Turbine A prime mover which converts heat energy into mechanical (shaft) work.

Back Pressure Turbine If exhaust pressure of turbine is above atmospheric The turbine is back pr. Turbine. Condensing turbine If exhaust pressure of turbine is below atmospheric and exhaust steam is taken to condenser the turbine is Condensing Turbine. Turbine piping Turbine seal Inter stage seals Gland seal Systems affiliated with turbine Lubricating oil system and Jacking oil system Turning gear Condensate system Cooling water system Vacuum generating system Balancing leak-off Gland seal piping Extraction lines Exhaust hood spray line Casing drains

Balancing Leak- Off & Exhaust hood Spray

Exhaust hood

Sol. v/v
BALANCING LEAK-OFF LINE

Steam to
EXTRACTION -III

Condenser Exhaust hood spray line

(Water from CEP)

1

Gland Sealing Arrangement in 31.4 MW Turbine

Vent to atmosphere Vent to atmosphere

Front Side Arrangement

Rear Side Arrangement

Steam I/L (0.03kg/sqcm, 250degC)

Steam to condenser

Extraction Piping

Safety v/v

QC

Drain to atmosphere

Pilot valve Manual valve Drain to condenser

Trip oil line

Secondary Oil Line

2

GLAND Steam &Extraction Flow Diagram

Vent Vent

Spray Water from CEP

31.4 MW Turbine

1000 mm

1000 mm

Ext-I Ext-II Ext-III

From Process To Condenser

Lube Oil Scheme of 31.4 MW Turbine

Lube Oil Drain Header
MOP

Turbine
Coupling

Coupling

Generator

Exciter

Lube Oil Supply Header

Jacking Oil Header
Orifice

OVEF EOP AOP-1 AOP-2

Duplex Filter Oil Cooler Jacking Oil Pump

Main Oil Tank

Oil Centrifuge

OPERATIONAL SEQUANCE 12345678LUB OIL ESTABLISHMENT TURNING GEAR OPERATION LINE HEATING(UP TO MS-O1) VACUUM PULLING SOAKING ROLLING SYNCHRONISING RESTORATION

1- LUB OIL ESTABLISHMENT PURPOSE: A-TO LUBRICATE AND COOL BEARINGS AND OTHER MATING PARTS PROCEDURE:

GET ALL THE CLEARANCES FILL THE OIL IN M.O.T. WELL ABOVE PRIME COOLER & FILTER START OVEF START DC OIL PUMP FIRSTWHY WAIT TO RESUME PRESSURE CHECK FOR ANY LEAKAGE

NORMAL LEVEL

START AOP CHECK THE OIL FLOW THROUGH ALL MAINTAIN LUB OIL TEMP 40-45 DEG C
PROTECTION TURBINE TRIP EOP (DC) START 1.1 kg/sqcm 1.0 kg/cm

THE BEARINGS

2-TURNING GEAR OPERATION PURPOSE: A- TO MAINTAIN ECCENTRICITY OF ROTOR B- EVEN HEATING/COOLING OF ROTOR AND CASING C- TURNING OF ROTOR DURING MAINT. WORK PROCEDURE:

ESTABLISH LUB OIL SYSTEM START JACKING OIL PUMP ENGAGE TURNING GEAR ROTATE TURNING GEAR WHEEL MANUALLY TO CHECK
FREENESS OF ROTOR OR ANY RUBBING SOUND

START TURNING GEAR

PROTECTION Turning gear motor will not take start below 1.5 kg/sq.cm oil pr. 3-LINE HEATING PURPOSE: TO PROVIDE DRY STEAM TO TURBINE PROCEDURE:

OPEN THE LINE DRAINS WIDE OPEN THE LINE VENTS START WITH LOW PRESSURE STEAM MAINTAIN TEMP RISE RATE (3-4 deg C/min) TAKE THE LINE TEMP ABOUT 375 degC TO AVOID CONDENSATION
PROTECTION: NIL 4-VACUUM PULLING PURPOSE: TO MAINTAIN VACUUM IN CONDENSER FOR BETTER CYCLE EFFICIENCY PROCEDURE:

CHECK THE TURBINE IS ON TURNING GEAR COOLING TOWER LEVEL IS ABOVE NORMAL AND CT HEADER V/V ARE OPEN CIRCULATING WATER PUMP IS READY CONDENSER COOLING WATER PATH IS OK HOTWELL LEVEL IS ABOVE NORMAL CEP IS READY AND STANDBY IS AVAILABLE HOTWELL MAKEUP IS THROUGH ESTABLISH CONDENSER COOLING WATER SYSTEM START CEP IN RE-CIRCULATION,KEEP STAND-BY CEP IN AUTO
5

CLOSE VACUUM BREAKER AND CHARGE SEALING LINE TO ALL VALVES PRE-HEAT GLAND STEAM LINE UPTO CONTROL VALVE(UP TO 250 degC) CHARGE HOGGING EJECTOR CHARGE TURBINE GLAND SEAL AFTER 0.2 kg/sqcm VACUUM GETTING ABOUT 0.78 kg/sqcm VACUUM TAKE MAIN EJECTOR IN SERVICE AND
HOGGING EJECTOR

ISOLATE THE

MAINTAIN THE VACUUM 0.88 kg/sqcm AND GIVE GLAND SEAL PR.IN AUTO
300mmWc(0.03kg/sqcm) PROTECTION: TURBINE TRIP AT EXHAUST PR VV HIGH -0.70 kg/cmsq (35 mw turbine) -0.30 kg/cmsq (31.4 mw turbine)

AT

5-SOAKING PURPOSE: A-TO PREHEAT TURBINE STEAM CHEST GRADUALLY TO AVOID THERMAL SHOCK B-TO PROVIDE DRY STEAM TO ENTER THE TURBINE INTERNALS PROCEDURE:

PREHEAT THE LINE UPTO ESV AS PER LINE HEATING PROCEDURE OPEN STEAM CHEST DRAIN,EXTRACTION LINE (BEFORE QC NRV)
DRAINS WIDE

DRAIN AND ALL THE CASING

RESET THE TURBINE OPEN ESV AND FOLLOW THE SOAKING CURVE PROVIDED BY THE

SUPPLIER

(STEAM MUST BE AT LEAST 50 deg SUPERHEAT AT THAT PRESSURE) PROTECTION: NIL 6-ROLLING PURPOSE: A- HEAT-UP THE TURBINE BEFORE LOADING B- ATAIN THE TURBINE SPEED UPTO SYNCHRONOUS SPEED PROCEDURE:

GIVE HOTWELL LEVEL CONTROL IN AUTO

A- CO-GEN-I

INCREASE RPM SLOWLY, SWITCH OFF TURNING GEAR MOTER STOP JOP ABOUT 300 RPM GRADUALLY TAKE RPM TO 500 KEEP STRICT WATCH ON VIBRATION,BEARING TEMP, FOLLOW THE ROLLING CURVE RAISE THE SPEED CONTINUOUSLY IN CRITICAL SPEED RANGE
CRITICAL SPEED RANGE 31.4MW&35MW TURBINE 1750-2200 RPM 5.6MW&6MW TURBINE 4500-5500 RPM B- CO-GEN-II: AXIAL SHAFT DISPLACEMENT,DIFFERENTIAL EXPANSION AND CASING TEMP.

SELECT THE START MODE

AS REQUIRED I. COLD START MODE

II. WARM START MODE III. HOT START MODE

PRESS THE AUTO RUN COMMAND STOP TURNING GEAR AND JOP WATCH THE PARAMETERS SAID ABOVE
PROTECTION TURBINE SHAFT VIBRATION V HIGH TURBINE BEARING VIBRATION V HIGH BEARING TEMPERATURE V HIGH AXIAL SHAFT DISPLACEMENT V HIGH DIFFERENTIAL EXPANSION V HIGH 240 microns 18 mm/sec 120 degC +/- 0.7mm 3.0 mm

7-SYNCHRONIZATION PURPOSE TO SUPPLY POWER TO (ALREADY) RUNNING BUS PROCEDURE:

CHARGE GENERATOR AIR COOLER START CT FANS AS REQUIRED KEEP THE BREAKER SELECTOR ON GENERATOR CB AND
CHECK

SYNCHRONISATION SELECTOR ON

SWITCH ON THE EXCITER AND MATCH M/C VOLTAGE TO BUS VOLTAGE MATCH THE M/C FREQUENCY TO BUS FREQUENCY SWITCH ON SYNCHRONOSCOPE KEEP IT MOVING SLOWLY IN CLOCKWISE (+) DIRECTION CLOSE THE GENERATOR BREAKER WHEN THE NIDDLE IS AT 12OCLOCK (+/- 5 DEGREE)
POSITION AND CHECK SYN. LAMP IS GLOWING

INCREASE GENERATOR LOAD GRADUALLY

PROTECTION: GENERATOR PROTECTION 8-RESTORATION

STOP AOP IN CASE OF COGEN Ist AT 10% TURBINE LOAD CLOSE THE CASING DRAINS TO CRACK OPEN DIVERT 11 ATA LINE (IN CASE OF 5.6MW TG) TO EXT-II CLOSE STEAM LINE DRAINS FILLY MAINTAIN CT BASIN TEMPERATURE (START MORE CT FANS)
SOME IMPORTANT PARAMETERS TO OBSERVE VIBRATION (CONDITION FOR TURBINE VIBRATION HIGH) -SUDDEN DROP IN LIVE STEAM TEMP. -SUDDEN DROP IN LIVE STEAM PRESSURE. -CARRYOVER FROM BOILER -LUBRICATING OIL PRESS. LOW -HIGH DIFFERENTIAL EXPANSION, AXIAL AND ECCENTRICITY -MOISTURE IN GLAND STEAM -TURBINE BLADE FAILURE -TURBINE BLADE LACING/SHROUDS FAILURE -UNEVEN SILICA DEPOSITION MACHINE ON CRITICAL SPEED

-VIBRATION DUE TO UNBALANCE IN GENERATOR ROTOR -FAILURE OF GENERATOR COOLING FAN -UNBALANCE IN EXCITER -TURBINE FOUNDATION PROBLEM -MISALIGNMENT OF GENERATOR , EXCITER , MAIN OIL PUMP ETC -TURBINE LUB. OILTEMP. HIGH / MOISTURE IN LUB. OIL -CONDENSER LOW VACUUM -EXHAUST HOOD TEMP. HIGH -HIGH RPM/HIGH FREQUENCY -COLD START UP WITH VERY HIGH STEAM TEMP. -SPEED RAISING VERY FAST -UNEQUAL EXPANSION OF CASING /VALVE BLOCK -SEAL DAMAGE BETWEEN DIFFERENT STAGES BEARING FAILURE / WHITE METAL DAMAGED -BEARING FOUNDATION LOOSE -BEARING FITTING LOOSE -FAILURE OF CONDENSER BOTTOM SPRING -CONDENSER SPRING NOT FREE FOR EXPANSION / COMPRESSION -TENSION IN EXTRACTION STEAM PIPES -VIBRATION IN EXTRACTION STEAM PIPES -TENSION IN BEARING LUB. OIL PIPES -VIBRATION IN LUB. OIL PIPES -FAILURE OF HANGERS OF EXTRACTION STEAM LINE PIPES -UNEQUAL CHOKAGE IN BOTH PASS OF CONDENSER TUBES -FAILURE OF BALANCING WEIGHT LOCKING -SHIFTING OF BALANCING WEIGHT FROM ITS POSITION OR COMING OUT.

Turbine differential expansion high (Positive) Conditions Cold start up with very high steam temperature. Fast heating and rolling of cold machine. Fast loading of cold machine. Outage of turning gear during soaking. Wet casing insulation. Condenser vacuum too high and exhaust hood temperature too low during soaking. Gland sealing pressure and temperature very high during soaking. Thrust failure. Turbine differential expansion high (Negative) Conditions : Hot start up with low steam temperature. Keeping hot turbine on no load or low load for longer time. Gland steam temperature low during hot start up of turbine. Reductions of load slowly at lower range of load. Condenser vacuum low. Drop in main steam temperature Carry over from boiler. Turbine Axial Displacement High : Conditions -Sudden drop in steam temperature. -Sudden drop in condenser vacuum. -Load pull up too fast. -Sudden drop in load. -Too high load. -Silica deposition on turbine blades. -Lubricating oil system failure. -Water carryover into the turbine. EMERGENCY OPERATIONS 1- BLACK-OUT

START EOP(DC) OIL PUMP IF NOT STARTED IN AUTO OPERATE THE TURNING GEAR MANUALLY RESUME POWER FROM DG SET START AOPCHECK OIL PR. START TURNING GEAR STOP EOP(DC) OIL PUMP

2- CEP TRIP/HOT WELL LEVEL HIGH

STANDBY CEP WILL TAKE START IN AUTO. IF NOT, START IT MANUALLY REDUCE TURBINE LOAD INCREASE ALL THE EXTRACTION FLOW

3-SUDDEN FALL IN VACUUM CHARGE HOGGING EJECTOR IMMEDIATELY REDUCE TURBINE LOAD,INCREASE EXTRACTION FLOW CHECK CW PUMP: ITS CURRENT AND DISCHARGE PR CHECK GLAND STEAM PR CHECK CEP/HOTWELL LEVEL

4-FEED WATER HEATER LEVEL HIGH ENSURE THE LEVEL CONTROL VALVES ARE WORKING WELL CHECK SHELL PRESSURE IF IT IS HIGH IF HOT WELL LEVEL MAKE UP IS LOW ISOLATE HEATER FROM STEAM SIDE BY PASS THE FEED WATER LINE

5-IF RUNNING M/C TRIPS FIND OUT THE REASON BY CHECKING RELAY PANAL GET THE CAUSE REMOVED OPEN ESV WAIT FOR 20 MINUTES GIVE COMMAND TO HOT ROLLING SYNCHRONISE

GOVERNING SYSTEM IN STEAM TURBINES

CONCEPT OF GOVERNING WHAT IS GOVERNING TYPES OF GOV. SYSTEM MAIN REQUIREMENT OF GOV. SYSTEM CHARACTERISTICS OF GOV. SYSTEM SUB-SYSTEM OF GOV. SYSTEM

WHAT IS GOVERNING IT IS A GROUP OF DEVICES PROVIDED IN STEAM TURBINE SYSTEM WHICH WORK IN COHERENCE TO MAINTAIN THE SPEED OF T-G SET CONSTANT THIS CAN ALSO BE DEFINED AS: IT IS A GROUP OF DEVICES WHICH INITIATE THE CORRECTIVE ACTION TO RECTIFY THE DEVIATION OCURRED DUE TO VARIATION IN SET RELATION BETWEEN INPUT AND OUTPUT WHAT GOVERNING DOES IN STEAM TURBINE SYSTEM

MAINTAIN THE SPEED SUBSTANTIALLY CONSTANT AT ALL LOADS WHEN TURBINE IS CONNECTED TO GRID. PROVIDE VERY FAST CONTROLLING ACTI0N. LARGE STATIC

SUCCESSFULLY LIFT AND CLOSE THE CONTROL VALVES ON WHICH VERY AND DYNAMIC FORCES ACT. PROVIDE A LINEAR RELATIONSHIP BETWEEN VALVE LIFT V/S LOAD.

TO BE VERY SENSITIVE TO SPEED CHANGES SAY TO THE BETTER THAN SPEED (ie 1.8 rpm).

0.06% OF RATED

TO BE FREE FROM HUNTING AND NOT TO HAVE INDUCED OSCILATIONS. (FOR ENSURING GOOD STABILITY A FEEDBACK SIGNAL IS PROVIDED AT EVERY STAGE OF SIGNAL AMPLIFICATION. THE SENSTIVITY AND STABILITY OF THE CONTROL SYSTEM DEPENDS ON THE OVERALL GAIN / AMPLIFICATION AND THE COMPATIBILITY BETWEEN FORWARD AND BACKWARD LOOP. Turbine Governing System Primary task is to maintain a balance between energy demand and energy input Does this task by controlling valve opening and thereby energy input Has to take care of other emergencies and requirements e.g. Load shedding, valve trimming, stress consistent loading, frequency support etc. STEADY STATE OPERATION IDEALLY INPUT = OUTPUT EFFICIENCY 100% BUT LOSSES IS BOUND TO BE THERE THERMAL, MECHANICAL, WINDAGE INPUT IS NOT EQAL TO OUTPUT AIM :----TO MAINTAIN THE SPEED OF T-G SET CONSTANT AND THEREBY TO ACHIEVE OUTPUT FREQUENCY CONSTANT NXP f = --------------120 CHANGE IN OUTPUT FREQUENCY IS UNDESIRABLE STEADY STATE SPEED REGULATION

10

FOR EFFECTIVE PREDETERMIND LOAD SHARING, SPEED DROOP CHARACTERISTICS IS PROVIDED IN ALL STEAM TURBINES. IT IS THE CHANGE IN STEADY STATE SPEED EXPRESSED IN % OF RATED SPEED IN THE STEAM TURBINES EQUIPDED WITH ELECTRO- HYDRAULIC GOVERNING SYSTEM REGULATION CAN BE ADJUSTED BETWEEN 2.5 TO 8% IN VERY FINE STEPS. IN LMW TURBINES WITH HYDROMECHANICAL GOVERNING IT IS OF THE ORDER OF 4+/- 1% DEAD BAND DUE TO INHERENT INERTIA OF THE COMPONENTS OF GOVERNING ELEMENTS AND FRICTION PRESENT IN GOVERING SYSTEM, CERTAIN MOTION OF GOVERNING SYSTEM IS LOST BEFORE CORRECTIVE SIGNAL CAN ACTUATED CONTROL VALVES.THE LOST MOTION IS CALLED DEAD BAND OF THE SYSTEM AND IS EXPRESSED AS PERCENTAGE OF THE RATED SPEED. LMW TURBINE IT IS OF THE ORDER OF 0.3 WHILE IN KWU TURBINE IT IS 0.1 TRANSIENT SPEED RISE IN THE EVENT OF FULL LOAD REJECTION OR TURBINE SHUT DOWN, SPEED OF THE T-G SET SHOOTS UP TEMPORARILY BEFORE SETTING DOWN TO STEADY STATE VALUE. THIS TEMPORARY SPEED INCREASE IS CALLED TRANSIENT SPEED RISE AND IS EXPRESSED AS PERCENTAGE SPEED RISE OF RATED SPEED. VALUE OF TEMPORARY SPEED RISE IS RESTRICTED TO 8% CLASSIFICATION/TYPE OF GOVERNING SYSTEM MECHANICAL SPEED REFERENCE FROM MECHANICAL GOVERNOR HYDRAULIC SPEED REFERENCE FROM HYDRAULIC GOVERNOR HYDRO-MECHANICAL AMPLIFICATION OF SIGNAL IS HYDRAULIC (LMW TURBINES) ELECTRO-HYDRAULIC AMPLIFICATION OF SIGNAL IS ELECTRO-HYDRAULIC (KWU-TURBINES)

MECHANICAL: Pure mechanical governing system are not used for utility turbines now a days. In this speed transducer is mechanical centrifugal type speed governor. Which actuates control valves through mechanical linkages.

11

SPRING

FLY WEIGHT

n n 1 2 n 3

max V 0

SLEEVE

FIXED FULCRUM

CONTROL VALVE

WORM GEAR

TURBINE ROTOR

(n1-n3) x 100 Droop (in %) = (n1+n3) /2

HYDRAULIC In hydraulic governing system speed transducer is a centrifugal pump whose discharge pressure is proportional to square of speed. This signal is sent to hydraulic converter / transformer which generates a signal which is proportional to valve opening/closure required. Before applying it to control valves servomotors this signal is suitably amplified. HYDRO-MECHANICAL In hydro mechanical governing system speed transducer is usually mechanical centrifugal type speed governor. It is connected to hydraulic system either hydraulically or mechanically. In the hydraulic system this signal is amplified so that control valves servomotors can be actuated.

Block Diagram - HYDRAULIC Controller

12

ELECTRO-HYDRAULIC: The electro-hydraulic governing offers certain advantages over other three types of governing systems and is becoming popular for units rating larger than 200 MW. Due to large interconnected systems and growing automation of turbine generator sets, governing system has to meet many additional requirements. The combined advantages of electrical measuring and signal processing and hydraulic controls provide a very good combination. Features of Electrohydraulic Controller (EHC) EHC backed-up by Mechanical Hydraulic Controller (MHC) Tracking device for bumpless transfer from EHC to MHC Electrical processing ensures high sensitivity, quick response and dynamic stability Hydraulic actuation of valves provides continuous control of large forces Provision for frequency support Interfacing with Unit Coordinated Control Dependable control during load rejection Can accept control inputs from Auto Load Dispatch Station Speed, Load and Pressure controllers act as leading controller Selection circuit to select output of one of the three controllers as the final one Valve Position Controller acts as the subordinate controller Output of valve position controller acts on Electro-hydraulic controller which converts the electrical positioning signal to hydraulic one

13

Signal from mechanical and electro-hydraulic controllers are linked together though a hydraulic minimum gate Tracking device keeps the mechanical controller signal approx. 10% higher EHC - ADDITIONAL POINTS Actual speed is measured using three speed transducers TSE influence acts on the speed reference to modify the rate of change of speed Speed controller is used during start-up upto block loading and shut-down It controls the set during load shedding to arrest transient speed rise It is a Proportional Derivative (PD) controller Actual load is measured using three transducers TSE influence acts on load reference to modify the rate of change of load Load controller is normally used for load operation It is a PI controller Pressure controller has two modes of operation - Limit Pressure and Initial pressure For feedback to Position Controller, two LVDTs are used to measure the position of E-H converter Balance voltage of the plunger coil (Steady state) is approx. -1V

EHC BLOCK DIAGRAM

CLASSIFICATION/TYPE OF GOVERNING SYSTEM Classification of governing is also done W.R.T. Mode of regulation of steam mass flow to the turbine corresponding to speed change - NOZZLE CONTROL GOVERNING - THROTTLE CONTROLLED GOVERNING Unit in both cases operating at constant pressure or variable pressure or a combination of two. NOZZLE GOVERNING : in nozzle controlled turbines, steam flow is controlled by sequential opening or closing of control valves allowing steam to flow to associated nozzle groups. THROTTLE GOVERNING

14

In throttle controlled turbines, steam Flow is controlled by opening and closing of all the control valves simultaneously to the extent require By load and admitting the steam to the group of nozzles located on the entire Periphery. SUB SYSTEMS OF GOV. SYSTEM SPEED GOVERNING SPEED CONTROLS ANTICIPATORY GOVERNING PROTECTIVE SYSTEM SPEED GOVERNING: To maintain turbine speed as per steady state regulation characteristics. SPEED CONTROLS: Speed control unit is superimposed on speed Governing and acts in parallel to speed Governing, to change the speed of turbine usually 92 to 108 0f rated speed. Also called speed control. ANTICIPATORY GOVERNING: governing is employed. To prevent tripping of turbine on large load rejections anticipatory

PROTECTIVE SYSTEM: Shuts off steam supply to Turbine by closing stop valves and control valves in the following possible hazards

ELEMENTS OF GOVERNING AND PROTECTION SYSTEM 1. SPEED GOVERNOR 2. SPEED GOVERNOR PILOT VALVE ( SGPV ) BLOCK: a) Speeder gear pilot valve b) Follow pilot valve c) Summation pilot valve 3.ADDITIONAL PROTECTION LINE 4.INTERMEDIATE PILOT VALVE ( IPV ) 5.CONTROL VALVE SERVOMOTOR ( CVSM ) 6.ESV AND IV SERVOMOTORS 7DIFFERENTIATOR 8LOAD LIMITER 9.EMERGENCY GOVERNORS 10.EMERGENCY GOVERNOR PILOT VALVES ( EGPVs ) 11.TURBINE TRIP SWITCH ( TTS ) 12.ELECTRIC HYDRAULIC TRANSDUCER ( EHT ) 13.INITIAL STEAM PRESSURE UNLOADING GEAR ( ISPUG )

B BO OI IL LE ER RS SP PE EC CI IF FI IC CA AT TI IO ON N:: -Make: Bharat Heavy Electricals ltd. High Pressure Boiler Plant, Tiruchirappalli 620 014

Proposed Fuel: Coal (FC%21.78,Vol % 21.00,M % 16.00,A%41.22,S % 0.25) HHV 2950 Kcal/Kg, Grindability 48-50 HGI Fuel Firing System: Main Burners Type Fixed Tangential burner Make & Nos BHEL & 16 Control Air Damper Capacity- 12.6 Mkcal / H / Compartment Disposition Corners

15

Stabilization Burners Type LDO burner Make & Nos BHEL & 8 Control Air Damper Capacity- 3.0 Mkcal / H / Compartment Disposition Corners Mills Type XRP 623 Make & Nos BHEL & 4 Capacity- 15.16 T/Hrs Motor- 310KW / 980RPM System Cold PA Pressurised Furnace: Type- Balance Draft, fusion Welded Furnace 6070 x 6070 Volume 750 M3 (Including Platen) Fuel Heat Input 118.5 Mkcal / h Natural Circulation, Bi Drum Design Pressure -130Kg/CM2 Super Heater Outlet Pressure - 111Kg/CM2 Super Heater- Platen & final Super Heater Attemperator Spary type, single stage

Boiler

Boiler Auxiliaries: FD Fan Type- NDV 13SIDOR Make- BHEL Nos2 Flow16.5M3/s Pressure440mmwc Temp 50C Drive Motor Speed 1480 rpm Motor 110KW Control Inlet Damper

Bearing particulars: Drive end details Bearing housing: Lock nut Bearing Drive end details Bearing housing:

Make Model

Antimu SOFN 216BF48

Make Model

Antimu SOFN 216BF55

Lock nut Bearing FD FAN Specification of lubrications: Motor Bearing DE Servo gem-3 Fan bearing DE/NDE Servoprime-68

NDE Servo gem-3

PA Fan

Type- NDV 19 HERAK Make- BHEL Nos2

16

Flow21.5M3/s Pressure1295mmwc Temp 50C Drive Motor Speed 1480 rpm Motor 375KW Control Inlet Damper PA FAN Specification of lubrications: Motor Bearing DE Servo gem-3 ID Fan Fan bearing DE/NDE Servoprime-32

NDE Servo gem-3

Type- NDZV 22 HERAK Make- BHEL Nos2 Flow49.7M3/s Pressure295mmwc Temp 155C Drive Motor Speed 740 rpm Motor 200KW Control Inlet Damper ID FAN Specification of lubrications: Motor Bearing DE Servo gem-3 Fan bearing DE/NDE Servoprime-68

NDE Servo gem-3

Seal Air Fan

Type- NDM6 Make- BHEL NosFlowPressureTemp Drive Speed Motor Control IGV Specification of lubrications: Motor Bearing DE Servo gem-3

2 4.25M3/s 508mmwc 50C Motor 2880 rpm 37KW

NDE Servo gem-3

Fan bearing DE/NDE

Soot Blower

Location Furnace Type Wall Blowers Make BHEL Nos 24 + 6F Medium SH Steam Location Type Make Nos Medium SH & Boiler Bank Long Retractable LRD-IE BHEL 4 + 2F SH Steam

17

Location Type Make Nos Medium Boiler Mounting Safety Valves Drum

Economiser Rotary Blowers BHEL - + 3F SH Steam

1728 WB 130.0 Set Pr (Kg/cm2) 1738 WB 133.9 Set Pr (Kg/cm2) SH Outlet 1728 WD 120.3 Set Pr (Kg/cm2 ERV 1538 vx-10W, 117.3 Set Pr (Kg/cm2

Main Parameter: UNIT T/h Mkcal/h Kg/cm2 C C C C T/h T/h C % MCR 165 118.6 111.00 535 208 30 264 40.2 202.3 137 85.30 NCR 150 107.4 111.0 535 208 30 259 36.4 183.1 133 85.44

Flow Super heater Total heat to Boiler Pressure at Super heater Out let Temp at super heater Out let Feed water temp Ambient Air Temp Combustion air Temp Fuel Quantity Air Quantity Temp of gas at boiler outlet Efficiency

Dust Collector

Electrostatic Precipitator (FAA-6x37.5M-120150-2) Make BHEL Field 6 Nos 1 Inlet dust concentration -88.6gms/Nm3 Gas Weight 267.2 t/h Pressure loss 20mmwc (Max) Power Consumption 135KW Flue Gas Flow 93.2m3/s Efficiency 99.943%

ESP: BAPCON (BHELs ADVANCE D PRECIPITATOR CONTROLLER)

PRINCIPAL OF OPERATION The high voltage DC fed to the precipitator field is controlled using back connection thyristors on the primary side of the TR sets. The thyristers are in turn fired based on the feed back signals of current in the ESP field and sparking etc.

18

INTERMITTENT CHARGING Normally the thyristors are charged every half cycle alternatively. We can call this as charge ratio 1:1. the above controller will able to skip some of the half cycles thus charging fields intermittently , e.g. if one out of the three cycle is fired , then the charging ratio is 1:3 .this type of charging ESP has been found to reduce the out let emission and also reduces the corona power consumption in the ESP intermittent charging is effective for combating back corona in ESPs as described below. Back corona is a discharge from the ash layer on the collecting plate. This is detrimental to precipitation, since it emits charges of opposite sign that neutralizes the negative charge on the particles and hence particle collection is impaired. This back corona is caused due to the resistivity of the fly ash layer. If the resistivity is high the back corona can occur due to electrical break down of the ash layer when normal corona current passes through the layer. Back corona can be avoided by reducing the average current, at the same time maintaining the corona discharge from the emitting electrodes in a uniform condition by increasing the peak voltage during discharge. This is precisely what the BAPCON does. It provides a suitable corona discharge by giving high peak voltage during the fired half cycle and the average current can be kept below corona levels by setting the discharge ratio BAPCON can provide charge ratio up to 1:159.

CARGING RATIO (C.R) OPTIMISATION MODE The charge ratio selected on BAPCON has a range of 1:1 to 1:159 in manual mode, any charge ratio within this range can be set by the operator. In the optimizer mode option, BAPCON will select the best charge ratio based on the electrical characteristics of the field. However the charge ratio is very high i.e. 1:1 to 1:159, it is preferable to have a smaller range for automatic charge ratio optimization within the total charge. Necessary provision is available for the operator to select the range. The above facility of optimization control logic is activated using touch sensitivity switch provided in the front fascia. BASE CHARGING When the operating is intermittent charging mode the voltage on the ESP slowly reduces in the between the charging pulses. Hence when the charge ratios are high, the average voltage obtained is low. BAPCON provides a unique feature called base charging, which provides for an increased based voltage in between the normal intermittent charging pulses by firing the thyristors with a small firing angle in the half cycles by the intermittent charging. Base charging has been found very effective in increasing the average voltage under high charge ratio operation, without causing back corona. This provides an improved ESP performance. BAPCON provides in addition to base charging setting, base charging measurement provision to enable proper setting of base charge.

PEAK AND VALLEY kV MEASUREMENT In addition to the average kV measurement, BAPCON provides peak kV and valley kV measurement through special hardware and software features. The peak kV indication is very useful to ensure normal condition inside the ESP. any misalignment in the electrode or loose electrode etc., will be reflected as a poor peak kV value and hence the measurement is extremely useful for the diagnosis and troubleshooting. The valley voltage also can indicate any abnormal leakage in the field. A comparison of the peak kV and valley kV of different fields in the ESPs can quickly indicate whether all the fields are working in normal conditions. Thus the BAPCON provides very useful indication on the ESP fields.

ADVANTAGE OF BAPCON a) Reduction in the outlet emission due to intermittent and base charging techniques compared to conventional charging.

19

b) Reduction in corona power consumption. c) Peak and valley kV measurement of the ESP operating voltage, which is useful to ensure healthiness of ESP fields. d) Automatic selection of optimum charge ration is available. e) Electrical conditions can be tuned to varying coal and boiler conditions. f) Back corona and excessive sparking can be avoided. g) Connection to integrated operating system to facilitate centralized monitoring and control. h) More reliable and up-to date electronics is used in BAPCON. i) BAPCON is easily replaceable as it is provided as a plug in the module.

RAPCON (RAPPER CONTROLLER) The rapper controller (RAPCON) is a microprocessor-based controller to control the rapping motors as per the settings in the controller. The setting are start time, repeat time and run time for the motors. The operator can program all these settings by using the keyboard and alphanumeric display of the RAPCON. The setting can be changed ON LINE, i.e., without disturbing the working of the rapping system. In the controller, 32sets of program sequence for all the motors can be stored and the operator can select any one by selecting the program set number. The RAPCON will cross check whether the rapping motor is running or not by checking the feedback from the same . if any motor is not running within a time limit of two second after start command, the RAPCON will annunciate an error. The RAPCON is provided with a serial communication facility and hence compatible for control by integrated operating system(ISO), when the RAPCON is selected in remote operation mode. The following LED indications are provided in the RAPCON for each of the 16 motors 1. Motor selected for operation 2. Motor running. 3. Motor not running

20

Lube Oil Scheme of 31.4 MW Turbine

Lube Oil Drain Header
MOP

Turbine
Coupling

Coupling

Generator

Exciter

Lube Oil Supply Header

Jacking Oil Header
Orifice

OVEF EOP AOP-1 AOP-2

Duplex Filter Oil Cooler Jacking Oil Pump

Main Oil Tank

Oil Centrifuge

GLAND Steam &Extraction Flow Diagram

Vent Vent

Spray Water from CEP

31.4 MW Turbine

1000 mm

1000 mm

Ext-I Ext-II Ext-III

From Process To Condenser

21

Extraction piping

Safety v/v

QC NRV

Drain to atmosphere

Pilot valve Manual valve Drain to condenser

Trip oil line

Secondary oil line

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