Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
1X500 MW HTPS, KW
1
I. FLOW
HP Heaters In HP
U
Description Heaters
nit BMCR 500MW 400MW 300MW 250MW
out
Steam
t/h 1590.0 1457.9 1167.3 887.6 755.4 1385.5
Superheater outlet
t/h 1358.0 1302.1 1052.2 808.3 656.8 1379.0
Reheater outlet
Water
Feed Water t/h 1590.0 1432.9 1087.3 796.6 678.4 1297.5
SH spray t/h 0 25 80 91 77 88
RH spray t/h 2 0 0 0 0 13
Air
t/h 652 582 460 363 357 626
AH outlet (Primary)
t/h 15 4 26 23 10 41
Tempering air
t/h 1155 1067 841 610 464 1157
AH outlet (Secondary)
t/h 2024 1855 1529 1198 1033 2026
Total Combustion Air
Gas
Flue gas at RAPH inlet
(Primary & Secondary) t/h 2245 2057 1695 1329 1145 2247
Flue gas at RAPH outlet t/h 2444 2253 1882 1508 1318 2443
(Primary & Secondary) t/h 820 737 614 506 501 800
Inlet PAH t/h 1425 1320 1081 823 644 1447
Inlet SAH t/h 930 847 722 611 603 909
Outlet PAH t/h 1514 1406 1160 897 715 1534
Outlet SAH
Fuel
t/h 374 347 285 224 193 376
Coal
2
II. TEMPERATURE
HP Heaters In HP
U
Description Heaters
nit BMCR 500MW 400MW 300MW 250MW
out
Steam
0
Sat. temp. in Drum C 362.0 361.0 358.0 355.0 354.0 360.0
0
LTSH inlet C 365.0 364.0 363.0 362.0 362.0 365.0
0
LTSH outlet C 397.0 395.0 399.0 398.0 400.0 406.0
0
SH Panel Inlet C 397.0 389.0 378.0 367.0 365.0 383.0
0
SH Panel Outlet C 467.0 464.0 455.0 444.0 439.0 456.0
0
SH Platen Inlet C 467.0 464.0 455.0 444.0 439.0 456.0
0
SH Platen Outlet C 540.0 540.0 540.0 540.0 540.0 540.0
0
RH Stage-I Inlet C 338.0 337.0 329.0 322.0 311.0 351.0
0
RH Stage-I Outlet C 487.0 492.0 494.0 499.0 502.0 502.0
0
RH Stage-II Inlet C 487.0 492.0 494.0 499.0 502.0 502.0
0
RH Stage-II Outlet C 568.0 568.0 568.0 568.0 568.0 568.0
Water
0
Economizer Inlet C 255 253 243 230 219 169
0
Economizer Outlet C 318 315 309 305 297 286
Air
0
Ambient C 27 27 27 27 27 27
0
AH outlet (Primary) C 313 309 294 275 262 269
0
AH outlet (Secondary) C 311 305 294 275 262 266
Gas
0
SH Panel Inlet C 1378 1377 1383 1400 1392 1379
0
SH Platen Inlet C 1128 1115 1091 1067 1043 1125
0
RH Front Inlet C 1029 1013 981 944 914 1027
0
RH Rear Inlet C 852 836 799 756 726 855
0
LTSH Inlet C 673 658 626 590 567 678
0
Economizer inlet C 549 537 513 486 470 554
0
Airheater Inlet C 339 332 314 293 279 289
0
Airheater Outlet C 126 125 120 117 114 110
3
4
5
6
MAIN BOILER
7
General Specification
Furnace Specification
Type - Controlled Circulation
Wall - Water Steam cooled
Bottom - Dry
Draft - Balanced
Tube arrangement - Membrane
Explosion/Implosion
Withstand capacity at 67%
Yield point - +/- 660 mmWC
Residence time for fuel particles
in the furnace - 3 second
Effective volume used to calculate
The residence time (M3) - 14790
Height from furnace bottom ash
Hopper to furnace roof (M) - 62. 735
Depth (M) - 16.115
Width (M) - 19.177
Furnace projected area (M2) - 7610
Furnace volume (M3) - 17599
Attemperator
Type - Spray
No. of Stages - Single Stage
Medium of Spray - Feed Water
8
Re heater
Type -Stage I Pendant Platen
-Stage II Pendant Spaced
Total H.S. - 8620 m2
Control - Burner Tilt & Excess Air
Economizer
Type - Plain Tube
Total H.S. - 15200 m2
No. of Blocks - 3
Air Heater
Type - Bisector PAPH-27.5 VI 2000
Bisector SAPH-30.0 VI 2000
Total H.S - PAPH-40070 m2, SAPH-62740 m2
Motor - PAPH-11.0 KW, SAPH-18.5 KW
Safety Valves
9
Location of
SV Blow
Down S.No. Location Make set pr Value (kg/cm2)
Capacity
KGS/Hr.
KGS/Hr.
9. Consol 185.5
129850
1538 VX
ERV 10. Consol 185.5
129850
10
SUPER 1538 VX
HEATER 11. Consol 186.6
129850
1538 VX
12. Consol 186.6
129850
1538 VX
13. Consol 186.6
129850
1538 VX
Location of
SV Blow
Down S.No. Location Make set pr Value (kg/cm2)
KGS/Hr.
11
1786 WE
21. RHS SV-21 Consol 49.90
164265
REHEATER 1785 WE
OUTLET 22. R22 Consol 47.4
164265
HRH 1785 WE
23. R22 Consol 47.4
164265
1785 WE
24. R22 Consol 47.9
164265
1785 WE
25. R22 Consol 47.9
164265
1785 WE
MAIN PARAMETERS
FUEL DESIGN COAL
UNIT 100% 100% 50%
BMCR TMCR TMCR
GENERATOR MW - 500 250
Superheat Flow t/h 1590 1457.9 755.4
Reheat Flow t/h 1358 1302.1 656.8
Total Heat Output of System (Q Duty) Mkcal/h 1046.6 969.7 538.6
Pressure at Super heater Outlet Kg/cm2(g) 178 176.6 171.1
0
Temperature at SH Outlet C 540 540 540
Pressure at Re heater Inlet Kg/cm2(g) 45.02 43.19 21.45
0
Temperature at Re heater Inlet C 337.5 337.1 310.7
Pressure at Re heater Outlet Kg/cm2(g) 42.37 40.65 20.17
12
0
Temperature at Re heater Outlet C 568 568 568
0
Feed Water Temperature (ECO Inlet) C 254.5 253.4 219.4
0
Ambient Air Temperature C 27 27 27
0
Combustion Air Temp (secondary) C 311 305 262
Fuel Quantity t/h 374 347 193
Air Quantity (Total Combustion Air) t/h 2024 1855 1033
0
Temp of Flue Gas at Boiler C 126 125 114
Exit(corrected)
0
Temp of Recirculation Gas C - - -
Quantity of Recirculation Gas t/h - - -
Efficiency Based on HHV(BSEN 12953- % 84.84 84.85 84.74
15:2003)
13
CHEMICAL CONTROL LIMITS (WATER/STEAM CYCLE)
Parameters Cond Feed Boiler Steam
Drum
-------------------------------------------------------------------------
pH at 250C 9.0- 9.0 9.1 9.0
9.2 9.2 9.4 9.2
Sp. - - <30 -
Conductivity
µs/cm
Phosphate as <2
PO4 ppm
Sodium as Na <5
ppb Max.
GENERATOR SYSTEM
ECW pH at 250 C
(Controlled by) 8.5-9.0
Dozing Caustic
Solution)
15
BOILER AUXILIARIES
BOILER WATER CIRCULATING PUMP
Number off : 3 Nos. (2+1)
Electrical Supply : 6600 Volts - 3 phase - 50 Hz.
Make : Torishima Pumps (India) Pvt Ltd
Type & Size : Single suction-Double Discharge
HLAV 2x300-460/1C
Design pressure : 214 Kg/cm2
Design temp : 3700C
Capacity : 2987 m3/Hr
Total Head : 31.26 m
MOTOR CHARACTERISTICS
Type : Wet Stator-Squirrel Cage-Induction
Frame : HCV-55/40035-665
Output : 350 KW.
Voltage : 6600 V
Current : 47.9 A
RPM : 1470
Connection : Star
ID FAN
Type : Radial fan NDZV 47 S (SIDOR)
Make : BHEL
Suction Orientation : 60o top left
Delivery Orientation : Bottom Horizontal Right
Medium handled : Flue Gas
Location : Outdoor
No per Boiler : 2
16
Direction of rotation as viewed
From driving end : Clockwise
KW rating : 4075 KW
RPM : 580 (max)
Stator Volts : 2X2.3 kV
Stator Amp : 2X629 A
Excitation Volts : 98 Volts
Excitation Amp : 334 A
Connection : Double Star.
F.D. FAN
Type : Axial reaction API-26/16
No. per Boiler : Two
Fan design rating
Capacity : 277m3/sec
Medium Handled : Fresh air
Location : Outdoor
Total Head Developed : 410 mmWC
Temp. Of medium : 500C
Specific wt. of medium : 1.046 Kg/m3
Fan speed : 980 rpm
Type of coupling : Flexible
Fan wt. : 25.84Ton
Fan efficiency at 100% MCR : 81%
Lubrication equipment
Fan lubrication : Forced oil circulation
Motor lubrication : Grease lubricated
Type of fan regulation : Blade pitch control
Bearings
Fixed bearings : Cyl Roller Brg NU 248 C3, Angular
Contact Ball Bearing 7248 B
Expansion bearings : Cyl-Roller Brg. NU 248C3
F. D. FAN MOTOR
Manufacturer : M/s BHEL
Motor type : SQ Induction motor
Direction of rotation as viewed
From Non driving end : CCW
Rating for specified
Normal condition i.e. 500C : 1525Kw
Rated voltage : 6600 V
Full load current : 166 A
17
Speed : 980 rpm
PA FAN
Lubricating equipment
Fan Lubrication : Forced Oil circulation
Motor Lubrication : Grease
Type of Fan Regulation : Blade Pitch Control
18
Discharge pressure : 16 bar
AIR HEATER
PRIMARY AIR HEATER
Type : Bisector
Air Heater Size : 27.5 VIM 2000
Rotor Drive Motor : Energy Saver, 11 KW GEC,1460 RPM, 415 V,20 Amp.
Speed Reducer : Type-ID,3 Input, Up shaft, APC (FALK) 110:1
Approx. oil Capacity : 50 Litres
Coupling : 11.5 FCU (Fluid Coupling)
19
Bushings : Taper lock Bush & Adapter
No. per Boiler : 2
Filter Lubricator : Valjan 1 '' BSP
AUXILIARY DRIVE
Air Motor : Pneumatic Air Motor
IR 92RA014, 5.51:1
Coupling : Bibby Coupling 124 - A
Rotor Support Bearing : Spherical Roller thrust Bearing SKF - 294/500E
Rotor Guide Brg : Spherical Roller taper bore, 23060/CCK/C3/W33
RTD : 1” BSP (M) Duplex-Thermo well
Oil Capacity of support brg housing : 100 litres
Oil Capacity or guide brg housing : 50 litres
SECONDARY AIR HEATER
Nos. per Boiler : Two
Heater size : 30 VIM 2000
ROTOR DRIVE
Motor TEFC : 18.5 KW, 1460 RPM, 415 V, 3 PHASE,
50 HZ, 32 Amp (FL)
Speed Reducer : 7 AP, FALK 130.36:1
Oil Capacity : 98 Litres (approx)
Couplings : 12.75 FCU (Fluid coupling)
Bushings : Worthingdon Hub
Filter Lubricator : 1'' BSP
AUXILIARY DRIVE
Air Motor : Pneaumatic Air Motor
IR 92RA022,
Coupling : Bibby Coupling - 124 C
Rotor Support brg : Spherical roller thurst brg. SKF 294/750E
Rotor Guide Brg : Spherical Roller bearing 23072/CCK/C3/W33
RTD : 1” BSP (M) Duplex-Thermo well
Oil capacity of support brg housing : 150 litres
Oil capacity of Guide brg housing : 50 litres.
20
Pre heater (mms)
7. Installed Operation Horizontal Horizontal
FOR BEARINGS
DRIVE END NON DRIVE END
a. Type : NU -230 6230 C3 NU - 226
B. Recommended lubricant : Grease - Servo Gem 30 F IOC
COAL BURNERS
Type : Tilting tangential
Make : BHEL
No. of Coal Burners feed by each : 4
Pulveriser.
No. of elevation of Burners : 10
Total No of Coal burners : 40
Temp. of Coal Air Mixture : 66- 770C
Max allowable temp. of Burners : 8500 C
Turn down ratio : 4:1
22
PRESSURE REDUCING AND DESUPERHEATING STATION
PRD Valves : One per unit
Flow Capacity of each valve : 110.3 T/hr.
Type of actuator : pneumatic
Body Material : WCB
Trim Material : S4 S420 J2 + H2
Body design pressure : 600 lbs class
Design Temp. : 3550C
De superheating water pressure : 314 kg/cm2
Temp. : 1850C
THERMAL INSULATION
OTHER
H. P. PIPING EQUIPMET TURBINE
-------------------------------------------------------------------
Insulation Material Mineral Wool Mineral Wool Mineral wool
(Rockwool)
Type of Insulation Boded type Boded Type Spray Type
Material (LRB -8183) Mattress Max temp
Insulating
Mat. Can withstand 7500C 750 0C 7500C
Insulating Material IS- 8183/98 IS- 8183/98 IS-8185/98
Standard
Density of
Insulating Material 150 kg/ m 3
SOOT BLOWER(Wall)
Blower Nos. : 1 to 88
Travel : 305mm
Blowing Pressure : 11 kg/cm2
Speed (axial) : 6.1 MPM
Speed (rotary) : 0.7 RPM
23
Operating Time : 1.5 min
Cycles per day : 3
Blowing Angle : 3600
LFO Specifications
Standard : IS 1460
Pumping Temperature : 400C
Firing Temperature : 400C
Viscosity : 2.2 to 15.7 cst @ firing temp.
Total Sulfur : 1.8% by weight
Density at 40oC : 0.830 Kg/liter
High heating value : 10,000 Kcal/Kg approx.
24
Location of Guns : AB, CD, EF, GH & JK (in Aux. air
nozzle)
HFO flow/gun : 2220 kg/hr (max), 850 kg/hr (min)
HFO pressure : 9.3 kg/cm2 (max), 3.5 kg/cm2 (min)
Minimum allowable HFO pressure : 3.0 kg/cm2
Minimum allowable steam pressure : 5.25 kg/cm2
Oil viscosity at the gun : 15 to 30 cst
Steam quality minimum : 10 to 150C superheat
HFO Specifications
Standard : IS 1593
Pumping Temperature : 570C
Firing Temperature : 1200C
Viscosity : 370 cst @ 500C temp.
Total Sulfur : 4.5% by weight
Specific gravity : 0.925@ 570C
Gross heating value : 10,270 Kcal/Kg approx
ELECTROSTATIC PRECIPITATOR
Design condition
Gas flow rate : 834.1 m3/ Sec
Temperature : 125 0C
Inlet Dust Concentration : 59.1 gm/Nm3
Outlet Dust Concentration : 19 gm/Nm3
ESP efficiency : 99.968 %
Type : 4xFAA - 9x45M2- 2x92150 -2
No of precipitator per boiler : Four
No. of Gas path per ESP : Two
No. of fields in series in each gas : Nine
Path
Pressure drop across the precipitator: 20 mmWC
for design condition
Velocity of gas inside ESP : 0.76 m/Sec
Treatment time : 53.29 Sec.
Specific collection area (M2/M3/sec) : 167.7
Guaranteed collection efficiency (%) : 99.52
Guaranteed air-in-leakage rate (M3/sec) : 2.8
Collecting Electrodes
No. of rows of Collecting electrodes per field : 2340
No. Collecting electrodes per field : 282
25
No. Collecting plates arranged in each row : 06
Total No. collecting plates per boiler : 10152
Nominal height of collecting plate : 15 meters
Nominal length of collecting plate : 750 mm
Specific collecting area : 268.03 m2
Emitting Electrode
Type : Spiral with Hooks.
Size : 2.7 mm Dia.
No. of electrodes in the frame forming one row : 54
No. of electrodes in each field : 2484
Total no. of electrodes per Boiler : 89424
Total length of electrodes per field : 15750 meters
Plate/wire spacing : 200 mm (400MM Pitch)
RAPPERS FOR COLLECTING ELECTRODES
No. and type of Rappers: One drop Hammer per row of collecting electrode having a
Collecting surface of 135 m2
Rapper Size : 4.9 kgs
Frequency of Rap: Varying from 12 raps/ hr at the inlet field to 0.1 rap/ hr at
the exit field. The frequency of rapping at intermediate
fields can be adjusted between 12 and 0.1rap per hour
according to requirements.
Hoppers
26
Type : Pyramidal
No. of hoppers/ ESP : 36
Total No. of hoppers : 144
Heating Element : Panel type, Electric heating provided at the bottom of
hoppers, Rating – 10kW, 1 Phase, 415V AC
Recommended thermostat setting for heater trip –
120oC
Baffling arrangement : 2 Sets of deflector Plates for each hopper across the
gas flow direction underneath the collecting plates
to prevent gas sneakage.
Rectifier
Rating : 95 kV DC (peak), 1000mA DC (mean)
Quantity / ESP : 18
Type : Silicon Oil, Silicon Diode, Full wave bridge
connection
Location : Mounted on the roof of precipitator
27
TURBINE AND AUXILIARIES
WEIGHT (Tones):
HP IP LP
----------------------------------------------------------------------------------------------------
a) Rotor : 16 23 100
b) Cylinder Assembled : 95 42 86.0
c) Main stop & control valve : 22
d) Reheat stop & control valve : 32
29
c) Limit value for tripping : 106 microns 320 microns
(Manual)
® Differential Expansions
a) H.P. Turbine : + 5mm - 3mm
b) I. P. Turbine : +8mm - 2mm
c) L.P. Turbine : +30mm - 3mm
MATERIAL OF CONSTRUCTION
Casings
H.P. Outer Casing/ Barrel Casing : GS 17 Cr Mov 511
H.P. Blade carrier : GS 17 Cr Mov 511
I.P. Casing : GS 22 MO 4
L.P. Casing : Outer St. 37-2 N
: Inner I- GS M04,H II, 15
M03
: Inner II St. 37- 2N
Shafts
H.P. Shaft : 28 Cr. MONI 59
I.P. Shaft : 30 Cr. MONIV 511
L.P. Shaft : 26 Ni Cr. NOV 145
Moving Blades
H.P. Turbine first stage : x 22 cr Mov 121
H.P. Turbine other stages : x 20 cr 13 / x 22 cr
Mov121
I.P Turbine stages : x 20 cr mo 13 / x
20 cr 30
L.P. Turbine stages : x 20 cr 13
Fixed Blades
H.P Turbine First stage : x 22 Cr MOV 121
30
IP/LP cross over/ cross around piping ST. 37/ St 42 W
No. of bearings including Thrust Bearing of Turbine: 4 Journal + 1 Thrust
Size of bearing
I II III IV
------------------------------------------------------------------------------------------
Diameter mm 280 380 560 560
Length mm 140 290 500 560
31
Oil Supply System
a) Oil tank rated capacity : 25/40 m3
b) Highest Oil level from top of : 900 mm
Tank
c) Lowest oil level from top of : 950mm
Tank
d) First oil filling : 53 m3
e) Flushing Oil quantity : 25m3
33
l) Permissible gauge pressure : 9.8 at
during operation water side.
m) Test gauge pressure water side : 14.7 at
n) Permissible gauge pressure during : 7.85 at
Operation fluid Oil side
o) Test gauge Pressure fluid side : 11.77 at
D) Barring Gear
a) Type of Drive : Hydraulic turbine
b) Method of engagement : Hydraulic
c) Cut in / cut speed : 210/240 rpm
d) Barring speed : 80-200 rpm
E) Governing
There are two speed controlling devices, Speed Sensor
i) Hydraulic speed Governor : Primary Oil pump
ii) Electro- Hydraulic controller : Hall Generator.
(There are 3 in Nos.
One in spare)
iii) Over Speed Set Value : 10- 11 %
F) Gland Sealing System
a) Electro - Hydraulic, self sealing after : 40% Load
G) Motor
Make- Siemens, 121 KW, 415 V, 200 Amp, 2984 rpm
34
Shaft power (Kw) 264 345
Speed (rpm) 1495 1720
E) BFP Turbine
Manufacturer : Delaval - Stork
Type/ : KJ- MV- SF- 7R
Output (KW) : 7262
Max. Cont. Speed (rpm) : 5567
35
Rotation (Seen in Direction of : C.C.W
Steam flow)
Ist Lateral critical speed (rpm) : 3710
Steam Inlet pressure (ata) : 7.486
Auxiliary steam inlet press (ata) : 26.5
Steam inlet temperature, (0C) : 299
Auxiliary steam Inlet Temp (0C) : 340
Exhaust pressure (ata) : 0.1
Over speed Trip at, (rpm) : 5900
F) Gear Box (T.D.)
Manufacturer : Tacke
Type : TNB 200
Input speed, (rpm) : 5406
Output speed, (rpm) : 1740
Power (KW) : 401
Agma Service factor : 2.0
G) Lube and Control Oil for BFP
Tank capacity (Max) 5750 Liters
Capacity (Operating level) 4050 liters
I) Motor
Make : GEC
Type : D225 MD
Power : 37 KW
Speed : 3000 rpm
Power supply : 240/415 V, 3 ph, 5o Hz
Insulation : Class B
36
K) Motor
Make : GEC
Type : YD 200 LAD
Power : 7.5 KW
Speed : 3000 rpm
Power supply : 220 VDC
Insulation : Class B
DEAERATOR
No of stages = One
Pump rated speed = 590 rpm
Rotor/ vane tip Speed = 21.9 m/sec
Motor
160 KW, 50 Hz, 0.415 kV, 3 Phase
a) Type squirrel cage, induction motor
b) Full load current 305 Amps
c) Power factor at rated load 0.78
d) Rated speed 590 rpm
e) Efficiency 93.8%
37
CONDENSATE EXTRACTION PUMP
Supplier BHEL
Type of First Impeller Double Suction
Number of stages 4
Design Flow rate capacity 817. 36 m3 /hr
Inlet - Temperature 43.1 0C
Inlet - specific Gravity (specific wt) 0.991 kg/dm3
NPSH required 3.4 meter
Discharge pressure 32 ata
Total dynamic Head 320 meters
shut off Head 398 meters
pump Speed 1485 rpm
Power Consumption at design condition
i) Power input at the motor Driver H.P 886.1KW
ii) Losses in the motor 34.1 KW
iii) Power input to the pump 852 KW
iv) Efficiency of the pump alone 82.8 %
v) Overall efficiency of the pump motor 79. 6%
Motor of Condensate Extraction pump
Manufacturer BHEL
Motor type ORNVG X 630 ia 4
Direction of rotation as COUNTERCLOCKWISE
Viewed from non- driving end
Standard continuous rating
at 50 0C ambient temperature
as per Indian Standard ( KW) 900 KW
Rated voltage (Volts) 6600 V
CONDENSER
Type Single
Area of Condenser surface Area 26612 sq. meters
Number of cooling tubes 24398
Length of each tube 14630 mm
Size of tubes - 22.225 x 0.7112
(OD X thickness in mm)
Tube material - SS. 304
Weight of empty condenser 600 TE
Weight of tubes 144.8 TE
C.W. flow 54000 M3 /hr
C.W. velocity 1.8288 M/sec.
C.W. design 28oC
C.W. Max Inlet temperature 33oC
C.W. Max outlet temp 43.05 oC
38
Back Pressure at MCR 65.278 mm of Hg
at 28oC
Condenser Temperature rise max 10.050C
Terminal temperature Difference with 3.32oC
C.W. flows with steam
Pressure loss condenser 4050 mmWCl
Fouling factor 90%
Cleanliness factor 0.90
39
Connection Star
Self Cleaning Strainer
Make BHEL
Normal/Maximum Water Flow 3400 m3/Hr, / 4080 m3/Hr
Operating/Test Pressure 3.0 to 3.5 Bar / 11.25 Bar
Design Pressure 7.5 Kg/cm2
Design Temperature 600C
Fluid Handled Clarified Water
40
GENERATOR & AUXILIARIES
GENERATOR
General
Make BHEL (KWU)
Type THDF 115/59
Code IEC 34-1, VDE 0530
Cooling Stator winding directly water cooled.
Stator core & Rotor directly hydrogen cooled.
RATING
Apparent power 588 MVA
Active Power 500 MW
Power factor 0.85 (lag)
Terminal voltage 21 KV
Permissible variation in + 58 %
Voltage
Speed/ Frequency rpm/Hz 3000/50
Stator current 16200 Amps
Hydrogen pressure kg / cm2 4
Short Circuit Ratio 0.48
Field current (Calculated value) 4040 A
Field Voltage 340V
Class and type of Insulation MICALSTIC (Similar to class F)
No. of terminals brought out 6
Resistance in ohms at 20oC
Stator winding between terminals u-x 0.001414
v-y 0.001417
w-z 0.001420
Rotor winding F1- F 2 0.068293
MAIN EXCITER
Active Power 3780 KW
Current 6300 A
Voltage 600 V
Speed 3000 rpm
Pilot Exciter
Apparent power 65 KVA
41
Current 195A
Voltage 220V (1+ 10%)
Frequency 400 Hz
PF 0.6
CRITICAL SPEEDS
1. Critical speed (Calculated) nk1 14.4 S-1 (VGEN)
nk2 30.1 S-1 (V-EXC)
nk3 39.8 S-1 (S-GEN)
* STP = Standard temperature and pressure. O 0C and 1.013 bar to DIN 1343.
** Volume required with unit at stand still with the unit on turning gear, the volume will
be higher.
*** Co2 quantity kept on stock must always be sufficient for removal of the existing
hydrogen filling . All values are approximate.
GENERATOR PROTECTIONS
Generators are high quality machines for securing the best possible continuity of power supply.
In addition to a suitable technical design and responsible mode of operation, provision has
therefore been made for automatic protection facility the following protections have been
provided in the 500 MW TG.
43
PRIMARY WATER SYSTEM
Primary water pumps 1 and 2 SS11 DOO1/SS11
DOO2
Kind of pump Centrifugal pump
type Cpk -cm 65- 250
( KSB)
Speed 47 S -1
Capacity 19 dm3/s
Discharge head 80 m
pump motor type ILA 4207 - 2AA90
(CG)
Rating 37 KW, 64 Amp
Voltage 415V, three phase AC
Frequency 50 Hz
Speed 2690 rpm
Type of enclosure IP 54
No. 2 Nos. full-capacity
EXCITATION SYSTEM
A- Wheel (negative polarity)
SPECIFICATIONS OF TRANSFORMERS
Generator Transformer
1. Manufacturer BHEL
2. Nos. of units 4 Nos.
3. Rating HV & LV (MVA) 200 MVA
4. Rated Voltage, HV 420 KV
5. Rated Voltage. LV 21 KV
6. Rated current, HV 825 Amps
44
7. Rated current, LV 9520 Amps
8. No. of phases 1
9. Frequency 50 Hz
10. Type of cooling OF AF
11. Connection symbol when YD5
formed a bank.
12. Impedance at principal tap 12.5%
(750C)
13. OFF CKT Tap Changer Tapings in 5 equal steps of
2.5% each provided on HV
Winding to give + 5% to - 5%
14. Temperature rises Variation of high voltage
i. Oil by thermometer 500C
ii. Winding by resistance 550C
Manufacturer : Atlas
Type of compressor : Horizontal Balanced Opposed
45
Numbers : Instrument Air : 2 Nos.
: Service Air : 1 Nos.
Actual capacity of each compressor : 30.0 Nm3/min
Discharge pressure Kg/cm2 gauge : 8.0
Design ambient temperature : 50 deg C
Design ambient pressure : 0.99753 Kg/cm2 abs
Design ambient humidity : 100%
Exact capacity considering worst : 39.05(at45 deg.C&75%RH)
Ambient condition as stated in data
Alternator
KW : 600
KVA : 750
Pf : 0.8
Stator Current : 1043 A
Speed : 1500 rpm
48
BOILER & AUXILIARIES
AIR PREHEATER INTERLOCKS :
ID FAN INTERLOCKS :
ID Fan PERMISSIVES
a. ID Fan discharge gate in closed position.
b. Inlet guide vane minimum.
c. Scoop position minimum (<5%).
d. Inlet gate closed.
e. Bearing temp normal, motor NDE/DE. Fan NDE/DE bearing temp normal (<85 0C)
f. Oil temp after cooler adequate. (< 50 Deg. C)
g. Stack Path available. (Any two ESP available)
h. Any APH to ESP available / any ID Fan ON.
- With local push button released, If ID fan is started, ID fan will take start and inlet/out
dampers will open.
- If the dampers fail to open within 180 seconds the running fan will trip.
i. ID Fan Lube Oil Tank Level > minimum (Switch)
j. Fan Either Lube Oil Pump ON.
k. Fan motor & Exciter winding Temp Not High. (Exciter<90 0C, Motor<120 0C)
ID Fan PROTECTION:
49
4. Bearing temp High-High. (MOTOR/FAN)
(Motor - 90 Deg. C, Fan - 82 Deg. C)
5. Lube Oil pressure Very low < 0.4 kg/cm2
6. Fan running & inlet/outlet gate close.
7. Motor / Fan bearing vibration Hi-Hi (Motor Brg - 9 microns/Sec, Fan Brg – 12.6 mm/sec).
(TD = 10 Sec)
8. Corresponding FD fan trip (for ID fan-A, FD fan-B running and FD
fan-A tripped) (for ID fan-B, FD fan-A running and FD fan-B tripped)
9. Post purge fan trip (FSSS)
10. ID Fan Motor Winding Temp High (>130 Deg C)
11. ID Fan Exciter Bearing Temp High (>120 Deg C)
FD FAN INTERLOCKS:-
FD Fan PERMISSIVES
1. Discharge Damper closed.
2. Blade pitch minimum (<5%).
3. Lube Oil pressure adequate > 0.8 Kg/cm2.
4. Oil tank level adequate.
5. Control oil pressure adequate > 8 Kg/cm2
6. Any Lube oil Pump running.
7. Fan/ motor bearing temp. (Fan < 90 Deg. C, Motor < 85 Deg C)
8. ID Fan permits.
9. Fan Motor winding Temp Not High (< 110 Deg C)
10. FD Fan Lube Oil Tank Level > minimum (Switch)
11. Oil temp after cooler adequate. (< 65 Deg. C)
FD Fan PROTECTION:
1. Electrical protections trip.
2. Emergency push button pressed.
3. Stop command from UCB.
4. One ID Fan and one FD already in service & corresponding ID Fan not running.
5. Fan bearing temp. High > 110 Deg. C (TD 2 Sec)
6. Motor bearing temp. High > 90 Deg. C (TD 2 Sec)
7. Motor Winding temp. High > 130 Deg C (TD 2 Sec)
8. Outlet Damper fails to open within preset time/fan running and
discharge damper closed for more than. 120 seconds.
9. Vibration more than preset value. (Motor – 15.5 mm/s, Fan – 19.8 mm/s, TD – 10 Sec)
50
10. All ID Fans stopped
11. Post Purge Fan trip
12. Lube Oil pressure Lo < 0.4 Kg/cm2, Control Oil pressure Lo < 4 Kg/cm2, TD – 10 Sec.
PA FAN INTERLOCKS:
PA FAN PERMISSIVES-
1. Blade pitch in minimum position (< 5%).
2. Discharge Damper closed.
3. Lube Oil pressure adequate > 0.8 Kg/Cm2
4. Control Oil pressure adequate > (Set 8 Kg/Cm2).
5. Lube oil tank level adequate (not low).
6. Fan / Motor bearing temp Not high. ( Motor < 80 0C, Fan < 85 0C, TD – 10 Sec)
7. Any one Oil Pump running.
8. Both PAPH ON & Air Path available OR [any PAPH ON] & Air Path available & PAF-B
OFF].
9. PA Fan start permissive available OR other PA Fan ON.
10. Local push button in released condition.
11. Lube Oil cooler outlet temperature not high (< 50 0C).
12. Motor winding temp Not high. ( < 110 0C)
PA FAN PROTECTIONS:
1. Electrical protection trip.
2. Stop command from UCB.
3. Emergency push button pressed.
4. Fan/motor bearing temp High (> 90 Deg C), TD- 10 Sec.
5. M.F. T. operated
6. Fan Running & Outlet Damper fails to open After 90 Sec.
7. Motor/Fan Bearing Vibration Hi-Hi (Fan > 19.8 mm/s, Motor > 15.5 mm/s, TD-10 Sec)
8. Motor Winding Temp High (> 130 0C, TD 2 Sec)
9. Lube Oil pressure Lo < 0.4 Kg/cm2, Control Oil pressure Lo < 4 Kg/cm2, TD – 5 Sec.
10. Both FD Fans OFF.
51
or
c. Scanner duct to furnace DP High> 600mm WC for 10 secs.
DC SCANNER FAN:-
a. It can he started from FSSS console
3. Either PA fan ON & seal air header to cold air duct delta- P <101.6mm WCL)
4. No stop command.
52
TRIP CONDITION
1. Neither of the fan discharge damper Open.
2. Stop push button.
3. Neither PA fan is on for more than 15 sec.
PULVERISERS:
53
2. Seal air to header under bowl DP > 200mm WCL.
3. Pulveriser not on.
4. Ignition permit available (3 out of 4 oil guns in service and boiler load >30% and
adjacent feeder running at>50% loading).
5. Start command given.
MILL - A
(a) AB elevation 3 out of 4 guns in service. OR
(b) Feeder B is proven and feeder speed > 50% and boiler load > 30%
MILL - B
a. 3 Out of 4 AB guns in service
OR
b. 3 Out of 4 CD guns in service and feeder C is proven with
feeder speed > 50%
OR
c. Feeder A or C are proven with> 50% feeder speed & boiler load > 30%
MILL - C
a. 3 out of a 4 CD elevation guns in service
OR
b. 3 out of 4 AB elevation guns in service and feeder B speed>50%
OR
c. Feeder B or D proven with feeder speed > 50% and boiler load > 30%
MILL - D
a. 3 Out of 4 CD Elevation guns in service
OR
b. Feeder ''G'' or ''E'' proven with feeder speed>50% and boiler load>30%
MILL - E
a. 3 out of 4 EF elevation guns in service
OR
b. 3 out of 4 elevation guns in sevice with feeder ''D'' proven and speed>50%
OR
c. Feeder 'D' or 'F' in service with speed >50% and boiler load>30%
MILL - F
a. 3 out of 4 EF Elevation guns in service.
OR
b. Feeder 'E' Or 'G' In Service With Speed >50% And Boiler Load>30%
54
MILL - G
a. 3 Out of 4 EF guns in service and feeder 'F' in service with speed>50%
OR
b. Feeder 'F' or ' H' in service with feeder speed > 50% and boiler load > 30%
MILL - H
a. 3 out of 4 HJ guns in service.
OR
b. Feeder 'G' or 'J' in service with feeder speed > 50% and boiler load > 30%
MILL - I
a. 3 out of 4 HJ guns in service
OR
b. 3 feeder ' H' Is proven with speed > 50% and boiler load > 30%
[B] After feeder starting within 5 seconds, coal on belt should be established. Otherwise feeder
will trip. Ignition permit should be available for 180 seconds from the moment start command
to feeder is given.
PULVERISERS PROTECTIONS:-
1. Stop button is operated.
2. Primary Air trip command is present
3. Boiler Trip
55
4. Mill Discharge valve not open.
5. Ignition permit required and lost within 180 second.
6. Lube Oil pump trip (a) lube oil pump ON and pressure low with a delay of 10 seconds.
(b) Pulveriser ON and lube oil pump NOT ON for more than 10 seconds.
7. EPB trip.
8. Seal air header/minimum bowl DP< 128 mmWC with a delay of 1 minute.
9. Elevation power not available for > 2 sec
10. Auto stop command is present
11. Pulveriser start command is persisting but pulveriser not on within 10 seconds.
CC Pumps Permissive:
FSSS: LOGICS
MFT CONDITIONS:
Master fuel trip is initiated if any one of the following occurs:
a) All FD fans tripped.
b) All ID fans Tripped.
c) Inadequate water wall Circulation for more than 5 Sec.
d) Both EPB-1, 2 Pressed.
e) Loss of Re heater Protection for More than 10 seconds.
f) Both Secondary APHS Tripped.
g) All Boiler Feed pump tripped (TD-10 Sec)
h) Drum level low-low for > 5 sec (-375 mm)
i) Drum level High-high for> 10 sec (+250 mm)
j) Furnace Pressure high - high (2/3 Logic) (> +150mmwcl)
k) Furnace pressure low-low (2/3 LOGIC) (< -175mmwcl).
l) Loss of all fuel.
56
m) Unit Flame Failure trip.
n) EPB trip of Boiler.
o) Loss of 220 Volts DC supply for> 2 seconds.
p) Loss of 24 V DC.
q) Air flow < 30 % (< 600 TPH)
r) Less than Fire Ball & Loss of 110 V AC in any Elevation in service.
PURGE CYCLE:
Purge Ready signal will appear when:
a. HFO trip valve closed
b. All HFO Nozzle valves are closed
c. All Pulverizes off
d. All Feeders off
e. No Boiler trip
f. All scanners sense No Flame (Fireball AB, BC, DE, FG, GH, HJ AND
DISCRIMINATING AB, CD, EF, & HJ)
g. Air Flow > 30%
h. All Hot Air Gates Closed
i. Drum level Satisfactory
j. All Aux air dampers modulating (AA to JJ).
k. Both PA fans off
l. Wind box/ Furnace delta `p' adequate (25mmWC). (When `push to purge' Button is
Pressed, Purging will Start for five Minutes.)
B. When Boiler load crosses 30% the set point of wind box Pressure is Increased
automatically to another preset value and all aux, air dampers except where there is oil
firing, Start closing from top to bottom in a sequential Manner to Maintain the new delta
p.
C. Aux air dampers associated with oil elevations go to a fixed opening of 35% the setting
of 35 % Has been provided by BHEL during Commissioning.
D. All fuel air dampers A,B,C,D, E,F,G,H&J Modulate according to Feeder speed after the
feeder is proven UP TO 50% of feeder speed the Designated Damper remaining closed
and between feeder speed variation for 50 to 100% fuel air damper modulates from 0 to
20 %
E. Aux. air dampers Associated with oil Elevations closes during HEA Igniter start and
opens after oil Nozzle valves full open, Elevation Started and start time has expired.
57
F. All fuel air dampers close after 50 Seconds of respective Feeder Trip.
G. When Boiler load falls down to < 30% all aux. air dampers (except fuel air) Starts
opening from Bottom to top in a sequential manner at a time interval of 10 sec, each.
58
All three pumps in service & DP<10 psi
OR
Any one discharge valve of each of the pump is not open. Pump off is sensed From switch
gear service contact, DV- 1/DV-2 discharge valve not open is sensed from valve limit
switches and low diff. Pressure transmitter. Boiler tripping would occur only when all the 6
transmitters sense low DP together.
01. Enabling when Boiler is working and main steam pressure > 30 kg/sq. CM
02. Arming when HP bypass BP1 or HP bypass BP2 open >2% and LP bypass V/V open.
03. On Re heater protection tripping for boiler is as follows.
i) Turbine is in tripped condition and boiler is working if BP1 & BP2 are not open boiler
will trip after 15 seconds.
OR
LP bypass Command is > 35% and both LP bypass v/v not open for >35 seconds boiler
will be tripped.
Once the protection is armed the protection will disarm only after boiler Tripping.
ARMING:
1. Boiler lighted up / no MFT
and
2. Boiler Pressure > 25 kg/cm2
and
3. Either BP1 or BP2 open 2% and LP bypass open > 2% once only after that self
Latching.
PROTECTION:
1. Protection arming
And
2. Turbine trip from CH-1 and CH-2
And
3. Either LP bypass close or both HP bypass valves close (<2% open) then boiler will
trip after a time delay of 15 seconds.
59
ELECTRICAL
a. Emergency trip from UCB Yes.
b. Remote trip during ATT (Prot. program)
c. Fire Prot. I (PB PUSH)
d. Fire protection II (PB PUSH)
e. MOT level low-low 1150 mm from top
f. Generator protection
g. Boiler fire off or boiler trip
h. MCB turbine trip ATRS S/D Program
I. Condenser VAC .low-low 0.3 Kg/cm2 (2 out of 3)
60
7. HPCF Cir pump 1 & 2 off
8. Vacuum Breaker open
CEP INTERLOCKS
CEP PERMISSIVES
1. Suction valve open 100 %
2. Discharge Valve Closed/Discharge header PR. > 28 kg/cm2 Square
3. Recirculation valve open 100 %
4. Bearing temp < preset value
5. Discharge vent valve 100 % open
6. Hot well level Greater than Preset value
CEP PROTECTIONS:
1. Hot well level low-low (2 out of 2)
2. Suction valve close (0%)
3. Bearing temp high - high (100 0C)
61
4. Discharge pressure low -low (22 kg/ cm2 Falling and CEP running) standby CEP comes
in service at a discharge pressure of 26 ksc CEP discharge header pressure low alarm
comes at 27 KSC
TD BFP
START PERMISSIVE:-
1. Lube Oil pressure normal > 3.5 KSC at O` MTR near oil tank.
2. TD BFP control valve closed.
3. Position controller output 0 %
4. Disconnecting coupling engaged.
5. Pump Delta T low < 25 D.C.
6. Deaerator level normal
7. Pump discharge valve closed (80% Open)
8. Recirculation valve open (100%)
9. Suction valve open (100%)
10. Warm-up valve closed (0%)
PROTECTION:
1. Suction valve not open
2. Exhaust valve not open
3. Main pump bearing temp high-high > 120 Deg. CEL
4. Turbine bearing temp high-high > 120 0C.
5. Trip oil pressure low-low < 2 Kg/cm2 (2/3 logic Switches)
6. Lube oil pressure low- low < 1.0 Kg/cm2. (2/3 logic Switches)
7. Vacuum low-low <0.2 KSC
8. Axial shift of main pump high > +/- 0.70 mm (2/3 logic)
9. Axial shift of turbine high > +/- 0.70 mm (2/2 logic)
10. Over Speed trip at 6300 rpm
11. Seal water temp high for main pump > 85 0C DE/NDE side.
12. Deaerator level low- low <-1650 mm, level switches)
13. Local trip (mech.) -1.
14. Local trip (Elect) (2/2)
15. UCB trip manual (Elect) (2/2)
16. Governing oil pressure low- low < 4.5 Kg/cm2. (2/3 logic Switches)
62
17. TDBFP Exhaust steam temperature very high > 120 Deg C, (2/3 logic Switches)
18. TDBFP Exhaust steam pressure very high > 0.4 Kg/cm2, (2/3 logic Switches)
19. TDBFP Live steam pressure v. high > 12.5 Kg/cm2, (2/3 logic Switch)
20. Turbine Eccentricity very high > 92 mic
21. Turbine GB i/p vibration very high > 70 micron (TD – 5 Sec)
22. Turbine GB o/p vibration very high > 70 micron (TD – 5 Sec)
23. Turbine FJB vibration very high > 70 micron (TD – 5 Sec)
24. Turbine RJB vibration very high > 70 micron (TD – 5 Sec)
25. TDBFP DE vibration very high > 18 micron (TD – 5 Sec)
26. TDBFP NDE vibration very high > 18 micron (TD – 5 Sec)
27. Turbine GB Temperature very high > 120 Deg C, (TD – 30 Sec)
28. Turbine Bearing Temperature very high > 120 Deg C, (TD – 30 Sec)
29. Booster Pump Brg Temperature very high > 95 Deg C for NDE
30. Booster Pump Brg Temperature very high > 105 Deg C for DE
31. Booster Pump Thrust Brg Temp very high > 105 Deg C for NDE, (TD-10 Sec)
32. BFP Bearing Temperature very high > 95 Deg C, (TD – 30 Sec)
33. TDBFP working AND Suction Flow Low < Variable set point as per speed.
34. FW Suction / Discharge DT high > 15 Deg C (Speed>3500 rpm & ESV Open & Control
v/v >2% OR Aux Steam control v/v > 3%)
MD BFP:
START PERMISSIVES:
1. Seal water header pr. normal > 15 ksc.
2. Deaerator level normal (> -20 mm).
3. Pump bearing temp normal < 90O C
4. Motor DE/NDE bearing temp normal < 90O C
5. Hydraulic Coupling bearing temp normal <90O C
6. Discharge valve closed or header pressure not low.
7. Lube oil pressure normal > 2.0 KSC.
8. Recirculation valve open 100 %
9. Pump suction valve open.
10. Warm-up valve closed.
11. Main pump delta T Normal < 250 C
12. Hydraulic coupling scoop in min. position.
13. MDBFP AOP ON.
63
7. Lube Oil pressure normal > 1.2 ksc.
8. Recirculation valve open 100%
9. Pump suction valve open 100%
10. BEP "C" on auto
11. BFP ' A ' Tripped or BFP ` B tripped or BEP ` A `Running and suction flow> one pump
capacity or BFP `B` running and suction flow > one pump capacity.
MDBFP PROTECTION:
1. Axial Displacement very high> 7 mm
2. Bearing temp very high > 100 O C.
3. Deaerator level low-low.
4. Lube oil pressure very low< 0. 8KSC.
5. Suction valve not open.
6. Seal water temp (suction side) very high > 85O C.
7. Seal water temp (disch side) very high >85O C
8. Push button stops.
9. UCB manual stop.
GENERATOR PROTECTIONS
Generator & Aux. Data
Rated MW Capacity : 500 MW
Rated MVA Capacity : 588 MVA
Rated Terminal Voltage : 21 KV
Synchronous reactance : 193 %
Transient reactance : 24%
Sub-Transient reactance : 17%
Rated Power Factor : 0.85
NGT Details
Make : FRANCE TRANSFC France
: 21 kV/240V.3.3A/250A. 60kVA
: % Z - 7.5
: Secondary mid pt. earthed
: Secondary earthing resist.
o.4 Ω, 400A, 250 V
Generator I2t : 10
Continuous Neg. Seq.
Withstand capacity : 8%
Generator Transformer
Rated MVA Capacity : 3 x 200 MVA
Voltage Ratio : 420/V3/21kV
Vector Group : Yd5
Cooling : OFAF
64
% Impedance : 12.59
Grounding : Solid
GENERATOR PROTECTIONS
1. Generator Differential 87G
2. Generator & Generator Transformer
Over all differential 87 GT
3. Generator loss of Excitation 40 G
Generator loss of Excitation 2A/40G
Generator loss of Excitation 2B/ 40g
Generator loss of Excitation 40 GX
4. GT over fluxing 99 GT, 2/99GT.
5. Low forward power inter lock A 37 GA
Low Forward Power 2/ 37 GA
6. Low forward power inter lock B 37 GB
Low forward power 2A/37 GB
Motoring Alarm AB/37 GB
7. Back up impedance 21/G
Back up impedance. 2/21G
8. Stator Earth Fault 1 64 G1
Stator earth Fault 2 64 G2
Stator earth Fault Standby 64 G3
9. Inter turn fault 95 G
10. Rotor Earth Fault SIEMENS
11. GT HV Winding differ 87 HV
12. GT Standby E/F 51 NGT
13. Generator over voltage 59 G
Generator over voltage 2/59 G
14. O/H line differential 87 L
15. Negative Phase Seq. 46 G
16. Generator Overload 51 O/L, (51G)
17. Local Breaker Backup 50Z
Local Breaker Backup 2/50Z, 2/50ZX
18. Pole Slipping 98 G
65
Resistive Finder Relay 98 GY
19. Generator under frequency (Alarm) 81 G
Generator Under frequency (Alarm) 2/81 G
20. UAT Differential 87 UTA
UAT Differential 87 UTB
21. UAT Backup over current 51 UTA
UAT Backup over current 51 UTB
22. GT Differential 87 T
23. UAT Back up E/F 51 NUTA, 51 NUTB
24. Gen. VT fuse fail 160/260/360X
66
02. Generator Negative Sequence Protection 46G
03. Generator Overload alarm (Alarm Only) 51 G
04. Generator Inter Turn Fault Protection 95 G
05. Generator Stator Standby Earth Fault Protection 64 G2
06. GT Over Fluxing 99 GT
07. Generator Field Fail Protection 40G
08. Generator low forward power protection 37GBX, 2A/37GB
09. Generator Transformer Diff Protection. 87T
10. L.B.B. Protection 2/50ZX
11. UAT A Differential Protection 87UTA
12. UAT B Differential Protection 87UTB
13. UATA Backup E/F Protection 51NUTA
14. UATB Backup E/F Protection 51NUTB
15. GT Pressure Relief Device Flag Relay 30 P
16. GT Fire Protection 30 J
17. UAT A& B Fire Protection Flag Relay 30H, 30K
18. B/B Protection Trip Flag Relay 30M, 96X
19. UAT A&B UTI & OTI (Only for UAT Incomer Trip) 30L, 30N
67
b. Trip 400 KV Generator Breaker & 6.6 KV UAT I/C Breaker and field Breaker
Six numbers of cooler units, each unit consists of a fan and a pump. 1, 3, 5 Cooler units
take start along with closing of field breaker & stop with field breaker off.
2, 4,6 Cooler units take start at 80O C. Winding temp & Stop at 70 deg C. winding temp.
UAT’S
UAT’S Has The Following Protections:-
01. Bucholz relay
02. On load tap changer Bucholz
03. Winding temperature high Alarm at 90 Deg. C
Trip at 100 Deg. C.
o4. Oil Temperature High Alarm at 80 Deg. C
Trip at 90 Deg. C
***On Temperature high of winding & oil it offloads the UAT.
68
There are four fans two auto & two standbys i.e. per radiator one main & one reserve. The
main fan takes start at 65O C winding Temperature and stops at 55 Deg. C. winding
temperature. If the main fan trips due to any reason reserve fan takes start automatically.
Step 1: Ensure Generator Breaker is opened, if not then open it from Local.
Step 2: Ensure the availability of 220 Volt DC supply.
Step 3: Ensure DC lighting is in service, if not DC light should be ON manually.
Step 4: Ensure DG set started in auto, if not DG set should be started manually.
Step 5: Take DG set on load and charge DG MCC.
Turbine Side:
All Bearings of turbine and generator needs proper lubrications and Seal Oil at
the ends of casing (DC EOP, DC SOP & DC JOP must be in running condition).
Step 1: Ensure DC EOP has started on auto, if not, start it from DCS/Local.
Step 2: For healthiness of Seal Oil System, ensure that DC Seal Oil pump had
started in auto. In case it does not start on auto. Start DC SOP from local.
Step 3: Ensure vacuum breaker valve opened in auto.
Step 4: Start DC JOP at 510 RPM, if AC JOP does not came on auto.
Step 5: Turbine rotor needs uniform cooling. Barring should ensured otherwise
hand barring should be done.
Step 6: Safety of LP turbine diaphragm – Entry of steam into the condenser to be
restricted & vacuum breaker should be open and seal steam to be
isolated.
Step 7: Both TDBFPs DC EOP should be started in auto, otherwise start manually.
Boiler Side :
69
Step 2: AH needs uniform cooling. Start APH by Air Motor; if air motor is not
running open the by-pass manual valve.
Step 3: Take diesel hydrant pump is in service.
After charging DG MCC ensure that :-
Changeover DC Aux to AC Aux.(i.e., JOP, EOP, Scanner fan etc,)
Start SOP (H2-side).
Unit DCDB main charger is in service.
Start JOP & LOP of both TDBFPs and stop DC EOP.
Keep MOT vapor extraction fan B in service.
Start all Air Pre Heaters electrically.
Start LOPs of ID fans, FD fans, PA fans & Mills.
If LT supply is restored, then all electrically operated valves should be closed
from control room.
At 510 RPM of Turbine , start AC JOP if not then start DC JOP and turning gear
motor should be ON. Engage barring gear when turbine come to rest, then
hand barring of turbine is required for uniform cooling of rotor. The rotor
should be rotated by handle intermittently.
70
Unit Start-up Procedure
1. Total no. Of permits issued during shut-down ......................
2. Total no. Of permits cancelled ......................
3. List of pending permits not essential for rolling a. ......................
b. ......................
c. ......................
10. Ensure clearance from BMD for lit up (for cold start) ........................
71
16. Start MD-BFP Time.-.................
17. Inform AHP for LP pump availability and boiler –furnace sealing ...................
19. Check all flue gas path dampers/ gate of Air-heater Inlet/Outlet (should be opened)
21. All boiler drum vent should be opened if drum pressure < 3Kg/cm2 .................
22. All super-heater drains should be opened if drum pressure < 3Kg/cm2 ..............
23 Start one of set of the ID / FD fan and maintain 30% air flow with balanced draft.
26. Add two more HSD guns after 30minutes Time - .................
27. Check all turbine area drains and MAL drains. (Open/Close) .....................
29. Open Gland sealing lines drain at 17 mtr and 8.5 mtr near station ....................
g) Make sure line and bus isolator connected to reference bus .....................
72
32. Close all drum air vents at 3 kg/cm2 of drum pressure time................
39. Add HFO guns as soon as aux steam ready for heating and atomising.
48. Line up of both TDBFP from Feed water line & gland sealing time................
52. Observe required steam parameter with gradual rising of firing rate for fulfilment of Turbine
criteria
73
(Observe furnace temp then rise gradual loading of mill)
a. Ensure controller in EHG. Check settings of EHTC & CMC page in DCS.
64. Give command for 360rpm & observe all Turbovisory parameters and observe LPT exhaust
hood temp.
68. Give command 3000 rpm in speed controller & observe all Turbovisory parameters
73. Close HP/LP Bypass gradually and mal drains too. ...........................
74
74. Take all fuel oil tank levels (HSD & HFO) ..........................
75. Observe the following very important parameters going before 100 MW
77. Raise Load gradually (up to 230MW) with respect of rising of firing rate.
78. Start second PA Fan and Mills one by one according to required parameters.
81. Feed ctrl v/v change over from 30% to 100 % (at 180Mw). Time...................
86. Start HPHs charging from steam side at 250MW - 275MW. Time...................
87. Take fuel oil tank level after complete oil guns withdrawn. ..........................
75
Shift in Charge
Group...........
1X500 MW
(Extn.)
SHUT-DOWN PROCEDURE
1. Ensure that the Unit is on CMC mode with limit pressure mode (Load Control Active) in
service and Boiler Master in auto mode. ………….…..……..
2. Check the load gradient is set at 5 MW/min on both the consoles and MS Pr Set Pt in auto
mode. ………….…..……..
3. Reduce the load demand to 400 MW & wait till load reduces to 400MW.………….……
4. Take the MS Pr controller in manual and gradually reduce the throttle pressure set point to
about 130Kg/cm². ………….…..……..
5. Drop the MS temperature and RH temperature to cool the turbine (up to 510°C).
………….…..
……..
6. Take Unit on Turbine Follow mode (Pressure Control Mode). ………….…..……..
7. Stop the top most pulveriser to reduce the firing. ………….…..……..
8. Close the extraction block valves of HP heater 6 from steam side. ………….…..……..
9. Further reduce the firing to reduce the steam temp and Unit load up to 375MW.
………….…..
……..
10. Maintain the furnace pressure, boiler drum level and PA header pressure during the transient.
………….…..
……..
11. Check that HP casing temperature and HP shaft temperature drops as per the main steam
temperature. ………….…..……..
76
12. Check that flame intensity at elevations corresponding to running feeders and also the furnace
pressure. ………….…..……..
13. Select the pulveriser which is at the top most elevation. Reduce the loading of the feeder to
minimum. Stop the feeder. ………….…..……..
14. Wait till the pulveriser grinding current comes to No Load Current. Check that the mill outlet
temp and bowl differential pressure. ………….…..……..
15. Check that the turbine pressure controller is active and Unit is in turbine follow mode from
CMC. ………….…..……..
16. Reduce the fuel input by decreasing the maximum limit (feed rate) of individual running
feeder from CMC console. ………….…..……..
17. Reduce the throttle steam pressure set point gradually by lowering the set point on CMC
console. ………….…..……..
18. When Load approaches 350MW, start MDBFP, take it on load & stop one TDBFP.
………….…..
……..
19. Ensure the Load reduced up to 270 MW, Stop the second TDBFP & ensure MDBFP is
working normal. ………….…..……..
20. Close the extraction block valves of HP heater 5 from steam side. ………….…..……..
21. Transfer the furnace pressure controller to manual mode and reduce the loading on one ID
Fan and load the other fan. ………….…..……..
22. Transfer the FD Fan blade pitch control to manual mode and unload the FD Fan
corresponding to above ID Fan which is unloaded. ………….…..……..
23. Maintain the furnace pressure and air flow during above operation. ………….…..……..
24. Stop one ID Fan and one PA fan. ………….…..……..
25. Ensure the flame stability within the furnace; if necessary Cut-in the oil support (Three
feeders with loading above 75% may not need the oil support). ………….…..……..
77
26. Adjust the HP bypass pressure set point to match existing throttle pressure.
………….…..
……..
27. Transfer the Initial pressure mode to limit pressure mode and reduce the throttle pressure set
point to keep the deviation positive. ………….…..……..
28. Reduce the target load (load reference) value from the governing console (Pr ref. & Pr limit
comes down at a rate set by the load gradient). ………….…..……..
29. Ensure that LP bypass controller is kept on auto with fixed set point slightly below the sliding
set point. ………….…..……..
30. As the throttle pressure increases on reduction of load the HP bypass valves will open on auto
causing the cold reheat pressure to go up. Once this pressure exceeds the sliding set point, LP
bypass valves will also open. ………….…..……..
31. Further reduce the load set point from the governing console. Check that the opening of HP
by pass valves increases further. The hot reheat temperature can be controlled by controlling
reheat temperature by HP bypass attemperation valves. ………….…..……..
32. Change over from unit supply to station supply for 6.6KV A and B buses using synchroscope.
………….…..
……..
33. Cut-in oil support at AB elevation with minimum oil pressure to stabilize the flame.
………….…..
……..
34. Transfer all the three running feeders to manual mode and reduce the loading in one of the
pulverisers. ………….…..……..
35. Take out top pulveriser. ………….…..……..
36. Close the extraction steam block valves to LPH1,2 &3 once load has come below 20%. Check
that the drain control valves closes. Open the drains of the extraction line.………….….
37. Transfer the low load feed regulation station to auto mode and take the three element feed
water control to manual mode. ………….…..……..
38. Stop one CEP also by giving a stop command from the UCB hand switch after opening the
recirculation valve fully. ………….…..……..
39. Cut in one more oil elevation and maintain the oil pressure & temp.………….…..……..
40. Change over the 16 ata header from existing unit by opening the tie valve.
………….…..
……..
78
41. Reduce the attemperation if the main steam temperature has come to around 380°C
………….…..
……..
42. Maintain the hot well, deaerator level during this transient operation.………….…..……..
43. Ensure that unit status is safe. ………….…..……..
44. Take the HP/LP bypass valves in manual mode and reduce the opening of HP/LP bypass.
………….…..
……..
45. Stop bottom pulveriser as per the instruction given earlier. ………….…..……..
46. Check that all the fuel air dampers close from top to bottom. ………….…..……..
47. Bring the burner tilt to horizontal position. ………….…..……..
48. Check that start permit is available, burner tilt horizontal and air flow less than 40%.
………….…..
……..
49. Remove the oil guns at CD elevation by pressing pair 1-3 and 2-4 stop push buttons.
………….…..
……..
50. Check that 5 min. scavenging operation is complete and gun retracts back.
………….…..
……..
51. Remove the oil guns at AB elevation.
52. The moment oil nozzle valve for 4th corner closes, the boiler will trip and loss of all fuel to
furnace alarm will come. ………….…..……..
53. MFR tripped alarm comes. Both the MFR A/B relays trip red lamp comes.………….…..……
TURBINE ON BARRING GEAR
54. At 2850 RPM, ensure that one AOP cut-in to operation (If AOP fails to start in Auto mode
then start it manually). ………….…..……..
55. At about 540 RPM ensure that jacking oil pump takes start and jacking oil pressure comes to
about 125 Kg/cm². ………….…..……..
56. At about 210RPM check that the barring gear valve starts opening and turbine speed is
maintained to about 190 RPM. ………….…..……..
57. Open the HP casing drain manually after switching off the SLC. ………….…..……..
58. Open the entire four drains upstream interceptor valve at valve seat.………….…..……..
79
59. Open the main steam strainer drain valve. ………….…..……..
60. Open the drains upstream of ESV at valve seat. ………….…..……..
61. Ensure the SLC drain for various drain valve in ‘ON’. ………….…..……..
62. Check the differential expansions of all the three casing within limits.………….…..…..
63. Check the bearing temperature for all the bearing should start coming down.
………….…..
……..
64. Check that the seal steam pressure is maintained and condenser Vacuum satisfactory.
………….…..
……..
65. Reduce the fixed set point of LP bypass to maintain flow through reheater. The opening of the
LP bypass control valve increases. ………….…..……..
66. Reduce the attemperation controllers to minimum for SH and RH. ………….…..……..
VACCUM BREAK
………….…..……..
67. Stop Vacuum Pump.
68. When condenser pressure approaches 0.7 to 0.8 kg/cm², open Vacuum Breaker.
………….…..
……..
69. Break Seal Steam Supply and Stop Seal Steam Exhauster fan. ………….…..……..
OBJECTIVE
A. To trip the boiler and carry out the purging. ………….…..……..
B. To fill the boiler to highest drum level. ………….…..……..
OPERATIONAL STEPS
80
70. Check that HOTV closes and green lamp comes on. ………….…..……..
71. Bring the air flow to less than 40% by FD fan blade pitch. ………….…..……..
72. Check that all the purge permissive are satisfied and purge ready lamp comes.
………….…..
……..
73. Close that HP/LP bypass manually and increase the set pressure higher than the existing
pressure. ………….…..……..
74. Push the ‘Push to purge’ switch from FSSS consol. The purging light glows and stays for 5
mins. and purge complete light comes once purging is over. The MFR A and B relay reset.
………….…..
……..
75. Wait till the fuel air damper starts closing from top. Maintain the air flow in between 30 to
40%. ………….…..……..
76. Raise the MDBFP discharge pressure by raising the scoop. ………….…..……..
77. Open the low range feed control valve to start the drum filling. Check that the level in drum
which will gradually increases. ………….…..……..
78. Stop the drum filling once all the ports of the hydra step are indicating water (green lamp on).
Ensure that blow down valves are closed including emergency blow down.………….…..……
79. Stop the HP dosing system from local. ………….…..……..
80. Stop the MDBFP. Ensure that barring gear of the BFP turbine engages.………….…..……..
81. Stop the LP dosing pump. ………….…..……..
82. Close the manual isolation valve to HP bypass desuperheating valve from local.
………….…..
……..
83. Check that MDBFP discharge pressure and flow drops to zero. ………….…..……..
84. Close the equipment cooling water to MDBFP motor. ………….…..……..
85. Check the plant status with boiler in tripped condition and purging carried out.
………….…..
……..
86. In manual mode reduce the FD fan blade pitch to 0%. Check that the air flow reduces and
generates an alarm below 30%. ………….…..……..
81
87. Check that the first cause of trip red flags comes on FSSS console as air flow is less than
30%. Both the MFR trip and red lamp comes on. ………….…..……..
88. Stop the FD fan by turning the switch to OFF position. ………….…..……..
89. Check that the fan current drops down to zero and discharge pressure starts dropping down.
………….…..
……..
90. Check that discharge dampers of both the fans open fully. ………….…..……..
91. Check that scanner fan emergency damper from atmosphere opens. ………….…..……..
92. Stop the ID fan by turning the switch to OFF position. ………….…..……..
93. Check that the fan Amps drops down to zero and inlet/outlet pressure decreases.
………….…..
……..
94. Ensure that the dampers for all three fans open fully on interlock. ………….…..……..
95. Keep the lube oil pumps of the entire fan running till the bearing temp of the fans come down.
………….…..
……..
96. Check that the flue gas temp. entering the air heater goes less than 120°C. Stop secondary
APH A & B motor. ………….…..……..
97. Keep open all the flue gas inlet /outlet dampers on air side as well as flue gas side in order to
allow the natural air circulation for cooling. ………….…..……..
98. Check and close all air preheater cold end temp. controllers. ………….…..……..
99. Close the steam inlet valves to primary and secondary APH. ………….…..……..
100.Ensure that ESP fields are not charged. ………….…..……..
101.Stop the DC scanner air fan, once the furnace is sufficiently cooled.………….…..……..
82