ORISSA POWER GENERATION CORPORATION

Technical Diary
2210 MW

IB THERMAL POWER STATION

BANHARPALI, JHARSUGUDA ORISSA, INDIA

TECHNICAL DIARY ORISSA POWER GENERATION CORPORATION LIMITED.

IB THERMAL POWER STATION (2210 MW) BANHARPALI, JHARSUGUDA. 768234

First Publication 2003 All rights reserved. No part of this publication may be reproduced, stored in a retrievalsystem, copied or transmitted in any form by any other means, electronic, mechanical,photocopying or otherwise without the prior permission of the copyright owner. For private circulation only.

FOREWORD
"OPGCs vision is to become a leading profitable power utility by ensuring safe, environmentally responsible, commercially prudent, reliable and efficient power generation. To achieve this vision, it is essential to excel in the Operation and Maintenance of IB Thermal Power station. Our O&M team has brought out a Technical Diary compiling the technical details of the plant like design data, interlocks and protections, permissives covering all functions of the plant. It has been seen that a handy technical diary can serve as a valuable reference for use of plant personnel. I appreciate the efforts of the O&M team, in particular Shri P.K.Dora, for bringing out this edition of the Technical Diary in the shortest possible time. "

Sankaran Subramaniam DIRECTOR (OPERATION)

MESSAGE

"I'm happy and proud once more that OPGC is ready with a techncal document, i which is going to serve the long felt need of people to have a handy technical reference on the Ib Thermal Power Station. My sincere thanks to Mr.P.K Dora and his team for the hard work they have put in to make this possible.

Anil K. Gupta, Advisor, AES

MESSAGE

It is my pleasure to know that a technical diary of ITPS being brought out by the in house effort of our own staffs. This technical diary contains plant data, equipment design specifications, interlocks and protections. I hope this will be of great help as a reference hand book to all the employees.

A.Gochait, DGM (PSM)

INTRODUCTION

1. Name & Location

Orissa Power Generation Corporation. Ib Thermal Power Station. Banharpali, Dist-Jharsuguda (Orissa), India. Latitude-210 42 North Longitude- 830 52 East. 420 MW(2x210 MW Units) Max. Temp- 490C Min Temp- 70C Max relative humidity-95 % 797.51 Acres 493.16 Acres 13.01 Acres 85.96 Acres 476.12 Acres 100% Coal, oil support for initial starting & stabilization. i) Transportation from Lakhanpur mines 15 km distance by merry go round system in bottom discharge wagons. Loading point is approx.10 km from plant ii) Consumption8016 MT/day for design coal. Through 2x55 MVA, 220/6.9 K.V.3- station transformer. Closed Loop with forced draft cooling tower. 60% of MCR. 2500 Kcal/ Kwh. Disposed to ash pond in form of ash slurry with 100% ash water recycling system. RCC multi flue, 220 m. High.

2. Station Capacity 3. Climatic condition

4. Land utilization Main Plant Ash Pond (A+B) Ash Pipe Complex Merry Go Round System Town ship, Roads & Market 5. Fuel

6. Start up Power 7. Cooling Water System 8. HP/LP By pass Capacity 9. Heat Rate 10.Ash disposal 11.Chimney

SECTION 1 BOILER & AUXILIARIES

1.1 GENERAL SPECIFICATION

i) Manufacture ii)Type iii) Boiler designation BHEL (C.E. design). Single reheat, natural circulation type, single drum, balanced draft, dry bottom type designed for firing coal as main fuel. 13868 181 63.5 1778 NCRR, 10592 130 63.5 Design code: ISO-R 831 Tilting tangential. Drum 177 SH O/L 164 Generating surface Drum Economiser Super heater Reheater Total water volume Economiser Super heater Reheater Water wall Total heating surface 125.00 40.00 20.00 95.00 50.00_ 330.00 8087.00 7416.00 2656.00 3493.00 21652.00

iv) Type of firing v) Design pressure, Ksc vi) Water volume, m3

vii)Heating surface, m2

viii) Minimum load at which steam generator can be operated continuously with complete flame stability without oil support.

2 Mills at 50% capacity.

1.2 FURNACE SPECIFICATION

i) Type ii) Dimension iii)Total volume iv) Combustion chamber volume Fusion welded wall. 10,592 x 13,868 x 43,130 mm (DWH) 5240m3 4100m3

iv)Bottom v)Draft vi)Effective projected radiant surface vii)Design pressure viii)Heat liberated by fuel Per unit furnace vol. ix)Fuel heat input

Dry Balanced 2100m3 400mm wc @67% yield strength 1,01,300 (Kcal/hr/m2) at 100% 65,550 (Kcal/hr/m2) at 60% 534.0 x 10 6 Kcal/hr.

1.3 WATER WALLS

i)No.of Tubes ii)Dia(mm) iii)Material iv)Thickness v)Design pr.(Ksc) vi)Down comers. a)Nos b)Dia(mm) c)Pressure d)Material vii)Water wall headers a)Nos. b)Dia (mm) c)Material d)Design pr.(Ksc) i) Material ii) Design Pressure, Ksc iii) Drum operating pr. Ksc iv) Design temp v) Overall length, mm vi) Shell length from weld to weld, mm vii) I.D/O.D, mm viii) Thickness, in mm (straight portion/dished portion) ix) No of distribution headers x) No of cyclone separator/ secondary drier xi) Permissible temp difference between Top& Bottom Front wall Sidewall Rear wall Furnace roof 2nd pass 181 130 181 120 120 63.5 63.5 63.5 51.0 44.5 --- -----------SA210 Gr.C--------------SA209T1 SA210Gr.A1 -------------------5.5 mm-------------- 4.5 mm 4.5 m ------------------179.8 ---------------- 176.8 174.8 6 406.4 179.5 Ksc. SA 105 Gr.C Bottom Ring header 04 273.0 SA 106 Gr.C 175.4 Water wall header 07 219.1 SA 106 Gr.C 177.0

1.4 DRUM
SA-299 177.00 166.00 3540C 15,000

10,620 1778/2079 170/135 6 58/58 500C

xii) Drum level indicator Location a) MCR b) Drum c) Firemans floor

Type Conductivity DWLG Conductivity

No & make 2,BHEL 2,Yarway 2,BHEL

1.5 SUPER HEATER

LTSH i) Type ii) Direction of flow iii) Heating surface (m2) iv) No of Tubes v) O.D.(mm) vi) No of elements/assembly vii)Tube pitch, mm (across gas path/along gas path) viii) Material SH HEADER i) Max operative pressure, Ksc ii)O.D, mm iii)Thickness, mm iv) Max SH steam temp. convection counter 3035 480 44.5 4 114/96 PSH Radiant parallel 1097 232 47.63 8 457.2/57 FSH Radiant parallel 1543 357 44.5 3 114.3/96

SA210 Gr C SA213 TP347H SA213T22 SA 213T11 SA 213T22 SA 213T22 155.00 406.4 44.5 540 + 50C

1.6 REHEATER
i)Type ii)Design pressure, Ksc iii)Max operating pressure, Ksc iv)Total heating surface, m2 v)Control vi) Gross length per tube vii) Total No of tube viii) O.D, mm ix) Tube thickness, mm x) Tube material xi) Tube pitch, mm a)Front RH-Pendent b)Rear RH spaced. 44.45. 38.5 2656 Burner tilt. 10,000 mm (approx.) 59 assemblies 54.00 3.6 SA 213 T22,T11, T91, SA209 T1 a) across gas path-228.60 b) along gas path- 100.00

xii) Reheater Header a) Material b) O.D, mm c) Thickness, mm

SA-213 P22 Inlet-406.4, outlet-558.8 Inlet-46.0, outlet-45.0

1.7 SUPER HEATER & REHEATER TEMP. CONTROL 1.7.1 SH ATTEMPERATOR

i)Type ii)Location iii)No of stages iv)Material v)SH temp range that can be maintained between 60% to 100% of boiler MCR vi) Spray water flow, T/hr vii)Spray water source Spray mixing type. Between LTSH & Platen SH. One SA 335 P 12 5400C+5 max-34, normal-17, min-1.7 BFP discharge.

1.7.2 RH PRIMARY TEMP. CONTROL (BURNER TILT CONTROL)

i)Max. angle of tilt ii)Tilt mechanism iii)RH temp range that can be maintained between 60% to 100% boiler MCR + 300 Power cylinder. 5400C +5

1.7.3 RH EMERGENCY TEMP.CONTROL

i)Type ii)No. of stages iii)Location iv)Material v)Spray water source Spray mixing type. One Cold RH Line. SA 106 Gr. B BFP discharge.

1.8 ECONOMISER
i)Type ii)No. of blocks iii)Material iv) OD/thickness(mm) v) Tube pitch (mm) vi ) Heating surface Plain tube, seamless, continuous loop in line 2 SA 210 Gr. A 44.5 / 4.5 a) across gas path-96 b) along gas path-130 8070 m2

vii) Gas velocity at 2nd pass of boiler at100% MCR viii) Design pressure x) Economiser Header a)Material b)Outer diameter, mm c)Max. operating pr. Ksc

8.0 m/sec 181.9 Ksc. I/L Header SA-106 Gr. C 323.9 171.5

O/L Header SA- 106 Gr. C 323.9 171.5

1.9 REGENERATIVE AIR PREHEATER

i) Type ii) Size iii) No. per boiler iv) Arrangement v) Element Height vi )Heating elements. a) Hot end/hot intermediate Element type Height Material b)Cold end /cold intermediate Element type Height Material vii)Rotor Seals. a)Radial seals hot end Radial seals cold end b)Axial seals c)By pass seals d)Rotor post seal hot end Rotor post seal cold end viii)Bearings a)Support bearings b)Guide bearings ix)Oil capacity. a)Support bearing b)Guide bearings x)Oil circulation system Guide bearing a)Pump Bisector, Regenerative 27 VIM 2000 (Bisector) Two Vertical 2000 mm DU (24 gauge) 850 mm carbon steel DU (22 gauge) 300 mm corten A 2.5 mm thick corten A 2.5 mm thick corten A 2.5 mm thick corten A 1.6 mm thick corten A 6 mm BM-C20 6 mm BM-C20 Spherical roller thrust SKF/FAG294/500 Spherical roller SKF/FAG-23060 CCK/W 33 150 litres. 25 litres.

Hypo screw pump

No. per boiler Model No. Type Size Capacity b)Drive motor Support Bearing. a)Pump No. per boiler Model No. Type Size Capacity b)Drive motor Heat exchanger xi)Cleaning device a)Motor detail b)Reducer c)Steam consumption x)Rotor stoppage Alarm Go switch Input power Alarm power

4 HSTR 3 976 1 x 1 15 LMP 0.55 Kw, 3, 50 HZ, 415V, 910 rpm, Insulation class F Hypo screw pump 4 HSTF 3 976 1 x 1 15 LMP TEFC rating 0.55 Kw, 3-,50 HZ, 415V, 910 rpm, insulation class F Horizontal & shell & tubular type, capacity 7500 KL/hr. Power driven soot blowing 0.18 kw,3,50 HZ,415 V,1380 rpm, insulation class F Allroyd gear, reduction ratio 4000:1 2000 Kg/hr/service, at 18 Ksc,150oC APCO 105-135 V, 50HZ 120 or 230 V AC 10 Amps 10-150 V DC 2 Amps

1.10 ID FAN
i)Manufacturer ii)No.per boiler. iii)Type Orientation Delivery iv) Medium handled v) Fan drive & type vi)Fan regulation vii)Fan design rating Capacity Total head developed viii)Temp. & specific wt. of medium ix)Fan reserve over MCR BHEL 02 NDZV 31 SIDOR, Top horizontal Radial, double suction, central discharge. Flue gas Hydraulic coupling SVNL 1150, Voith Hydraulic coupling 224.15 m3/sec. 445 mmwc 1500C & 0.7918 Kg/m3

Flow Pressure x) Fan Diameter of impeller No. of blades Weight Moment of inertia referred to fan shaft. xi)Bearings Fixed bearing Expansion bearing x)Drive motor Make Type Rating Duty type Efficiency at 100% load Weight of motor

26.3% 32.0% 3255 mm 11 51,000 kg. 48,870 kg/m2 Sleeve bearing. Thrust collar 2 nos. 8x c 8 x c BHEL, Hardwar. Squirrel cage induction motor 1500 KW, 6600V, 3-, 50 HZ, 750 rpm Continuous duty, 167.4A 95.6 % 11,600 kg.

1.11 FD FAN
i) Manufacturer ii) No. per boiler iii) Type iv) Medium handled v) Location vi) Orientation vii) Type of fan regulation viii)Fan Design Rating Capacity, m3/sec Total head developed, mmwc Temp. of medium Specific wt. Of medium Speed ix)Fan Reserve. Flow Pressure x)Fan Impeller diameter No. of blades Material of blade Hub diameter Wt. Of fan BHEL, Ranipet 02 AP 1-20/11, axial reaction. Ambient air Ground level Horizontal delivery Blade pitch type 150 465 550C 1.0535 kg/m3 1480 rpm 30.7% 56.0% 1990 mm 23 Aerofoil type Al Mg Si lF 2 1100 mm 8500 kg.

Fan drive coupling xi)Bearings Fixed Bearings Expansion bearing xii)Drive motor. Make Frame size Type Rating Weight of motor xiii)Lubrication Fan Motor xiv)Lube Oil System No. of oil pumps Make Capacity Discharge pressure Max. operating pressure Alternative pump make Lube oil pump motor No. of coolers Oil tank capacity Oil heater

Regiflex type NU 230C3, 7230 BVA NU 230 C3 BHEL, Hardwar. LC 00710 H 04 AIH Squirrel cage induction motor 920 KW, 6.6K V, 50 HZ, 1500 rpm, Continuous duty, 100.2A 7730 kg. Forced oil lubrication Grease lubrication Two Hypo gear pump 70 rpm 12 bar 16 Ksc. IMO screw pump 3.7 Kw,415 V,50HZ,1450 rpm, class of insulation B Two 450 litres Oil immersion type, 4 KW, 415V, 3-, 50HZ.

1.12 P.A. FAN

i) Manufacturer ii)No. per boiler iii)Type iv)Medium handled v)Orientation vi)Location vii) Type Of Regulation viii)Fan Design Rating Capacity, m3/sec Total head developed, mmwc Temp. of medium Specific wt. of medium Speed BHEL 03 NDZV 20 HERAKLES. Hot Air. Bottom delivery with 450 inclined suction chamber. Ground mounted on concrete floor Inlet damper control 71.50 808 3120C 0.5817 Ksc. 1480 rpm

ix)Fan Reserve Flow Pressure x)Fan Driving Coupling xi)Fan Impeller dia Wt. Of fan(without motor & coupling) xii) Drive motor Make Frame size Type Rating Weight of motor xiii)Lubrication Fan Motor xiv)Bearings Fixed Bearings Expansion bearing xv)Lube Oil System Pump type Design pressure, Ksc LOP Motor. Lub oil filter Lub oil cooler Oil tank capacity

24.3% 30.7% BHEL make pin type flexible 2113 mm 8500 kg. BHEL, Hardwar. LC 00710 H 04 A-2H Squirrel cage induction motor 800 KW, 6.6KV, 50 HZ, 15500 rpm Continuous duty, 85A 9540 kg. Forced oil lubrication Grease lubrication Dodge sleeve 5 .7/16 RT Sleeve bearing 5.7/16 RT Screw pump. 8.0 1.5 KW, 415V, 3-, 1440 rpm, class of insulation B, Squirrel cage motor. 2 nos. basket type, SS mesh, 60 microns. 2 nos. horizontal tubular type 315 litres

1.13 FUEL PREPARATION AND FIRING SYSTEM 1.13.1 OIL BURNER L.F.O BURNER
i)Service ii)No. of oil guns . iii)Burner iv)Atomiser media v)Atomiser designation vi)Max. capacity vii)Min. allowable LFO pressure viii)Min. allowable air Initial start up purpose. 4 nos. oil guns in each AB, CD, EF elevation. Tilting tangential, corner fired. External mixed ,constant pressure service air. Spray plate 90 J16, 90 J14 7.5% MCR heat input per elevation & total 22.5% MCR. 2.1 Ksc 5.25 Ksc.

IGNITORS
Make Service Type Location Input Output Duty cycle Spark rod Igniter tip, mm Operating temp. Retractor Assembly Air cycle stroke Air pressure Flexible cable Length Bend radius Simmonds, USA Oil burner light off High energy arc ignitor (HEA) Burner mounting panel 110V AC, 50HZ, 5A rms Min. 4 sparks/sec, 12 joules/spark. 15 min. ON, 30 min. OFF. 5/8 SS tube with flexible SS wire braid, 18ft long. Length-191, Diameter-15.9 + 0.15 650C max. 300 mm 5 to 7 Ksc. 7.6 mtr. Max. 100 mm

FUEL OIL SPEFICATION

i)Standard ii)Flash point min (PMCC) iii)Viscosity max. iv)Total sulpher, max. v)Gross heating value(Typical) LFO LDO to IS-1460/1994 560C 2.5 to 15.7 CST at 380C 1.8% by weight 10720 Kcl/kg .

FUEL OIL PRESSURISING UNIT i)Light diesel oil pump Make Capacity Drive motor ii) Heavy fuel oil pump Make Pressure Drive motor 2 nos per both units. Tushaco, Delta corp. 110 LPM at min cst. 7.5 KW, 415V, 50HZ, 3-, 910 rpm, Insulation class B,15.4A 4 nos.for both units. Tushaco, Delta corp. 20 Ksc. 22 KW, 415 V, 50HZ, 3- Insulation class B, 1460 rpm.

FUEL OIL STORAGE TANK

Type Capacity Numbers Size, m Vertical cylindrical 5000m3 02 20.0 x 18.0 Vertical cylindrical 1000m3 02 10.0 x 15.0

BURNER TYPE Pressure (Ksc) Max Rating 4.00 Min Rating 2.1 During Scavenge 0

LFO BURNER LFO Flow (Kg/hr) Pressure (Ksc) 1000.00 5.25 600.00 5.25 0 5.25

DATA CHART.

AIR Flow (Kg/hr) 135.00 145.00 180.00

At present LFO is burned in all the elevations.

1.13.2 GRAVIMETRIC COAL FEEDER

i) Make ii)Type iii)Capacity vi)RPM vii)Main drive vii)Cleanout conveyor drive BHEL, U/L Stock Equipment Company, USA 36 GF 76CD, 70 T/hr per feeder. 959 5.5 Kw,415V,3,50HZ. 0.25kw,415v,3, 50HZ,910rpm.

1.13.3 PULVERISER
i)Make ii)No. per Boiler iii)Type iv)Capacity v)Fineness vi)Max. feed size to mill vii)Size of grinding roll viii)Min. mill capacity without chattering BHEL 03 BBD11-4760 105 T/hr./mill. 70% through 200 mesh. 25 mm. 1/3-50mm 1/3-40 mm 1/3-30 mm 30 T/hr.

ix)Mill operating temp. x)Design. Air flow xi)Design pressure xii)Drive motor Make Rating Bearings xii)Lub Oil System a) L.P. Pump Make / Type Number Flow Operating Pressure Drive details Electrical heaters in tank b)H.P. Pump Number Flow Max pressure Drive details c) B & S Pump Number Flow Max pressure Drive details d)Dual basket filter Quantity Type Filtration nominal Normal flow e) Oil Cooler Qty. Type Oil flow rate Oil pump inlet/out let. Fresh water flow rate Water pump inlet/out let Heat exchanger surface

80-900 C 70 T/hr 1500 mmwc BHEL 2250 KW, 6.6KV, 50 Hz, 3-, 266.5A, 993rpm, squirrel cage induction motor, Insulation class-F DE NV 240 EM & 6240 MC3 NDE NV 240 EM. Allweiler Tushaco/ Screw Pump 02 per mill. 135 lpm at 10 bar LP side 244 lpm 6 Ksc. 7.5 kw,415V,50 HZ, 3-, 715rpm, Insulation class-F 1 W/cm2, 23 KW, 415V,One heater heats 1700 litres From 100 to 350C in 5 hours. 2 Per Mill. 4 x 10 Lpm. 100 bar. 11 KW, 415 V, 50 Hz 3-, 960rpm, 22.7A 01 Per Mill. 2 x 3.5Lpm. 60 bar. 1.5 KW, 415 V, 50 HZ, 3-. 01 per Mill. RFL DP 661F10B3, 1/50,8062+BM 20 Micron. 660 lpm. One per Mill MAL 353 K2K3C. 135 lpm. 550C/450C 250 lpm. 380C /40.40C 7.40 m2

f) Rectangular Oil Reservoir. Dimension Capacity Qty Nominal capacity g) Aux Reducer Make Reduction type High/ Low speed Oil Drive details h) Fluid Coupling. Make Model RPM i)Main Sped Reducer (MSR) Make Type Pinion, mm Length of teeth Quantity j) MSR Lube Oil Pump Type Flow Drive details Quantity k) Girth Gear Greasing Unit. No.of spray Nozzles/valve manifold Quantity Flow Air consumption Drive

1.8m x 1.2m x 1m 1770 litres One per Mill. 950 litres. C.Messian Durand, France. H3 H19 1450/14.58 rpm 80 litres. 37 kw,63A,50 HZ, 3, 415 V, Insulation class F. Fluidomat ltd, Dewas SM 06 1500 Flender Macneil, India SZN 630 825.6 OD, 760.48 PCD. 560 mm One per Mill Gear pump 220 lpm. 5.5 kw,12A,50 HZ.3, 415 V, Insulation class F, 945rpm. One per mill. 06 One per Mill 3.8 cm3/cycle 5.0 m3/hr at 2 bar 0.55 kw,50 HZ.3, 415 V, 1400rpm

1.13.4 COAL PIPE

i) Pipe Size, OD (mm) ii) Material 558.0, thickness 12.5 AP1 5L Gr B

Type No.per Boiler Capacity Position Control

1.13.5 COAL BURNER

Tilting tangential 24 38 x10 6 Kcal/hr/burner Corner Air Damper.

1.13.6 SEAL AIR FAN

No. of fan/Mill Type Orientation Developed pressure Drive motor 2(One working, one stand by) Single stage centrifugal Horizontal suction, 1662 mmwc Crompton Greaves make, 120KW, 415V, 3, 50HZ, 2960 rpm, Insulation Class-B

1.14 SCANNER AIR FAN

No. per boiler Duty Medium to be handle Max.dust con Capacity Presure developed Driving motor D.C. motor Fan speed 1 AC driven,1 DC driven Continuous Dust laden air 300 mg/m3 5000 m3/hr. 200 mmwc 415V, 3,50HZ, 5.5kw 10A, Insulation class-B 5.6 KW, KEC make,33 A, Insulation Class-F 2850 rpm

1.15 SOOT BLOWERS

Type . Source of steam Fully automatic sequentially controlled micro processor based steam soot blowing. SHH-10 (LTSH-O/L Headers) / PRDS

Wall blower i)Number ii)Type iii)Motor power iv)Cleaning medium Pressure Temperature Consumption (per cycle) v)Blow duration vi)Cycle 56 WBIE 0.56 KW Steam 20 Ksc 3000C 3292.8 kg 1.5 min/blower 84 minute

LRSB. 18 LRDIE 0.37 KW 0.45 KW Steam 20 Ksc 3000C 8013.6 kg. 9 min/ blower 162minute

1.16 ELECTROSTATIC PRECIPITATOR

i)Manufacture ii)Type iii)No.of precipitators/boiler iv)No. of gas path/boiler v)No. of fields in service in each gas path vi) In let design conditions Gas flow rate Temp. Dust conditions vii)Guaranteed collection efficiency for design conditions viii)Pressure drop across the precipitator for design conditions ix)Velocity of gas at electrode zone on total area x)Treatment time xi)Collecting electrodes. a)No. of collecting electrodes per field b)No. of collecting electrodes plates(six plates are arranged in each row per field) c)Space between the centers of collecting electrodes across the gas path in mm d)Nominal length of collecting electrodes per field in the direction of gas flow e)Total No. of collecting plates per boiler f)Nominal length/Height of collecting plates g)Sp. Collecting area BHEL FAA-6 x 45-2 x90135-2 Two Two Six 351.27/m2/sec. 1430c 82.44 gms/Nm3 99.82% 20 mmwc 0.72 m/sec. 37.5 Sec. 61 366 300 4.5 m. 4392 750/1350 mm 249 m2/m3/sec.

h)Total projected collecting surface xii)Emitting Electrodes a)Type b)Size c)No. of the electrodes in the frame forming one row d)No. of electrodes in each field e)Total No. of electrodes /boiler f)Total length of electrodes per field g)Plates/wire spacing xiii) Rappers for emitting electrodes a)No. & types of rappers b)Rapper size c)Frequency of rap. d)Drive xiv)Hoppers a)Type & No. b)Capacity c)Heating

87,480 m2 Spiral with hooks 2.7 mm diameter 54 3240 38880 18176.4 m. 150mm One drop hammer for two nos. of electrodes. 30 kg. 10 raps/hour Geared electric motor controlled by synchronous programmer. Pyramidial,48 8 hours storage Electrical heating provided for bottom of hoppers. Inlet perforated plate 2 set Outlet U-shaped thin sheet 1 set

xv) Gas Distribution System Type Quantity xvi) Electrical items. 1) Rectifier Rating Number Type Location 2) Rectifier control panel Number Type Location 3) Motors for emitting and collecting rappers Quantity Rapping Location

70KV(peak),1000mA(Mean) 24 Silicon diode, full wave bridge Connection. Top of precipitator. 24 Thyristor. In control room at ground level 24 nos. 415V, 3, 50HZ, 0.26kw 1A, 1310rpm, continuous rapping. On roof top of ESP.

4) Heating elements a)Hoppers for 48 hoppers @ 6 KW per hopper b)Shaft insulators for 24 insulators @ 1 KW per insulator c)Support insulators for 96 insulators @ 1 KW per insulator d)Estimated power consumption including heating elements & rappers 5) Recommended current setting Fields Current in mA xvii) Operating sequence of rapping mechanism

288 Kw 24 Kw. 96 kw 630 Kw. 1 2 3 4 5 6 250 400 550 700 850 1000 Auto

1.17 PRESSURE REDUCING & DESUPERHEATING STATION (PRDS) i)Steam source ii)Flow capacity iii)Spray water iv)Operating pressure v)Operating temp. vi)Header size vii)Material MS Line at 150 Ksc & 5400c Design-80t/hr. Normal-56t/hr. BFP discharge 16 (Ksc) g 2200c 273 x 635 mm SA 335 P22 1.18 MAIN PIPELINES No. of lines ID x Thickness, (in mm) Material Main steam 2 255.6x47.0 SA335P22 Hot reheat 2 508.6x28.0 SA335P22 Cold reheat 2 457x20.0 SA335P22 SA106Gr.c Feed water 1 323.9x36.0 SA106Grc

1.19 BLOWDOWN VESSELS Test Pressure Max working Pressure Operating Temp Capacity, m3 IBD 4.5 ksc 3.0 ksc 200 0C 2.205 CBD 13.5 ksc 8.0 ksc 180 0C 3.930

1.20 SAFETY VALVES

Sr No Valve Tag Location Type of Safety Valve Valve Size mm / inch INLET OUTLET Butt Welded Flange Welded 1 SV1 2 SV2 3 SV3 4 SV4 5 SV5 6 SV6 7 SV7 8 SV8 9 SV9 10 SVS8 Boiler Drum Boiler Drum Boiler Drum Super Heater ERV CRH HRH HRH HRH S.B.Line Consol 1750WB Consol 1750WB Consol 1750WB Consol 1740WD Consol 1538VX Consol 1786WB Consol 1786WD Consol 1786WD Consol 1786WD Consol 1811JB 76.2 / 3" 76.2 / 3" 76.2 / 3" 76.2 / 3" 63.5 / 2.5" 152.4 / 6" 152.4 / 6" 152.4 / 6" 152.4 / 6" 38.1 / 1.5" 152.4 / 6" 152.4 / 6" 152.4 / 6" 152.4 / 6" 101.6 / 4" 203.7 / 8" 203.7 / 8" 203.7 / 8" 203.7 / 8" 63.5 / 2.5"

Valve Set Pr. Ksc Blow Relieving Tot Down Capacity,kg / hr Capacity OPEN CLOSE

177 180.5 182.3 163.75 162.1 45 42.35 42.7 44.5 40

169.9 171.5 173.2 158.8 158.8 42.75 40.23 40.57 42.23 38.4

4 5 5 3 2 5 5 5 5 4

180360 183924 1,2,3 185760 161523 101017 176760 140256 1411372 7,8,9 42 147240 14590

1.21 CHIMNEY i)No. of flue ii)Wind shield material iii)Flue material iv)Chimney height v)Chimney base dia vi)Chimney raft dia vii)Flue dia 02 Reinforced concrete Steel 220 m 28.948 m 36.0 m 4.60 m 1.22 FUEL The fuel data on which guarantees given are as follows: PROXIMATE ANALYSIS Description Fixed carbon % Volatile material% Ash % Moisture ULTMATE ANALYSIS. Fixed carbon % Ash % Moisture % Performance Coal 23.0 23.0 42.0 12.0 31.29 42.0 12.0

Hydrogen % Sulphur % Oxygen % Nitrogen %

2.44 0.50 11.08 0.69

1.23 CHEMICAL COMPOSITION OF ASH GENERATED IN ITPS Carbonate % 0.72 Higher heating value 3000 Kcal/kg Grindability index, HGI 55 Analysis in wt Maximum value Minimum value Average value Ash fusion temp. 1400c 12000c 47.98 Sio2 Initial deformation temp. 61.76 54.5 Fe2O3 17.84 4.19 12 Al2O3 29.17 23.02 26.31 CaC 3.01 0.55 1.81 MgO 1.58 0.56 1.06 Na2O 2.51 0.34 1.425 K2O 0.9 0.66 0.78 TiO2 3.4 1.75 2.51 Slagging index of Ash Rba 0.27 0.08 0.2 PREDICTED PERFORMANCES
I-FLOW T/HR. DESCRIPTION STEAM Supper heater out let Reheater out let WATER Feed water Supper heater spray AIR Air heater outlet(Primary) Tempering Air Air heater outlet(secondary) Total combustion air FUEL Coal (HHV=3800 Kcal/kg) 178 165.6 112.5 170.2 190.24 82.76 563.72 880.77 175.54 91.02 508.39 819 131.37 110.87 270.41 656.7 209.6 58.8 529.7 842.1 690 0 620.5 16.2 379.4 34.6 554.9 29.2 690 597.9 636.7 572.9 410 377.6 584.1 577.4 HP.HEATERS IN SERVICE MCR NCR CL 60% HP HEATERS OUT NCR.

FLUE GAS Air heater out let TOTAL HEAT TO BOILER (Heat Duty) Kcl /hr. II.TEMP( C) STEAM Standard Temp. in Drum LTSH O/L SH platen T/L SH platen O/L SH final O/L RH I/L RH O/L WATER Eco I/L Eco. O/L AIR Ambient AH O/L(Primary) AH O/L(Secondary) GAS SH platen inlet RH front inlet RH Rear inlet LTSH inlet Economiser inlet Air heater inlet Air heater outlet 349 390 390 500 540 342 540 349 393 384 500 540 342 540 345 399 366 506 540 330 540 347 401 378 496 540 351 540
0

1048.5 452.4

972 420.8

665.3 284.9

1000.7 437.9

246 310

245 309

225 295

166.5 267

40 335 335

40 332 332

40 306 306

40 290 290

1184 1029 885 652 549 359 114

1187 1023 876 643 541 353 143

1139 950 796 583 498 314 147

1157 1044 865 641 541 311 124

III.PRESSURE (KG /CM ) PRESSURE SH outlet LTSH outlet Drum Eco I/L RH O/L

155 162.9 166.1 171.1 34.483

154.1 160.9 163.7 168.2 34.968

151 154.3 155.5 158.6 22.821

153.2 159 161.4 165.6 35.885

RH I/L PRESSURE DROP SH System Re heater Economiser(Including static head) IV- PRESURE & DRAFT (AIR & GAS) MMWC. PRIMARY AIR PA Fan I/l PA fan O/L Mill I/L Mill O/L SECONDARY AIR FD fan I/L FD fan O/L AH I/L AH O/L Wind box pressure Wind box to furnace diff. Furnace SH platen I/L RH I/L LTSH I/L Eco. I/L AH I/L EP I/L ID fan I/L ID fan O/L Flue gas velocity in second pass 8.00 m/sec. V-MILL AND BURNER PERFORMANCE. No.of Mill in operation Coal flow/Mill(T/hr.) Ball charge per Mill(T/hr) Air flow/Mill (T/hr) Air temp. at mill I/L(0c) Mill output temp.(0c) Fineness % (through 200 mesh) Mill pressure drop including classifier(in mmwc) Burner tilt (in degree)

38.497

36.898

24.088

37.812

11.1 2.014 5

9.6 1.93 4.5

4.3 1.267 3.1

8.2 1.927 4.2

69 687 632 292

66 644 595 273

55 467 436 188

65 647 596 267

-16 282 227 157 125 -5 -5 -6 -22 -27 -62 -265 -303 34

-14 258 210 150 100 125 -5 -5 -6 -20 -24 -55 -235 -268 30

-7 167 146 123 100 125 -5 -5 -6 -13 -15 -32 -138 -143 14

-15 263 212 151 100 125 -5 -5 -6 -20 -24 -55 -230 -259 28

2 89.5 96 136.5 243 75 76 340 0

2 82.6 96 133.28 232 75 79 322 9

2 56.1 96 121.12 184 75 79 248 24

2 85.1 96 134.2 236 75 77 329 -7

VI-O , CO2 (DRY VOL) AND EXCESS AIR(%) O2 in gas at Eco O/L% CO2 in gas at Eco O/L % Excess air gas at Eco O/L % VII-HEAT BALANCE : LOSSES IN % Dry Gas H2o & H2 in fuel H2o in Air Unburnt carbon Radiation Unaccounted Manufacturer's margin Total loss Guaranteed efficiency 4.31 7.05 0.23 2 0.2 0.5 1 15.29 84.71 4.27 7.04 0.23 2 0.22 0.5 1 15.26 84.74 4.48 7.07 0.24 2 0.31 0.5 1 15.6 84.4 3.43 6.93 0.19 2 0.2 0.5 1 14.25 85.75 3.55 15.57 20 3.55 15.57 20 3.55 15.57 20 3.55 15.57 20

SECTION 2 TURBINE & AUXILIARIES

2.0 MAIN TURBINE 2.1 TECHNICAL SPECIFICATION 2.1.1 STEAM TURBINE i) ii) Make Type BHEL, Kraftwerk Union Design Tandem compound, regenerative, reheat, cylinder having single flow HP turbine, double flow IP & LP turbine HP 25 no. IP 20 x 2 no. LP 8 x 2 no. HPT Reaction, barrel type, single flow IPT Reaction, barrel type, double flow axially split type LPT Reaction, barrel type, double flow three shell design 210 mw 230 mw 3000 rpm 3090/2850 rpm (51.5 to 47.5 Hz) 700 to 2850 rpm 11% 2.1.2 DIMENSIONS (IN MM) i) ii) iii) iv) v) vi) Height of first stage moving blade Mean dia. of 1st stage moving blade Height of last stage moving blade Overall length of turbine Overall width with cross around pipe Total exhaust area (LP turbine) HPT IPT 43 66 643 756 95 100 15.725 m 10.5 m (approx.) 6.3 x 4.75 m2 LPT 75.5 1473.5 668.8

iii) iv)

No. of stages Type HP/IP/LP turbine

v) vi) vii) viii) ix) x)

Nominal rating Peak loading Rated speed Max./Min. speed Speed exclusion range Over speed set value

No.1 No.2 No.3 No.4 No.5 No.6 No.7 Lining material for all bearings

2.1.3 BEARINGS Journal, 280 x 140 mm Radial cum thrust, tilting pad 290 x Journal, 450 Journal, 400 Journal, 400 Journal, 400 Journal, 200 Babbit

2.1.4 VALVES i) ii) iii) iv) 2 main stop & control valves 2 reheat stop & control valves 2 swing check valves in CRH line 2 bypass stop & control valves Type EV160 Type IV320 DN 450 DN 200 No valve 1 swing check valve with aux. actuator 1 swing check valve 1 swing check valve 1 swing check valve No valve 2.1.5 WEIGHTS (TONNES) Rotor Rotor Cylinder assembled (with steam inserts) HPT 7.5 56.0 IPT 15.8 37.0 LPT 48.0 81.0

Extraction Swing check valves: v) Extraction 1 vi) Extraction 2 vii) Extraction 3 viii) Extraction 4 ix) Extraction 5 x) Extraction 6

2.1.6 CASING TEMPERATURE (0C) Wall temperature HP turbine casing exhaust Outer casing of LP cylinder Spray water to LP turbine Alarm at 480 90 Must be switched on at 90oc Machine must be shut down at 500 110

2.1.7 BEARING TEMEPRATURE (0C) Normal operating Below 75oc Above 75oc Alarm at 90oc 100oc Machine must be shut down at 120oc 120oc

2.1.8 TEMPERATURE DIFFERENCE (0C) (Between Upper & Lower casing section) Alarm at HP turbine middle IP turbine front IP turbine rear 30oc 30oc 30oc Machine must be shut down at 45 45 45

2.1.9 DIFFERENTIAL EXPANSION HP turbine differential expansion IP turbine differential expansion LP turbine differential expansion Alarm +4.5, -2.50 +5.00, -2.00 +25.00, -5.00 Trip +5.50, -3.50 +6.00, -3.00 +30.00, -7.00

2.1.10 VIBRATION (ABSOLUTE) Nominal value for alarm Maximum value for alarm Limit value for tripping Of bearing housing 35m 45m Of shaft 30m above normal value 120m 200m

2.1.11 LOW VACUUM TRIP SETTING Hydraulic low vacuum Trip Electric low vacuum Trip Hydraulic low vacuum Trip (Bypass operation) < 0.3 bar < 0.3 bar < 0.6 bar

2.1.12 MW OUTPUT HPT 56.40 MW 28% IPT 53.73 MW 26% LPT 93.03 MW 46%

2.1.13 STEAM PURITY 1)Conductivity at 25 c continuous measurement at the sampling point. a)Direct measurement i)Alkaline method ii)Neutral method b)following a strongly acid cation exchange method i)Alkaline method ii)Neutral method 2)Silcic acid (SiO2) 3)Total iron (Fe) 4)Total Copper (Cu) 5)Sodium (Na)
o

Continuous operation

Start up

Unit

Not specified < 0.15 < 0.10 < 0.10 < 0.10 < 0.005 < 0.001 < 0.005

-< 0.50 < 0.50 < 0.50 < 0.050 < 0.050 < 0.010 < 0.020

s/cm s/cm s/cm s/cm mg/kg mg/kg mg/kg mg/kg

2.2 TURBINE LUBE OIL SYSTEM 2.2.1 OIL SUPPLY i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) Oil tank capacity Highest/lowest oil level from top of the tank during operation Lube oil temperature at cooler outlet during operation Oil temperature rise across bearings Oil temperature at cooler O/L(under shutdown) First oil filling (estimated) Flushing of oil quantity (estimated) Pressure limiting value in jacking oil system Safety valve in jacking oil system Jacking oil pump must be switched on at Jacking oil pump must be switched off at 32 m3 800/850 mm Min 37oc, Normal 45oc Max. 47oc Normal 20oc Max. 25oc Max. 75oc 30m3 20m3 120 bar Max. 170 bar 510 rpm 540 rpm

2.2.2 OIL PUMPS Nos Make Type Rated capacity Rated discharge pressure Speed, rpm Drive Make Voltage, V Frequency, Hz Motor Power, KW Rated current, Amp 139 m3/hr 8.2 ata 3000 Turbine M.O.P. 1 BHEL A.O.P. 2 KSB ETA 15050VL centrifugal 152.24 m3/hr 6.8 ata 1485 AC motor GEC 415 50 100 175 DC E.O.P. 1 KSB ETA 10033VL centrifugal 108 m3/hr 2.3 ata 1425 DC motor Crompton Greaves 220 13 128 JOP (AC) 1 Allweiler SDF 40R54 GQW112 76 LPM 120 bar 2950 AC motor Siemens 415 50 27.6 47.5 JOP (DC) 1 Allweiler AG SDF 40R54 GQW112 76 LPM 120 bar 2950 DC motor Wirrkelmann 220 28 152

2.2.3 OIL COOLER i) ii) iii) iv) v) Type & no. Cooling surface Oil outlet temperature of cooler In operation In shutdown Tube material & no. of tubes Design pressure & temperature shell side tube side Shell & tube type, 2 x 100% 218 m2 Min. 38oc, Normal 45oc, Max. 47oc Max 75oc Admirality Brass IS1545 Total no.1250 10 kg/cm2 & 100oc 10 kg/cm2 & 100oc

2.2.4 OIL FILTER i) ii) iii) Duplex oil filter type & no. Filtration particle size of thrust bearing duplex filter Filtration particle size of MOT filter DN 100 type, 2.82.9.200.500.10 37 m 250 m

2.2.5 ESTIMATED OIL REQUIREMENTS OF BEARINGS Bearing 1 (HPT) front pedestal) Bearing 2 Bearing 3 Bearing 4 Front generator bearing Rear generator bearing 0.8 dm3/s 9.1 dm3/s 4.0 dm3/s 3.5 dm3/s 3.5 dm3/s 5.0 dm3/s 2.2.6 BARRING GEAR i) ii) iii) iv) v) Type of drive Method of engagement Cut in/ cut out speed Power to rotate turbine Barring speed Hydraulic turbine Hydraulic 240/210 rpm 45 KW 80 210 rpm

2.2.7 MAIN OIL CENTRIFUGE i) ii) iii) iv) v) vi) vii) viii) ix) x) Manufacturer Capacity Model Centrifuge motor Bowl speed Revolution/counter Rpm Antiflood tank capacity Feed pumps Capacity of dirty oil tank Capacity of clean oil tank Alpha - Laval 4500 Lph (2 nos) MAB 205+54 KW Indirect heater 5.5 KW, 415V, 2430 rpm, 11A, Cl.B. inst. 8425 rpm apprx. 118/125 45 lit 4500 lit/hr, at 5 ksc 35 m3 35 m3

2.2.8 OIL CHARACTERISTICS (As per IS: 1448) i) ii) iii) iv) v) vi) vii) viii) ix) Kinetic viscosity at 37.8oc Kinetic viscocity at 50oc Specific gravity at 50oc Flash point Pour point Ash content Water content by weight Mechanical solid impurities Viscosity Index Inorganic acidity 47.5 c.s. to 49.5 c.s. 28 c.s. 0.852 Min. 200oc -6oc 0.01 (% by weight) Below the limit of quantitative detectability - do Min. 97 Nil

x) xi) xii)

Organic acidity Neutralization number Copper strip corrosion test at 100oc for 3 hrs Emulsion characteristics

Max. 0.14 mg of KOH per gm of oil Max. 0.2 mg of KOH per gm Not worse than no.1 40-40-0 (20 minute) 2.3 VACUUM SYSTEM 2.3.1 CONDENSER

i) ii) a) b) c) iii) iv) v) vi) vii) viii)

Type Design conditions: Design pressure Test pressure Design temperature Design CW flow Design CW temperature Design back pressure No. of tubes length of each tube Tube O.D thickness for top row (thickness) Tube material

Surface type, double pass with divided water box construction Steam side full vacuum Filling by water up to 1.0 m above tubes 85oc 27,000 m3/hr 33oc 7600 mm 25.4 mm x 1 mm 1.2466 mm 17,902 nos. -90/10 Cu-Ni to BS 2871 in condensing zone 1316 nos. SS ASTMA-249, T1304 in air air cooling zone 11,495 m2 3.6 mwc 8.8oc to 9oc 1.9 m/sec 320 MT 530 MT 640 MT Water side 3.5 ksc & full vacuum 4.5 kg/cm2g 50oc

ix) x) xi) xii) xiii)

Surface area Pressure drop in CW side CW temperature rise Water velocity in tube Weight Dry Operating Flooded (1.0 m above tubes)

2.3.2 MAIN EJECTOR i) ii) iii) Make Steam required Min. condensate flow BHEL, Hardwar 1000 kg/hr 103 T/hr

iv) v) vi) vii) viii) ix) x) xi)

Normal condensate flow Tube side pressure Tube side test pressure Shell side test pressure Motive steam pressure Motive steam temperature Weight Empty Operational Material: Tube plate steel Diffuser stage Tube Nozzle

254.6 T/hr 24 ksc 36 kg/cm2g 2.5 kg/cm2g 6.5 ksc 210oc 2875 kg 3245 kg 42W IS202 I,II,III steel IS 2073 Gr.C-20 Admirality Brass CZIII BS 2871 Stainless steel SS 30CR 13 hot rolled Annealed 136603

2.3.3 STARTING EJECTOR i) ii) iii) iv) v) Steam requirement of the ejector Working pressure of steam Hydraulic test pressure Air removal capacity at 500 mm Hg vacuum Design temperature 3300 kg/hr 6.5 kg/cm2g at 210oc 1.5 kg/cm2 7350 SCFM 250oc

2.3.4 GLAND SEALING SYSTEM i) ii) iii) iv) v) iii) Type of control Model Oil used G.S. control valve actuator L.S. control valve actuator Self sealing after Electro-Hydraulic ESS HI Servo control-46/HLP-68 REINEKE, GMBH REINEKE, GMBH 40% load

2.3.5 GLAND STEAM VAPOUR FAN i) ii) iii) iv) Fan Type Make Capacity Drive SHSH S.K.Systems, New Delhi 1080 m3 /hr 3 H.P. 2840 rpm. 2.3.6 CONDENSER ON LOAD CLEANING DEVICE Manufacturer Debris Filter System i) Type ii) Quantity / unit GEA Energy Systems 574 V type Two

iii) iv) v) vi) vii) viii)

Perforation of screen Screen thickness Flow, m3/hr Design DP for filter screen Discharge during flushing, m3/hr Geared motor drive

5 mm 2.0 mm 13,500 2 bar (g) 400 415V, 3-, 50 Hz, 0.55 KW, 1.4A Centrifugal, horizontal 170 415V, 3- , 50 Hz, 11 KW, 1460 rpm

Flushing Pump ix) Type x) Capacity, m3/hr xi) Motor Tube Cleaning System Ball Separator i) Quantity / unit ii) No. of ball extraction points iii) No. of screens/ball separator iv) Normal flow, m3/hr Ball Recirculation Pump i) Type ii) Quantity / unit iii) Capacity, m3/hr iv) Design head mmwc v) Design efficiency vi) Motor Cleaning Balls i) ii) iii) iv) Type Diameter, mm Density, g/m3 Design temperature, 0C

Two Two Two 13,500 Centrifugal horizontal non-clogging type Two 60 15 60% 1440 rpm, Insulation class B Normal Balls Soft 26 0.22 80 Abrasive Balls Abrasive 25 0.2759 80

2.4 CONDENSATE SYSTEM 2.4.1 CONDENSATE EXTRACTION PUMP i) ii) iii) iv) Manufacturing No. of pumps & capacity Type No. of stages BHEL, Hyderabad 2 100% EN5J40 (2 shaft), vertical centrifugal canister type 5

v) vi) vii) viii) ix)

Discharge capacity Diff. Head Input power to pump Density of medium handled NPSH required at the eye of the 1st impeller x) RPM xi) Efficiency of pump xii) Coupling xiii) Direction of rotation viewed from drive end xiv) Suction bore diameter xv) Discharge bore diameter xvi) Minimum flow through pump xvii) Bearings xviii) Lub. Oil xix) Motor Manufacturer Type KW rating Power supply Class of insulation Efficiency at rated output Rated speed Full load current Weight of motor Bearing DE 6226-c3 NDE 7322-B

675 m3/hr 220 m 494 KW 0.9896 tonne/m3 3.0 mlc 1482 81% Flexible Clockwise 400 mm 300 mm 175 m3/hr Taper roller bearing 29420E FAG/SKF IOC turbine oil 46/Servo prime 46 BHEL, Hardwar Squirrel cage induction motor 600 KW 6600V, 3-, 50Hz F 94.5% 1485 rpm 66A 4010 kg NU 224M cyl. Roller bearing 7322 B Angular, con. Ball bearing

2.4.2 DRAIN COOLER i) ii) iii) iv) v) vi) vii) viii) x) xi) xii) Position No. Type Cooling surface area Design pressure Hydraulic test pressure Design temperature Tube OD Length Tube material No. of tubes Operating weight Horizontal 1 Tube & shell type 35 m3 Tube side Shell side 28.1 ksc, g Full vacuum & 3.5 ksc, g 42.15 ksc, g 5.25 ksc, g 150oc 100oc 16 mm 1395 mm Austenitic S.S. welded 501 3185 kg

2.4.3 GLAND STEAM CONDENSER i) ii) iii) iv) Position Horizontal No. 1 Type Tube & shell type Allowable/Design flow of main condensate: Minimum 180 T/hr Design 561.343 T/hr Max. 760 T/hr Tube ODX length 19 mm 1150 mm Material Welded S.S. tubes, ASTM A249 TP304 No. of tubes 313 Surface area 20 m2 Exhauster fan 2 nos, centrifugal, 1000 m3/hr, 2860 rpm, 3 HP 2.4.4 LOW PRESSURE HEATER i) ii) iii) iv) v) vi) vii) viii) ix) Type Position No. Operating pressure shell side (ksc abs) Operating temp. shell side(0c) Tube OD thickness in mm No. of tubes WeightDry Operating Flooded Tube material LPH-1 LPH-2 Shell & tube type Horizontal Horizontal One One 0.1992 0.8104 LPH-3 Horizontal One 2.2671 200.0 498 9960 12250 17200

v) vi) vii) viii) ix)

59.54 107.8 16 0.889 498 498 7625 11096 9165 13700 12550 19360 S.S.

2.5 FEED WATER SYSTEM 2.5.1 DEAERATOR i) ii) iii) iv) Manufacturer Type Design pressure/op. Pressure Design temp. / op. Temperature BHEL, Hyderabad Spray cum Tray type 7.4 ksc(g) / 6.83 ksc (g) 250oc / 163.15oc

v) vi)

vii)

Shell ID thickness, mm Feed water storage tank ID thickness, mm Total length, mm Steam inlet quantity, T/hr Inlet steam pressure ksc Inlet steam temperature, 0C Safety relief valve set pr. Ksc Total working weight Flooded weight

2400 16 3500 20 22000 38064 6.827 313.4 6.77 197000 kg (storage tank + header) 262000 kg

2.5.2 BOILER FEED PUMP i) ii) No. & capacity Make 3 50% BHEL, Hyderabad

Pump data Booster Pump Feed Pump iii) Pump type FA1B-56 FK6D-30 iv) Liquid pumped -------Boiler feed water---------- v) SG at suction temp. kg/dm3 0.9046 0.9046 o vi) Suction temperature, c 163 163 vii) Diff. Head, m/c 99 2222 3 viii) Flow rate, m /hr 455 455 ix) Efficiency, % 81.3 81.9 x) Speed, rpm 1485 5245 xi) Power, KW 136.5 3041 xii) NPSH required, m 4.05 24.68 xiii) Thrust bearing The Glacier Metal The Glacier Metal Co. Co. Ltd, Double thrust Ltd, Double thrust, CK CK range, size 811/2kp-2kp range size, 8159/2kp-2kp xiv) xv) xvi) xvii) Mechanical seal Min. recirculation flow, T/hr Direction of rotation viewed from drive end No. of stages Durametallic/ sealol type 4.250 PTO/type 503 100 -------------- Anti-clockwise--------- Six DRIVE MOTOR i) ii) iii) iv) Make Type Rating Degree of protection, type of enclosure, method of cooling BHEL, Hardwar Squirrel cage induction motor 4000 KW IP54, CACW, ICW 37A81

v) vi) vii) viii) ix) x) xi) xii)

Power supply Rated speed Insulation class Efficiency F.L. current Weight Winding temp. rise at rated output over cooling air Bearing DE NDE

6600V, 3-, 50 Hz 1500 (synch.) F 96.5% 407 A 13360 kg 700C (by resistance), 80oc (RTD) Sleeve bearing 160 140 Sleeve bearing 125 115 (Insulated)

HYDRAULIC TURBO COUPLING i) ii) iii) iv) v) vi) vii) viii) ix) Manufacturer Type Power requirement of drive machine Gear ratio, type Speed input/output Regulating range Full load slip Oil tank filling Oil used Voith , India R16k-1 3240 KW 148/41, step up gear unit 1485/5249 rpm 4:1 downwards 2.1% 700 lit (approx.) Servo Torque 10 of IOCL. AUX. LUB OIL PUMP i) ii) iii) iv) Type Lube oil flow Pressure Motor Gear pump Approx. 120 litres/min. 2.5 bar 5.5 kw, 415 volt, 50 Hz OIL/WATER HEAT EXCHANGER WORKING OIL i) ii) iii) iv) v) vi) vii) viii) Type Heat exchange capacity Cooling water inlet temp. Cooling water outlet temp. Nominal oil flow rate Oil I/L temp., 0C Oil O/L temp,0C Max. permissible working L1 N1 09 17 04-D 71 litres 37 47 32 m2/hr 95 57 LUB OIL L1 N1 07 04-D 47 litres 37 47 13.5 m2/hr 69 53

x)

pressure oil side, ksc water side, ksc Max. permissible working oil temperature, 0C

16 10 119 TYPE OF COUPLING

16 10 119

i)

Turbo coupling / pump flexible coupling: Manufacturer Type Motor/turbo coupling flexible coupling: Manufacturer Type Motor/Booster pump flexible coupling Manufacturer Type Torsiflex Ltd HBS1000-8x Torsiflex Ltd HBS-3600-8 Torsiflex Ltd HB4-140x (insulated) 2.5.3 HP HEATERS HPH5 HPH6

ii)

iii)

i) ii) iii) iv) v)

vi)

vii)

Manufacturer BHEL BHEL Type & arrangement ----- ------ U tube Horizontal---------No. of shell passes 3 zones 3 zones No. of tube passes 2 2 Tubes: Type of tubes Seamless Seamless Total no of U tubes 830 830 Effective length of U tubes, mm 7915 9715 Outer dia., mm 15.875 15.875 Design pressure, ksc(g) 280 280 Design temp. 0C 215 265 Shell I.D., mm 1250 1250 Design pressure, ksc(g) 19.0 & full vacuum 45.0 & full vacuum Design temp. skirt/shell, 0C 440/215 370/260 Shell side relief valve set Pressure kgf/cm2(g) 19.0 45.0 Velocity through tubes at 2.14 2.25 670 T/hr flow, m/sec

viii) ix) x)

Tube side pressure drop at 670 T/hr flow, kg/cm2 Surface area, m2 De superheating/Condensing/ Drain cooling zone Total effective area, m2

0.85

1.15

83/485/112 680

104/642/82 828

2.6 HP/LP BYPASS SYSTEM Capacity 60% MCR 420 t/hr of main steam flow at the inlet of HP bypass valve
STEAM VALVE

i)

HP BYPASS

Valves designation Design pressure Design temperature Body material Nozzle material Medium ACTUATOR Type Hydraulic system pressure Positioning time OIL SUPPLY UNIT Oil pump type Supply capacity Motor detail Oil tank volume/usable volume Oil pump cut in at Cut out at Back up protection cut in/cut out Relief valve setting

BP1/BP2 valve 170/50 ata 540/485oc 10 Cr MO910 10 Cr MO910 Main steam

SPRAY VALVE

BPE1, 2 valves 280 175oc 15MO3 15MO3 Spray water

ii)

Hydraulic 100 bar 10/3 sec (3 sec for fast opening device) OV-32 24 lit/min. 7.5 KW, 415V, 3-, 50 Hz, 1440 rpm,14.2 A 70/50 lit 100 ksc 16 ksc 110 ksc/170 ksc 150 ksc

iii)

2.7 FLASH TANK/FLASH BOX 2.7.1 UNIT FLASH TANK i) ii) iii) iv) v) vi) Type/Quantity Design code Design pressure Design temperature Fluid handled Shell material Vertical cylindrical / one per unit ASME SEC VIII div.1 Full vacuum & 1.5 ksc (g) 210oc Steam/water IS2062 Gr FE410 WB

vii) viii) ix) x)

ODX height Shell thickness Corrosion allowance List of connections Vent to atmosphere Drain to waste Drain to manifold Spray water Manhole Spare

1000 x 2700 mm 12 mm 3.2 mm 1 1 2 1 1 1 2.7.2 CONDENSER FLASH BOX

i) ii) iii) iv) v) vi) vii) viii) ix) x) a)

` b)

Type Design code Design pressure Design temperature 0C Fluid handled Shell material Size OD height, mm Shell thickness, mm Corrosion allowance, mm List of connections: FB-1 Vent to condenser Drain to hot well LPH-2 alt. Drain LPH-3 alt. Drain LP ext. line drain manifold Spare (blanked) Manhole FB-2 Vent to condenser Drain to hot well HPH-5 alt. Drain HPH-6 alt. Drain HPH ext. line drain manifold HRH/CRH/LPBP line drain Valve gland sealing header Drain from Aux.5/CRH to gland sealing

FB-1 FB-2 FB-3 Vertical cylindrical ------------------ ASME Sec VIII div.1 -------------- 1.5 ksc(g) & full vacuum 210 215 210 ----------------- Water / Steam ----------------- ----------IS2062 Gr.FE410.WB ------------- 1400 x 2100 2200 x 3300 800 x 1800 10 16 10 3.2 3.2 3.2 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1

Manhole Spare (blanked) c) FB-3 Vent to condenser Drain to hot well Drain cooler drain GSC drain Drain from main ejector CEP discharge vent Manhole Spare (blanked)

1 1 1 1 1 1 2 1 1 1

PREDICTED PERFORMANCE OF TURBINE STEAM PRESSURE (BAR) DESCRIPTION Initial steam Before 1st HP drain stage HP cylinder exhaust IP cylinder stop valve inlet Extraction 6 Extraction 5 Extraction 4 Extraction 3 Extraction 2 Extraction 1 HP cylinder exhaust Rated value (bar) 147.1 132.6 39.23 34.13 39.23 16.75 7.06 2.37 0.858 0.216 0.118 Long time operation (bar) 147.1 137.9 45.11 39.59 45.11 19.84 8.46 2.91 1.09 0.374 0.3 Short time operation (bar) 176.5 145.9 47.08* 40.96** 47.08 19.84 8.46 2.91 1.09 0.374 0.3

*These values correspond to 210 MW with 3% make up and 0.1187 bar backpressure with all heaters in service & rated steam conditions. **The safety valves are set such that these short-time values are not exceeded. Long time operation: Short time operation: Upper limit value, permissible without the time limit. Permissible momentary value. The aggregate duration of such swings must not exceed 12 hours in any one year.

STEAM TEMPERATURE, 0C DESCRIPTION Rated value Annual mean value 535 535 Long time value but keeping within annual mean value 543 543 400 hr per annum 549 549 80 hr per annum max. 15 min in individual case 563 563

Initial steam IP cyl. Stop valve inlet DESCRIPTION HP cylinder exhaust Extraction 6 Extraction 5 Extraction 4 Extraction 3 Extraction 2 Extraction 1 LP cylinder exhaust

Rated value 343 343 433 316 200 107 62 49

Long time operation 359 359 438 326 211 127 82 70

80 hr per annum, max. 15 min. in individual case 425 425 473 366 255 167 127 70

In special cases at no load. 500 500

100

These values correspond to 210 MW load with 3% make up & 0.1187 bar back pressure with all heater. Only valid for the no load period with high reheat pressure after trip-out from full load operation. For the individual case approx.15 min. The turbine is immediately re-loaded or the boiler immediately reduced to minimum load, if no-load operation is maintained. Permissible differential temperature between parallel steam supply lines: No time limitation- 170C. Short time period (15 min.)- 280C.

In the hottest line the limitations indicated for initial steam & reheat temperature must not be exceeded.

 CONDE NSAT E WAT E R Description CEP suction CEP discharge GSC outlet Drain cooler outlet LPH 1 outlet LPH 2 outlet LPH 3 outlet HE AT E R DR AI N Description GSC drain to FB-3 LPH3 to LPH2 LPH2 to LPH1 LPH1 to drain cooler Drain cooler to FB-3 HPH 6 to HPH 5 HPH 5 to deaerator F E E D WAT E R Description BFP suction BFP discharge HPH 5 outlet HPH 6 outlet Pressure Kg/cm2 6.405 205.0 204.09 203.18 Temperature oc 160.7 164.1 200.0 247.0 Flow t/hr 639.27 639.27 639.27 639.27 Temperature oc 99.9 123.5 93.4 60.3 52.8 206.0 170.0 Flow T/hr 0.299 27.589 57.651 63.437 63.437 61.091 95.807 Pressure Kg/cm2 0.1033 19.379 1054 10.08 9.63 9.18 8.72 Temperature 0C 46.1 46.3 46.6 47.8 56.6 90.6 120.7 Flow T/hr 508.83 508.83 508.83 508.83 508.83 508.83 508.83

Pa me rs a give whe unit a 210 M W, 0% make-up water, 76 mm backpressure & ra te re n n t constant pressure operation.

SECTION 3 GENERATOR & AUXILIARIES

3.1 GENERATOR TECHNICAL SPECIFICATION Make Type MW rating MVA rating Rated Terminal voltage Rated Stator current Rated p.f. Rated speed/frequency Negative sequence current capability (I2t) Efficiency at MCR condition Short circuit ratio Phase connection No. of terminal brought out Generator stator winding resistance in each phase Generator rotor winding resistance Cooling of stator winding Cooling of stator core & rotor Direction of rotation BHEL Two Pole, Cylindrical, Steam turbine driven 210 247 15.75 KV 9050 A 0.85 lag 3000 rpm/50 Hz 8 98.55 % 0.49 Double star 9 (6 neutral & 3 phase) 0.00155 a 20 c t 0.0896 a 20 c t Directly water cooled Directly hydrogen cooled Anti clockwise viewed from turbine end

STATIC EXCITATION EQUIPMENT Make SEE Rating Accuracy of Excitation control Range of voltage control in auto Range of voltage control in manual No load field voltage No load field current Max. continuous rated field voltage Max. continuous rated field current Ceiling voltage (Excitation voltage at field forcing) Ceiling current Frequency range of operation No. of parallel bridges including redundant bridge No. of redundant bridge Protection class Station battery supply BHEL Voltage-310V DC Current-2600A DC 0.5% 90-110% 80-110% 102V DC 917 A 355V DC 3000 A 620V DC 4500A 47.5 52Hz 4 1 IP20 220V DC

Duration of field forcing Response time

10 sec. 40 msec.

EXCITATION TRANSFORMER DETAIL Make Rating Voltage rating Vector group Insulation level Cooling BHEL 3150 KVA 15750 / 575 V DYn5 50 KV RMS / min Natural 3.2DESIGN AND CONSTRUCTION FEATURES MATERIAL Rotor shaft Rotor winding Rotor slot wedges Rotor rating ring Stator frame Stator core stamping Bearing body Shaft seal ring Bearing & seal Babbitt Carbon brushes Grade No. of brushes reqd. Steel forging 35Ni 13cr 12Mo 35V12 Chromium nickel molybdenum & vanadium steel Silver bearing copper Duralumin 60Mn Ni85Cr 35 W75, Non magnetic steel ST42W Cold rolled silicon steel CSW C25 IS: 2856-64 ST-42W Grade 84 HM6R 112+1

WEIGHT AND OVERALL DIMENSIONS i) ii) iii) iv) v) vi) vii) viii) ix) x) Wt of the heaviest lift (Stator with Gas cooler & lifting trunions) Wt of rotor Wt of gas cooler Wt of terminal bushings Wt of end shields Total wt. Of generator Overall dia of stator Overall dia of rotor Overall length of stator Overall length of rotor 175.0 MT 42.2 MT 1415 Kg 85 Kg 2000 Kg 270 MT (without exciter) 3960 mm 1075 mm 6580 mm 9770 mm

TORQUES, CRITICAL SPEEDS ETC i) ii) iii) iv) v) Torque under normal working condition Ratio of short circuit torque to F.L. torque Flywheel moment of rotor 1st critical speed of rotor (calculated) 2ndcritical speed of rotor (calculated) OIL CONSUMPTION i) ii) iii) Consumption of oil per generator bearing (excluding shaft seal) Oil pressure at inlet of bearing Consumption of oil in both shaft seals 300 lit/min 0.3 to 0.5 Kg/cm2 77 lit/min 76.32 T 8 21.1 TM2 1370 rpm 3400 rpm

3.3 GENERATOR GAS SYSTEM 3.3.1 H2 IN STATOR CASING i) ii) iii) iv) v) vi) vii) viii) ix) x) Nominal pressure of H2 Permissible variation Max temperature of cold gas Max permissible hot gas temperature Min. required purity of H2 Max. oxygen content Relative humidity of hydrogen at casing pr. (max) Max moisture content in generator casing Total gas volume of the generator Max make up hydrogen per day Hydrogen cylinder capacity 3.5 Kg/cm2 0.2 Kg/cm2(g) 44oc 75 0C 97% 1.2% 30% 15 gm/m3 of H2 56 m3 15 m3 6.8 m3 at 150 ata

3.3.2. GENERATOR FILLING QUANTITIES i) ii) iii) iv) v) vi) Amount of CO2 required to remove air expressed at NTP CO2 for expelling H2 H2 filling quantity Compressed air required for purifying of CO2 from gen. Quantity of compressed air reqd. (at NTP) for carrying out air tightening test Capacity of CO2 cylinder M/c stand still 120 m3 120 m3 300 m3 150 m3 500 m3 27Kg M/c under rolling 150 m3 168 m3 336 m3

3.3.3 HYDROGEN COOLER At rated Hydrogen pressure 3.5 ksc (g) i) No. of coolers/generator ii) Gas flow per cooler iii) Max water inlet temperature iv) Design pressure water side of cooler v) Max permissible operating pressure water side of cooler vi) Pressure drop through cooler vii) Material of tubes/fins viii) Material of water boxes/tube sheets ix) Heat load x) No. of passes of water on water cooler 4 7-5 m3/sec 37oc 6 ksc(g) 3 ksc(g) 17.5 mmwc Admiralty brass/copper Carbon steel 528 KW 2

3.3.4 HYDROGEN DRIER i) ii) iii) iv) Type Working pressure Dew point of dried gas at working pressure Thermal load, ie. Compressor capacity Refrigeration type, freon 12 4 ksc max. 3 to 5oc 1100 Kcal/hr

3.3.5 SETTING VALUES FOR ALARM i) ii) iii) iv) v) vi) vii) viii) Gen. Bearing & seal Babbitt temp. Gen. Bearing oil oil O/L temp. Stator winding temp. Hot gas temp. Cold gas temp. Stator core temp Rotor temp Temp of inlet water to gas cooler High 750C 600C 750C 75oc 45oc 95oc 110oc 38oc V. High 850C 700C --------55oc ----115oc 48oc

3.4STATOR WATER SYSTEM 3.4.1 STATOR WATER COOLER i) ii) iii) iv) v) No. of coolers/system & type Max permissible operating pr.(Primary shell) Max permissible operating pr.(cooling tube) Primary water inlet/outlet temp Primary water flow Two, shell & tube type 8.0 ksc 5.0 ksc 72.6/45oc 27 m3/hr

vi) vii) viii) ix) x) xi) xii)

Cooling water flow Pressure drop in primary water Pressure drop in cooling water Max. cooling water inlet temperature Heat load Heat transfer area Nominal gauge pressure at inlet of winding

110 m3/hr 6.5 mmwc 0.8 mmwc 36oc 790 KW 33 m3 3.3 ksc (g)

3.4.2 STATOR WATER PUMP i) ii) iii) iv) v) vi) No. & make Flow Head Speed Motor Ambient temperature 2x100% single stage centrifugal with spiral casing & overhung impeller CPK CM50-200, KSB make 39.6 m3/hr 45 mtr 2930 rpm GEC make, 9.3 KW/12.5 hp, 415V, 3-, 50Hz, 18A Insl. Cl.B, 2930 rpm 50oc STATOR WATER MAKE UP PUMP i) ii) iii) iv) No. & make Flow Head Motor 2 per unit, KBL make 1.39 L/s 50 m 415V, 3- , 50Hz, 2.62KW, 2850 rpm, 7A, Insulation class E 3.4.3 STATOR WATER FILTER i) ii) iii) iv) v) Make & type No./unit Ratio Discharge Working pressure Max. size of filter that can be filtered: BHEL, Hardwar, Wiremesh Disc type, F-26 2 30 dm3/hr 6 Kg/cm2 0.224 mm

3.4.4 MAGNETIC FILTER i) ii) iii) iv) v) vi) vii) viii) No./unit Make Type Magnet type Working pressure Working temperature Capacity Type of particles filtered 2 Boll and Kirch Filter bar GmbH P.53.1-MA.220 500DN 100 YQ-36 Permanent Magnet 10 ksc 60oc 36 m3/hr Highly & medium magnetic

3.4.5 EXPANSION TANK i) ii) iii) iv) Type Material N2 pressure in the tank Wt. of the assembly Hermetically sealed cylindrical type Stainless steel 0.2 ksc (g) 825 Kg

3.4.6 QUALITY OF DISTILLATE i) ii) iii) iv) v) vi) vii) Conductivity PH Dissolved O2 Dissolved CO2 Dissolved Cu content Content of ammonia, hydrazine, phosphate & chlorine Iron content (Dissolved & undissolved) Less than 5 mho/cm preferably 1 mho/cm 7 to 8.5 Minimum preferably less than 50 ppb but not greater than 100 ppb Should be nil 25ppb to 200 ppb to avoid copper pick up Nil preferably nil, but not more than 20 ppb

3.4.7 SETTING VALUES OF STATOR WATER SYSTEM 1 2. 3. 4. 5. 6. 7. 8. Expansion tank level Pressure in the expansion tank Changeover from working pump to stand by pump due to pressure fall Pressure drop across water filter at which cleaning is recommended Distillate flow in stator winding Distillate conductivity Distillate outlet temperature Distillate inlet temp. to winding Low 0.4 ksc 4.5 ksc (g) 0.4 ksc (g) Low Emergency High V. High High High V. High 21 m3/hr 13 m3/hr 13.3 mho/cm 20 mho/cm 85oc 46oc 48oc 800 mm

3.5 SEAL OIL SYSTEM i) ii) iii) iv) v) Type of shaft seals H2 Pressure at generator casing Seal oil-H2 diff. Pressure Quantity of seal oil per seal Quantity of seal oil towards Air side Hydrogen side Single flow ring type 3.5 0.2 ksc min 1.0, normal 1.5, max 1.7 ksc 38.5 l/min
rd rd

3.5.1 SEAL OIL COOLER i) ii) iii) iv) v) Make No.of cooler/system: Type Heat transfer area Design pressure tube side/shell side Test pressure tube side/shell side BHEL, Hardwar 2x100 Surface type 14.3 m2 10.5 ksc 18 ksc

3.5.2 SEAL OIL PUMPS I) i) ii) iii) iv) v) vi) II) i) ii) iii) A.C. Seal Oil Pump Make & type No./Unit Pump discharge Pump speed Pump head Motor D.C. Seal Oil Pump Pump Pump/unit Motor Tushaco,Delta Corp.,Three screw positive displacement 2 200 lpm0 1450 rpm 12 ksc 415V, 3-, 50 Hz, 7.5 K W, 15.5A, 1450 rpm Insl. class B Same as A.C. pump 1 220V DC, 11KW, 1450 rpm, Insl. Class F, Shunt wound self-excited D.C. motor 3.5.3 VACUUM PUMP ii) iii) iv) v) Type Suction capacity Ultimate pressure Motor Single stage, rotary vane type (SB-4) 5.77 m3/hr < 1.06 mbar 415V, 3-, 50 Hz, 0.45 K W, 1500 rpm 3.5.4 OIL FILTER i) ii) iii) iv) Type Flow rate Mesh size Design pressure Wire & mesh type 12 m3/hr max. 0.10 mm max. 16 ksc max.

3.6 SPECIFICATIONS OF TRANSFORMERS 3.6.1 GENERATOR TRANSFORMER i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) Manufacturing BHEL, Bhopal No./Unit One Rating 240 MVA No load voltage HV/LV 230/15.75 KV Rated current HV/LV 602/45/8797.72 A Frequency 50 Hz No. of phase 3, type of connection - HV-Star, LV-Delta Type of cooling ONAN/ONAF/OFAF cooled Vector group Ynd1 Type of tap changer OFTC Off load tap changer range -5% to +5% in steps of 2.5% Impedance voltage at HV-LV 14% (normal tap) Temperature rises above an ambient temp. of 50oc Oil by thermometer 50oc Winding by resistance ONAV/ONAF 50oc OFAF 50oc 3.6.2 STATION TRANSFORMER i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) Manufacturer No. / unit Rated output Voltage ratio HV/LV1/LV2 Winding connection HV/ LV1/LV2 Line current HV/LV1/LV2 Type of tap changer & range Type of cooling Rating at different cooling BHEL, Bhopal 1 55 MVA Star 144.5/972.1/3015.8 A 50 Hz OLTC, +10% to 10% in steps of 1.25% on HV winding, total 16 steps ONAN/ONAF 60% 80% 100% ONAN ONAF ONAF

Temperature rise over ambient temp. 50oc in oil 40oc in winding 50oc Bushing HV Type oil immersed Min creepage distance(mm) 6125

LV air insulated 440

HV neutral oil immersed 900

xii)

Guaranteed positive sequence Impedance at 75oc with 100% Rating at principal tap

HV-LV1 16.5%

HV-LV2 16.5%

LV1-LV2 26.5%

3.6.3 UNIT AUXILIARY TRANSFORMER i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) Manufacturer Type of construction No. / unit Rating Voltage ratio Winding connection HV/LV Vector group Type of cooling Rated frequency Phase Rated current HV/LV Type of tap changer & range Temperature rise above ambient of 50oc in oil in winding Bushings TELK, Kerala Core type Two 16 MVA 15.75 / 6.9 KV Delta/Star DY11 ONAN 50 Hz 3 587/1340 A OLTC, +10% to 10% in steps of 1.25% on hv winding in 1 step 40oc 50oc HV oil filled LV oil filled LV neutral oil filled

xIv)

3.6.4 VARIOUS SERVICE TRANSFORMERS i) ii) iii) iv) v) vi) vii) viii) ix) x) No. Make Type Rated KVA Type of cooling Voltage ratio Vector group Winding connection HV/LV Percentage impedance Tap changer type & range Temperature rise over an ambient of 50oc in oil in winding 12 Voltas, Pune Dry type, cast resin, indoor type 2000 & 1600 AN 6600V/433 V Dyn 11 Delta / Star Gang operated off ckt. +5% to 5% in steps of 2.5% 50oc 55oc

3.7 H.T. MOTORS Sl. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Equipment ID fan FD fan PA fan Mill BFP CEP CW BCW RAW Ash slurry pump motor Ash recycling transfer water pump motor Conveyor 7A/7B Conveyor 5A/5B Conveyor 2A/2B Conveyor 1A/1B Conveyor TRH 1A/1B DE system 5&6 Conveyor 8A/8B Ring granulator Conveyor SR1 Quantity 4 4 6 6 6 4 6 6 6 12 3 2 2 2 2 2 2 2 4 2 Rating (KW) 1500 925 800 2250 4000 600 1470 275 304 185 700 520 400 330 300 200 180 165 825 300

3.8 BATTERY & BATTERY CHARGER 3.8.1 220 V DC BATTERY i) ii) Make Type Amoco Lead Acid, sealed type Unit 1-110, unit II-110, station-110, S.Y -110, CHP-110 2000 AH (Unit-I, II & Station), 350 AH (S.Y), 400 AH (CHP) 2V 1200 220 V FLOAT CUM BOOST BATTERY CHARGER i) ii) Manufacturer Service Chhabi Electricals Pvt Ltd & Caldyne Pvt Ltd (for CHP) Float & Boost charging

No. of cells Capacity Each cell voltage Specific gravity

iii) iv)

A.C. input D.C. output voltage

3-, 50 Hz, 415V 10% Plant S.Y. CHP Plant S.Y. CHP 3% 80% 240 V 80 A AN Inst 50oc Float 240 240 240 0-350 A 0-100 A 0-100 A Boost 158-297 158-297 158-297 0-280 A 0-49 A 0-40 A

Current

v) vi) vii) viii) ix) x) xi)

Ripple Efficiency at full load Voltage setting range Current setting range Cooling Response time Maximum ambient temperature

3.8.2 +24V DC BATTERY i) ii) iii) No. of cells Capacity Each cell voltage Unit I (main-13, standby-13) Unit II (main-13, standby-13) 1000 AH (U#1, 2 & CHP) 2V +24 V/1000 AH DC BATTERY CHARGER i) ii) iii) iv) v) vi) Manufacturer Type AC Input DC output DC voltage DC current Number Max.ambient temperature Chhabi Electric Float cum Boost 41510%, 3-, 50 Hz Float 281%V 600 A Two/unit 50oc

Boost 24 to 35V 1402%A

24V/600A FLOAT CHARGER i) ii) iii) Make Number Input Amar Raja Power Systems Ltd Two/unit 41510%, 3-, 50 Hz, 50 A

iv) v) vi)

D.C. output Capacity Max. ambient temp.

29.25 DC volt & 600 Amp 1455 AH 45oc

24V/175 A BOOST CHARGER CUM DC DB i) ii) iii) iv) v) vi) Make Input D.C. output Capacity Max. ambient temperature Number Amar Raja Power Systems Ltd 415V 10%, 3-, 50 Hz, 12.4 A 29.9 V DC & 175 A 1455 AH 45oc Two/unit

48V DC/70A FLOAT CUM BOOST CUM DCDB i) ii) iii) iv) v) Input DC output Capacity Max. ambient temperature Number 415V 10%, 3-, 50 Hz, 19A, 5A 48V DC, 58A 120 AH 500C One/unit

3.8.3 24V DC BATTERY i) ii) iii) i) ii) iii) iv) No. of cells Capacity Each cell voltage Manufacturer Type AC input DC output DC voltage DC current Unit I(main-13, standby-13), Unit II(main-13, standby-13) 200 AH (Unit # 1&2) 2V -24 V DC BATTERY CHARGER Chhabi Electric Float cum Boost charger 415V 10%, 3-, 50 Hz Float Boost 28.12% 24 to 35 0-110A 282%A 50oc 3% 3.8.4 UPS SYSTEM i) ii) No. / Unit Rated output One 2 x 60 KVA, 240V AC, 1-, 50 Hz

v) vi)

Max.ambient temperature Ripple

iii) iv) v) vi) vii) viii) ix) x) xi) xii)

Input Output Power walk in Nominal DC bus voltage Capacity Discharge battery voltage No. of cells Each cell voltage Battery float voltage/cell Ripple

415V 10%, 3-, 4 wire, 506% Hz, 110A nominal 240 1%V AC, 1-, 2 wire, 50 Hz, 250A 10 to 15 seconds 405 V DC 450 AH 315 V DC 180 cells 2 V/cell 2.25 V/cell 3% (max. rms)

GENERATOR RELAY PANEL Sr No Protection 1. 2. 3. 4. Generator differential protection Generator negative phase sequence protection Generator loss of excitation protection Generator pole slipping protection Generator back up impedance protection Generator stator interturn fault protection Generator stator E / F protection Generator stator stand by E / F protection Generator rotor E / F protection Designation Operating Time 87G 46G 40G 98G Inst 4 sec. Inst 50 msec Remarks Generator winding insulation protection. Generator unbalanced current protection. Generator field failure protection. Protection against generator falling out of slip Back up protection against external faults Protection against insulation failure between two windings 1 sec IDMT 2 sec 0.5 sec Inst Main protection against generator windings.

5. 6. 7. 8. 9. 10.

21G 95G 64G1 64G2 Stg-II Alarm

1.5 sec

Generator stator water 30P conductivity high (20 mho)

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

Generator stator water flow low (13 m3/ hr) Generator low forward power protection Generator overload protection Generator U/F protection Generator O/F protection Generator O/V alarm

30P 37A & B 51G 81G 81G 59G

50 sec 2 sec 20 sec 10 sec 10 sec Protection for generator before motoring takes place

GENERATOR TRANSFORMER Sr No Protection 1. 2. 3. 4. 5. 6. 7. GT overall differential protection GT bay C.B. LBB protection GT over fluxing Protection GT bucholtz trip TBC LBB Protection GT winding temp. high trip GT oil temp high high trip Designation Operating Time 87GT 50Z 99GT 63GT 50L Inst 0.2 sec. Inst. Inst. 0.2 sec Inst Inst Protection for insulation winding failure. Protection for oil degradation Protection against internal fault. Remarks Winding insulation protection

UAT Sr No Protection Designation Operating Time 87UAT Inst Remarks

1.

UAT differential protection

Protection against winding insulation failure

2. 3.

UAT over current protection UAT bucholtz trip

51 UAT 63 UAT

Inst Inst Protection against internal fault

SECTION 4 CONTROL & INSTRUMENTATION

4.1 UNIT C & I SYSTEM SG (FSSS) TG (ATRS) Measurements Automation DAS Make Supplier :-Procontrol P13/42(ABB) :-Iskamatic A & B(KWU, Germany) :-MOD 300 :-MOD 300 :-ABB :-ABB

MOD-300 constitutes of: i)Open Loop control system ii)Close Loop Control system iii)Information system iv)Sequence of Event Recorder stand alone OLCS/CLCS System Configuration No. of groups (OLCS) No. of groups (CLCS) No. of function groups(OLCS) No. of function group(CLCS) No. of OLCS cubicles No. of CLCS cubicles No. of control loops Processor for OLCS Processor for CLCS System Redundancy 4 5 12 16 19 12 31 32-bit, Motorola 68020 micro processor MC 68000 R8 (8 MHZ), Address Bus =24 Data bus =16 100% Parallel operation available through CRT Key board and P.B. on the panel. Redundant power supply of 240V Ac through UPS for DAS, operator station, engineer station, history station for OLCS & CLCS.

INFORMATION SYSTEM No. of memory nests Memory capacity hard disk No. of control operating station No. of monitoring st.(PS-U) No. of CRT & Keybord(on desk) 2 (consists of mass memory & redundant mass memory) 2 GB 2 per Unit 3 per Unit 4 CRT & 4 Key board.

IS. Configuration monitoring functions. Analog Inputs 384 (CLCS only)+903 (DAS) (1100 remote inputs) Digital Inputs 5100 (DAS) + 2120 (OLCS) 40 remote inputs+287 common inputs STANDARD DISPLAYS Alarm display Curve display Bar display Op. area display Graphic display Function group op. display 01 20 34 10 87 29

SEQUENCE OF EVENT RECORDER Make Model No. of active points Input per card Resolution Alarm debounce time Contact integration voltage Acceptability of NO/NC contract Archiving facility SER Terminal M/S Highland, Rochestor Instrument, Scotland. DEP 90 302 16 (16 input circuits) 1 MS Responds to inputs greater than 40 ms duration. 48 V ungrounded. Yes WYSE make PC H-31 green WYSE, model WY-30+

INTERFACE WITH FSSS/ATRS THROUGH RELAY PANEL (Only Binary communication) Model Make Supplier Software language No. of stations No. of processors Type of processor Procontrol P13/42 BBC BHEL, EDN, Bangalore Procontrol10 19 20 70 PR 03(Dedicated type) Program memory 4096 bytes, (EPPDMS)

System Configuration 1. No. of Intra-planel bus 2. No. of stations/IPB 3. No. of stations/entire system 4.Modules per local bus Data Communication Local Bus Service address 2 is every 10 m sec. i) Useful Address Max. 256 ii)Time Cycle (Set) 20ms iii)Information bit rate 204.8 KBAVD iv)Type of modulation Pulse modulation v)Amplitude 10V low active vi)Data security Parity bit, clock monitoring, data valancy on local bus, address cycle, watchdog timer. vii)Distance bt. IPB & IB 3m (max.) Intra-Panel Bus(IPB) i)No. of address ii)Time required/one telegram iii)Information bit rate iv)Signal code v)Amplitude vi)Data security 256 x No. of stations,16384 max. 60 s 266.7 KBAUD DPDM + 15 v Parity bit, counting of binary characters, monitoring of time & amplitude per bit. 2 (max. 10) Hot redundant fuses for each IPB IPB1=15, IPB2=19 19 Maximum 64

vii)Transmission means Inputs/Outputs

Coaxial cable RG 213U of 50 characteristic.

4-20 mA ,100 I/P resistance 10V to +10V, 100 K Analog O/P 4-20mA,500 , max. permissible load 10 to + 10 V, 4mA Binary I/P For 0 signal 30V to +30 V. For1 signal 11.2V to 30V. Binary O/P For 0 signal 0 to + 1V. For 1 signal 11.7V to 30V. All modules are protected against short circuit and over load. Analog I/P Contact Inputs Voltage between terminals with open contract 48 V DC Contact current for closed contact 5 mA Procontrol system is powered by 24V/1000A redundant charger with battery backup. Interface with ATRS/MOD 300 through relay cabinet mounted inside FSSS cabinet (Only binary communication)

ELECTRONIC AUTOMATION SYSTEM FOR STEAM TURBINE (EAST) Manufacturer East package comprises ISKAMATIC-A 1.Turbine stress Evaluator 2.Flectro hydraulic governing control 3.L.P. Bypass, seal/leak steam control 4.Vibration & position monitoring 5.Analog signal conditioning 6.Turbine protections 7.Auto synchronizer 8.Load shedding Relay. BHEL, Bangalore ISKAMATIC A & B ISKAMATIC-B 1.Logic subgroup control 2.Limit valve monitoring (Linear, nonlinear, variables) 3.Drive control modules (valves, pumps/solenoids) 4.Relay cabinets

COMMON FEATURES 1.Separate ref. voltages for analog (HQ) / Binary (M) signal conditioning. 2.Only one connection exists between M & HQ, at the cabinet power supply bus. 3.Decoupling of signal conditioning paths. 4.Selectivee fusing & use of ICs Each package is powered by +24/-24 V redundant battery charger (chhabi make) with battery back-up with load current 231/100A with 1% ripple. FSSS, MOD 300 & East are powered by their own dedicated power sources. Signal communication in between FSSS/MOD 300/East is done through coupling relay cabinet CRA01 02 with complete isolation. UNINTERRUPTED POWER SUPPLY i)Make ii)Capacity(KVA) iii)Voltage rating iv)Frequency v)Battery Rating Make Type Capacity No. of cells Each cell voltage Tata libert 60 240 V AC + 1% output. 50 HZ 405V DC (common for both UPS) Exide Gauntlet tubular 450 AH 180 2.25 V (Float) 2.00V (Nominal) LAN & IT Network Connectivity Local Area Network based on Fast Ethernet Fiber-Optic Switched Backbone and Structured Cabling System. 36 users. Network cabling is done for 66 nodal points. Remote Users 5. Coal handling Plant, MGR Systems, water Treatment Plant, Switchyard and Workshop. Facility exists for 16 remote users. Compaq Prolient 3000, PIII 500MHZ, 512MB ECC SDRAM (upgradeable up to 2GB, 512KB L2 Cache, 3X9.1 GB Hot Swap SCASI HDD, 10/100 TX PCI UTP Controller. Compaq Prolient 1600, PIII 500MHZ, 128MB ECC SD RAM, 512 L2 Cache, 9.1GB SCSI HDD, 10/100 TX PCI UTP Controller.

Main Application Server

Exchange Server

Network Management Station LAN Node PCs: Main Chassis Based Switch Workgroup Switch: Remote Access Server For Dial up facility: Modem for Remote Access: FO Connection: (Main Switch to Workgroup switch) UTP Connection: (Workgroup Switch to Nodes) Network Management Software: Main Sever System Operating System Database Application Software Logistic Modules

1 No Compaq Deskpro EP PIII 450MHZ, 64MB SD RAM 8.4GBHDD 41 Nos Datamini PIII 450MHZ, 64MB SD RAM 8.4GB HDD 1 No Cabletron Smart Switch 6000 with 16X10/100Base Tx Ports, 6X100 Base Fx Ports 5Nos Cabletron Smart Stack 100 with 22x10/100 BaseTx full Duplex auto negotiating ports + 2X100 Base Fx Ports. CISCO 2500, 1X10Base T + 16 Async. Sl. Ports 33.6Kbps Dial-up/Leased Line Modem 6 core Multimode Fiber Optic

E CAT5 UTP Cable.

Cabletron NMS Software

Win NT4, MS SQL Server 7.0 RAMCO e-Application 3.1 Inventory Module Purchase Module Maintenance Module AP Module

Exchange Server System Operating System Mail System Antivirus Software Internet Access

Windows 2000 Exchange Server 5.5 Norton Antivirus for Server & PC 64Kbps VSAT connection from HSCL

VSAT Router Proxy Server IB TPS DOMAIN

CISCO 2600 PIII PC with Linux System www.opgc.co.in

4.2 INTERLOCK PROTECTION 4.2.1 BOILER AND AUX. FURNACE SAFEGUARD SUPERVISORY SYSTEM 1. Purge Permissive a) All system power supply (AC & DC) ON b) At least one ID and one FD in service. c) A min. of 30% of full load air (>268 T/hr) d) A proper water level in drum e) LOTV closed f) HOTV closed g) All LONV closed h) All HONV closed i) No boiler trip condition permit j) All scanner no flame k) All mills off l) All PA fans off m) All O/L gates closed 2. a. b. c. Purge Sequence Purge ready (all purge permissives are satisfied) Purging (5 minute cycle) Purge complete Alarm +100 - 100 +100 -100 Trip + 250mmwc - 250mmwc +300mmwc -300mmwc

3. First Cause Trip (Master Fuel Trip) a. Both ID fan off b. Both FD fan off c. Furnace pressure V. High d. Furnace pressure V. Low (2/3 logic) e. Drum level V. High (for more than 10 sec.) f. Drum level V. Hi (for more than 10 sec.) g. Emergency trip h. Loss of 220V DC for more than 2 sec. I. Air flow less than 30% j. Reheat protection trip* k. Less than fireball and loss of A.C. power at any elevation in service** l. Loss of all fuel trip***

m. Flame failure trip**** n. Loss of unit critical power +24V DC * Reheater Protection Trip 1. Generator breaker open or turbine tripped OR Boiler working and turbine not working. Any HP or LP bypass valve is closed The reheater protections armed with time delay of 5 sec. OR 2. HP bypass 1 or 2 or LP bypass 1 or 2 less than 2% open and turbine working and load shedding relay operated with 11 sec. off delay than reheat protection is armed with time delay of 10 sec. Turbine trip is armed if, All ESV and 4 IV open and first stage pressure more than 35 bar and any ESV or IV closes or turbine trip Turbine working is armed if, All ESV and IV open and first stage pressure is greater than 35 bar. Boiler working is armed if, a. Main steam pressure left is more than 50 bar and main steam temp left is more than 513 0C and b. Main steam pressure right is more than 50 bar and main steam temp right is more than 513 0C and c. Boiler fire ON, provided HP bypass valve 1 & 2, and LP bypass valve 1 & 2 opened more than 2% once. ** Less Than Fire Ball And Loss Of AC Power At Any Elevation In Service. Any elevation started and there is a loss of AC power at any elevation in service for more than 2 sec. *** Loss Of All Fuel Trip a. Loss of fuel trip arming (i.e. elevation AB or CD or EF any nozzle valve open and no MFR trip) and b. All coal outlet gates closed and c. LOTV does not open, or elevation AB all LONV closed and d. HOTV not does open, or elevation AB, CD, & EF back up trip. **** Flame Failure Trip Elevation A, B, C, D, E, & F voted and unit flame failure trip armed (i.e. any mill outlet gate proven for more than 3 sec.)

Elevation A voted: a. Elevation A coal O/L gates do not open >2 sec. b. Elevation AB started & loss of AC power > 2 sec. c. Elevation AB 2/4 nozzle valves are not proven open and elevation AB scanner show no flame. Elevation B voted; a. Elevation B coal O/L gates do not open > 2 sec. b. Elevation AB started & loss of AC power > 2 sec. c. Elevation AB 2/4 nozzle valves are not proven open, and d. Elevation AB scanners show no flame, and elevation BC scanners show no flame. Elevation C voted: a. Elevation C coal O/L gates not open > 2 sec. b. Elevation CD started & loss of AC power >2 sec. c. Elevation CD 2/4 nozzle valves are not proven open and elevation CD scanners show no flame and elevation BC scanners show no flame. Elevation D voted: a. Elevation D coal O/L gates not open >2 sec. b. Elevation CD started & loss of AC power > 2 sec. c. Elevation CD 2/4 nozzle valves are not proven open and elevation CD scanners show no flame and elevation DE scanner show no flame. Elevation E voted: a. Elevation E coal O/L gates not open > 2 sec. b. Elevation EF started & loss of AC power > 2 sec. c. Elevation EF 2/4 nozzle valves are not proven open and elevation EF Scanner show no flame and elevation DE scanner show no flame. Elevation F voted: a. Elevation F coal O/L gates not open > 2 sec. b. Elevation EF started and loss of AC power > 2 sec. c. Elevation EF 2/4 nozzle valves are not proven open and elevation EF scanner show no flame.

PULVERISER 1. PERMISSIVE a. Purge air dampers closed. b. Electromagnetic brake is released.

c. d. e. f. g. h. i. j. k. l.

Girth gear seal air fan motor on. Mill lubrication is OK. Mill starting sequence step-1 completed. Any seal air fan on & mill/seal air Pressure DP OK. Aux. Motor off (Initially aux. Motor is on, it stops when main motor starts) No MFT. Mill side-1 or side-2 START order. Mill ignition energy available. PA fan ON. PAD & BAD dampers closed.

PROTECTION a. Ignition energy not available b. MFT relay operated c. Centrifugal switch d. PA fan OFF e. E.M. Brake engaged f. Aux. Motor ON g. Bearing temp very HI (650C) h. Seal air pressure NOT OK i. P.A. pressure Very low j. Mill lubrication NOT OK k. Mill main motor trip l. Seal air Fan A & Fan B trip m. Emergency trip from Mill FSSS/Local trip 2.Mill Lubrication Mill lubrication OK When all the following conditions are present: a. Mill bearing lubrication OK. b. Mill reducer lubrication OK. c. Girth gear greasing sequence OK. Mill lubrication NOT OK a. Mill bearing lubrication not OK > 2 se b. Mill reducer lubrication not OK for > 10 sec. c. Girth gear greasing sequence not OK for > 15 min. Mill bearing lubrication Mill bearing lubrication OK is generated if all the conditions present i) Any LP pump is in operation. ii) Lube oil flow in LP circuit OK. iii) Any HP pump in operation and pressure at HP pump discharge OK (>20 Ksc) Mill bearing lubrication NOT OK is generated if any of the above conditions is not present.

Mill reducer lubrication Mill reducer lubrication OK is generated if, i) Reducer lube oil pump ON ii) Reducer oil flow is OK iii) Reducer oil temp is OK. Mill reducer lubrication NOT OK condition is generated if any one of the above is not present. Girth Gear Greasing System Girth gear greasing sequence OK is generated if all the following conditions are present. i) Grease pump motor ON ii) Time between two successive limit switch activations does not exceed two minutes. iii) Grease atomizing air pressure correct (>4Ksc) after 2 sec of energizing the solenoid valve. 3. Ignition Permit Coal Elevation A: i) nozzle valves proven in Elevation AB OR ii) Elevation B air flow > 24 T/hr AND boiler load > 30% MCR Coal Elevation B: i) nozzle valves proven in elevation AB or ii) Elevation A or C air flow > 24 T/hr AND boiler load > 30% MCR. Coal Elevation C: i) nozzle valves proven in AB AND elevation B air flow > 24 T/hr OR Elevation B or D air flow > 24 T/hr AND boiler load > 30% MCR. Coal Elevation D: i) Elevation C or E air flow > 24 T/hr AND boiler load > 30% MCR OR ii) nozzle valves proven in Elevation CD Coal Elevation E i) nozzle valves proven in elevation EF OR ii) nozzle valves in elevation CD is proven in service and elevation D air flow > 24 T/hr OR iii) Elevation D or F air flow > 24 T/hr AND boiler load >30% MCR. Coal Elevation F i) nozzle valves in elevation EF is proven in service OR ii) Elevation E air flow > 24 T/hr AND boiler load > 30% MCR. COAL FEEDER Start Permissive 1) Feeder switch in remote condition.

2) No MFR trip 3) Elevation DC power available 4) Mill elevation on. 5) Coal on belt. 6) Mill outlet temp OK. 7) No stop command for feeder. OIL GUN HEAVY OIL TRIP VALVE Open Permissive 1) No MFR trip. 2) HFO supply pressure adequate. 3) All HONV closed. 4) Atomizing steam pressure not low. 5) Heavy Oil Trip Valve not open. 6) No stop command for HOTV OR HORV open and all HONV closed. Close Protection 1) Loss of unit 24 DC 2) MFR trip 3) HFO header pressure low or atomizing steam pressure very low for more than 2 Sec. and HORV does not open.

LIGHT OIL TRIP VALVE Open Permissive 1) No MFR trip 2) LFO supply pressure adequate 3) All LOVT closed. 4) Atomizing air pressure not low 5) LOVT does not open and no stop command. Close Protection 1) Loss of unit 24 V DC power 2) MRF trip 3) Any LONV open and LFO pressure very low (2.1 Ksc) for more than 2 Sec OR any LONV open and atomizing air pressure very low (2.5 Ksc) for more than 2 Sec. and at the same elevation no start /stop command.

FUEL OIL SELECTION Either light oil or heavy oil can be fired at elevation AB when selected. Heavy oil can be fired at elevation CD & EF. But presently in ITPS, LFO is fired at all the elevations. I) ELEVATION MODE OPERATION Elevation mode operation is automatically selected when either of the adjacent coal elevations associated with warm up (L.O./H.O.) oil elevation is in service. II) PAIR MODE OPERATION Pair mode operation is selected when, All coal elevations are not in service OR Both coal elevations A & B are not in service and elevation AB back up trip exists. START SEQUENCE (Typical for AB 1&3 pair) 1) Start command given to pair 1 & 3 .The seventy second elevation start (for corner 1 & 3) counting period is rest. The elevation back up trip signal is removed, positioning the associated elevation dampers for warm up oil firing. 2) AB 1 steam/air atomizing valve open. 3) HEA igniter advance feed back available. 4) HEA spark command if HEA fully advance feed back available and HONV 1 open. 5) Spark for 15 Sec. 6) Scanners show flame, gun hold. 7) After 15 Sec. of AB 1 command to AB3 start. SCANNER AIR FAN

Interlock 1. AC scanner air fan trips, DC scanner air fan starts. 2. AC scanner air fan in service & scanner air duct to furnace DP is less than 150 mmwc, DC scanner fan starts. 4. Both FD fans off, emergency air damper opens. REGENERATIVE AIR PRE HEATER Permissive i) Any guide bearing LOP healthy or lub oil temp NOT HI ii) Any support bearing LOP healthy or lub oil temp NOT HI iii) All ESP I /L, O / L, Flue gas I / L & Secondary air O / L dampers open. iv) For air motor, air pressure before solenoid valve more than 5.0 kg / cm2

Interlock If electric motor trips and air pressure more than 5.0 kg / cm2, air motor starts.

ID FAN Permissive i) Fan & motor bearing temperature less than 800C ii) Hydro coupling bearing temperature less than 1100C iii) RAPH A/B ON iv) Hydro coupling oil cooler outlet temperature less than 700C v) Stack path available vi) ID fan inlet gate closed vii) ID fan outlet gate closed viii) Scoop tube control minimum ix) Hydro coupling DP across filter NOT HI x) Electrical switchgear OK Damper Interlock i) Fan starts, inlet & outlet dampers open ii) Fan stops/trips, inlet & outlet dampers close Protection i) ID fan bearing temperature more than 850C ii) ID fan ON & lube oil pressure very LOW (0.2 Ksc) iii) Hydro coupling working oil cooler outlet temperature very HI 900C iv) Hydro coupling scoop tube out let temperature very HI 1100C v) DP across filter very HI (0.6 Ksc) Permissive i) Lube oil pressure more than 0.9 kg/cm2 ii) Control oil pressure more than 9.0 kg/cm2 iii) Fan bearing temperature less than 80oc iv) ID fan A/B motor ON v) Blade pitch minimum vi) Discharge damper closed vii) Lube oil pump A/B ON viii) Electric switchgear OK FD FAN

Interlock i) Discharge damper interlock: a) Fan starts, discharge damper opens b) Fan motor OFF, discharge damper close

ii)

LOP interlock a) LOP B trip, LOP A starts & vice versa b) LOP B on & lube oil pressure less than 0.8 kg/cm2, LOP A starts with time delay of 5 seconds & vice versa c) LOP B fails to start when start command is given, LOP A starts with time delay of 5 sec. & vice versa

Protection i) Lube oil pressure less than 0.4 kg/cm2 ii) Bearing temperature fan very HI (850C) iii) Discharge damper closed with time delay of 60 sec. iv) Both ID fan off v) Electrical switchgear protection PA FAN Permissive i) Fan bearing temperature less than 800C ii) Lube oil pressure more than 0.8 kg/cm2 iii) Either FD fan on iv) Electrical switchgear O.K. v) Regulating vane (I.G.V) minimum Interlock i) Damper interlock: a) Fan starts PA General gate open b) Fan trips PA General gate closed ii) LOP interlock: a) LOP B trips, LOP A starts & vice versa b) LOP B on and lub oil pressure less than 0.6 kg/cm2, LOP A starts with time delay of 1 second & vice versa for LOP A c) LOP B fails to start when start command is given, LOP A starts with time delay of 2 seconds & vice versa. Protection i) Fan bearing temperature very HI (850C) ii) Lube oil pressure less than 0.4 kg/cm2 iii) Tripping of corresponding mill iv) MFR trip

4.2.2 TURBINE AND AUXILIARIES TURBINE PROTECTION Sl. 01. 02. 03. 04. 05. 06. 07. 08. 09. 10. 11. 12. 13. 14. 15. 16. Description Drum level v. high M.F.T. channel Generator protection channel Lube oil pressure very LOW, ksc Condenser vacuum LOW, ksc Low vacuum mech. Trip, ksc Fire protection channel M.O.T. level low Main steam temperature low Axial shift Local trip Emergency push button trip from unit control board Over speed trip Fire protection 1 operated Fire protection 2 operated M.O.T. level low Alarm value Trip value +125 +225 ----------1.20 0.80 0.70 0.80 0.76 kg/cm2 -50 -100 mm -50 -100 mm (Zero level 800 mm down from top of M.O.T.) 5000C 4800C ------------Remarks

2/3 logic arming at 0.80

arming at 5100C

--3330 rpm Turbine trip gear operated & vacuum breaker opens Turbine trip gear operated, Vacuum breaker opens AOP1, AOP2, AC JOP OFF & DC EOP, DC JOP ON with SLC ON. Gate gearing valve closed. Same as fire protection 2 & Thrust bearing trip device operated. TURBINE OIL PUMP

i) ii) iii) iv)

AOP1 starts on Auto AOP2 starts on Auto EOP starts on Auto JOP1 starts on Auto JOP1 stops on Auto

: : : : : :

SLC AOP1 is on and AOP2 trips, or lube oil pressure less than 4.50 kg/cm2 SLC AOP-2 is ON & AOP1 trip or lube oil pressure is less than 4.50 kg/cm2 Lub oil pressure less than 1.20 kg/cm2 SLC of JOP on & turbine speed less than 510 rpm. Turbine speed > 540 rpm SLC JOP on & JOP1 trip OR Jacking oil pr. < 100 kg/cm2 & turbine speed < 510 rpm

v)

JOP2 starts on Auto

TURNING GEAR i) ii) Turning gear valve open on auto Turning gear valve closes on auto SLC of turning gear is on and turbine speed < 210 rpm. Turbine speed more than 247, OR Both AOP1 & AOP2 OFF, OR Fire protection 2 operated, OR MOT Level Low protection operated, OR Lub oil pressure after duplex filter LOW.

BOILER FEED PUMP Permissive i) Suction/Discharge temperature not HI (120C) ii) Lube oil pressure O.K. (2.0Ksc) iii) Recirculation valve open iv) DP across oil filter not HI v) Electrical switchgear OK vi) AOP ON vii) Discharge valve Closed for standby pump. viii) Suction valve open ix) Scoop tube control minimum x) Working oil temperature not HI < 85oc xi) Deaerator level normal xii) Bearing temperature < 85oc xiii) Hydraulic coupling bearing temperature less than 85oc (for bearing No.1&2) Interlocks i) BFP motor ON, motor cooling water valve opens ii) BFP motor ON, Discharge valve opens iii) AOP cut in oil pressure 1.5 kg/cm2 AOP cut out oil pressure 2.9 kg/cm2 Protection i) Lube oil pressure less than 1.0 kg/cm2 ii) Deaerator level very LOW iii) Working oil temp at cooler inlet more than 1300C iv) Working oil temp at cooler outlet more than 850C v) Lube oil temp after cooler 600C vi) Thrust Bearing temperature more than 950C

vii) viii) ix) x) xi)

Suction/Discharge differential temp very HI (150C) Hydraulic coupling bearing temperature > 950C & for bearing 3&4 temp > 900C Suction valve open and BFP booster pump suction pressure less than 10 kg/cm2 DP across filter very HI (0.6 kg/cm2) Recirculation control valve is open & feed water flow < 110 T/hr CONDENSATE EXTRACTION PUMP

Permissive i) Suction valve open ii) Hot well level normal iv) Hot well recirculation valve open v) Discharge valve close & the equalizing valve open vi) Electrical switchgear O.K.

Interlock i) 1st CEP motor ON, discharge valves of both the pumps open. Protection i) Hot well level very low (-1250 mm) ii) Pump bearing temp very HI (850C) iii) CEP discharge header pressure very low, standby pump auto starts on SLC. HP/LP BYPASS SYSTEM HP Bypass system i) HP bypass oil pump cut in at 100 kg/cm2 oil pump cut out at header pressure 160 kg/cm2 ii) iii) iv) HPBP valves can be open if condenser vacuum > 0.67 kg/cm2 AND priority closure at condenser vacuum < 0.67 kg/cm2 HPBP downstream temperature exceeds 3760C-HPBP valves closes. HPBP valve position less than 2% auto closure of HPBP.

LP Bypass System Permissive i) Condenser vacuum more than 0.67 kg/cm2 ii) Condensate header pressure more than 18.5 kg/cm2 iii) Steam pressure upstream of LP bypass valve more than 21.2 kg/cm2 Protection i) Condenser vacuum less than 0.67 kg/cm2 ii) Condensate header pressure less than 18.5 kg/cm2 iii) Condensate wall temp. at exhaust hood > 90oc (LP injection valve opens) iv) LP bypass upstream steam pressure less than 21.2 ksc

Interlock i) Booster pump motor can be started if main centrifuge motor ON ii) iii) iv) v) vi) vii) viii) Centrifuge motor trip, solenoid valve in oil suction line de-energise. Solenoid valve opens when centrifuge motor ON Centrifuge motor overload or booster pump motor overload, both motors trip and heater II & III cut off, heater I remains ON. Broken liquid seal, centrifuge, booster pump, heater II & III trip, heater I remains ON. Polishing filter choke, centrifuge, booster pump, heater II & III trip, heater I remains ON. Centrifuge motor ON, heater II & III can be made ON Oil temperature more than 60oc, heater III cut off. Oil temperature more than 70oc, all heater cut off. Water temperature more than 90oc all heaters cut off Water level low all heaters cut off. REGENERATIVE HEATER SYSTEM Low Pressure Heater-1 i) Very high drip level Cascade drain control valve DR 21 closes & heater is bypassed from condensate side by opening CD25 & closing CD26 & CD27. Extraction block valve closes. Extraction block valve Ex 10 closes Extraction drain valve Ex.101 & Ex. 102 opens Normal cascade drain control valve DR16 closes Extraction line NRV closes Alternate drain control valve DR 24 opens. Extraction block valve Ex.11 closes Extraction drain valve Ex.103 opens Extraction NRV closes Alternate drain control valve DR19 opens

MAIN OIL CENTRIFUGE

Low Pressure Heater-2 i) Very high drip level 300 mm above normalwater level) Low Pressure Heater-3 i) Very high drip level (300 mm above normal water level) -

Deaerator Deaerator pressure control: a) Cold start up b) Hot and warm start up & bypass operation-

2.5 ata by auxiliary steam. 3.5 ata by auxiliary steam.

c) Turbine load more than More than 3.5 ata to 6.6 ata by FY 15 valve 55% when extraction steam pressure exceeds pegging steam pressure High Pressure Heater-5 (HPH) i) Very high heater level (335 mm above LWL)ii) Pressure falls below a preset value Extraction block valve Ex.13 closes. Extraction NRV closes Extraction drain valve Ex.112 opens Repeat command to full open alternate drain control valve DR14 & normal drain control valve DR11 Heater bypassed from feed water side by opening bypass valve FD9 and closing FD7 & FD8. Normal drain control valve of HPH-6, DR2 closes. Overriding command to close DR2

High Pressure Heater-6 i) Very high heater level (345 mm above NWL) -

Extraction steam block valve EX12 & NRV closes. Extraction drain valve Ex.110 opens Alternate drain valve DR39 and normal drain valve DR2 opens fully. Heater bypassed from feed water side by opening bypass valve FD12 & closing FD10 & FD11. Repeat command to open alternate drain valve DR39 and normal drain valve DR2 / DR6.

STATOR WATER PUMP Permissive i) Expansion tank level more than 410 mm Interlock i) Header pressure less than 4.5 ksc standby pump starts. Protection i) Expansion tank level low, less than 350 mm.

Interlock i) Seal oil header pressure less than 4.1 kg/cm2, D.C. SOP starts. AIR CONDITIONING PLANT AC COMPRESSOR

SEAL OIL SYSTEM

Permissive i) BCW flow adequate. ii) Chilled water pump in service. iii) AHU in service. iv) Oil reset switch activated. Protection i) BCW flow LOW. ii) Suction gas pressure LOW < 35 psi iii) Discharge gas pressure HI < 260 psi iv) DP between oil & gas suction pressure < 0.9 bar v) Chilled water flow LOW. vi) Anti freezing protection (<30C)

SECTION 5 OFFSITE AUXILIARIES

5.1 RAW WATER SYSTEM i) ii) Raw Water source Intake channel Length Bed width Width at top Bed level Hirakud reservoir through intake channel 5450 m 3.5 m 7.0 m 174.5 m RL at down stream end RAW WATER PUMP i) ii) iii) iv) v) vi) vii) viii) ix) Manufacturer Type No. of pumps No. of stages Capacity Head Speed Discharge size Motor Make Rating Kirloskar Brothers, Pune BHR 50-22 ISTG (vertical) 6 for both units (4 working, 2 stand by) One 1400 m3/hr 60.35 m 1485 rpm 450 mm KEC 304 KW, 6.6 KV, 3-, 50 Hz, Insulation Class F

5.2 CIRCULATING WATER SYSTEM 5.2.1 i) ii) iii) iv) v) vi) viii) Manufacturer No. of pumps Type Outlet size Min. fore bay water level Max. fore bay water level Duty Condition: Capacity Total head at pump discharge Total head loss from suction ball to discharge flange Rated speed Pump efficiency at design capacity Pump input design capacity C.W. PUMP KBL 6 for both units (4 working, 2 stand by) BHQ 92 (vertical) 1200 193.5 m 195.5 m 15000 m3/hr 27.5 m 0.11 mwc 494 rpm 89.1% 1268.8 KW

ix)

Bowl head Motor Make Rating Discharge valve

27.61 m BHEL 1470 KW, 6.6 KV, 3-, 50 Hz, continuous duty Insulation Class F, 166.8 A Butterfly tight, shut off type, 1600 mm NB 5.2.2 COOLING TOWER

x)

i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv) xv) xvi)

Type No. of cells/unit Model Height excluding diffuser Width Length Total no. of towers Cooling water flow Hot water inlet temperature Range of cooling Re-cooled water temperature Ambient wet bulb temperature Drift loss % Evaporation loss % Blow down for 2% conc. Blow down for 4% conc.

Induced draft type 11 (10 working, 1 stand by) 1514-11 (RCC fill) 10.345 m 25.21 m 154.25 m 2 (1 for each unit) 9166.67 LPS 420C 100C 320C 26.20C 0.05 1.676 1.63 0.509 Axial flow propeller type 39oc 31978 m3/min. 4 per cell 500 Nb 48 KW, 415V, 3-, 50 Hz, Insulation Class F 2 nos 112.5 kg/hr V notch vacuum feed

Fans i) Type ii) Design exit air temperature iii) Air flow rate / cell Flow Control Valves i) No. ii) size iii) Drive Chlorinators i) No. ii) Capacity iii) Type

Chlorinator Booster Pump i) No. ii) Capacity iii) Head

2 nos 9 m3/hr 50 mwc

5.3 BEARING COOLING WATER SYSTEM 5.3.1 BCW PUMP i) ii) iii) iv) v) vi) vii) viii) ix) Make No. Type Rated capacity Total dynamic head Size Pump input Speed Motor Details: Duty Rating KBL 6 for both units (4 working, 2 standby) BHR 42-30 (2 stage) 930 m3/hr 80.2 mwc 350 mm 238.492 KW 1450 rpm Continuous 6.6 KV, 3-, 50Hz, 275 KW, 29.5 A, 1486 rpm, Insulation Class F.

BCW Supply i) Plant DG set ii) A/C for switchyard iii) BCW overhead tanks iv) Compressor house v) H2 cooler of the generator vi) Stator cooler of the generator BCW supply to Headers (for each unit) i) ii) iii) Boiler BCW Header Turbine BCW Header Air conditioning plant (common for both units)

Size 250 NB 500 NB 250 NB

Flow (m3/hr) 294 1070 330

BCW Sump i) Capacity ii) Size iii) Bottom level BCW Overhead Tank i) Nos ii) Type iii) Capacity iv) Size

1500 m3 24.0 m x 15.0 m 4.0 m 195.00 mtr RL 1 for each unit Rectangular 210 m 17.0 m x 4.5 m x 3.25 m

5.3.2 PLATE HEAT EXCHANGER i) ii) iii) iv) v) vi) Fluid circulated Total fluid entering, m3/hr Inlet temperature, 0C Outlet temperature, 0C No. of pass Heat exchanged Primary side Filtered water 950 40 34 One --Secondary side Raw water 814 32 39 One 5650240 Kcal/hr

5.4 SERVICE WATER SYSTEM Service Water Pump i) No. ii) Type iii) Capacity iv) Total head v) Motor detail Service Water Overhead Tank i) No. ii) Type iii) Capacity iv) Size Three (1 working, 2 standby) Single stage horizontal centrifugal pump 60 m3/hr 90 m 415V, 3-, 50Hz, 30 KW, 52A, 2955 rpm, Insulation Class F. 1 for each unit Rectangular, vertical 75 m3 10.0 m x 3.5 m x 3.0 m

5.5 WATER TREATMENT PLANT 5.5.1 PRE-TREATMENT PLANT RAW WATER QUALITY i) PH value ii) TDS, mg/l iii) Permanganate value iv) Iron as Fe, mg/l v) P. Alkalinity as CaCo3 vi) M. Alkalinity as CaCo3 7.5-8.5 200 02 ppm 1.5 Nil 90.0

TREATED WATER QUALITY Constituent i) Calcium (ca) ii) Magnesium iii) Sodium & Potassium (mg) vi) Sulphate (So4) v) Chloride (Cl) Total Anions vi) Iron vii) Free carbon dioxide viii)Silica ix) pH value x) Turbidity NTU xi) Organic matter, ppm xii) Manganese content, ppm FLASH MIXER i) No of units ii) Material of construction iii) Size iv) Rated flow to each unit v) Agitator CLARIFLOCCULATOR i) No of units ii) Material of construction iii) Rated flow of each ccf iv) Overall size v) Detention time (for rated flow) Flocculator zone Clarification zone FILTER BEDS i) No of units ii) Material of construction iii) Capacity (each) iv) Size v) Rate of filtration FILTER BACK WASH i) Duration of air scouring ii) No of air blowers iii) Capacity

As CaCo3 CaCo3 CaCo3 CaCo3 CaCo3 CaCo3 Fe CO2 SiO2 -------------

Analysis 90 ppm 40 ppm 40 ppm 60 ppm 15 ppm 172 ppm 0.2 ppm Not traceable 9 ppm (colloidal) 6 ppm (reactive) 7.5 to 8.5 Not to exceed 10 Traces Not traceable

2 (one for each clariflocculator) RCC 2.5 m2X 4.1 mswd 1200 m3/hr One, 7.5 HP, 1500 rpm 2 RCC 1200 m3/hr 31 m2 X 2.7 mswd 30 min 158 min (approx) 5 RCC 500 m3/hr 7.2 m X 4.375 m 500 m3/hr 3 to 5 min 2 (1 working + 1 stand by) 1350 m3/hr

iv) Backwashing No of pumps Make/ model Capacity (each) Motor CHLORINATION SYSTEM (PT) i) No of chlorinator ii) Make/ model ii) Capacity (each) iv) Booster Pumps No Capacity Motor

By backwash pump 3 (2 working + 1 stand by) Worthington, C18 TC 610 m3/hr 55 kw/ 4 pole 3 V-711 10 kg/hr 2 9 m3/hr at 50 mwc 5.5 Kw

5.5 .2 D. M. PLANT EFFLUENT QUALITY a) Activated carbon filter outlet Free chlorine & iron Turbidity b) Cation exchanger outlet Sodium as Na c) Degasser outlet Free carbon dioxide as CO2 d) Anion outlet Silica as SiO2 (reactive) Chloride Conductivity at 250C Organics e) Mixed bed outlet Total electrolyte Silica as SiO2 (reactive) Free CO2 as CO2 Iron as Fe Total hardness PH value Conductivity at 250C

Not detectable Not to exceed 0.5 NTU < 0.05 ppm < 5 ppm Not to exceed 0.1 mg/l BDL Not to exceed 2 micro mho/cm Nil Not to exceed 0.1 mg/l Not to exceed 0.02 mg/l Not detectable < 0.01 Not detectable 6.8 7.2 < 0.2 micro mho/cm

ACF & EXCHANGER DATA Activated carbon filter i)No. of units ii)Normal flow rate m3/hr iii)Max. flow rate m3/hr iv)Regeneration interval hours v)Net output between two regeneration, m3 vi)Filling media vii)Quantity of Operating Media (m3) Operating Inert 3 75 90 20 1500 Activated Strong acidic cation exchanger 3 75 90 20 1500 Strong basic anion exchanger 3 75 90 20 1500 Mixed bed exchanger 3 75 90 160 12000 A-27 (MP) & T-42, Thermax 1.27 & 1.27 --

T-42 Thermax A-27 (MP) Thermax

---

5.38 0.318

4.46 0.312

RELEVANT DATA FOR REGENERATION 1. a) b) c) d) e) f) 2. 3. Chemical Required for Regeneration 100% HCl, kg 30% HCl, kg 30% HCl, litres 100% NaOH, kg 45% NaOH, kg 45% NaOH, litres Acid dilution water flow rate, m3/hr Alkali dilution water flow, rate m3/hr Cation group 215.2 718 624 ---21.5 -Anion group ---156.1 347 240 -15.0 MB cation 88.9 296 257 ---6.0 -MB Anion ---88.9 198 136 -4.0

LIMITING VALUES OF BOILER WATER CHEMISTRY Sample pH CONDUCTIVIT Y In micro siemens DC ACC <50 <6 <6 <6 <6 <0.2 <0.3 <0.3 <0.3 <0.3 <0.2 SiO2 ppb <300 <20 <20 <20 <20 <20 PO4 ppm 1 to 6 N2H4 ppb TH ppm 0 0 0 0 0 0 ClAs NaCl ppm <2 BDL BDL BDL BDL BDL DO ppb NH3 Fe Cu

ppb ppb

Boiler Drum Sat. Steam Main Steam Condensate Feed Water DM-Make up

9.2-9.8 8.8-9.2 8.8-9.2 8.8-9.1 8.8-9.2 6.8-7.2

20

<20 <7

<0.5 <0.5

<10

<5

Silica limit for Drum is given at maximum operating drum pressure i.e.160 ksc. However at drum pressure <160 ksc, the silica in drum may be allowed >300 ppb. The exact relationship of silica to drum pressure can be referred from the Drum Pressure vs Silica graph.

DM WATER TRANFER PUMP i) ii) iii) iv) v) vi) No. & type Manufacturing Design capacity, m3/hr Total head Speed, rpm Motor 3, centrifugal Kirloskar 85 40 m 1475 22 KW, Crompton Greaves make

MISCELLANEOUS PUMPS Filter back wash pump i)No. ii)Make 3 Worthingto n iii)Type/ Vertical stages turbine/sing le iv)Operation continuous v)Discharge 20 mwc head vii)Shut off head viii)Drive motor 26.6 mwc 55 kw Degassed water pumps 5 Kirloskar Centrifugal/ single continuous 50 mwc Acid transfer pump 2 Antico Caustic transfer pump 2 Kirloskar Waste water disposal pump 4 -Blower Degas air Mixed bed blower air blower 4 Universal

2 Kay International Centrifugal/ Centrifugal/ Centrifugal/ Centrifugal/ Rotary/single single single single one intermittent 20 mwc intermittent 20 mwc intermittent 30 mwc -100 mm WG suction2200 m3/hr -2.2 kw -Suction480 m3/hr ---

50.3 mwc 30 kw

-3.7 kw

20.5 mwc 7.5 kw

30.4 mwc 11 kw

5.6 STANDARD LIMITS OF ENVIRONMENTAL EMISSION (CONSENT REQUIREMENT) STACK EMISSION Quantity of Flue Gas Suspended Particulate Matter 90104 Nm3/hr/unit <150 mg/Nm3

AMBIENT AIR QUALITY STANDARDS Pollutant 1 Sulphor Dioxide (SO2) Oxides of Nitrogen As NOX Time Weighted Average 2 Annual avg. 24 hours Annual avg 24 hours Concentration in Ambient Air Industrial Residential Area Area 3 4 80 g/m3 120 g/m3 80 g/m3 120 g/m 60 g/m3 80 g/m3 60 g/m3 80 g/m

Suspended Particulate Matter (SPM) Respirable Particulate Matter (Size less than 10 g/m3) (RPM) Lead (Pb) Carbon Monoxide (CO)

Annual avg. 24 hours Annual avg. 24 hours Annual avg. 24 hours 8 hours 1 hour

360 g/m3 500 g/m 120 g/m3 150 g/m3 1.0 g/m3 1.5 g/m3 5.0 mg/m3 10.0 mg/m3

140 g/m3 200 g/m 60 g/m3 100 g/m3 0.75 g/m3 1.0 g/m3 2.0 mg/m3 4.0 mg/m3

COMBINED INDUSTRIAL EFFLUENT pH TSS, ppm BOD, ppm COD, ppm Oil & Grease, ppm Cl, ppm Quantity 5.5 to 9.0 100 max 30 250 10 1000 1500 KL/day (max.)

5.7 COAL TRANSPORTATION AND COAL HANDLING SYSTEM 5.7.1 i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) COAL TRANSPORTATION SYSTEM Ib Valley Lakhanpur mine Merry Go Round System 36 (including 6 standby) 4 4 hours 32 minutes 19.3 km 25.25 km 33.6 km 1676 mm Bottom discharge type, Texmaco make 27.5 T Diesel Locomotive Works, Varanasi 2 WDM2/ Co-Co

Source of coal Means of transportation No. of wagons No. of rakes required per day Total cycle time of one rake Total distance Total cycle length Track length Track gauge Type of wagon & make Tare weight of wagon Locomotive: Make Nos. Model / type

Horsepower Max speed Gear ratio Max. Radius of curvature

2400 hp 120 kmph 65/18 73.2 m

FILLING STATION FOR DIESEL LOCOMOTIVE Location Capacity MGR Workshop panel building 270 KL 5.7.2 COAL HANDLING SYSTEM Track Hopper: i) No. of hoppers ii) Type of hopper iii) Length of track hopper iv) Breadth of track hopper v) Height of track hopper Paddle Feeder i) Location ii) No. of paddle feeder iii) Type of paddle feeder iv) Design/Rated capacity v) Range of travel Vibration Grizzle Feeder i) Location ii) No. of vibrating grizzly feeder iii) Capacity rated / design iv) Frequency v) Motor Crusher House i) No. & make of crusher ii) Type & size iii) Main crusher capacity iv) Max. coal size before crusher v) Coal size after crusher vi) Motor rating One RCC underground 200 m 6.8 m 7.15 Underneath Track hopper 4 Rotary type 1200 / 1000 T/hr 210 m At crusher house 4 nos 1000 / 1200 T/hr 1000 rpm (nominal) 25KW, 415V, 3-, 50 Hz, KEC make 4, Elecon Engineering Co. Ring granulator, EKK 48 x 114 1000 TPH each 300 mm 20 mm KEC make, 825 KW, 6.6 KV, 3-, 50 Hz, 720 rpm, 92 A, Insulation Class F

Conveyor i) No. of belt conveyors ii) Design / rated capacity Main belt conveyor iii)Belt speed (m/sec) iv)Belt width (mm) v)No. of plies vi)Top cover thickness (mm) vii)Bottom cover thickness (mm) viii)Cover grade ix)Conveyor motor: Rating (KW) F.L. Current, (A) Power supply x) xi) xii) xiii) xiv) TRH1A/ 1B 2.9 4 5 3 ----------1A/1B 3.02

26 2200 TPH / 2000 TPH 2A/2B 3.02 3A/3B 2.97 1600 4 5 3 4 5 3 4 5 3 4 5 3 4 5 3 4 5 3 4 5 3 5A/5B 7A/7B 8A/8B SR1 3.02 3.02 2.97 3.02

Fire resistant (FR)

------------------------

200 23 ..

330 34

330 157 35 26 6.6KV, 3,

400 43.5 50Hz

520 66 ..

165 19 ..

300 34

No. of metal detectors No. of belt weigher No. of sampling unit No. & type of magnetic separators No. of suspended magnet

5 (on conveyor 2A/2B, 7A/7B & SR-1) 6 (on conveyor 1A/1B, 2A/2B, 7A/7B) 4 5, suspended type 2 Travelling type 2 2200 t/hr 14.5 m/min. 11 KW Thruster operated 1 ASK 965 2000 / 2200 TPH 2000 TPH Reversible slip ring motor, 6 nos, 10 KW each

Tripper i) Type ii) No. iii) Capacity iv) Travel speed v) Motor for tripper vi) Brake Stacker / Re claimer i) No. ii) Model iii) Stacking capacity (rated/design) iv) Reclaiming capacity v) Travel Motor

vi) Bucket motor vii) Boom conveyor speed viii) Boom conveyor motor Type & Rating ix) x) Slew speed Slew motion motor

Squirrel cage, 125 KW, 415 V, 3, 50 Hz 3 m/sec Squirrel cage reversible type,110 KW, 415V, 3, 50 Hz 6 m/min. to 32 m/min. (step less) D.C. type, 2 x 14 KW

Dust Extraction System i) Total No. of units ii) iii) iv) Fan Dust velocity Cyclone collecting efficiency

DE-1 to 6 for section-I & DE-7 to 13 for Section-II Centrifugal 4 m/sec. (at hood) 85% (base on 10 microns) 45 days, coal storage requirement 450000 m3 of coal approx 505 m / 9.5 m

Stock Yard i) Capacity ii) Length/height of each pile

5.8 ASH HANDLING SYSTEM 5.8.1 i) ii) iii) iv) v) Quantity Shape Capacity No. of outlet opening Maximum level up to which ash can be stored 5.8.2 i) ii) iii) iv) Location Capacity Quantity Hopper evacuation time No. No. BOTTOM ASH HOPPER One W type 200 m3 (effective) Four 300 mm below hopper overflow nozzle elevation. CLINKER GRINDER Feed Gate housing 75 TPH Four per unit 70 minutes 4 per unit 4 per unit

FEED GATE HOUSING HYDROEJECTOR

5.8.3

HORIZONTAL ASH WATER PUMPS Fly Ash Pump Bottom Ash (LP) Pump Ash Water Pump House Horizontal, Centrifugal 3 3 Clear Water 600 400 55 75 1480 Flooded Continuous Flexible 415 V, 3-, 50 Hz Seal Water Pump 3 60 180

i)Location ii)Type iii)Quantity iv)Fluid Handled v)Capacity(m3/hr) vi)Total Dynamic Head (mwc) vii)Speed (rpm) viii)Suction condition ix)Duty x)Coupling xi)Drive Details: Supply Rating (KW/A)

Fly Ash Pump (HP) 3 250 75

75/132

125/213

120/204

50/88

5.8.4 ASH DISPOSAL PUMP i) ii) iii) iv) v) vi) Make Type No. Capacity Total dynamic head (mwc) Drive Details: Make Rating Indure D-85-D Horizontal, Centrifugal & non-log type 6 (3 working, 3 standby) 850 m3/hr 37.5 NGEF 6.6 KV, 3-, 50 Hz, 185 KW, 21A, 1481 rpm, Insulation class F

5.8.5 ASH COLLECTION RATE Collection point i) ii) iii) iv) v) Furnace bottom hopper Economizer hopper Air heater hopper Duct hopper ESP hopper: No. of Hoppers One 4 6 2 Collection rate of each hopper (kg/hr) 19200 4800 4800 2400 Ash Temp. 0C 1000 361 144 144

First field Second field Third field Fourth field Fifth field Sixth field Stack For two units at full load i) Bottom ash collection ii) Coarse ash collection iii) Fly ash collection iv) Total collection

8 8 8 8 8 8 1

61440 11212.8 2611.2 998.4 307.2 88.32 Balance 36.8 TPH 18.4 TPH 147.2 TPH 202.4 TPH maximum

144 144 144 144 144 144 144

5.9 ASH POND AND ASH WATER RECYCLE SYSTEM PONDA i) Gross area, acres/m2 ii) Top elevation of dyke, m (RL) iii) Average base level, m (RL) iv) Average height of dyke, m v) Max. level of ash deposit, m (RL) vi) Minimum freeboard, m vii)Available depth of ash deposition, m viii)Area covered by bund, m2 ix) Net area (excluding settling tank), m2 x) Capacity, m2 150/6,07,040 197.00 187.00 10.00 197.00 1.50 8.50 2,47,760 3,41,280 29,00,880 PONDB 242/9,80,000 202.00 189.00 13.00 200.50 1.50 11.50 2,94,000 6,86,000 76,82,000

Presently ash pond B is receiving ash effluent from the two units of the power plant. Ash water is collected through collector well & treated in primary settling tank. Then it is taken to secondary settling tank by gravity through one no. 600 M.S. pipe. Secondary settling tank comprises two sections & each section has got three cascading / decanting chambers for settlement of remaining ash. Decanted water flows in to the Transfer water sump from which pumping is done through two nos. vertical turbine pumps for reuse in the plant. Transfer Water Pump i) Nos. ii) Manufacturer iii) Type iv) Model

3 Voltas Ltd Vertical Turbine Pump BK 450-022

v) No. of stages vi) Rated capacity, m3/hr vii) Total dynamic head, mwc viii)Recommended min./max. flow through the pump, m3/hr ix) Thrust bearing x) Coupling xi) Material Suction bell Impeller Motor i) Manufacturer ii) Rating iii) Driven equipment demand Normal / Maximum, KW 33KV / 6.9KV, 450 KVA Transformer i) Manufacturer ii) Continuous rating iii) Rated no load voltage HV winding LV winding iv) Connection HV winding LV winding v) Vector group vi) On load/off circuits vii) No. of steps viii)Type of cooling 150 KVA AUX. Transformer i) Continuous rating ii) Type iii) Type of cooling iv) Rated voltage HV LV v) Vector group vi) Type of taps vii) No. of taps

4 1000 180 700/1400 Antifriction type, SKF/FAG 29428E Pin & Bush type, NBCB (Fenner) Cast steel, WCB, ASTM A-216 CF8M, ASTM A-743 BHEL, Hardwar 6.6 KV, 50 Hz, 78.9 A, 1485 rpm Insulation class-F 609.21 / 620.86 K.E.C. Ltd, Bangalore 4.5 MVA, 50 Hz, 3- 33KV 6.9KV Star Star Ynyno On-load tap changer 8 steps 9 positions ONAN 150 KVA Dry AN 6.6 KV 433 V Dyn11 Off circuit 5 (2 X 2.5%)

5.10 FIRE FIGHTING SYSTEM 5.10.1 FIRE DETECTION AND ALARM SYSTEM Microprocessor Based Detector System The plant is divided in to 22 no. of loops connected to zones with BS-100 type control panel suitable to addressable analogue type sensors. ____________________________________________________________________________ Panel No of loops Location SIP-A 11 Main control room of unit 1 & 2 SIP-B 6 Service building, ESP control room, CW pump house, 220 KV switch yard SIP-C 4 CHP control room SIP-D 1 Fuel oil pump house All these BS-100 panels (SIP-A & SIP-B) are interfaced to EA-2 computer and Video Display Unit (VDU) located in main control room. In addition to above, a separate panel is provided for ROR (Thermocouple Type) detectors used for conveyor protection. This panel is located at CHP control room and interfaced with SIP-C located in the same area and with EA-2 computer. Zone fire relay contact (from each zone) of ROR panel is connected to individual interface unit in the addressable loop of SIP-C. Detector Types i) ii) iii) iv) v) vi) vii) viii) Area Cable trench, cable gallery. Generator seal oil unit, oil tank, oil purification unit. Boiler burner fronts. Generator Transformer, Station Transformer, UAT HT/LT switchgear, battery room, MCC room MCR, DAS room, UPS room SWAS room CHP control room & building Type Of Detectors Used ISD, PSD, LHS cable, Quatrozoid bulb. HVW, Quatrozoid bulb Manual Call Point HVW, Quatrozoid bulb ISD, Heat Detector ISD, PSD ISD ISD

ix) x) xi)

Coal conveyor Switch yard Service Building

LHS cable, ROR (Thermocouple type) ISD ISD, Heat Detector 5.10.2 FIRE SUPPRESSION SYSTEM

FIRE HYDRANT PUMP i) No. ii) iii) iv) v) vi) vii) viii) ix) x) Location Make Area where used Rated capacity (m /hr) Total dynamic head (mwc) Size of pump discharge (mm) Speed Power required at coupling at duty point (kw) Drive detail: Make Rated Power Speed
3

3 2 Electrical driven, 1 diesel engine driven circulating water pump house Warthington Pump India Ltd Total plant area, bunkers, track hoppers Electric driven 273 90.84 200 NB 1470 rpm 88.57 KEC 110 KW, 415 V 3-, 50Hz, 182A, Insulation class B, 1482 rpm Diesel engine driven 273 90.84 200 NB 1500 rpm 87.62 Kirloskar Cummins Ltd 173 bhp 1500 rpm

AUTOMATIC MULSIFIRE FIRE SYSTEM i) Area where used Generator Transformer Station Transformer, Unit Auxiliary Transformer, Turbine Oil tank & Coolers, Clean & dirty oil tank, Cable gallery, Coal conveyors, FO Tanks ii) No. of pumps 2 iii) Location C.W. pump house iv) Make Worthington Pump India Ltd v) Type Wet pit non-pullout type vertical turbine pump vi) vii) viii) ix) x) xi) Rated capacity (m /hr) Total head (mwc) Size of pump discharge (mm) Speed (rpm) No. of stages Drive detail:
3

Electrical driven 410 91.4 250 1470 5

Diesel driven 410 91.4 250 1500 5

Make

NGEF

Ruston & Hornsby (India) Ltd

Power JOCKEY PUMP i) No. of pump ii) Stage iii) Rated capacity (m3/hr) iv) Total dynamic head (mwc) v) Drive HYDRO PNEUMATIC TANK i) Type ii) Capacity iii) Design pressure iv) Working pressure AIR COMPRESSOR i) Make ii) Type iii) Quantity iv) Capacity v) Head vi) Air receiver capacity vii) Working pressure FOAM SYSTEM i) Area where used ii) Type of system iii) iv) v) vi) vii) Application rate Foam concentration Type Foam delivery rate Foam compound consumption

160KW, 415V, Rated bhp 230 at 3-, 50Hz,1500 rpm 1500 rpm 2 7 stages 11 92.8 7.5 KW, 415V, 3-, 50Hz, 2900 rpm Vertical cylindrical 10 m3 192 psi 175 psi Ingersol Rand Single stage, single cylinder, reciprocating 1 0.56m3/min 10 Kg/cm2 225 litre 175 psi HFO/LDO system Fixed foam low expansion delivered gently in oil surface 5 lpm/m2 liquid surface area 30% profein based Foam maker with vapour 393 & 768 LPM 3% Cerberus Guinard Main control room, Instrumentation pane rooms, UPS, DAS & excitation rooms Halon1301 gas 5% at design temperature 30 sec.

HALON SYSTEM i) Make ii) Area where used iii) iv) v) Extinguishing agent Concentration Gas discharge duration

5.11 AIR COMPRESSOR Manufacturer Type No. of compressors : : : Kirloskar Pneumatics Ltd Reciprocating, horizontal, balance opposed, oil free type 4 per unit Two Balanced opposed 1 x 355 mm 1 x 215 mm 150 mm 2.5 ksc 3.5 ksc 3.5 ksc Direct through belt drive Split sleeve Forced feed by gear pump 80oc By gear pump/splash type 2 to 4 kg/cm2(g)

CONSTRUCTION FEATURES i) No. of stages ii) Cylinder arrangement iii) Cylinder bore LP HP iv) Stroke v) Cooling water pressure vi) Inter cooling water pressure vii) Type of drive viii) Main bearing type ix) Method of lubrication x) Max. allowable lube oil temp. xi) Cross head lubrication HPC/LPC xii) Lube oil pressure

PERFORMANCE DATA i) Volumetric efficiency at design condition 78.9% iii) Air temp. after first/last stage of Compressor 153oc / 147oc iii) Outlet air temp. (After after-cooler) 8oc above BCW inlet temperature AIR DRYING PLANT i) No. ii) Desiccant iii) Duty iv) Drying cycle v) Type of drying vi) Type of reactivation Type of change Motor i) Manufacturer ii) Rated output 3 for both units Silica gel as per IS 4301 Continuous 6 hours Absorption Open thro-system Automatic with provision for manual KEC Ltd., Bangalore 125 KW

iii) iv) v) vi)

Frame size Class of insulation Rated speed Power supply

LD 315 MMK 11 B 1484 rpm 415 V, 3-, 50 Hz 10 min 3 hours 1 hour 15 min

REGENERATION CYCLE i) Depressurisation ii) Heating iii) Cooling iv) Re pressurising

5.12 AIR CONDITIONING PLANT Description Capacity (tons) Refrigerant used Compressor No. Make Model No. of cylinders Cylinder bore(mm) Stroke (mm) Direction of rotation Max. operating pressure (bar) Capacity control(%) Lube oil Motor Main chilling plant Control room/Service bldg. 7034 R-22 7032 R-22 Switchyard A.C. plant (Direct expansion AHU) 3032(condensing units) R-22

4 2 2 ----------------------Kirloskar Pneumatic Ltd--------------------------AC-880 AC-880 AC-470 8 8 4 95 95 85 70 70 70 ----------------------Both directions permitted---------------------------21 21 21 ----------------------25, 50, 75, 100--------------------------------------------------------------Servofiz F-57 (10C )--------------------------------GEC make, 415 volt, 3-, 50Hz GEC make, 415 volt, 3-, 93 kw, 169A, 1485 rpm 50Hz,37kw,69A,1470rpm

Shell And Tube Condenser Make Model No. No of tubes No of passes Tube material Max Working pressure i) Water side (kg/cm2) ii) Refrigerant side ---------------------------------Blue star Ltd-------------------------------CDS-1686 CDS-1686 CDS-1260 4 2 2 172 172 110 3 3 4 Copper Copper Copper 7 7 7

(kg/cm2) Mode of flow Heat rejection rate Chiller Make

21 21 21 -------------------------Water through tubes------------------------------------265313 kcl/hr----------------110185 kcl/hr No chiller as direct

--------Blue star Ltd---------------expansion AHU Model ---------DXC-2009-----------------Mode of flow ------Refrigerant through tubes---No of tubes 252 252 No of passes 8 8 Water inlet temp (0C) 12.78 12.78 0 Water outlet temp ( C) 7.22 7.22 Total water flow (m3/hr) 38 38 Air Handling Unit Make No Model Fan type Air quantity (m3/hr) Electric strip heaters Motor Rating

-------------------------- Blue star Ltd---------------------------------4 4 1 Size-12 Size-9, 11 Size-11 --------------------Centrifugal forward curved-----------------------40,000 21367 (size-9) 22700 31600 (size-11 3318kw 339kw 239kw ------------------GEC make, 415 volt, 3-, 50Hz --------------------15kw 7.5/5.5 kw 7.5 kw

Packaged Air Conditioners Location Capacity Make Model Electric strip heater Condenser cooling Compressor Compressor speed Suction / condensing temp ESP control room U#1 & 2 (3 Nos. each) 7 ton each Blue star Ltd PWC-711 236kw Water cooled (shell & tube type) Hermatically sealed, Copeland make, 3- motor 2900 rpm 4.4/ 42 0C SPLIT AIR CONDITIONER Location No Capacity Annunciation panel room of unit 2 and Halon cylinder room 3 7.5 ton

Make Model Condenser type Compressor

Blue star Ltd SAC 711A Air cooled fan coil type Hermatically sealed, Copeland make, 3- motor. 5.13 MAIN PLANT DG SET

Total Nos. Diesel Engine: i) Make ii) Model iii) No. of cylinders iv) Displacement, cub inch(litres) v) HP at 1500 rpm vi) Engine breathing vii) Method of cooling of engine & lube oil Alternator: i) Make i) Rated capacity at 40oc ii) Rated terminal voltage & frequency iii) Rated stator current iv) Class of insulation v) Excitation current & voltage at rated output & power factor Diesel Tank: Capacity

3 Kirloskar Cummins KTA-2300 G 12 2300 (37.8) 890 Turbocharged after cooled Radiator water cooled / forced air blast

Kirloskar Electric Co. Ltd. 750 KVA 433 V, 50 Hz 1000 A F 20A, 64.1 V 900 litres

SECTION 6 ANNEXURE

ANNEXURE - 1

TURBINE ROLLING CURVE-1 DT (HP ESV1 HP CASING) >5.1 STEP / CRITERIA 11/4

DT (HP ESV 1 - HP Casing)

600 500
Metal temp ESV

400 300 200 100 0 0

Recommended

Not Recommended

200

400
HP casing temp

600

800

TURBINE ROLLING CURVE-2 DT (HP ESV2 HPSHAFT) >5.2 STEP / CRITERIA 11/5

DT(HP ESV2-HP Shaft)

600 500
Metal temp ESV2

400 300 200 100 0 0 200 400

HP Shaft mean metal temp

600

800

TURBINE ROLLING CURVE-3 DT (HP BP1 HP SHAFT) < X6 STEP / CRITERIA 14/2

DT (HP BP - HP Shaft) 700

MS temp before HPBP

600 500 400 300 200 100 0 0

Not Recommended

Recommended

200

400
HP shaft metal temp

600

800

TURBINE ROLLING CURVE-4 DT (LP BP1 IP SHAFT) < X7 STEP / CRITERIA 19/2

DT (LP BP1 - IP Shaft)

HRH steam temp before LPBP

700 600 500 400 300 200 100 0 0 200 400

IP shaft mean wall temp
Recommended Not Recommended

600

800

TURBINE ROLLING CURVE -5 STEAM BEFORE ESV1 S/H > X 4.1 STEAM BEFORE ESV2 S/H > X 4.2 STEP / CRITERIA 11/2 11/3

Steam Before HP ESV1 S/H

300
Temperature (C)

250 200 150 100 50 0 0 10 20 30 40 50 60 70

Pressure (bar)

TURBINE ROLLING CURVE-6 DT (HP BP1 HPCV1) < X1.1 DT (HP BP2 HPCV2) < X1.2 STEP / CRITERIA 4/6 4/7

DT(HP BP - Control Valve)

600 MS temp before HP BP 500 400 300 200 100 0 0 200 400 600 800 HP CV mean metal temp

TURBINE ROLLING CURVE-7 DT (WET STEAM HP CV1) <X2.1 DT (WET STEAM HP CV2) < X2.2 STEP / CRITERIA 4/9 4/10

DT (Wet Steam - Control Valve)

600 MS temp before HPBP 500 400 300 200 100 0 0 100 200 300 400 500 600 HP CV mean metal temp

ANNEXURE - 2 GENERATOR OPERATING LIMITS DESIGN POINT OUT PUT OUT PUT POWER FACTOR STATOR VOLTAGE STATOR CURRENT SPEED H2 PRESSURE 147 MVA 210 MW 0.85 LAG 15.75 KV 9050 AMP 3000 RPM 3.5 KG/CM2

GENERATOR CAPABILITY
250 200 150 100 50 0 -100 -50 0 50 100 150 200 Series1 Series2 Series3 Series4 Series5

-------Leading MVAR Series 1 Series 2 Series 4 Series 5

Lagging MVAR ---------------

Turbine Limit (210MW) Rotor Heating Limit Rotor Angle Limiter Rotor Current Limiter

ANNEXURE -3 UNLOADING SCHEDULE DUE TO HIGH DISTILLATE TEMPERATURE

9100 PERMISSIBLE STATOR CURRENT-AMP 9000 8900 8800 8700 8600 8500 8400 8300 8200 8100 42 44 46 48 50 TEMP OF DISTILLATE AT INLET OF STATOR WINDING DEGREE C Series1 Series2 Series3 Series4 Series5 Series6

Series 1 Series 2 Series 3 Series 4 Series 5 Series 6

POWER OUTPUT NORMAL TEMP OF DISTILLATE 450C RATED STATOR CURRENT 9050A STATOR CURRENT RATED OUTPUT MVA OUTPUT

Note Operation of Generator with distillate temperature more than 480C is not permitted.

ANNEXURE 4 STEAM TABLE SATURATED PROPERTIES OF WATER AND STEAM WITH PRESSURE AS PARAMETER --------------------------------------------------------------------------------------------------Pressure Temp Specific Volume Specific Enthalpy Specific Entropy P Kcal/kg-k Kcal/kg-k Kcal/kg-K ata oC Vf, Vg, lit/kg m3/kg hf hfg hg sf sg --------------------------------------------------------------------------------------------------0.02 17.204 1.003 68.26 17.25 587.6 604.9 0.0612 2.0849 0.05 32.35 1.0053 28.73 32.58 578.9 611.5 0.1127 2.0065 0.06 35.82 1.0064 24.18 35.84 577.2 613.0 0.1233 1.9912 0.08 41.16 1.0084 18.45 41.17 574.0 615.2 0.1402 1.9664 0.10 45.45 1.0101 14.95 45.45 571.6 617.0 0.1540 1.9480 0.20 59.67 1.0169 7.789 59.65 563.0 623.0 0.1976 1.8903 0.30 68.68 1.0221 5.324 68.66 558.0 626.0 0.2242 1.8567 0.40 75.42 1.0261 4.066 75.41 554.1 629.5 0.2438 1.8338 0.50 80.86 1.0296 3.299 80.86 550.7 631.6 0.2593 1.8149 0.60 85.45 1.0327 2.781 85.47 548.0 633.5 0.2722 1.8003 0.70 89.45 1.0355 2.409 89.49 545.6 635.1 0.2833 1.7881 0.80 92.99 1.0381 2.126 93.05 543.4 636.4 0.2931 1.7772 0.90 96.18 1.0405 1.904 96.25 541.3 637.7 0.3019 1.7675 1.0 99.09 1.0428 1.725 99.18 539.5 638.7 0.3097 1.7589 1.5 110.79 1.0521 1.180 110.99 532.1 643.1 0.3409 1.7267 2.0 119.62 1.0600 0.9019 199.9 526.4 646.3 0.3640 1.7040 2.5 126.79 1.0666 0.7319 127.3 521.4 648.7 0.3823 1.6860 3.0 132.88 1.0726 0.6160 133.5 517.3 650.8 0.3976 1.6716 3.5 138.19 1.0780 0.5338 138.9 513.5 652.4 0.4109 1.6592 4.0 142.92 1.0829 0.4708 143.7 510.2 653.9 0.4226 1.6488 4.5 147.20 1.0875 0.4215 148.1 507.1 655.2 0.4331 1.6394 5.0 151.11 1.0918 0.3818 152.1 504.2 656.3 0.4426 1.6309 6.0 158.08 1.1000 0.3214 159.4 498.9 658.3 0.4594 1.6164 7.0 164.17 1.1071 0.2778 165.7 494.2 659.9 0.4740 1.6040 8.0 169.61 1.1140 0.2448 171.4 489.8 661.2 0.4868 1.5930 9.0 174.53 1.1202 0.2190 176.5 485.8 662.3 0.4983 1.5833 10.0 179.04 1.1262 0.1980 181.2 482.1 663.3 0.5088 1.5749 15.0 197.36 1.1524 0.1342 200.7 466.0 666.7 0.5508 1.5412

1.2583 1.2427 1.2258 1.2075 1.1864 1.1606 1.1222

20.0 211.38 1.1751 0.1016 215.9 452.6 668.5 0.5822 1.5162 25.0 222.90 1.1953 0.08150 228.6 440.7 669.3 0.6078 1.4962 30.0 232.76 1.2142 0.06798 239.6 429.9 669.5 0.6295 1.4793 35.0 241.42 1.2320 0.05819 249.5 420.0 669.5 0.6484 1.4646 40.0 249.18 1.2493 0.05078 258.4 410.6 669.0 0.6654 1.4515 -------------------------------------------------------------------------------------------------Pressure Temp Specific Volume Specific Enthalpy Specific Entropy P Kcal/kg-k Kcal/kg-k Kcal/kg-K ata oC Vf, Vg, lit/kg m3/kg hf hfg hg sf sg --------------------------------------------------------------------------------------------------50.0 262.70 1.2826 0.04026 274.3 393.2 667.5 0.6950 1.4289 60.0 274.09 1.3147 0.03312 288.4 377.0 665.4 0.7203 1.4089 70.0 284.48 1.3466 0.02798 301.0 361.6 662.6 0.7428 1.3911 80.0 293.62 1.3787 0.02405 312.8 346.6 659.4 0.7632 1.3747 90.0 301.92 1.4115 0.02097 323.8 331.9 655.7 0.7817 1.3589 100.0 309.53 1.4453 0.01846 334.3 317.4 651.7 0.7992 1.3439 110.0 316.58 1.481 0.01638 344.2 302.9 647.1 0.8157 1.3293 120.0 323.15 1.518 0.01462 353.9 288.5 642.4 0.8316 1.3154 130.0 329.30 1.558 0.01314 363.3 274.0 637.3 0.8466 1.3031 140.0 335.09 1.600 0.01182 372.6 259.0 631.6 0.8614 1.2872 150.0 340.56 1.644 0.01067 381.9 243.7 625.6 0.8758 1.2729 160.0 345.74 1.693 0.00963 391.0 227.9 618.9 0.8901 170.0 350.66 180.0 355.35 190.0 359.82 200.0 364.08 210.0 368.16 220.0 372.1 1.750 1.812 1.889 1.99 2.13 2.39 0.00868 0.00780 0.00697 0.00618 0.00535 0.00438 400.4 410.1 420.2 431.4 444.6 463.0 211.0 192.7 172.7 149.7 121.4 79.3 611.4 602.8 592.9 581.1 566.0 542.3 0.9045 0.9192 0.9347 0.9515 0.9713 0.9993

PROPERTIES OF SUPERHEATED STEAM Temperature, 0C

-------------------------------------------------------------------------------------------------------------------ata 200 220 250 270 300 320 350 370 400 450 500 550 600 650 t, -------------------------------------------------------------------------------------------------------------------15.0 v 0.2070 (197.4) h 1.7375 s 0.1352 0.1436 0.2234 668.4 681.1 803.5 829.6 1.5445 1.5699 1.7748 0.1043 0.1667 674.4 828.3 1.5280 1.7414 0.1550 0.2397 698.0 855.8 1.6036 1.8098 0.1138 0.1790 693.1 854.7 1.5645 1.7767 0.1624 0.2559 708.8 882.3 1.6241 1.8427 0.1197 0.1913 704.6 881.3 1.5863 1.8100 0.0940 0.1527 700.2 880.5 1.5556 1.7844 0.1731 0.2720 724.7 909.0 1.6527 1.8739 0.1281 0.2035 721.3 908.2 1.6166 1.8415 0.1010 0.1624 717.8 907.5 1.5874 1.8160 0.1800 0.1901 0.1970 0.2880 735.2 751.2 761.8 777.5 1.6709 1.6970 1.7137 1.9038 0.1334 0.1412 0.1465 0.2156 732.4 748.8 759.4 775.5 1.6354 1.6621 1.6791 1.8715 0.1055 0.1120 0.1162 0.1722 729.1 746.1 757.1 773.4 1.6071 1.6345 1.6518 1.8462

20.0 v 0.1542 (211.4) h 1.7035 s

801.9

25.0 v 0.1225 (222.9) h 1.6767 s

800.4

0.0891 0.1328 0.1426 687.9 827.0 853.7 1.5325 1.7152 1.7509

30.0 v 0.1013 (232.8) h 1.6542 s

798.7

0.0123 0.1101 1.1185 682.1 825.7 852.6 1 .5038 1.6934 1.7295 0.0510 0.0816 0.0882 669.7 823.0 850.4 1.4530 1.6583 1.6953

0.0768 0.1269 695.5 879.6 1.5289 1.7632 0.0550 0.0946 685.7 877.7 1.4825 1.7296

0.0829 0.1350 714.2 906.7 1.5624 1.7950 0.0602 0.1008 706.6 905.1 1.5201 1.7617 0.0465 0.0803 698.4 903.4 1.4842 1.7356

0.0868 0.0924 0.0960 0.1432 726.1 743.5 754.8 771.4 1.5827 1.6112 1.6290 1.8254 0.0634 0.0678 0.0707 0.1071 719.6 737.9 749.7 767.2 1.5423 1.5729 1.5914 1.7924 0.0493 0.0531 0.0555 0.0853 712.5 732.2 744.7 762.9 1.5087 1.5412 1.5609 1.7666

40.0 v 0.0749 (249.2) h 1.6177 s

795.4

50.0 v 0.0590 (262.7) h 1.5885 s

792.0

0.0416 0.0646 0.0700 0.0752 674.2 820.3 848.2 875.8 1.4410 1.6302 1.6681 1.7029

-------------------------------------------------------------------------------------------------------------------ata 300 320 350 370 400 420 450 470 500 550 600 650 700 750 t, -------------------------------------------------------------------------------------------------------------------60.0 v 0.0579 (27403) h 1.6453 s 0.0371 0.0399 0.0623 689.0 705.1 845.8 873.8 1.4512 1.4788 1.6809 0.0432 0.0666 726.4 901.7 1.5140 1.7138 0.0454 0.0708 739.7 929.9 1.5349 1.7451 0.0485 0.0749 758.7 958.3 1.5635 1.7750 0.0505 0.0533 0.0551 0.0791 770.9 788.5 800.1 817.5 1.5813 1.6065 1.6225 1.8035

80.0 v 0.0427

0.0250 0.0276 0.0308 0.0326 0.0351 0.0367 0.0390 0.0405 0.0461 0.0494 0.0527 0.0559 0.0590

(293.6) h 1.6082 s

667.0 688.0 841.1 869.8 1.3875 1.4239 1.6449 0.0199 0.0364 666.0 865.8 1.3688 1.6161

713.9 898.4 1.4665 1.6788 0.0231 0.0392 669.0 895.0 1.4231 1.6509

428.8 927.1 1.4902 1.7107 0.0248 0.0418 716.5 925.3 1.4508 1.6835 0.0195 0.0346 703.0 921.5 1.4137 1.6606

749.5 762.6 781.5 793.8 811.8 956.0 1.5217 1.5408 1.5676 1.5844 1.7411 1.7700 0.0271 0.0444 739.8 953.5 1.4858 1.7142 0.0217 0.0368 729.5 951.1 1.4537 1.6917 0.0161 0.0291 712.2 947.4 1.4083 1.6639 0.0103 0.0215 676.0 941.3 1.3327 1.6265 0.0285 0.0305 0.0317 0.0470 754.4 774.4 787.3 806.1 1.5065 1.5353 1.5532 1.7434 0.0229 0.0247 0.0258 0.0289 745.5 766.9 780.4 800.1 1.4765 1.5074 1.5261 1.7211 0.0173 0.0189 0.199 0.0309 731.2 754.8 769.7 1.4364 1.4698 1.4905 1.6941 0.0116 0.0131 0.0139 0.0229 702.2 732.7 750.6 775.0 1.3710 1.4140 1.4385 1.6578

100.0 v 0.0335 (309.5) h 1.5781 s

836.3

120.0 v 0.0274 (309.5) h 1.5522 s

831.5

0.0178 0.0299 0.0323 681.5 861.8 891.7 1.3798 1.5916 1.6273

150.0 v 0.0213 (340.6) h 1.5188 s

824.1

0.0120 0.0140 0.0234 0.0254 0.0273 6 47.6 678.0 855.6 886.6 917.0 1.3083 1.3567 1.5604 1.5976 1.6319 0.0746 0.0185 0.0201 610.5 845.3 878.2 910.1 1.2320 1.5168 1.5567 1.5930 0.169

791.0

200.0 v 0.0151 (364.1) h 1.4709 s

811.4

ANNEXURE - 4 STATUATORY CLEARANCES

Subject 1. Certificate of Incorporation as OPGC under Companies Act. 2. Generating Company under Electricity (supply) Act, 1948 3. Orissa river board clearance for Effluent discharge. 4. Water availability from Hirakud Reservoir 5. Environmental Clearance 6. Forest Clearance

Clearance Authority Registrar of Companies, Orissa. Govt. of Orissa in I & P Deptt. Director of Industries, Orissa. E.I.C. Irrigation, Govt. of Orissa, I & P Deptt. State Prevention & Control Pollution Board, Orissa. Ministry of Forest, Fisheries & Animal Husbandry, Govt. of Orissa. Govt. of India, Deptt. of I & P. Planning Commission, Govt. of India. Central Electricity Authority, Govt. of India. Central Electricity Authority, Govt. of India. National Airport Authority, India Deptt. of Coal & Mines, Govt. of India.

7. Principle Clearance 8. In principle Clearance 9. Techno-Economic Clearance 10. Power Evacuation 11. Civil Aviation Clearance 12. Coal Linkage

13. Financing by Financial Institutions

Govt. of India. ANNEXURE - 5 LICENSES

License 1.Factory Registration under Factories Act 2.Boiler Registration under Indian Boiler Act 3.Registration under Contract Labour (R&A) Act 4. Fuel Oil Tank inside Main Plant 5. Filling Station for Diesel Locomotive 6. Storage of Chlorine Cylinder 7. Consumer Pump 8. Waste Management Authorization under Hazardous Waste Management Handling Rule, 1989 9. E.P.F. Coverage under EPF (MP) Act.

License No. JH 78 U # 1 - 512 U # 2 516 3199 P-12 (14) / OR-1551 P-12 (14) 442 GC- (OG) S-138/OR OR- 1616

Ind/TV/HW/187(70)/10531 SRO/RKL/7395/292/19-01-98