TG PG Test PDF

BHEL/ POWER SECTOR-EASTERN REGION(HQ)/TECHNICAL SERVICES
ट�जी और सहायक पॉवर उपभोग हे तु �नष्पाद गारं ट� पर��ण प्र�क

(संशोधन-00)
PERFORMANCE GUARANTEE TEST PROCEDURE

FOR TG CYCLE & AUXILIARY POWER CONSUMPTION
(REV-00)
प�रयोजना नाम: �संगरे नी को�लयर�ज ट� पी एस।
भारत हे वी इलेिक्ट्र �ल�मटे ड प�रयोजना स्था: बी एच ई एल साइट कायार्ल

(भारत सरकार का उपक्) (2X600 मेगावाट), �संगरे नी ट�पीपी, पगडपललट (गांव),
पावर सेक्ट:पूव� �ेत:: कोलकाता जयपुर (मंडल) िजला: अ�दलाबाद, आंध प्रद-504216.
Project name: SINGARENI COLLIERIES TPS

Bharat Heavy Electricals Limited
(A GOVERNMENT OF INDIA UNDERTAKING) Project location: BHEL SITE OFFICE (2X600 MW),
Power Sector: Eastern Region: Kolkata SINGARENI TPP, PEGADAPALLI (VILLAGE), JAIPUR
(MONDAL) DIST. ADILABAD, ANDHRA PRADESH-
504216.
भारत हे वीइलेिक्ट्रकल्स�ल�
पावर सेक्ट:पूव� �ेत, कोलकाता,प्लॉटसंड़ीज- 9/1, सेक्ट-II,
Signature Not Rकरुणामय,
Digitally signed
by PVerified
SEN
सॉल्टलेकसीट,कोलकाता-700 091.रिजकायार ्लयःबीएचईए, �सर�फोटर13:45:26
, नयी�दल्ल-
Date: 2016.08.10
़ IST -110 049
Reason: CAT II
Location:
Bharat Heavy Electricals LimitedNTPCEOC
POWER SECTOR-EASTERN REGION (HQ), DJ-9/1, SECTOR-II KARUNAMAYEE
SALT LAKE CITY, KOLKATA-700091,PHONE: 033 2321 1958.Registered Office: BHEL
House, Siri Fort, New Delhi - 110 049.
STG PG TEST PROCEDURE FOR MAITHON POWER LIMITED 2X525MW MAITHON RIGHT BANK TPP Page 1/41
Comments on the document is attached
please.

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS
INDEX

TITLE
TITLE PAGE NO
NO.

1.0 OBJECTIVE 4
2.0 TEST CODE 6
3.0 TEST SCHEMATIC 6
4.0 SELECTION OF MEASURING INSTRUMENTS 6
5.0 ADVANCE PLANNING FOR THE TEST 7
6.0 PREPARING THE TG CYCLE FOR THE TEST 7‐8
7.0 PRETEST SHUT DOWN ACTIVITIES BY BHEL 8
8.0. INSTALLATION OF TEST INSTRUMENTS 8‐9
9.0 GENERAL GUIDELINES 9‐10
10.0 INSTRUMENTS CALIBRATION AND CORRECTION 10
11.0 ITEMS ESSENTIAL FOR AGREEMENT 10
12.0 NUMBER OF TEST RUNS 10
13.0 FREQUENCY OF OBSERVATION 10
14.0 RECORDING OF READINGS 11
15.0 DURATION OF TESTS 11
16.0 ACTIVITIES BEFORE OFFICIAL TEST 11
17.0 POST TEST ACTIVITIES 12
18.0 AGEING 12
19.0 ANNEXURE ( 1 TO 25 ) 13‐129
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1.0 OBJECTIVE

 To carry out the performance guarantee tests in line with the contract document
 To prove “HEAT RATE” and output of the turbine cycle
 To prove guaranteed Auxiliary power consumption and other contractual guarantees related to Turbine and
its auxiliaries.
2.0 GUARANTEED PARAMETERS UNDER LIQUIDATED DAMAGES (Category‐I)

Sr. no. Guaranteed Parameters Guaranteed figures
(i) Turbine cycle Heat Rate in Kcal/Kwhr under rated steam conditions at 1927.1 Kcal/Kwhr

design condenser pressure with zero make up at 600 MW unit load.
(HBD. NO. PE‐DC‐381‐100‐N151)
(ii) Turbine cycle Heat Rate in Kcal/Kwhr under rated steam conditions at 1975.7 Kcal/Kwhr
design condenser pressure with zero make up at 480 MW unit load.
(HBD. NO. PE‐DC‐381‐100‐N152)
(iii) Continuous TG output of 600 MW under rated steam conditions at 600MW
worst condenser pressure with 3% make up.
(HBD. NO. PE‐DC‐381‐100‐N161)
(iv) Condenser pressure in mm Hg(abs) measured at300mm above the top 77mmHg(abs)
row of condenser tubes under VWO condition, 3% make up, design CW Refer to annexure‐21
temperature and CW flow.
(v) CW pumping power in KW for design CW flow and the pressure drop in 1037 KW (per unit
CW side by measure bunker for terminal points. (Power consumption basis)
shall be computed based on overall efficiency of 83.1 of CW pump and Refer to annexure‐22
drive set.
(vi) The total unit auxiliary power consumption for all the Turbine 19,659 (Per unit) KW
Generator Auxiliaries, steam generator auxiliaries, ESP and turbine
cycle and other common auxiliaries required for continuous unit Refer to annexure‐18
operation at 100% TMCR (600MW unit load) under rated steam
conditions at worst condenser pressure with 3% make‐up and with
ambient air temperature of 270C and RH of 60% shall be guaranteed.
(vii) The total unit auxiliary power consumption for all the Turbine 15,301 (Per Unit) KW
Generator Auxiliaries, steam generator auxiliaries, ESP and turbine
cycle equipment and other common auxiliaries required for continuous Refer to annexure‐18
unit operation at 80 % TMCR(480MW unit load) under rated steam
conditions at worst condenser pressure with 3% make‐up and with
ambient air temperature of 270C and RH of 60% shall be guaranteed.

2.1 Demonstration parameters / capabilities for Turbine Generator
Sr. no. TURBINE GENERATOR SET CAPABILITY Value/Remarks
(i) The steam turbine generator unit shall be capable of delivering the As per HBD No. PE‐DC‐
output at generator terminals corresponding to VWO condition under 381‐100‐N167
rated conditions at design condenser pressure 0% make‐up.
(ii) The steam turbine generator unit shall be capable of maximum 600 MW
continuous output at generator terminals corresponding to all HP HBD no. PE‐DC‐381‐100‐
heaters out of operation, under rated steam conditions at a design N170
condenser pressure and 3% make up. Refer to annexure‐16

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2.2 Demonstration parameters / Turbine Auxiliaries –
Sr. STEAM CONDENSING PLANT Remarks

no.
1. Life of sponge rubber balls and number of balls lost during 1000hrs of plant Refer to annexure‐23
operation shall be as indicated: Life of sponge ball = 3 Weeks. Balls lost during
1000 Hrs of plant operation less than or equal to 10%
Sr. FEED WATER HEATERS & DEAERATORS Remarks
no.
1. The Dissolved Oxygen content in feed water at De‐aerator effluent at De‐aerator Refer to annexure‐19
outlet without chemical dosing at all loads shall not exceed 0.005cc/litre.
2. Difference between the saturation temperature of the steam entering the De‐ Refer to annexure‐20
aerator and temperature of the feed water leaving De‐aerator.
Sr. Condensate extraction pumps Remarks
no.
1. Each CEP set shall be capable of delivering flow & total dynamic head Refer to annexure‐24
corresponding to run out point as specified.
2. The vibration, noise level and parallel operation of any two of three pumps shall
be demonstrated.
Sr. Boiler feed pumps Remarks
no.
1. Each BFP set shall be capable of delivery flow and total dynamic head Refer to annexure‐25
corresponding to run out point.
2. The vibration level and parallel operation of any two of the three pumps shall be
demonstrated‐ Noise level‐85 db (With acoustic enclosure)
3. Cold/Hot start ups of the unit using TDBFP with motive steam from auxiliary steam
header.
Sr. Noise Remarks
no.
1.
Noise level measurement shall be carried out using applicable and internationally

acceptable standards. The measurement shall be carried out with a calibrated

integrating Sound level meter meeting the requirement of IEC 651 or BS:5969 or

IS:9779. The steam turbine generator unit shall perform continuously without

exceeding the level of noise 90 db (A) for TG set and 85 db (A) for auxiliaries over

the entire range of output and operating frequency. During HPLP bypass
‐‐
operation, sound level may go to 110 db (A)for short duration.
Sound pressure shall be measured all around the equipment at a distance of 1.0m
horizontally from the nearest Surface of the machine and at a height of 1.5m from
the floor level in elevation.
A minimum of 6 points around each equipment shall be covered for
Measurement. Additional measurement Points shall be considered based on the
Applicable standards and the size of the equipment. The measurement shall be
done with slow response on the A‐weighting scale. The average of A‐weighted
sound pressure level measurements expressed in decibels to a Reference of
0.0002 microbars shall not exceed the guaranteed value. Corrections for
background noise shall be considered in line with the Applicable standards. All the
necessary Data for determining these corrections, In line with the applicable
standards, shall be collected during the tests.

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2.0 TEST CODE
Performance guarantee Test for heat rate & output will be carried out in line with contract test code ASME‐PTC‐6.
3.0 TEST SCHEMATIC
The approved test scheme titled “PERFORMANCE GUARANTEE TEST INSTRUMENTATAION SCHEME” of Drawing no.
PG‐DG‐381‐100‐N121 shall be used. Refer Annexure‐11

4.0 SELECTION OF MEASURING INSTRUMENTS
The instruments meeting accuracy/uncertainty requirements, as specified in ASME‐PTC‐6shall be selected and shall
be as per the TG PG test instrumentation schematic drawing no PE‐DG‐381‐100‐N121 Rev04.The brief detail of
instruments to be used during the PG test is provided in the following table. Refer Annexure‐11 for TG‐PG test
instrumentation list.
Sl Parameter Range Instruments Accuracy/Uncertain

No ty
1 Mass flow ‐‐ Nozzle/orifice As per Performance
supplied byBHEL test code
2 Differential pressure across the Various ranges upto DP Transmitter Accuracy +/‐ 0.05 %

flow orifice/ nozzle. 0‐2.5 Kg/cm2 or better.
3 Pressure various ranges up to Pressure Accuracy +/‐ 0.1 %
0‐250 kg/cm2 transmitters
4 Temperature 0‐350 0 C Platinum resistance Uncertainty ±0.55 0C
thermometer
5 Temperature 0‐650 0 C K type Uncertainty ±0.55 0C

thermocouple
6 Generator power ‐‐ Digital power Uncertainty +/‐ 0.1 %
Analyser
7 Auxiliary power measurement 0‐1A Power transducer Uncertainty +/‐ 0.1 %
0‐125V
0‐190.5W
8 LT drives power consumption 0‐440 Volt Digital‐Multimeter Accuracy 1%
(voltage), Clamp‐on
measurement 0‐400 A
meter(Amp) & Power
factor meter (pf)/three
phase power tong
tester.
8 Secondary measurement for ‐‐ Data logger Accuracy +/‐ 0.03 %
Voltage (PT, DPT, TC & Power
Transducer), Resistance (RTD).
9 Atmospheric pressure 0‐780mmHG Barometer or abs Accuracy +/‐ 0.1 % or

pressure better
transmitter
10 Ambient temp. 0‐350degC RTD connected to Uncertainty ±0.55 0C
data‐logger

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5.0 ADVANCE PLANNING FOR THE TEST

During the commissioning/erection period of the unit every effort shall be made to ensure the provision of all
test‐tapping points as per test scheme.
Any missing tapping points or practical difficulty to make availability of tapping points and point of measurement
due to unavoidable reasons will be mutually discussed between BHEL and Customer at site and agreed upon prior
to start of final test . Effort had been made to keep PG test tapings points separate from the normal operational
measurement points, however in case of practical difficulties and extreme emergency, things will be discussed
with customer and agreed upon for taking measurement through existing operational points at the time of test.
5.1 All tapping points will be checked by BHEL during commissioning stage that no pipeline or installation etc.
interferes with approach to the tapping points as far as possible. The temperature elements are of 300‐400 mm
length and enough space should be made available, so that the test temperature elements can be inserted
without any difficulty. In case of any obstruction, an alternate/operational test stub is to be used as far as possible.
5.2 Welded type thermo‐wells shall be used by BHEL for all critical lines (High temperature / pressure). These thermo‐
wells will remain permanently installed on the pipelines. Screwed type thermo‐wells (Low pressure / temperature)
shall be used for temperature measurement and may be installed in the unit just prior to the test. For these
thermo‐wells, matching stub with suitable plug will be provided in the erection stage itself.
5.3 All pressure tapping are supplied with single or double root valves depending upon the pressure rating of the
pipelines. In case some of the pressure tapings are found not available, the same will be provided or alternatively.
Either a 'T‐off shall be taken from the process tapping point or process point itself shall be used after mutual
agreement. Impulse pipe of suitable size and strength shall be laid during pre‐test preparation stage. The pressure
lines will be rigid enough to withstand any type of vibrations.
5.4 Test CTs and PTs of 0.2 accuracy class are to be provided by the BUS duct supplier. The installation and/or test
data for ratio and phase angle errors at different VA burdens and power factors shall be provided by the Customer
for accurate power calculations. Additionally, test certificates giving the above information as submitted by the
Generator bus duct supplier shall also be arranged for BHEL use.
5.5 CT terminals should be provided with termination arrangement for shorting/opening links. Effects of connecting
leads shall be neutralised in power calculations by measuring voltage drop across Pt terminals in bus duct and
measuring point.
6.0 PREPARING THE TG CYCLE FOR THE TEST
Efforts are to be made by BHEL to ensure that all the TG systems /equipment are brought into service at the time
of trial operation. The unit readiness for conducting the PG test is to be ensured as per the checklist given below.
6.1 Ensure that all the heaters are in normal operation and drips of these heaters are cascading properly as per the
cycle. It is to be checked that there is no bypassing of the drips either to condenser or to de‐aerator and this is to
be ensured for sufficient time before actual commencement of the test.
6.3 Check that there should not be any tube leakage in the heaters.
6.3 If required, ensure the cleanliness of condenser tubes and get the same cleaned, if called for, during the shutdown
prior to the test.
6.4 Ensure that pressures of main steam, CRH, HRH and extractions to various heaters and condenser back pressure for
full load are near to their expected values. Ensure that all test flow elements are available at site with all their
matching flanges and fasteners.

6.5 Ensure that the pressure drop of cooling water across the inlet and outlet of the condenser is within design figure
and there is no tube leakage in condenser. Conductivity and oxygen content at condenser hot‐well should also be
within the prescribed limit.

6.6 Ensure that requisite tapings are available in flow element to be used for condensate flow measurement.

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6.7 Ensure the cleanliness of the E.S.V strainers. In case of the excessive pressure drop across it, the same shall be
cleaned.

6.8 System tightness check to be carried out during commissioning of the machine i.e. de‐aerator level drop
test may be done for around two hours by keeping the interconnection with other units (if any) on
steam and feed side isolated and also by closing the make‐up inlet and by keeping the CBD, EBD isolated.
The de‐aerator level is to be raised to the maximum permissible before this exercise. Fall in de‐aerator
level i.e. system losses are then to be observed. The problem, if any, is to be identified and rectified and
the efforts shall be made to bring down the system leakages to minimum. (Ref drawing/ calculation
procedure for de‐aerator level drop, which is enclosed).
When the system is properly isolated for a performance test, the unaccounted leakage shall not exceed
0.1% of design throttle flow at full load. To achieve the above value of unaccounted leakages, BHEL shall
prepare the unit during pre‐test available shutdown. However, during the test, if it is found that the
unaccounted leakage is more than 0.1% of design throttle flow at that load, the heat rate will be
increased by an amount equal to half the difference between actual unaccounted for leakage expressed
as percentage of design throttle flow at that load and 0.1% (allowed by the code). However, if the
unaccounted leakage during the test shall be more than 0.5% of design throttle flow at that load and
appreciable leakage is visible in boiler area, mutual agreement shall be made regarding consideration of
excess leakage in the calculation of test result.

6.9 Ensure the proper tightness of the valves for passing etc.

6.10 Ensure the best availability of all test tapings points as per test scheme.

7.0 PRE‐TEST SHUTDOWN ACTIVITIES BY BHEL
After the unit is ensured ready for the test, a suitable shutdown shall have to be agreed between BHEL and
Customer. BHEL shall supply the calibrated test instruments prior to the start of the shutdown. Major activities to
be carried out during this shut down shall be as follows.
7.1 Mounting/Installing screwed type thermo‐wells, provision for 'T'‐offs, laying‐out of impulse pipelines etc.
7.2 Providing any additional test tapping points if found necessary/applicable.
7.3 Necessary arrangement/rectifications for meeting the system isolation i.e required defective/passing valves
identified during the joint inspection to be attended.
7.4 Mounting of temperature elements in identified hot areas and laying‐out their cables.
7.5 Laying‐out impulse pipeline (if not already laid) from the root valves in hot zones and terminating with pressure
transmitter isolating valves. Their root valves to be kept open.
7.6 If required, Condenser tube cleaning and condenser air tightness checks to be carried out and any leakages to be
got attended.
8.0 INSTALLATION OF TEST INSTRUMENTS
8.1 Flow measuring devices
The flow assembly with matching flanges is supplied during commissioning stage. Flow measuring devices is to be
mounted by replacing the spool piece provided in condensate line preferably during the planned shutdown for PG
test so that these are used for minimum duration prior to the test. However the actual mounting may vary from
site to site as per availability of material. The actual drawing with calibration certificate will be furnished before
PG test. A typical installation sketch for DP transmitters for measuring assemblies is enclosed. Installation sketch
of flow assembly as per requirement shall be arranged by BHEL prior to pre‐test shutdown. It is preferable to
check the impulse pipeline connections after installation for any leakage/chocking etc. by pressurizing the system
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by running condensate pump to the extent possible during the unit shutdown itself. Problem noticed if any has to
be attended during the shutdown itself.
8.2 Temperature measuring instruments
K‐Type Thermocouple and platinum resistance thermometer elements will be used for temperature
measurements. After connecting extension leads (Chromel‐Alumal compensating cable for TCs and copper cable
for PRTs), these elements shall be mounted into thermo‐wells as per instrument allocation list and PG test
scheme. The connection to measuring instruments to be made as per the sketch enclosed. Thermocouple wire is
to be connected such that Chromel portion of the extension lead is connected to Chromel part and Alumel
portion to Alumel part of the sensor. To identify this, a positive sign has been marked on each Chromel terminal.
The reference junction temperature for thermocouples will be maintained at zero degree by using ice box or
through electronic zero degree reference junction compensator. The mV output from the thermocouples and
Ohms output from PRTs shall be measured with precision data logger.
8.3 Pressure measuring instruments
Impulse pipelines (of appropriate length) with isolation valves are to be laid for mounting the pressure
transmitters. Impulse pipeline for the vacuum (negative pressure) measurement points should be laid such that
transmitter is mounted above the tapping point. Thus these lines should be laid with upward slope. All the
impulse lines should be rigid enough to avoid any vibration in the instrument. For water height correction, the
vertical distance from the centre of the transmitter to the tapping points is to be measured for each tag number
and joint protocol by BHEL and Customer to be signed prior to test. The vertical distance above the tapping point
is to be taken as positive whereas same below the tapping is to be taken as negative for pressure correction. The
impulse pipelines are to be purged/ flushed sufficiently and steam to be allowed to condense before mounting
the transmitters. A transmitter will be charged only before use otherwise it should be kept isolated to avoid
exposure to vacuum in case the unit trips.
8.4 Power measuring Instruments
CTs and PTs for PG test use should be identified well in advance and locations of their terminals in panels checked
for the connection of the power meters referring the generator schematic drawings. The lead resistance voltage
drop in the circuit of PTs shall be measured if required along with customer and protocol for the same to be
made during the PG test. The digital power meter will be connected to the identified CTs and PTs terminals
preferably in three‐phase four‐wire mode.
8.5 Level measurement
Level measurement in 5 minutes of interval are to be recorded for all the storage tanks by means of digital
recording system (MAX /DAS panel) available at site with metric scales. A sample data sheet for readings to be
recorded is enclosed herewith.
8.6 Secondary measurement by data acquisition system
Data acquisition system is based on a digital processor. It is interfaced with computer that utilizes software to
activate the logger to view and analyse the collected data. Data acquisition system consists of many components
that are integrated to sense electrical parameter sent by the transducers (RTD, TC, Pressure transmitter & Power
transducer) mounted in the field.

9.0 GENERAL GUIDELINES
9.1 All electrical instruments should be placed away from any magnetic field. Their proper levelling should also be
ensured.
9.2 The tips of thermocouples and PRTs should always touch the bottom of the thermo wells. If felt necessary, the
adjustable mounting coupling can be removed and in that case the element should be properly pressed downward
and tied with a piece of wire. Stub projections and sensor stems, which are protruding out of thermo‐well, should
be covered with asbestos rope providing thermal insulation.
9.3 All the instruments should be stored in clean dry place nearer to unit under test preferably at turbine floor level.
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9.4 At least two tags (including Tag No./service etc.) should be provided each at the instrument end near tapping points
and Data‐logger end.
9.5 All the pressure transmitters should be mounted in vertical position.
9.6 Depending upon the likelihood of completion of the above activities, date of conductance of final test will be
jointly agreed with the customer under mutually agreed deviations, if any.

10.0 INSTRUMENTS CALIBRATION AND CORRECTION
10.1 All the test instruments and other applicable instruments shall be duly calibrated at NABL accredited BICC (BHEL
Instruments Calibration Centre) at Noida or any other NABL accredited lab. Calibration of Pressure transmitters,
RTD, TC sensors may also be carried out at site/HQ by BHEL engineer/NABL agency before conductance of the test
in presence of customer representative (if felt necessary). In general the validity of calibration for all PG Test
sensors (RTD, TC, PT, Transducer & Power meter) will be of two years from the date of calibration.
10.2 All Copy of valid calibration certificate (on the day of installation) will be handed over to customer suitably before
the start of test.
10.3 Pressure transmitters' readings shall be additionally corrected for water column height corrections by measuring
the difference in levels between centre of the transmitter and the corresponding tapping point‐(Height correction).
Note: Calibration validity for all the PG test instruments will be ensured on the day of installation for conductance of TG
cycle PG test.
11.0 ITEMS ESSENTIAL FOR AGREEMENT
11.1 Nomination of test coordinating Engineer from customer side.
11.2 All the test instruments shall be transported to site as per the proposed date.
11.3 Means for obtaining steady operating parameters at their specified values.
11.4 Provision of a separate room of adequate size on the turbine floor for storing the test instruments and materials
for use during the test under lock and key shall be in the scope of the customer.
11.5 Deployment of round the clock proper security personnel from the time of installation of sensors till removal of all
equipment/sensors, if not in the scope of BHEL.
11.6 Provision of illumination by Customer at all measuring junctions and working places.
11.7 Provision of T&P by Customer like UPS power supply of 15 Ampere to at‐least five locations under TG area for Data‐
loggers station, Compressed air etc.
12.0 NUMBER OF TEST RUNS

In addition to trial run and Preliminary test, Duplicate heat rate tests will be performed at 600MW and 480 MW unit
loads to prove the heat rate. The test result of the duplicate test runs shall agree within +/‐ 0.25%. If they differ more
than 0.25%, a third test shall be run at the same test points. Corrected results of any one of the three tests runs, which
deviate from the corrected average heat rate of all the three by more than 0.25%, shall be eliminated. Otherwise, the
results of all the three test runs shall be acceptable.

Further one test shall be carried out to prove unit output and condenser back pressure/CW pumping power at VWO
condition as stipulated under category‐1 and demonstration tests category.

13.0 FREQUENCY OF OBSERVATION

It will be carried out meeting the requirements of clause no. 3.9.1, ASME PTC‐6 which is as follows:

For Heat rate tests and Output Tests, the readings for pressures, flows, temperatures and Generator Power shall be
recorded in the data‐logger at an interval of minimum 30 seconds. In case, Digital power meter for measurement of
Generator Power not hooked up with Data‐logger, measurement shall be recorded with the help of manual reading of the
Digital Power meter at an interval of one minute. Other parameters at the interval of 5 minutes shall be taken either from
DCS or by manual recording.
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14.0 RECORDING OF READINGS

14.1 Data logger will be used to record the test readings at an interval of minimum 30 seconds in raw values for the
following:

Sl. Parameter Unit
No.
1 Pressure /DP transmitter output Volt
2 PRT output Ohms
3 TC output mV
4 Power transducer output Volt
5 Power meter output Watt
14.2 Recording will be done for every 5 Minute during the test through MAX/DAS system or manually for the following
data
A De‐aerator level mm
B Hot‐well level mm
C CST Level mm
D Boiler drum level mm
E Generator Hydrogen Pressure ata
F Frequency Hz

15.0 DURATION OF TESTS

As per ASME PTC‐6, Tests shall be normally carried out at a steady state run of two our duration. However,
duration will be mutually decided depending upon the conditions prevailing during conductance of PG tests.Any
deviations of parameters from the rated conditions shall be corrected with the help of correction curves. The
applicable correction curves as per the “Method of Computation of Heat Rate” for heat rate correction & Output
correction are enclosed as per annexure‐14.

16.0 ACTIVITIES BEFORE OFFICIAL TEST
16.1 The completion of test preparation, mounting of instruments, isolation of thermal cycle and briefing of the local
observers.
16.2 The load is brought to rated capacity with rated parameters for taking a set of trial readings of all instruments.
16.3 The readings of the mock test to be analysed for their correctness, if they are correct, final test can be started.
16.4 The following operations shall not take place during the test, for which the isolation is carried out.
 Continuous Blow Down
 Dusting of the Associated Boiler Unit
 Steam Supply to Fuel atomisation, if any
 Fuel Heating and SCAPH, if any
 Soot blowing
 Water and steam sampling
 Any other flow from the system which affects the Heat Rate

16.5 The system is isolated so that no unaccounted steam goes out or comes into cycle. The makeup quantity shall be
measured / estimated by noting down the level drop in de‐aerator/hot‐well and also taking into consideration the
various storage tanks' levels at periodic intervals of the test.

16.6 Any other unaccounted losses like high gland leakage from CEP, if exists, shall be measured/estimated for their
quantity.

16.7 Sensitivity of the condenser hot well level control shall be reduced or preferably the level controlled be on manual
mode to avoid excessive fluctuation in the condensate flow to de‐aerator.
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16.8 PRDS control valve spindle cooling water, atmospheric valve gland sealing water flow shall be adjusted for
minimum flow.

16.9 Proper sealing water supply to vacuum system especially to atmospheric valve seals shall be ensured.

16.10 All means shall be put to maintain the parameters constant through out the test.
17.0 POST TEST ACTIVITIES

17.1 All the test readings of average value shall be jointly signed & one copy will be handed over to
site/customer/consultant after completion of all tests. One set of average readings signed by customer shall be
retained by BHEL for calculation of test results and submission of test reports.

17.2 A shut down of the unit is to be arranged for a minimum period of 5 days for dismantling of all the test instruments
and flow measuring assemblies, if called for.

18.0 AGEING

Ageing allowance will be given during evaluation of PG test results and hence guaranteed heat rates shall be
increased by the amount calculated as per the formula given in cl. No. 3.07, sub‐sesction‐3 of ASME‐PTC‐6 report
1985 (Reaffirmed 1991). Period of ageing shall be considered from the date of successful completion of initial
operation to the date of conductance of PG test, irrespective of the reasons for delay in conducting the PG test
attributable to employer or contractor.
In calculating the above factor any period(s) during which the turbine has not been in operation at a stretch for
more than a week shall not be considered.

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19.0 Annexure:

 List of Annexure
ANNEX.
TITLE Page no
NO
1 Details of welded type test thermo‐well pocket (with plug) 14
2 Details of screwed type test thermo‐well 15
3 Details of pressure stub 16
4 Diagram for connection between pressure source and transmitter 17
5 Diagram for connection between vacuum source and transmitter 18
Diagram for connection between flow orifice to differential
6 19
pressure transmitter
7 Temperature measurement lay out scheme for RTD 20
8 Temperature measurement lay out scheme for T/C 21
9 Pressure measurement lay out scheme for PT 22
Typical connections for measuring Electrical power output by the
10 three wattmeter method 23
11 PG test instrumentation scheme & list 24‐33

12 Computation procedure for De‐aerator level drop 34
13 Computation procedure for hot well level drop 35
14 Method for computation of heat rate 36‐47
15 Correction curves 48‐70
16 Heat balance diagram 71‐76
17 System check list 77
18 Auxiliary power consumption test procedure 78‐80
19 DISSOLVED OXYGEN CONTENT AT DEAERATOR OUTLE 81

DIFFERENCE BETWEEN THE SATURATION TEMPERATURE OF THE
20 STEAM ENTERING THE DE‐AERATOR AND 82
THE TEMPERARTURE OF THE FEED WATER LEAVING DE AERATO
21 Condenser Back Pressure test procedure 83‐99
22 TEST PROCEDURE FOR CW PUMPING POWER 100‐105
TEST PROCEDURE FOR CONDENSER ON LOAD TUBE CLEANING
23 106‐110
SYSTEM
24 PG TEST PROCEDURE FOR CONDENSATE EXTRACTION PUMP 111‐118
25 PG TEST PROCEDURE FOR BOILER FEED PUMP 119‐129
13 of 129

ANNEXURE –1

 Details of welded type test thermo‐well pocket (with plug):

1. M‐type of stub and thermowell to be used for main steam, CRH,HRH, bled steam (To HPH‐5 & DEA)
feed water lines, HPH drains, HPT rear (1st leak off) HPT front (2nd leak off), IPT front (1st leak off).
2. N‐type of stub to be used on condensate, cooling water and law pressure/temp steam pipe lines
(Bled steam to LPHs, Ejectors, GSC, LPH drain lines, IP rear leak off, mixture of leak offs to EXT‐4,
cross over pipe lines, exhaust hood, BFP suction line, sealing steam to glands. )
3. M‐type of stub to be provided with welded thermowell .
4. ‘X’ to be fixed based on pipe wall thickness.
14 of 129

ANNEXURE – 2

 Details of screwed type test thermo‐well:

PIPE DIA ‘U’
100‐180 120
180‐260 160
260‐360 200
360‐500 250
Above 500 320
Working Pressure 180 Kg/cm2
Working 550 Deg C
Temperature
Test Pressure 360 Kg/cm2

Note:
1. All dimensions are in MM.
2. Material AISI 316 SS.
3. ‘U’ to be decided based on Pipe Diameter.
4. To be I.B.R. Approved.
5. Each thermowell to be provided with 2MM TH. Annealed copper washer &
M20X1.5 Carbon steel Bolt.
15 of 129

ANNEX
XURE – 3
3

 Deetails of prressure stub:

Note:

1. This stub is to
o be used for a
all the pressu re test tappin
ng coming und
der performannce test schem
me.
2. For pressure above 40ata, two root valvve to be used.
3. For pressure below 40ata, one root valvve to be used.
4. Impulse pipe material same or equivalenntas the stub material.

16 of 129

ANNEXURE – 4

 Diagram for connection between pressure source and transmitter:

Note:
I.
II.
Gauge may be above, below or level with pressure tap.
Gauge must not be subjected to vacuum.
III. Shut valve immediately if turbine is tripped out or before shut down.
IV. Impulse/Connecting pipe shall not be less than 3/8 inch (10mm) inside diameter and ½ inch
(13mm) nominal outside diameter or equivalent tubing.
V. For pressure greater than 40kg/cm2 use 3mm wall thick impulse pipe.
VI. For pressure less than 40kg/cm2 use 2.5mm wall thick impulse pipe.
17 of 129

ANNEX
XURE – 5
5

 Diagrram for co
onnection
n between
n vacuum source an
nd transm
mitter:

18 of 129


ANNE
EXURE–6
6

 Diaagram fo
or connecction bettween flo
ow orificce to diffferential pressure
e
traansmitter

ASME P
PTC 6

19 of 129


ANNE
EXURE–7
7

 Temperaturre measurrement layy out sche
eme for RT
TD

20 of 129

ANNEXURE –8
8

 Tem
mperature
e measure
ement lay out schem
me for T/C
C

21 of 129

ANNEXURE –9
9

 Presssure meassurement lay out sccheme forr PT

22 of 129

ANNEXURE 10
0

 Typiccal connecctions for measurin
ng Electriccal power output byy the thre
ee
wattmmeter me ethod

23 of 129


ANN
NEXURE – 11
PG test instru
umenta
ation sch
heme

&

Instrum
mentatiion list ffor 2X60
00MW Singareeni TPS

24 of 129
25 of 129

TG PG test instrumentation list for 2x600MW Singareni TPS
TEMPERATURE MEASUREMENT
*APPROXIMATE

S. No Tag No Service VALUES AT 100%
Inst.
LOAD (In deg c)
1 TW01 SH Spray Comm. Header T/C ‐
2 TW02 SH Spray Comm. Header T/C ‐
3 TW03 HPT inlet bef. Strainer (L) T/C 537
4 TW04 HPT inlet bef. Strainer (L) T/C 537
5 TW05 HPT inlet bef. Strainer (R) T/C 537
6 TW06 HPT inlet bef. Strainer (R) T/C 537
7 TW07 Extraction 7 to HPH 7 (TE) T/C 391.3
9 TW09 Extraction 7 to HPH 7A (HE) T/C 389.1
11 TW11 Extraction 7 to HPH 7B (HE) T/C 389.1
13 TW13 HPT Exhaust steam PRT 332.7
14 TW14 HPT Exhaust steam PRT 332.7
15 TW15 CRH steam after HPBP PRT 332.7
16 TW16 CRH steam after HPBP PRT 332.7
17 TW17 CRH Before spray (L) PRT 332.7
18 TW18 CRH Before spray (R) PRT 332.7
19 TW19 Downstream of HPBP T/C ‐
20 TW20 Downstream of HPBP T/C ‐
21 TW21 Extraction 6 to HPH 6A (HE) PRT 330.6
22 TW22 Extraction 6 to HPH 6A (HE) PRT 330.6
23 TW23 Extraction 6 to HPH 6B (HE) PRT 330.6
24 TW24 Extraction 6 to HPH 6B (HE) PRT 330.6
25 TW25 Steam to PRDS hdr. T/C ‐
26 TW26 Steam to PRDS hdr. T/C ‐
27 TW27 HRH bef. Strainer (L) T/C 565.0
28 TW28 HRH bef. Strainer (L) T/C 565.0
29 TW29 HRH bef. Strainer (R) T/C 565.0
30 TW30 HRH bef. Strainer (R) T/C 565.0
32 TW32 Extraction 5 to HPH 5(TE) T/C 463.4
37 TW37 IPT Exhaust steam (L) PRT 328.2
38 TW38 IPT Exhaust steam (L) PRT 328.2
39 TW39 IPT Exhaust steam (R) PRT 328.2
40 TW40 IPT Exhaust steam (R) PRT 328.2
41 TW41 LPT I/L steam common header (R) PRT 328.2
42 TW42 LPT I/L steam common header (R) PRT 328.2
43 TW43 LPT I/L steam common header (L) PRT 328.2
0
* APPROXIMATE VALUES AT 100% LOAD (In C) ARE GIVEN FOR REFERENCE ONLY.
26 of 129

*APPROXIMATE
Sl.
Tag No Service Inst. VALUES AT 100%
No
LOAD (In deg c)
44 TW44 LPT I/L steam common header (L) PRT 328.2
45 TW45 Extrn.4 to Deaerator (TE) PRT 328.2
46 TW46 Extrn.4 to Deaerator (DE) PRT 327.5
47 TW47 Extrn.4 to Deaerator (DE) PRT 327.5
48 TW48 TDBFP‐A steam inlet PRT 327.2
49 TW49 TDBFP‐B steam inlet PRT 327.2
50 TW50 FW BFP A discharge PRT 167.3
51 TW51 FW BFP B discharge PRT 167.3
52 TW52 RH spray comm. Header PRT ‐
53 TW53 RH spray comm. Header PRT ‐
54 TW54 FW inlet to HPH 5A PRT 167.3
55 TW55 FW inlet to HPH 5A PRT 167.3
56 TW56 FW inlet to HPH 5B PRT 167.3
57 TW57 FW inlet to HPH 5B PRT 167.3
58 TW58 FW HPH 5A outlet PRT 207.5
60 TW60 FW HPH 5B outlet PRT 207.5
62 TW62 FW HPH 6A inlet PRT 207.5
64 TW64 FW HPH 6B inlet PRT 207.5
71 TW71 ' FW HPH 7A inlet PRT 250.8
78 TW78 FW before economiser PRT 278.0
79 TW79 FW before economiser PRT 278.0
80 TW80 HPH 7A Drain to HPH 6A PRT 255.6
82 TW82 HPH 7B Drain to HPH 6B PRT 255.6
88 TW88 HPH 5A drain to DEA (HE) PRT 172.2
89 TW89 HPH 5A drain to DEA (HE) PRT 172.2
90 TW90 HPH 5B drain to DEA (HE) PRT 172.2
91 TW91 HPH 5B drain to DEA (HE) PRT 172.2
92 TW92 CRH bef. Mixing to Extraction 4 PRT 332.7
93 TW93 CRH after spray (R) PRT ‐
94 TW94 CRH after spray (R) PRT ‐
95 TW95 CRH after spray (L) PRT ‐
* APPROXIMATE VALUES AT 100% LOAD (In 0C) ARE GIVEN FOR REFERENCE ONLY.
27 of 129

*APPROXIMATE
Sl.
No
LOAD (In deg c)
96 TW96 CRH after spray (L) PRT ‐
97 TW97 TDBFP A exhaust steam to condenser‐A PRT 0.9635
98 TW98 TDBFP B exhaust steam to condenser‐B PRT 0.9635
103 TP01 CEP inlet from condenser‐A hot‐well PRT 46.4
104 TP02 CEP inlet from condenser‐A hot‐well PRT 46.4
105 TP03 CEP inlet from condenser‐B hot‐well PRT 46.4
106 TP04 CEP inlet from condenser‐B hot‐well PRT 46.4
107 TP05 GSC drain to Flash Tank PRT ‐
108 TP06 Main condensate inlet GSC PRT 46.6
109 TP07 Main condensate outlet. GSC PRT 47
110 TP08 Gland steam to GSC PRT ‐
111 TP09 Main condensate inlet DC PRT 47
112 TP10 Main condensate inlet DC PRT 47
113 TP11 Main condensate inlet LPH 1A PRT 49.9
114 TP12 Main condensate outlet LPH 1A PRT 71.6
115 TP13 Main condensate outlet LPH 1B PRT 71.6
116 TP14 Main cond. O/L LPH1A&B common header PRT 71.6
117 TP15 Main condensate inlet LPH 2 PRT 71.6
118 TP16 Main condensate outlet LPH 2 PRT 94.7
122 TP20 Main cond. aft LPH3 aft mixing PRT 123.6
123 TP21 Main cond. to Dea. after flow element PRT 123.6
124 TP22 Main condensate to Dea. After NRV PRT 123.6
125 TP23 Main condensate to Dea. After NRV PRT 123.6
126 TP24 Extraction 3 to LPH 3 (TE) from LPT‐A PRT 209.2
127 TP25 Extraction 3 to LPH 3 (HE) PRT 208.9
129 TP27 Extraction 2 to LPH 2 (TE) PRT 118.6
132 TP30 LPH 3 drain to LPH 2 near LPH3 PRT 99.5
133 TP31 LPH 2 drain to LPH 1A&B near LPH2 PRT 76.4
134 TP32 LPH 1A drain to DC PRT 74.4
135 TP33 LPH 1B drain to DC PRT 74.4
136 TP34 DC drain to CFT PRT 51.8
137 TP35 CW inlet to COND‐A (L) PRT ‐
138 TP36 CW inlet to COND‐A (L) PRT ‐
139 TP37 CW inlet to COND‐A (R) PRT ‐
140 TP38 CW inlet to COND‐A (R) PRT ‐
141 TP39 CW inlet to COND‐B (L) PRT ‐
142 TP40 CW inlet to COND‐B (L) PRT ‐
143 TP41 CW inlet to COND‐B (R) PRT ‐
144 TP42 CW inlet to COND‐B (R) PRT ‐
* APPROXIMATE VALUES AT 100% LOAD (In 0C) ARE GIVEN FOR REFERENCE ONLY.
28 of 129

*APPROXIMATE
Sl.
No
LOAD (In deg c)
145 TP43 CW outletto COND‐A (L) PRT ‐
146 TP44 CW outlet to COND‐A (L) PRT ‐
148 TP46 CW outletto COND‐A (L) PRT ‐
151 TP49 CW outlet to COND‐A (R) PRT ‐
157 TP55 CW outletto COND‐B (L) PRT ‐
158 TP56 CW outlet to COND‐B (L) PRT ‐
160 TP58 CW outletto COND‐B (L) PRT ‐
163 TP61 CW outlet to COND‐B (R) PRT ‐
169 TP67 Vacuum pump Suction L of COND‐A PRT ‐
170 TP68 Vacuum pump Suction R of COND‐A PRT ‐
171 TP69 Vacuum pump Suction L of COND‐B PRT ‐
172 TP70 Vacuum pump Suction R of COND‐B PRT ‐
173 TP71 Vacuum Pump SucCommhdr of COND‐A PRT ‐
174 TP72 Vacuum Pump SucCommhdr of COND‐B PRT ‐
175 TP73 LPBP to COND‐A PRT ‐
176 TP74 LPBP to COND‐B PRT ‐
177 TP75 TDBFP B booster pump suction PRT 163.8
178 TP76 TDBFP B booster pump suction PRT 163.8
179 TP77 TDBFP A booster pump suction PRT 163.8
180 TP78 TDBFP A booster pump suction PRT 163.8
181 TP79 Extraction 3 to LPH 3 (TE) from LPT‐B PRT 209.2
182 TP80 Extraction 2 to LPH 2 (TE) from LPT‐B PRT 118.6
183 TP81 LPH 2 drain to LPH 1A near LPH 1A PRT 76.4
184 TP82 LPH 2 drain to LPH 1B near LPH 1B PRT 76.4
185 TP83 Main condensate inlet LPH 1B PRT 49.9
186 TP84 DC drain to CFT PRT 51.8
189 TP87 LPH 3 drain to LPH 2 near LPH2 PRT 99.5
191 TP89 Main cond. to Dea. after flow element PRT 123.6
* APPROXIMATE VALUES AT 100% LOAD (In deg c) ARE GIVEN FOR REFERENCE ONLY.
29 of 129

TG PG test instrumentation list for 2x600MW Singareni 1X600 MW TPS
PRESSURE MEASUREMENT
* APPROXIMATE
S. No Tag No Service Range (in kg/cm2) VALUES AT 100%
LOAD (in kg/cm2)
1 PD01 MS to HPT bef. Strainer R 0‐250 170
2 PD02 MS to HPT bef. Strainer L 0‐250 170
3 PD03 HPT 1 st stage 0‐250 ‐
4 PD04 Extraction 7 to HPH 7 (TE) 0‐100 65.54
5 PD05 Extraction 7 to HPH 7A (HE) 0‐100 62.59
6 PD06 Extraction 7 to HPH 7B (HE) 0‐100 62.59
7 PD07 HPT Exhaust (TE) 0‐60 43.03
8 PD08 CRH steam 0‐60 43.03
9 PD09 CRH before spray L 0‐60 43.03
10 PD10 CRH before spray R 0‐60 43.03
11 PD11 PRDS steam 0‐60 ‐
14 PD14 HRH to IPT L before strainer 0‐40 38.72
15 PD15 HRH to IPT R before strainer 0‐40 38.72
16 PD16 IPT Inlet L 0‐40 38.72
17 PD17 IPT Inlet R 0‐40 38.72
22 PD22 FW BFP A discharge 0‐250 205.02
23 PD23 FW BFP B discharge 0‐250 205.02
24 PD24 RH Spray common header 0‐250 ‐
25 PD25 SH Spray common header 0‐250 ‐
26 PD26 FW HPH 5A inlet 0‐250 205.02
27 PD27 FW HPH 5B inlet 0‐250 205.02
28 PD28 FW HPH 5A outlet 0‐250 ‐
29 PD29 FW HPH 5B outlet 0‐250 ‐
30 PD30 FW HPH 6A outlet 0‐250 ‐
29 PD31 FW HPH 6B outlet 0‐250 ‐
30 PD32 FW HPH 7A outlet 0‐250 202.02
31 PD33 FW HPH 7B outlet 0‐250 202.02
32 PD34 HPH‐7A drain to HPH‐6A 0‐100 ‐
33 PD35 HPH‐7B drain to HPH‐6B 0‐100 ‐
34 PD36 HPH‐6A drain to HPH‐5A 0‐60 ‐
35 PD37 HPH‐6B drain to HPH‐5B 0‐60 ‐
36 PD38 HPH‐5A drain to Deaerator 0‐25 ‐
37 PD39 HPH‐5B drain to Deaerator 0‐25 ‐

* APPROXIMATE VALUES AT 100% LOAD (In Kg/cm2) ARE GIVEN FOR REFERENCE ONLY.
30 of 129

* APPROXIMATE
Range(in VALUES AT 100%
S. No Tag No Service kg/cm2) LOAD (in kg/cm2)
38 PA01 CW DP L ‐ COND‐A 0‐1 ‐
39 PA02 CW DP R ‐ COND‐A 0‐1 ‐
40 PA03 CW DP L ‐ COND‐B 0‐1 ‐
41 PA04 CW DP R ‐ COND‐B 0‐1 ‐
42 PA05 IPT exhaust L 0‐10 7.7
43 PA06 IPT exhaust R 0‐10 7.7
44 PA07 LPT inlet steam to common header(L) 0‐10 7.7
45 PA08 LPT inlet steam to common header(R) 0‐10 7.7
d (R)
46 PA09 Extraction 3 to LPH 3 (TE) from LPT‐A 0‐4 2.597
47 PA10 Extraction 3 to LPH 3 (HE) 0‐4 2.468
48 PA11 Extrn.4 to deaerator (TE) 0‐10 7.7
49 PA12 Extrn.4 to deaerator (DE) 0‐10 7.08
50 PA13 Extraction 2 to LPH 2 (HE) 0‐780 mmHg 0.944
51 PA14 TDBFP‐A steam inlet 0‐10 6.78
52 PA15 TDBFP‐B steam I/L 0‐10 6.78
53 PA16 Extraction 2 to LPH 2 (TE) from LPT‐A 0‐780 mmHg 0.944
54 PA17 Gland steam to GSC 0‐780 mmHg ‐
55 PA18 Main condensate inlet GSC 0‐25 21.99
56 PA19 Main condensate inlet DC 0‐25 ‐
57 PA20 MC to Deaerator after Flow Element 0‐10 ‐
58 PA21 Deaerator shell pressure 0‐10 ‐
59 PA22 TDBFP B booster pump suction 0‐10 6.93
60 PA23 TDBFP A booster pump suction 0‐10 6.93
61 PA24 TDBFP A exhaust steam to Cond. A 0‐780 mmHg 0.106
62 PA25 TDBFP B exhaust steam to Cond. B 0‐780 mmHg 0.106
63 PA 26 CW I/L pressure (L) Condenser‐A 0‐10 ‐
64 PA27 CW O/L pressure (L) Condenser‐A 0‐10 ‐
65 PA 28 CW I/L pressure (R) Condenser‐A 0‐10 ‐
66 PA29 CW O/L pressure (R) Condenser‐A 0‐10 ‐
67 PA30 CW I/L pressure (L) Condenser‐B 0‐10 ‐
68 PA31 CW O/L pressure (L) Condenser‐B 0‐10 ‐
69 PA32 CW I/L pressure (R) Condenser‐B 0‐10 ‐
70 PA33 CW O/L pressure (R) Condenser‐B 0‐10 ‐
71 PA34 Condenser vacuum L COND‐A 0‐780 mm Hg 0.1047
72 PA35 Condenser vacuum L COND‐A 0‐780 mmHg 0.1047
75 PA38 Condenser vacuum R COND‐A 0‐780 mmHg 0.1047
* APPROXIMATE VALUES AT 100% LOAD (In Kg/cm2) ARE GIVEN FOR REFERENCE ONLY
31 of 129

* APPROXIMATE
Range(in VALUES AT 100%
S. No Tag No Service kg/cm2) LOAD (in kg/cm2)
79 PA42 Condenser vacuum L COND‐B 0‐780 mmHg 0.1047
83 PA46 Condenser vacuum R COND‐B 0‐780 mmHg 0.1047
87 PA50 CEP I/L from Condenser‐A Hot‐well 0‐780 mmHg ‐
88 PA51 CEP I/L from Condenser‐A Hot‐well 0‐780 mmHg ‐
89 PA52 CEP I/L from Condenser‐B Hot‐well 0‐780 mmHg ‐
90 PA53 CEP I/L from Condenser‐B Hot‐well 0‐780 mmHg ‐
91 PA54 LPBP to COND‐A 0‐60 ‐
92 PA55 LPBP to COND‐B 0‐60 ‐
93 PA56 Extraction 3 to LPH 3 (TE) from LPT‐B 0‐4 2.597
94 PA57 Extraction 2 to LPH 2 (TE) from LPT‐B 0‐780 mmHg 0.994
95 PA58 Extraction 1 to LPH 1B 0‐780 mmHg 0.402
96 PA59 Extraction 1 to LPH 1A 0‐780 mmHg 0.402
97 PA60 TDBFP‐A steam inlet 0‐10 6.78
98 PA61 TDBFP‐B steam inlet 0‐10 6.78

* APPROXIMATE VALUES AT 100% LOAD (In Kg/cm2) ARE GIVEN FOR REFERENCE ONLY
32 of 129

FLOW MEASUREMENT
S.No Tag No Service Range(in kg/cm2)
1 FP01A Condensate flow to deaerator 0‐2.5

2 FP01B Condensate flow to deaerator 0‐2.5
3 FP02 Steam flow to TDBFP A 0‐0.5
4 FP03 Steam flow to TDBFP B 0‐0.5
5 FP04 SH Spray L 0‐0.5
6 FP05 SH Spray R 0‐0.5
7 FP06 RH Spray L 0‐0.5
8 FP07 RH Spray R 0‐0.5
9 FP08 Auxiliary steam 0‐0.5
10 FP09 Makeup from DM System to COND‐A 0‐0.5
11 FP10 Makeup from DM System to COND‐B 0‐0.5
Note ‐ FP02 TO FP09: PROCESS NOZZLE WITH PGT INSTRUMENTS.
LEVEL MEASUREMENT
S.No Tag No Service Remarks
1 Lvl1 Deaerator Readings will be taken from DCS
2 Lvl 2 Hot well COND‐A Readings will be taken from DCS
3 Lvl 2 Hot well COND‐B Readings will be taken from DCS
POWER MEASUREMENT
S.No Tag No Service 100% Value in MW
1 PWM POWER MEASUREMENT 600

33 of 129

ANNE
EXURE – 12
CA
ALCULATIION PROCCEDURE FO
OR DEAER
RATOR LEV
VEL DROP
P

L’ = L + 2(2/3) H

H mean = ((h1+h2)/2 ‐ D//2

D/2) 2 – (h meann) 2
Slant Heiight(S) = 2 ( D
L’ x S x h x  x 60
Qm = ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐
t x 1000
Where:
h = h1 –– h2
h1 = Startt reading of le
evel from botttom of tank in
n m = H1 + D/2 + y
h2 = End reading of levvel from bottoom of tank in m
m = H2 + D/2 + y
+
H1 = Start Gauge level reading from
m NWL in m
H2 = End Gauge level rreading from N
NWL
H = Lengtth of Dished e
end of Tank inn m
 = Density of fluid in
n Kg/m3
t = Time of measurem
ment in min
y = Heiight of NWL frrom Tank cen tre line in m.
Qm = Rate of Level dro
op/ rise in T/H r.

For 2x6000MW Singaareni TPS
60 mm
L= 4566 D= 3600 mm
m
F= 4761
10 mm y= 457 mm
H= 975 mm
34 of 129

ANNEXURE – 13
CALCULATION PROCEDURE FOR HOTWELL LEVEL DROP

For levels in straight portion of tank
Qm = (W1 – W2) x 60 in T/Hr
1000x t
Where:
W1 = Start Weight of condensate corresponding to H1 in T
= W x L x H1 x d
W2 = End Weight of condensate corresponding to H2 in T
= W x L x H2 x d
d = Density of condensate in Hotwell in Kg/m3
H1 = Start Gauge level reading from NWL in m
H2 = End Gauge level reading from NWL in m
t = Time of measurement in min
Qm = Rate of Level drop/ rise in T/Hr
For 2x600MW Singareni TPS
L = 12700 mm
W = 6968 mm
35 of 129


ANN
NEXUR
RE – 1
14
METH
HOD FO
OR COM
MPUTAT
TION O
OF
H
HEAT RA
ATE

36 of 129
37 of 129
38 of 129
DOCUMENT TITLE: DOCUMENT NUMBER:

METHOD FOR COMPUTATION OF HEAT RATE PE-DC-381-100-N122 REV 04
PROJECT TITLE: 2X600 MW SINGERENI TPP AT ADILABAD PAGE 2 OF 10
1.0 HEAT AND MASS BALANCE ACROSS HP HEATERS:
Steam extractions to HP heaters is to be evaluated from thermal balance of the heaters. Feed water Mffw going to the economizer
comprises of the feed water quantities Ma and Mb coming from HP heater trains A and B respectively.
The heat and mass balance equations at this point are:
Ma+Mb = Mffw (A)
Ma.H6a + Mb.H6b = Mffw.H14 (B)
From these two equations, the value of Ma and Mb can be evaluated in terms of Mffw.
1.1 HEAT BALANCE ACROSS HPH-7A:
Ma.(H6a-H5a) = Za.(H12a-H7a) (C)
1.2 HEAT BALANCE ACROSS HPH-7B:
Mb.(H6b-H5b) = Zb.(H12b-H7b) (D)
Ma.(H5a-H4a) = Za.(H7a-H8a)+Ya.(H11a-H8a) (E)
Mb.(H5b-H4b) = Zb.(H7b-H8b)+Yb.(H11b-H8b) (F)
Ma.(H4a-H3a) = (Ya+Za).(H8a-H9a)+Xa.(H10a-H9a) (G)
39 of 129

Mb.(H4b-H3b) = (Yb+Zb).(H8b-H9b)+Xb.(H10b-H9b) (H)
Putting the values of Ma and Mb in terms of Mffw, we can calculate the values of Za, Zb, Ya, Yb, Xa & Xb in terms of Mffw.
2.0 HEAT AND MASS BALANCE ACROSS THE DEAERATOR:
M2.H2 = (Xa+Ya+Za).H9a+(Xb+Yb+Zb).H9b+W.H1+M1.H13 (I)
M2 = M1+W+Xa+Xb+Ya+Yb+Za+Zb± Mdea (J)
From the equations (I) and (J), the value of M2 can be calculated in terms of Mffw.
3.0 FINAL FEED WATER FLOW:
Mffw = M2 –Mshs-Mrhs (K)
Mshs = 0, when spray is taken from HPH outlet.
In the above equation,Mshs and Mrhs is measured and M2 is calculated in terms of Mffw.
Hence, the value of Mffw can be calculated.
NOTE:
1. When there is an increase in the level of Deaerator, -ve sign shall be used for Mdea.
2. When there is a decrease in the level of Deaerator, +ve sign shall be used for Mdea.
3. When there is an increase in the level of Boiler Drum, -ve sign shall be used for Mdrum.
4. When there is a decrease in the level of Boiler Drum, +ve sign shall be used for Mdrum.
4.0 SUM OF STORAGES [Msto] INCREASES OR DECREASES FOR THE FOLLOWING TANKS:
a) Hotwell Storage
b) Drum Storage
40 of 129

c) Condensate Make up storage

d) Deaerator Storage
NOTE:
For the above storages if there is a net increase in the level, +ve sign is to be taken for Msto and if there is a net decrease in level, -ve
sign is to be used for Msto to arrive at the Total Cycle Losses to be reflected in the main steam flow [Mms].
Mms = Mffw ± Msto ± mdrum + Mshs (L)
Mshs = 0, when spray is taken from HPH outlet.
Reheat Steam Flow, Mrh = Mms-Za-Zb-Ya-Yb-Md+Mrhs (M)
5.0 SYMBOLS:
M1 = Mass flow measured from flow measuring device FP01 [Condensate flow to deaerator] (Kg/hr)
Md = Gland leakages A, B and C from HP turbine to be computed (Kg/hr)
Msto = Total increase/decrease of storage in system [from level gauges] during test (Kg/hr)
Mdea = Change in deaerator storage during the test (Kg/hr)
Mdrum = Change in drum level during test (Kg/hr)
W = Extraction steam flow to deaerator [Calculated from thermal balance] (Kg/hr)
Xa = Extraction flow to HPH-5A [Calculated from thermal balance] (Kg/hr)
Xb = Extraction flow to HPH-5B [Calculated from thermal balance] (Kg/hr)
Ya = Extraction flow to HPH-6A [Calculated from thermal balance] (Kg/hr)
41 of 129

Yb = Extraction flow to HPH-6B [Calculated from thermal balance] (Kg/hr)
Za = Extraction flow to HPH-7A [Calculated from thermal balance] (Kg/hr)
Zb = Extraction flow to HPH-7B [Calculated from thermal balance] (Kg/hr)
H1 = Enthalpy of steam entering deaerator based on measurements PA12 & TW46, TW47 (Kcal/kg)
H2 = Enthalpy of feed water at deaerator outlet based on measurements (PA22, TP75 & TP76) and (PA23, TP77 & TP78) (Kcal/kg)
H3a = Enthalpy of feed water at HPH-5A inlet based on measurements PD26, TW54 & TW55 (Kcal/kg)
H3b = Enthalpy of feed water at HPH-5B inlet based on measurements PD27, TW56 & TW57 (Kcal/kg)
H4a = Enthalpy of feed water at HPH-5A outlet based on measurements PD28, TW58, TW59, TW62 & TW63 (Kcal/kg)
H4b = Enthalpy of feed water at HPH-5B outlet based on measurements PD29, TW60, TW61, TW64 & TW65 (Kcal/kg)
H5a = Enthalpy of feed water at HPH-6A outlet based on measurements PD30, TW66, TW67, TW70 & TW71 (Kcal/kg)
H5b = Enthalpy of feed water at HPH-6B outlet based on measurements PD31, TW68, TW69, TW72 & TW73 (Kcal/kg)
H6a = Enthalpy of feed water at HPH-7A outlet based on measurements PD32, TW74 & TW75 (Kcal/kg)
H6b = Enthalpy of feed water at HPH-7B outlet based on measurements PD33, TW76 & TW77 (Kcal/kg)
H7a = Enthalpy of HPH-7A drain based on measurements PD34, TW80 & TW81 (Kcal/kg)
H7b = Enthalpy of HPH-7B drain based on measurements PD35, TW82 & TW83 (Kcal/kg)
42 of 129

H10a = Enthalpy of extraction steam entering HPH-5A based on measurements PD20, TW33 & TW34 (Kcal/kg)
H10b = Enthalpy of extraction steam entering HPH-5B based on measurements PD21, TW35 & TW36 (Kcal/kg)
H13 = Enthalpy of condensate entering deaerator based on measurements PA20, TP22 & TP23 (Kcal/kg)
Ta = calculated on the basis of PD07 and Enthalpy correspondinmg to PD01, PD02 and TW03 to TW06…………..………….(Deg C)
6.0 HEAT RATE:
Mms[Hms-Hffw] + Mrh[Hrho-Hrhi] + Mshs[Hffw-Hshs]+ Mrhs[Hrhi-Hrhs]

HR = Pnet (N)
HR = Heat Rate (Kcal/KW.Hr)
Mms = Main steam flow at HPT inlet [As calculated] (Kg/Hr)
Mrh = Reheat steam flow at IPT inlet [As calculated] (Kg/Hr)
Mshs = Superheater attemperation flow measured from plant flow measuring device FP04 & FP05 (Kg/Hr)
43 of 129

Mrhs = Reheater attemperation flow measured from Plant Flow measuring device FP06 & FP07 (Kg/Hr)
Hms = Enthalpy of steam before ESV based on measurements PD01 to PD02 & TW03 to TW06 (Kcal/Kg)
Hffw = Enthalpy of final feed water after HP heaters based on measurements PD32, PD33 & TW78, TW79 (Kcal/Kg)
Hrho = Enthalpy of Hot Reheat steam before IV based on measurements PD14 to PD15 & TW27 to TW30 (Kcal/Kg)
Hrhi = Enthalpy of Cold Reheat steam based on measurements PD07 & TW13 to TW14 (Kcal/Kg)
Hshs = Enthalpy of superheater attemperation based on measurements PD25 & TW01, TW02 (Kcal/Kg)
Hrhs = Enthalpy of Reheater attemperation based on measurements PD24, TW52 & TW53 (Kcal/Kg)
Pnet = Pgen-Paux (kW)
Pgen = Power measured at Generator Terminals (kW)
Paux = Power required for Turbine Integral Auxiliaries (150KW) (kW)
NOTE:
When SH spray is tapped from downstream of HP heaters then Hshs = Hffw and accordingly SH term becomes redundant in the HR
(Eq. N) calculation.
7.0 COMPUTATION OF TOTAL GLAND LEAKAGES:
Steam leakage through the glands A, B and C is calculated using the formula given below:
2 2
[P1 – P2 ]
G=KX
[P1.V1]
44 of 129

G = Steam Leakage through the Glands (T/Hr)
P1 = Pressure before the Glands (Ata)
P2 = Pressure after the Glands (Ata)

3
V1 = Specific volume at inlet conditions to the Glands (m /kg)
Data for guarantee case is given below [Refer HBD No. PE-DC-381-100-N151, REV 00]
PARAMETER HPT INLET END HPT OUTLET END
G 2.522 3.33
P1 43.03 43.03
P2 7.71 7.71
V1 *0.0791496 **0.0602803
* Based on 43.03 Ata and 810.7 Kcal/kg.

** Based on 43.03 Ata and 333.0°C.
For design case P1, P2 and V1 and G are known and hence K can be evaluated.
K values calculated for the design case are as given below:
A) For Gland Leakage from HPT inlet end K = 0.1099435

B) For Gland Leakage from HPT outlet end K = 0.126687
For test case, by putting this value of K and the test values of P1, P2 and V1 the computation of G can be done.
For the test case, the values of P1, P2 and V1 are determined as given below:
FOR HPT INLET END:

P1 is based on measurements PD07
45 of 129

P2 is based on measurements PA05 to PA06

V1 is based on measurements PD07 and Ta
Ta is calculated on the basis of PD07 and Enthalpy correspondinmg to PD01, PD02 and TW03 to TW06.
FOR HPT OUTLET END:

P1 is based on measurements PD07
P2 is based on measurements PA05 and PA06
V1 is based on measurements PD07 and TW13, TW14
8.0 NOTE:
1.0 The Heat Rate is guaranteed with 0% makeup and hence no makeup will be supplied to the condenser during the PG test. Under
these conditions the storage in the deaerator feed storage tank and Hotwell are utilized towards the leakages losses and the
measured Heat Rate shall be corrected using the correction curves viz. change in Heat Rate vs. change in storage of feed water
storage tank and change in Heat Rate vs change in Hotwell Level.
9.0 GUARANTEE CONDITION:
1. Turbine Cycle Heat Rate at 100% LOAD = 1927.1 Kcal/KWHr

(Refer HBD Nos. PE-DC-381-100-N151 REV00 Titled “600MW, 0%MU, 77mm Hg a Back Pr.” )
Turbine Cycle Heat Rate at 80% LOAD = 1975.7 Kcal/KWHr

(Refer HBD Nos. PE-DC-381-100-N152 REV00 Titled “480MW, 0%MU, 77mm Hg a Back Pr.” )
2. If the test is carried out later than three (3) months, after the date of commissioning, due to any reason whatsoever, Aeging shall be
applicable inline with the clause 2.05.04 (i) sub section-V, Part-A page 44 of 48 of the tender specification and S.No 11 of
Amendment-1 to technical specification.
46 of 129

10.0 LIST OF CORRECTION CURVES:
HEAT RATE CORRECTION CURVES:
1. Throttle Steam Pressure

2. Main Steam Temperature
3. Reheat Steam Temperature
4. Condenser Back Pressure
5. Change in Deaerator Level
6. Change in Hot Well Level
7. Power Factor
8. Frequency
9. Generator Hydrogen Pressure
10. Generator Voltage
11. SuperHeater Spray (Applicable only when SH spray is taken after BFP discharge)
OUTPUT CORRECTION CURVES:

1. Throttle Steam Pressure
2. Main Steam Temperature
3. Reheat Steam Temperature
4. Condenser Back Pressure
5. Change in Deaerator Level
6. Power Factor
7. Frequency
8. Generator Hydrogen Pressure
9. Generator Voltage
10. Change in Hot Well Level
11. SuperHeater Spray (Applicable only when SH spray is taken after BFP discharge)
47 of 129


ANNE
A EXUREE – 15

CORREC
C CTION C
CURVES

48 of 129
49 of 129
2X600 MW SINGERENI TPP AT ADILABAD
LIST OF CORRECTION CURVES
Slon. DOCUMENT TITLE DRAWING No. REV. NO.
1 HEAT RATE CORRECTION CURVE FOR THROTTLE STEAM PRESSURE PE‐DC‐324‐100‐N221 00
2 HEAT CORRECTION CURVE FOR MAIN STEAM TEMP PE‐DC‐324‐100‐N222 00
3 HEAT RATE CORRECTION CURVE FOR REHEAT STEAM TEMP. PE‐DC‐324‐100‐N223 00
4 HEAT RATE CORRECTION CURVE FOR CONDENSER PRESSURE. PE‐DC‐324‐100‐N224 01
5 HEAT RATE CORRECTION CURVE FOR CHANGE IN DEA. LEVEL PE‐DC‐324‐100‐N225 00
6 HEAT RATE CORRECTION CURVE FOR GENERATOR VOLTAGE. PE‐DC‐324‐100‐N226 01
7 HEAT RATE CORRECTION CURVE FOR FREQUENCY. PE‐DC‐324‐100‐N227 01
8 HEAT RATE CORRECTION CURVE FOR POWER FACTOR PE‐DC‐324‐100‐N228 01
9 HEAT RATE CORRECTION CURVE FOR GEN. HYDROGEN PRESSURE PE‐DC‐324‐100‐N229 01
10 OUTPUT CORRECTION CURVE FOR MAIN STEAM PRESSURE PE‐DC‐324‐100‐N230 00
11 OUTPUT CORRECTION CURVE FOR MAIN STEAM TEMP. PE‐DC‐324‐100‐N231 00
12 OUTPUT CORRECTION CURVE FOR REHEAT STEAM TEMP. PE‐DC‐324‐100‐N232 00
13 OUTPUT CORRECTION CURVE FOR CONDENSER PRESSURE PE‐DC‐324‐100‐N233 01
14 OUTPUT CORRECTION CURVE FOR GENERATOR VOLTAGE PE‐DC‐324‐100‐N234 00
15 OUTPUT CORRECTION CURVE FOR FREQUENCY PE‐DC‐324‐100‐N235 00
16 OUTPUT CORRECTION CURVE FOR POWER FACTOR PE‐DC‐324‐100‐N236 00
17 OUTPUT CORRECTION CURVE FOR GENERATOR HYDROGEN PRESSURE PE‐DC‐324‐100‐N237 01
18 OUTPUT CORRECTION CURVE FOR CHANGE IN DEA. LEVEL PE‐DC‐324‐100‐N239 00
19 OUTPUT CORRECTION CURVE FOR CHANGE IN HOT‐WELL LEVEL PE‐DC‐324‐100‐N241 01
20 HEAT RATE CORRECTION CURVE FOR CHANGE IN HOTWELL LEVEL PE‐DC‐324‐100‐N245 00
50 of 129
51 of 129
52 of 129
53 of 129
0.1047 ATA
01
54 of 129
55 of 129
2X600MW SINGERENI TPP AT ADILABAD
GUARANTEED VOLTAGE : 21.0 KV
HEAT RATE CORRECTION FACTOR Vs. GENERATOR VOLTAGE
1.001
100%
80%
HEAT RATECORRECTION FACTOR
0.999
19.500 20.000 20.500 21.000 21.500 22.000 22.500
GENERATOR VOLTAGE < kV>
1. Correction curves for operating conditions deviating from guarantee conditions.

2. To obtain the corrected value multiply the measured value by the correction factor. REV-01
Doc. No.: PE-DC-381-100-N226 PREP: AKS

BHEL PEM
DEPARTMENT: MSE CHECKED: AKS
NOIDA APPD. : AK
56 of 129
HEAT RATE CORRECTION CURVE FOR FREQUENCY

GUARANTEED FREQUENCY = 50 Hz
1.00025
1.00020
1.00015
1.00010
1.00005
1.00000
0.99995
HEAT RATE CORRECTION FACTOR
0.99990
0.99985
0.99980
100%MCR
0.99975
0.99970
80%MCR
0.99965
0.99960
0.99955
0.99950
0.99945
0.99940
0.99935
0.99930
0.99925
47 47.5 48 48.5 49 49.5 50 50.5 51 51.5 52
FREQUENCY (Hz)
REV-01
2. To obtain the corrected value multiply the measured value by the correction factor.
DEPARTMENT: MSE CHECKED:AKS

BHEL PEM
NOIDA APPD. : AK
57 of 129
GUARANTEED POWER FACTOR : 0.85
HEAT RATE CORRECTION FACTOR Vs. POWER FACTOR
1.0036
1.0031
1.0026
1.0021
1.0016
100%
1.0011
80%
1.0006
1.0001
0.9996
0.9991
0.9986
0.80 0.85 0.90 0.95 1.00
POWER FACTOR
REV-01

BHEL PEM
NOIDA APPD. : AK
58 of 129
GUARANTEED GEN HYDROGEN PR = 5.0 BAR(g)
HEAT RATE CORRECTION FACTOR Vs. GEN. HYDROGEN PR.
1.00016
1.00012
100%
80%
1.00008
1.00004
0.99996
4.250 4.450 4.650 4.850 5.050 5.250
GEN. HYDROGEN PR. <BAR(g)>

2. To obtain the corrected value multiply the measured value by the correction factor. REV-01

BHEL PEM
NOIDA APPD. : AK
59 of 129
60 of 129
61 of 129
62 of 129
0.1047 ATA
REV-01
63 of 129
VOLTAGE CORRECTION CURVES FOR 600 MW GENERATOR

(THDF 115/67 + BRUSHLESS EXCITATION)
(RATED VALUES : 600 MW / 21.0 KV / 0.85 PF / 5.0 BAR(g) H2 PR. / 50 HZ)
250
200
150
100
CORRECTION (KW)
21.000 KV
50 21.525 KV
22.050 KV
0 20.475 KV
19.950 KV
-50
-100
-150
-200
0 0.25 0.5 0.75 1
MW LOAD (P.U.)
REV. NO. 00
DATE: 17.11.2009
PE-DC-381-100-N234 PREPARED BY: A.K. GOYAL CURVE NO.: TG:THDF 115/67:026
64 of 129
FREQUENCY CORRECTION CURVES FOR 600 MW GENERATOR

400
350
300
250
200 50.0 HZ
CORRECTION (KW)
50.5 HZ
150 51.0 HZ
51.5 HZ
100 49.5 HZ
48.0 HZ
50 47.5 HZ
-50
-100
-150
0 0.25 0.5 0.75 1
MW LOAD (P.U.)
REV. NO. 00
DATE: 17.11.2009
65 of 129
P.F. CORRECTION CURVES FOR 600 MW GENERATOR

1000
500
0
CORRECTION (KW)
0.85 P.F.
-500
0.90 P.F.
0.95 P.F.
1.00 P.F.
-1000
0.80 P.F.
-1500
-2000
-2500
0 0.25 0.5 0.75 1
MW LOAD (P.U.)
REV. NO. 00
DATE: 17.11.2009
66 of 129
HYDROGEN PRESSURE CORRECTION CURVES FOR 600 MW GENERATOR

50
30
10
CORRECTION (KW)
5.00 bar(g)
-10 4.75 bar(g)
4.50 bar(g)
-30
-50
-70
0 0.25 0.5 0.75 1
MW LOAD (P.U.)
REV. NO.:00
DATE: 17.11.2009
67 of 129
2X600 MW SINGARENI TPP AT ADILABAD
RATED VALUE OF DEA. LEVEL DROP = 0%
CHANGE IN DEA. LEVEL VS OUTPUT CORRECTION CURVE.
1.00700
1.00600
1.00500
OUTPUT CORRECTION FACTOR.
1.00400
1.00300
1.00200
1.00100
1.00000
0.99900
0.00 1.00 2.00 3.00 4.00 5.00
DROP IN DEA. LEVEL (% OF MS FLOW)

3. This curve is applicable for load conditon of 600MW & 480MW.
Doc. No.: PE-DC-381-100-N239 PREP: VJ

BHEL PEM
NOIDA APPD. : AK
68 of 129

REV-01
RATED VALUE OF BLOW DOWN = 3%

RATED VALUE OF BACK PR. = 0.1047 ATA
OUTPUT CORRECTION CURVE Vs CHANGE IN HOTWELL LEVEL
1.004
1.002
1.000
OUTPUT CORRECTION FACTOR.
0.998
0.996
0.994
0.992
0.990
-3 -2 -1 0 1 2 3 4 5
CHANGE IN HOTWELL LEVEL<%OF MS FLOW>

3. This curve is applicable for load conditon of 600MW & 480MW.

BHEL PEM
NOIDA APPD. : AK
69 of 129
HEAT RATE CORRECTION CURVE FOR CHANGE IN HOTWELL LEVEL
HEAT RATE vs CHANGE IN HOTWELL LEVEL
1.013
1.008
1.003
0.998
0.993
0.988
-3 -2 -1 0 1 2 3
CHANGE IN HOTWELL LEVEL (% OF MS FLOW)

3. This curve is applicable for load conditons of 600MW, 480MW and 360MW.
DR.No:PE-DC-381-100-N245 PREP: VJ

BHEL PEM
NOIDA APPD. : AK
70 of 129


ANNEXURE – 16
HEAT BALANCE DIAGRAM

Sr. no. Document title Drawing No. Page No.

1 600MW, 0 % MU, 77 mmHg (A) BACK PR. PE-DC-381-100-N151 72



PE-DC-381-100-N167
4 VWO, 0% MU, 77 mmHg(A) BACK PR. 75

600MW, 3 % MU, 77 mmHg (A) BACK PR
5 PE-DC-381-100-N170 76
(All HP Heaters out of service)
71 of 129
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T\RBll£ GROSS DJTPUT • 489.175 NY
AT Ioc
lLSS I£CH UISSES
LESS liDIERl'lllll UISSES
lLSS I'INEII IIEilUIIIEII Fill
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• 6.SIII IN
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76 of 129 T.. TEHPEAATUA .. 'C DATE 23 05.1 2 DRG NO PE - DC - 381 - 100-N170 01
REV

ANNEXURE – 17
System check list‐

Ensure the plant is able to operate without any constraints at full load for a minimum of 4 hrs with following
conditions.
1. Plant to run at rated steam parameters.
2. All equipment which are needed for proper functioning of TG to be in service.
3. De‐aerator level drop test to be carried out & effort to be made to keep leakage level at lowest.
4. All HP & LP Heaters to be in normal operation and drips of these heaters to be cascaded properly without any
bypassing to HP/LP flash tank of condenser.
5. All connections to and from external sources like plant PRDS header, make up, dozing, steam for external use,
boiler drains and blow‐down , external spray to flash tanks ,valves etc. to be cut off/minimised.
6. Alternate lines which are not designed for normal use like CRH pegging to De‐ aerator/BFPT, auxiliary pegging
to de‐aerator/BFPT, De‐aerator initial heating system & fill lines, HPH6 drain to de‐aerator, etc should not be
charged.
7. System would be tight as per Design Heat Balance Diagram.
8. Any equipment required from boiler side should be available so to get the steady required steam parameter.
9. Sealing line for CEP & Vacuum Pumps to be connected from CEP discharge and supply from DM MU to this line
to be closed.
10. Turbine/ Boiler controls should be fine tuned, so that tests can be done at stable conditions.

77 of 129

ANNEXURE – 18

Auxiliary Power Consumption Test Procedure

OBJECTIVE:
To prove total auxiliary power consumption of the applicable HT and LT drives as per contract guarantee schedule at
following TMCR conditions.
Sr. no. Parameter Guarantee Value
I) The total auxiliary power consumption for all the Turbine Generator At 100% TMCR
Auxiliaries, steam generator auxiliaries, ESP and turbine cycle and other 19,659 (Per unit) KW
common auxiliaries required for continuous unit operation at 100%
TMCR (600MW unit load) under rated steam conditions at worst
condenser pressure with 3% make‐up and with ambient air
temperature of 27deg c and RH of 60% shall be guaranteed.
II) The total auxiliary power consumption for all the Turbine Generator At 80% TMCR
Auxiliaries, steam generator auxiliaries, ESP and turbine cycle 15,301 (Per Unit) KW
equipment and other common auxiliaries required for continuous unit
operation at 80 %(480MW unit load) TMCR under rated steam
conditions, and at worst condenser pressure of with 3% make‐up and
with ambient air temperature of 27deg c and RH of 60% shall be
guaranteed.

a. The power consumption (HT/LT) of SG & ESP auxiliaires will be measured separately during Boiler PG & ESP PG
test.
b. The power consumption of TG auxiliaries and other continuously operating equipment will be measured during
TG PG test.
c. Total auxiliary power consumption will be calculated after completion of Boiler, ESP and TG PG tests.

PREPARING THE MACHINE FOR 600MW FOR CONDUCTANCE OF PG TEST
Turbine–Generator and associated equipment will be raised to the rated load of 600 MW. The auxiliary power
consumption test is to be conducted during main PG test at 600 MW as per the guarantee clause mentioned
above.

GENERAL GUIDE LINES
a. All HT power will be measured through power transducers/ power meter. Output of the power transducers (if
used) will be connected to data logger.
b. It will be ensured that the power transducers are connected in the correct phase sequence.
c. All LT power will be measured through use of digital multi‐meter (voltage), Clamp‐on meter (Amp.) & Power
factor meter (pf) / three phase power tong tester.
d. For measurement of Transformer losses, shop test results shall be used.
e. Shop test results /type test/rated power/ data sheet, if required for computation of Aux. Power consumption
due to non availability of specific drive, shall be made available during PG test and will be used for calculation of
total power, if called for.
78 of 129


LIST OF INSTRUMENTS AND ITS ACCURACY
a. All the identified CTs and PTs used in the existing panel of each HT drives will be connected to power transducers
and hooked on to the main data logger for recording.
b. Power transducers using input : 110V, (0‐1A)for an output of (4‐20)mA, with an uncertainty equal to or better
than+/‐0.1%.
c. 3.5 digit Digital multi‐meter (voltage), Clamp‐on meter (Amp) & Power factor meter (pf) / Three phase power
tong tester will be usedfor measurement of power for LT drives and data will be recordedmanually.
d. All valid calibration certificatesshall be furnished at the time of the test.

LIST OF AUXILIARIES CONSIDERED FOR AUXILIARY POWER CONSUMPTION
2X600MWSingareniTPP(Rev02)
(I) UNIT AUXILIARIES POWER POWER

CONSUMPTION CONSUMPTION
(KW) (KW)
(INDICATIVE (INDICATIVE
BREAKUP) BREAKUP)
600MW load 480MW load

a) Unit oil purifier
b) Unit control oil purifier.
85 85
c) Electric oil heater for lube oil.
d) Feed and discharge pumps of oil purification system.
e) Condenser air evacuation pumps.
f) Condenser tube cleaning systems pumps.
g) Condensate extraction pumps.
1700 1648
h) Drip Pumps (Not envisaged)
i) Hydrazine dosing pumps.
j) Ammonia dosing pumps.
k) Oil purifiers of 2x 50% TDBFPs, and their feed and discharge pumps.
l) Lube oil pumps of 2x 50% TDBFPs, and their electrical oil heater for lube oil.
m) Auxiliary oil pumps for MDBFP. 250 250
n) Oil pumps for HP‐LP bypass system.
o) Motor driven boiler feed pump
(for this purpose only 15% of the deemed power consumed by the MDBFP 1421 0
is considered at 100% TMCR only)
P Mills/PA Fans/FD Fans/ID Fans/Air heaters/Coal Feeders/Seal Air Fans/Lube
to oil pumps for Fans/Fuel oil pressurizing pump/Boiler water circulation
aa) pump/Scanner air fans/Air heater and mill system/Electrostatic
Precipitators(corona only) 11970 9430

AA Total for (I) 15426 11413
79 of 129

(II) Common auxiliaries (Power consumption indicated is per unit basis) POWER POWER

(KW) (KW)
BREAKUP) BREAKUP)
600MW load 480MW load
ab) DM Cooling (Normally working) water pumps to supply cooling water
on the primary (DM) side of the plate type heat exchangers in the
closed loop Equipment cooling (Unit auxiliaries) water system.

ac) Auxiliary Cooling (normally working) water pumps to supply cooling
water on the secondary side of the plate type heat exchangers in the 850 850
closed loop Equipment cooling (unit auxiliary) water system.

ad) Power consumption of any other continuously operating auxiliary for
unit operation at different guarantee point loads (Condensate transfer
pump)

Air Conditioning (Main control room ESP control room) & Ventilation
ae)
System.

773 773
af) Mill Reject System

Total for (II) 1623 1623
TOTAL GUARANTEED AUXILIARY POWER CONSUMPTION PER UNIT (Pu)
17049 13036
(Total for (I)+ Total for (II))
(III) Transformers (Power consumption indicated is per unit basis) POWER POWER

(KW) (KW)
BREAKUP) BREAKUP)
Transformer losses (GT/ST/UT/UAT/MSST/LT) 2610 2265
BB TOTAL GUARANTEED LOSSES PER UNIT TRANSFORMER (TL) 2610 2265

Notes:

1. The auxiliary power consumption break‐up given above is for indicative purpose & total value as indicated in
guarantee schedule is guaranteed.
2. Auxiliary power consumption for common steam generator and auxiliaries corresponds to design coal & 27 0C
ambient, 60%c RH design coal with moisture.
3. Auxiliary power consumption for common station auxiliaries has been proportionately considered for single
unit.
4. ‘TL’ losses of transformers under bidder’s scope. Total power ‘Pa’ as arrived is as follows

Pa (KW) = PU + TL = 17049 + 2610 = 19659 KW (for 100% Load)
Pa (KW) = PU + TL = 13036 + 2265 = 15301 KW (for 800% Load)
Pa (KW) = Guaranteed Auxiliary Power Consumption
PU (KW) = Power consumed by auxiliaries of unit under test
TL (KW) = Losses of the transformer supplied by the bidder.

5. Transformer losses are at actual loading of transformer at TMCR load.

6. Normal operation of transformers without outage is considered.

80 of 129


Annexure‐19

DISSOLVED OXYGEN CONTENT AT DEAERATOR OUTLET
The dissolved oxgen content in feed water at Deaerator outlet shall be measure in the power plant laboratory
by the Indigo‐Carmine method or ASTM D‐888 reference method‐A.
Deaerator is considered to be performing satisfactorily if the measured value is less than 0.005 cc/litre at al
loads and without chemical dosing.
This test shall be carried out before PG test or along with PG test.
BHEL shall ensure protocol with Customer at site.
BHEL CUSTOMER
81 of 129

Annexure‐20

DIFFERENCE BETWEEN THE SATURATION TEMPERATURE OF THE STEAM ENTERING THE DE‐AERATOR AND
THE TEMPERARTURE OF THE FEED WATER LEAVING DE‐AERATOR
Difference between the saturation temperature of the steam entering the De‐aerator and temperature of the
feed water leaving De‐aerator shall be evaluated /measured and it shall be 1.11 deg.C.
This test shall be done along with PG test.
BHEL shall ensure protocol with Customer at site.
BHEL CUSTOMER
82 of 129


ANNEXURE – 21

Condenser Back Pressure test
procedure

83 of 129
2X600 MW SCCL STPP
THE SINGARENI COLLIERIES COMPANY LTD.

POWER PROJECT DIVISION
CONDENSER BACK PRESSURE TEST PROCEDURE

(PROCEDURE NO: HXE - PT - CONDR - 073- 00)
HEAT EXCHANGER ENGINEERING

HARDWAR
84 of 129
HXE-PT-CONDR-073-00
Rev. No. : 00
Dated : 11/06/2016
Page 1 of 15
HEAT EXCHANGER ENGG
BHEL, HARDWAR
PROCEDURE FOR BACK PRESSURE DEMONSTRATION TEST ON STEAM

SURFACE CONDENSER
(PROCEDURE NO: HXE-PT-CONDR-073-00)
1.0: SCOPE:
The purpose of this write-up is to provide detailed procedure for demonstrating the
performance of steam surface condenser with regard to the following:
1.1 : The absolute back pressure of 77 mmHg(a) achieved by the equipment 300
mm above the top rows of condenser tubes when turbine operation
corresponds to VWO conditions, at 3% make-up, at design inlet cooling water
temperature of 33oC, at design circulating water flow rate and tube cleanliness
factor of 0.9.
2.0: COMPARISON:
The condenser is said to have fulfilled its design requirement when the measured
back pressure when corrected for differences in measured and designed values of
C.W. quantity, heat rejected in condenser, C.W. inlet temperature and cooling
surface area is found to be equal or less than the designed back pressure of 77
mmHg(a).
Worked By : Checked By : Approved By :
Deepak Kr. Yadav Deepak Kr. Yadav Naveen Prakash
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3.0: DESCRIPTION AND DEFINITION OF BASIC TERMS
Term Symbol Description Unit
Condenser
Rate at which heat is rejected to
Load H Kcal / hr
circulating water in condenser
Inlet Steam Saturation temperature of steam
o
Temperature ts corresponding to back pressure Ps C
(measured in mm HgC)
Inlet Temperature of cooling water o
tw1 C
Temperature measured at condenser inlet
Outlet Temperature of cooling water o

tw2 C
Temperature measured at condenser outlet
Temperature Increase of cooling water temperature

tw o
C
rise from inlet to outlet.
Cooling water Quantity of cooling water circulating

Qw m3/hr
flow through condenser per unit time
Specific heat Cp Specific heat of cooling water kcal/kg-oC
4.0: COMPLIANCE TO STANDARD:
The procedure is guided by recommendations of ASME-PTC 12.2 for steam surface

condenser.
5.0: MEASUREMENT:
The test scheme and mounting of instruments is as per approved PG Test

instrumentation scheme and approved write-up on Performance Guarantee test for
TG Package.
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Page 3 of 15
5.1 : Condenser Back Pressure:
12 Nos. (6 nos on each condenser) measurement points will be located 300 mm

above top row of tubes. These are fitted with ASME basket to ensure static pressure
measurement. These shall be uniformly located so as to cover total area above
tubes.
5.2 : Circulating Water Temperature:
5.2.1 : Inlet Temperature:
For PG Test measurement purpose of inlet temperature eight nos. (Four nos for
each condenser) test points, two nos. on each condenser inlet nozzle will be
provided.
5.2.2 : Outlet Temperature:
For PG Test purpose outlet temperature will be measured by providing six nos.
symmetrically spaced measurement points on each outlet pipe at least five meters
away from condenser nozzle. The points may be provided after bends and the
length of insertion of each point will be different to obtain bulk mean temperatures.
5.2.3 : Correction:
All temperatures will be measured with the help of RTDs in conjunction with digital
multimeters. Test data-logger can also be used with prior agreement. The following
corrections shall be applied to the measured values for arriving at the test values:
- PRT/ RTD, Instrument calibrations.
- Lead wire resistance, if applicable.
87 of 129
HXE-PT-CONDR-073-00
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Page 4 of 15
5.3 : Circulating Water Flow:
No direct method shall be employed for measurement of C.W. quantity flowing

through condenser. The same shall be computed from heat rejected to condenser
obtained from test heat rate calculations. Hence condenser test shall be conducted
in conjunction with turbine test. Details are as per Annexure-3.
5.4 : Cleanliness Factor:
Prior to test, physical/chemical cleaning of the tubes and water boxes shall be done
to obtain the desired tube cleanliness. After cleaning, the following cleanliness factor
will be considered for computation of results:
Titanium Tubes: 0.9
5.5 : Specific Heat:
Specific heat of water which is used in condensers at Singreni will be taken as 1.0
Kcal/Kg C.
6.0 : CONDITIONS FOR TEST:
6.1 : General Condition:
During condenser demonstration test, the air leakage into the vacuum systems
should not exceed 16 kg/hr. Air shall be measured by the flow device provided on
the air evacuating device.
88 of 129
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Page 5 of 15
6.2 : Machine Load:
Demonstration of Condenser Back Pressure will be carried out in conjunction with

turbine test. The machine load shall be kept corresponding to VWO condition of
Turbine with 3% make-up.
6.3 : Make-Up:
Condensate make-up of approx. 3% will be added to condenser during the test. This
shall be accounted for by opening the CBD during the test with quantity of blow
down set at 3% of condensate flow. Level of hot well and De-aerator shall be
maintained by adding make-up. Any other method can also be decided during test.
6.4 : Leakage/By-pass of Drains/Steams:
Prior to test, it will be ensured that drain flow to condenser (direct or through flash
boxes) will be strictly as per the design load regimes. Any bypass of drains /steam to
condenser must be identified and isolated.
6.5 : Allowable Deviations:

Testing shall be performed under conditions of inlet-water temperature, heat load,
and cooling-water flow within the limits as specified in Table 3.1 of ASME PTC 12.2.
Testing Parameters Deviations from specified conditions
Inlet Water Temperature +/- 10 oF
Heat Load +/- 5%
Cooling Water Flow +/- 5%
89 of 129
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Page 6 of 15
7.0 : INSTRUMENTS AND THEIR ACCURACIES (PRESSURE / TEMPERATURE

GAUGE):
The accuracy of various gauges shall generally conform to the recommendations of

ASME PTC 12.2 for steam surface condensers (refer enclosed Annexure - 1) or as
agreed between SCCLPPD and BHEL.
8.0 : FREQUENCY AND DURATION OF MEASUREMENT:
In case the readings are recorded through PG. Test data-logger, the frequency of
recording shall be governed by the data-logger characteristics. However for manual
recordings, the frequency of readings shall be 5 min. both for back pressure
readings and C W inlet/outlet readings. For condenser calculations, one hour data
will be considered from minimum test duration of two hour period during steady state
condition.
9.0 : COMPUTATION OF RESULTS:
9.1 : Heat rejected to condenser will be calculated based on the uncorrected and
actual heat rate of the Turbine Generator package at the time of test. Heat
rejected to condenser will be the difference of Heat supplied to the Turbine less
the Turbine output (Generator output corrected for mechanical / electrical
losses and turbine losses). Enclosed Annexure - 3 gives detailed relationship
for computation of condenser heat load.
9.2 : Computation of circulating water quantity / velocity will be done based on

circulating water temperature measurements, heat load on condenser as per
item 9.1 above and actual total tube sectional area per pass. Details of
calculations will also be as per Annexure - 3.
90 of 129
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Page 7 of 15
9.3 : The next step determines the actual (test) log mean temperature difference.
Annexure - 4 gives the procedure for calculation of the same. The test LMTD
corresponds to measured back pressure, C.W. velocity, actual surface area
and C.W. inlet temperature. Hence, it shall be corrected for designed C.W. inlet
temperature, velocity, surface area and heat rejected as identified in Annexure-
2. The corrected condenser back pressure will be computed from corrected
test LMTD as per Annexure-5. Correction curves for the above varying
parameters are enclosed as Annexure-6, 7 & 8.
9.4 : The corrected back pressure will be compared with the design back pressure
for the purpose of final evaluation.

91 of 129
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Page 8 of 15
ANNEXURE – 1
INSTRUMENT LIST FOR SURFACE CONDENSER TEST
SL MEASUREMENT NOMINAL TYPE OF RANGE OF ACCURACY OF

REMARKS
NO PARAMETERS VALUE INSTRUMENT INSTRUMENT INSTRUMENT
Absolute
Manometer/
60-89 U-tube 0-780 +0.10 With vernier
01 Back Pressure
mmHgC Manometer/ mmHgC mmHgC attachment
Pressure
Transmitter
C.W. inlet RTD / Glass

02 15 -40oC 0 -50 oC +/-0.1 oC
temperature thermometers
C.W. outlet RTD / Glass

03 25 -46oC 0 -50 oC +/-0.1 oC
temperature thermometers
Fortins With vernier

Atmospheric 700 –760 0-760 +0.25
04 Barometer attachment
Pressure mmHgC mmHgC mmHgC
(Site Lab.) and scale
92 of 129
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Page 9 of 15
ANNEXURE-2
GUARANTEE DATA
Sl Guarantee
Symbol Description Unit
No. Data
01 - Design, Mfg and Testing Code - HEI
6
02 Hlg Heat Load kcal/hr 325.93 x 10
03 Qg Cooling Water Flow per condenser 31650 31650
o
04 tw1d Cooling Water Inlet Temperature C 33.0
05 Psg Back Pressure mmHgC 77.0
06 L Effective Tube Length mm 13000
07 N Number of Tubes no. 17266
08 do x t Tube outside dia. x thickness mm x mm 28.575X0.7112
Dissolved Oxygen in
09 - cc/l 0.015
hotwell condensate
93 of 129
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Page 10 of 15
ANNEXURE – 3
MAIN CALCULATION
Station: 2X 600 MW SCCL STPP Date:
Unit: Duration :
Symbol Description Derivation Units Value
o
tw1m Mean C W in temp (tw11 + tw12) / 2 C
o
tw2m Mean C W out temp (tw21 + tw22) / 2 C
tw Mean C W temp rise (tw2m – tw1m) o

C
 Density of water - kg/m3 1000
Cp Specific Heat of water - kcal/kg 1
Ha Heat added in the cycle HR x Pg kcal/hr
To Output of Turbine (Pg / g + 1500) kcal/hr

x 859.846
Hr Heat rejected to condenser* (Ha – To)/2 kcal/hr
Qw C W flow rate Hr / (tw x  x Cp) m3/hr
Aw C W flow area 0.785 x di2 x N / p m2
V C W velocity Qw / Aw x 3600 m/sec.
A Condensing surface area  x do x L x N m2
LEGEND :
tw11: C W Inlet temp – 1st half Pg : Generator output, KW
tw12 nd
: C W Inlet temp – 2 half g : Generator efficiency
tw21: C W Outlet temp – 1st half di : tube inside dia., mm
nd
tw22: C W Outlet temp – 2 half p : number of C W passes
HR : Cycle Heat Rate
‘*” : Heat rejection to condenser is for one condenser.
94 of 129
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Page 11 of 15
ANNEXURE – 4
TEST LMTD COMPUTATION
Pa Measured condenser - ata

Pressure
o
ts Saturation temperature Corres to Ps C
 LMTD tw/ln[(ts–tw1m)/ts–tw2m)] oC
95 of 129
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ANNEXURE – 5
CORRECTION OF LMTD AND BACK PRESSURE
ft C W inlet temp correction Annexure – 6 -

factor
-
fv C W Velocity correction Annexure – 7
factor
fh Heat load correction Annexure – 8 -

factor
c Corrected LMTD  x ft x fv x fh o
C
X Exponential exp (twd / c ) -
twd Design C W Temp. rise hlg/ (Qg x  x Cp) o

C
tsc Corrected steam temp. tw1d + X x twd /(X – 1) o

C
Psc Test condenser pressure Saturation pressure mmHgC

corrected to design point corresponding to tsc
96 of 129
HXE-PT-CONDR-073-00
Rev. No. : 00
Dated : 11/06/2016
Page 13 of 15
97 of 129
HXE-PT-CONDR-073-00
Rev. No. : 00
Dated : 11/06/2016
Page 14 of 15
98 of 129
HXE-PT-CONDR-073-00
Rev. No. : 00
Dated : 11/06/2016
Page 15 of 15
99 of 129


ANNEXURE – 22
PROJECT: 2X600 MW SCCL ADILABAD TPP
TEST PROCEDURE FOR CW PUMPING

POWER
100 of 129
TEST PROCEDURE FOR CW PUMPING POWER
101 of 129
2 X 600 MW SCCL ADIALABD TPP
Procedure For Measurement Of Equivalent CW Pumping Power: for Pressure Drop In CW

system Between BHEL Terminal Points.
1.0 This procedure covers the calculation of equivalent CW pumping power for Design flow through
condenser corresponding to pressure drop in CW system within BHEL Terminal points (Refer Section
VI, Part A, Functional Guarantees & Liquidated Damages, Cl.1.01.01 (iv) of technical specification).
The total pressure drop within BHEL Terminal points constitutes of pressure drop through following:
 Condenser
 Balls collecting strainer of Condenser on Load Tube cleaning System
 Piping and fittings
2.0 The equivalent pumping power thus can be obtained from the pressure drops measured in these
components for the CW flow through them, using following calculations.
The formula used for calculating the Test CW pumping power (Ptest) with reference to design
conditions, within BHEL terminal points is as follows:
Ptest = Qdesign * DPcorrected

-----------------------
367.2 * o
Where:
Qdesign = Design Condenser CW flow = 28000 m3/hr
o = Overall efficiency of CW pump & Drive Set

= 0.83 (as per Section VI, Part A, Functional Guarantees & Liquidated Damages,
Cl.1.01.01 (iv), of technical specification)
DPcorrected = Test pressure drop corrected for design conditions
= ( Qdesign / Qtest )1.75 * DPtest * ( Ctd / Ctt )

Here;
Qtest = Test flow through condenser as computed.
(VWO, 3% Make-Up condition)
DPtest = Test CW side pressure drop within BHEL terminal points measured across Pressure
Test points.
Ctd = Design temperature correction factor for friction loss as per HEI (Ref Annexure-I)
Ctt = Test temperature correction factor for friction loss as per HEI (Ref Annexure-I)
102 of 129
3.0 The pressure drop for Condenser, Balls Collecting Strainer, piping and fittings within BHEL terminal
points can be measured directly at site across the Pressure Test Points (PTP’s) (viz. the pressure
drop measured across pressure test points shall include the pressure drop of condenser, COLTCS,
piping and fittings within BHEL terminal points) and tabulated in the log sheet attached as Annexure
II. The PTP’s shall be calibrated before the test in an approved reputed test lab. The calibration
certificate in original shall be submitted to customer before start of the PG Test for their acceptance.
4.0 The design CW pressure drop within BHEL terminal points is 6 MWC at design CW flow (viz.
condenser – 4.10, Ball strainer – 0.15 MWC and Piping and fittings – 1.75 MWC)
The Condenser On Load Tube Cleaning System should be in clean condition for the purpose of test
and this is to be ensured after backwashing the strainer.
103 of 129
HXE-PT-CONDR-074-00
Rev. No. : 00
Dated : 11/06/2016
Page 3 of 3
ANNEXURE-1
DK Yadav DK Yadav N Prakash
104 of 129
Annexure II
Log sheet for CW Pumping Power Test

Project: 2X600 MW SCCL ADILABAD TPP
Pressure at PTP provided Pressure at PTP provided at Flow as calculated Differential pressure between
S.No. at BHEL’s supply Terminal BHEL’s return Terminal Qtest BHEL terminal points, DPtest DPcorrected
Point Point
(1) (2) (3) (4) (5) = (3) - (2)
105 of 129


ANNEXURE – 23
TEST PROCEDURE FOR CONDENSER ON

LOAD TUBE CLEANING SYSTEM
106 of 129
9661-110-27PE-PVM-W-004, Rev-00
107 of 129
108 of 129
109 of 129
110 of 129

ANNEXURE – 24
PG TEST PROCEDURE FOR CONDENSATE

EXTRACTION PUMP
111 of 129
112 of 129
FP 12947
PRODUCT STANDARD
Rev No. 05
TD-106-1
PUMPS Rev No. 00

Form No.
HYDERABAD
HYDERABAD Page 2 of 6
SINGARENI THERMAL POWER PROJECT (2X600MW)
PROCEDURE FOR PERFORMANCE GUARANTEE TEST OF CEPs AT SITE

The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED,
It must not be used directly or indirectly in any way detrimental to the interest of the company.
1.0.0 OBJECT OF TEST :

The site performance guarantee tests shall cover the following tests on CEPs against
“Guarantees under category-III”.
1.1.0 Each CEP shall be capable of delivery flow and total dynamic head corresponding to
to Run out point.
1.2.0 The vibration, Noise level and parallel operation of any two of the three pumps shall be
demonstrated ,
COPYRIGHT AND CONFIDENTIAL
2.0.0 GUARANTEE PARAMETERS:

SI.NO CONDITION FLOW DYNAMIC TEMP SPEED
cubic HEAD °C RPM
M/hr MLC
01 RUN OUT CONDITION 975 190 46.4 1485
3.0.0 TEST SCHEME :

The Schematic arrangement for conducting the test is indicated in sheet-6.
4.0.0 TEST MEASUREMENT:
4.1.0 FLOW:
Suction flow shall be measured using the plant flow orifice. Differential pressure across flow
nozzle shall be measured using differential pressure transmitter of accuracy 0.25% and flow
shall be calculated based on the calibration data of flow orifice.
4.2.0 HEAD :
Head shall be measured by pressure transmitters having an accuracy of ±0.10%.
Revisions : Prepared : Approved : Date :

FP10495
Ref. Doc
07.06.16
Refer to record of revisions : (ROHIT P) (SRINIVAS P)
113 of 129
FP 12947
PRODUCT STANDARD
Rev No. 5
TD-106-2
Rev No.00
PUMPS
Form No.
HYDERABAD
4.4.0 Temperature:
Temperature shall be measured using platinum RTDs.
4.5.0 Speed:
Speed shall be measured using digital, Non-contact type optical speed indictor
The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED .
having an accuracy of 1 RPM/STROBOSCOPE.

4.5.0 Vibration:
Vibration of CEP shall be measured at BEP condition using portable vibration meter.
4.6.0 Noise level:
Noise level shall be measured at BEP condition at a distance of 1.0m from the outer most surface of
CEP and 1.5m above floor level, using portable noise level meter. Correction for back ground noise
shall be applied in line with HIS.
4.7.0 List of instruments:

The list of instruments required for the PG tests are indicated in sheet-6.
4.8.0 Calibration of instruments:
All Instruments used for Pumps PG test will be calibrated at BHEL(R & D) prior to the PG test,
and calibration certificates shall be furnished to NTPC.
4.9.0 Data logging:
Primary sensors of flow, pressure and temperature will be connected to a data logger
And recorded for evaluation.
5.0.0 PERFORMANCE AT RUN OUT CONDITION:
The pump flow will be adjusted to the Run out condition, and measurements will be made for all
parameters. Various parameters will be logged at interval of 1 minute. 15 sets of reading will be
recorded continuously. Average of at least 10 sets of consistent data shall be considered for
evaluating the performance guarantee data.
Run out condition: - Test will be conducted at 3 flow point. i.e Run out point, +5% and -10% of Run
out condition flow.
Curve for flow vs head will be plotted after applying speed and temperature correction. Guarantee
parameters will be read from this curve.
114 of 129
FP 12947
PRODUCT STANDARD
Rev No. 5
TD-106-2
Rev No.00
PUMPS
Form No.
6.0.0 PARALLEL OPERATION :
Parallel operation of any two CEPs will be demonstrated at best efficiency point. 15 sets
of flow reading will be recorded continuously at 1 minute intervals.
Average of at least 10 consistent readings will be considered for evaluating the performance
guarantee data.
Test will be conducted at 1 flow point i.e at BFP point (615 Cu.m/hr).
7.0.0 ACCEPTANCE CRITERIA FOR TESTS :
7.1.0 Capability at Run out condition :
Total dynamic head of CEP at Run out condition shall not be less than the guaranteed
dynamic head of CEP at relevant operating condition flow.
7.2.0 Parallel operation: variation in flow between the pumps shall not exceed 5%.
7.3.0 Vibrations: Vibration shall not exceed 7.0 mm/sec (rms.)
7.4.0 Noise Level: Noise level shall not exceed 85 dBA.
7.5.0 Sample calculations :
7.5.1 Flow calculations :
(a) Correction for temperature :

Q1 = Q/WT
Where ,Q = Measured flow in T / Hr, Q1 = corrected flow in Cu.M/Hr

WT = Sp.Weight at test temperature
(b) Correction for speed :

QS = Q1 (NS /NT)
Where ,QS = Flow in Cu.M/Hr at specified speed

NS = Specified speed
NT = Test speed
115 of 129
FP 12947
PRODUCT STANDARD
Rev No. 5
TD-106-2
Rev No.00
PUMPS
Form No.
7.5.2 Head calculations :
(a) Correction for temperature :

H = ( P2- P1) X10/WT
Where, P2 = CEP disch. Pr.in kg/sq.cm

P1 = CEP suct. Pr. in kg/sq.cm
H = Dynamic head of CEP in MLC at test speed
(b) Correction for speed :

HS = H X SQUARE (NS /NT)
Where ,HS = Dynamic head of CEP in MLC at specified speed

116 of 129
117 of 129
REV DATE ALTERED: AS KALYAN

450
01 27-07-2012 APPROVED: M M RAO
M IN. RE CIRC FLOW
400
THE NPSHR VALUE IS UPDATED TO SECOND DECIMAL PLACE
350
A
Head (m)
300
D FLOW HEAD ACT. TEMP (deg. SP. WT SPEED

REF HEAD (mlc) EFFIC (%) POWER (KW) NPSHR (mlc)
(cu.m/hr) (mlc) C) (kg/m3) (RPM)
250
C E A 900 290 290 49.2 988.4 80.5 873 1485 3.35

200 B B 975 190 267 46.4 989.6 79.2 885 1485 3.54
C 715 240 329 46.4 989.6 80.5 787 1485 2.89

150
D 825 290 309 49.2 988.3 81.1 845 1485 3.16
100 E 1015 215 252 59.7 983.3 78.2 877 1485 3.65
1200
A - Design condition
1000 51.5 HZ
A
POWER (KW)
B - Runout Condition
D
800 B E 50 HZ C - Best Efficiency Point
C 47.5 HZ D - HPH out Condition
600
E - Maximum Capability condition
400
200
90.0 5.5
90 18
A A NOTE :
80.0 5
80 16 1. SHUT OFF HEAD AT 50Hz = 367 mlc.
2. INPUT POWERS AT B , C , D & E ARE CALCULATED

70.0 4.5
70 14
Efficiency (%)
BASED ON ACTUAL HEADS GENERATED AT 50 Hz.

60.0 4
60 12
Efficiency (%)
B
50.0
50 A E 10 3.5 NPSH (R) m Digitally signed
Signature Not Verified
NPSH (R) m
by Sign Sunil
Jumde
NTPC DRAWING NO: 9661-110-02HY-PVM-N-002, REV-01
40.0
40
C D 8 3 Date: 2012.08.03
14:41:13 IST
JOB NO. : 381 M/s The Singareni Colliries Company
C CUSTOMER:
Reason: CAT IV
Limited (SCCL)
30.0
30 A 6 2.5 STATUS: CONTRACT Location:
NTPCEOC
CONSULTANT: M/s NTPC Ltd.
51.5 HZ B DRG./REF.NO. (INTERNAL)
20
20.0 4 2 SCCL COAL BASED THERMAL POWER
50 HZ FP12910 PROJECT:
PLANT (2X600MW)
10 2
PUMPS ENGINEERING NAME SIGN DATE
10.0 1.5
BHARAT HEAVY ELECTRICALS PRPD. AS Kalyan -- 05-05-2012
CHKD. M M RAO -- 05-05-2012
0 0 LTD. HYDERABAD APPD. B RAJKUMAR -- 05-05-2012
0.0 1
00 200
100 400
200 600
300 400800 5001000 600 1200 700 1400 800 1600 900 1800
1000 2000
1100 1200 TITLE: DRG. NO. HY-DG-4-FP12910
Flow (m3/ h) REV 01
Flow (m3/ h) ESTIMATED PERFORMANCE CURVES OF CEP
SHEET NO: 1 NO. OF SHEETS: 1
118 of 129

ANNEXURE – 25
PG TEST PROCEDURE FOR BOILER FEED

PUMP
119 of 129
120 of 129
FP 12948
PRODUCT STANDARD
Rev No. 05
TD-106-1
PUMPS Rev No.00

Form No.
HYDERABAD
SINGARENI THERMAL POWER PROJECT (2X600MW)

PROCEDURE FOR PERFORMANCE GUARANTEE TEST OF BFP SETS AT SITE
1.0.0 OBJECT OF TEST :

The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED,
The site performance guarantee tests shall cover the following tests on BFP sets
against “Guarantees under category –III”.

1.1.0 Each BFP set shall be capable of delivery flow and total dynamic head corresponding
to Run out point.
1.2.0 The vibration, Noise level and parallel operation of any two of the three pumps shall
be demonstrated
2.0.0 GUARANTEE PARAMETERS:
2.1.0 Run-out condition:
SI.NO EQUIPMENT FLOW TOTAL DYNAMIC TEMP BP/ BFP

Cubic m/hr HEAD (BP+BFP) °C SPEED
m/c rpm
01 MD BFP SET 1350 2025 148.7 1495 / 5630
02 TD BFP SET 1350 2025 148.7 1475 / 5635
3.0.0 TEST SCHEME:

The Schematic arrangement for conducting the test is indicated in sheet-6.
4.0.0 TEST MEASUREMENTS:
4.1.0 FLOW:
Suction flow shall be measured using the plant flow nozzle. Differential pressure across flow
nozzle shall be measured using differential pressure transmitter of accuracy 0.25% and flow shall
be calculated based on the calibration data of flow nozzle.
4.2.0 HEAD :
Head shall be measured by pressure transmitters having an accuracy of ±0.10%.
4.3.0 Temperature:
Temperature shall be measured using platinum RTDs.
Revisions : Prepared : Approved : Date :

FP10
Ref.
Doc
495
Refer to record of revisions : (ROHIT.P) (P.SRINIVAS) 07.06.16
121 of 129
FP 12948
PRODUCT STANDARD
Rev No. 5
TD-106-2
Rev No.00
PUMPS
Form No. HYDERABAD
4.4.0 Speed
TD Booster pump speed,MD Booster pump speed and MD BFP Speed shall be measured using
digital,non-contact type optical speed indicator having an accuracy of 1 RPM/STROBOSCOPE.
TD BFP Speed will be derived from measured TD BP Speed, using gear box gear ratio.
4.5.0 Vibration:
Vibration of BFP at BEP point shall be measured using portable vibration meter.
4.6.0 Noise level:
Noise level shall be measured at a distance of 1.0m from the outer most surface of BFP and
1.5m above floor level, using portable noise level meter. Correction for back ground noise shall
be applied in line with HIS.
4.7.0 List of instruments:
The list of instruments required for the PG tests are indicated in sheet-6.
4.8.0 Calibration of instruments:
All Instruments used for Pumps PG test will be calibrated at BHEL(R & D) prior to the PG test,
& calibration certificates shall be furnished to NTPC.
4.9.0 Data logging:
Primary sensors of flow, pressure and temperature will be connected to data logger
And recorded for evalution.
5.0.0 PERFORMANCE AT RUN OUT CONDITION:

The pumps flow and pressure will be adjusted to the RUN out condition, and measurement will
be made for all parameters. The inter stage and kicker-stage lines will be closed during the test
.Various parameters of Booster pump & BFP will be logged at interval of 1minute. 15 sets of
reading will be recorded continuously.
Average of at least 10 sets of consistent data shall be considers for evaluating the performance
guarantee data.
Run out condition :- Test will be conducted at 3 flow points.i.e Run out point,+5% and (-)10% of
Run out condition flow.
Curve for flow vs. head will be plotted after applying speed and temperature Correction,
Guarantee parameters will be read from this curve.
Total dynamic head of BFP set is the sum of Booster pump head and BFP head at guaranteed
flow.
122 of 129
FP 12948
Rev No. 5
TD-106-2
PRODUCT STANDARD
Rev No.00
Form No.
PUMPS
HYDERABAD
Page 4 of 6
6.0.0 PARALLEL OPERATION:
Parallel operation of two TD BFP sets will be demonstrated at Best efficiency point.
The inter-stage and kicker-stage lines shall be closed during the test. 15 sets of reading will be
recorded continuously at 1 minute intervals.
Average of at least 10 consistent reading will be considered for evaluating the performance
guarantee data.
Test will be conducted at 1 flow point i.e at BEP point (855 Cu. m/hr).
7.0.0 ACCEPTANCE CRITERIA FOR TESTS:

7.1.0 Capability at Run out Condition:
Total dynamic head of BFP set at Run out condition read from the site tested curve shall not be
less than the guarantee dynamic head of BFP set at relevant operating condition flow.
7.2.0 Parallel operation of BFP sets:

The variation in flow between the pumps shall not exceed 5%.
7.2.0 Vibrations:
Vibration will be measured and the same shall not exceed 7.0 mm/sec (rms.)
7.3.0 Noise Level:
Noise level shall not exceed 85 dBA.
7.4.0 Sample calculations:
7.4.1 Flow calculations:
(a) Correction for temperature:

Q1 = Q/WT1
Where, Q = Measured flow in T/Hr

Q1 = Corrected flow in Cu.M/Hr
WT1 = sp. Weight at BFP suction temperature
(b) correction for speed :

QS = Q1 (NS / NT)
Where, QS = flow in Cu.M/Hr at specified speed

NS = specified speed
NT = Test speed
123 of 129
FP 12948
PRODUCT STANDARD
Rev No. 5
TD-106-2
Rev No.00
PUMPS
Form No.
7.4.2 Head calculations for BP
(a) correction for temperature

HBP = (P2- P1) X 10/ WT1
Where, P2 = BP Disch./BFP Suction Pr.in kg/Sq.cm

P1 = Booster pump suction Pr.in kg/Sq.cm
HBP = Dynamic head of BP in MLC at test speed
(b) correction for speed

HBPs = HBP X SQUARE (NS /NT)
Where, HBPs = Dynamic head of BP in MLC at specified speed
7.4.3 Head calculations for BFP

(a) correction for temperature
HBFP = (P3 –P2) X 10/WT2
P3 = BFP discharge pressure in kg/sq.cm

P2 = BFP Suction / BP Disch . Pr.in kg/sq.cm
WT2 = SP.Weight at BFP Disch.Temperature.
HBFP = Dynamic head of BFP in MLC at test speed
(b) correction for speed
HBFPs = HBFP X SQUARE(NS / NT)

Where ,HBFPs = Dynamic head of BFP in MLC at specified speed
124 of 129
125 of 129
Rev-02 Rev-01
3100 Test code updated. NPSHR values revised as per

MIN RC FLOW
9661-110-03HY-PVM-N-008, pump frame
2800 and test code indicated.
2500
D FLOW HEAD EFFICIENCY POWER SPEED NPSHR
E REF
(m3/hr) (mlc)
SP. GR.
(%) (KW) (RPM) (mlc)
F
ead (m)
2200
A 1220 2127 0.903 80.2 7957 5710 68.5
A B 1350 1840 0.918 77.9 7972 5630 87.8
Head
C 1055 2048 0.904 81.2 6551 5430 54.9

C D 1165 2409 0.904 80.7 8562 5910 62.9
1900 B E 1195 2365 0.904 80.5 8643 5905 65.8
F 1165 2339 0.903 80.7 8304 5845 62.9
1600
1300 A- DESIGN POINT

B- RUNOUT POINT
C- BEST EFFICIENCY POINT
1000 D- EMERGENCY POINT
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
E- U/F CASE 1
Flow (m3/h) F- U/F CASE 2
10000
D E
8000
F A B
ER (KW)
6000 C
POWER
4000 NOTE :
1. DISCHARGE FLOW AT THE DESIGN CONDITION
2000 IS WITH INTER STAGE CLOSED.
2. MIN. RC FLOW INDICATED IS FOR BFP OPERATION. THIS IS
INDICATED ONLY FOR THE PURPOSE OF CALCULATING
0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
BFP SET SHUT OFF PRESSURES AT RC FLOW.
Flow (m3/h) 3. HYDRAULIC COUPLING MAXIMUM OUTPUT SPEED = 6010 RPM
90
A
80 100
70 B
60 75 PUMP FRAME MODEL: FK4E36

iency (%)
F E TEST CODE: ANSI/ HI 14.6-2011

Digitally signed
Efficienc
50 A Signature Not
by PVerified
D R SEN
NPSH (R) m
NTPC
Date: DRAWING NO: 9661-110-03HY-PVM-N-001
2013.04.17
40 C 50
JOB NO. : 381
14:04:55 IST M/s The Singareni Colliries Company Limited
Reason: CAT IV
CUSTOMER:
Location: (SCCL)
30 STATUS: CONTRACT
NTPCEOC
CONSULTANT: M/s NTPC
DRG./REF.NO. (INTERNAL)
20 25 SCCL COAL BASED THERMAL POWER PLANT
FP12880 PROJECT:
(2X600MW)
10
PRPD. AS Kalyan -- 13-08-2012
BHARAT HEAVY ELECTRICALS LTD.
CHKD. M M RAO -- 13-08-2012
0 0 HYDERABAD APPD. B RAJKUMAR -- 13-08-2012
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 TITLE: DRG. NO. HY-DG-4-FP12880
Flow (m3/h) ESTIMATED PERFORMANCE CURVES OF MD REV 02
BOILER FEED PUMP SHEET NO: 1 NO. OF SHEETS: 1
126 of 129
Rev-03 Rev-02 Rev-01

260
Test code updated. Test code updated. Pump frame and test code are
MIN. RE CIRC. FLOW

240
220
C
200 D E 51.5 HZ
Head (m)
F A B
180
50 HZ
160 47.5 HZ
FLOW EFFICIENC POWER SPEED NPSHR
REF HEAD (mlc) SP. GR.
(m3/hr) Y (%) (KW) (RPM) (mlc)
140
A 1220 193 0.9030 82.3 704 1495 5.75
120 B 1350 185 0.9180 81.5 766 1495 6.64
C 1055 202 0.9040 81.8 641 1495 4.79

100
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 D 1165 196 0.9040 82.3 683 1495 5.41
E 1195 195 0.9040 82.3 697 1495 5.60
Flow (m3/h) F 1165 196 0.9030 82.2 683 1495 5.41
900
51.5 HZ
800
E A- DESIGN POINT
700 D B 50 HZ
POWER (KW)
B- RUNOUT POINT
A
600
C F 47.5 HZ C- BEST EFFICIENCY POINT
D- EMERGENCY POINT
500
E- U/F CASE 1
POW
400 F- U/F CASE 2

300
200
NOTE :
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
Flow (m3/h) 1. DISCHARGE FLOW AT THE DESIGN CONDITION
IS WITH INTER STAGE CLOSED.
90 9
A 2. MIN. RC FLOW INDICATED IS FOR BFP OPERATION. THIS IS
80 8 BFP SET SHUT OFF PRESSURES AT RC FLOW.
70 B 7
60 A 6 PUMP FRAME MODEL: FA1B75

E
Efficiency (%)
F TEST CODE: ANSI/ HI 14.6-2011

50 C D 5
NPSH (R) m
NTPCDigitally
DRAWING signed
NO: 9661-110-03HY-PVM-N-002
Signature Not
by PVerified
R SEN
40 4 JOB NO. : 381 Date: 2013.04.25 M/s The Singareni Colliries Company Limited
51.5 HZ CUSTOMER:
19:25:04 IST (SCCL)
50 HZ STATUS: CONTRACT Reason: CAT IV
30 3
N
47.5 HZ Location:
DRG./REF.NO. (INTERNAL) NTPCEOC
20 2 SCCL COAL BASED THERMAL POWER PLANT
FP12881 PROJECT:
(2X600MW)
10 1 PUMPS ENGINEERING NAME SIGN DATE
CHKD. M M RAO -- 13-08-2012
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
TITLE: DRG. NO. HY-DG-4-FP12881
Flow (m3/h) ESTIMATED PERFORMANCE CURVES OF MD REV 03
BOOSTER PUMP SHEET NO: 1 NO. OF SHEETS: 1
127 of 129
Rev-02 Rev-01
3400
Test code updated. NPSHR values revised as per
9661-110-03HY-PVM-N-008, pump frame
3100
and test code indicated
MIN RC FLOW
2800
2500
D
Head (m)
2200
C A
H
1900 B
FLOW EFFICIENCY POWER SPEED NPSHR
1600 REF HEAD (mlc) SP. GR.
(m3/hr) (%) (KW) (RPM) (mlc)
A 1220 2127 0.903 80.2 7956 5710 68.5
1300 B 1350 1846 0.918 77.9 7999 5635 87.8
C 1055 2068 0.904 81.2 6615 5450 54.9
D 1165 2394 0.904 80.7 8507 5895 62.9
1000
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
Flow (m3/h)
10000 A- DESIGN POINT
B- RUNOUT POINT
D B C- BEST EFFICIENCY POINT
8000
A D- EMERGENCY POINT
(KW)
POWER (KW
6000
C
4000 NOTE :
1. DISCHARGE FLOW AT THE DESIGN CONDITION
2. MIN. RC FLOW INDICATED IS FOR BFP OPERATION. THIS IS
0
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500
BFP SET SHUT OFF PRESSURES AT RC FLOW.
Flow (m3/h) 3. DRIVE TURBINE TRIP SPEED= 6281 RPM
90
80
A 100
B
70
Efficiency (%)
60 75 PUMP FRAME MODEL: FK4E36
50 A TEST CODE: ANSI/ HI 14.6-2011

NPSH (R) m
D NTPC DRAWING NO: 9661-110-03HY-PVM-N-003

Digitally signed
40 C 50 Signature Not
JOB NO. : 381 by PVerified
R SEN M/s The Singareni Colliries Company Limited
CUSTOMER:
Date: 2013.04.17 (SCCL)
30 STATUS: CONTRACT 17:18:25 IST
DRG./REF.NO. (INTERNAL)Reason: CAT IV
20 25
Location: SCCL COAL BASED THERMAL POWER PLANT
FP12882 NTPCEOC PROJECT:
(2X600MW)
10
CHKD. M M RAO -- 13-08-2012
0 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 TITLE: DRG. NO. HY-DG-4-FP12882
Flow (m3/h) ESTIMATED PERFORMANCE CURVES OF TD REV 02
BOILER FEED PUMP SHEET NO: 1 NO. OF SHEETS: 1
128 of 129
Rev-03 Rev-02 Rev-01

Test code updated Test code updated. Pump frame and test code are indicated
300
280
260
MIN. RE CIRC. FLOW
250 T-TRIP(BP) 1645RPM
240
480 m3/hr for
Condition - A
220
200 C D
A
200 167.8889645
Head(m)
(m)
150
B A B
Head
180
C
FLOW EFFICIEN POWER SPEED NPSHR
160
100 REF HEAD (mlc) SP. GR.
(m3/hr) CY (%) (KW) (RPM) (mlc)
140 A 1220 193 0.9030 82.3 704 1495 5.75

50 B 1350 179 0.9180 81.5 741 1475 6.59
120
C 1055 182 0.9040 81.8 578 1427 4.61
100
0 D 1165 211 0.9040 82.3 735 1543 5.54
00 100 200200 300
400 400 600500 600
800 7001000800 1200
900 10001400
1100 1200
1600 13001800
1400 1500
2000
Flow
Flow(m3/h)
(m3/h)
800
900 A- DESIGN POINT
B- RUNOUT POINT
800
700 A B C- BEST EFFICIENCY POINT
C D D- EMERGENCY POINT
700
A
(KW)
600
600
NOTE :
(KW)
500
B C
POWER
500 1. DISCHARGE FLOW AT THE DESIGN CONDITION

400
POWER

300 2. MIN. RC FLOW INDICATED IS FOR BFP OPERATION. THIS IS
300
200 BFP SET SHUT OFF PRESSURES AT RC FLOW.
00 100 200200 300
400 400 600500 600
800 7001000800 1200
900 10001400
1100 1200
1600 13001800
1400 1500
2000
Flow (m3/h)
Flow (m3/h)
90
90 9
18
A A
80
80 8
16
70 7
70
B 14
Efficiency (%)
(%
PUMP FRAME MODEL: FA1B75

60
60 A 6
12
Efficiency (%)
D TEST CODE: ANSI/ HI 14.6-2011

50 C 5 Digitally
SignatureNTPC
Not signed
by PVerified
50 10 DRAWING NO: 9661-110-03HY-PVM-N-004
(R) m
m
R SEN
NPSH(R)
JOB NO. : 381 Date: 2013.04.25 M/s The Singareni Colliries Company Limited
40
40 84 CUSTOMER:
19:23:06 IST
C (SCCL)
NPSH
STATUS: CONTRACT Reason: CAT IV

Location:
30
30 A 63 DRG./REF.NO. (INTERNAL)
CONSULTANT:
NTPCEOC
M/s NTPC
B SCCL COAL BASED THERMAL POWER PLANT
20
20 42 FP12883 PROJECT:
(2X600MW)
10 PUMPS ENGINEERING NAME SIGN DATE
10 21
BHARAT HEAVY ELECTRICALS
CHKD. M M RAO -- 13-08-2012
00 LTD. HYDERABAD
00 APPD. B RAJKUMAR -- 13-08-2012
00 100 200200 300
400 400600500 600
800 7001000800 900
1200 1000
14001100 1200
1600 1300
18001400 2000
1500 TITLE: DRG. NO. HY-DG-4-FP12883
Flow (m3/h)
Flow (m3/h) ESTIMATED PERFORMANCE CURVES OF TD REV 03
BOOSTER PUMP SHEET NO: 1 NO. OF SHEETS: 1
129 of 129

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BHEL/ POWER SECTOR-EASTERN REGION(HQ)/TECHNICAL SERVICES

ट�जी और सहायक पॉवर उपभोग हे तु �नष्पाद गारं ट� पर��ण प्र�क

PERFORMANCE GUARANTEE TEST PROCEDURE

प�रयोजना नाम: �संगरे नी को�लयर�ज ट� पी एस।

भारत हे वी इलेिक्ट्र �ल�मटे ड प�रयोजना स्था: बी एच ई एल साइट कायार्ल

Project name: SINGARENI COLLIERIES TPS

6.0 PREPARING THE TG CYCLE FOR THE TEST 7‐8

8.0. INSTALLATION OF TEST INSTRUMENTS 8‐9

9.0 GENERAL GUIDELINES 9‐10

10.0 INSTRUMENTS CALIBRATION AND CORRECTION 10

11.0 ITEMS ESSENTIAL FOR AGREEMENT 10

12.0 NUMBER OF TEST RUNS 10

13.0 FREQUENCY OF OBSERVATION 10

14.0 RECORDING OF READINGS 11

15.0 DURATION OF TESTS 11

16.0 ACTIVITIES BEFORE OFFICIAL TEST 11

17.0 POST TEST ACTIVITIES 12

18.0 AGEING 12

19.0 ANNEXURE ( 1 TO 25 ) 13‐129

Sr. no. Guaranteed Parameters Guaranteed figures

(i) Turbine cycle Heat Rate in Kcal/Kwhr under rated steam conditions at 1927.1 Kcal/Kwhr

Sr. no. TURBINE GENERATOR SET CAPABILITY Value/Remarks

Sr. STEAM CONDENSING PLANT Remarks

Sl Parameter Range Instruments Accuracy/Uncertain

2 Differential pressure across the Various ranges upto DP Transmitter Accuracy +/‐ 0.05 %

5 Temperature 0‐650 0 C K type Uncertainty ±0.55 0C

9 Atmospheric pressure 0‐780mmHG Barometer or abs Accuracy +/‐ 0.1 % or

11 PG test instrumentation scheme & list 24‐33

19 DISSOLVED OXYGEN CONTENT AT DEAERATOR OUTLE 81

24 PG TEST PROCEDURE FOR CONDENSATE EXTRACTION PUMP 111‐118

25 PG TEST PROCEDURE FOR BOILER FEED PUMP 119‐129

93 PA56 Extraction 3 to LPH 3 (TE) from LPT‐B 0‐4 2.597

94 PA57 Extraction 2 to LPH 2 (TE) from LPT‐B 0‐780 mmHg 0.994

95 PA58 Extraction 1 to LPH 1B 0‐780 mmHg 0.402

96 PA59 Extraction 1 to LPH 1A 0‐780 mmHg 0.402

97 PA60 TDBFP‐A steam inlet 0‐10 6.78

98 PA61 TDBFP‐B steam inlet 0‐10 6.78

S.No Tag No Service Range(in kg/cm2)

1 FP01A Condensate flow to deaerator 0‐2.5

DOCUMENT TITLE: DOCUMENT NUMBER:

1.0 HEAT AND MASS BALANCE ACROSS HP HEATERS:

Ma+Mb = Mffw (A)

Ma.H6a + Mb.H6b = Mffw.H14 (B)

1.1 HEAT BALANCE ACROSS HPH-7A:

Ma.(H6a-H5a) = Za.(H12a-H7a) (C)

1.2 HEAT BALANCE ACROSS HPH-7B:

Mb.(H6b-H5b) = Zb.(H12b-H7b) (D)

1.3 HEAT BALANCE ACROSS HPH-6A:

Ma.(H5a-H4a) = Za.(H7a-H8a)+Ya.(H11a-H8a) (E)

1.4 HEAT BALANCE ACROSS HPH-6B:

Mb.(H5b-H4b) = Zb.(H7b-H8b)+Yb.(H11b-H8b) (F)

1.5 HEAT BALANCE ACROSS HPH-5A:

Ma.(H4a-H3a) = (Ya+Za).(H8a-H9a)+Xa.(H10a-H9a) (G)

DOCUMENT TITLE: DOCUMENT NUMBER:

1.6 HEAT BALANCE ACROSS HPH-5B:

Mb.(H4b-H3b) = (Yb+Zb).(H8b-H9b)+Xb.(H10b-H9b) (H)

2.0 HEAT AND MASS BALANCE ACROSS THE DEAERATOR:

M2.H2 = (Xa+Ya+Za).H9a+(Xb+Yb+Zb).H9b+W.H1+M1.H13 (I)

M2 = M1+W+Xa+Xb+Ya+Yb+Za+Zb± Mdea (J)

3.0 FINAL FEED WATER FLOW:

Mffw = M2 –Mshs-Mrhs (K)

Mshs = 0, when spray is taken from HPH outlet.

DOCUMENT TITLE: DOCUMENT NUMBER: