ELECTRICALS LIMITED, It must not be used directly or indirectly in any way detrimental to the interest of the company.

COPYRIGHT AND CONFIDENTIAL - The information in this document is the property of BHARAT HEAVY
INDEX

SL. NO.DESCRIPTION PAGE NO.

1 GENRAL DESCRIPTION & SCOPE 2

2 SYSTEM DESIGN CRITERIA 3
3 MATERIALS OF CONSTRUCTION 5
4 CONTROLS & INSTRUMENTATION 6

REV DATE ALTD CHKD APPD

04 23.03.07 BK VKY AKT
STATUS INDICATION AT
UCR FOR VARIOUS
TRANSMITTERS
INCORPORATED.
REV DATE ALTD CHKD APPD
03 01.02.07 VKY VKY AKT
UPDATED AS PER DISCUS
WITH GIPCL/ TCE DTD.
30.01.07 TO 1.02.07 AT
PEM ,NOIDA
REV DATE ALTD CHKD APPD
02 16.12.06 VKY VKY AKT
UPDATED AS PER GIPCL /
TCE COMMENTS DTD.
12.12.06

JOB NO. ### GUJARAT INDUSTRIES POWER COMPANY LIMITED

STATUS CONTRACT 2X125 MW SURAT LIGNITE POWER PROJECT
DISTRIBUTION BHARAT HEAVY ELECTRICALS LTD. DEPTT NAME SIGN
TO POWER SECTOR CODE DESN. BK sd/-
NO PROJECT ENGINEERIING MANAGEMENT N CHD. VKY sd/-
REV DATE ALTD CHKD APPD NEW DELHI APPD. AKT sd/-
01 10.11.06 BK VKY AKT TITLE:
UPDATED
CW & CCW
ASSYSTEM
PER GIPCL
DESIGN
/ PHILOSOPHY & SYSTEM WRITE-UP
TCE COMMENTS DTD. DEPTT DOCUMENT NO:
07.10.06 PE-DC-253-165-N002
SIGN
DATEPage 1 of 10 REV – 04
SIGN DATE
sd/- 10-08-06
sd/- 10-08-06
sd/- 10-08-06
 2 X1 25 MW SURAT LIGNITE POWER PROJECT DOCUMENT NO. PE-DC-253-165-N002
REVISION NO. 04
CW & CCW SYSTEM DESIGN PHILOSOPHY & WRITE-UP DATE: 23.03.07

INTRODUCTION:

This document gives the system description, Design Philosophy and Control & Instrumentation Philosophy
covering Cooling Water & Circulating Cooling Water Systems.

1.0 CW and CCW SYSTEM - General Description and Scope:

(Reference Drg. No. PE-DG-253-165-N001)

1.1 CW System:

The CW System envisaged for each unit shall be closed circuit recirculating type with Induced draft Cooling
Tower. The CW system will deliver cooling water to Condenser and CCW system.

Cooling water shall be supplied to Condenser and CCW system through CW pumps installed in CW pump
House. The hot water return from Condenser & CCW system of each unit shall be led together to respective
Cooling Tower for cooling. The cooled water from cooling tower shall be returned to CW sump by gravity for
recirculation in the closed cycle CW system. Make up water shall be added in the CW forebay of CW system
(refer details in Plant water P&ID).

Tapping of water for Side stream filteration plant shall be taken from the CW supply whereas tappining
for blow down shall be taken from the hot water return from Condenser & CCW system for each unit.
The blow down from both the units shall be combined together & taken to the guard pond.
(For details refer Plant water P&ID).

COLTCS:

The condenser on load tube cleaning system shall be provided to prevent the formation of scales in the condens.
tubes. Cleaning balls shall be transported through the condenser tubes by the cooling water flow and after
cleaning of the tubes they shall be separated from the cooling water by the balls separator installed at condenser
outlet. The balls are then extracted by balls recirculation pump and reinjected into the condenser CW inlet line.

CW System comprises of:

a) 3 nos. CW Pumps with drive motors for both units (ie. 1 no./ unit - each 100% duty with 1 no. common
standby).
b) 2 nos. Cooling towers (viz. one per unit).
c) 1 no. Rubber Expansion (RE) Joint at discharge of each CW Pump.
d) CW Pump discharge Motor actuated BFV (6 nos.) for both units (ie. 1 no. per pump & 2 nos. for common
standby pump)
e) 2 nos. Rubber Expansion (RE) Joint at each inlet & outlet of condenser.
f) Motor actuated BFV at each inlet & outlet of condenser.
g) CW recirculation line with 1 no. isolating BFV.
h) Condenser on-load tube cleaning system (2 sets per unit) (ie. 1 no. for each condenser half)
Each set of COLTCS comprises of:
_x0 Ball seperator (1 no.)
_x0 Balls recirculating skid (1 no.) with Ball recirculating pump (1 no.), ball collector (1 no.) and one no.
 manual sorter of Bucket type with sieves.
_x0 Ball monitoring system with Ball recirculation monitor (1 no.) and Balls oversize monitor (1 no.)
_x0 COLTCS system Pipework with isolation/ process valves etc.
i) CW pipe work complete with air release valves, drain valves and vent valves as required as per layout for
each unit. 600 NB Manhole with 200 NB vent valve shall also be provided @ 125 M to 150 M interval.
j) C.W. Pump house (1 no.consisting of MCC room & transformer yard) for both units with EOT crane (1 no.)
for handling CW Pumps.
k) Coarse bar screen at upstream of each CW pump sump bay (3 nos.) for both units.
l) Stop log guides at inlet of each CW pump sump bay.
m) Stop log and Screen at each chamber.
n) Semi Gantry crane for handling Stop log & Coarse bar screens (1 no.) for both units

o) Portable Submersible pumps for drainage of CW P/H and CW Sump bays (2 nos. for both units)
p) Annubar on CW supply line of each unit.
q) Instruments/ interlocks/ protections, etc. as briefed in the succeeding paras herein.

1.2 CCW System:

A tap off shall be provided from CW system header for supplying cooling water to plate heat exchangers
of CCW system and Vacuum pump heat exchangers with pressure boosted through CCW Pumps with
cooling water further filtered through Basket strainers. The hot water return from PHE's shall be returned in
CW return header for further cooling in CW system's cooling Tower.

CCW System comprises of:

a) CCW Pumps with drives (3 nos. per unit of 50% duty each).
b) Duplex Basket Strainers (2 nos. per unit, one at CCW pumps suction header and one at Vacuum pumps
heat exchangers inlet header).
c) Plate type heat exchangers (3 nos.of 50% duty each per unit,viz. 2 working + 1 standby per unit).
d) CCW Pipework with Isolating BFV's, drain valves and vent valves as required as per layout.
e) Instruments/ interlocks/ protections, etc. as briefed in the succeeding paras herein.

2.0 CW & CCW SYSTEM DESIGN CRITERIA:

2.1 C.W. Pumps :

a) Rated Capacity = Condenser flow + CCW flow + side stream filteration plant flow
(when the power plant is operating at its full rated capacity)
b) Total Head = Static lift from Min. water level in CW sump to the Cooling tower top
+ Friction Drop with 10% margin in the CW system piping and fittings from CW
Pump discharge up to Cooling towers.

2.2 Condenser On load Tube Cleaning System:

a) Time duration for operation = As per manufacturer's recommendation.

b) No. of balls per COLTCS = Approx. 10% of no. of tubes of one pass of one half of condenser.

2.3 Cooling Tower:

a) Type of cooling Tower = Induced Draft Counter flow

 b) Type of fills = PVC Film type fills
c) No. of Cells = As required + 1 no. spare cell
d) Capacity per tower = Condenser design flow + CCW design flow (viz;19000 cubm per hr)
e) Cooling Range = Design CW temperature rise across Condenser + 10C (viz; 110C)
f) Design Cold water temp at CT outlet = 31.5 oC
g) Max. Water level in CT basin = 0.0 M w.r.t FGL
h) Min. Water level in CT basin (-) 1.0 M w.r.t. FGL
i) Design WBT including Recirculation = 27.4 oC
j) Approach = 4.1 oC
k) Basin storage capacity = 6 min of design CT flow (between Maxm & Min Water levels)

2.4 Piping:

a) The pipe sizes shall be calculated for design flow.

The maximum allowable velocities in M/sec. shall be as below:

Pump suction = Same as Pump suction nozzle size

Pump discharge = Same as Pump discharge nozzle size
Pipe work other than pump suction & discharge = 3.0 M/ sec

b) The friction loss in pipes shall be calculated as per William & Hazen formula as under:

i 0.54 = V
0.8492 x C x r0.63

Where:

i = Friction Head loss per unit length of pipe (MWC/M)

C = 100, for carbon steel pipe
r = Hydraulic Radius (D/4)
D = Diameter of pipe (M)
V = Velocity of fluid (M/sec)

c) The pressure drop in Valves & Fittings are based on the following formula:

HL = K x V2
2g

Where:

HL = Friction Head loss (MWC)

K = Friction factor based on Crane Handbook
g = Acceleration due to gravity (M2/Sec.)
V = Velocity of fluid (M/sec)

d) The hydraulic transient analysis shall be carried out for CW system by method of characteristics
for various possible start/ stop/ trip eventualities of CW pumps to avoid pressure surges in the system.
2.5 CW Pump House:

The sump design for the pump house shall be based on BHRA/ HIS. The sump model hydraulic studies shall
be conducted to achieve vortex free flow around bell-mouth of CW Pumps.

2.6 Coarse Bars Screens:

Spacing between bars = 50 mm

2.7 CCW Pumps:

a) Capacity = System requirement + 10% margin ( Pumps shall be capale of running for
0-130% of rated flow)
b) Head = As per System requirement + 10% margin on friction head
c) Type = Horizontal centrifugal
d) Casing = Axial horizontal split
e) Impeller = Closed
f) Speed = 1500 (max.)
g) Seal = Self water/ Gland
h) Lubrication = Oil/ Grease/ Self-liquid
i) Motor rating = Motor rating at 50 deg. C ambient temperature shall be 10% above the
maximum power requirement at any condition on the entire characteristic
curve of the pump.
2.8 Basket Strainer:

a) Clear opening = 2 mm for CCW pumps suction header & 1.5 mm for vacuum pump HE inlet.
b) Area of screen basket = 600% of inlet pipe area.

2.9 Plate type Heat Exchangers:

Refer PHE design requirement in ACW system (document no PE-DC-253-179-N002)

3.0 MATERIALS OF CONSTRUCTION (CW & CCW SYSTEM):

3.1 Piping:

Material shall be as indicated in P & ID for CW & CCW system

3.3 Valves:

3.3.1 Check Valves

_x0 Body & bonnet
_x0 Seating surface & stem
_x0 Disc for check valve
_x0 Hinge pin for check valve
_x0 Design standard
= CI, IS 210 Gr. FG 260/ BS 1452 Gr. 14, Flanged ends
= 13% Chromium Steel
= CI, IS 210 Gr. FG 260/ BS 1452 Gr. 14
= AISI – 316
= BS 5153/ API 594
3.3.2 Ball Valves (all isolating & regulating valves < 50 Nb shall be Ball Valves)

_x0 Body, Bonnet & trim = CS

_x0 Design Standard = BS 5351

3.3.3 B.F. Valves (all isolating & regulating valves > 65 Nb shall be BFV’s)

_x0 Body & Disc = 2% Ni CI as per IS 210, FG 260/ ASTM A 48, Gr. 40 or fabricated as per IS
2062/ 2002 and epoxy coated.
_x0 Shaft = SS – 410/ BS-970 431 S-291
_x0 Seal = Buna-N
_x0 Seating, retaining segment = SS – 316
& Internals
_x0 Companion flange = Carbon steel as per IS – 2062/ 2002
_x0 Design Standard = AWWA C 504/ BS 5155

3.3.4 Air Release Valve:

_x0 Body & Cover = 2 % Ni.CI, IS 210 FG 260

3.4 Condenser On load Tube Cleaning System:

3.4.1 Balls Seperator:

_x0 Housing = Carbon Steel to IS –2062
_x0 Strainer & other internals = SS – 316

3.4.2 Balls Collector:

_x0 Housing = Carbon Steel to IS –2062
_x0 Strainer & other internals = SS – 316

3.4.3 Balls recirculating pumps:

_x0 Casing = CI to IS 210 FG-260
_x0 Impeller = SS – 316 or equivalent
_x0 Shaft = SS – 316 or equivalent

3.5 Coarse bar screens:

_x0 Bar Screens = SS304

_x0 Seating,Retaining ring = SS410

3.6 Stop Log Gates:

_x0 Gates = Carbon Steel to IS-2062

_x0 Guides and embedded parts = Carbon steel to IS-2062/ CI, IS 210, Gr.FG 260

3.7 CW Pumps:

Material of Construction shall be as per BHEL/ Hyderabad technical data sheets & CW pump drawing.
3.8 CCW Pumps:

a) Casing = 2.5 % Ni CI to IS 210 Gr. FG 260

b) Impeller = SS304
c) Wearing ring = SS 316
d) Shaft = SS410
e) Shaft Sleeve = SS 316
f) Gland = 2.5 % Ni CI to IS 210 Gr. FG 260
g) Lantern ring = SS 316
h) Gland packing = PTFE/TEFLON
i) Base plate = MS fabricated IS-2062 (min 6 mm thick)
j) Stuffing box = 2.5 % Ni CI to IS 210 Gr. FG 260

3.9 Basket Strainer:

a) Housing = CS to IS 2062
b) Screen & internals = SS 316

3.10 Plate type Heat Exchangers:

Refer PHE MOC in ACW system (document no PE-DC-253-179-N002)

4.0 CONTROL & INSTRUMENTATION:

The instruments shall be provided as per CW & CCW system PID Drg. No. PE-DG-253-165-N001.

The Controls of CW & CCW system shall be through Unit control room (UCR).

4.1 Control/ Interlocks for CW Pumps and respective Discharge BFV's.

a) CW Pumps controls shall be from:

_x0 CW Pumps Start/ Stop shall be from Operator work station (OWS) in Unit control room (UCR)
_x0 Lockable emergency Stop push button shall also be provided Local to CW Pump drives.

Note:
_x0 All Control logics, Interlocks etc. shall be realised in DCS.
_x0 All alarms shall be annunciated in UCR.

b) CW Pumps start permissive interlocks:

_x0 Sump level = "Sump level normal"

_x0 CW Pump discharge BFV = "Closed"
_x0 Motor winding temp. = "Not High"
_x0 Motor bearing temp. = "Not High"
_x0 Pump bearing temp = "Not High"
_x0 Pump reverse rotation = "Not existing"

_x0 Switchgear = "Available"

 _x0 Switchgear = "Not disturbed"

Note:
_x0 Alarm to be anunciated if permissive conditions is otherwise than above.

c) Common CW standby Pump shall start automatically in the event of running CW Pump tripping due to any fault

d) CW Pumps tripping interlocks:

_x0 Sump level = "Low Low with time delay"

_x0 CW Pump discharge Pressure = "High with time delay"
_x0 CW Pump discharge Pressure = "Low with time delay"
_x0 Motor bearing temp. = "High High"
_x0 Motor winding temp. = "High High"
_x0 Pump bearing temp = "High High"
_x0 Pump/ Motor Vibration = "High High"
_x0 Pump discharge BFV = "Close" (viz. pump in On condition and BFV gets accidently closed)
Note:
_x0 Alarm to be anunciated for above conditions.

e) CW Pump discharge BFV interlocks:

_x0 CW discharge BFV open/ close shall be from Operator work station (OWS) in Unit control room (UCR)
_x0 Open/ close push buttons (lockable) shall also be provided for these valves.

Following interlocks shall be provided for CW Pumps discharge BFV:

_x0 Start command to CW Pump shall simultaneously open the BFV to 10 degrees.
_x0 "Adequate" pressure signal from CW Pumps discharge header shall open the BFV from 10 to 90 degrees.
_x0 Stopping or tripping CW Pump shall fully close the BFV.

Note:
_x0 For BFV's of common standby CW Pump, the above interlocks shall be applicable for the BFV connected
towards failed CW Pump.
_x0 Alarm shall be annunciated if BFV fails to open/ close after time delay for manual assistance.

f) Status of following shall be indicated in UCR:

_x0 CW Pumps Status : On/ Off/ Trip

_x0 Discharge BFV status : Open/ Close
_x0 Pump Discharge presssure
_x0 Pump Discharge header presssure
_x0 Discharge header flow

g) Alarm anunciation of following shall be provided in UCR:

_x0 Sump level : Low

_x0 Forebay level : Low Low/ High High
_x0 Motor Bearing temp. : High
_x0 Motor winding temp. : High
_x0 Pump bearing temp. : High
 _x0 Pump/ Motor vibration : High

4.2 Condenser Instrumentation Controls:

Status of following shall be indicated in UCR:

_x0 Condenser inlet/ outlet temp.

_x0 Differential pressure across Condenser

_x0 Condenser inlet/outlet pressure

4.3 Condenser Inlet/ Outlet BF Valves Controls/ Interlocks:

_x0 The open/ close facility for each butterfly valve shall be provided in the UCR
_x0 Open/ close push buttons (lockable) shall also be provided for these valves.
_x0 Indication for each BF valve open/ close status shall be provided in UCR.
_x0 No process interlocks are envisaged for these valves.

4.4 Condenser Onload Tube Cleaning System Control/ Interlocks:

COLTCS operation shall be from Hot redundant PLC-based LCP.

COLTCS shall be operated for a specified time period based on manufacturer's recommendation and control
philosophy, However following minimum control/ interlocks shall be provided.

Note: PLC system fault signal shall be provided to DCS

a) Ball seperator Screen backwashing shall take place when:

_x0 Differential pressure across Screen is "High" through DPT provided across Screen
_x0 Differential pressure across Screen is "High High" through backup DPS provided across Screen
Alarm shall also be annuciated in LCP for this case.

b) Balls Monitoring System interlock: ð Alarm in LCP for balls charge replacement.
ð Alarm in LCP for adding balls to meet shortfall.
_x0 Majority of Balls in recirculation are undersize
_x0 Balls in recirculation are less than a preset
value (based on manf. Recomm.)

c) Balls recirculating Pump interlock:

In the event of tripping of both CW Pumps for unit, Balls recirculating Pump of both COLTCS set of that
unit shall also trip.

4.5 Cooling Tower Controls/ Interlocks:

The Controls of Cooling Tower shall be through Unit control room (UCR).

a) Cooling tower Fans controls shall be from:

_x0 Start/Stop of Fans shall be from Operator work station (OWS) in UCR.
_x0 Start/ Stop (lockable) push button shall also be provided Local to Fan drive on CT fan deck.
The selection for UCR and local (from fan deck) operation shall be through UCR.
b) Cooling tower Fans Trip interlock:

_x0 Fan bearing vibration = "High High"

_x0 Gear box oil level = "Low Low"
_x0 Bearing temperature = "High High"
_x0 CT fan Motor = "Overload"

Note:
_x0 Alarm to be anunciated for above conditions.

c) CT fan On/ Off/ Trip Status shall be provided in UCR.

4.6 CCW Pumps Controls/ Interlocks:

a) CCW Pumps controls shall be from:

_x0 CCW Pumps start/ stop shall be from Operator work station (OWS) in Unit control room (UCR)
_x0 Emergency Stop push button shall be provided Local to CCW Pumps drive.

b) CCW Pumps start permissives:

_x0 Pump Suction pressure = "Not Low Low"

_x0 Pump Suction BFV = "Open"

Note:
_x0 Alarm to be anunciated if permissive conditions is otherwise than above.

c) Standby Pump shall start automatically in the event of running Pump tripping due to any fault

d) CCW Pumps tripping interlocks:

_x0 Suction header pressure = "Low Low with time delay"

_x0 Discharge header pressure = "Low with time delay"

Note:
_x0 Alarm to be anunciated for above conditions.

e) CCW Pump discharge BFV interlocks:

_x0 Discharge BFV open/ close shall be from Operator work station (OWS) in Unit control room (UCR)
_x0 Open/ close push buttons (lockable) shall also be provided for these valves.

f) Status of following shall be provided in UCR.

_x0 Pumps status : On / Off / Trip
_x0 Pumps Suction Header pressure
 _x0 Pumps Discharge Header pressure
_x0 CW header flow

g) Alarm anunciation of following shall be provided in UCR:

_x0 Pump Discharge header pressure : High

_x0 Pumps Suction header pressure : Low Low
_x0 Pumps discharge pressure : Low

4.7 Basket Strainer Controls/ Interlocks:

Status of following shall be indicated in UCR:

_x0 Differential pressure across Strainer.

Alarm shall be annuciated in UCR for differential pressure high.

4.8 Plate type Heat exchanger Controls/ Interlocks:

_x0 No process interlocks are envisaged for PHE's.

Status of following shall be indicated in UCR:

_x0 PHE inlet header temp

_x0 PHE outlet header temp

4.9 CW Make - up control valve Controls/ Interlocks:

_x0 CW make-up control valve shall be modulated based on CW forebay level.

_x0 CW M/U line flow shall be indicated in the UCR.

4.10 CW Forebay Controls/ Interlocks:

Status of following shall be indicated in UCR:

_x0 Forebay level

_x0 pH value

Note: pH value shall be indicated at DM plant also.

4.11 CW Blowdown line Control / Interlock:

Status of CW B/D line flow shall be indicated in UCR.

 -253-165-N002

by gravity for

es in the condens.

alled at condenser
er CW inlet line.
per layout for

T crane (1 no.)

be returned in

tings from CW
;19000 cubm per hr)
er + 10C (viz; 110C)

Water levels)
 e of running for

0% above the
ire characteristic

m pump HE inlet.
icated as per IS
 due to any fault

ccidently closed)

o 90 degrees.
n and control