1.

1 SPECIFICATIONS
1.1.1 TYPE Natural circulation , Dry Bottom , Tangentially fired , Balanced Draft , Radiant Reheat type with direct fired
pulverised coal system.
1.1.2 DESIGNED Volatile
Moisture
Ash
Grindibility High Heating
FUEL Indian
Matter
(HGI )
Value
Bituminous Coal
Fixed Carbon
38 %
26 %
8%
28 %
55
4860 Kcal / Kg
1.1.3 FURNACE Fusion
Welded Type Width
13.86 m

Depth

Height

Volume

10.59 m

42.79 m

5210 cu. m

1.1.4 SUPERHEATER , REHEATER & ECOMOMISER

S. No. Description
Heating
No. of
Surface
Coils / Tube
( sq. m )
1.
Low Temp. S/H 8209.5
Upper Bank 67
Lower Bank 67
Terminal Tubes 67
x 6 = 402
2.

Platen S/H

944.5

29

Size (mm)

Material

44.5 x 5
1 Cr , Mo
44.5 x 4.5
( SA 213 T11 )
44.5 x 4.5
SA210CrAl
44.5 x 4.5
SA209T1
SA213T11
1 Cr , Mo
( SA 213T11 ) &
a) 51 x
SA213T22
4.5/5.6/
7.1/8.8

3.

Final S/H

1036

119
a) 47.6 x 7.1
b) 47.6 x 6.6
c) 47.6 x 8.6

4.

Ceiling &
Enclosures

540

Roof Panels 120

Front Wall 181
Rear Wall 136
Side Wall 66 x 2

54 x 4.5
51x 4.5
51 x 4.5

5.

Reheater

2650

Front assembly
59
Rear assembly 89

54 x 3.6
47.6 x 3.4

6.

Economiser

5440

67

44.5 x 4.5

1.1.5 ATTEMPERATOR
Type

No. of Stages

Location

2 Cr , 1 Mo
( SA 213T22 )

Carbon Mo
(SA209T1)
Carbon Steel
(SA210GrA1)
Carbon Steel
(SA210GrA1
Carbon Mo
(SA209T)
2 Cr , 1 Mo
( SA 213T22 )
1 Cr , Mo
( SA 213T11 )
SA213T22
SA213Tp347A
Carbon Steel
(SA210A

Medium of Spray

Spray

One

Between
Horizontal &
Platen S/H

Feed Water

1.1.6 FUEL SPECIFICATIONS

A) COAL
i. Fixed Carbon 38.%
ii. Volatile Matter 26%
iii. Moisture 8.0%
iv. Ash 28%
v. Grindability 55HGI
vi. High Heat 4860 Kcal/Kg
vii. Coal size to Mill 20 mm
B) OIL
i. Low Heat value 10000 kcal/kg
ii. Sulpher 4.5% w/w
iii. Moisture 1% w/w
iv. Flash point 660 C.
v. Viscosity 1500 redwood at 37.80 C .
vi. Sp. Weight 0.98 at 380 C.
1.1.7 SAFETY VALVES
Location
Make & type
Drum

Super
Heater
SH-electro
magnetic
Relief valve
Reheater inlet

Reheater
outlet

a)dresser
1749wa
b)dresser
1749wa
dresser
1739wd
dresser
1538-vx
a)dresser
1775wa
b)dresser
1785
dresser
1705 rwd

1.2.1 DESIGNED
PARAMETERS
Description

No.
per
boiler
1
2

Size

Set pressure
(kg/cm2)

Relieving
capacity (t/hr.)

3
3

158.2
161
162.41

190.04
162.08
195.08

144

86.73

142

88.06

1
3

4
6

33.4
33.75
34
34.45
30.58

94.7
136.01
137.38
138.76
114.93

Flow (t/hr) Load

MCR NCR
60%MCR
210mw

1.2 PERFORMANCE DATA

Temperature ( C0.)
Pressure (kg/ cm2)
MCR NCR
60%MCR
210mw

MCR NCR
60%MCR
210mw

Steam
Steam at final SH
Outlet
Steam at
Reheater Outlet
Steam at Reheater
Steam from Drum
Steam leaving
Horizontal SH
Steam leaving
Platen SH
Water
Feed water entering
economiser
Feed water leaving
Economiser
Flue gas
Flue gas leaving
Furnace
Flue gas entering
Reheater
Flue gas entering
Horizontal SH
Flue gas entering Eco.

700 662 420

540 540 540

137 136 13.2

580 575 375

540 540 540

24.5 24.7 14.9

----

332 331 293

342 340 334
430 433 452

26.4 26.5 16.0

150.7 148 137.4
146 144 135.5

--

514 514 512

--

700 643 371

247 246 220

153 150 139.2

--

278 277 262

--

--

1125 1135 1118

--

--

1020 1017 981

--

--

697 690 670

463 459 433

Flue gas entering APH

364 366 336

Flue gas leaving APH

146 143 129

Air
PA flow at APH
Outlet
SA flow at APH
Outlet
Tempering

96.7 77.8 70.3

338 336 316

678.3 624.5 481.5

330 329 311

120.8 85.5 92.9

38 38 38

air
Total combustion 919.3 869.3
air
668.2
Fuel
110.1 105.1 71.5
Coal(HHV=5000
Kcal/Kg.)
1.2.2 PRESSURE AND DRAFT (AIR &GAS)
PRIMARY AIR Units
MCR
Description
P.A. Fan Outlet
mmwc
740
A.H. Inlet
mmwc
727
A.H.Outlet
mmwc
672
Mill Inlet
mmwc
634
Mill Outlet
mmwc
228
SECONDARY
Units
MCR
AIR Description
F.D.FanOutlet
mmwc
317
SCAH Inlet
mmwc
312

NCR
734
723
672
634
228
NCR
291
286

Control load
60% MCR
700
691
661
634
228
Control load
60% MCR
213
211

SCAH Outlet
AH Inlet
AH Outlet
Aerofoil Inlet
Windbox Pr.
Windbox to
Furnace Diff.

mmwc
mmwc
mmwc
mmwc
mmwc
mmwc

FLUE GAS
Description
SH Platen Inlet
RH Inlet
Finish SH Inlet

LTSH Inlet
Economiser
Inlet
A.H. Inlet
E.P. Inlet
I.D. Fan
Inlet( Includi
ng Static
Head)

287
282
193
180
140
140

265
261
185
174
140
140

Units

MCR

NCR

mmwc
mmwc
mmwc

-5
-6
-14

-5
-6
-13

201
198
162
157
140
140

Control load
60% MCR
-5
-6
-9

mmwc
mmwc

-20
-37

-19
-35

-12
-20

mmwc
mmwc
mmwc

-54
-184
-242

-49
-165
-222

-31
-84
-128

1.2.3 MILL AND BURNER PERFORMANCE

Description
Units
MCR

NCR

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

16

16

Control load
60% MCR
12

Degree
-

0
4

+10
4

+30
3

%
T/hr

80
52.3

79
52.3

70
52.3

0C

172

171

160

0C

77

77

77

% Thru 200
Mesh

70

70

70

1.2.4 O2, CO2

Units

MCR

NCR

( BY
VOLUME )
AND EXCESS
AIR Description
O2 in Gas at

Control load
60% MCR

4.3

4.3

5.5

Economiser
Outlet
CO2 in Gas at

Economiser
Outlet
Excess air in Gas %
at Economiser
Outlet

14.9

14.8

13.7

25

25

36

1.2.5 DESIGNED PRESSURE DROPS

Description
Units
MCR
SH System
RH System
Economiser
System

NCR

Kg/cm2
Kg/cm2

13.7

12.0

Control load
60% MCR
5.4

1.9

1.8

1.1

Kg/cm2

2.1

2.0

1.8

A. Air mmwc
Wind-box 115
APH 94
Air-duct 63
Aero-foil 25
B Across Pulv. 305
Fuel Piping 308
C. Flue Gas mmwc
Furnace 4
S/H & R/H 48
Eco 19
Flue gas Duct & Dampers 52
Regenerative APH 110
Static Head 20
Velocity Head & Exit Loss 20
ESPS 22
Total Loss 295
1.2.6 HEAT BALANCE
Dry gas loss 4.63%
Carbon loss 2%
Radiation loss 0.26%
Unaccounted loss 1.5%
H2 in air and H2O in fuel 4.9%
Total loss 13.3%
Efficiency 86.7%
1.2.7 RECOMMENDED FEED WATER LIMITS
Drum operating Pr. in kg/cm2 61-100 101 & above
1. Hardness Nil Nil
2. ph at 250 C.(Copper alloy pre-boiler syms.) 8.8-9.2 8.8-9.2
3. ph at 250 C.(Copper free pre-boiler syms.) 9.0-9.4 9.0-9.4

4. Dissolved Oxygen(max) ppm 0.007 0.007

5. Total Iron(max)ppm 0.01 0.01
6. Total Silica(max)ppm 0.02 0.02
7. After Cation Column Conductivity at 0.5 0.3
250 C( micro-mhos/cm),online
8. Hydrazine residual(ppm) 0.02-0.04 0.02 - 0.04
9. Permanganate consumption(ppm) Nil Nil
10.Oil Not allowed Not allowed
11 Chlorides not allowed Not allowed Not allowed
12.Copper(max)ppm 0.005 0.005
1.2.8 RECOMMENDED BOILER WATER LIMITS
Drum operating Pr. (kg/ cm2) 61-100 101 & above
1. Total dissolved solids (max)ppm 100 50
2. Conductivity at 250Cmicro-mhos/cm 200 100
3. Phosphate residual(ppm) <20 2-4 #
4. ph at 250C. 9.0-10.0 9.0-9.5
5. Silica(max)ppm 2.0 0.4 *
6. Chlorides(max.)ppb <4000 <2000
7. Total hardness Nil Nil
Note: # If the Boiler water pH is not maintained in the prescribed limit, residual
Phosphate may be increased but upto 10 ppm only.
Silica value in Boiler water should commensurate with the drum pressure.
1.3 FURNACE SAFEGUARD SUPERVISORY SYSTEM (FSSS)
FSSS facilitates remote manual/automatic control of fuel firing equipment through mechanized system and suitable
interlocks/logics. The system provides protection against malfunctions of fuel firing equipment and associated air
systems.
1.3.1 FSSS INTERLOCKS AND PROTECTION
1. PURGE READY CONDITIONS
i) 220vDC and 110vAC supply to FSSS panel estd.(crl 53 and tdr 10 are both on)
ii) Boiler Drum level normal(CR 169 is off)
iii) At least one ID and one FD fan running(CR 151 is off)
iv) Ignitor trip v/v proven closed(CR 263 is on)
v) Warm-up trip v/v proven closed(CR 279 is on)
vi) All Ignitors oil/air v/vs proven closed(CR12 is on)
vii) All WO and HO nozzle hydromotor v/vs proven closed(CR16 is on)
viii)All Pulv. are off(CR 26 is on)
ix) All RC Feeders are off (CR 28 is on)
x) All mills HAGs closed and CADs open , less than 5%(CR 43 is on)
xi) All Aux Sec. air dampers modulating to maintain adequate WB to furnace DP(CR 480 is on)
xii) All el. Flame scanners show No Flame(CR 22 is on)
xiii)No boiler trip command persisting(1CR 148 is off)

SR. NO.

DESCRIPTIO

PERMISSIVE

INTERLOCK

PROTECTION

1.

2.

3.

N
Ignitor trip v/v

Heavy Oil Trip

Valve

Heavy Oil
Elevation start

1. Ignitor Oil
Supply Pr. Is
Adequate
(>13kg /Sq.Cm)
2. All Ignitor V/Vs
are closed(cr12
on)

1. Boiler trip
circuit (MFR) is
reset. (2 CRL 61 is
ON)
2. All HO nozzle
valves of AB, CD
& EF oil guns are
proven fully
closed. (1 CRL
107 AB, CD, EF
are ON)
3. HO supply
pressure is
adequate (more
than 7 Kg/Sq.Cm)
4. HO pressure
not low (less
than 1.5
Kg/Sq.Cm for
more than 2
sec. ) TDR 281
is OFF.

Pressing one pair (lo or

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

a. ignitor oil header pr.

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

1. DC power available (TDR 51 is ON)

2. Ignitor trip valve proven fully open (1 CRL 259 is ON)
3. No boiler trip command persists
4. Heavy oil temp above 100 deg C
5. Air flow adjusted between 30 to 40% of full load air flow
6. Burner tilt placed in horizontal position

Heavy Oil
corner start

1. The main oil gun is

inserted in guide pipe &
coupled
2. The local maintenance
control switch is placed in
remote
3. HO manual isolation
valve is open
4. Atomising steam manual
isolation valve is open

1. In first 10 secs of pair start time

trial the associated elevation
ignitors are started. When ignitors
are proven ignitor ON signal
comes (CR 29 AB 1, 2, 3, 4 are
ON) If the flame is not provend
spark will cease and jamesbury
valve will close after 10 secs.
1 When minimum 3 out of 4
ignitors at the associated elevation
are proven ON (1 CR131 AB
is ON)
2 25 secs later a start
command is sent to corner
3 (when pair 1&3 are
started) or 4 (when 2&4 is
started)
3 When the gun is fully
advanced the atimising
steam nozzle valve opens.
4 When the atomising
steam valve is proven fully
open the heavy oil nozzle
valve opens placing HO
gun in service. (Total time
taken for proving the pair
of guns is 90 secs)

HO elevation
shut down

1.4.1
Descri
SPECI ption
FICA
TION
S
Sr.No.
A
ID Fan
B

FD
Fan

Depressing the associated elevation pair button will initiate a 375

secs stop time trial to shut down the scavenge the associated pair
of LO guns as follows.

1.4 FANS
Press. Temp
KW
mmwc 0C

Type

No Of
Boiler

Capac
ity
m3/sec

Axial
Impuls
e Type
Axial
Reacti
on
Type

230.9

387

150

103.8

520.5

50

Motor
Voltag
e
KV/V

RPM

1300

6.6

990

800

6.6

490

PA Fan

Ignitor
Air
Fan
Scanne
r Air
Fan
Seal
Air
Fan

E
F

Radial 2
Backw
ard
Curved
Centrif 2
u Gal

65.3

1345.5

50

1250

6.6

1485

400
Sefm

4WG

11

415v

1460

-do-

1100
M3

160

50

1.1

415v

3000

-do-

11000
M3

150

50

10

440V

2850

1.4.2 FAN LUBE SYSTEM AND CONTROL

A : ID FAN
LUBE OIL
SYSTEM
S.N.
PUMP
MOTOR
FAN
I
TYPE-Gear type
Power-0.5HP
II
Capacity-5LPM
Voltage-415v
Frequency-50C/S,3 Ph.
Inlet vane control
III
Operating Press-2Kg/cm2 Speed-1380 RPM
IV
Relief Pr-7 Kg/cm2
Rated current-1.08 Amps
B: FD FAN LUB OIL
Motor
Fan control
SYSTEM: Pump
I
Type-Gear type
Power-4KW
II
Capacity-79.2 LPM Voltage-415V,
Variable pitch blade
Frequency-50c/s,3Ph
control
III
Lub oil Pr. 0.8 to3ata (g)
Speed-1400 rpm
Rated Current-11 Amp
C: PA FAN
PUMP
MOTOR
FAN
LUBE OIL
SYSTEM Sr.N
I
TYPE-Gear type
Power-0.5HP
II
Capacity-5LPM
Voltage-415v
Frequency-50C/S,3 Ph.
Inlet Guide vane
III
Operating PressSpeed-1425 RPM
contol
2Kg/cm2
IV
Relief Pr-7 Kg/cm2
Rated current
1.2 Amps

1.5 AIR HEATER

1.5.1 STEAM COIL AIR PRE-HEATER
TYPE
Steam Coil R2-10
No.Of Boiler
2
Medium
Secondary Air
H.S. IN M2
770 per Air Heater
1.5.2 RE- GENERATIVE AIR PRE-HEATER
Type Tri Sector Regenerative 27 vi 72 (T)
No. Boiler 2
Medium i)Primary Air
ii) Secondary Air
iii) Flue gas
H.S. IN M2 19000 per Air Heater
HEATING ELEMENT ROTOR DRIVE CLEANING DEVICE
i) Hot layer-864 mm
i) Motor-GE 15 HP
i) Motor-0.25 HP
Open hearth steel
ii) Intermediate
ii) Voltage-415v
ii) Speed reducer
Layer-864mm
4800:1
Open hearth steel
iii) Speed-960 rpm
iii) Cold layer-305mm iv) Speed-110:1 reducer
corten A steel
v) Oil Capacity-13G
SUPPORTING
BEARING GUIDE
BEARING AUX.AIR
MOTOR
i) Type- Spherical Thurst
Double roller Motor-4
BHP
Bearing bearing
ii) Lubrication-Oil Oil
Bath Air Pr.-5.6 Kg/cm2
bath type
iii) 18 Gallons Oil
capacity-4 Speed-255 rpm
Gallons
iv) Motor rating-3/4 HP 1
to 0.5 HP
1.5.3
PERFORMAN
CE OF AIR
PREHEATER
500 PA

500 PA
REVERSE
ROTATION

NORMAL
ROTATION
FLOW t/hr
PRI
SEC
GAS

Air In
Air In
Gas In

720 PA REVERSE
ROTATION

mmWC

mmWC

NORMAL

180
681
999

165
697
999

163
699
999

20%
MORE
182
837
1199

20% LESS
144
561
799

PRI
Air Out
SEC
Air Out
GAS
Gas Out
TEMPERATURE

97
680
1084
0C

97
680
1085
0C

97
680
1085
0C

116
816
1286
0C

PRI
Air In
SEC
Air In
GAS
Gas In
PRI
Air Out
SEC
Air Out
GAS
Gas Out
PRESSUR DROP
PRI
Air
SEC
Air
GAS
112

38
41
369
337
329
146
mmWC C
44
90
112

38
41
369
325
333
146
mmWC
44
90
112

38
41
369
326
334
146
mmWC
22
124

38
41
369
321
332
149
mmWC
29
159

1.6 SOOT
BLOWER
Location
i) Furnace

Header Pr
(Kg/cm2)
30
30

ii)
Platen,Convent
ion

Type

146
Qty./Boiler

78
544
884
0C
38
41
369
331
338
142
mmWC
14
107
75

Medium

Wall blowers
RWSE
Long
retractable

56
20

Super heated
steam
Super heated

Swiveling

Super heated steam

Super heater &

Re-heater
30
ii) Air Heater

1 DESIGN CONDITIONS UNIT # 4 UNIT # 5

i) Gas flow rate 1333709 m3/hr. 133380 m3/hr
ii) Temprature 1500 C 1460 C
iii) Dust concentraion 31.8 gm/m3 28.3 gm/Nm3
iv) Inlet pressure 2000mmwc 2000mmwc
v) Type 2 FAAX .5x36-9590-2 2FAA. 5x32-11190-2
vi) NO. of boilers 2 2
vii) No. off fields in series 5 5
in each gas path
viii) No. of parallel pass per 4 4
boiler
ix) Design pressure drop 99% 99%
across precipitator
x) Design pressure drop 15MMWC 15MMWC
across precipitator
xi) Gas velocity at electrode 1.08 m/sec. 0.93 m/sec
Zone
xii) Treatment time 16.62 sec. 17.243 sec
1.7.2 COLLECTING PLATES EMITTING ELECTRODES
i) No. of rows per field 38 No of electrodes in each rows 32
ii) No. of collecting plates 384 No of electrodes in each field 1184

per field (8plates in each row)

iii) Total no. of plates/boiler 6080 No .of electrodes / boiler 23680
iv) Nominal height of 9 M Total length of electrodes 6829M
Collecting plates per field
v) Nominal length of 400 MM Size 2.5 mm
Collecting plates
vi) Specific collecting area 132.88 m2 Plate/wire spacing 150mm
Type Spiral with hooks
1.7.3 RAPERS FOR COLLECTING RAPERS FOR EMITTING PLATES ELECTRODES
i) No. & type of One drop hammer Type & no. Spiral hooks
rappers Per row for collecting approx one
Surface area of 57.6m2 dropHammer/
ii) Rapper weight 4.9 kg. Rapper wt. 3 kg.
iii) Frequency varies from 6 raps/hr.at Frequency 10 raps/hr Inlet field to 1 rap/hr. at
Exit field
iv) Drive ` Geared electric motor Drive Geared elec
controlled by synchronous tric motor
programmer with synch
ronous programmer
1.7.4 HOPPERS
i) Type & quality Pyramidal
ii) No. of hoppers 40 (2 per field)
iii) Capacity 8 hrs. storage
iv) Heating Electrical heating at hopper bottom
1.7.5 GAS DISTRIBUTION SYSTEM
i) Type & quality Perforated plate 25 sets
ii) Location Inlet of precipitator
1.7.6 ELECTRICAL SYSTEM
A) RECTIFIER UNIT # 4 UNIT # 5
i) Rating 60kv (peak/800 m.a.) 70 kv (peak/1000 m.a.)
ii)Number 20 20
iii) Type Silicon diode full wave bridge connection
iv) Location Mounted on precipitator top
B) RECTIFIER CONTROL PANEL
i) Type & control Thyristor/microprocessor based)
on controller(PRECICON
ii)Number 20
iii) Location In the control room at ground level
C) AUX.CONTROL PANEL
i)Number 4
ii)Equipment controlled Geared motors for rapping mechanism, heating
elements om hoppers & shaft insulators.
iii) Location In the control room at ground level
D) MOTORS
For both emitting electrodes
i) Quantity 20 Nos.
ii) Rating 0.5 HP,1.1 rpm at 3 ph,50 c/s , 415v
iii) Location on the casing side panel
E) HEATING ELEMENTS
i) HOPPERS
For forty hoppers at the rate of 6 kw /hopper = 240 kw
ii) SHAFT INSULATORS

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

Support insulators for 80 insulators at the rate of 1 kw = 80 kw
1.8 COAL BURNERS,IGNITORS & OIL GUNS
A) COAL BURNERS
i) Type Titling tangential fired corner
ii) No. of boiler 24 (4 each in 6 elevation)
iii) Titling limit +/- 30 deg. Cent.
B) IGNITORS
i) Type 6 eddy plate oil side ignitors air atomised
ii) NO. off 12 (4 per elevation)
iii) Location Elevation AB,CD,EF
iv) Capacity 0.5 millions k.cal./hour
v) Turn down ratio Nil
vi) Oil pr. At control cabinet 12.5 to 14 kg/cm2
vii) Oil firing rate 50 kg/hr/ignitor
viii) Atomising air quality Water free service
ix) Atomising air pr. 5.5 to 7 kg/cm2
x) Atomising air consumptio 14.5 Nm3 / hr/ ignitor-when off
xi) Combustion air quality 560 Nm3 / hr / ignitor
xii) Combustion air pr. At wind box 75 MMWC
C LIGHT OIL (W.U.) GUNS
i) Type Tilting, tangential, air atomized internal mix
ii) No. off 4
iii) Location Elevation AB corners

iv) Capacity 10% of boiler MCR

v)Turn down ratio 2.5 :1
vi) Oil firing rate 1265 kg / hr / gun
vii) Atomising air quality Service air water free
viii) Atomising air consumption 190 Nm3 hr / gun
ix) Atomising air pr. 5.36 kg/cm2
Differencial pr. Between oil & air 1 kg/cm2
C) FUEL (LDO) OIL GUNS

i) Type Tilting,tangential steam atomised internal mix

ii) No. off 12 (4 per elevation)
iii) Location Elevation AB,CD,EF corners
iv) Capacity 20% of boiler MCR in total
v)Turn down ratio 4 : 1
vi) Oil firing rate 1320 kg / hr / gun
vii) Oil pr. At gun 8.5 kg / cm2
viii) Atomising steam quality Super heated by 10-15 deg.cent.
ix) Steam consumption 150 kg / hr / gun
x) Steam pressure at gun 9.5 kg / cm2
)Differential pressure 1 kg / cm2
between oil & steam
1.9 COAL MILL
i) Type XRP 783 Bowl Mills
ii) No. of boiler 6
iii) System pressurised
iv) Capacity 39.7 mt / hr
v) Coal grindibility 55 HGI
vi) Max. moisture content 12%

vii)Finness through 200 mesh 70%

MOTORS
i) Rating 340 kw
ii) Voltage 6.6 kv 3 phase
iii) Frequency 50 c/s
iv) RPM 990
v) Rated current 41.7 Amps
vi) No load current 15-16 Amps
1.10 RAW COAL FEEDER
i) Type chain type
ii) Width 600 mm
iii) Length 12400 mm
iv) Speed variation 1 : 6
v) Depth of coal bed 120-200 mm
vi) Capacity max. 45 mt / hr.
MOTORS
i) Rating 7.5 kw
ii) Voltage 415v
iii) Current 15.5 Amps
iv) Speed 975 rpm
1.11 FUEL OIL TRANSFER PUMPS
DESCRIPTION TRANSFERPUMP DRAIN PUMPS
i) Capacity 120 m3 /hr 5 m3 / hr
ii) Discharge 80 MMWC 40 MMWC
iii) Suction 5 MMWC 5 MMWC
iv) Max. temp. of oil handle 600 C 600 C
By the pump
1.12 DOSING SYSTEM
DESCRIPTION PHOSPHATE HYDRAZINE
i) Soln. preparation tank 1 no. 600 ltr. 1 no. 500 ltr.
ii) Metering tank 1 no. 600 ltr. 1 no. 500 ltr.
A) PUMP
I) No. of boiler 2 2
ii) Capacity 0-100 ltr./hr. 0-30 ltr./hr
iii) Type Horizontal Horizontal reciprocating reciprocating
iv) Head 195 kg / cm2 110 MMWC
MOTOR
i) Rating 2.2 kw
ii) Voltage 415 v,50 c/s
iii) Speed 1430 rpm
iv) Current rating 4.8 amps.
1.13 ASH HANDLING SYSTEM
A) MAX.ASH COLLECTION RATE
i) Bottom ash hopper: (1 No.) 12 ton/hr. ii) Air heater hopper (4 No.) 2.08 ton/hr.
iii) Economiser hopper (4 No.) 1.74ton/hr
iv) EP hopper (4 No.) 52.36 ton hr/
v) Stack hopper (2 No.) 0.79 ton/hr
vi) Bottom ash 12 ton/hr.

vii) Fly ash 56.97 ton/hr.

viii) Total ash 66.97 ton / hr.
ix) Gross storage volume 33 M3
of BA Hopper
x) HP Water pressure 9.5 kg/cm2
xi) LP Water pressure 5.5 kg/cm2
B) ASH PUMP:
i) Quantity of sealing water 15 m3/hr.
ii) Pressure of sealing water 8 kg/cm2
iii) Pump capacity 1000 m3 / hr
iv) Head developed 23-33 MMWC
v) Speed 800 rpm
C) ASH ANALYSIS
i) Silica 55.09-68.8 %
ii) Alumina 19.8-29.8 %
iii) Iron oxide 3.05-18.3 %
iv) Titanium oxide 10.0-2.05 %
v) Lime 1.1-2.1 %
vi) Magnesia 0.26-1.2 %
vii) Sulfuric acid hydrous 0.4-1.8 %
viii) Phosphoric Anhydride 0.19-0.28 %
ix) Alkalis 0.16-3.04 %
1.14 MAKE UP SYSTEM
No .of DM Water storage tank 5
1.14.1 MAKE UP PUMP
MOTORS

i) No. 2 Make-Crompton greaves

ii) Make: Mather & platt
iii) Type: 4/5,two stage MEDI Type-Induction motor
Voltage-415v,3 phase
iv) Discharge-100 m3/hr. Current-49 amps
v) Head-50 MMc Speed-1475 rpm
vi) Speed-1480 rpm
Connected to hot well, unit drain tank & deaerator.
1.14.2 FILL PUMPS MOTORS
i) No.-2 nos Make-Crompton greaves
ii) Make : IIIplurovane,5 CHR Type-AC induction motor
iii) Discharge-200 m3/hr. KW/HP- 187/250,voltage-6000v
21 amps.
iv) Head 200 mwc
v) Speed 1480 rpm Speed 1483 rpm
Connected to-boiler drum & deaerator.
1.14.3 QUANTITY OF WATER REQUIRED FOR BOILER FILLING:
SYSTEM UNIT ENTIRELY UNIT FILLED TO
FILLED (M3) OPERATING LEVEL (M3)
1676 internal dia drum 37.20 11.53
Water walls 126.3 126.30
Super heater 97.18 ---Reheater 48.10 ---Economiser 25.17 25.17
Main steam piping 12.05 ---------------- ------------TOTAL 345.00 163.00

------------- ------------1.15 COAL MILL REJECT HANDLING SYSTEM

1.15.1 CLIENTS ORDER REFERENCE:
For Design, Manufacture & supply of imported equipments- A/T No. BTPS/PUR/P3/IMP/86-87/2427 dated 31-12-86.
For Design, manufacturer & supply of indigenous equipments Erection, Testing & Commissioning of complete system.
A/T No.BTPS/PUR/P3/IMP/86-87/2428 dt. 31-12-86
SUPPLIERS:
FOREIGN: Simon-Macawber Limited,
Shawlane Industrial Estate
Doncaster
South Yorkshire
DN2 4SE, UK
INDIGENOUS: Bakhtawar Singh Balkrishan & Co
"Beekay House"
L-8, Green Park extension
New Delhi - 110016.
1.15.2 DESIGN BASIS & DATA
BASIS Normal Reject rate of mills < 5%
Reject rate considered for design is 10%
DESIGN DATA:
Maximum Quantity of rejects per mill 3 TPH
Normal Quantity of reject per mill 1.7 TPH
Average Mean Reject rate per unit of 210 M 9.8 TPH
Average quantity of rejects per day for 470 Tones
2 x 210 MW units
Density of mill rejects is taken as 1.6 T/m3 for volumetric computations
and 2.2 T/ m3 for load/strength computations.
1.15.3 DESIGN CAPACITY PROVIDED IN THE SYSTEM:
Removal capacity at each mill 3 TPH
Removal from storage bunker to tube mill of 100 MW unit 5 TPH
Storage bunker capacity 80 m3
1.15.4 COMPRESSED AIR REQUIREMENTS:
Compressed air is required in the system for conveying and controls as below:
For primary system at 9.8 TPH per unit of 210 MW 8.82 m 3/min

For Secondary system at 5.0 TPH per unit 10 m3/min

x2)=37.64 m 3/min
Provided 4 Nos compressors with maximum 3 Nos working and 1 No as standby, each of 14.7 m 3 capacity (FAD)
delivering at 7 kg/cm2 (g)

1.15.5 AIR RECEIVERS:

Nos per Boiler : 2
Capacity each : 5 m3
SECONDARY SYSTEM:
From storage bins to stage-I mills 2C & 3C
Air receiver capacity for secondary system: 10 m3
1.15.6 DENSEVEYOR
Model 12/8

System : batch conveying 12 Ft3

Vessel capacity:
Pipe size 150 mm
Design Code BS5500 Class III
Safe working pressure 110 lb/in2 (7 kg/cm2)
Hydraulic test pressure 150 lb/in2 (10 kg/cm2 )
1.15.7 AIR COMPRESSORS
Type Screw
Model & Type SES-520 single stage
Capacity 520 cfm +/- 5%
Make Khosla Indair
Drive Motors NGEF
Discharge Pressure 7 kg/cm2
Speed 4500 RPM
Actual Quantity of free air compressed FAD 520 +/- 5% cfm
Volumetric efficiency 91%
Brake HP required at Comp.shaft at 105.0 HP
rated load
Motor Rating 130.0 HP
Type of bearings for rotors Cylindrical roller and 4 point
Bearings
Details of lubrication Oil flooded (forced feed)
Materials of construction:
Rotors EN-8
Gears EN-41B
Bearings Mfd.Std.
Frame and running gear (coupling) forged steel,
rubber flexible
Shaft EN-8

Base plate MS
Type and size of suction and Butterfly suction valves discharge valve MS (CI body) DK-100 (4")
Details of special features After cooler and oil coolers
Total cooling water quantity 150 LPM
required at 360C
Cooling water out let temp. 100 C above inlet temp. Oil
cooler and after cooler.
1.15.8 AIR FILTER CUM SILENCER
Type Dry filter type
Max. particle size removed after 10 Microns
cooler and Inter cooler
Type Shell and tube type
(water through tube)
Material of construction
Shell IS-226
Tubes Copper 3/8"
Tube sheets MS
Tube support plates MS
No of passes 2 passes
Cooling surface

Oil Cooler 9.6 m2

After Cooler 5.5 m2
Air Pressure drop through the after cooler/oil cooler 2-3 psi
Cooling water inlet/outlet size 1" & 3/4" BSP
Cooling water quantity required at 36 0 C 150 LPM
Air outlet temp. 100 C above cooling water
temp.
1.15.9 VIBRATORY FEEDER
Equipment & Model Electromagnetic vibratory feeder - Model F-33
Duty For handling coal mill rejects
Manufacturer Internal Combustion
Quantity 2
Maximum capacity 25 T/Hr
Particle size 30 - 35 mm (Max.)
Bulk density of material 1600 kg/ m3
Inclination to horizontal 6/8 deg
Power supply 400/440 V
Power consumption 525 Watts
Feeders through size 450 mm x 1100 mm
Material of trough MS
Type of suspension Suitable for suspension type arrangement
Approx. weight 940 lb
Type of control panel Thyristor controller
Type of protection of control Conforming to IP - 54.
panel

SECTION - II

TURBINE
AND
AUXILIARIES

2.1 SPECIFICATION
2.1.1 TURBINE MAIN DATA Rated Power 210MW
Rated Speed 3000 rpm
Rated Steam(Pressure) before ESV 130 Kg/cm2 abs
Rated Steam Temp. before ESV 5350 C
Rated Steam pressure Before IV 27 Kg/cm 2 abs
Rated Steam temp. Before IV 5350 C
Rated Steam Flow 670 T/Hr
HPT Exhaust Pressure 27 Kg/cm2
HPT Exhaust Temperature 3270 C
Rated circulating water quantity 27000 M 3
through condenser
Condenser back pressure 0.09 Kg/cm2
Critical Speed 1585,1881,2017&2489
Rated condenser cooling water inlet 24 0 C to 330 C
temperature
Rated condenser cooling water 1.0 to 1 Kg/cm 2
pressure
Type of governing Hydro mechanical
Nozzle type governing
Type of turbine condensing, Tandom compound
Three cylinder, Horizontal
Nos. of bearing 5 Nos.( for turbine side only &
HPC front bearing
is combined thrust & journal bearing
Barring gear 3.4rpm, ac motor of 30kw, 730rpm, 50c/s,
415v, 220:1 Ratio
Location of anchor point of At the middle foundation frame of front
the turbine exhaust part of the L.P. Cylinder
2.1.2 CONSTRUCTIONAL DETAILS
i) H.P. CYLINDER 12 stages (1st is governing stage) each stage
Consists of a diaphragm & a set of moving
Blades connected on a disc
BODY In two valves made of Creep Resistance
(Cr-Mo-V) steel
STUDS & NUTS High Creep Resistance (Cr-Mo-V) steel
Forgings
NOZZLE & STEAM 4 Nos (2 on Top & 2 on sides) made
CHEST of High Creep resisting (Cr-Mo-V)
Steel casting
ii) I .P. CYLINDER 11 stages
BODY 2 parts (a ) Pressure part made of
Creep Resisting (Cr-Mo-V) steel
Casting in 2 halves (b ) exhaust part
Made of fabricated steel structure
In 2 halves.
STUDS & NUTS Creep Resisting (Cr-Mo-V)
steel Forgings
NOZZLE BOXES Cast integral with the casing.

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

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

2.1.3 STEAM EXTRACTIONS

No of
Steam
Connected
extractions
extraction
to
stages

Ext, steam
press in Kg/
cm2

Ist (HPT)

Ext.steam
temp.in 0C

Steam flow
T/hr.

9th
12th

HPH-7

39.06

in
337

400

HPH-6/D/A

26.2

314

77

15th
18th

HPH-5/D/A

11.96

433

16.2

LPH4

6.47

26

LPH3

2.78

VI (IPT)

21st
23rd

3680C
252

LPH2

1.28

172

28

VII (LPT)

25th

LPH1

0.28

12.6

Iind (CRH
IIIrd (IPT
IV (IPT)
V (IPT)

23

2.2 GOVERNING SYSTEM

TYPE: Hydro mechanical automatic governing.
i) SPEED GOVERNOR:
Directly coupled to turbine rotor through coupling & hydraulically coupled to speed governor pilot block
located front pedestal.
PUPPOSE: Sensing of any speed due to difference between power generated by turbine & load on it. For this
governor sleeve moves proportional to speed change. ( Range is 4+1% speed change.)
ii) FOLLOW PILOT VALVE:
FUNCTION: It follows the governor sleeve in case of change of speed & maintains the gap between
governor sleeve & nozzle tip to move summation pilot valve accordingly.
iii) LOAD SPEED CONTROL PILOT VALVE:

PURPOSE: For initial charging of protections oil in governing system through emergency governor pilot
valve & to open ESV, IV & control valve.
iv) SUMMATION PILOT VALVE:
PURPOSE: To receive movement signals from follow pilot valve & gives command to intermediate pilot
valve to open or close the control valves.
v) INTERMEDIATE PILOT VALVE:
PURPOSE: To amplify the hydraulic signal form summation pilot valve, differentiator, electro hydraulic
transducer and emergency governor pilot valve & transmit to control valve servomotor.
vi) CONTROL VALVE SERVO MOTOR:
PURPOSE: It receives hydraulic signal from intermediate pilot valve & actuates HPT and IPT control
valves.
vii) LOAD LIMITER:
PURPOSE: To limit the load raising beyond set point by limiting the opening the control valve by speed
governor.( its continuos operation is not recommended.)
viii) DIFFERENTIATOR: PURPOSE: It prevents undue speed rise in case of more than 50% load through
off which causes anticipatory closure of control valve of HPT and IPT.
ix) ELECTRO HYDRAULIC TRANSDUCER:
PURPOSE: It converts electric signals of 2 seconds diverted from generator circuit breaker (when opens)
into hydraulic signal & momentarily closes the control valve for 2 seconds to avoid overspeed.
x) INTIAL STEAM PRESSURE UNLOADING GEAR:
PURPOSE: When main steam pressure falls below 90% +/- 2% of rated value it throttles the control valves
& when main stem pressure falls to 70%, completely closes the control valve.
xi) EMERGENCY GOVERNOR:
PURPOSR: It consists of two centrifugal strikers which operates and trip the turbine in case 11 to 12% of
over speed by closing ESV, IV , HPT and IPT
control valve.
xii) TURBINE SHUT DOWN SWITCH:
PURPOSE: TO manually trip the turbine locally or from UCB.
xiii) EMERGENCY GOVERNOR PILOT VALVE:
PURPOSE: It receives emergency signal from emergency governor & turbine shut down switch & trip the
turbine.
xiv) BACK UP PROTECTION(SPEED GOVERNOR PIOLT BLOCK):
PURPOSE: It trips the turbine at 14 to 15% over speed if emergency governor fails to operate.
2.2.1 CONTROL GEAR:
READING OF CONTROL GEAR DRUM EVENT
4.6mm IV begins to open
5.5 mm ESV begins to open
5.9 mm IV fully open
6.65 mm ESV fully open
9.6 mm IPT & HPT control
valve begin to open
12.8 mm All control valves
fully open
2.3 TURBINE LUBRICATION SYSTEM
2.3.1 LUBRICATING OIL SPECIFICATION:
Type (Recommended oil for governing MOB DTE oil medium
system and bearing) or
Turbine oil -14
Or
Servo prime -14
Or
Turbinol-47
Specific gravity at 500C 0.852

Kinematic viscosity at 500C 28 Centistokes

Neutralization number 0.2
Flash point 2010C(min)
Pour point 66.600C(max)
Ash percentage by weight 0.01%
Mechanical impurities Nil
Oil pressure in governing system 20 Kg/cm 2 (Guage)
Oil pressure for lubrication of bearings 1 Kg/cm 2 (Guage)
2.3.2 MAIN OIL TANK
Capacity 28000 Lts
Oil capacity in systems 4000 Lts
Main oil centrifuge capacity 6000 Lts/Hr
Oil transfer pumps capacity for purifier unit 6000 Lts/Hr
Polishing filter capacity 6000 Lts/Hr
Impure and pure oil storage tank capacity 40 m 3 each
Impure and pure transfer oil pump capacity & head 45 m 3 /Hr, 18 MWC
2.3.3 MAIN OIL PUMP
Pressure corresponding to discharge of 4000lits/min 20 Atg
Pressure corresponding to discharge of 7000lits/min 16 Atg
Suction pressure 1Atg
Power consumption 250 Kw
Type of coupling with rotor Flexible gear type
No. of injectors 2 Nos.
Oil pressure developed by Ist injector 1 Kg/cm 2
Oil pressure developed by IInd injector 3 Kg/cm 2
Speed 3000 rpm

2.3.4 STARTING OIL PUMP

FOR NORMAL OPERATION
Type Plurovane III(Unit4) Plurovane III A(Unit 5) ( Multi stage
centrifugal pump),Mather& Platt
Capacity 200 m3 /Hr
Head 200 MWC(20 Kg/cm2 )
A.C.MOTOR
Capacity 200 Kw
Speed 1000 rpm
Voltage 6.6 KV,3 Ph, 50 C/s
Arrangement Horizontal
2.3.5 A.C.STANDBY OIL PUMP
PUMP MOTOR
Type 150COAV ,BHEL Type 22F Q UE/O
(multistage, centrifugal oil
Pump, driven by motor) Power 25 Kw
Capacity 150 m3 /Hr,(2500 L/Min) Speed 960 rpm
Head 30 MWC Current 52 amps
No. of stages 2 Voltage 415 volts,3 Ph, 50 C/S
Arrangement Vertical
Impeller material Bronze

Min. oil pressure 0.6 Kg/cm2 For auto starting

BEARING
Type Single Row Deep Grove Ball Bearing
( Thrust anti friction bearing)
Number S.K.F. 6306
Lubricant Mobile D.T.E. medium IOC
2.3.6 D.C. EMEGENCY OIL PUMP
PUMP MOTOR
Type 100 NCU centrifugal pump Power 13 Kw
driven by D.C. motor Voltage 220 volts D.C.
Min. oil pressure 0.5 Kg/cm2 Current 67.6 amps
for starting Speed 1500 rpm
interlock Type D-62

Capacity 108 m3 /Hr

(1800 L/min)
Head 22 MWC
BEARING
1. 1 no double row self aligning ball bearing for free end.
2. 1 no. double row self aligning spherical roller bearing.
2.3.7 MAIN CENTRIFUGE (OIL PURIFIER)
PUMP MOTOR
Type of oil purifier MAB-206-S-20 KW(HP) 7.5(10)
Capacity of purifier 6000 Lts/hr Frequency 50 Hz
Capacity of transfer pumps 6000 Lts/ hr Voltage 440 Volt
Oil pressure at inlet of separator 2.35 Kg/cm 2 Current 13.6 amps
Speed 1500 rpm (max) Speed 1440 rpm
LUBRICANTS
Lubrication points: (1) Worm gear housing (2) bowl
(2) Bowl spindle(4) bearing of coupling
(3) Gears of lifting devices (60 motor
HEATER
Type WH
KW 120
Voltage 440 volts
2.3.8 MAIN OIL COOLERS
No. of coolers 5 nos.(4 nos. at a time in service)
Cooling surface area of oil coolers 63 m2
Quantity of oil cooled 1500 Lit/min or 90 m 3 /Hr
Water consumption 130 m3 /Hr
No. of water paths 4
Designed oil pressure 5 Kg/cm2
Designed water pressure 5 Kg/cm2
Working pressure of oil 3 Kg/cm2
Working pressure of water 2.5 Kg/cm2
Inlet oil temperature 550C
Outlet oil temperature 450C
Inlet water temperature 330C(max360C)

Outlet water temperature 35.640C

Rated oil velocity 1.1 M/sec
Rated water velocity in tubes 1.25 M/sec
Frictional drop for the bank of operative 1.6 MWC
oil coolers on the cooling water side
Dia. of tubes 19/17 mm
Heat transfer coefficient 400 Kcal/m2 Hr 0C
Hydraulic resistance on oil side 1.48 Kg/cm2
No. of oil circulation passes 22
No. of partitions 21
Hydraulic test pressure of oil coolers 8 Kg/cm2

2.4 CONDENSATE SYSTEM

2.4.1 CONDENSER 2 (Nos, 50% capacity of 2 pass/condenser)
Design pressure (steam space) 0.1 Kg/cm2
Cooling water consumption 2*13500 m3/hr
No. of cooling tubes 2*7810=15620
Length of cooling tubes 10 mts
Dia of cooling tubes 30/28 mm
Weight of condenser without water 305 tonnes
Tube material Cooling Zone Cupronickel 190/10
Air zone Cupronickel 70/30
Water boxes material Rolled steel plates
Max. permissible design pressure of cooling tubes 5 Kg/cm 2 Gauge
2.4.2 CONDENSATE PUMP
PUMP MOTOR
3 nos (50% capacity each) Type AVM450M4
Type Multistage, vertical turbine type, 3 ph, 50 C/S, cos0 0.84
Centrifugal pump, Voltage 6.6 KV
low specific speed, Insulation Class B
medium head, medium capacity Current 25 amp
DHRC 28, size300*250 Power 220Kw, HP-300
Stages 8 RPM 1489
Direction Clockwise viewed Space heater 2 nos. of 250w,240w
of rotation from motor end
Discharge 281 tones/hr Ambient temperature 500C
Manometric head 201 mts Weight of motor 3000 Kg
B.H.P. 256
Caution Not to run below 193 mt manometric head
Normal discharge 20 Kg/cm2
header pressure RPM 1489

Max thrust bearing oil temperature 75 0C

Max motor bearing temperature 75 0C
Max vibration of gland housing 40 microns
& thrust bearing
Max condensate temperature 180 0C
2.5 LP HEATERS & AIR EECTION SYSTEM
2.5.1 L.P.HEATERS
2.5.2 GLAND STEAM COOLER I
FUNCTION
a. Eject steam and air mixture from turbine seals
b. Eject spindle leak off from ESV, IV & control valves
Gland sealing steam pressure 1.03 to 1.05 Kg/cm 2
Source of gland sealing steam 16 ATA header or D/A
Temperature of sealing steam 1300C to 1500C
Type of seals Labyrinth glands of radial clearance type
2.5.3 GLAND STEAM COOLER NO II
Connected to HPC and IPC leak off
( Construction same as LPH 2,3,&4)
2.5.4 DRIP PUMP
PUMP MOTOR
Nos. 2(100% capacity) Output 90 KW
Type 100 CJH, multistage centrifugal Voltage 415 V
Horizontal pump
No. of stages 9 Current 148 amp
LPH
Type
Location
Tube
Shell
No.
material
Material

Tube plate
material

2
3
4

Inside
upper part
of each
condenser(
in two
halves)
Mezzine
floor
--DO---DO--

No. of
relief
valve
2 Nos.(1
for steam
side& 1
for cond.
side

Horizontal
surface
type

U. shape
brass
16*10

Fabricated
from MS
plates

Mild Steel

Vertical
surface
type
--DO---DO--

--DO--

--DO--

--DO--

--DO--

--DO---DO--

--DO---DO--

--DO---DO--

--DO---DO--

2.6 FEED WATER SYSTEM

2.6.1 BOILER FEED PUMP
A) PUMP
No. of pumps 3 Nos. (50% capacity) Type Multi stage , Horizontal high pressure,
Barrel type pump 200 KHI
Nos. of stages 6
Max. rated suction pressure 12.3 ata
Discharge capacity 430T/hr
Head 1830MWC
Feed water temp. 164.20C
Speed 4320 rpm
Lubrication Forced
Stuffing box Mech seal
Quantity of water for 100 T/hr

minimum take off

Min. suction pressure of BFP 6 Kg/cm 2
Quantity of water for 8 T/hr
Heating take off
Cooling water consumption 280 T/min.(Approx)
Net weight of pump 5850 Kg
Drive Electric motor through hydraulic coupling
B) MOTOR
Manufacturers M/S BHEL Hardwar
Type ATD-4000
Output 4000 KW
Rated Voltage 6.6 KV
Current 421 amp
Speed 1483 rpm
Frequency/ power factor 50 C/S, 0.914
2.6.2 OPERATING DETAILS
Water pressure in equalizing pipe of balancing
Disc 3 to 4 kg/cm2 more than suction branch
pressure ( but not ore than 5 kg/cm2)
No. of bearings 2 Radial sleeve bearing and 1 thrust bearing
Motor bearing 2 Radial sleeve bearing
Hydraulic coupling bearing 4 Radial bearings and 2 tilting pad bearings
No. of oil coolers 2 nos.( one for hydraulic coupling working oil and
one for lubricating oil of bearings)
Auxiliary oil pump 415 V, 3 Ph, 50 C/S
Type of Aux. oil pump Gear type
Type of main oil pump Gear type
Oil pressure in radial bearing 0.8 to 1.00 Atg
Bearing temperature 650C(max)
Oil pressure for thrust bearing 0.5 Atg
Min. discharge pressure of BFP 120 kg/cm2
Max feed water temperature at BFP discharge 175 0C
Max BFP flow 475 T/hr
Max motor bearing temperature 800C
Max temperature difference of 30 0C
feed water and BFP body
Max motor hot air/ temp. 80 0C (600C normal)
Normal BFP discharge pressure 170 kg/cm2
Seal water temp. 650C-700C
2.6.3 BOOSTER PUMP
No. of pump one for each BFP
Use 1. To provide a positive suction pressure to BFP
& to avoid possibility of cavitations
2.To reduce the BFP stages
Make M/S Mather & Platt.
Type 8/10
Delivery quantity 460 T/hr
Speed 1475 rpm
Drive Main motor

Min. booster pump suction pressure 3.5 kg/cm 2

Delivery head 31 MWC
2.7 H.P.HEATERS (DESIGN SPECIFICATION)
Description
H.P.HEATER No.5
H.P.HEATER No6
Feed water inlet
166.76
184.92
temp. in 0C

H.P.HEATER No7
220.90

Enthalpy of F.W.
inlet in Kcal/kg
F.W. outlet temp in
0C

170.70

189.51

227.48

184.92

220.90

242.78

Enthalpy of F.W. at
outlet in Kcal/kg
F.W. flow (kg/hr)
Ext. stem inlet
pressure in kg/cm2

189.51

229.48

251.41

643165
11.96

643165
26.20

643165
39.06

Ext. stem inlet

temp. in 0C

433

314

377

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

796

727

754

16271
292

44777
288

29880
288

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

Without H.P. Heaters ma. Curtis wheel pressure 89 kg/cm 2
Full load Curtis wheel pressure with H.P. Heaters 102 kg/cm 2
2.8 CW PUMPS & CW BOOSTER PUMP
2.8.1 CIRCULATING WATER PUMP
No. of pumps 2 Nos.(100% capacity)
Make FLOWMORE
Number of stage One
Capacity of pump 15000 m3 /hr
Total dynamic head 11.5 MWC
Efficiency 86%
Speed 420 rpm
B.H.P. 740 HP
Motor BHEL, 950HP,6.6 KV splash proof type
Type of pump lubrication Self water lubricated
Direction of rotation Anti clock wise (from top)
Coupling of motor & pump Rigid type
CW water is used in Condenser, Main oil coolers& H 2 gas
coolers
2.8.2 C.W. BOOSTER PUMPS
PUMP
No. of pump 2 Nos.(100% capacity)
Lubrication in board & Mobilux grease No.2
Outboard bearing
Speed 1487 rpm
Make Mather Greaves Pvt. Ltd.
Discharge pressure 2.5 kg/cm2
Normal bearing temperature 600C

Normal pump vibration 40 microns

MOTOR
Output 55 KW
Speed 1487 rpm
Amps 96
Voltage 415 V
Make NGEF
2.9 H.P.& L.P. BYPASS SYSTEM
(i) Provided to increase the rate of steam temperature rise and warm up the HRH,CRH, IPT & transfer pipe lines ( at
60% MCR full pressure & temp. can be obtained i.e. 60% capacity)
(ii) All the HP & LP BYPASS valves are hydraulically operated for which oilat about 50 kg/cm 2 is supplied by a
separate oil supply unit.
2.9.1 DESIGN CAPACITY OF H.P. BYPASS STATION
Injector water Boiler feed water
Nos. of H.P. Bypass valve 1 for each MS line
Total capacity 200T/hr steam flow
Capacity of each bypass valve 100T/hr steam flow
Max. MS temp. 5400C
Max MS pressure 140 ATA
Down stream temp 3800C
2.9.2 DESIGN CAPACITY OF LP BYPASS STATION
Injector water Condensate water
Nos. of LP Bypass valve 1 for each HRH line
Capacity of each LP bypass valve 112T/hr steam flow
Total capacity 224T/hr steam flow
Design temp. 5400C
Down stream temp 2000C (max)
Steam pressure at upstream side 6 kg/cm2
2.10 TURBINE ROLLING & LOADING GUIDE LINES
2.10.1 TURBINE ROLLING GUIDE LINES
S. No.
If max metal temp of If max metal temp is If max metal temp is
HPT casing is less less than 1500C- more than 3500C
than 1500C
3500C
1
Speed from 0-500 Speed from 0-500 Speed from 0-1200
rpm
rpm
rpm
= 5 mts
= 5 mts
= 5 mts
2
Hold at 500 rpm =10 Hold at 500 rpm =5 Hold at 1200 rpm =5
mts
mts for checking mts for checking
differential
differential expansio
expansion, bearing
vib etc.
3
Speed from 500 rpm From 1200 rpm to 3000 rpm = 5 mts without
to 1200 rpm @ 50 any pause
rpm = 14 mts
4
Hold at 1200 rpm Raise the speed from 500 rpm to 1200 rpm =
(Soaking)= 20 mts
5 mts
5
Speed from 1200 rpm Hold for 3 mts for checking differential
to 3000 rpm =5 mts
expansion, bearing vib etc.
6
Hold at 3000 rpm Raise the speed from 1200 rpm to 3000 rpm =
(Soaking)= 20-25 mts 3 mts without any pause
7
Hold the turbine at this speed (3000 rpm) for

Total = 75 mts

checkings.
Toatl = 26 mts

Total = 15 mts

2.10.2 TURBINE LOADING GUIDE LINES

S. No.
If the max. casing
If the max. casing
metal temp. is less
metal temp. is less
than 1500C
than 1500C-3500C
1

Load up to 5 to 7
Mw
after
synchronization
Steam
pr
=30
2
Kg/cm

Load after synch. =

20 to 30 Mw
Steam
pr.
=70
2
Kg/cm

Steam
temp
temp. 3500C
Soaking
Steam temp. before time=10mts.
IV=3200C
Steam
=3500C

Soaking time =30

mts
5 Mw to 30 Mw @ 3
Mw/10 mts in 70 mts.
Steam pr before ESV =65
Kg/cm2
Steam Temp =4300C
Steam temp before
=4200C

temp
0
ESV=490 C
Steam

4
70 mts. @ 2 Mw/ min
Pr before ESV= 130 Kg/cm2
Temp before ESV= 5350C
Temp before IV= 5350

Load after synch. 20

to 30 Mw. After
taking mills ( one by
one) in service load
= can accordingly be
raised to 210 Mw
depending
upon
other conditions.

From 30 Mw to 65 Mw in
35 mts.
Soaking time =35 mts.
Steam pr =90 Kg/cm2
Steam temp =4500C

IV

Soaking time = 20 mts

( All the drain valves in
extraction lines of LP
heaters to be closed.)
Raise from 30 Mw to 70
Mw @ 1 Mw/ min in 50
mts.
Steam pr before ESV =105
Kg/cm2
Steam

If the max. casing

metal temp. is more
than 3500C

From 60 Mw to 210 Mw =
45 mts
Depending
upon
other
conditions

before

temp
before
0
IV=480 C
Soaking time= 30 mts
Raise from 70 Mw to 210 Mw in

SECTION-III

GENERATOR
AND
AUXLIARIES

3.1 GENERATOR SPECIFICATION

3.1.1 GENERATOR MAIN DATA (at rated H2 pressure and cooling water
temperature)
i) Maximum continuous KVA Rating 247000 KVA
ii) Maximum continous KW rating 210000 KW
iii) Rated terminal voltage 15750 V
iv) Rated stator current 9050 A
v) Rated Power factor 0.85 lag
vi) Excitation current at MCR condition 2600 A
vii) Slip ring voltage at MCR condition 310 V
viii) Rated speed 3000 rpm
ix) Rated frequency 50 Hz
x) Short circuit Ratio 0.49
xi) Efficiency at MCR condition 98.49%
xii) Negative sequence current capability 1 22t nots
xiii) Direction of rotation viewed from slip ring end Anticlockwise
xiv) Phase connection Double star
xv) No. of terminals brought out 9(6neutral & 3 phase)
xvi) Type THW-210-2
3.1.2 MAIN PARAMETERS OF THE COOLING MEDIUM
A. HYDROGEN IN STATOR CASING
i) Nominal hydrogen pressure 3. 5 Kg/cm 2
ii) Permissible variation +/- 0.2 Kg/cm2 (G)
iii) Nominal cold gas temperature 44 0C
iv) Hydrogen purity 97%
v) Relative humidity hydrogen at normal pressure 60%
vi) Oxygen content 1.2%
B. DISTILLATE TO STATOR WINDING
i) Nominal pressure at stator winding inlet 3.5 Kg/cm 2
ii) Permissive variation +/- 0.5 Kg/cm2
iii) Cold distillate nominal temperature at stator winding inlet 45 0C
iv) Permissible variation +30C (-100 C with
unloading)
v) Rated distillate flow 27 m3/Hr
vi) Permissible variation +/- 3 m 3/Hr
vii) Nominal specific resistivity of distillate 200 Kohm-cm
viii) Minimum permissible specific resistivity 75 Kohm- cm
C. WATER TO GAS COOLER
i) Nominak inlet cooling water temperature 37 0C
ii) Minimum allowable water temperature 15 0C
iii) nominal water flow 350 m3/Hr
iv) Maximum permissible cooling water 4 Kg/cm 2 (G)

pressure in the gas cooler

D. WATER TO STATOR WINDING WATER COOLER
i) Nominal consumption of cooling water at temp. of 35 0C 95 m3/Hr
ii) Nominal consumption of cooling water at temp. of 37 0C 110 m3/Hr
iii) ) Nominal consumption of cooling water at temp. of40 0C 130 m3/Hr
3.1.3 ELECTRICAL DATA
i) Resistance of stator winding per phase at 20 0C 0.00155 ohm
ii) Resistance of rotor winding per phase at 20 0C 0.0896 ohm
iii)Capacitance of the stator winding in hot condition (Calculated value) 0.69 microfarad
iv) Line charging capacity 75 MVAR
v) Basic impulse insulation level between turns 49,000 (Peak)
vi) Basic impulse insulation level with respect to body 49,000(peak)
3.1.4 GENERATOR EXCITATION DATA
i) Ratio of ceiling voltage to the rated excitation voltage 2.0
ii) Ratio of thre field forcing current to the nominal current 1.6
iii) Duration of field forcing 10 Secs
iv) Response Time 100 milisecs
3.1.5 SHORT CIRCUIT CURRENTS
i) Sub transient current on three phase short circuit 10 Pu
ii) Transient current on three phase short circuit 3.3 Pu
iii) Steady state current on three phase short circuit 1.4 Pu
3.1.6 REACTANCES
i) Direct axis sub transient reactance ( xd) 0.214 Pu
ii) Direct axis transient reactance (xd) 0.305 Pu
iii) Direct axis synchronous reactance (xd) 2.22 Pu
iv) Negative phase sequence reactance (xd 2 ) 0.26 Pu
v) Zero sequence reactance (xo) 0.105
3.1.7 PERMISSIBLE TEMPERATURE RATINGS
i) Maximum temperature of stator core 105 0 C
ii) Maximum temperature of stator winding 105 0 C
iii) Max temp of rotor wdg. 1150 C
iv) Permissible temperature rise of rotor winding 71 0 C
over cold gas temperature
v) Maximum temperature of hot gas 750 C
vi) Maximum distillate temperature at stator winding outlet 85 0 C
vii) Maximum stator winding temperature 750 C
3.1.8 TIME CONSTANTS
i) Field time constants with open circulated stator winding (Tdo) 7 secs
ii) Field time constants with three phase sort circuit 0.96 secs
current of stator winding(Td3)
iii) ) Field time constants with two phase sort circuit 1.5 secs
current of stator winding(Td2)
iv) Field time constants with one phase sort circuit
current of stator winding 1.73secs
v) Time constant of the aperiodic component for 3 phase short circuit(Ta3) 0.29 secs
vi) Time constant of the aperiodic component for 2 phase short circuit(Ta2) 0.24 secs
vii) Time constant of the aperiodic component for one phase short circuit( Ta1) 0.25 secs
viii) Time constant of the periodic component of the sub transient

current for 3 phase : 2 phase and 1 phase short circuit(Td) 0.121 secs
3.1.9 GENERATOR VOLUME AND FILLING QUANTITIES
i) Total gas volume of the generator 56 M3
ii) CO2 for expelling hydrogen with unit at standstill 120 M 3
iii) CO2 for expelling hydrogen with unit under rolling 168 M 3
iv) H2 filling quantity with unit at standstill 300 M 3
v) H2 filling quantity with unit rolling 340 M 3
vi) Make up Hydrogen required per day 15 M3
(max)
3.1.10 TORQUE, CRITICAL SPEED ETC
i) Torque under normal working condition 76.32 Tons
ii) Ratio short circuit torque to full load torque 8
iii) Flywheel moment of the rotor 21.1 T.M 2
iv) Ist critical speed of the rotor( calculated) 1370 rpm
v)2nd Critical speed of the rotor (calculated) 3400 rpm
3.1.11 OIL CONSUMPTION
i) Consumption of oil per generator bearing (Excluding shaft seals) 300lit/min
ii) Oil pressure at bearing inlet 0.3to 0.5
Kg/cm2
iii) Consumption of oil in both the shaft seals 160 lit/min
3.1.12 OVERALL DIMENSION AND WEIGHTS
i) Overall stator diameter 3960 mm
ii) Length of the stator 6580 mm
iii) Length of the rotor 9770 mm
iv) Diameter of the rotor barrel 1075 mm
v) Weight of the heaviest lift (Stator with gas coolers and turnions) 175,000 Kg
vi) Weight of gas cooler 1415 Kg
vii) weight of rotor 42,000 Kg
viii) Weight of bearings with brush gear along with foundation plates 49,500 Kg
ix) Weight of end terminals 85 Kg
x) Weight of end shield 2000 Kg
xi) Total weight of generator 239,000 Kg
3.2 SPECIFICATION OF STATIC EXCITATION SYSTEM UNIT IV & V
The Static Excitation Equipment has been designed and manufactured for machine having following technical details
A) TYPE OF MACHINE TURBO
___________________________________________________________________________
Sl.No Description Abbreviation Unit Value
1. Rated OUTPUT - MW/MVA 210/247
2. Stator voltage Un VAC 15750
3. Stator Current IN AAC 9094
4. Synchronous speed Ns rpm 3000
5. Power factor Cos - 0.85LAG
6. System frequency Hz c/s 50
7. Machine reactance:
a) Synchronous reactance
i) Direct acxis unsaturated xd p.u. 2.225
ii) Quadrature xq p.u. 2.11
b) Direct axis transient reactance
i) Saturated xd p.u. 0.234

ii) Unsaturated xdu p.u. 0.266

c) Direct axis sub-transient reactance
i) Saturated xd p.u. 0.179
ii) Unsaturated xdu p.u. 0.214
8. Machine Time Constants:
i) Direct axis transient open ckt Tdo sec. 7
ii) Direct axis transient close ckt Tdo sec. 0.84
iii) Sub-transient Td sec 0.03
iv) Armature Ta sec. 0.29
9. Field winding resistance at 20 oC Rf 20 ohm 0.0878
10 Field excitation requirement
i) No load field voltage ufo VDC 102
ii) No load field current Ifo ADC 917
iii) Nominal field voltage Ufn VDC 310
iv) Nominal field current Ifn ADC 2600
v) Max. cont. rated field voltage Ufmax VDC 338
vi) Max. cont. rated field current Ifmax ADC 2830
vii) Ceiling voltage Ud VDC 620
viii) Ceiling current Id ADC 4500
ix) Duration of field forcing -- Sec. 10
11. Field test voltage - Kvrms 12. Synchronising slip - % 13. AVR CT Ratio - AAC/AAC 10,000/5
14. AVR PT ratio - VAC/VAC 15750/110
15. Ambient - oC 50
16. Altitude - meters 1000
B) SPECIFICATION OF STATIC EXCITATION EQUIPMENT
1. Accuracy of excitation control - % + 0.5
2. Range of voltage control in auto - % 90 Ugn -110 Ugn
3. Range of voltage control man. - % 70 Ufo-110 Ifn
4. Range reactive current compensation - % upto + 15
5. Frequency range of operation - Hz 47.5-52
6. Total No of parallel THY. Bridges - No 4 *
7. No of redundant THY bridges - No 1 *
8. Protection class IP 31
9 Excitation equipment rating
a) Voltage - VDC 338 *
b) Current - ADC 2830 *
10 Range of MAVR regulation -MAX. LEAD-O-MAX-LAG
11 Station battery supply - VDC
220
Equipment not part of DVR supply
3.3 GENERATOR SEAL OIL SYSTEM 3.3.1 SPECIFICATION
i) Type of shaft seals Radial flow, double
chamber, thrust type
ii) Hydrogen pressure 3.5 Kg/cm2
iii) seal oil pressure 4.1 to 4.4 Kg/cm 2
iv) Inlet seal oil temperature 40 0 C
v) Quantity of seal oil/seal 80 lit/min
vi) Thrust oil pressure 1 to 2.2 Kg/cm2
vii) Oil required to fill the system 4000 liters
3.3.2 OIL INJECTION

i) Pressure of oil at inlet to injector from 20 Kg/cm 2

governing oil system
ii) Lub. Oil system 1 to 1.5 Kg/cm2
iii) Injector nozzle size 8 mm
iv) Oil pressure at injector outlet 10 Kg/cm 2
3.3.3 SEAL OIL PUMPS
A.C. SEAL OIL PUMPS D.C. SEAL OIL PUMPS
i) Type : Multistage vertical split i) Type : Multistage vertical split
centrifugal type centrifugal type
ii) Discharge: 3.34 lit/sec ii) Discharge: 4.16 lit/sec
iii) Head: 120 MWC iii) Head: 194 MWC
iv) Speed: 1465 or 2900 rpm iv) Shut off head: Not more than
12% of rated head
v) Shut off Head: Not more than 12% v) Min seal oil pressure : 5.5 Kg/cm 2
of the rated head below which DC
pump will start
vi) Minimum governing : 6.5 Kg/cm2
oil pressure below which
AC pump will start
MOTOR MOTOR
i) Type: Squirrel cage induction i) Type: Compound wound self excited type
ii) Voltage: 415V+/- 10% ii) Rating: 26 KW
iii) Frequency: 3 Phase, 50c/s iii) Voltage: 220VDC+10% & -20%
iv) Rating: 15 KW/20 HP iv) Speed: 1800 or 2900 rpm
v) Speed: 1465 or 290 rpm v) Rated current: 139 Amp.
vi) Rated Current: 27 Amp. vi) Operation Speed: 70-80% of rated speed
3.3.4 SEAL OIL COOLER
i) No. of coolers 2 Nos.
ii) Inlet temperature of oil 500C
iii) Temperaure of oil at cooler outlet 400C
iv) Quantity of oil to be cooled 160 lit/min
v) Inlet pressure of oil to cooler 10 Kg/cm 2
vi) No of cooling tubes 420
vii) Material & size of cooling tubes 15*1 mm, copper
viii) Pressure drop in the oil cooler 5 mwc
ix) Inlet cooling water temperature 33 0C
x) Outlet cooling water temperature 37.500C
xi) Cooling water designed pressure 5 Kg/cm 2 (Max)
xii) Cooling water quantity required 95 m3/Hr
xiii) Cooling water quality Clarified water
3.3.5 PRESSURE REGULATOR
Differential pressure regulator Thrust oil regulator
i) Type: Plunger type Plunger type
ii) Inlet oil pressure: 6 to 9 Kg/cm2 6 to 9 Kg/cm2
iii) Differential pressure maintained: 0.6 to 0.9 Kg/cm 2 1.0 to 2.2 kg/cm2
iv) Clearance between plunger and body : 0.03 mm 0.03 to 0.05 mm
3.4 STATOR WATER COOLING SYSTEM
A. STATOR WATER COOLING PUMP

PUMP
i) Type: Horizontal spindle, end suction directly driven, centrifugal type
ii) Discharge: 40 m3/Hr
iii) Head: 45 mwc
iv) Make: Kirloskar Brothers Limited
MOTOR
i) Type: Squirrel cage induction type
ii) Rating: 9.3 Kw
iii) Rated voltage: 415V+/-10V, 3 phase,50 c/s
iv) Rated current: 17 amp.
v) Speed: 2900rpm
vi) Make: Kirloskar Electric
B. STATOR WATER COOLERS
i) Nominal temperature of primary water to be cooled 65 0C ii) Nominal temperature of cooled primary water 40 0C
iii)Nominal tempearure of cooling D.M.water 33 0C
at inlet on the secondary side
iv)Nominal temperature of cooling water 36.5 0C
at the outlet on the secondary side
v) Quantity of D.M. Water on the secondary side 95m 3/Hr
vi) Secondary side D.M.water inlet pressure 5 Kg/cm 2(max)
vii) Tube dimensions 15*1mm
viii) Length of cooling tubes 1720mm
ix) No. of tubes per cooler 420
x)Tube material Copper
C. EXPANSION TANK
i) Material: Stainless Steel
ii) Tank volume 2.1 m3
iii) Volume inside the tank 250 to 300 mmof Hg
iv) Water level under normal operating 850 mm
conditions( from the bottom of the tank)
v) High water level which gives signal 1200mm
( from the bottom of the tank)
vi) Low/ emergency water level requiring tripping of TG 500mm
( from the bottom of the tank)
D. WATER JET EJECTOR
i) Quality of water Clarified
ii) Quantity of water required 7 to 10m3/Hr
iii) Pressure 2 Kg/cm2
iv) Temperature 330C
3.5 GENERTATOR & UAT TRANSFORMERS
3.5.1 GENERTATOR TRANSFORMER (T4)
TRANSFORMER RATING
Make M/S TELK, Kerala
Type of cooling OFB/OB/ON
MVA 240/168/120 MVA
Voltage (HV) 236 KV
Voltage (LV) 15.75 KV
Current (HV) 587/411/293 A

Current (LV) 8798/6158/4399 A

Phase HV/LV 3 / 3
Impedance 15.55 %
Frequency 50 Hz
Vector Group Yd1
Connection HV/LV Star / Delta
Max temp rise in oil 45 Deg C
Temp rise in winding 55 / 60 Deg C
Weight of core and winding 133000 Kg
Weight of oil 43100 Kg
Total weight 238900 Kg
Quantity of oil 42500 liter
Tap Off load
BUSHING CT
Ratio 600 / 1 Amp
Continuous current 800 Amp
Accuracy class P.S.
Minimum knee point voltage 1000 Volt
Max exciting current at knee point voltage 0.14 Amp.
Max secondary wdg. Resistance at 75 Deg C 3 Ohm
3.5.2 GENERTATOR TRANSFORMER (T5)
TRANSFORMER RATING
Make M/S BHEL, Bhopal
Type of cooling OFB/OB/ON
MVA 240/168/120 MVA
Voltage (HV) 236 KV
Voltage (LV) 15.75 KV
Current (HV) 587/411/293 A
Current (LV) 8798/6158/4399 A
Phase HV/LV 3 / 3
Impedance 14.75 %
Frequency 50 Hz
Vector Group Yd1
Connection HV/LV Star / Delta
Max temp rise in oil 45 Deg C
Temp rise in winding 55 / 60 Deg C
Weight of core and winding 138800 Kg
Weight of oil 37850 Kg
Total weight 234000 Kg
Quantity of oil 49540 liter
Tap Off load
BUSHING CT
Ratio 600 / 1 Amp
Continuous current 800 Amp
Accuracy class P.S.
Minimum knee point voltage 1000 Volt
Max exciting current at knee point voltage 0.14 Amp.
Max secondary wdg. Resistance at 75 Deg C 3 Ohm
3.5.3 UNIT AUXLIARY TRANSFORMERS (Unit 4 & 5)
RATING
No. 2 / Unit
Make EMCO, Mumbai
Capacity 12500 KVA
Voltage HV / LV 15.75 / 6,9 KV
Current HV / LV 458.2 / 1045.8 Amp

No. of phases HV / LV 3 / 3
Type of cooling ON
Vector Group Dd0
Impedance 7.877/7.57 (UAT4A/4B)
Impedance 7.762/7.725 (UAT 5A/5B)
Frequency 50 Hz.
Tap Changer On Load
Max rise in oil temp above ambient 45 Deg C
Weight of core and winding 12000 Kg
Weight of Oil 6430 Kg
Total weight 27100 Kg

SECTION IV

PROTECTION
AND
INTERLOCK
Sl.No.
1
2
3
4
5
6
7
8
9
10
11
12
13

14
15
16

4.1 UNIT PROTECTIONS

DESCRIPTIO ANNUNCIATI TRIPPING
TIME DELAY
N
ON
VALUE
Drum level low -100 mm
-175 mm
Drum level
+100 mm
+175 mm
high
Furnace
+25 mmwcl
+175 mmwcl
pressure high
Furnace
-25 mmwcl
-175 mmwcl
vacuum high
Loss of 220 V D.C.supply of More than 2 secs
FSSS
Less thanfire ball and loss of 110V D.C.
Supply
Loss of all fuel trip
On flame failure
Air flow less than 30%
Both ID fan tripped
Both FD fans tripped
Both PBS on FSSS pressed
Reheater protection( This protection will act
when there is no flow through R.H. &
furnace outlet temperature more than
5380C)
Condenser vacuum
H.P. heater level
very high
All BFPs
-

650 mm Hg
750 mm
-

540 mm Hg
4250 mm
15 secs

17
18
19
20
21
22

tripped
T.G.babbit metal
750C
800C
temperature
Turbine rotor axial
+1.2 mm
shift
-1.7 mm
Loss of voltage on
50% of rated value
5 to 10 secs
unit auxiliary bus
bar
Emergency governor
11% and 12% overspeed
overspeed tripping
Emergency governor backup 14% overspeed
Turbine lub oil
A.C. lub oil pump
0.3 kg/cm2
2
pressure
starts at 0.6 kg/cm ,
D.C. lub oil pump
starts at 0.5 kg/cm2

23

M.S. Temperature
low

5200C

4500C

24

Turbine shut down

switch

25

Manual tripping(UCB) through push buttons

4.2 PARTIAL LOAD CONDITION

1. One if two ID fans trips.
2. One if two FD fans trips.
3. One if two PA fans trips
4. One of the two BFPs trips and standby does not come up in more than 60 secs.
5. One of the two CW pump trips.
6. One of the two condensate pump trips and standby does not come up in more than 60 secs.
When this relay acts following sequential actions take place:
(a) Turbine load is reduced.
(b) One of the PA fans trips
(c) FSSS reduce boiler output
4.3 PROTECTION & INTERLOCK OF THE UNIT AUXLIARIES
4.3.1 BOILER AUXLIARIES
Sl. No.
Description
Permissives
Ineterlocks
Protections
1
ID Fans
a. Regulating
a. Opening of
a. Bearing
vane FG-10 in
outlet damper
temperature too
minimum
FG-12 after a
high
position
time delay of
b. Motor bearing
b. Outlet
60 secs.
temperature too
damper FG-12
b. Connecting
high
closed
the regulating
c. Lub. Oil
c. Fan/fan
vane (FG-10) to pressure for
motor bearing
regulator
motor bearing
temperature is
c. Opening the
low with T.D. of
not very high
interconnecting 0-3 mts.
damper FG-5& d. Both A.H.
FG-18
A&B off
d. Closing the
( Provided deinlet damper
interlocking in

FG-17& outlet

inter locked
position)

damper FG-13 of other fan

e. Bringing the other fan inlet vane to minimum position
f. Permiisive to start selected FD fan
2

FD fans
a. ID fan is
started
b. Control oil
pressure is
adequate(8
kg/cm2)
c. Fan impellar
blades are in
min. position.
(BA-1)
d. Outlet
damper (BA-3)
is in closed
position.
e. FD fan
bearing temp. is
not high.
f. FD fan motor
bearing temp. is
not high.

Air Heater

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

a. Opening the
outlet damper
BA-3 with T.D.
of 60 secs.
b. Connecting
the impellar
blade (BA-1)
control drive to
regulator.
c. Opening the
inter connecting
damper BA-2.
d. Closing the
outlet damper
of other fan.
e. Bringing the
impeller blades
of other fan to
min. position.

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

Wherever A.H.
trips impulse is
given for
starting air
motor provided
guide/supportbearing temp. is
less than 700C.

Temp. of
support and
guide bearing
700C.

When A.H.
trips impulse is
given for
closing the flue
gas inlet and
outlet dampers
FG-1 & FG-3
and air inlet &
outlet dampers
BA-12, 14,22&24.
Tripping of corresponding ID fans.

Air motor also

trips if temp. of
support/guide
bearing 700C.

Ignitor fan

At least one ID and

one FD fan must be
in service.
When start push
button is pressed.

Scanner fan
a. The scanner
duct to furnace
differential
pressure is less
than 115
mmwcl.
b. When start
push button is
pressed.

Discharge damper
will open & damper
of standby fan
closes.
The fan will start
automatically when
any ignitor or oil
elevation is initiated.
Discharge
Scanner air fan
damper will
emergency
open & damper damper opens
of standby fan
automatically
closes with T.D. when both FD
of 5 secs.
fans are off.

Primary air fan

a. Purge
complete & NO
boiler trip
condition is
present.
b. Regulating
vanes BA-17 in
min. position.
c. Outlet
damper BA-19
in closed
position.
d. Lub oil
pressure is
adequate
around 2
kg/cm2
e. PA fan
bearing temp
not very high.

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

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

leaving top three

mills in service
when one PA fan is
running.
g. When both PA
fan trips all running
mills will trip. h.

When one PA fan is

running partial load
relay is energised

Seal air fan

Pulveriser

One PA fan is
running

Manually fan
can be tripped
only if all the
mills are
stopped.
Only one seal
air fan can be
started at time.

Running seal air

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

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

a. Permissive to
open the hot air
gate.
b. Permissive to
start R.C.feeder.
c. Permissive
for regulators
impulse to act
on hot air
dampers.

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

i. Burner tilt is horizontal and air flow is less than 40%.( This is applicable only to the first
mill to be started.)
j. Pulveriser ignition energy is available.

Pulveriser A*
a) A min of 3 out of 4 elevation AB light
oil(or heavy oil) noozle valve proven open.
b) Boiler loading is greater than 30% and
pulveriser B is in service at greater than 50%
loading.
9

Raw coal feeder

1) No boiler trip
condition
persists
2) Elevation
D.C. is
available
3) Elevation
A.C. is
available
4) Ignition
energy is
available.
5) Pulverisor is
on
6) Hot air gate
is open
7) No stop
signal
8) Fuel damper
closed

1) To release
speed control to
auto after 50
secs.
2) To modulate
fuel air dampers
according to
feeder speed
after 50 secs.

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

above maximum set point.

B) Pulveriser bowl differnencial pressure is high an impulse will be given to bring R.C.
Feeders speed to minimum.

ID fan motor lubrication

oil system

FD fan lub oil system

Pump A will start

automatically if pump B
3)
trips provided A/M
switch is in auto position.
Pump A will start
automatically with a time
delay of 60 secs if oil
pressure falls below a set
value and pump B is
worki9ng provided A/M
switch in auto position.
Whenever the lub oil
pressure at entry to ID
fan motor bearing falls
below a set value impulse
shall be given after a
time of 0-3 mts to trip the
ID fan.
Pump A will start
automatically if pump B
4)
trips provided A/M
switch is in auto position.
Pump A will start
automatically with a time
delay of 0-60 secs if oil

*For pulveriser B to F all conditions regarding their permissive to start, interlock and protection will be similar as for
pulveriser A., except the adjacent elevation nozzle valves proven open or adjacent pulveriser should have loading more
than 50%
pressure below a set value and pump B is working provided
A/M switch is in auto position.
Pump B will start automatically after 1 secs if pump A trips
provided A/M switch is in auto position.

11

PA fan

12

Furnace
temp probe

Pump A will start

automatically if
pump B trips
provided A/M
switch is in auto
position .
Pump B will start
on auto with time
a delay of 1 secs if
pump A trips
provided A/M
switch is in auto
position.
Furnace
If furnace
temp probe
temp probe
shall be
is inside the
prohibited
furnace and
from being
temp.
advanced
exceeds
further into

the furnace if
furnace temp
sensed by it
is more than
5400C
4.3.2 TURBINE AUXLIARIES
Sl.No.
Description
1
Boiler feed
pump

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

Circulating
water pump

5400C it will
be retracted
back
automaticall
y

Permissive
1. Lubricating
oil pressure at
bearing

Interlock
1. If lub oil
pressure is

Protections
1.Main BFP will
trip if lub oil
pressure is below
0.5 kg/cm2

below 1 kg/cm2
A.O.P. will
come.
2. If BFP tripped its A.O.P.
2.Pump will trip if its motor
will come in auto as soon as
bearing temperature is more
lub oil pressure drops 1
than 800C
kg/cm2 .
3.Pump will trip if discharge
When any BFP put on
standby its A.O.P. will
come.
3. A.O.P.will trip after 10
secs when BFP lub oil
pressure goes to 4 kg/cm2.

flow is more than 500 T/hr.

4. Pump will trip if water
temperature at delivery of
BFP is more than1750C

4. At 200T/hr discharge flow

pump recirculation valve
should open & at 220 T/hr it
should get closed.
5. Standby BFP will come on
auto as soon as either
working BFP trips or
common header pressure at
discharge side is low.

for 12 secs.
6.Pump will trip if suction
pressure of main BFP is
below 6 kg/cm2

1.
Corresponding
condenser outlet
valve (CW1&2)
is fully open.

5.Pump will trip if discharge

pressure is less than kg/cm2

for 20secs, though it will

start.
7.On turbine trip one BFP
will trip if two are in
operation.
1. When any
CW pump is
1. On closing of
started its
discharge valve
corresponding
CW-1&2 pump
valve (CW3/4)
will trip.
on CW line to
2. CW pump
unit oil coolers
will trip if its
shall open.
motor bearing
2.when one CW temperature is
pump trips the
more than 800C
corresponding
3. When both
valve CW1&
CW pumps trip
CW3 or
CW booster
CW2&CW4
pump trips.
shall close and
partial load
relay will
operate.

pump)

CW boosr\ter
pump(Gas
cooler booster

1. If both CW
1. CW booster
pumps trip
pump will trip if
booster pump
both CW pump
will trip.
trip.
2.When running 2. Pump will trip
pump trip
if motor current
reserve pump
goes
will start
immediately
3.If discharge pressure falls
beyond 100 Amp.
2
below 2 kg/cm standby

pump will start.

Condensate pump
1. Reserve pump will
start as soon as
running pump trips.
2. Reserve pump will
start when common
discharge header
pressure falls below
10 kg/cm2.

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

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

6
7

1. At least one
CW pump
should be
inservice.

D.C. lube oil pump will come in auto if

Barring gear

bearing oil pressure goes down to 0.5 kg/cm2

Barring gear will
B/G will trip if lube
start only if lub oil
oil pressure goes to
pressure is more than 0.3 kg/cm2
0.3 kg/cm2
Barring gear will
engage only if rotor
is in engage
condition.

10

Drip pump

Pump will start

only if HD3( discharge
valve) is closed
& opening of
regulating valve
HD-3 is more
than a preset
value.

Heater 6

HP Heater 5

1. HD-3
Working drip
discharge valve pump will trip if
will be fully
LPH-2 drip level
closed if no drip falls to 200 mm
is running but
for 20 secs or
will start
HD-2 & HD-3are
opening as soon in closed
as drip pump
position.
starts.
2. Reserve drip
pump will start
as soon as
running drip
pump trips or
discharge
pressure of
working pump
falls below a
preset value for
10 secs.
1.If HPH-6 extraction
pressure falls tp preset value
its drip valve cascade to
deaerator & HD-29(to HPH5) will close & HD-30 will
open.
2.If HPH-6 extraction steam
pressure is above the preset
value HD-29 (to HPH-5) will
open & HD-30 will close.
1.If HPH-5
1.HPH will be
extraction steam
bypassed through
pressure falls below
group bypass
a preset value its
protection valve at
drain will cascade to 750 mm drip level.
LPH-4 i.e.HD-21(to 2.Turbine will trip at
LPH-4) will open & HPH level 4250 mm.
HD-31(to D/A) will
close.
2. if HPH-5
extraction steam
pressure is above the
preset value its drain
cascade to deaerator
i.e. HD-31(to D/A)
will open & HD21(to LPH-4) will
close.
3.If drip level in any
HPH rises up to 750
mm solenoid valve
(MC101&MC102)
for NRV of
extraction lines will
open.
4. Back up feed

water bypass valve

(BF-40) will open.
5. After full opening
of

BF-40, inlet and outlet valve BF-38 & BF39 will close.
6. Steam extraction valve Es-3, ES-4, ES-5 to HPH will close.
11
12

Deaerator
H.P.& L.P.
Bypass system

Deaerator drain valve DW-136 will open &

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