii) Frequency

varies from 6 raps/hr.at

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

iv) Drive

1.7.4

Rapper wt.

1.7.5

GAS DISTRIBUTION SYSTEM

Perforated plate 25 sets
Inlet of precipitator

ELECTRICAL SYSTEM
RECTIFIER

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

UNIT # 4

UNIT # 5

60kv (peak/800 m.a.)

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

RECTIFIER CONTROL PANEL

i) Type & control

Thyristor/microprocessor based)
on controller(PRECICON
20
In the control room at ground level

ii)Number
iii) Location
C)

Geared elec
tric motor
with synch
ronous programmer

Pyramidal
40 (2 per field)
8 hrs. storage
Electrical heating at hopper bottom

i) Type & quality

ii) Location

A)

10 raps/hr

HOPPERS
i) Type & quality
ii) No. of hoppers
iii) Capacity
iv) Heating

1.7.6

3 kg.

AUX.CONTROL PANEL
i)Number
ii)Equipment controlled
iii) Location

4
Geared motors for rapping mechanism, heating
elements om hoppers & shaft insulators.
In the control room at ground level

D)

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

E)

HEATING ELEMENTS
i) HOPPERS
For forty hoppers at the rate of 6 kw /hopper = 240 kw
ii) SHAFT INSULATORS
i)
ii)

For 20 insulators at the rate of 1 kw = 20 kw

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

1.8 COAL BURNERS,IGNITORS & OIL GUNS

A)

COAL BURNERS

i) Type
ii) No. of boiler
iii) Titling limit

Titling tangential fired corner

24 (4 each in 6 elevation)
+/- 30 deg. Cent.

B)
IGNITORS
i) Type
ii) NO. off
iii) Location
iv) Capacity
v) Turn down ratio
vi) Oil pr. At control cabinet
vii) Oil firing rate
viii) Atomising air quality
ix) Atomising air pr.
x) Atomising air consumptio
xi) Combustion air quality
xii) Combustion air pr. At wind box

6 eddy plate oil side ignitors air atomised

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

C LIGHT OIL (W.U.) GUNS

i) Type
ii) No. off
iii) Location

Tilting, tangential, air atomized internal mix

4
Elevation AB corners

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

10% of boiler MCR

2.5 :1
1265 kg / hr / gun
Service air water free
190 Nm3 hr / gun
5.36 kg/cm2
1 kg/cm2

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
ii) No. of boiler
iii) System
iv) Capacity
v) Coal grindibility
vi) Max. moisture content
vii)Finness through 200 mesh

XRP 783 Bowl Mills

6
pressurised
39.7 mt / hr
55 HGI
12%
70%

MOTORS
i) Rating
ii) Voltage
iii) Frequency
iv) RPM
v) Rated current
vi) No load current

340 kw
6.6 kv 3 phase
50 c/s
990
41.7 Amps
15-16 Amps

1.10 RAW COAL FEEDER

i) Type
ii) Width

chain type
600 mm

iii) Length
iv) Speed variation
v) Depth of coal bed
vi) Capacity max.

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

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

7.5 kw
415v
15.5 Amps
975 rpm

1.11 FUEL OIL TRANSFER PUMPS

DESCRIPTION
i)
ii)
iii)
iv)

Capacity
Discharge
Suction
Max. temp. of oil handle
By the pump

TRANSFERPUMP

DRAIN PUMPS

120 m3 /hr
80 MMWC
5 MMWC
600 C

5 m3 / hr
40 MMWC
5 MMWC
600 C

DESCRIPTION

PHOSPHATE

HYDRAZINE

i) Soln. preparation tank

ii) Metering tank

1 no. 600 ltr.

1 no. 600 ltr.

1 no. 500 ltr.

1 no. 500 ltr.

1.12 DOSING SYSTEM

A)

PUMP

I)
ii)
iii)

No. of boiler
Capacity
Type

2
0-100 ltr./hr.
Horizontal
reciprocating

2
0-30 ltr./hr
Horizontal
reciprocating

iv)

Head

195 kg / cm2

110 MMWC

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

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

1.13 ASH HANDLING SYSTEM

A)

MAX.ASH COLLECTION RATE

i) Bottom ash hopper: (1 No.)

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

12 ton/hr.
2.08 ton/hr.
1.74ton/hr
52.36 ton hr/
0.79 ton/hr
12 ton/hr.
56.97 ton/hr.
66.97 ton / hr.
33 M3
9.5 kg/cm2
5.5 kg/cm2

ASH PUMP:

i) Quantity of sealing water

15 m3/hr.

ii) Pressure of sealing water

iii) Pump capacity
iv) Head developed
v) Speed

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

C)

ASH ANALYSIS

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

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

1.14 MAKE UP SYSTEM

No .of DM Water storage tank
1.14.1

MAKE UP PUMP

5
MOTORS

i) No. 2
ii) Make: Mather & platt
iii) Type: 4/5,two stage MEDI
iv) Discharge-100 m3/hr.
v) Head-50 MMc
vi) Speed-1480 rpm

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

Connected to hot well, unit drain tank & deaerator.

1.14.2 FILL PUMPS

MOTORS

i) No.-2
nos
ii) Make : IIIplurovane,5 CHR
iii) Discharge-200 m3/hr.
iv) Head 200 mwc
v) Speed 1480 rpm
Connected to-boiler drum & deaerator.

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

1.14.3 QUANTITY OF WATER REQUIRED FOR BOILER FILLING:

SYSTEM

UNIT ENTIRELY
FILLED (M3)

1676 internal dia drum

Water walls
Super heater
Reheater
Economiser
Main steam piping
TOTAL
1.15

37.20
126.3
97.18
48.10
25.17
12.05
------------345.00
-------------

UNIT FILLED TO
OPERATING LEVEL (M3)
11.53
126.30
------25.17
---------------163.00
-------------

COAL MILL REJECT HANDLING SYSTEM

1.15.1 CLIENTS ORDER REFERENCE:

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

Shawlane Industrial Estate

Doncaster
South Yorkshire
DN2 4SE, UK
INDIGENOUS: Bakhtawar Singh Balkrishan & Co
"Beekay House"
L-8, Green Park extension
New Delhi - 110016.
1.15.2 DESIGN BASIS & DATA
BASIS

Normal Reject rate of mills < 5%

Reject rate considered for design is 10%

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

1.15.4 COMPRESSED AIR REQUIREMENTS:

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

1.15.5 AIR RECEIVERS:

Nos per Boiler :
Capacity each :

2
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
System : batch conveying
Vessel capacity:
Pipe size
Design Code
Safe working pressure
Hydraulic test pressure

12/8
12 Ft3
150 mm
BS5500 Class III
110 lb/in2 (7 kg/cm2)
150 lb/in2 (10 kg/cm2 )

1.15.7 AIR COMPRESSORS

Type
Model & Type
Capacity
Make
Drive Motors NGEF
Discharge Pressure
Speed
Actual Quantity of free air compressed
Volumetric efficiency
Brake HP required at Comp.shaft at
rated load
Motor Rating
Type of bearings for rotors
Details of lubrication
Materials of construction:
Rotors
Gears
Bearings
Frame and running gear
Shaft

Screw
SES-520 single stage
520 cfm +/- 5%
Khosla Indair
7 kg/cm2
4500 RPM
FAD 520 +/- 5% cfm
91%
105.0 HP
130.0 HP
Cylindrical roller and 4 point
Bearings
Oil flooded (forced feed)
EN-8
EN-41B
Mfd.Std.
(coupling) forged steel,
rubber flexible
EN-8

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

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

1.15.8 AIR FILTER CUM SILENCER

Type
Max. particle size removed after
cooler and Inter cooler
Type
Material of construction
Shell
Tubes
Tube sheets
Tube support plates
No of passes
Cooling surface
Oil Cooler
After Cooler

Dry filter type

10 Microns
Shell and tube type
(water through tube)
IS-226
Copper 3/8"
MS
MS
2 passes
9.6 m2
5.5 m2

Air Pressure drop through the after cooler/oil cooler 2-3 psi
Cooling water inlet/outlet size
1" & 3/4" BSP
Cooling water quantity required at 360 C
150 LPM
Air outlet temp.
100 C above cooling water
temp.
1.15.9

VIBRATORY FEEDER

Equipment & Model

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

Electromagnetic vibratory feeder - Model F-33

For handling coal mill rejects
Internal Combustion
2
25 T/Hr
30 - 35 mm (Max.)
1600 kg/ m3
6/8 deg
400/440 V
525 Watts
450 mm x 1100 mm
MS
Suitable for suspension type arrangement

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

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

12 stages (1st is governing stage) each stage

Consists of a diaphragm & a set of moving
Blades connected on a disc
In two valves made of Creep Resistance
(Cr-Mo-V) steel
High Creep Resistance (Cr-Mo-V) steel
Forgings
4 Nos (2 on Top & 2 on sides) made
of High Creep resisting (Cr-Mo-V)
Steel casting
11 stages
2 parts (a ) Pressure part made of
Creep Resisting (Cr-Mo-V) steel

Casting in 2 halves (b ) exhaust part

Made of fabricated steel structure
In 2 halves.
Creep Resisting (Cr-Mo-V)
steel Forgings
Cast integral with the casing.

STUDS & NUTS

NOZZLE BOXES
iii) L.P.CYLINDER

Stages 4( double flow) last but

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

BODY

iv) H.P.ROTOR

v) I.P.ROTOR

vi) L.P. ROTOR

vii) ROTOR BLADES

2.1.3

STEAM EXTRACTIONS

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

Steam
extraction
stages
9th
12th
15th
18th
21st
23rd
25th

Connected
to
HPH-7
HPH-6/D/A
HPH-5/D/A
LPH4
LPH3
LPH2
LPH1

Ext, steam
press in Kg/
cm2
39.06
26.2
11.96
6.47
2.78
1.28
0.28

Ext.steam
temp.in 0C
in
337
314
433
3680C
252
172
-

Steam flow
T/hr.
400
77
16.2
26
23
28
12.6

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
4.6mm
5.5 mm
5.9 mm
6.65 mm
9.6 mm

EVENT
IV begins to open
ESV begins to open
IV fully open
ESV fully open
IPT & HPT control
valve begin to open

12.8 mm

2.3

All control valves

fully open

TURBINE LUBRICATION SYSTEM

2.3.1 LUBRICATING OIL SPECIFICATION:

Type (Recommended oil for governing
system and bearing)

Specific gravity at 500C

Kinematic viscosity at 500C
Neutralization number
Flash point
Pour point
Ash percentage by weight
Mechanical impurities
Oil pressure in governing system
Oil pressure for lubrication of bearings

MOB DTE oil medium

or
Turbine oil -14
Or
Servo prime -14
Or
Turbinol-47
0.852
28 Centistokes
0.2
2010C(min)
66.600C(max)
0.01%
Nil
20 Kg/cm2 (Guage)
1 Kg/cm2 (Guage)

2.3.2 MAIN OIL TANK

Capacity
Oil capacity in systems
Main oil centrifuge capacity
Oil transfer pumps capacity for purifier unit
Polishing filter capacity
Impure and pure oil storage tank capacity
Impure and pure transfer oil pump capacity & head

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

2.3.3 MAIN OIL PUMP

Pressure corresponding to discharge of 4000lits/min
Pressure corresponding to discharge of 7000lits/min
Suction pressure
Power consumption
Type of coupling with rotor
No. of injectors
Oil pressure developed by Ist injector
Oil pressure developed by IInd injector
Speed

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

2.3.4 STARTING OIL PUMP

FOR NORMAL OPERATION
Type
Plurovane III(Unit4) Plurovane III A(Unit 5) ( Multi stage
centrifugal pump),Mather& Platt
Capacity
200 m3 /Hr
Head
200 MWC(20 Kg/cm2 )
A.C.MOTOR
Capacity
Speed
Voltage
Arrangement
2.3.5

200 Kw
1000 rpm
6.6 KV,3 Ph, 50 C/s
Horizontal

A.C.STANDBY OIL PUMP

PUMP
Type

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

Capacity
Head
No. of stages
C/S
Arrangement
Vertical
Impeller material Bronze
Min. oil pressure 0.6 Kg/cm2 For auto starting

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

BEARING
Type
Number
Lubricant
2.3.6

Single Row Deep Grove Ball Bearing

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

D.C. EMEGENCY OIL PUMP

PUMP
Type

100 NCU centrifugal pump

driven by D.C. motor
Min. oil pressure 0.5 Kg/cm2
for starting
interlock

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

Capacity
Head

108 m3 /Hr
(1800 L/min)
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

Capacity of purifier
Capacity of transfer pumps
Oil pressure at inlet of separator
Speed

MAB-206-S-20
6000 Lts/hr
6000 Lts/ hr
2.35 Kg/cm2
1500 rpm (max)

KW(HP)
7.5(10)
Frequency 50 Hz
Voltage
440 Volt
Current
13.6 amps
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
KW
Voltage
2.3.8

WH
120
440 volts

MAIN OIL COOLERS

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

5 nos.(4 nos. at a time in service)

63 m2
1500 Lit/min or 90 m3 /Hr
130 m3 /Hr
4
5 Kg/cm2
5 Kg/cm2
3 Kg/cm2
2.5 Kg/cm2
550C
450C
330C(max360C)
35.640C
1.1 M/sec

Rated water velocity in tubes

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

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

2.4 CONDENSATE SYSTEM

2.4.1

CONDENSER

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

Design pressure (steam space)
Cooling water consumption
No. of cooling tubes
Length of cooling tubes
Dia of cooling tubes
Weight of condenser without water
Tube material
Cooling Zone Cupronickel
Air zone Cupronickel
Water boxes material
Max. permissible design pressure of cooling tubes

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

2.4.2 CONDENSATE PUMP

PUMP
3 nos
Type

MOTOR

(50% capacity each)

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

Max thrust bearing oil temperature

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

75 0C
75 0C
40 microns
180 0C

2.5 LP HEATERS & AIR EECTION SYSTEM

2.5.1

L.P.HEATERS

LPH Type
No.
1
Inside upper
part of each
condenser( in
two halves)
2
Mezzine floor

Location

Tube
material
Horizontal
U. shape
surface type brass
16*10
Vertical
--DO-surface type
--DO---DO---DO---DO--

3
4

--DO---DO--

2.5.2

GLAND STEAM COOLER I

Shell
Tube plate No. of relief
Material
material
valve
Fabricated Mild Steel 2 Nos.(1 for
steam side&
from MS
1 for cond.
plates
side
--DO---DO---DO---DO---DO--

--DO---DO--

--DO---DO--

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
Nos. 2(100% capacity)
Type 100 CJH, multistage centrifugal
Horizontal pump
No. of stages
9

MOTOR
Output
Voltage

90 KW
415 V

Current

148 amp

Delivery quantity
Manometric head
Speed
Temp. of liquid
2.5.5

1416 L/min
195 MWC
1475 rpm
1000C max

Speed
Frequency

1475 rpm
50C/S

DEAERATOR

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

AIR EJECTOR SYSTEM

Steam
temp. in
0
C

Steam
consumption
in kg/hr

D/A or 16
ATA
header
--Do--

Steam
pressure
in
kg/cm2
4.5

250

1100 kg/hr

4.5

250

750 each

--Do--

4.5

250

1100

--Do--

4.5

250

Type of
ejector

Nos.

Range

Aux.
source of
steam

A)
Starting
ejector
B) Main
ejector

C)
Priming
ejector
D) Gland
steam
cooler
No.1

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

2.6 FEED WATER SYSTEM

2.6.1

BOILER FEED PUMP

A) PUMP
No. of pumps
Type
Nos. of stages
Max. rated suction pressure
Discharge capacity
Head
Feed water temp.
Speed
Lubrication
Stuffing box
Quantity of water for
minimum take off
Min. suction pressure of BFP
Quantity of water for
Heating take off
Cooling water consumption
Net weight of pump
Drive
B)

3 Nos. (50% capacity)

Multi stage , Horizontal high pressure,
Barrel type pump 200 KHI
6
12.3 ata
430T/hr
1830MWC
164.20C
4320 rpm
Forced
Mech seal
100 T/hr
6 Kg/cm2
8 T/hr
280 T/min.(Approx)
5850 Kg
Electric motor through hydraulic coupling

MOTOR

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

M/S BHEL Hardwar

ATD-4000
4000 KW
6.6 KV
421 amp
1483 rpm
50 C/S, 0.914

OPERATING DETAILS

Water pressure in equalizing pipe of balancing

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

Auxiliary oil pump

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

415 V, 3 Ph, 50 C/S

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

BOOSTER PUMP

No. of pump
Use

one for each BFP

1. To provide a positive suction pressure to BFP
& to avoid possibility of cavitations
2.To reduce the BFP stages
Make
M/S Mather & Platt.
Type
8/10
Delivery quantity
460 T/hr
Speed
1475 rpm
Drive
Main motor
Min. booster pump suction pressure 3.5 kg/cm2
Delivery head
31 MWC
2.7 H.P.HEATERS (DESIGN SPECIFICATION)
Description
Feed water inlet
temp. in 0C
Enthalpy of F.W.
inlet in Kcal/kg
F.W. outlet temp in
0
C
Enthalpy of F.W. at
outlet in Kcal/kg
F.W. flow (kg/hr)
Ext. stem inlet
pressure in kg/cm2
Ext. stem inlet temp.
in 0C

H.P.HEATER No.5
166.76

H.P.HEATER No6
184.92

H.P.HEATER No7
220.90

170.70

189.51

227.48

184.92

220.90

242.78

189.51

229.48

251.41

643165
11.96

643165
26.20

643165
39.06

433

314

377

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

796

727

754

16271
292

44777
288

29880
288

Load at which H.P. Heaters are taken into service

Without H.P. Heaters ma. Curtis wheel pressure
Full load Curtis wheel pressure with H.P. Heaters
2.8
2.8.1

CW PUMPS & CW BOOSTER PUMP

CIRCULATING WATER PUMP

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

2.8.2

60 to 70 Mw
89 kg/cm2
102 kg/cm2

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

C.W. BOOSTER PUMPS

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

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

MOTOR
Output
Speed
Amps

55 KW
1487 rpm
96

Voltage
Make

415 V
NGEF

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

(i)

(ii)

2.9.1

Provided to increase the rate of steam temperature rise and warm up the
HRH,CRH, IPT & transfer pipe lines ( at 60% MCR full pressure & temp. can
be obtained i.e. 60% capacity)
All the HP & LP BYPASS valves are hydraulically operated for which oilat
about 50 kg/cm2 is supplied by a separate oil supply unit.
DESIGN CAPACITY OF H.P. BYPASS STATION

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

2.9.2

Boiler feed water

1 for each MS line
200T/hr steam flow
100T/hr steam flow
5400C
140 ATA
3800C

DESIGN CAPACITY OF LP BYPASS STATION

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

Condensate water
1 for each HRH line
112T/hr steam flow
224T/hr steam flow
5400C
2000C (max)
6 kg/cm2

TURBINE ROLLING & LOADING GUIDE LINES

2.10.1 TURBINE ROLLING GUIDE LINES

S. No.
1

If max metal temp of HPT

casing is less than 1500C
Speed from 0-500 rpm
= 5 mts
Hold at 500 rpm =10 mts

If max metal temp is less than If max metal temp

1500C-3500C
is more than 3500C
Speed from 0-500 rpm
Speed from 0-1200
rpm
= 5 mts
= 5 mts
Hold at 500 rpm =5 mts for Hold at 1200 rpm
checking differential expansion, =5 mts for checking
differential
bearing vib etc.
expansion, bearing
vib etc.

4
5

7
8

From 1200 rpm to

3000 rpm = 5 mts
without any pause

Speed from 500 rpm to

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

Raise the speed from 500 rpm

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

2.10.2 TURBINE LOADING GUIDE LINES

S. No.

If the max. casing metal temp. is

less than 1500C

If the max. casing

metal temp. is less
than 1500C-3500C
Load up to 5 to 7 Mw after Load after synch. =
20 to 30 Mw
synchronization
Steam
pr.
=70
Steam pr =30 Kg/cm2
0
2
Kg/cm
Steam temp. =350 C
Steam temp. before IV=3200C
Steam temp = 3500C
Soaking time =30 mts
Soaking
time=10mts.

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

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

If the max. casing

metal temp. is
more than 3500C
Load after synch.
20 to 30 Mw. After
taking mills ( one
by one) in service
load
can
accordingly
be
raised to 210 Mw
depending
upon
other conditions.

70 mts. @ 2 Mw/ min

Pr before ESV= 130 Kg/cm2
Temp before ESV= 5350C
Temp before IV= 5350C

SECTION-III

GENERATOR
AND
AUXLIARIES

3.1 GENERATOR SPECIFICATION

3.1.1 GENERATOR MAIN DATA (at rated H2 pressure and cooling water
temperature)
i) Maximum continuous KVA Rating
ii) Maximum continous KW rating
iii) Rated terminal voltage
iv) Rated stator current
v) Rated Power factor
vi) Excitation current at MCR condition
vii) Slip ring voltage at MCR condition
viii) Rated speed
ix) Rated frequency
x) Short circuit Ratio
xi) Efficiency at MCR condition
xii) Negative sequence current capability
xiii) Direction of rotation viewed from slip ring end
xiv) Phase connection
xv) No. of terminals brought out
xvi) Type

247000 KVA
210000 KW
15750 V
9050 A
0.85 lag
2600 A
310 V
3000 rpm
50 Hz
0.49
98.49%
122t nots
Anticlockwise
Double star
9(6neutral & 3 phase)
THW-210-2

3.1.2

MAIN PARAMETERS OF THE COOLING MEDIUM

A.

HYDROGEN IN STATOR CASING

i) Nominal hydrogen pressure

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

3. 5 Kg/cm2
+/- 0.2 Kg/cm2 (G)
440C
97%
60%
1.2%

DISTILLATE TO STATOR WINDING

i) Nominal pressure at stator winding inlet

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

WATER TO GAS COOLER

i) Nominak inlet cooling water temperature

ii) Minimum allowable water temperature
iii) nominal water flow
iv) Maximum permissible cooling water
pressure in the gas cooler
D.

WATER TO STATOR WINDING WATER COOLER

i) Nominal consumption of cooling water at temp. of 350C

ii) Nominal consumption of cooling water at temp. of 370C
iii) ) Nominal consumption of cooling water at temp. of400C
3.1.3

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

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

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

ii) Ratio of thre field forcing current to the nominal current
iii) Duration of field forcing
iv) Response Time
3.1.5

SHORT CIRCUIT CURRENTS

i) Sub transient current on three phase short circuit

ii) Transient current on three phase short circuit
iii) Steady state current on three phase short circuit
3.1.6

10 Pu
3.3 Pu
1.4 Pu

REACTANCES

i) Direct axis sub transient reactance ( xd)

ii) Direct axis transient reactance (xd)
iii) Direct axis synchronous reactance (xd)
iv) Negative phase sequence reactance (xd2 )
v) Zero sequence reactance (xo)
3.1.7

2.0
1.6
10 Secs
100 milisecs

0.214 Pu
0.305 Pu
2.22 Pu
0.26 Pu
0.105

PERMISSIBLE TEMPERATURE RATINGS

i) Maximum temperature of stator core

1050 C

1050 C
1150 C
710 C

ii) Maximum temperature of stator winding

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

750 C
850 C
750 C

TIME CONSTANTS

i) Field time constants with open circulated stator winding (Tdo)

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

7 secs
0.96 secs
1.5 secs

1.73secs
0.29 secs
0.24 secs
0.25 secs
0.121 secs

GENERATOR VOLUME AND FILLING QUANTITIES

i) Total gas volume of the generator

ii) CO2 for expelling hydrogen with unit at standstill
iii) CO2 for expelling hydrogen with unit under rolling
iv) H2 filling quantity with unit at standstill
v) H2 filling quantity with unit rolling
vi) Make up Hydrogen required per day

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

3.1.10 TORQUE, CRITICAL SPEED ETC

i) Torque under normal working condition
ii) Ratio short circuit torque to full load torque
iii) Flywheel moment of the rotor
iv) Ist critical speed of the rotor( calculated)
v)2nd Critical speed of the rotor (calculated)

76.32 Tons
8
21.1 T.M2
1370 rpm
3400 rpm

3.1.11 OIL CONSUMPTION

i) Consumption of oil per generator bearing (Excluding shaft seals)
ii) Oil pressure at bearing inlet
iii) Consumption of oil in both the shaft seals

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

3.1.12 OVERALL DIMENSION AND WEIGHTS

i) Overall stator diameter
ii) Length of the stator
iii) Length of the rotor
iv) Diameter of the rotor barrel
v) Weight of the heaviest lift (Stator with gas coolers and turnions)
vi) Weight of gas cooler
vii) weight of rotor
viii) Weight of bearings with brush gear along with foundation plates
ix) Weight of end terminals
x) Weight of end shield
xi) Total weight of generator

3960 mm
6580 mm
9770 mm
1075 mm
175,000 Kg
1415 Kg
42,000 Kg
49,500 Kg
85 Kg
2000 Kg
239,000 Kg

3.2 SPECIFICATION OF STATIC EXCITATION SYSTEM UNIT IV & V

The Static Excitation Equipment has been designed and manufactured for machine
having following technical details
A) TYPE OF MACHINE
TURBO
___________________________________________________________________________
Sl.No Description
Abbreviation
Unit
Value
1.
Rated OUTPUT
MW/MVA
210/247
2.
Stator voltage
Un
VAC
15750
3.
Stator Current
IN
AAC
9094
4.
Synchronous speed
Ns
rpm
3000
5.
Power factor
Cos
0.85LAG
6.
System frequency
Hz
c/s
50
7.
Machine reactance:
a)
Synchronous reactance
i)
Direct acxis unsaturated
xd
p.u.
2.225
ii)
Quadrature
xq
p.u.
2.11
b)
i)
ii)

Direct axis transient reactance

Saturated
xd
Unsaturated
xdu

p.u.
p.u.

0.234
0.266

c)
i)
ii)

Direct axis sub-transient reactance

Saturated
xd
Unsaturated
xdu

p.u.
p.u.

0.179
0.214

8.
i)

Machine Time Constants:

Direct axis transient open ckt Tdo

sec.

ii)
iii)
iv)

Direct axis transient close ckt Tdo

Sub-transient
Td
Armature
Ta

sec.
sec
sec.

0.84
0.03
0.29

9.

Field winding resistance at 20 oC

Rf 20 ohm

0.0878

10
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
ix)

Field excitation requirement

No load field voltage
ufo
No load field current
Ifo
Nominal field voltage
Ufn
Nominal field current
Ifn
Max. cont. rated field voltage Ufmax
Max. cont. rated field current Ifmax
Ceiling voltage
Ud
Ceiling current
Id
Duration of field forcing
--

VDC
ADC
VDC
ADC
VDC
ADC
VDC
ADC
Sec.

102
917
310
2600
338
2830
620
4500
10

11.
12.
13.
14.
15.
16.

Field test voltage

Synchronising slip
AVR CT Ratio
10,000/5
AVR PT ratio
Ambient
Altitude

B)

SPECIFICATION OF STATIC EXCITATION EQUIPMENT

1.
2.
3.
4.
15
5.
6.
7.
8.
9

Accuracy of excitation control

Range of voltage control in auto
Range of voltage control man.
Range reactive current compensation

%
+ 0.5
% 90 Ugn -110 Ugn
% 70 Ufo-110 Ifn
%
upto +

Frequency range of operation

Total No of parallel THY. Bridges
No of redundant THY bridges
Protection class
Excitation equipment rating
a)
Voltage
b)
Current

Hz
No
No
IP

47.5-52
4*
1*
31

VDC
ADC

338 *
2830 *

10
11

Range of MAVR regulation

Station battery supply

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

Equipment not part of DVR supply

Kvrms
%
AAC/AAC

VAC/VAC
oC
meters

15750/110
50
1000

3.3

GENERATOR SEAL OIL SYSTEM

3.3.1 SPECIFICATION
i) Type of shaft seals
ii) Hydrogen pressure
iii) seal oil pressure
iv) Inlet seal oil temperature
v) Quantity of seal oil/seal
vi) Thrust oil pressure
vii) Oil required to fill the system

Radial flow, double

chamber, thrust type
3.5 Kg/cm2
4.1 to 4.4 Kg/cm2
40 0 C
80 lit/min
1 to 2.2 Kg/cm2
4000 liters

3.3.2 OIL INJECTION

i) Pressure of oil at inlet to injector from
governing oil system
ii) Lub. Oil system
iii) Injector nozzle size
iv) Oil pressure at injector outlet

20 Kg/cm2
1 to 1.5 Kg/cm2
8 mm
10 Kg/cm2

3.3.3 SEAL OIL PUMPS

A.C. SEAL OIL PUMPS

i) Type :
ii) Discharge:
iii) Head:
iv) Speed:

Multistage vertical split

centrifugal type
3.34 lit/sec
120 MWC
1465 or 2900 rpm

v) Shut off Head: Not more than 12%

of the rated head

D.C. SEAL OIL PUMPS

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

vi) Minimum governing : 6.5 Kg/cm2

oil pressure below which
AC pump will start
MOTOR
i) Type: Squirrel cage induction
ii) Voltage: 415V+/- 10%
iii) Frequency: 3 Phase, 50c/s
iv) Rating: 15 KW/20 HP
v) Speed: 1465 or 290 rpm
vi) Rated Current: 27 Amp.

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

3.3.4 SEAL OIL COOLER

i) No. of coolers
ii) Inlet temperature of oil
iii) Temperaure of oil at cooler outlet
iv) Quantity of oil to be cooled
v) Inlet pressure of oil to cooler
vi) No of cooling tubes
vii) Material & size of cooling tubes
viii) Pressure drop in the oil cooler
ix) Inlet cooling water temperature
x) Outlet cooling water temperature
xi) Cooling water designed pressure
xii) Cooling water quantity required
xiii) Cooling water quality
3.3.5

2 Nos.
500C
400C
160 lit/min
10 Kg/cm2
420
15*1 mm, copper
5 mwc
330C
37.500C
5 Kg/cm2 (Max)
95 m3/Hr
Clarified water

PRESSURE REGULATOR

Differential pressure regulator

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

Thrust oil regulator

Plunger type
6 to 9 Kg/cm2
1.0 to 2.2 kg/cm2
0.03 to 0.05 mm

STATOR WATER COOLING SYSTEM

A. STATOR WATER COOLING PUMP

PUMP
i)
ii)
iii)
iv)

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

Discharge: 40 m3/Hr
Head:
45 mwc
Make: Kirloskar Brothers Limited

MOTOR
i)
ii)
iii)
iv)
v)
vi)

Type: Squirrel cage induction type

Rating: 9.3 Kw
Rated voltage: 415V+/-10V, 3 phase,50 c/s
Rated current: 17 amp.
Speed: 2900rpm
Make: Kirloskar Electric

B. STATOR WATER COOLERS

i) Nominal temperature of primary water to be cooled
ii) Nominal temperature of cooled primary water
iii)Nominal tempearure of cooling D.M.water
at inlet on the secondary side
iv)Nominal temperature of cooling water
at the outlet on the secondary side
v) Quantity of D.M. Water on the secondary side
vi) Secondary side D.M.water inlet pressure
vii) Tube dimensions
viii) Length of cooling tubes
ix) No. of tubes per cooler
x)Tube material

650C
400C
330C
36.50C
95m3/Hr
5 Kg/cm2(max)
15*1mm
1720mm
420
Copper

C. EXPANSION TANK
i) Material:
ii) Tank volume
iii) Volume inside the tank
iv) Water level under normal operating
conditions( from the bottom of the tank)
v) High water level which gives signal
( from the bottom of the tank)
vi) Low/ emergency water level requiring tripping of TG
( from the bottom of the tank)

Stainless Steel
2.1 m3
250 to 300 mmof Hg
850 mm
1200mm
500mm

D. WATER JET EJECTOR

i) Quality of water
ii) Quantity of water required
iii) Pressure
iv) Temperature
3.5
3.5.1

Clarified
7 to 10m3/Hr
2 Kg/cm2
330C

GENERTATOR & UAT TRANSFORMERS

GENERTATOR TRANSFORMER (T4)

TRANSFORMER RATING
Make
Type of cooling
MVA
Voltage (HV)
Voltage (LV)

M/S TELK, Kerala

OFB/OB/ON
240/168/120 MVA
236 KV
15.75 KV

Current (HV)
Current (LV)
Phase HV/LV
Impedance
Frequency
Vector Group
Connection HV/LV
Max temp rise in oil
Temp rise in winding
Weight of core and winding
Weight of oil
Total weight
Quantity of oil
Tap

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

BUSHING CT
Ratio
Continuous current
Accuracy class
Minimum knee point voltage
Max exciting current at knee point voltage
Max secondary wdg. Resistance at 75 Deg C
3.5.2

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

GENERTATOR TRANSFORMER (T5)

TRANSFORMER RATING
Make
Type of cooling
MVA
Voltage (HV)
Voltage (LV)
Current (HV)
Current (LV)
Phase HV/LV
Impedance
Frequency
Vector Group
Connection HV/LV
Max temp rise in oil
Temp rise in winding
Weight of core and winding
Weight of oil
Total weight
Quantity of oil

M/S BHEL, Bhopal

OFB/OB/ON
240/168/120 MVA
236 KV
15.75 KV
587/411/293 A
8798/6158/4399 A
3/3
14.75 %
50 Hz
Yd1
Star / Delta
45 Deg C
55 / 60 Deg C
138800 Kg
37850 Kg
234000 Kg
49540 liter

Tap

Off load

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

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

3.5.3 UNIT AUXLIARY TRANSFORMERS (Unit 4 & 5)

RATING
No.
Make
Capacity
Voltage HV / LV
Current HV / LV
No. of phases HV / LV
Type of cooling
Vector Group
Impedance
Impedance
Frequency
Tap Changer
Max rise in oil temp above ambient
Weight of core and winding
Weight of Oil
Total weight

2 / Unit
EMCO, Mumbai
12500 KVA
15.75 / 6,9 KV
458.2 / 1045.8 Amp
3/3
ON
Dd0
7.877/7.57 (UAT4A/4B)
7.762/7.725 (UAT 5A/5B)
50 Hz.
On Load
45 Deg C
12000 Kg
6430 Kg
27100 Kg

SECTION IV

PROTECTION
AND
INTERLOCK

4.1
Sl.No.

DESCRIPTION

1
2
3
4
5

Drum level low

Drum level high
Furnace pressure high
Furnace vacuum high
Loss of 220 V
D.C.supply of FSSS
Less thanfire ball and
loss of 110V D.C.
Supply
Loss of all fuel trip
On flame failure
Air flow less than 30%
Both ID fan tripped
Both FD fans tripped
Both PBS on FSSS
pressed
Reheater protection(
This protection will act
when there is no flow
through R.H. & furnace
outlet temperature more
than 5380C)
Condenser vacuum
H.P. heater level very
high
All BFPs tripped
T.G.babbit metal
temperature
Turbine rotor axial shift

7
8
9
10
11
12
13

14
15
16
17
18
19
20
21
22

Loss of voltage on unit

auxiliary bus bar
Emergency governor
overspeed tripping
Emergency governor
backup
Turbine lub oil pressure

UNIT PROTECTIONS
ANNUNCIAT
ION
-100 mm
+100 mm
+25 mmwcl
-25 mmwcl

TRIPPING
VALUE
-175 mm
+175 mm
+175 mmwcl
-175 mmwcl

650 mm Hg
750 mm

540 mm Hg
4250 mm

750C

800C

15 secs

+1.2 mm
-1.7 mm
50% of rated
value
11% and 12%
overspeed
14% overspeed

A.C. lub oil

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

0.3 kg/cm2

TIME DELAY
More than 2
secs

5 to 10 secs

23
24
25

4.2

M.S. Temperature low

Turbine shut down
switch
Manual tripping(UCB)
through push buttons

5200C
-

4500C
-

PARTIAL LOAD CONDITION

1. One if two ID fans trips.

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

4.3

PROTECTION & INTERLOCK OF THE UNIT AUXLIARIES

4.3.1 BOILER AUXLIARIES

Sl.
No.
1

Descripti
on
ID Fans

Permissives

Ineterlocks

Protections

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

e.

f.

FD fans

Air
Heater

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

a. ID fan is
started
b. Control oil
pressure is
adequate(8
kg/cm2)
c. Fan impellar
blades are in
min.
position.(BA1)
d. Outlet damper
(BA-3) is in
closed
position.
e. FD fan
bearing temp.
is not high.
f. FD fan motor
bearing temp.
is not high.

a.

Establish electric
supply to A.H.
motor.
Take out the push
button of the
motor.

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

b.

c.

d.

e.

a. Bearing temp. too

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

Temp. of support and

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

Ignitor
fan

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

Scanner
fan

Primary
air fan

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

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

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

Scanner air fan

emergency damper opens
automatically when both
FD fans are off.

a. Fan bearing temp. too

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

Seal air
fan

One PA fan is
running

Pulverise
r

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

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

Running seal air fan will

trip automatically after 60
secs time delay when
both PA fan trips.

a. Boiler trip condition

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

Pulverise
r A*

Raw coal
feeder

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

R.C.Feeder will trip if:

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

above maximum set

point.
B) Pulveriser bowl
differnencial pressure
is high an impulse
will be given to bring
R.C. Feeders speed to
minimum.
ID fan
motor
lubricatio
n oil
system

Pump A will start

automatically if
pump B trips
provided A/M
switch is in auto
position.
Pump A will start
automatically
with a time delay
of 60 secs if oil
pressure falls
below a set value
and pump B is
worki9ng
provided A/M
switch in auto
position.
Whenever the lub
oil pressure at
entry to ID fan
motor bearing
falls below a set
value impulse
shall be given
after a time of 0-3
mts to trip the ID
fan.

3)

FD fan
lub oil
system

Pump A will start

automatically if
pump B trips
provided A/M
switch is in auto
position.
Pump A will start
automatically
with a time delay
of 0-60 secs if oil

4)

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

Description

Permissive

Interlock

Protections

Boiler feed
pump

1. Lubricating
oil pressure at
bearing

1. If lub oil pressure is

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

Circulating
water pump

CW
boosr\ter
pump(Gas
cooler
booster

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

2. If BFP tripped its

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

2.Pump will trip if its

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

1. When any CW pump is

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

1. At least one
CW pump
should be
inservice.

1. If both CW pumps trip

booster pump will trip.
2.When running pump trip
reserve pump will start
immediately

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

pump)

Condensate
pump

A.C. Lube
oil pump

3.If discharge pressure falls

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

beyond 100 Amp.

1. Working pump will

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

D.C. lube oil pump will

come in auto if bearing oil
pressure goes down to 0.5
kg/cm2
Barring gear Barring gear
will start only
if lub oil
pressure is
more than 0.3
kg/cm2
Barring gear
will engage
only if rotor is
in engage
condition.

B/G will trip if lube oil

pressure goes to 0.3
kg/cm2

Drip pump

Heater 6

10

HP Heater 5

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

1. HD-3 discharge valve

will be fully closed if no
drip is running but will
start opening as soon as
drip pump starts.
2. Reserve drip pump will
start as soon as running
drip pump trips or
discharge pressure of
working pump falls below
a preset value for 10 secs.
1.If HPH-6 extraction
pressure falls tp preset
value its drip valve cascade
to deaerator & HD-29(to
HPH-5) will close & HD30 will open.
2.If HPH-6 extraction
steam pressure is above the
preset value HD-29 (to
HPH-5) will open & HD30 will close.

Working drip pump

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

1.If HPH-5 extraction

steam pressure falls below
a preset value its drain will
cascade to LPH-4 i.e.HD21(to LPH-4) will open &
HD-31(to D/A) will close.
2. if HPH-5 extraction
steam pressure is above the
preset value its drain
cascade to deaerator i.e.
HD-31(to D/A) will open
& HD-21(to LPH-4) will
close.
3.If drip level in any HPH
rises up to 750 mm
solenoid valve
(MC101&MC102) for
NRV of extraction lines
will open.
4. Back up feed water
bypass valve (BF-40) will
open.
5. After full opening of

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

11

Deaerator

12

H.P.& L.P.
Bypass
system

BF-40, inlet and outlet

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

13

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

14

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

15

16

17

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

M/C load reduced when

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

18

A.C. Seal
oil pump

19

D.C. Seal
oil pump

C.V. Beyond set point but

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

SECTION V

PROTECTION
RELAYS
SETTINGS

5.1

RECOMMENDED SETTINS OF GENERATOR, GT & UATs

5.1.1 RECOMMENDED RELAY SETTING OF GENERATOR, GENERATOR

TRANSFORMER AND UAT (UNIT 4)

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

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

7. Gen Over Load Alarm

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

Relay
Type
CAG 34

CTR /
PTR
10000/5 Amp

CAG 14
DTH32

Range

Setting

0.25 - 1 A

0.25 Amp

3000 / 5 Amp

1- 4A

4.0 Amp

15% of 5 A

CDG 11

GEN &UAT10000/5
Bushing &
Switchyard 600/1
ICT 1.0 /
2.6 A
600/1

CAG 14

600/1

0.2-0.4 A

PS-0.2 A,
TMS-0.4
0.2 Amp.

VAGM
22
VTT 11

15750/110 V

110 140 %

121 Volt

1.0 to 10 sec

2.0 Sec.

CTU 12

10000/5 A

YCG 15
VTT11
VTT11
CAG 19
VTT 11
CTN 31

10000/5 A,
15750/110 V

VTT 11
CAG 37
VAT 11
VTT 11
DTH31

600/5A
10000/5A

600/5 A

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

Bias 15,30
& 45 %
High set
1000 %
Fixed
0.1-0.4 A

50 200 %
05 5 Sec

15 % of 5
Amp.
30 %
1000 %
Fixed

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

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

21. Generator Under

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

23. Check Synchronizing

Relay (25)

Relay
Type
VDG14

CTR /
PTR
15750/110 V

VME
VTT 11
CAEM
GTT21

15750/110 V

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

VTT 11
VTT 11
VAGM
22
ZTO 11

SKE 11

Range

Setting

V=5.4-20 V

PS=12.5V
TMS=0.3
4 mA
2.0 Sec
1.1 mA
K=1.125

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

2 Sec

0.5 %
1 10 Sec
12 - 120 Sec
0.5 5 Sec
6 60 Sec

0.5%
2 Sec
120 Sec
5 Sec
10 Sec

1-10 Sec
5-25 Sec
44 88 Volt

K1=0.845,
K2=3.5,
K3=0.5,
K4=3,
K5=18.6
2Sec
10Sec
PS-80.5 V

15750/110 V
10000/5A

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

T=15 Sec
0.5%

5.2 Amp
75 Deg elect
Offset=
3.156 Ohm,
T=52.5mSec
Phase
Angle=10%,
Voltge=6%,
F=0.11%

5.1.2 RECOMMENDED RELAY SETTING OF GENERATOR, GENERATOR

TRANSFORMER AND UAT (UNIT 5)

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

Relay
Type
CAG 34

CTR /
PTR
10000/5 Amp

CAG 14
DTH32

Range
0.25 - 1 A

0.25 Amp

3000 / 5 Amp

1- 4A

4.0 Amp

15% of 5 A

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

CDG 11

GEN &UAT10000/5
Bushing &
Switchyard 600/1
ICT 1.0 /
2.6 A
600/1

CAG 14

600/1

0.2-0.4 A

VTU 21

15750/110 V

105 110 %
0.5-5 Sec

7. Gen Over Load Alarm

(51 G1)
8. Gen Back up
Impedance
(21 G)
9. UAT Over load alarm
(51 T5A & T5B)
10. Generator Negative
Phase Sequence (46)

CTU 12

10000/5 A

50 200 %
05 5 Sec

YCG 15
VTT11
VTT11
CTU12

10000/5 A,
15750/110 V

CTN 31

10000/5A

11. UAT B/U O/C

(50 T5A & 50 T5B)
12. UAT Differential
(87 T5A & T5B)

VTT 11
CAG 37
VAT 11
VTT 11
DTH31

Setting

600/5A

600/5 A

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

Bias 15,30
& 45 %
High set
1000 %
Fixed
0.1-0.4 A

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

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

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

22. Generator Under

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

24. Check Synchronizing

Relay (25)

Relay
Type
VDG14

CTR /
PTR
15750/110 V

Range

Setting

V=5.4-20 V

PS=5.4V
TMS=0.3
T(119)-1
Sec, T(149)5 Sec
1.1 mA
2.0 Sec
1.1 mA
K=1.1

RAGEA

VAEM
VTT 11
CAEM
GTT21

15750/110 V

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

VTT 11
VTT 11
VAGM
22
ZTO 11

SKE 11

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

2 Sec

0.5 %
1 10 Sec

0.5%
2 Sec

1-10 Sec
12-120 Sec

5 Sec
60 Sec

1-10 Sec
5-25 Sec
44 88 Volt

K1=0.845,
K2=3.5,
K3=0.5,
K4=3,
K5=18.6
2Sec
10Sec
PS-80.5 V

15750/110 V
10000/5A

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

T=12 Sec
0.5%

5.2 Amp
75 Deg elect
Offset=
3.156 Ohm,
T=52.5mSec
Phase
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
No.
2000 / 5 10 40 Amp
CAG 37
1. Main Incoming Supply from
A
0.5 5 Sec
VTT 11
Station T/R 3 (3SA1 &
U/V
3SB1)

Setting

6. Main Supply to CSA at CSA

CAG 37
VTT 11
U/V

400/5 A

10 40 A
0.5 5 sec

7. Reserve Supply to CSA at

CSA

CAG 37
VTT 11
U/V

400/5 A

10 40 A
0.5 5 sec

8. Main Supply to WCA from

CSA at WCA

CAG 37
VTT 11
U/V

400/5 A

10 40 A
0.5 5 sec

9. Reserve Supply to WCA from

CSA at WCA

CAG 37
VTT 11
U/V

400/5 A

10 40 A
0.5 5 sec

10. Reserve Supply feeder for

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

CAG 37
VTT 11

1250/5 A

10 40 A
0.5 5 sec

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

CAG 37
VTT 11

1250/5 A

10 40 A
0.5 5 sec

10 A
0.8 Sec

2. Main Supply to CSA from

3SA at 3SA
3. Reserve Supply to CSA from
3SB at 3SB
4. Main Supply to CT3 (Cooling
Tower) from 3SA at 3SA
5. Main Supply to CT3 at CT3

CAG 37
VTT 11
U/V
CAG 37
VTT 11
U/V
CAG 37
VTT 11
U/V
CAG 37
VTT 11
U/V

800/5 A

10 40 A
0.5 5 sec

800/5 A

10 40 A
0.5 5 sec

800/5 A

10 40 A
0.5 5 sec

800/5 A

10 40 A
0.5 5 sec

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

Relay Type

CTR

Range

Setting

CAG 37
VTT 11
CAG 37
CAG 37
VTT 11
CAG 37
CAG 37
VTT 11
CAG 37
CAG 37
VTT 11
CAG 37
CAG 37
VTT 11
CAG 37
CAG 37
VTT 11
CAG 37
CAG 37
VTT 11
CAG 37
CAG 37
VTT 11
CAG 37
CAG 37
VTT 11
CAG 37
CDGM 62

200 / 5 A

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

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

200 / 5 A

150 / 5 A

150 / 5 A

150 / 5 A

200 / 5 A

150 / 5 A

150 / 5 A

100 / 5 A

150/5 A

25 100 A
U/V

22. HP Flush Water Pumps

(187 KW)
Full load current = 23 A
Starting current = 115 A
Starting time = 2.66/5.25 Sec

CDGM 62

23. Clarified Water Pumps

(280 KW)
Full load current = 111 A
Starting current = 577.2 A
Starting time = 1.67/4.76 Sec

CDGM 62

30/5 A

3.6 6.2 A
25 100 A

U/V

40/5 A

3.6 6.2 A
25 100 A

U/V

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

5.2.2

Relay Type

CTR

CDGM 62

40/5 A

Range
3.6 6.2 A
25 100 A

U/V
CDGM 62

30/5 A

3.6 6.2 A
25 100 A

U/V

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

RECOMMENDED RELAY SETTING OF 6.6 KV UNIT SECTION

STAGE - II (Unit - 4)

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

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

CTR

Range

150 / 5 A

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

U/V
CDGM
62

50 / 5 A

3.6 6.2
25 100 A

U/V
CDGM
62

150 / 5 A

a. 6.2
25 100 A

CTU 12
U/V
CDGM
62

30 / 5 A

3.6 6.2
25 100 A

U/V

Setting
18.7 A
0.5 Sec
68 Amp
18.7 A
0.5 Sec
75.7 A
22 Amp
05 Sec
PS = 3.6
TMS=0.35
30 Amp
No Trip
PS = 3.95
TMS=0.2
40 Amp
70%,0.5
Sec
PS = 4.35
TMS=1.0
40 A
9A,15 Sec
50%,9 Sec
PS = 4.35
TMS=0.25
34 A
70%,0.5
Sec

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

5.2.3

Relay
Type
CDGM
62

CTR
100 / 5 A

Range
3.6 6.2
25 100 A

U/V
CDGM
62

100 / 5 A

3.6 6.2
25 100 A

U/V
CDGM
62

30 / 5 A

3.6 6.2
25 100 A

U/V
CDGM
62

500 / 5 A

3.6 6.2
25 100 A
0.1 1 A

CAG 34
U/V

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

RECOMMENDED RELAY SETTING OF 6.6 KV

STATION SECTION STAGE - III

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

Relay Type

CTR

Range

Setting

CAG 37
VTT 11
U/V
CAG 37
VTT 11
U/V

800/5 A

10 40 A
0.5 5 sec

800/5 A

10 40 A
0.5 5 sec

3. Bus coupler between CT3 &

CT 4 Bus

CAG 37
VTT 11

800/5 A

10 40 A
0.5 5 sec

10 A
0.8 Sec
No Trip
10 A
0.5 Sec
20%,1.5
Sec
10 A
0.5 Sec

4. Station Auxiliary T/R

(TS5 / 1600 KVA)

CAG 37
VTT 11
CAG 37
CAG 37
VTT 11
CAG 37
CAG 37
VTT 11
CAG 37

200 / 5 A

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

10 A
0.5 Sec
66 A
10 A
0.5 Sec
66 A
10 A
0.5 Sec
65 A

5. Stand By T/R
(TR6 / 1600 KVA)
6. Lighting Transformer
(TL4 / 1000 KVA)

200 / 5 A

150 / 5 A

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

Relay Type

CTR

Range

Setting

CAG 37
VTT 11
CAG 37
CDGM 32

200 / 5 A

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

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

150/5 A

25 100 A

CAG 37
U/V

5.2.4

RECOMMENDED RELAY SETTING OF 6.6 KV UNIT SECTION

STAGE - II (Unit - 5)

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

Relay
Type
CAG 37
VTT 11
CAG 37
CAG 37
VTT 11
CAG 37
CAG 37
VTT 11
CDGM
32
CAG 37
U/V
CDGM
32
CAG 37
CTU 12
U/V
CDGM
32
CAG 37
CTU 12
U/V
CDGM
32
CAG 37
U/V

CTR

Range

150 / 5 A

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

3.6 6.2
25 100 A

150 / 5 A

b. 6.2
25 100 A

30 / 5 A

3.6 6.2
25 100 A

Setting
10 A
0.5 Sec
65 Amp
10 A
0.5 Sec
66 A
22 Amp
0.3 Sec
PS = 4.35
TMS=0.4
43 Amp
No Trip
PS = 3.95
TMS=0.2
40 Amp
8.1A,3 Sec
70%,0.5 S
PS = 4.35
TMS=0.8
40 A
9A,10 Sec
50%,9 Sec
PS = 3.6
TMS=0.2
34 A
70%,0.5
Sec

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

Relay
Type
CDGM
32
CAG 37
U/V

9. CEP Pumps A,B,C (220 KW)

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

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

CTR
100 / 5 A

Range
3.6 6.2
25 100 A

30 / 5 A

3.6 6.2
25 100 A

500 / 5 A

3.6 6.2
25 100 A
0.1 1 A

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

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

5.3 RECOMMENDED SETTING OF MCB RELAYS

Sr.
No.
1

Name of Feeder
IP1&IP2

Mehrauli 1&2

Type of
Protection
Distance
Protection

Relay Type

CTR/PTR

Range

Setting

Quadro mho

600/1 A
220KV/110V

Z1=1.792 Ohm
Z2=2.24 Ohm
(t2=350 ms)
Z3=2.56Ohm
(t3=1.05ms)
Z3=0.4 Ohm
E/F Comp.=130%
(R-Ph)O/C=150%
(B-Ph)O/C=150%
E/F
=20%
TMS=0.3 sec

Backup
Protection

CDD21
(Directional)

Distance
Protection

RR3V
Scheme

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

600/1 A

220KV/110V

Backup
Protection

IDMT
(Directional)

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

Z1=1.68 Ohm
Z2=3.15 Ohm
(t2=350 ms)
Z3=5.76Ohm
(t3=1.0 sec)
(R-Ph)O/C=150%
(B-Ph)O/C=150%
E/F
=20%
TMS=0.2 sec

Sr.
No.
3

Name of Feeder
Ballbhagarh 1&2

Relay
Type
Distance
Protection

CTR

Range

MM3V
Scheme

600/1 A

Setting
-

Z1=2.396 Ohm
Z2=3.355 Ohm
(t2=350 ms)
Z3=9.1Ohm
(t3=1.0 sec)

220KV/110V

Okhala 1

Okhala 2

NOIDA

Backup
Protection

IDMT
(Directional)

Distance
Protection

RR3V

Backup
Protection

IDMT
(Directional)

Distance
Protection

RR3V

Backup
Protection

IDMT
(Directional)

Distance
Protection

Backup
Protection

IDMT
(Directional)

600/1 A
220KV/110V

600/1 A
220KV/110V

600/1 A
220KV/110V

Sr. No.

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

(R-Ph)O/C=125%
(B-Ph)O/C=125%
E/F
=20%
TMS=0.3 sec
Z1=1.63 Ohm
Z2=2.44 Ohm
(t2=350 ms)
Z3=4.89Ohm
(t3=1.0 sec)

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

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

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

20-80%

Sr.
No.
7

Name of Feeder
Alwar

Bypass

Bus Coupler

Relay
Type
Distance
Protection

CTR

Range

Setting

Sr. No.

MM3V
Scheme

600/1 A
220KV/110V

Backup
Protection

IDMT
(Directional)

Distance
Protection
Backup
Protection

Quadro mho

Z1=13.44 Ohm
Z2=20.16 Ohm
(t2=450 ms)
Z3=26.88Ohm
(t3=1.0 sec)
(R-Ph)O/C=125%
(Y-Ph)O/C=125%
(B-Ph)O/C=125%
E/F
=20%
TMS=0.3 sec
Reqired setting
can be set
Reqired setting
can be set

Instantant
O/C

O/C
50-200%
E/F
20-80%
600/1 A
220KV/110V

IDMT
(Directional)

CAG33

1200/2 A
220KV/110V

10

11

12

Station Tr. 1&2

Station Tr. 3

Bus Bar
Differential

O/C
50-200%
E/F
20-80%
4 16
Amp.
2 8 Amp

E/F

Instantant
Dead time
O/C
E/F

CAG39

Backup
Protection

IDMT

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

DMH

IDMT

600/1 A
220KV/110V

600/1 A
220KV/110V

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

0.5-2Amp

1.8 A
(51A,51C)

0.5-2Amp

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

O/C
50-200%
E/F
20-80%
15-50%

30%

DTH-31

E/F
10-40%
-

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

CAG-14
CAG-34

5-20%
50-200%

10%
125%

600/1 A

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

SECTION VI

NEW C&I SYSTEM

COMMISSIONED

6.1

NEW SYSTEMS COMMISSIONED IN STAGE II UNITS

6.1.1 ELECTRONIC DRUM LEVEL INDICATORS: (#4,5)

Make
Total no. of probes
Range
Drum Pressure
Temperature
Power supply

:Levelstart
: 14
: 0-500 mmWCI
:200 kg/cm2
: 4000 C
: 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
Rating
Feeders
Features

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

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

Make
Sensor
Indication

: Masibus
: Inductive proximity switches
: Digital speed indication in UCB for
each feeder
: An immediate alarm is given in
case of stoppage of the feeder in
UCB

Alarm

6.1.4 LP/HP HEATER DRIP LEVEL CONTROLLERS (#4)

(Single loop PID controller)
Make
Output

: Fuji Tosdic
: 24 V pulsating

6.1.5 ANNUNCIATION SYSTEM :(#4,5)

Make
I/P supply

: ILK Mark II (CMOSbased)

: 230V AC

6.1.6 DISTRIBUTED CONTROL SYSTEM (DCS): (#5)

Make

: Siemens Teleperm ME Plus.

1.
a)
b)
c)
d)

Closed loop controls including:

PA header pressure
Furnace draft
SH attemperation
RH attemperation

2.

Analog & Digital Measurements

6.1.7 SEQUENCE OF EVENTS LOGGER (#5)

Make
Mode
No. of points
Time stamping

: Siemens
: Sieser
: 256
: 1 msec

SECTION VII

OFF-SITE
AUXLIARIES

7.1

7.1.1

SWITCHYARD

STATION TRANSFORMER (#1)

TRANSFORMER RATING
Make
MVA
Date Of First Charging
Voltage Ratio HV/LV (kV)
Current HV/LV (Amps.)
Phases
Frequency (Hz)
Vector Group
Type Of Cooling
Tap Changer Type
Impedance %
7.1.2

BHEL
31.5
11-10-1982
220/7
82.67/2598.15
3
50
Yd1
ON
OLTC
13.67

STATION TRANSFORMER (#2)

TRANSFORMER RATING
Make
MVA
Date Of First Charging
Voltage Ratio HV/LV (kV)
Current HV/LV (Amps.)
Phases
Frequency (Hz)
Vector Group
Type Of Cooling
Tap Changer Type
Impedance %
7.1.3

BHEL
63/43/20
1973
220/6.9
163.3/1673
3
50
Yd1
OFB
OLTC
16.75

STATION TRANSFORMER (#3)

TRANSFORMER RATING
Make
MVA
Date Of First Charging
Voltage Ratio HV/LV (kV)
Current HV/LV (Amps.)
Phases
Frequency (Hz)

BHEL
25
15-06-1977
220/7
65.6/2062
3
50

Vector Group
Type Of Cooling
Tap Changer Type
Impedance %

7.1.4

Yd1
ON/AB
OLTC
12.62

BUS BARS SCHEME

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

NORMAL OPERATION

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

MAINTENANCE OF BUS-I AND BUS-II

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

220KV CIRCUIT BREAKERS

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

220 KV CURRENT TRANSFORMERS

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

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

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

7.1.9
1

2
3
4
5
6
7.1.10

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

At 47.8 c/s - 220KV Badarpur / Sahibabad feeder will trip

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

220KV BUS-I AND II (as the case may be) may become dead if any of the five unit
breakers is under trip position and its Bus and line Isolators are in closed position and the
air pressure drops to 16 kg/ cm2 (approx.)
7.1.11
1
2
3
4
5
6
7
8

IMPORTANT ANNUNCIATIONS (required immediate attention)

Control Circuit faulty
Breaker Air Pressure Low
V.T. fuse faulty
Line V.T.fuse faulty
Bus Protection Bus wire faulty
Bus connection disturbed
Bus Differential protection DC faulty
Bus protection zones combined

Bus bars paralleled by isolators.

There are 20 Bays in 220KV switchyard connected to 220KV Bus-I and Bus-II as per
following description:BUS-I
1
2
3
4
5
6
7

IP-I
Station I, III
Okhla-I
Ballabhgarh-I
Units-I, III, V
Jaipur
Mehrauli-I

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

7.2
7.2.1

AIR COMPRESSORS

STATION AIR COMPRESSOR

Total Nos.
Jacket water pressure
H.P. Cylinder outlet
Water Temp
7.2.2

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

COMPRESSOR NO. 1 & 2

Make
Type
Speed
Nos. of Cylinder
Pressure

Pneumatic Tool company

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

Max. working pressure

No.
Capacity

120 Psig
2
21m3/hr

MOTOR
Motor capacity
Voltage
RPM
Amps
Make

126 KW
415V
1500
221
Siemens

RECEIVER
Capacity
Working pressure
Test pressure
7.2.3

250C.F.
125 Psig
185 Psig

COMPRESSOR NO 3

Make

Working pressure
Max. Unloading Pressure
No.

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

RECEIVER
Capacity
Design pressure
Test pressure

10 M3.
9.2 kg/cm2
13.8 Kg/cm2

MOTOR
Capacity
Voltage
RPM
Amps
Make

132 KW
415V+ 10%
1500
227
Siemens

Type

Speed
Capacity

7.2.4

PLANT AIR COMPRESSORS(ST-II & III)

No
Capacity
Pressure
Make

2
30 m3/min
70 MWC
Kirlosker Pneumatic

MOTOR
Capacity
Voltage
RPM
Amps
Make

200 KW
6.6 KV
988
23
Kirlosker

7.2.5

INSTRUMENTAIR COMPRESSOR (U#4)

Make
Type

K.G.Khosla Compressor Ltd.

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

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

750 RPM
14.6 m3/min.
8.0 kg/cm2
7 kg/cm2
2
1.5 to 2 kg/cm2
8 kg/cm2
1100 F to 1200 F

MOTOR
Capacity
Voltage
Amps
Make
Speed

100 KW
415 Volts
173/177
Kirlosker Electric
1500 RPM

RECEIVER
Capacity

5 M3

Hydraulic Test Pressure

Working Pressure

16.19 kg/cm2
10.15 kg/cm2

AIR DRYING UNIT

1) Type
2) Flow Rate
3) Inlet Pressure
4) Outlet pressure
5) Inlet Temp.
6) Outlet Temp.
7) Outlet Moisture
content
8) Cycle Time
a) For absorption
b) For regeneration
c) For cooling
9) Service
10) Drying Agent
11) Design Pressure

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

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

7.2.6

INSTRUMENT AIR COMPRESSORS (U#5)

7.2.7

COMPRESSURE 1&2

Make
Capacity
Pressure

Kirlosker Pneumatic
18 m3./min
(2 Nos)
7 kg/cm2

MOTOR
Capacity
Voltage
RPM
Amps
Make

120 KW
415 V
1000
212
Kirlosker

7.2.8

COMPRESSURE 3

Make
Type

K.G.Khosla Compressor Ltd.

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

Speed
Free air Delivery

750 RPM
14.6 m3/min.

8.0 kg/cm2

Working/cut-off
Pressure
Re-starting Pressure
Lubrication oil
Pressure
Jacket water pressure
HPC outlet water
Temperature

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

MOTOR
Capacity
Voltage
RPM
Amps
Make

100KW
415 V
1500
173
Kirlosker

AIR DRYING UNIT

1) Type
2) Flow Rate
3) Inlet Pressure
4) Outlet pressure
5) Inlet Temp.
6) Outlet Temp.
7) Outlet Moisture
content
8) Cycle Time
a) For absorption
b) For regeneration
c) For cooling
9) Service
10) Drying Agent
11) Design Pressure

7.3
7.3.1

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

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

CONTROL STRUCTURE PUMP HOUSE

HP FLUSH WATER PUMP

No -I, II, III, IV

Make
Type
Capacity
Head
Speed

4
Worthigton
Multistage Vertical Turbine Pump
500 m3/Hr
94.5 MWC
1500 RPM

MOTOR
Make
Type
Rating
RPM

Kirloskar
Induction Motor
6.6 KV,187 KW ,22Amp.
1485

7.3.2

H.P. WATER PUMPS

No-V, VI
Make
Type
Capacity
Head

2
Kirloskar
Multistage Vertical Turbine Pump
400 m3/Hr
94.5 MWC

MOTOR
Make
Type
Rating
RPM
7.3.3

Kirloskar
Induction Motor (IP23/IC01)
6.6 KV,150 KW
1485
FIRE & SCREEN PUMP

Make
No
Type
Capacity
Head

Worthigton
2
Multistage Vertical Turbine Pump
500 m3/Hr
94.5 MWC

MOTOR
Make
Type
Rating
RPM

Kirloskar
Induction Motor
6.6 KV,185 KW
1485

7.3.4 DEISEL FIRE PUMP

Make
Type
Capacity
Pressure
Engine Model
Rating

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

7.3.5

LP FLUSH WATER PUMPS

No
Make
Type
Capacity
Head
Speed

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

MOTOR
Make
Type
Rating
RPM
7.3.6

Jyoti Limited, Baroda

Induction Motor (IP23/IC01)
415 V,132 KW ,230Amp
1470
CLARIFIED RAW WATER PUMP(CRW)

Make
No
Capacity
Head

Kirloskar,(CRW1)/Flowmore(CRW2,3)
3
3500 m3/Hr
20.5 MWC

MOTOR
Make
Type
Rating
RPM
7.3.7

Kirloskar.
Induction Motor
6.6 KV,280 KW
985
TRAVELLING WATER SCREENS

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

BSBK
7 nos
20000 cu mt /hr

SCREEN WASH PUMPS

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

Type
Capacity
Head
Drive Motor

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

7.3.10

MAKE-UP PUMP AT AGRA CANAL

Drive Motor
7.3.11
No.
Type
Capacity
Head
Speed
Motor

1425RPM, 14.1Amp, 415V

DEDS PUMPS
3
Vertical Turbine Pump
200 m3/Hr
120MWC
1480
110KW/1485RPM/197Amp/Kirlosker
7.4

7.4.1
Make
Model
Capacity
Pressure :
Quantity
Speed
Motor

ASH HANDLING PLANT

ASH PUMP (OLD)

Flowmore
D85
1000 m3/hr
3.3 kg/cm2
1.
800 RPM
194 KW

MOTOR
Capacity
Voltage
RPM
Amps
Make
7.4.2
Make
Model
Capacity:
Pressure
Quantity

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

MOTOR
Capacity
Voltage
RPM
Amps
Make
7.4.3

322 KW
6.6 KV
991
35
Kirlosker
BOTTOM ASH PUMPS

Quantity
Make
Model
Capacity
Pressure
Motor

2 nos.
Beacon Weir
SDC 200/200
410 m3/hr
8.0 kg/cm2
160KW/1485RPM/220Amp/NGEF
7.5

Intake Channel Level (Normal)

COOLING TOWER
202 mtrs

7.5.1 C.T PUMP

Nos
Dischrge
Head
Speed
Make

2 for each 210 MW unit

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

MOTOR
Type
Speed
KW
Current
Volts
Make

Induction motor
421 rpm
930
108.5 amps
6600 volts, 3 Ph. 50 C/S
BHEL

7.5.2 COOLING TOWER

Make
Number
No. of cells/tower
Rate of flow /unit

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

100C
500C

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

Fan Type
No. off fans/Tower
No. off blades/fan
No. off row of fan
Dia.
Reduction gear Ratio
Fan speed
Type
Make
Lub oil

Axial Induced Draft

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

MOTORS
Make
Volts
Current
K.W.
Speed

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

7.6

DIESEL GENERATOR

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

10.6.1 SPECIFICATION
10.6.2 GENERATOR
No
Make
Rated output

2
Jyoti Ltd.
250KVA

Power Factor/ Voltage

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

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

7.7 WATER TREATMENT PLANT

7.7.1 WATER ANALYSIS as CaCo3 p.p.m.
COMPONENTS
Calcium
Magnesium
Sodium & Potassium
Total Cations
Total Hardness
M.C. Alkalinity
Sulphate
Chlorides
Total Anions
Iron as Fe
Silica ( Reactive) as SiO2
Turbidity J.T.U.
Permanganate No or B.O.D.
Conductivity at 25 C

RAW WATER
240
64
306
612
304
326
72
214
612
0.1
13.0
3500
72
1300

MODIFIED FOR DESIGN

300
64
312
676
265
363
97
216
676
0.1
13.0
-

Note: Modified analysis is after 50 ppm Alum,

37ppm lime & 2ppm sodium sulphite done.
7.7.2

TREATED WATER QUALITY

ANION EXCHANGER
Silica (Reactive) as SiO2
Conductivity at 20 C
Total dissolved solids

0.2 ppm (max.)

10 micro-mhos/cm
2ppm as such

7.7.3

PRETREATMENT SECTION

Description

Nos. off
Dimensions
Concentratio
n of solution
High Speed
Mixture

7.7.4

Alum Prep.
Cum storage
tank
2
12300x1200D

Const. Head tank

for Alum

Lime
solution tank

Const. Head tank

for lime

1
765Lx380Wx380H

1
765Lx380Wx380H

10%

10%

1
16200
x1480D
10%

2 Nos.

Nil

1 Nos.

Nil

CLARIFLOCULATOR

Nos.
Size
Capacity
7.7.5

One
168000 x 4000D
400 m3/Hr.

FLASH MIXER MECHANISM

Nos.
Make
7.7.6

One set
Hindustan Door Oliver
CHLORINATOR

Nos.
Capacity
Model
Type
Capacity
Operating Pressure/
Unit
Operating water
Qty/Unit
7.7.7

10%

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

TANKS

LOCATION

MODEL

HP/RPM
0.5/1440

MAKE/FRAM
E SIZE
Kirloskar/N80

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

PH 5

PM 1

QTY.
3

1.0/1000

Kirloskar/N90L

clarifloculator
Sodium sulphite
Soln. Tank
Alkali dilution
tank
Lime prepn.
Tank for
neutraliasation

PM 5

0.5/1440

Kirloskar/N80

PM 10

1.0/1000

Kirloskar/NPOL

PH 5

0.5/1440

Kirloskar/N80

7.7.8
DESCRIPTION

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

Nos.
Capacity
Discharge Head
Model No.
Make
Motor
HP/RPM
Make
D.P.

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

7.7.9 DEMINERALISATING SECTION

DESCRIPTION
Nos.
Size
Filtering Media
Max/min. Treatment flow
m3/Hr.
Back wash flow rate m3/Hr.
Duration of back wash
Air scour flow rate m3/Hr.

PRESSURE
FILTER(DUEL MEDIA)
4
30000 x 1350H

ALKALI CARBON
FILTER
1
8000 x 2300H

Sand+Anthracite
55/28

Active Carbon
-

170
5 mints
4.65

10
5 mints
-

DESCRIPTION

BACKWASH
WATER PUMP

AIR BLOWER

Nos.
Capacity
Discharge Head
Medium

2
170 M3/Hr.
20 MWC
Water

2
4.65 m3/min
0.21 kg/cm2
Air

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

Motors HP/RPM

25/1440

DESCRIPTION

7.5/1440

BACKWASH WATER
PUMP
1
1000Lx6000Wx2580H
-

Nos.
Size
Concentration of Soln.
High speed Mixture

soution
0.5/1440

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

DESCRIPTION
Nos.
Type

CATION UNIT
4
Strongly Acidic

ANION UNIT
4
Strongly basic

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

4.0

5.3

MIXED BED UNIT

4
Strongly Acidic &
Basic
5.3

80/28

70/28

47/28

35

35

35

850

706

700

110

80

25

55 mints.

115 mints.

115 mints.

Hcl
880

NaOH
500

Hcl & NaOH

38.5

2K 225
12.5

DANIP
6.695

ZK225/DAFFIP
0.77/2.10

FLOW-M3/HR.
55.4

TIME-MIN
5

52.8

20

7.7.10 REGENERATION FLOW

UNIT
3K

OPERATION
Back wash (once in a
week)
Acid Injection 5%
w/v

D.A.

M.B.

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

79.8
52.8
79.2
35.0
13.6
22.2
22.2
67.0
14.0

20
25
25
5
5
30
5
60
1

14.0
15.3
6.9
14.9
6.9
25.2
7.5

6
30
30
5
5
20
6

3.5
7.4
3.0 M3/Min.
3.5

6
10
5
10
10

7.7.11
DESCRIPTION

DEGASSER TOWER

Nos.
Size

2
2000Lx2000Wx3400H

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

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

DEGASSED WATERSUMP
2
7500Lx7500Wx2750H

MIXED BED AIR

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

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

DESCRIP
TION

ALKALI
PREPAR
ATION
TANK

BULK
ALKALI
STORAG
E TANK

Nos.
Size

Two
12000
x1200D
-

One
16000 x
4500L
-

Solution
Concentrat
ion in
Tank

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

DESCRIPTIO
N
Nos
Size mm.

DESCRIPTION

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

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

ACID
MEASUR
ING
TANK
FOR ZK
Two
18000
x1500D
30%

BULK
ACID
STORAG
E TANK
Five
34000
x6200L
30%

ACID
MEASUR
ING
TRANSF
ER MB
Two
4570
x762D
30%

ACID
TRANSFER
PUMP
1
25
17.5

EFFLUENT
DISCHARGE
PUMP
2
150
18

ALKALI
TRANSFER
PUMP
2
15
20

ALKALI
INJECTION
PUMP
2
5
25

32% Hcl
5/1440

Acid/Alkali
20/1440

20% NaOH
5/1440

Alkali
7.5/1440

Kirloskar

Kirloskar

Kirloskar

Kirloskar

PRIMING
CHAMBER
One
6000 x900D

LIME PREPN.
TANK
One
12000 x1200D

NEUTRALISING PIT
One
10000Lx10000Wx3000H

MIXED BED UNIT

STRONGLY
ACIDIC CATION
UNIT
Four
Strongly Acidic
2800 x3600H
3.6

STRONGLY
BASIC ANION
UNIT
Four
Strongly Basic
2400 x2600H
4.6

Four
1400 x3000H
4.6

28

28

28

80

70

47

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

35

35

35

850

706

700

20

20

20

110

80

25

55

115

115

RESINTYPE

INDIAN 225

INDIAN NIP
6695

ANION
INDIAN FFIP
2100

CATION
INDIAN 225
770

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

12500
Hcl

NaOH

NaOH

Hcl

880

544

Through fan
with 5BA

38.5

7.7.12 REGENERATION FLOWS

UNIT
Strong Acidic cation
unit

Strong basic Anion

Unit

Mixed Bed

OPERATION
Middle collector
flushing
Down Flow
Back wash
Acid Injection @ 5%
Down Flow
Acid Rinse
Final Rinse
Back wash
Caustic Injection @
5%
Caustic Transfer
Caustic Rinse
Flushing/ Back wash
Up flow
Caustic Injection 7.2
%
Up flow

FLOW(M3/Hr.)
55.4

TIME(Min.)
1

79.2
55.4
52.8
79.2
52.8
35.0
13.6

20
5
20
25
25
5
5

22.2

30

22.2
67.0
14.0
6.9
15.3

5
60
6
30
30

6.9

20

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

25.2
6.9
6.9
3.5
7.4

20
5
5
10
10

180
35

5
10
10

7.7.13 GEO-MILLER CLARIFLOCULATOR

Nos.
Type
Capacity
Overload
Size

2
Radial flow clarifloculator
3200 m3/Hr./unit
20 % (Max.)
54300 Dia x4915 Deep.

7.7.14 FLASH MIXER MECHANISM

Nos.
Make
Detension Time
Dia.
Gate
Draining

2(one/unit)
Geo-Miller Private Ltd.
60 Secs.
3.7 mts.
2/unit
Service valve 150 DA.

7.7.15 ALUM DOSING UNIT

Nos.
Capacity/Tank

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

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
R.P.M.
Gear base ratio

2 H.P
1550
1:50

7.7.17 OPERATING HOIST FOR ALUM

Nos

Capacity
Type

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

7.7.18 LIME DOSING UNIT

TANK
Type
Size
Capacity

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

PADDLES
Material
Type
Motor

M.S.
Rotation about horizontal axis
2 H.P., 1500r.p.m., gear ratio 1:

7.7.19 DESLUDGING PUMP

Capcity
Total Head
BHP absorbed

300 m3 /hr
15 M.
23.4

MOTOR
HP
Speed

30
1450 rpm

7.7.20 ECHNICAL SPECIFICATION OF ACTIVATED CARBON

FILTERS (ACF)
SR NO.
1.
2.
3.
4.
5.
6.
7.

FEATURES
Quantity (No.)
Type
Normal operating flow
Operating Pressure
Dimensions Dia x HOS
Material of construction
Back wash Time

8.
9.

Max. allowable Pressure drop.

Type of operation

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

7.7.21

DETAILS OF FILTER MEDIA IN ACF

SR.
NO.

MATERIAL

1.

Pebble

2x 1
1 x 1
1 x
x

2164.00 x 4 kgs
541.00 x 4 kgs
541.00 x 4 kgs
541.00 x 4 kgs

2.
3.
4.

Quartz cylex
Mixed sand
Activated Carbon

x
-

513 x 4 kgs
93500 x 4 kgs
2508 x 4 kgs

7.8
7.8.1

SIZE

QUANTITY

OLD COAL HANDLING PLANT

COAL CHARACTERISTICS AT BTPS

Description

At relative humidity 60 % & air

temp. 400 C
6-9%
24-33%
24-28%
4778-4944 kcal/kg
45-50
0.8 Tonne/m3
250 mm

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

DESIGN CAPACITY OF COAL HANDLING PLANT

( 3X100MW + 2X210MW UNITS)
DESCRIPTION

UNIT

3X100MW

3X100+2X210MW

Coal consumption
Max.daily
Consumption
Average daily
Coal consumption
Annual Coal

Tonnes/Hr
Tonnes

187.5
4500

450
10800

Tonnes

3600

8000

Tonnes

1312500

315,00,00

7.8.3

WAGON TIPPLER
Nos.

Make
Type
Total Time for Tripping
Max.angle of rotation
Total Weight
Capacity

Tata Robins-Fraser Ltd.

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

MOTOR
R.P.M.
Amps
H.P.
Voltage

1480
100
75
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

b) Hoisting Rope

7.8.5

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

CAR PULLER

Rope Size
Braking
Coupling
Speed Reducer

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

MOTOR
Capacity
Amps
RPM

30KW/40 HP
52.5
960

7.8.6
COAL CRUSHERS
Make
Type
Coal size input
Coal size output

TRF
Non-reversible ring granulator type
250 mm
20mm

Capacity
Nos.
Working oil temp.
Limit
Rotor Speed
Rotor dia
Rotor length

600 MT/Hr. per crusher

2
500C-850C
720 rpm
360 mm
3875 mm

MOTOR
Voltage
Amps
RPM
Capacity
7.8.7

6.6KV
33.5
1490
300KW

BELT CONVEYERS

Carrying Capacity
Speed
Width
Material

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

7.8.8
CONVEYER
NO.
1A & 1B
2A & 2B
3A & 3B

LENGTH & MM

PLY

171548
164345
156371

4
4
4

4
5
6

92087
100262
223778

4
4
4

7
8
9
10A&10B

177000
153832
20900

4
4
4
4

MOTOR SPECIFICATIONS
Speed
Voltage
CONVEYOR NO.
1A & 1B

CAPACITY
150 HP

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

1440 rpm
415 V
REDUCTION RATIO
35.5:1

2A & 2B
3A & 3B
4
5
6
7
8
9
10A & 10B
7.8.9

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

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

TRIPPER

Type
Quantity
Belt width
Drum Dia
Speed

Motor Propelled Tripper

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

MOTOR
Type
Capacity
(Traverse Drive)
Speed
Voltage
Telescopic Chute
drive capacity

3 ph.Squirrel cage Induction Motor

7.5 H.P.
1500rpm
415 V
5 H.P.

7.8.10 ROTORY PLOUGH FEEDER

Quantity
Overall Length
Height
Width

2
11700 mm
3500 mm
1980 mm

MOTOR

TRAVERSE MOTOR

PLOUGH MOTOR

Type
Capacity
Speed
Voltage
Speed

Induction Motor
7.5 H.P.
720 rpm
415 V
20 to 30 ft/minute

Induction Motor
40 H.P.
1430 rpm
425V
-

7.8.11
SR. NO.
1.0
2.0

BELT WEIGHER
DESCRIPTION
Location
Quantity

SPECIFICATION
Belt conveyor 2 A,2B
2

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

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

15.2

Type of totalising counter

Mechanical

15.3

Power supply

230V AC +/- 10%, 50 Hz

7.8.12 MAGNETIC SEPERATOR

Make
Type
Nos.
Size
Power Required
Operating Voltage
7.8.13

Mechanical
Gillanders Arbuthnot & Co. Ltd.
Mechanical
Mechanical

600 MTPH
750 MTPH
120 MTPH
10.50%
By test chain
46.85 Kg / m
Moving coil meter
EM counter
6
Yes
NA

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

METAL DETECTOR

Metal detector specification for OCHP is same as NCHP.

7.8.14

LIST OF FLUID COUPLINGS

S.NO.
1
2
3

TYPE OF COUPLINGS
STD 08
STD 07
STD 06

]
]
] M/s Fludomate make

STD - -5A

] (Conveyors)

5
6
7
8

FCU 17.75
FCU 16.5
FCU 14.5
FCU 12.75

]
] M/s Pembril Greaves make
] (Conveyors)
]

9
10

HFD 10 B
HFD 14B

] M/s Fludomate make (Crushers).

]

11

SCR 41 R

] M/s Pembril make (Crushers)

7.8.15

ROTECTION & INTERLOCKS

DESC
RIPTIO
N
Belt

PERMISSIVE

Conveyor

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

Screens
Tripper

Respective
conveyor

INTERLOCK

i)

If any belt trips the

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

PROTECTION

i)

ii)

iii)

iv)

If one belt runs out

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

Plough
Feeder

Car
Puller &
Beetle
Charger
Wagon
Trippler

should be in
operation.
Respective
conveyor
should be in
service.
Wagon trippler
should not be in
operation.

The traverses can not be

effected unless the blade cutter
is previously started.

Car puller or
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.
1.0
2.0
3.0
4.0
5.0
6.0

DESCRIPTION
Manufacturer
Type & Model No.
Gross Load Capacity
Minimum nos. of tippling/hr
Maximum angle of rotation
Type of brakes

7.0
8.0
9.0
10.0
11.0

Type of Inhaul Machine

Type of Outhaul Machine
Type of Reduction Unit
Dust Suppression System
provided
Wagon Tippler Drive system

12.0

Control system

7.9.2

RING GRANULATOR (CRUSHER)

SR. NO.
1.0

DESCRIPTION
Type

SPECIFICATION
Elecon Engineering Company Ltd.
Rota side
90T
17
150 Degree
Automatic Electro Hydraulic Thrust
Operated
Beetle Charger
Beetle Charger
Helical Gear Box
Yes
Through 98KW slip ring motor, reduction
gear unit, fluid coupling, flexible brake
coupling, spur and pinion gears
From control desk provided in the wagon
tippler control room.

SPECIFICATION
Ring Type Granulator

2.0
3.0
4.0

Make
Model No.
Quantity

Mcnally Bharat Engineering Co. Ltd.

RG-729
2

5.0

600 MT/hr
750Mt/hr
R.O.M.Coal
750
50-70
(-) 100 mm
20%
O.B.T./m
100%
(-) 20 mm

16.0
16.1
16.2
16.3
16.4

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

17.0

Granulator weight

7.9.3

VIBRATORY FEEDER

6.0
7.0
8.0
9.0
10.0
11.0
12.0

13.0
13.1
13.2
13.3
13.4
13.5
13.6
14.0
15.0

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

Sr.No.
1

Description
Location

Specification
Below wagon
tippler hopper

Type

Manufacture

Model No. & size

Mechanical turflo
type
Tata Robins Fraser
Ltd.
TE-9
3X8

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

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

5
6
7
8
9
10

Numbers
Guaranteed capacity
Designed capacity
Length of tray
With of tray
Slope of tray

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

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

11
12
13

Operating Speed
Feeder stroke
Material of
construction
Tray
Liner

800 rpm

800 rpm

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

M.S. IS-226
10 mm thick tiscral

14

Type of feed
rate controller

By changing the
rpm of feeder

15

HP rating of each
feeder
Approximate weight
Recommended
clearance between
feeder and stationary
chute

10

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

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

1960 Kg
51 mm

2520 Kg
51 mm

3750 Kg
51 mm

16
17

7.9.4

BELT WEIGHER

SR.
NO.
1.0
2.0
3.0

DESCRIPTION

SPECIFICATION

Location
Quantity
Type

4.0
5.0
6.0
7.0
8.0
8.1
8.2
8.3
9.0

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

On conveyor 12 A,12B,15A &15B

4
Electronic load cell single idler sensing
system with rate indicator and integrator
(Totalizer)
Integrated process automation
AC Digital Tacho
Strain gauge
1
600 MTPH
750 MTPH
120 MTPH

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

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

At rated ty(Guaranteed)
At maximum
capacity(Guaranteed)
At minimum pacity(Guaranteed)
Calibration
Weight per unit length of chain
Type of flow indicator
Type of totalising counter
No. of Digits
Whether zero reset button
provided
Remote Panel
Type of flow indicator
Type of totalising counter
Power supply required
Power Demand

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

Moving core type indicator

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

METAL DETECTOR
DESCRIPTION
Type
Make
Model No.
Location
Quantity
Sensitivity at normal working
condition
At maximum capacity with
maximum moisture content
Particular to sensitivity
to other
non ferrous material
Power requirement (Watt)
Power supply required
Enclosure material and
thickness
Degree of protection
Hooter

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

MAGNETIC SEPARATOR
DESCRIPTION
Type
Manufacturer

SPECIFICATION
Overband, inline magnetic separator
Electrometike

3.0
4.0

Number & Location

Tramp iron size & weight
(both maximum &
minimum )
to be separated

5.0
6.0
6.1
6.2
6.3
6.4
6.5
7.0
8.0
9.0
10.0

Type of drive system

Details of cross belt
Make
With
Number of plies
Top/ Bottom cover
thickness
Material specification
Weight of equipment
Type of rectifier
Magnetic core material
Field density

11.0
12.0

Magnet coil material

Total power requirement

13.0
13.1

Details of drive
Rating

13.2

Make

14.0

Operating voltage
Of magnet

7.9.7
Sr.No.
1.01
1.02

1.03
1.04

1.04.02
1.04.03
1.04.04

2 Nos, for 14A, 14B

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

CONVEYER BELT

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

Total lift (M)

Type of fabric
Is belt flat or

11A/B

12A/B

13A/B

Specification
14A/B 15A/B

16

17A/B

18A/B

600 TPH
750 TPH
1000 mm
A
210.29
B
209.98
23.35

210.3

51.25

21.05

6.0

248.25

170.9

29.8
28.4
Nylon
Troughed

124.45

15.7

A
128.09
B
108.82
14.75

116.7

14.966

troughed
Trughing angle
(Deg)
Belt joints
Cover grade
Belt type/ No.
of plies
Thickness of
covers (M)
Top (mm)
Bottom (mm)
Belt
speed(m/sec)
Allowable
working tension
(KN)
Supplier data of
working tension
(KN/m)

1.04.05
1.04.06
1.05.05
1.06.00
1.09
1.09.01
1.09.02
1.10.00
1.11.00

1.12.00

7.9.8

35
Vulcanised
Fire resistance
800/4
800/4

800/4

800/4

80/4

800/4

800/4

800/4

5
2
2.9

5
2
2.9

5
2
2.5

5
2
2.5

5
2
2.5

5
2
2.5

5
2
2.5

5
2
1.0

48

44.64

24.72

64.8

56.76

40.68

38.04

26.04

50

50

40.1

70

50

50

40

40

FLUID COUPLING (SCOOP TYPE)

Sr. No.
1
2
3
4

Description
Location
Type
Nos.
Manufacturer

5
6
7
8
9
10
11
12
13

Model No.
Rating of motor
Rated KW transmitted
Rated torque transmitting capacity with
torque
Rated input speed
Rated Slip
Temperature at which plug fuses
Weight of the coupling unfilled (Kg)
Type of bearing and life

14

Quantity of oil for coupling

15

MATERIAL OF CONSTRUCTION
a. Impeller
b. Runner
c. Casing

Specification
Ring granulator (Crusher)
Scoop type
2
PEMBRIL FLUIDRIVE LTD,
Auranagabad
41 SWGR 25W Scaled version
550 KW
500 KW
150 to 275% of full load torque
750 rpm
3%
1800 C+/-50 C
1654 Kg
Spherical roller bearing Approx.
Life-3000 working hours
184 Lits of SHELL TELLOS
OIL-29
Aluminum alloy
Aluminum alloy
Aluminum alloy

d. Shaft
e. Flanges for input and output coupling

EN-8
Forged Steel

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

17. Equipment should be dynamically balanced.
7.9.9

FLUID COUPLING (TRACTION TYPE)

Sr. No.
1
2
3

Description
Manufacturer
Type
Type of prime mover

4
5

Input rpm
Max. no. of starts per hour

6
7
8
9

Whether Acceleration torque limitation

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

10

Direction of rotation

11

Bearing lubrication

12
13
14

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

Specification
Fluidomat
Traction type
Direct on squirrel cage
induction motor
1470 Approx
2 consecutive starts or 3
starts/hr spaced
No
Yes
3%
Adjustable in the range of
150% to 275 % of full
required torque
Should be capable of
rotation in both direction
Lubrication of bearing
should preferably be done
with the fluid itself
Flexible/Semiflexible
Dynamically balanced
High tensile aluminum
alloy
High tensile aluminum
alloy
High tensile aluminum
alloy
EN-8
Forged steel

7.9.10

SCHEDULE OF FLUID COUPLING (TRACTION TYPE)

Sr.No.

Location Quantity
Motor
Conveyor
rating(KW)

1
2
3
4
5
6
7
8

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

7.9.11
Sr.No.
1.0
2.0
2.1
2.2
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
11.1
11.2
11.3
11.3.1
11.4
11.5
12.0
12.1
12.1.1

2
2
2
2
2
1
2
2

125
125
55
150
150
110
110
37

RPM

1470
1470
1470
1470
1470
1470
1470
1470

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

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

Model No.

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

BELT FEEDER
Description
Location
Capacity
Rated capacity (TPH)
Designed capacity (TPH)
Quantity & Type
Manufacturer
Feeder Length (M)
Material handled
Bulk density (T/m3)
Design ambient temperature
(0C)
Moisture content of coal (%)
Hours of operation per day
Belt
Belt width
Belt Speed (m/min) approx
Type of fabric
Cover thickness (mm/min)
Top/Bottom
Cover grade
Type of loading & Discharging
Idlers
Carrying idlers
Type

Specification
Crusher house
Breaker house
600
750
750
750
2 (Unidirectional)
2(reveesible)
M/S McNally Bharat engineering Co. Ltd.
6.0
11.0
100 mm crushed coal 20 mm crushed coal
0.8
50
20 (max)
24
1200 mm
24.0
Nylon
9/2
Fire resistant
Through chutes

152.4 mm dia rubber disc single roll, impact

type

12.1.2
12.1.3

Configuration
Spacing

12.1.4

Disc material

12.1.5

Type of fixing arrangements

for discs

12.1.6

Lubrication & seal

12.2
12.2.1
12.2.2
12.3
12.4
12.5
12.6
13.0
13.1
13.2
13.3

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

13.4
13.5
13.6
13.7

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

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

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

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

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

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

Flexible pin-bush type

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

Inside head end chutes

Rubber edge V- type
Near tail pulley

1 no. at each conveyor

2 pair at suitable location of feeder per feeder

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

Cooling water temp- Engine inlet

Engine outlet
Lub oil pressure
Lowest under load
Rated engine speed
At idling speed
Suction Height
7.9.13
Type
Voltage
Output

ELECTRIACL STARTER
TF-24 V1595 Bosch
24 V
1000 watts

7.9.14

DOZER (D155A-1)

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

Total
Make

6 Nos.
BEMLD155A-1

No.
Model

2
KOMATSU S6D 155-4D
Diesel Engine
2000
320 HP
144 KgM
24 V, 11 KW
5780 Kg
1000 mm

Rated RPM
Rated Horse Power
Maximum torque ( at about 1400 rpm)
Start system- starting motor
Equipment weight
Maximum tilt
7.9.15
CUMMINS DIESEL ENGINE
No.
No. of cylinder
Bore stroke (mm)
Displacement CID/Lit
Maximum HP
Rim
Peak torque (Ft-Lb)
7.10
7.10.1

KT(A)1150
4
6
159 x 159
1150/18.9
525
2100
1550

FUEL OIL SYSTEM

FUEL OIL UNLOADING SYSTEM

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

7.10.2

STORAGE FACILITIES

Three light oil storage tanks of 2,000 m3 capacity each have been installed at the
back of the fuel oil pump house. Each tank is provided with immersion type steam heater
to keep the oil temp. at around 500 C in case of HFO unloading.
SPECIFICATION OF EQUIPMENT
7.10.3

FUEL (L.D.O.) TRANSFER PUMPS

No. of pumps available

Type of model no.
Liquid to be pumped
Capacity m3/hr
Suction pressure MWC
Discharge pressure MWC
Total Dynamic head MWC
Efficiency
Pump speed
Maximum Temp. Of liquid to
be pumped
Setting pressure in kg/cm2

3
Rotary Gear
L.D.O.
120
5
80
85
45.50%
975 rpm
600 C
9

MOTORS
Type/Make
RPM
Voltage
H.P.
Temp. rise over an ambient temp. of
450 C

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

FILTERS
No. Of coarse filters
Type/Manufacturer
Design Pressure
Maximum pressure drop at 75 %
Cleanliness
7.10.4

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

FUEL (LDO) PRESSURE PUMP

No. off
Type
Discharge pressure

4
Multi screw positive
displacement
25 kg/cm2

Capacity

250 lit/min.

MOTOR
Manufacturer
Type
Rating
7.10.5

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

No. off
Make
Capacity

1
AROTA
40 m3/hr

MOTOR
Type
Rating
7.10.6

3ph. Induction motor.

18.5KW, 1500 rpm
LIGHT OIL (HSD) PRESSURE PUMP (STAGE II &III)

No. off
Model No.
Capacity
Pressure

2
PDE-45-4 GR-22 AU2
250 Lit/min at 2 CST
25 Kg/cm2

MOTOR
Type
Rating
7.10.7

3ph. Induction motor.

18.5KW, 1500 rpm
FUEL OIL (LDO) PRESSURE PUMP (UNIT #4)

No. off
Type
Make
Model No.
Capacity
Discharge pressure

2
Multi screw positive
displacement , Horizontal
TUSHACO
PDHU-5-4
250 lit/min.
25 kg/cm2

MOTOR
Manufacturer
Type
Rating

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

7.10.8

FUEL OIL (LDO) PRESSURE PUMP (UNIT #5)

No. off
Type
Make
Model No.
Capacity
Discharge pressure

2
Multi screw positive
Displacement, Vertical
TUSHACO
PDH-60-SDEF
250 lit/min.
25 kg/cm2

MOTOR
Manufacturer
Type
Rating
7.10.9

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

LIGHT OIL CHARACTERISTICS

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

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