ORISSA POWER GENERATION CORPORATION

Technical Diary
2×210 MW

IB THERMAL POWER STATION

BANHARPALI, JHARSUGUDA
ORISSA, INDIA
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TECHNICAL DIARY

ORISSA POWER GENERATION CORPORATION LIMITED.

IB THERMAL POWER STATION

(2210 MW)
BANHARPALI, JHARSUGUDA. 768234

First Publication 2003

All rights reserved. No part of this publication may be reproduced, stored in a retrieval
system, 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.

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FOREWORD

"OPGC’s 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)
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MESSAGE

"I'm happy and proud once more that OPGC is ready with a technical document,
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)
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CONTENTS

INTRODUCTION 9

SECTION 1 BOILER & AUXILLIARIES

1.1 General Specification 11
1.2 Furnace Specification 11
1.3 Water Walls 12
1.4 Drum 12
1.5 Super Heater 13
1.6 Reheater 13
1.7 Super Heater & Reheater Temperature Control 14
1 SH Attemperator
2 RH Primary Temp. Control ( Burner Tilt Control)
3 RH Emergency Temp. Control
1.8 Economiser 14
1.9 Regenerative Air Preheater 15
1.10 I.D. Fan 16
1.11 F.D Fan 17
1.12 P.A. Fan 18
1.13 Fuel Preparation & Firing System 19
1 Oil Burner 19-20
LFO Burner, Ignitors, Fuel Oil Specification, Fuel Oil
Pressurising Unit, Fuel Oil Storage Tank, Data Chart
2 Gravimetric Coal Feeder 21
3 Pulveriser 21
4 Coal Pipe 23
5 Coal Burner 23
6 Seal Air Fan 23
1.14 Scanner Air Fan 24
1.15 Soot Blowers 24
1.16 Electrostatic Precipitator 24
1.17 Pressure Reducing & Desuperheating Station (PRDS) 26
1.18 Main Pipe lines 27
1.19 Boiler Chemical Dozing 27
1.20 Blowdown Vessels 27
1.21 Safety Valves 28
1.22 Chimney 28
1.23 Fuel 28
1.24 Chemical Composition of Ash Generated in ITPS 29
1.25 Predicted Performances 29-32
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SECTION 2 TURBINE & AUXILLIARIES

2.1 Turbine Technical Specification 34-37

1.Steam Turbine, 2.Dimensions, 3.Bearings, 4.Valves,
5.Weights, 6.Casing Temperatures, 7.Turbine Bearing Temp,
8.Temp. Difference, 9.Differential Expansion, 10.Vibration
11.Low Vacuum Trip Setting, 12.MW Output, 13.Steam Purity.
2.2 Turbine Lub Oil System 37-39
1.Oil Supply, 2.Oil Pumps, 3.Oil Cooler, 4.Oil Filter
5.Estimated Oil Requirements of Bearings, 6.Barring Gear,
7.Main Oil Centrifuge, 8.Oil Characteristics
2.3 Vacuum System 40-42
1.Condenser, 2.Main Ejector, 3.Starting Ejector
4.Gland Steam Vapour Fan 5.Gland Sealing System
6.Condenser On Load Cleaning Device
2.4 Condensate System 42-44
1.Condensate Extraction Pump, 2.Drain Cooler
3.Gland Steam Condenser, 4.Low Pressure Heaters
2.5 Feed Water System 44-47
1.Deaerator, 2.Boiler Feed Pump (Hydro Turbo Coupling,
AOP, Oil/Water Heat Exchanger), 3.H.P. Heaters
2.6 HP Bypass System 48
2.7 Flash Tank/Flash Box 48-50
1.Unit Flash Tank,
2. Turbine Flash Box
3.Condenser Flash Box
2.8 Predicted Performance of Turbine 50-52

SECTION 3 GENERATOR & AUXILLIARIES

3.1 Generator Technical Specification 54-55

Static Excitation Equipment,
Excitation Transformer Detail
3.2 Design & Construction Features 55-56
Material, Weight & overall Dimensions,
Torques, Critical Speeds etc, Oil Consumption
3.3 Generator Gas System 56-57
1.H2 in Stator Casing, 2.Generator Filling Quantities
3.Hydrogen Cooler, 4.Hydrogen Drier,
5.Setting Values For Alarm
3.4 Stator Water System 57-59
1.Stator Water Cooler, 2.Stator Water Pump
Stator Water Make Up Pump
3.Stator Water Filter, 4.Magnetic Filter,
5.Expansion Tank, 6.Quality of Distillate
7.Setting Values of Stator Water System
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3.5 Seal Oil System 59-60

1.Seal Oil Cooler, 2.Seal Oil Pumps
3.Vacuum Pump, 4.Oil Filter
3.6 Specification of Transformers 61-62
1.GT, 2.ST, 3.UAT,
4.Various Service Transformers
3.7 H.T. Motors 62
3.8 Battery & Battery Charger 63-65
1.220V DC Battery, 2. +24V Battery
3. –24V DC Battery, 4.UPS System
Generator Relay Panel 65
G.T. & U.A.T. Relay Panel 67

SECTION 4 CONTROL & INSTRUMENTATION

4.1 Unit C&I System 69-73

OLCS/CLCS, Information System, Standard Displays,
Sequence of Event Recorder, Interface With FSSS/ATRS
Relay Panel (Only Binary Communication)
Electronic Automation System for Steam Turbine
Uninterrupted Power Supply
LAN & IT 73
4.2 Interlock Protection 74
4.2.1 Boiler & Aux., Pulveriser, Coal Feeder, Oil Gun 74-82
Fuel Oil Selection, Scanner Air Fan, RAPH,
ID Fan, FD Fan, PA Fan
4.2.2 Turbine & Aux, Turbine Protection, Turbine Oil Pump, 83-88
Turning Gear, BFP, CEP, HP/LP Bypass System,
Main Oil Centrifuge, Regenerative Heater System,
Stator Water Pump, Seal Oil System, Air Conditioning
Plant

SECTION 5 OFFSITE AUXILLIARIES

5.1 Raw water System 90

Raw Water Pump
5.2 Circulating Water System 90-91
1 C.W. Pump,
2 Cooling Tower
5.3 BCW System 92-93
1 BCW Pump,
2 Plate Heat Exchanger
5.4 Service Water System 93
5.5 Water Treatment Plant 93
1 Pre-Treatment Plant 93-95
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2 D.M. Plant 95-98

Effluent Quality, ACF & Exchanger Data, Relevant
Data for Regeneration, Miscellaneous Pumps,
Limiting Values of Boiler Water Chemistry.
5.6 Standard Limits of Environmental Emission 98
5.7 Coal Transportation & Coal Handling System 99-100
1 Coal Transportation System, Filling Station
For Diesel Locomotive
2 Coal Handling System 100-102
Track Hopper, Paddle Feeder, Vibration
Grizzle Feeder, Crusher House, Conveyor,
Tripper, Stacker/Reclaimer, DE System, Stock Yard
5.8 Ash Handling System 102-104
1 Bottom Ash Hopper,
2 Clinker Grinder,
3 Horizontal Ash Water Pumps,
4 Ash Disposal Pump
5 Ash Collection Rate
5.9 Ash Pond & Ash Water Recycle System 104
Transfer Water Pump, 33 KV/6.9 KV, 450 KVA
Transformer, 150 Kva Aux. Transformer
5.10 Fire Fighting System 106-108
1 Fire Detection & Alarm System
2 Fire Suppression System, Fire Hydrant Pump,
Automatic Mulsifire Fire System, Jockey Pump,
Hydro Pneumatic Tank, Air Compressor,
Foam System, Halon System
5.11 Air Compressor 109
5.12 Air Conditioning Plant 110
5.13 Main Plant DG Set 112

SECTION 6 ANNEXURE

Annexure 1 Turbine Rolling Curves 114-120

Annexure 2 Generator Operating Limits 121
Annexure 3 Unloading Schedule Due To High
Distillate Temperatures 122
Annexure 4 Statutory Clearances 123
Annexure 5 Lincences 124
Annexure 6 Steam Table 125-128
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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.

2. Station Capacity 420 MW(2x210 MW Units)

3. Climatic condition Max. Temp- 490C

Min Temp- 70C
Max relative humidity-95 %

4. Land utilization
Main Plant 797.51 Acres
Ash Pond (A+B) 493.16 Acres
Ash Pipe Complex 13.01 Acres
Merry Go Round System 85.96 Acres
Town ship, Roads & Market 476.12 Acres

5. Fuel 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) Consumption–8016 MT/day for design
coal.

6. Start up Power Through 2x55 MVA, 220/6.9 K.V.3-Ø station

transformer.

7. Cooling Water System Closed Loop with induced draft cooling tower.
8. HP/LP By pass Capacity 60% of MCR.
9. Heat Rate 2500 Kcal/ Kwh.
10.Ash disposal Disposed to ash pond in form of ash slurry
with 100% ash water recycling system.
11.Chimney RCC multi flue, 220 m. High.
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SECTION – 1

BOILER & AUXILIARIES

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1.1 GENERAL SPECIFICATION

i) Manufacture BHEL (C.E. design).

ii)Type Single reheat, natural circulation type,
single drum, balanced draft, dry bottom type
designed for firing coal as main fuel.
iii) Boiler designation 13868 181 63.5 1778 NCRR,
10592 130 63.5
Design code: ISO-R 831

iv) Type of firing Tilting tangential.

v) Design pressure, Ksc Drum 177
SH O/L 164
vi) Water volume, m3
Generating surface 125.00
Drum 40.00
Economiser 20.00
Super heater 95.00
Reheater 50.00_
Total water volume 330.00

vii)Heating surface, m2
Economiser 8087.00
Super heater 7416.00
Reheater 2656.00
Water wall 3493.00
Total heating surface 21652.00

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 Fusion welded wall.

ii) Dimension 10,592 x 13,868 x 43,130 mm (D×W×H)
iii)Total volume 5240m3
iv) Combustion
chamber volume 4100m3
iv)Bottom Dry
v)Draft Balanced
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vi)Effective projected radiant

surface 2100m3
vii)Design pressure ±400mm wc @67% yield strength
viii)Heat liberated by fuel 1,01,300 (Kcal/hr/m2) at 100%
Per unit furnace vol. 65,550 (Kcal/hr/m2) at 60%
ix)Fuel heat input 534.0 x 10 6 Kcal/hr.

1.3 WATER WALLS

Front wall Sidewall Rear wall Furnace roof 2nd pass

i)No.of Tubes 181 130 181 120 120
ii)Dia(mm) 63.5 63.5 63.5 51.0 44.5
iii)Material --- -----------SA210 Gr.C--------------SA209T1 SA210Gr.A1
iv)Thickness -------------------5.5 mm-------------- 4.5 mm 4.5 m
v)Design pr.(Ksc) --------- --------- 179.8 ---------------- 176.8 174.8
vi)Down comers.
a)Nos 6
b)Dia(mm) 406.4
c)Pressure 179.5 Ksc.
d)Material SA 105 Gr.C

vii)Water wall headers Bottom Ring header Water wall header

a)Nos. 04 07
b)Dia (mm) 273.0 219.1
c)Material SA 106 Gr.C SA 106 Gr.C
d)Design pr.(Ksc) 175.4 177.0

1.4 DRUM
i) Material SA-299
ii) Design Pressure, Ksc 177.00
iii) Drum operating pr. Ksc 166.00
iv) Design temp 3540C
v) Overall length, mm 15,000
vi) Shell length from
weld to weld, mm 10,620
vii) I.D/O.D, mm 1778/2079
viii) Thickness, in mm
(straight portion/dished portion) 170/135
ix) No of distribution headers 6
x) No of cyclone separator/
secondary drier 58/58
xi) Permissible temp difference
between Top& Bottom 500C

xii) Drum level indicator

Location Type No & make
a) MCR Conductivity 2,BHEL
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b) Drum DWLG 2,Yarway

c) Fireman’s floor Conductivity 2,BHEL

1.5 SUPER HEATER

LTSH PSH FSH

i) Type convection Radiant Radiant

ii) Direction of flow counter parallel
parallel
iii) Heating surface (m2) 3035 1097 1543
iv) No of Tubes 480 232 357
v) O.D.(mm) 44.5 47.63 44.5
vi) No of elements/assembly 4 8 3
vii)Tube pitch, mm 114/96 457.2/57 114.3/96
(across gas path/along gas path)
viii) Material SA210 Gr C SA213 TP347H SA213T22
SA 213T11 SA 213T22 SA 213T22

SH HEADER
i) Max operative pressure, Ksc 155.00
ii)O.D, mm 406.4
iii)Thickness, mm 44.5
iv) Max SH steam temp. 540 + 50C

1.6 REHEATER

i)Type a)Front RH-Pendent

b)Rear RH –spaced.
ii)Design pressure, Ksc 44.45.
iii)Max operating pressure, Ksc 38.5
iv)Total heating surface, m2 2656
v)Control Burner tilt.
vi) Gross length per tube 10,000 mm (approx.)
vii) Total No of tube 59 assemblies
viii) O.D, mm 54.00
ix) Tube thickness, mm 3.6
x) Tube material SA 213 T22,T11, T91, SA209 T1

xi) Tube pitch, mm a) across gas path-228.60

b) along gas path- 100.00

xii) Reheater Header

a) Material SA-213 P22
b) O.D, mm Inlet-406.4, outlet-558.8
c) Thickness, mm Inlet-46.0, outlet-45.0
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1.7 SUPER HEATER & REHEATER TEMP. CONTROL

1.7.1 SH ATTEMPERATOR

i)Type Spray mixing type.

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

1.7.2 RH PRIMARY TEMP. CONTROL (BURNER TILT CONTROL)

i)Max. angle of tilt + 300

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

1.7.3 RH EMERGENCY TEMP.CONTROL

i)Type Spray mixing type.

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

1.8 ECONOMISER

i)Type Plain tube, seamless, continuous loop in line

ii)No. of blocks 2
iii)Material SA 210 Gr. A
iv) OD/thickness(mm) 44.5 / 4.5
v) Tube pitch (mm) a) across gas path-96
b) along gas path-130
vi ) Heating surface 8070 m2
vii) Gas velocity at 2nd pass
of boiler at100% MCR 8.0 m/sec
viii) Design pressure 181.9 Ksc.
x) Economiser Header I/L Header O/L Header
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a)Material SA-106 Gr. C SA- 106 Gr. C

b)Outer diameter, mm 323.9 323.9
c)Max. operating pr. Ksc 171.5 171.5

1.9 REGENERATIVE AIR PREHEATER

i) Type Bisector, Regenerative

ii) Size 27 VIM 2000 (Bisector)
iii) No. per boiler Two
iv) Arrangement Vertical
v) Element Height 2000 mm
vi )Heating elements.
a) Hot end/hot intermediate
Element type DU (24 gauge)
Height 850 mm
Material carbon steel

b)Cold end /cold intermediate

Element type DU (22 gauge)
Height 300 mm
Material corten A
vii)Rotor Seals.
a)Radial seals hot end 2.5 mm thick corten A
Radial seals cold end 2.5 mm thick corten A
b)Axial seals 2.5 mm thick corten A
c)By pass seals 1.6 mm thick corten A
d)Rotor post seal hot end 6 mm BM-C20
Rotor post seal cold end 6 mm BM-C20

viii)Bearings
a)Support bearings Spherical roller thrust SKF/FAG-
294/500
b)Guide bearings Spherical roller SKF/FAG-23060
CCK/W 33
ix)Oil capacity.
a)Support bearing 150 litres.
b)Guide bearings 25 litres.

x)Oil circulation system

Guide bearing
a)Pump Hypo screw pump
No. per boiler 4
Model No. HSTR 3
Type 976
Size 1” x 1”
Capacity 15 LMP
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b)Drive motor 0.55 Kw, 3, 50 HZ, 415V, 910 rpm,

Insulation class F

Support Bearing.
a)Pump Hypo screw pump
No. per boiler 4
Model No. HSTF 3
Type 976
Size 1” x 1 “
Capacity 15 LMP
b)Drive motor TEFC rating 0.55 Kw, 3-,50 HZ,
415V, 910 rpm, insulation class F
Heat exchanger Horizontal & shell & tubular type,
capacity 7500 KL/hr.
xi)Cleaning device Power driven soot blowing
a)Motor detail 0.18 kw,3,50 HZ,415 V,1380
rpm, insulation class F
b)Reducer Allroyd gear, reduction ratio 4000:1
c)Steam consumption 2000 Kg/hr/service, at 18 Ksc,150oC
x)Rotor stoppage Alarm
Go switch APCO
Input power 105-135 V, 50HZ
Alarm power 120 or 230 V AC 10 Amps
10-150 V DC 2 Amps

1.10 ID FAN

i)Manufacturer BHEL
ii)No.per boiler. 02
iii)Type NDZV 31 SIDOR,
Orientation Top horizontal
Delivery Radial, double suction,
central discharge.
iv) Medium handled Flue gas
v) Fan drive & type Hydraulic coupling
SVNL 1150, Voith
vi)Fan regulation Hydraulic coupling
vii)Fan design rating
Capacity 224.15 m3/sec.
Total head developed 445 mmwc
viii)Temp. & specific wt. of medium 1500C & 0.7918 Kg/m3
ix)Fan reserve over MCR
Flow 26.3%
Pressure 32.0%
x) Fan
Diameter of impeller 3255 mm
No. of blades 11
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Weight 51,000 kg.

Moment of inertia
referred to fan shaft. 48,870 kg/m2

xi)Bearings Sleeve bearing.

Fixed bearing Thrust collar 2 nos. 8”x c
Expansion bearing 8” x c

x)Drive motor
Make BHEL, Hardwar.
Type Squirrel cage induction motor
Rating 1500 KW, 6600V, 3-, 50 HZ, 750 rpm
Duty type Continuous duty, 167.4A
Efficiency at 100% load 95.6 %
Weight of motor 11,600 kg.

1.11 FD FAN
i) Manufacturer BHEL, Ranipet
ii) No. per boiler 02
iii) Type AP 1-20/11, axial reaction.
iv) Medium handled Ambient air
v) Location Ground level
vi) Orientation Horizontal delivery
vii) Type of fan regulation Blade pitch type
viii)Fan Design Rating
Capacity, m3/sec 150
Total head developed, mmwc 465
Temp. of medium 550C
Specific wt. Of medium 1.0535 kg/m3
Speed 1480 rpm
ix)Fan Reserve.
Flow 30.7%
Pressure 56.0%
x)Fan
Impeller diameter 1990 mm
No. of blades 23 Aerofoil type
Material of blade Al Mg Si lF 2
Hub diameter 1100 mm
Wt. Of fan 8500 kg.
Fan drive coupling Regiflex type
xi)Bearings
Fixed Bearings NU 230C3, 7230 BVA
Expansion bearing NU 230 C3

xii)Drive motor.
Make BHEL, Hardwar.
Frame size LC 00710 H 04 AIH
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Type Squirrel cage induction motor

Rating 920 KW, 6.6K V, 50 HZ, 1500 rpm,
Continuous duty, 100.2A
Weight of motor 7730 kg.
xiii)Lubrication
Fan Forced oil lubrication
Motor Grease lubrication
xiv)Lube Oil System
No. of oil pumps Two
Make Hypo gear pump
Capacity 70 rpm
Discharge pressure 12 bar
Max. operating pressure 16 Ksc.
Alternative pump make IMO screw pump
Lube oil pump motor 3.7 Kw,415 V,50HZ,1450 rpm,
class of insulation B
No. of coolers Two
Oil tank capacity 450 litres
Oil heater Oil immersion type, 4 KW, 415V,
3-, 50HZ.

1.12 P.A. FAN

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

ix)Fan Reserve
Flow 24.3%
Pressure 30.7%
x)Fan Driving Coupling BHEL make pin type flexible
xi)Fan
Impeller dia 2113 mm
Wt. Of fan(without motor & coupling) 8500 kg.
xii) Drive motor
Make BHEL, Hardwar.
 - 19 -

Frame size LC 00710 H 04 A-2H

Type Squirrel cage induction motor
Rating 800 KW, 6.6KV, 50 HZ, 15500 rpm
Continuous duty, 85A
Weight of motor 9540 kg.
xiii)Lubrication
Fan Forced oil lubrication
Motor Grease lubrication
xiv)Bearings
Fixed Bearings Dodge sleeve 5 .7/16” RT
Expansion bearing Sleeve bearing 5.7/16” RT
xv)Lube Oil System
Pump type Screw pump.
Design pressure, Ksc 8.0
LOP Motor. 1.5 KW, 415V, 3-, 1440 rpm, class
of insulation B, Squirrel cage motor.
Lub oil filter 2 nos. basket type, SS mesh, 60 microns.
Lub oil cooler 2 nos. horizontal tubular type
Oil tank capacity 315 litres

1.13 FUEL PREPARATION AND FIRING SYSTEM

1.13.1 OIL BURNER
L.F.O BURNER

i)Service Initial start up purpose.

ii)No. of oil guns 4 nos. oil guns in each AB, CD, EF
elevation.
. iii)Burner Tilting tangential, corner fired.
iv)Atomiser media External mixed ,constant
pressure service air.
v)Atomiser designation Spray plate 90 J16, 90 J14
vi)Max. capacity 7.5% MCR heat input per
elevation & total 22.5% MCR.
vii)Min. allowable LFO pressure 2.1 Ksc
viii)Min. allowable air 5.25 Ksc.

IGNITORS
Make Simmonds, USA
Service Oil burner light off
Type High energy arc ignitor (HEA)
Location Burner mounting panel
Input 110V AC, 50HZ, 5A rms
Output Min. 4 sparks/sec, 12 joules/spark.
Duty cycle 15 min. ON, 30 min. OFF.
Spark rod 5/8” SS tube with flexible SS wire
 - 20 -

braid, 18ft long.

Igniter tip, mm Length-191, Diameter-15.9 + 0.15
Operating temp. 650C max.
Retractor Assembly
Air cycle stroke 300 mm
Air pressure 5 to 7 Ksc.

Flexible cable
Length 7.6 mtr. Max.
Bend radius 100 mm

FUEL OIL SPEFICATION

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

FUEL OIL PRESSURISING UNIT

i)Light diesel oil pump 2 nos per both units.

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

FUEL OIL STORAGE TANK

Type Vertical cylindrical Vertical cylindrical

Capacity 5000m3 1000m3
Numbers 02 02
Size, m 20.0  x 18.0 10.0 x 15.0

DATA CHART.
BURNER LFO BURNER
TYPE LFO AIR
Pressure (Ksc) Flow (Kg/hr) Pressure (Ksc) Flow (Kg/hr)
Max Rating 4.00 1000.00 5.25 135.00
Min Rating 2.1 600.00 5.25 145.00
 - 21 -

During Scavenge 0 0 5.25 180.00

† At present LFO is burned in all the elevations.

1.13.2 GRAVIMETRIC COAL FEEDER

i) Make BHEL, U/L Stock Equipment

Company, USA
ii)Type 36” GF 76’CD,
iii)Capacity 70 T/hr per feeder.
vi)RPM 959
vii)Main drive 5.5 Kw,415V,3,50HZ.
vii)Cleanout conveyor drive 0.25kw,415v,3, 50HZ,910rpm.

1.13.3 PULVERISER

i)Make BHEL
ii)No. per Boiler 03
iii)Type BBD11-4760
iv)Capacity 105 T/hr./mill.
v)Fineness 70% through 200 mesh.
vi)Max. feed size to mill 25 mm.
vii)Size of grinding roll 1/3-50mm
1/3-40 mm
1/3-30 mm
viii)Min. mill capacity
without chattering 30 T/hr.
ix)Mill operating temp. 80-900 C
x)Design. Air flow 70 T/hr
xi)Design pressure 1500 mmwc
xii)Drive motor
Make BHEL
Rating 2250 KW, 6.6KV, 50 Hz, 3-,
266.5A, 993rpm, squirrel cage
induction motor, Insulation class-F
Bearings DE NV 240 EM & 6240 MC3
NDE NV 240 EM.
xii)Lub Oil System
a) L.P. Pump
Make / Type Allweiler Tushaco/ Screw Pump
Number 02 per mill.
Flow 135 lpm at 10 bar
LP side 2×44 lpm
Operating Pressure 6 Ksc.
 - 22 -

Drive details 7.5 kw,415V,50 HZ, 3-,

715rpm, Insulation class-F
Electrical heaters in tank 1 W/cm2, 2×3 KW, 415V,One heater heats
1700 litres From 100 to 350C in 5 hours.
b)H.P. Pump
Number 2 Per Mill.
Flow 4 x 10 Lpm.
Max pressure 100 bar.
Drive details 11 KW, 415 V, 50 Hz
3-, 960rpm, 22.7A
c) B & S Pump
Number 01 Per Mill.
Flow 2 x 3.5Lpm.
Max pressure 60 bar.
Drive details 1.5 KW, 415 V, 50 HZ, 3-.
d)Dual basket filter
Quantity 01 per Mill.
Type RFL DP 661F10B3, 1/50,8062+BM
Filtration nominal 20 Micron.
Normal flow 660 lpm.
e) Oil Cooler
Qty. One per Mill
Type MAL 353 K2K3C.
Oil flow rate 135 lpm.
Oil pump inlet/out let. 550C/450C
Fresh water flow rate 250 lpm.
Water pump inlet/out let 380C /40.40C
Heat exchanger surface 7.40 m2

f) Rectangular Oil Reservoir.

Dimension 1.8m x 1.2m x 1m
Capacity 1770 litres
Qty One per Mill.
Nominal capacity 950 litres.
g) Aux Reducer
Make C.Messian Durand, France.
Reduction type H3 H19
High/ Low speed 1450/14.58 rpm
Oil 80 litres.
Drive details 37 kw,63A,50 HZ, 3,
415 V, Insulation class –F.
h) Fluid Coupling.
Make Fluidomat ltd, Dewas
Model SM 06
RPM 1500
i)Main Sped Reducer (MSR)
Make Flender Macneil, India
 - 23 -

Type SZN 630

Pinion, mm 825.6 OD, 760.48 PCD.
Length of teeth 560 mm
Quantity One per Mill

j) MSR Lube Oil Pump

Type Gear pump
Flow 220 lpm.
Drive details 5.5 kw,12A,50 HZ.3, 415 V,
Insulation class F, 945rpm.
Quantity One per mill.

k) Girth Gear Greasing Unit.

No.of spray Nozzles/valve manifold 06
Quantity One per Mill
Flow 3.8 cm3/cycle
Air consumption 5.0 m3/hr at 2 bar
Drive 0.55 kw,50
HZ.3, 415 V, 1400rpm

1.13.4 COAL PIPE

i) Pipe Size, OD (mm) 558.0, thickness 12.5

ii) Material AP1 5L Gr B

1.13.5 COAL BURNER

Type Tilting tangential
No.per Boiler 24
Capacity 38 x10 6 Kcal/hr/burner
Position Corner
Control Air Damper.

1.13.6 SEAL AIR FAN

No. of fan/Mill 2(One working, one stand by)

Type Single stage centrifugal
Orientation Horizontal suction,
Developed pressure 1662 mmwc
Drive motor Crompton Greaves make,
120KW, 415V, 3, 50HZ, 2960 rpm,
 - 24 -

Insulation Class-B

1.14 SCANNER AIR FAN

No. per boiler 1 AC driven,1 DC driven

Duty Continuous
Medium to be handle Dust laden air
Max.dust con 300 mg/m3
Capacity 5000 m3/hr.
Presure developed 200 mmwc
Driving motor 415V, 3,50HZ, 5.5kw
10A, Insulation class-B

D.C. motor 5.6 KW, KEC make,33 A,

Insulation Class-F
Fan speed 2850 rpm

1.15 SOOT BLOWERS

Type Fully automatic sequentially

controlled micro processor
. based steam soot blowing.

Source of steam SHH-10 (LTSH-O/L Headers) / PRDS

Wall blower LRSB.

i)Number 56 18
ii)Type WBIE LRDIE
iii)Motor power 0.56 KW 0.37 KW
0.45 KW
iv)Cleaning medium Steam Steam
Pressure 20 Ksc 20 Ksc
Temperature 3000C 3000C
Consumption (per cycle) 3292.8 kg 8013.6 kg.
v)Blow duration 1.5 min/blower 9 min/ blower
vi)Cycle 84 minute 162minute

1.16 ELECTROSTATIC PRECIPITATOR

i)Manufacture BHEL
ii)Type FAA-6 x 45-2 x90135-2
iii)No.of precipitators/boiler Two
iv)No. of gas path/boiler Two
 - 25 -

v)No. of fields in service in each gas path Six

vi) In let design conditions
Gas flow rate 351.27/m2/sec.
Temp. 1430c
Dust conditions 82.44 gms/Nm3
vii)Guaranteed collection efficiency for
design conditions 99.82%
viii)Pressure drop across the precipitator
for design conditions 20 mmwc
ix)Velocity of gas at electrode zone on total area 0.72 m/sec.
x)Treatment time 37.5 Sec.
xi)Collecting electrodes.
a)No. of collecting electrodes per field 61
b)No. of collecting electrodes plates(six
plates are arranged in each row per field) 366
c)Space between the centers of collecting
electrodes across the gas path in mm 300
d)Nominal length of collecting electrodes
per field in the direction of gas flow 4.5 m.
e)Total No. of collecting plates per boiler 4392
f)Nominal length/Height of collecting plates 750/1350 mm
g)Sp. Collecting area 249 m2/m3/sec.
h)Total projected collecting surface 87,480 m2
xii)Emitting Electrodes
a)Type Spiral with hooks
b)Size 2.7 mm diameter
c)No. of the electrodes in the frame
forming one row 54
d)No. of electrodes in each field 3240
e)Total No. of electrodes /boiler 38880
f)Total length of electrodes per field 18176.4 m.
g)Plates/wire spacing 150mm
xiii) Rappers for emitting electrodes
a)No. & types of rappers One drop hammer for two nos.
of electrodes.
b)Rapper size 30 kg.
c)Frequency of rap. 10 raps/hour
d)Drive Geared electric motor controlled
by synchronous programmer.
xiv)Hoppers
a)Type & No. Pyramidial,48
b)Capacity 8 hours storage
c)Heating Electrical heating provided for
bottom of hoppers.

xv) Gas Distribution System Inlet Outlet

 - 26 -

Type perforated plate U-shaped thin

sheet
Quantity 2 set 1 set

xvi) Electrical items.

1) Rectifier
Rating 70KV(peak),1000mA(Mean)
Number 24
Type Silicon diode, full wave bridge
Connection.
Location Top of precipitator.
2) Rectifier control panel
Number 24
Type Thyristor.
Location In control room at ground level
3) Motors for emitting and collecting rappers
Quantity 24 nos.
Rapping 415V, 3, 50HZ, 0.26kw 1A,
1310rpm, continuous rapping.
Location On roof top of ESP.

4) Heating elements
a)Hoppers for 48 hoppers @
6 KW per hopper 288 Kw
b)Shaft insulators for 24 insulators @
1 KW per insulator 24 Kw.
c)Support insulators for 96 insulators
@ 1 KW per insulator 96 kw
d)Estimated power consumption including
heating elements & rappers 630 Kw.
5) Recommended current setting
Fields 1 2 3 4 5 6
Current in mA 250 400 550 700 850 1000
xvii) Operating sequence of rapping mechanism Auto

1.17 PRESSURE REDUCING & DESUPERHEATING STATION (PRDS)

i)Steam source MS Line at 150 Ksc & 5400c

ii)Flow capacity Design-80t/hr.
Normal-56t/hr.
iii)Spray water BFP discharge
iv)Operating pressure 16 (Ksc) g
v)Operating temp. 2200c
vi)Header size 273 x 635 mm
vii)Material SA 335 P22
 - 27 -

1.18 MAIN PIPELINES

Main steam Hot reheat Cold reheat Feed water

No. of lines 2 2 2 1
ID x Thickness, 255.6x47.0 508.6x28.0 457x20.0 323.9x36.0
(in mm)
Material SA335P22 SA335P22 SA335P22 SA106Grc
SA106Gr.c

1.19 BOILER CHEMICAL DOZING

Phosphate Dozing
i) No. of Pumps 4
ii) No. in Operation 1 per unit
iii) Discharge Pressure 200 Kg/cm2
iv) Pump Motor 1.5 KW, 1425 rpm
v) Dozing Tank Capacity 1760 litres
vi) Stirrer
Make Shurtek
Motor 0.75 KW, 1405 rpm

Hydrazine & Ammonia Dozing

i) Tank Capacity 2200 litres
i) No. of Pumps 4
ii) No. in Operation 1 per unit
iii) Pump Type Reciprocating Plunger
iv) Discharge Pressure 35 Kg/cm2 (max)
v) Pump Motor 0.75 KW, 1405 rpm
vi) Stirrer
Make Shurtek
Motor 0.75 KW, 1405 rpm

1.20 BLOWDOWN VESSELS

IBD CBD
Test Pressure 4.5 ksc 13.5 ksc
Max working Pressure 3.0 ksc 8.0 ksc
Operating Temp 200 0C 180 0C
Capacity, m3 2.205 3.930
 - 28 -

1.21 SAFETY VALVES

Sr No Valve Tag Location Type of Valve Size mm / inch Valve Set Pr. Ksc Blow Relieving Tot
Safety Valve Down Capacity,kg / hr Capacity
INLET OUTLET OPEN CLOSE
Butt Welded Flange Welded

1 SV1 Boiler Drum Consol 1750WB 76.2 / 3" 152.4 / 6" 177 169.9 4 180360
2 SV2 Boiler Drum Consol 1750WB 76.2 / 3" 152.4 / 6" 180.5 171.5 5 183924 1,2,3
3 SV3 Boiler Drum Consol 1750WB 76.2 / 3" 152.4 / 6" 182.3 173.2 5 185760
4 SV4 Super Heater Consol 1740WD 76.2 / 3" 152.4 / 6" 163.75 158.8 3 161523
5 SV5 ERV Consol 1538VX 63.5 / 2.5" 101.6 / 4" 162.1 158.8 2 101017
6 SV6 CRH Consol 1786WB 152.4 / 6" 203.7 / 8" 45 42.75 5 176760
7 SV7 HRH Consol 1786WD 152.4 / 6" 203.7 / 8" 42.35 40.23 5 140256
8 SV8 HRH Consol 1786WD 152.4 / 6" 203.7 / 8" 42.7 40.57 5 1411372 7,8,9 42
9 SV9 HRH Consol 1786WD 152.4 / 6" 203.7 / 8" 44.5 42.23 5 147240
10 SVS8 S.B.Line Consol 1811JB 38.1 / 1.5" 63.5 / 2.5" 40 38.4 4 14590

1.22 CHIMNEY

i)No. of flue 02
ii)Wind shield material Reinforced concrete
iii)Flue material Steel
iv)Chimney height 220 m
v)Chimney base dia 28.948 m
vi)Chimney raft dia 36.0 m
vii)Flue dia 4.60 m

1.23 FUEL

The fuel data on which guarantees given are as follows:

PROXIMATE ANALYSIS
Description Performance Coal
Fixed carbon % 23.0
Volatile material% 23.0
Ash % 42.0
Moisture 12.0

ULTMATE ANALYSIS.
Fixed carbon % 31.29
Ash % 42.0
Moisture % 12.0
Hydrogen % 2.44
 - 29 -

Sulphur % 0.50
Oxygen % 11.08
Nitrogen % 0.69

1.24 CHEMICAL COMPOSITION OF ASH GENERATED IN ITPS

Analysis in wt Max value Min value Average value

Carbonate
% Sio2 61.76 47.98 54.5
Fe2O3 17.84 4.19 12 0.72
Al2O3 29.17 23.02 26.31
CaC 3.01 0.55 1.81 Higher
heating MgO 1.58 0.56 1.06 value
3000 Kcal/kg
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
Grindability index, HGI 55
Ash fusion temp. 1400c
Initial deformation temp. 12000c

1.25 PREDICTED PERFORMANCES

I-FLOW T/HR.

DESCRIPTION HP HEATERS IN SERVICE HP HEATERS OUT

MCR NCR CL 60% NCR
STEAM

Supper heater out let 690 636.7 410 584.1

Reheater out let 597.9 572.9 377.6 577.4

WATER

Feed water 690 620.5 379.4 554.9

Supper heater spray 0 16.2 34.6 29.2

AIR

Air heater outlet(Primary) 190.24 175.54 131.37 209.6

Tempering Air 82.76 91.02 110.87 58.8
 - 30 -

Air heater outlet(secondary) 563.72 508.39 270.41 529.7

Total combustion air 880.77 819 656.7 842.1

FUEL

Coal (HHV=3800 Kcal/kg) 178 165.6 112.5 170.2

FLUE GAS

Air heater out let 1048.5 972 665.3 1000.7

TOTAL HEAT TO BOILER
(Heat Duty) Kcl /hr. 452.4 420.8 284.9 437.9

II.TEMP(0C)

STEAM

Standard Temp. in Drum 349 349 345 347

LTSH O/L 390 393 399 401
SH platen T/L 390 384 366 378
SH platen O/L 500 500 506 496
SH final O/L 540 540 540 540
RH I/L 342 342 330 351
RH O/L 540 540 540 540

WATER
Eco I/L 246 245 225 166.5
Eco. O/L 310 309 295 267

AIR
Ambient 40 40 40 40
AH O/L(Primary) 335 332 306 290
AH O/L(Secondary) 335 332 306 290

GAS
SH platen inlet 1184 1187 1139 1157
RH front inlet 1029 1023 950 1044
RH Rear inlet 885 876 796 865
LTSH inlet 652 643 583 641
Economiser inlet 549 541 498 541
Air heater inlet 359 353 314 311
Air heater outlet 114 143 147 124

III.PRESSURE (KG /CM2)

PRESSURE
SH outlet 155 154.1 151 153.2
LTSH outlet 162.9 160.9 154.3 159
 - 31 -

Drum 166.1 163.7 155.5 161.4

Eco I/L 171.1 168.2 158.6 165.6
RH O/L 34.483 34.968 22.821 35.885
RH I/L 38.497 36.898 24.088 37.812

PRESSURE DROP
SH System 11.1 9.6 4.3 8.2
Re heater 2.014 1.93 1.267 1.927
Economiser(Including static head) 5 4.5 3.1 4.2

IV- PRESURE & DRAFT (AIR & GAS) MMWC.

PRIMARY AIR
PA Fan I/l 69 66 55 65
PA fan O/L 687 644 467 647
Mill I/L 632 595 436 596
Mill O/L 292 273 188 267

SECONDARY AIR
FD fan I/L -16 -14 -7 -15
FD fan O/L 282 258 167 263
AH I/L 227 210 146 212
AH O/L 157 150 123 151
Wind box pressure 100 100 100
Wind box to furnace diff. 125 125 125 125
Furnace -5 -5 -5 -5
SH platen I/L -5 -5 -5 -5
RH I/L -6 -6 -6 -6
LTSH I/L -22 -20 -13 -20
Eco. I/L -27 -24 -15 -24
AH I/L -62 -55 -32 -55
EP I/L -265 -235 -138 -230
ID fan I/L -303 -268 -143 -259
ID fan O/L 34 30 14 28
Flue gas velocity in second pass 8.00 m/sec.

V-MILL AND BURNER PERFORMANCE.

No.of Mill in operation 2 2 2 2

Coal flow/Mill(T/hr.) 89.5 82.6 56.1 85.1
Ball charge per Mill(T/hr) 96 96 96 96
Air flow/Mill (T/hr) 136.5 133.28 121.12 134.2
Air temp. at mill I/L(0c) 243 232 184 236
Mill output temp.(0c) 75 75 75 75
Fineness % (through 200 mesh) 76 79 79 77
Mill pressure drop including
classifier(in mmwc) 340 322 248 329
 - 32 -

Burner tilt (in degree) 0 9 24 -7

VI-O2, CO2 (DRY VOL) AND EXCESS AIR(%)

O2 in gas at Eco O/L% 3.55 3.55 3.55 3.55

CO2 in gas at Eco O/L % 15.57 15.57 15.57 15.57
Excess air gas at Eco O/L % 20 20 20 20

VII-HEAT BALANCE : LOSSES IN %

Dry Gas 4.31 4.27 4.48 3.43

H2o & H2 in fuel 7.05 7.04 7.07 6.93
H2o in Air 0.23 0.23 0.24 0.19
Unburnt carbon 2 2 2 2
Radiation 0.2 0.22 0.31 0.2
Unaccounted 0.5 0.5 0.5 0.5
Manufacturer's margin 1 1 1 1
Total loss 15.29 15.26 15.6 14.25
Guaranteed efficiency 84.71 84.74 84.4 85.75
 - 33 -

SECTION – 2

TURBINE & AUXILIARIES

 - 34 -

2.0 MAIN TURBINE

2.1 TECHNICAL SPECIFICATION

2.1.1 STEAM TURBINE

i) Make BHEL, Kraftwerk Union Design

ii) Type Tandem compound, regenerative, reheat,
cylinder having single flow HP turbine, double flow
IP & LP turbine

iii) No. of stages HP 25 no.

IP 20 x 2 no.
LP 8 x 2 no.
iv) Type HP/IP/LP turbine HPT – Reaction, barrel type, single flow
IPT – Reaction, barrel type, double flow axially split type
LPT – Reaction, barrel type, double flow three shell design

v) Nominal rating 210 mw

vi) Peak loading 230 mw
vii) Rated speed 3000 rpm
viii) Max./Min. speed 3090/2850 rpm (51.5 to 47.5 Hz)
ix) Speed exclusion range 700 to 2850 rpm
x) Over speed set value 11%

2.1.2 DIMENSIONS (IN MM)

HPT IPT LPT

i) Height of first stage moving blade 43 66 75.5
ii) Mean dia. of 1st stage moving blade 643 756 1473.5
iii) Height of last stage moving blade 95 100 668.8
iv) Overall length of turbine 15.725 m
v) Overall width with cross around pipe 10.5 m (approx.)
vi) Total exhaust area (LP turbine) 6.3 x 4.75 m2

2.1.3 BEARINGS
No.1 Journal, ø 280 x 140 mm
No.2 Radial cum thrust, tilting pad ø 290 x
 - 35 -

No.3 Journal, ø 450

No.4 Journal, ø 400
No.5 Journal, ø 400
No.6 Journal, ø 400
No.7 Journal, ø 200
Lining material for all bearings Babbit

2.1.4 VALVES

i) 2 main stop & control valves Type EV160

ii) 2 reheat stop & control valves Type IV320
iii) 2 swing check valves in CRH line DN 450
iv) 2 bypass stop & control valves DN 200

Extraction Swing check valves:

v) Extraction 1 No valve
vi) Extraction 2 1 swing check valve with aux. actuator
vii) Extraction 3 1 swing check valve
viii) Extraction 4 1 swing check valve
ix) Extraction 5 1 swing check valve
x) Extraction 6 No valve

2.1.5 WEIGHTS (TONNES)

Rotor HPT IPT LPT

Rotor 7.5 15.8 48.0
Cylinder assembled (with steam 56.0 37.0 81.0
inserts)

2.1.6 CASING TEMPERATURE (0C)

Wall temperature Alarm at Machine must be shut

down at
HP turbine casing 480 500
exhaust
Outer casing of LP 90 110
cylinder
Spray water to LP Must be switched on at
turbine 90oc

2.1.7 BEARING TEMEPRATURE (0C)

Normal operating Alarm at Machine must be shut

down at
Below 75oc 90oc 120oc
 - 36 -

Above 75oc 100oc 120oc

2.1.8 TEMPERATURE DIFFERENCE (0C)

(Between Upper & Lower casing section)

Alarm at Machine must be shut

down at
HP turbine middle ±30oc ±45
IP turbine front ±30oc ±45
IP turbine rear ±30oc ±45

2.1.9 DIFFERENTIAL EXPANSION

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

2.1.10 VIBRATION (ABSOLUTE)

Of bearing housing Of shaft

Nominal value for alarm 35µm 30µm above normal value
Maximum value for alarm - 120µm
Limit value for tripping 45µm 200µm

2.1.11 LOW VACUUM TRIP SETTING

Hydraulic low vacuum Trip < 0.3 bar

Electric low vacuum Trip < 0.3 bar
Hydraulic low vacuum Trip < 0.6 bar
(Bypass operation)

2.1.12 MW OUTPUT

HPT IPT LPT

 - 37 -

56.40 MW 53.73 MW 93.03 MW

28% 26% 46%

2.1.13 STEAM PURITY

Continuous operation Start up Unit

1)Conductivity at 25oc
continuous measurement
at the sampling point.
a)Direct measurement
i)Alkaline method Not specified -- µs/cm
ii)Neutral method < 0.15 < 0.50 µs/cm
b)following a strongly
acid
cation exchange method < 0.10 < 0.50 µs/cm
i)Alkaline method < 0.10 < 0.50 µs/cm
ii)Neutral method
2)Silcic acid (SiO2) < 0.10 < 0.050 mg/kg
3)Total iron (Fe) < 0.005 < 0.050 mg/kg
4)Total Copper (Cu) < 0.001 < 0.010 mg/kg
5)Sodium (Na) < 0.005 < 0.020 mg/kg

2.2 TURBINE LUBE OIL SYSTEM

2.2.1 OIL SUPPLY

i) Oil tank capacity 32 m3

ii) Highest/lowest oil level from top of 800/850 mm
the tank during operation
iii) Lube oil temperature at cooler outlet Min 37oc,
during operation Normal 45oc
Max. 47oc
iv) Oil temperature rise across bearings Normal 20oc
Max. 25oc
v) Oil temperature at cooler O/L(under shutdown) Max. 75oc
vi) First oil filling (estimated) 30m3
vii) Flushing of oil quantity (estimated) 20m3
viii) Pressure limiting value in
jacking oil system 120 bar
 - 38 -

ix) Safety valve in jacking oil system Max. 170 bar

x) Jacking oil pump must be switched on at 510 rpm
xi) Jacking oil pump must be switched off at 540 rpm

2.2.2 OIL PUMPS

M.O.P. A.O.P. DC E.O.P. JOP (AC) JOP (DC)

Nos 1 2 1 1 1
Make BHEL KSB KSB Allweiler Allweiler
AG
Type ETA 150- ETA 100- SDF 40- SDF 40-
50VL 33VL R54 GQW- R54 GQW-
centrifugal centrifugal 112 112
Rated capacity 139 152.24 108 m3/hr 76 LPM 76 LPM
m3/hr m3/hr
Rated discharge 8.2 ata 6.8 ata 2.3 ata 120 bar 120 bar
pressure
Speed, rpm 3000 1485 1425 2950 2950
Drive Turbine AC motor DC motor AC motor DC motor
Make - GEC Crompton Siemens Wirrkelmann
Greaves
Voltage, V - 415 220 415 220
Frequency, Hz - 50 - 50 -
Motor Power, - 100 13 27.6 28
KW
Rated current, - 175 128 47.5 152
Amp

2.2.3 OIL COOLER

i) Type & no. Shell & tube type, 2 x 100%

ii) Cooling surface 218 m2
iii) Oil outlet temperature of cooler
In operation Min. 38oc, Normal 45oc, Max. 47oc
In shutdown Max 75oc
iv) Tube material & no. of tubes Admirality Brass IS1545
Total no.1250
v) Design pressure & temperature
shell side 10 kg/cm2 & 100oc
 - 39 -

tube side 10 kg/cm2 & 100oc

2.2.4 OIL FILTER

i) Duplex oil filter type & no. DN 100 type, 2.82.9.200.500.10

ii) Filtration particle size of
thrust bearing duplex filter 37 µm
iii) Filtration particle size of
MOT filter 250 µm

2.2.5 ESTIMATED OIL REQUIREMENTS OF BEARINGS

Bearing 1 (HPT) front pedestal) 0.8 dm3/s

Bearing 2 9.1 dm3/s
Bearing 3 4.0 dm3/s
Bearing 4 3.5 dm3/s
Front generator bearing 3.5 dm3/s
Rear generator bearing 5.0 dm3/s

2.2.6 BARRING GEAR

i) Type of drive Hydraulic turbine

ii) Method of engagement Hydraulic
iii) Cut in/ cut out speed 240/210 rpm
iv) Power to rotate turbine 45 KW
v) Barring speed 80 – 210 rpm

2.2.7 MAIN OIL CENTRIFUGE

i) Manufacturer Alpha - Laval

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

2.2.8 OIL CHARACTERISTICS

(As per IS: 1448)

i) Kinetic viscosity at 37.8oc 47.5 c.s. to 49.5 c.s.

Kinetic viscocity at 50oc 28 c.s.
 - 40 -

ii) Specific gravity at 50oc 0.852

iii) Flash point Min. 200oc
iv) Pour point -6oc
v) Ash content 0.01 (% by weight)
vi) Water content by weight Below the limit of quantitative detectability
vii) Mechanical solid impurities - do -
viii) Viscosity Index Min. 97

ix) Inorganic acidity Nil

Organic acidity Max. 0.14 mg of KOH per gm of oil
x) Neutralization number Max. 0.2 mg of KOH per gm
xi) Copper strip corrosion Not worse than no.1
test at 100oc for 3 hrs
xii) Emulsion characteristics 40-40-0 (20 minute)

2.3 VACUUM SYSTEM

2.3.1 CONDENSER

i) Type Surface type, double pass with

divided water box construction

ii) Design conditions: Steam side Water side

a) Design pressure full vacuum 3.5 ksc & full
vacuum
b) Test pressure Filling by water up to 4.5 kg/cm2g
1.0 m above tubes

c) Design temperature 85oc 50oc

iii) Design CW flow 27,000 m3/hr

iv) Design CW temperature 33oc
v) Design back pressure
vi) No. of tubes length of each tube 7600 mm
vii) Tube O.D × thickness 25.4 mm x 1 mm
for top row (thickness) 1.2466 mm
viii) Tube material 17,902 nos. -90/10 Cu-Ni to BS 2871 in
condensing zone
1316 nos. – SS ASTMA-249, T1304 in air
air cooling zone
ix) Surface area 11,495 m2
x) Pressure drop in CW side 3.6 mwc
xi) CW temperature rise 8.8oc to 9oc
xii) Water velocity in tube 1.9 m/sec
xiii) Weight
Dry 320 MT
 - 41 -

Operating 530 MT
Flooded (1.0 m above tubes) 640 MT

2.3.2 MAIN EJECTOR

i) Make BHEL, Hardwar

ii) Steam required 1000 kg/hr
iii) Min. condensate flow 103 T/hr
iv) Normal condensate flow 254.6 T/hr
v) Tube side pressure 24 ksc
vi) Tube side test pressure 36 kg/cm2g
vii) Shell side test pressure 2.5 kg/cm2g
viii) Motive steam pressure 6.5 ksc
ix) Motive steam temperature 210oc
x) Weight Empty 2875 kg
Operational 3245 kg
xi) Material:
Tube plate steel 42W IS202
Diffuser stage I,II,III steel IS 2073 Gr.C-20
Tube Admirality Brass CZIII BS 2871
Nozzle Stainless steel SS 30CR 13 hot rolled
Annealed 136603

2.3.3 STARTING EJECTOR

i) Steam requirement of the ejector 3300 kg/hr

ii) Working pressure of steam 6.5 kg/cm2g at 210oc
iii) Hydraulic test pressure 1.5 kg/cm2
iv) Air removal capacity at 500 mm Hg vacuum 7350 SCFM
v) Design temperature 250oc

2.3.4 GLAND SEALING SYSTEM

i) Type of control Electro-Hydraulic

ii) Model ESS HI
iii) Oil used Servo control-46/HLP-68
iv) G.S. control valve actuator REINEKE, GMBH
v) L.S. control valve actuator REINEKE, GMBH
iii) Self sealing after 40% load

2.3.5 GLAND STEAM VAPOUR FAN

i) Fan Type SHSH

ii) Make S.K.Systems, New Delhi
iii) Capacity 1080 m3 /hr
iv) Drive 3 H.P. 2840 rpm.
 - 42 -

2.3.6 CONDENSER ON LOAD CLEANING DEVICE

Manufacturer GEA Energy Systems

Debris Filter System
i) Type 574 – ‘V’ type
ii) Quantity / unit Two
iii) Perforation of screen 5 mm
iv) Screen thickness 2.0 mm
v) Flow, m3/hr 13,500
vi) Design DP for filter screen 2 bar (g)
vii) Discharge during flushing, m3/hr 400
viii) Geared motor drive 415V, 3-ø, 50 Hz, 0.55 KW, 1.4A

Flushing Pump
ix) Type Centrifugal, horizontal
x) Capacity, m3/hr 170
xi) Motor 415V, 3- ø, 50 Hz, 11 KW, 1460 rpm

Tube Cleaning System

Ball Separator
i) Quantity / unit Two
ii) No. of ball extraction points Two
iii) No. of screens/ball separator Two
iv) Normal flow, m3/hr 13,500

Ball Recirculation Pump

i) Type Centrifugal horizontal non-clogging type
ii) Quantity / unit Two
iii) Capacity, m3/hr 60
iv) Design head mmwc 15
v) Design efficiency 60%
vi) Motor 1440 rpm, Insulation class B

Cleaning Balls
Normal Balls Abrasive Balls
i) Type Soft Abrasive
ii) Diameter, mm 26 25
iii) Density, g/m3 0.22 0.2759
iv) Design temperature, 0C 80 80

2.4 CONDENSATE SYSTEM

2.4.1 CONDENSATE EXTRACTION PUMP

 - 43 -

i) Manufacturing BHEL, Hyderabad

ii) No. of pumps & capacity 2 ×100%
iii) Type EN5J40 (2 shaft), vertical centrifugal
canister type
iv) No. of stages 5
v) Discharge capacity 675 m3/hr
vi) Diff. Head 220 m
vii) Input power to pump 494 KW
viii) Density of medium handled 0.9896 tonne/m3
ix) NPSH required at the eye
of the 1st impeller 3.0 mlc
x) RPM 1482
xi) Efficiency of pump 81%
xii) Coupling Flexible
xiii) Direction of rotation
viewed from drive end Clockwise
xiv) Suction bore diameter 400 mm
xv) Discharge bore diameter 300 mm
xvi) Minimum flow through pump 175 m3/hr
xvii) Bearings Taper roller bearing 29420E FAG/SKF
xviii) Lub. Oil IOC turbine oil 46/Servo prime 46

xix) Motor
Manufacturer BHEL, Hardwar
Type Squirrel cage induction motor
KW rating 600 KW
Power supply 6600V, 3-Ф, 50Hz
Class of insulation F
Efficiency at rated output 94.5%
Rated speed 1485 rpm
Full load current 66A
Weight of motor 4010 kg
Bearing DE 6226-c3 NU 224M cyl. Roller bearing
NDE 7322-B 7322 B Angular, con. Ball bearing

2.4.2 DRAIN COOLER

i) Position Horizontal
ii) No. 1
iii) Type Tube & shell type
iv) Cooling surface area 35 m3
Tube side Shell side
v) Design pressure 28.1 ksc, g Full vacuum & 3.5 ksc, g
vi) Hydraulic test pressure 42.15 ksc, g 5.25 ksc, g
vii) Design temperature 150oc 100oc
 - 44 -

viii) Tube OD × Length 16 mm × 1395 mm

x) Tube material Austenitic S.S. welded
xi) No. of tubes 501
xii) Operating weight 3185 kg

2.4.3 GLAND STEAM CONDENSER

i) Position Horizontal
ii) No. 1
iii) Type Tube & shell type
iv) Allowable/Design flow of main condensate:
Minimum 180 T/hr
Design 561.343 T/hr
Max. 760 T/hr
v) Tube ODX length 19 mm × 1150 mm
vi) Material Welded S.S. tubes, ASTM A249 TP304
vii) No. of tubes 313
viii) Surface area 20 m2
ix) Exhauster fan 2 nos, centrifugal, 1000 m3/hr, 2860 rpm,
3 HP

2.4.4 LOW PRESSURE HEATER

LPH-1 LPH-2 LPH-3

i) Type ← Shell & tube type →
ii) Position Horizontal Horizontal Horizontal
iii) No. One One One
iv) Operating pressure
shell side (ksc abs) 0.1992 0.8104 2.2671

v) Operating temp. shell side(0c) 59.54 107.8 200.0

vi) Tube OD × thickness in mm ← 16 × 0.889 →
vii) No. of tubes 498 498 498
viii) Weight- Dry 7625 11096 9960
Operating 9165 13700 12250
Flooded 12550 19360 17200
ix) Tube material ← S.S. →

2.5 FEED WATER SYSTEM

2.5.1 DEAERATOR
 - 45 -

i) Manufacturer BHEL, Hyderabad

ii) Type Spray cum Tray type
iii) Design pressure/op. Pressure 7.4 ksc(g) / 6.83 ksc (g)
iv) Design temp. / op. Temperature 250oc / 163.15oc
v) Shell ID × thickness, mm 2400 × 16
vi) Feed water storage tank
ID × thickness, mm 3500 × 20
Total length, mm 22000
Steam inlet quantity, T/hr 38064
Inlet steam pressure ksc 6.827
Inlet steam temperature, 0C 313.4
Safety relief valve set pr. Ksc 6.77
vii) Total working weight 197000 kg (storage tank + header)
Flooded weight 262000 kg

2.5.2 BOILER FEED PUMP

i) No. & capacity 3 × 50%

ii) Make 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
viii) Flow rate, m3/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) Mechanical seal Durametallic/ sealol type

4.250” PTO/type 503
xv) Min. recirculation flow, T/hr 100
xvi) Direction of rotation viewed
from drive end ←-------------- Anti-clockwise---------→
xvii) No. of stages Six

DRIVE MOTOR

i) Make BHEL, Hardwar

ii) Type Squirrel cage induction motor
 - 46 -

iii) Rating 4000 KW

iv) Degree of protection, type
of enclosure, method of cooling IP54, CACW, ICW 37A81
v) Power supply 6600V, 3-ø, 50 Hz
vi) Rated speed 1500 (synch.)
vii) Insulation class F
viii) Efficiency 96.5%
ix) F.L. current 407 A
x) Weight 13360 kg
xi) Winding temp. rise at rated
output over cooling air 700C (by resistance), 80oc (RTD)
xii) Bearing DE Sleeve bearing 160 × 140
NDE Sleeve bearing 125 × 115 (Insulated)

HYDRAULIC TURBO COUPLING

i) Manufacturer Voith , India

ii) Type R16k-1
iii) Power requirement of
drive machine 3240 KW

iv) Gear ratio, type 148/41, step up gear unit

v) Speed input/output 1485/5249 rpm
vi) Regulating range 4:1 downwards
vii) Full load slip 2.1%
viii) Oil tank filling 700 lit (approx.)
ix) Oil used Servo Torque 10 of IOCL.

AUX. LUB OIL PUMP

i) Type Gear pump

ii) Lube oil flow Approx. 120 litres/min.
iii) Pressure 2.5 bar
iv) Motor 5.5 kw, 415 volt, 50 Hz

OIL/WATER HEAT EXCHANGER

WORKING OIL LUB OIL

i) Type L1 N1 09 17 04-D L1 N1 07 04-D

ii) Heat exchange capacity 71 litres 47 litres
iii) Cooling water inlet temp. 37 37
iv) Cooling water outlet temp. 47 47
v) Nominal oil flow rate 32 m2/hr 13.5 m2/hr
vi) Oil I/L temp., 0C 95 69
 - 47 -

vii) Oil O/L temp,0C 57 53

viii) Max. permissible working
pressure oil side, ksc 16 16
water side, ksc 10 10
x) Max. permissible working
oil temperature, 0C 119 119

TYPE OF COUPLING

i) Turbo coupling / pump flexible coupling:

Manufacturer Torsiflex Ltd

Type HBS1000-8x
ii) Motor/turbo coupling flexible coupling:

Manufacturer Torsiflex Ltd

Type HBS-3600-8
iii) Motor/Booster pump flexible coupling

Manufacturer Torsiflex Ltd

Type HB4-140x (insulated)

2.5.3 HP HEATERS

HPH5 HPH6

i) Manufacturer BHEL BHEL

ii) Type & arrangement ----------- U tube Horizontal----------
iii) No. of shell passes 3 zones 3 zones
iv) No. of tube passes 2 2
v) 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
0
Design temp. C 215 265
vi) 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
 - 48 -

vii) Velocity through tubes at 2.14 2.25

670 T/hr flow, m/sec

viii) Tube side pressure drop at 0.85 1.15

670 T/hr flow, kg/cm2
ix) Surface area, m2
De superheating/Condensing/
Drain cooling zone 83/485/112 104/642/82
x) Total effective area, m2 680 828

2.6 HP BYPASS SYSTEM

Capacity 60% MCR

420 t/hr of main steam flow at the inlet
of HP bypass valve
HP BYPASS STEAM VALVE SPRAY VALVE
i) Valves designation BP1/BP2 valve BPE1, 2 valves
Design pressure 170/50 ata 280
Design temperature 540/485oc 175oc
Body material 10 Cr MO910 15MO3
Nozzle material 10 Cr MO910 15MO3
Medium Main steam Spray water

ii) ACTUATOR
Type Hydraulic
Hydraulic system pressure 100 bar
Positioning time 10/3 sec (3 sec for fast opening device)

iii) OIL SUPPLY UNIT

Oil pump type OV-32
Supply capacity 24 lit/min.
Motor detail 7.5 KW, 415V, 3-ø, 50 Hz, 1440 rpm,14.2 A
Oil tank volume/usable volume 70/50 lit
Oil pump cut in at 100 ksc
Cut out at 16 ksc
Back up protection cut in/cut out 110 ksc/170 ksc
Relief valve setting 150 ksc

2.7 FLASH TANK/FLASH BOX

2.7.1 UNIT FLASH TANK

i) Type/Quantity Vertical cylindrical / one per unit

ii) Design code ASME SEC VIII div.1
iii) Design pressure Full vacuum & 1.5 ksc (g)
 - 49 -

iv) Design temperature 210oc

v) Fluid handled Steam/water
vi) Shell material IS2062 Gr FE410 WB
vii) ODX height 1000 x 2700 mm
viii) Shell thickness 12 mm
ix) Corrosion allowance 3.2 mm

x) List of connections
Vent to atmosphere 1
Drain to waste 1
Drain to manifold 2
Spray water 1
Manhole 1
Spare 1

2.7.2 TURBINE FLASH BOX

*TFB -1
HEADER 1 MAL 65
MAL 66

HEADER 4 MAL 15
MAL 16
MAL 22
MAL 31
MAL 32

HEADER 5 MAL 11
MAL 26

*TFB –2
HEADER 2 MAL 47
MAL 51
MAL 55
MAL 81
MAL 84

HEADER 3 MAL 12
MAL 27

*Drains connected to Hot well & vents connected to steam space of condenser.

2.7.3 CONDENSER FLASH BOX

FB-1 FB-2 FB-3

 - 50 -

i) Type ← Vertical cylindrical →

ii) Design code ------------------ ASME Sec VIII div.1 ---------------
iii) Design pressure ← 1.5 ksc(g) & full vacuum →
iv) Design temperature 0C 210 215 210
v) Fluid handled ----------------- Water / Steam ------------------
vi) Shell material ←----------- IS2062 Gr.FE410.WB-------------→
vii) Size OD ×height, mm 1400 x 2100 2200 x 3300 800 x 1800
viii) Shell thickness, mm 10 16 10
ix) Corrosion allowance, mm 3.2 3.2 3.2
x) List of connections:
a) FB-1
Vent to condenser 1
Drain to hot well 1
LPH-2 alt. Drain 1
LPH-3 alt. Drain 1
LP ext. line drain manifold 1
Spare (blanked) 1
` Manhole 1

b) FB-2
Vent to condenser 1
Drain to hot well 1
HPH-5 alt. Drain 1
HPH-6 alt. Drain 1
HPH ext. line drain manifold 1
HRH/CRH/LPBP line drain 1
Valve gland sealing header 1
Drain from Aux.5/CRH to
gland sealing 1
Manhole 1
Spare (blanked) 1

c) FB-3
Vent to condenser 1
Drain to hot well 1
Drain cooler drain 1
GSC drain 1
Drain from main ejector 2
CEP discharge vent 1
Manhole 1
Spare (blanked) 1

2.8 PREDICTED PERFORMANCE OF TURBINE

 - 51 -

STEAM PRESSURE (BAR)

DESCRIPTION Rated value Long time Short time operation

(bar) operation (bar) (bar)
Initial steam 147.1 147.1 176.5
Before 1st HP drain 132.6 137.9 145.9
stage
HP cylinder exhaust 39.23 45.11 47.08*
IP cylinder stop valve 34.13 39.59 40.96**
inlet
Extraction 6 39.23 45.11 47.08
Extraction 5 16.75 19.84 19.84
Extraction 4 7.06 8.46 8.46
Extraction 3 2.37 2.91 2.91
Extraction 2 0.858 1.09 1.09
Extraction 1 0.216 0.374 0.374
HP cylinder exhaust 0.118 0.3 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: Upper limit value, permissible without the time limit.

Short time operation: Permissible momentary value. The aggregate duration of such
swings must not exceed 12 hours in any one year.

STEAM TEMPERATURE, 0C

DESCRIPTION Rated value Long time value 400 hr per 80 hr per

Annual but keeping annum annum max.
mean value within annual 15 min in
mean value individual case
Initial steam 535 543 549 563
IP cyl. Stop valve 535 543 549 563
inlet

DESCRIPTION Rated value Long time 80 hr per annum, In special cases

operation max. 15 min. in at no load.
individual case
HP cylinder 343 359 425 500†
exhaust
Extraction 6 343 359 425 500‡
 - 52 -

Extraction 5 433 438 473

Extraction 4 316 326 366
Extraction 3 200 211 255
Extraction 2 107 127 167
Extraction 1 62 82 127
LP cylinder exhaust 49 70 70 100

†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 No time limitation- 170C.

between parallel steam supply lines: Short time period (15 min.)- 280C.

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

♠CONDENSATE WATER

Description Pressure Kg/cm2 Temperature 0C Flow T/hr

CEP suction 0.1033 46.1 508.83
CEP discharge 19.379 46.3 508.83
GSC outlet 1054 46.6 508.83
Drain cooler outlet 10.08 47.8 508.83
LPH 1 outlet 9.63 56.6 508.83
LPH 2 outlet 9.18 90.6 508.83
LPH 3 outlet 8.72 120.7 508.83

♠HEATER DRAIN

Description Temperature oc Flow T/hr

GSC drain to FB-3 99.9 0.299
LPH3 to LPH2 123.5 27.589
LPH2 to LPH1 93.4 57.651
LPH1 to drain cooler 60.3 63.437
Drain cooler to FB-3 52.8 63.437
HPH 6 to HPH 5 206.0 61.091
HPH 5 to deaerator 170.0 95.807

♠FEED WATER
 - 53 -

Description Pressure Kg/cm2 Temperature oc Flow t/hr

BFP suction 6.405 160.7 639.27
BFP discharge 205.0 164.1 639.27
HPH 5 outlet 204.09 200.0 639.27
HPH 6 outlet 203.18 247.0 639.27

♠Parameters are given when unit at 210 MW, 0% make-up water, 76 mm backpressure & constant
pressure operation.

SECTION – 3

GENERATOR
&
AUXILIARIES
 - 54 -

3.1 GENERATOR TECHNICAL SPECIFICATION

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

STATIC EXCITATION EQUIPMENT

Make BHEL
SEE Rating Voltage-310V DC
Current-2600A DC
Accuracy of Excitation control ±0.5%
Range of voltage control in auto 90-110%
Range of voltage control in manual 80-110%
No load field voltage 102V DC
No load field current 917 A
Max. continuous rated field voltage 355V DC
Max. continuous rated field current 3000 A
Ceiling voltage 620V DC
 - 55 -

(Excitation voltage at field forcing)

Ceiling current 4500A
Min./Max. frequency range of operation 47.5 – 52Hz
No. of parallel bridges including
redundant bridge 4
No. of redundant bridge 1
Protection class IP20
Station battery supply 220V DC
Duration of field forcing 10 sec.
Response time 40 msec.

EXCITATION TRANSFORMER DETAIL

Make BHEL
Rating 3150 KVA
Voltage rating 15750 / 575 V
Vector group DYn5
Insulation level 50 KV RMS / min
Cooling Natural

3.2DESIGN AND CONSTRUCTION FEATURES

MATERIAL

Rotor shaft Steel forging 35Ni 13cr 12Mo 35V12

Chromium nickel molybdenum & vanadium steel
Rotor winding Silver bearing copper
Rotor slot wedges Duralumin
Rotor rating ring 60Mn Ni85Cr 35 W75, Non magnetic steel
Stator frame ST42W
Stator core stamping Cold rolled silicon steel
Bearing body CSW C25 IS: 2856-64
Shaft seal ring ST-42W
Bearing & seal Babbitt Grade 84
Carbon brushes:
Grade HM6R
No. of brushes reqd. 112+1

WEIGHT AND OVERALL DIMENSIONS

i) Wt of the heaviest lift (Stator with

Gas cooler & lifting trunions) 175.0 MT
ii) Wt of rotor 42.2 MT
iii) Wt of gas cooler 1415 Kg
iv) Wt of terminal bushings 85 Kg
v) Wt of end shields 2000 Kg
vi) Total wt. Of generator 270 MT (without exciter)
 - 56 -

vii) Overall dia of stator 3960 mm

viii) Overall dia of rotor 1075 mm
ix) Overall length of stator 6580 mm
x) Overall length of rotor 9770 mm

TORQUES, CRITICAL SPEEDS ETC

i) Torque under normal working condition 76.32 T
ii) Ratio of short circuit torque to F.L. torque 8
iii) Flywheel moment of rotor 21.1 TM2
st
iv) 1 critical speed of rotor (calculated) 1370 rpm
nd
v) 2 critical speed of rotor (calculated) 3400 rpm

OIL CONSUMPTION

i) Consumption of oil per generator

bearing (excluding shaft seal) 300 lit/min
ii) Oil pressure at inlet of bearing 0.3 to 0.5 Kg/cm2
iii) Consumption of oil in both shaft seals 77 lit/min

3.3 GENERATOR GAS SYSTEM

3.3.1 H2 IN STATOR CASING

i) Nominal pressure of H2 3.5 Kg/cm2

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

3.3.2. GENERATOR FILLING QUANTITIES

M/c stand still M/c under rolling

i) Amount of CO2 required
to remove air expressed at NTP 120 m3 150 m3
ii) CO2 for expelling H2 120 m3 168 m3
iii) H2 filling quantity 300 m3 336 m3
iv) Compressed air required for
purifying of CO2 from gen. 150 m3
v) Quantity of compressed air reqd.
(at NTP) for carrying out air 500 m3
 - 57 -

tightening test
vi) Capacity of CO2 cylinder 27Kg

3.3.3 HYDROGEN COOLER

At rated Hydrogen pressure 3.5 ksc (g)

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

3.3.4 HYDROGEN DRIER

i) Type Refrigeration type, freon 12

ii) Working pressure 4 ksc max.
iii) Dew point of dried gas
at working pressure 3 to 5oc
iv) Thermal load, ie. Compressor capacity 1100 Kcal/hr

3.3.5 SETTING VALUES FOR ALARM

i) Gen. Bearing & seal Babbitt temp. High V. High

0 0
75 C 85 C
ii) Gen. Bearing oil oil O/L temp. 600C 700C
iii) Stator winding temp. 750C -----
iv) Hot gas temp. 75oc -----
v) Cold gas temp. 45oc 55oc
vi) Stator core temp 95oc -----
vii) Rotor temp 110oc 115oc
viii) Temp of inlet water to gas cooler 38oc 48oc

3.4STATOR WATER SYSTEM

3.4.1 STATOR WATER COOLER

i) No. of coolers/system & type Two, shell & tube type

ii) Max permissible operating pr.(Primary shell) 8.0 ksc
iii) Max permissible operating pr.(cooling tube) 5.0 ksc
 - 58 -

iv) Primary water inlet/outlet temp 72.6/45oc

v) Primary water flow 27 m3/hr
vi) Cooling water flow 110 m3/hr
vii) Pressure drop in primary water 6.5 mmwc
viii) Pressure drop in cooling water 0.8 mmwc
ix) Max. cooling water inlet temperature 36oc
x) Heat load 790 KW
xi) Heat transfer area 33 m3
xii) Nominal gauge pressure at inlet of winding 3.3 ksc (g)

3.4.2 STATOR WATER PUMP

i) No. & make 2x100% single stage centrifugal with spiral casing
& overhung impeller CPK CM50-200, KSB make
ii) Flow 39.6 m3/hr
iii) Head 45 mtr
iv) Speed 2930 rpm
v) Motor GEC make, 9.3 KW/12.5 hp, 415V, 3-ø, 50Hz, 18A
Insulation Class B, 2930 rpm
vi) Ambient temperature 50oc

STATOR WATER MAKE UP PUMP

i) No. & make 2 per ø unit, KBL make

ii) Flow 1.39 L/s
iii) Head 50 m
iv) Motor 415V, 3- ø, 50Hz, 2.62KW, 2850 rpm, 7A,
Insulation class E

3.4.3 STATOR WATER FILTER

i) Make & type BHEL, Hardwar, Wiremesh Disc

type, F-26
ii) No./unit 2
iii) Ratio Discharge 30 dm3/hr
iv) Working pressure 6 Kg/cm2
v) Max. size of filter that can be filtered 0.224 mm

3.4.4 MAGNETIC FILTER

i) No./unit 2
ii) Make Boll and Kirch Filter bar GmbH
iii) Type P.53.1-MA.220 500DN 100 YQ-36
iv) Magnet type Permanent Magnet
v) Working pressure 10 ksc
vi) Working temperature 60oc
 - 59 -

vii) Capacity 36 m3/hr

viii) Type of particles filtered Highly & medium magnetic

3.4.5 EXPANSION TANK

i) Type Hermetically sealed cylindrical type

ii) Material Stainless steel
iii) N2 pressure in the tank 0.2 ksc (g)
iv) Wt. of the assembly 825 Kg

3.4.6 QUALITY OF DISTILLATE

i) Conductivity Less than 5µ mho/cm preferably 1µ mho/cm

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

3.4.7 SETTING VALUES OF STATOR WATER SYSTEM

1 Expansion tank level Low 800 mm

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

3.5 SEAL OIL SYSTEM

i) Type of shaft seals Single flow ring type

ii) H2 Pressure at generator casing 3.5 ±0.2 ksc
iii) Seal oil-H2 diff. Pressure min 1.0, normal 1.5, max 1.7 ksc
iv) Quantity of seal oil per seal 38.5 l/min
v) Quantity of seal oil towards
 - 60 -

Air side ⅔rd

Hydrogen side ⅓rd

3.5.1 SEAL OIL COOLER

i) Make BHEL, Hardwar

No.of cooler/system: 2x100
ii) Type Surface type
iii) Heat transfer area 14.3 m2
iv) Design pressure tube side/shell side 10.5 ksc
v) Test pressure tube side/shell side 18 ksc

3.5.2 SEAL OIL PUMPS

I) A.C. Seal Oil Pump

i) Make & type Tushaco,Delta Corp.,Three screw positive
displacement
ii) No./Unit 2
iii) Pump discharge 200 lpm0
iv) Pump speed 1450 rpm
v) Pump head 12 ksc
vi) Motor 415V, 3-Φ, 50 Hz, 7.5 KW, 15.5A, 1450 rpm
Insl. class B

II) D.C. Seal Oil Pump

i) Pump Same as A.C. pump
ii) Pump/unit 1
iii) Motor 220V DC, 11KW, 1450 rpm, Insl. Class F,
Shunt wound self-excited D.C. motor

3.5.3 VACUUM PUMP

ii) Type Single stage, rotary vane type (SB-4)

iii) Suction capacity 5.77 m3/hr
iv) Ultimate pressure < 1.06 mbar
v) Motor 415V, 3-Φ, 50 Hz, 0.45 KW, 1500 rpm

3.5.4 OIL FILTER

i) Type Wire & mesh type

ii) Flow rate 12 m3/hr max.
iii) Mesh size 0.10 mm max.
iv) Design pressure 16 ksc max.
 - 61 -

3.6 SPECIFICATIONS OF TRANSFORMERS

3.6.1 GENERATOR TRANSFORMER

i) Manufacturing BHEL, Bhopal

ii) No./Unit One
iii) Rating 240 MVA
iv) No load voltage HV/LV 230/15.75 KV
v) Rated current HV/LV 602/45/8797.72 A
vi) Frequency 50 Hz
vii) No. of phase 3, type of connection - HV-Star, LV-Delta
viii) Type of cooling ONAN/ONAF/OFAF cooled
ix) Vector group Ynd1
x) Type of tap changer OFTC
xi) Off load tap changer range -5% to +5% in steps of 2.5%
xii) Impedance voltage at
HV-LV 14%
(normal tap)
xiii) 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) Manufacturer BHEL, Bhopal

ii) No. / unit 1
iii) Rated output 55 MVA
iv) Voltage ratio HV/LV1/LV2 Star
v) Winding connection HV/ LV1/LV2 144.5/972.1/3015.8 A
vi) Line current HV/LV1/LV2 50 Hz
vii) Type of tap changer & range OLTC, +10% to –10% in steps of 1.25%
on HV winding, total 16 steps
viii) Type of cooling ONAN/ONAF
ix) Rating at different cooling 60% 80% 100%
ONAN ONAF ONAF
x) Temperature rise over ambient temp. 50oc
in oil 40oc
in winding 50oc
xi) Bushing HV LV HV neutral
Type oil immersed air insulated oil immersed
Min creepage
distance(mm) 6125 440 900
 - 62 -

xii) Guaranteed positive sequence HV-LV1 HV-LV2 LV1-LV2

Impedance at 75oc with 100%
Rating at principal tap 16.5% 16.5% 26.5%

3.6.3 UNIT AUXILIARY TRANSFORMER

i) Manufacturer TELK, Kerala

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

xIv) Bushings HV LV LV neutral

oil filled oil filled oil filled

3.6.4 VARIOUS SERVICE TRANSFORMERS

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

3.7 H.T. MOTORS

 - 63 -

Sl. Equipment Quantity Rating (KW)

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

3.8 BATTERY & BATTERY CHARGER

3.8.1 220 V DC BATTERY

i) Make Amoco
ii) Type Lead Acid, sealed type

No. of cells Unit 1-110, unit II-110, station-110, S.Y -110, CHP-110
Capacity 2000 AH (Unit-I, II & Station), 350 AH (S.Y), 400 AH (CHP)

Each cell voltage 2V

Specific gravity 1200

220 V FLOAT CUM BOOST BATTERY CHARGER

i) Manufacturer Chhabi Electricals Pvt Ltd & Caldyne Pvt

Ltd (for CHP)

ii) Service Float & Boost charging

iii) A.C. input 3-ø, 50 Hz, 415V ±10%

iv) D.C. output voltage Float Boost

 - 64 -

Plant 240 158-297

S.Y. 240 158-297
CHP 240 158-297

Current Plant 0-350 A 0-280 A

S.Y. 0-100 A 0-49 A
CHP 0-100 A 0-40 A

v) Ripple 3%
vi) Efficiency at full load 80%
vii) Voltage setting range 240 V
viii) Current setting range 80 A
ix) Cooling AN
x) Response time Inst
xi) Maximum ambient temperature 50oc

3.8.2 +24V DC BATTERY

i) No. of cells Unit I (main-13, standby-13)

Unit II (main-13, standby-13)
ii) Capacity 1000 AH (U#1, 2 & CHP)
iii) Each cell voltage 2V

+24 V/1000 AH DC BATTERY CHARGER

i) Manufacturer Chhabi Electric

ii) Type Float cum Boost
iii) AC Input 415±10%, 3-ø, 50 Hz
iv) DC output Float Boost
DC voltage 28±1%V 24 to 35V
DC current 600 A 140±2%A
v) Number Two/unit
vi) Max.ambient temperature 50oc

24V/600A FLOAT CHARGER

i) Make Amar Raja Power Systems Ltd

ii) Number Two/unit
iii) Input 415±10%, 3-ø, 50 Hz, 50 A
iv) D.C. output 29.25 DC volt & 600 Amp
v) Capacity 1455 AH
vi) Max. ambient temp. 45oc
 - 65 -

24V/175 A BOOST CHARGER CUM DC DB

i) Make Amar Raja Power Systems Ltd

ii) Input 415V ±10%, 3-ø, 50 Hz, 12.4 A
iii) D.C. output 29.9 V DC & 175 A
iv) Capacity 1455 AH
v) Max. ambient temperature 45oc
vi) Number Two/unit

48V DC/70A FLOAT CUM BOOST CUM DCDB

i) Input 415V ±10%, 3-ø, 50 Hz, 19A, 5A

ii) DC output 48V DC, 58A
iii) Capacity 120 AH
iv) Max. ambient temperature 500C
v) Number One/unit

3.8.3 –24V DC BATTERY

i) No. of cells Unit I(main-13, standby-13), Unit II(main-13,

standby-13)
ii) Capacity 200 AH (Unit # 1&2)
iii) Each cell voltage 2V

-24 V DC BATTERY CHARGER

i) Manufacturer Chhabi Electric

ii) Type Float cum Boost charger
iii) AC input 415V ±10%, 3-ø, 50 Hz
iv) DC output Float Boost
DC voltage 28.1±2% 24 to 35
DC current 0-110A 28±2%A v)
Max. ambient temperature 50oc
vi) Ripple 3%

3.8.4 UPS SYSTEM

i) No. / Unit One
ii) Rated output 2 x 60 KVA, 240V AC, 1-ø, 50 Hz
iii) Input 415V ±10%, 3-ø, 4 wire, 50±6% Hz, 110A nominal
iv) Output 240 ±1%V AC, 1-ø, 2 wire, 50 Hz, 250A
v) Power walk in 10 to 15 seconds
vi) Nominal DC bus voltage 405 V DC
vii) Capacity 450 AH
viii) Discharge battery voltage 315 V DC
ix) No. of cells 180 cells
x) Each cell voltage 2 V/cell
 - 66 -

xi) Battery float voltage/cell 2.25 V/cell

xii) Ripple 3% (max. rms)

GENERATOR RELAY PANEL

Sr No Protection Designation Operating Remarks

Time

1. Generator differential 87G Inst Generator winding

protection insulation protection.

2. Generator negative phase 46G 4 sec. Generator unbalanced

sequence protection current protection.

3. Generator loss of 40G Inst Generator field failure

excitation protection protection.

4. Generator pole slipping 98G 50 msec Protection against

protection generator falling out of slip

5. Generator back up 21G 1.5 sec Back up protection against

impedance protection external faults

6. Generator stator interturn 95G Protection against insulation

fault protection failure between two windings

7. Generator stator E / F 64G1 1 sec Main protection against

protection generator windings.

8. Generator stator stand by 64G2 IDMT

E / F protection

9. Generator rotor E / F Stg-II 2 sec

protection Alarm 0.5 sec

10. Generator stator water 30P Inst

conductivity high (20 µmho)

11. Generator stator water 30P 50 sec

flow low (13 m3/ hr)

12. Generator low forward 37A & B 2 sec Protection for generator
power protection before motoring takes place

13. Generator overload 51G 20 sec

protection
 - 67 -

14. Generator U/F 81G 10 sec

protection

15. Generator O/F 81G 10 sec

protection

16. Generator O/V alarm 59G

GENERATOR TRANSFORMER

Sr No Protection Designation Operating Remarks

Time

1. GT overall differential 87GT Inst Winding insulation

protection protection

2. GT bay C.B. LBB 50Z 0.2 sec.

protection

3. GT over fluxing 99GT Inst.

Protection

4. GT bucholtz trip 63GT Inst. Protection against

internal fault.

5. TBC LBB Protection 50L 0.2 sec

6. GT winding temp. Inst Protection for insulation high

trip winding failure.

7. GT oil temp high Inst Protection for oil

high trip degradation

UAT

Sr No Protection Designation Operating Remarks

Time

1. UAT differential 87UAT Inst Protection

protection against winding
insulation failure
 - 68 -

2. UAT over current

protection 51 UAT Inst

3. UAT bucholtz trip 63 UAT Inst Protection against

internal fault

SECTION – 4

CONTROL
&
INSTRUMENTATION
 - 69 -

4.1 UNIT C & I SYSTEM

SG (FSSS) Procontrol P13/42(ABB)

TG (ATRS) Iskamatic A & B (KWU, Germany)

Measurements
Automation MOD 300
DAS MOD 300
Make ABB
Supplier 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 OLCS CLCS

No. of groups 4 5
No. of function groups 12 16
No. of cubicles 19 12
Processor 32-bit, Motorola MC 68000
68020 micro processor R8 (8 MHZ)
Address Bus =24
Data bus =16

System Redundancy 100% Parallel operation available

through CRT Key board and P.B. on
the panel. Redundant power supply of
 - 70 -

240V Ac through UPS for DAS, operator

station, engineer station, history station for
OLCS & CLCS.

No. of control loops 31

INFORMATION SYSTEM

No. of memory nests 2 (consists of mass memory &

redundant mass memory)
Memory capacity hard disk 2 GB
No. of control operating station 2 per Unit
No. of monitoring st.(PS-U) 3 per Unit
No. of CRT & Keybord(on desk) 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 01
Curve display 20
Bar display 34
Op. area display 10
Graphic display 87
Function group op. display 29

SEQUENCE OF EVENT RECORDER

Make M/S Highland, Rochestor

Instrument, Scotland.
Model DEP 90
No. of active points 302
Input per card 16 (16 input circuits)
Resolution 1 MS
 - 71 -

Alarm debounce time Responds to inputs greater than 40 ms

duration.
Contact integration voltage 48 V ungrounded.
Acceptability of NO/NC contract Yes
Archiving facility WYSE make PC
SER Terminal H-31 green WYSE, model WY-30+

INTERFACE WITH FSSS/ATRS THROUGH RELAY PANEL

(Only Binary communication)

Model Procontrol P13/42

Make BBC
Supplier BHEL, EDN, Bangalore
Software language Procontrol10
No. of stations 19
No. of processors 20
Type of processor 70 PR 03(Dedicated type)
Program memory 4096
bytes, (EPPDMS)

System Configuration

1. No. of Intra-panel bus 2 (max. 10) Hot redundant fuses for

each IPB
2. No. of stations/IPB IPB1=15, IPB2=19
3. No. of stations/entire system 19
4.Modules per local bus Maximum 64

Data Communication

Local Bus Service address 2 in every 10 msec.

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)
 - 72 -

i)No. of address 256 x No. of stations,16384 max.

ii)Time required/one telegram 60 s
iii)Information bit rate 266.7 KBAUD
iv)Signal code DPDM
v)Amplitude + 15 v
vi)Data security Parity bit, counting of binary
characters, monitoring of time &
amplitude per bit.
vii)Transmission means Coaxial cable RG 213U of 50 
characteristic.

Inputs/Outputs
Analog I/P 4-20 mA ,100 
I/P resistance –10V to +10V, 100 KΩ
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.

Contact Inputs
Voltage between terminals with open contact 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 BHEL, Bangalore

East package comprises ISKAMATIC A & B

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

COMMON FEATURES
 - 73 -

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 IC’s
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 Tata libert

ii)Capacity(KVA) 60
iii)Voltage rating 240 V AC + 1% output.
iv)Frequency 50 HZ
v)Battery
Rating 405V DC (common for both UPS)
Make Exide
Type Gauntlet tubular
Capacity 450 AH
No. of cells 180
Each cell voltage 2.25 V (Float)
2.00V (Nominal)

LAN & IT

Network Local Area Network based on Fast Ethernet Fiber-Optic Switched

Backbone and Structured Cabling System.

Connectivity 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.

Main Application Server 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.

Exchange Server Compaq Prolient 1600, PIII 500MHZ, 128MB ECC SD RAM, 512
L2 Cache, 9.1GB SCSI HDD, 10/100 TX PCI UTP Controller.

Network Management 1 No Compaq Deskpro EP PIII 450MHZ, 64MB SD RAM

Station 8.4GBHDD
 - 74 -

LAN Node PCs 41 Nos Datamini PIII 450MHZ, 64MB SD RAM 8.4GB HDD

Main Chassis Based 1 No Cabletron Smart Switch 6000 with 16X10/100Base Tx

Switch Ports, 6X100 Base Fx Ports

Workgroup Switch 5Nos Cabletron Smart Stack 100 with 22x10/100 BaseTx full
Duplex auto negotiating ports + 2X100 Base Fx Ports.

Remote Access Server CISCO 2500, 1X10Base T + 16 Async. Sl. Ports

For Dial up facility

Modem for 33.6Kbps Dial-up/Leased Line Modem

Remote Access

FO Connection 6 core Multimode Fiber Optic

(Main Switch to
Workgroup switch)

UTP Connection E CAT5 UTP Cable.

(Workgroup Switch to
Nodes)
Network Management Cabletron NMS Software
Software:

Main Server System

Operating System Win NT4,
Database MS SQL Server 7.0
Application Software RAMCO e-Application 3.1

Logistic Modules Inventory Module

Purchase Module
Maintenance Module
AP Module
Exchange Server System
Operating System Windows 2000
Mail System Exchange Server 5.5
Antivirus Software Norton Antivirus for Server & PC
Internet Access 64Kbps VSAT connection from HSCL
VSAT Router CISCO 2600
Proxy Server PIII PC with Linux System
IB TPS DOMAIN www.opgc.co.in

4.2 INTERLOCK PROTECTION

4.2.1 BOILER AND AUX.

 - 75 -

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. Purge Sequence
a. Purge ready (all purge permissives are satisfied)
b. Purging (5 minute cycle)
c. Purge complete

3. First Cause Trip (Master Fuel Trip) Alarm Trip

a. Both ID fan off - -
b. Both FD fan off - -
c. Furnace pressure V. High +100 + 250mmwc
d. Furnace pressure V. Low (2/3 logic) - 100 - 250mmwc
e. Drum level V. High (for more than 10 sec.) +100 +300mmwc
f. Drum level V. Low (for more than 10 sec.) -100 -300mmwc
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.
 - 76 -

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
0
C 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 ¾ 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 ¾ scanners show no flame, and elevation BC ¾ scanners show no flame.
 - 77 -

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 ¾ scanners show no
flame and elevation BC ¾ 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 ¾ scanners show no
flame and elevation DE ¾ 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 ¾ Scanner show no
flame and elevation DE ¾ 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 ¾ scanner show no
flame.

PULVERISER

1. PERMISSIVE
a. Purge air dampers closed.
b. Electromagnetic brake is released.
c. Girth gear seal air fan motor on.
d. Mill lubrication is OK.
e. Mill starting sequence step-1 completed.
f. Any seal air fan on & mill/seal air Pressure DP OK.
g. Aux. Motor off (Initially aux. Motor is on, it stops when main motor starts)
h. No MFT.
i. Mill side-1 or side-2 START order.
j. Mill ignition energy available.
k. PA fan ON.
l. PAD & BAD dampers closed.

PROTECTION
a. Ignition energy not available
b. MFT relay operated
c. Centrifugal switch
 - 78 -

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) ¾ nozzle valves proven in Elevation AB OR
ii) Elevation B air flow > 24 T/hr AND boiler load > 30% MCR
 - 79 -

Coal Elevation B:
i) ¾ 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) ¾ 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) ¾ nozzle valves proven in Elevation CD

Coal Elevation E
i) ¾ nozzle valves proven in elevation EF OR
ii) ¾ 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) ¾ 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
 - 80 -

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.
 - 81 -

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)

FD FAN
 - 82 -

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

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
 - 83 -

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. Description Alarm value Trip value Remarks

01. Drum level v. high +125 +225
02. M.F.T. channel ½ --- ---
03. Generator protection channel ½ --- ---
04. Lube oil pressure very LOW, ksc --- 1.20 2/3 logic
05. Condenser vacuum LOW, ksc 0.80 0.70 arming at 0.80
2
06. Low vacuum mech. Trip, ksc 0.80 0.76 kg/cm
07. Fire protection channel -50 -100 mm
08. M.O.T. level low -50 -100 mm
(Zero level 800 mm down from top of M.O.T.)

09. Main steam temperature low 5000C 4800C arming at 5100C

10. Axial shift --- ---
11. Local trip --- ---
12. Emergency push button trip from --- ---
unit control board

13. Over speed trip --- 3330 rpm

14. Fire protection 1 operated Turbine trip gear operated & vacuum breaker opens
15. Fire protection 2 operated Turbine trip gear operated, Vacuum breaker opens
AOP1, AOP2, AC JOP OFF & DC EOP, DC JOP ON
with SLC ON. Gate gearing valve closed.
16. M.O.T. level low Same as fire protection 2 & Thrust bearing trip
device operated.

TURBINE OIL PUMP

i) AOP1 starts on Auto : SLC AOP1 is on and AOP2 trips, or

lube oil pressure less than 4.50 kg/cm2

ii) AOP2 starts on Auto : SLC AOP-2 is ON & AOP1 trip or

lube oil pressure is less than 4.50 kg/cm2

iii) EOP starts on Auto : Lub oil pressure less than 1.20 kg/cm2
 - 84 -

iv) JOP1 starts on Auto : SLC of JOP on & turbine speed less
than 510 rpm.
JOP1 stops on Auto : Turbine speed > 540 rpm

v) JOP2 starts on Auto : SLC JOP on & JOP1 trip

OR
Jacking oil pr. < 100 kg/cm2
& turbine speed < 510 rpm

TURNING GEAR
i) Turning gear valve open on auto SLC of turning gear is on and
turbine speed < 210 rpm.

ii) Turning gear valve closes on auto 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
 - 85 -

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) Suction/Discharge differential temp very HI (150C)
viii) Hydraulic coupling bearing temperature > 950C & for bearing 3&4 temp > 900C
ix) Suction valve open and BFP booster pump suction pressure less than 10 kg/cm2
x) DP across filter very HI (0.6 kg/cm2) xi)
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) HPBP valves can be open if condenser vacuum > 0.67 kg/cm2
AND priority closure at condenser vacuum < 0.67 kg/cm2

iii) HPBP downstream temperature exceeds 3760C-HPBP valves closes.

iv) 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
 - 86 -

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

MAIN OIL CENTRIFUGE

Interlock
i) Booster pump motor can be started if main centrifuge motor ON

ii) Centrifuge motor trip, solenoid valve in oil suction line de-energise.
Solenoid valve opens when centrifuge motor ON

iii) Centrifuge motor overload or booster pump motor overload, both motors
trip and heater II & III cut off, heater I remains ON.

iv) Broken liquid seal, centrifuge, booster pump, heater II & III trip,
heater I remains ON.

v) Polishing filter choke, centrifuge, booster pump, heater II & III trip,
heater I remains ON.

vi) Centrifuge motor ON, heater II & III can be made ON

vii) Oil temperature more than 60oc, heater III cut off.

viii) 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.

Low Pressure Heater-2

i) Very high drip level - Extraction block valve Ex 10 closes
300 mm above normal- Extraction drain valve Ex.101 & Ex. 102 opens
water level) - Normal cascade drain control valve DR16 closes
- Extraction line NRV closes
- Alternate drain control valve DR 24 opens.
 - 87 -

Low Pressure Heater-3

i) Very high drip level - Extraction block valve Ex.11 closes
(300 mm above - Extraction drain valve Ex.103 opens
normal water level) - Extraction NRV closes
- Alternate drain control valve DR19 opens

Deaerator
Deaerator pressure control:
a) Cold start up - 2.5 ata by auxiliary steam.

b) Hot and warm start

up & bypass operation- 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- Extraction block valve Ex.13 closes.
(335 mm above LWL)- 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.

ii) Pressure falls below - Overriding command to close DR2

a preset value

High Pressure Heater-6

i) Very high heater level- Extraction steam block valve EX12 &
(345 mm above NWL) 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

 - 88 -

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.

SEAL OIL SYSTEM

Interlock
i) Seal oil header pressure less than 4.1 kg/cm2, D.C. SOP starts.

AIR CONDITIONING PLANT

AC COMPRESSOR
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)
 - 89 -

SECTION – 5

OFFSITE AUXILIARIES
 - 90 -

5.1 RAW WATER SYSTEM

i) Raw Water source Hirakud reservoir through intake channel

ii) Intake channel
Length 5450 m
Bed width 3.5 m
Width at top 7.0 m
Bed level 174.5 m RL at down stream end

RAW WATER PUMP

i) Manufacturer Kirloskar Brothers, Pune

ii) Type BHR 50-22½ ISTG (vertical)
iii) No. of pumps 6 for both units (4 working, 2 stand by)
iv) No. of stages One
v) Capacity 1400 m3/hr
vi) Head 60.35 m
vii) Speed 1485 rpm
viii) Discharge size 450 mm
ix) Motor
Make KEC
Rating 304 KW, 6.6 KV, 3-ø, 50 Hz, Insulation
Class F

5.2 CIRCULATING WATER SYSTEM

5.2.1 C.W. PUMP

i) Manufacturer KBL
ii) No. of pumps 6 for both units (4 working, 2 stand by)
iii) Type BHQ 92 (vertical)
iv) Outlet size 1200
v) Min. fore bay water level 193.5 m
vi) Max. fore bay water level 195.5 m
viii) Duty Condition:
Capacity 15000 m3/hr
Total head at pump discharge 27.5 m
 - 91 -

Total head loss from suction 0.11 mwc

ball to discharge flange
Rated speed 494 rpm
Pump efficiency at design capacity 89.1%
Pump input design capacity 1268.8 KW
Bowl head 27.61 m
ix) Motor
Make BHEL
Rating 1470 KW, 6.6 KV, 3-ø, 50 Hz, continuous
duty Insulation Class F, 166.8 A
x) Discharge valve Butterfly tight, shut off type, 1600 mm NB

5.2.2 COOLING TOWER

i) Type Induced draft type

ii) No. of cells/unit 11 (10 working, 1 stand by)
iii) Model 1514-11 (RCC fill)
iv) Height excluding diffuser 10.345 m
v) Width 25.21 m
vi) Length 154.25 m
vii) Total no. of towers 2 (1 for each unit)
viii) Cooling water flow 9166.67 LPS
ix) Hot water inlet temperature 420C
x) Range of cooling 100C
xi) Re-cooled water temperature 320C
xii) Ambient wet bulb temperature 26.20C
xiii) Drift loss % 0.05
xiv) Evaporation loss % 1.676
xv) Blow down for 2% conc. 1.63
xvi) Blow down for 4% conc. 0.509

Fans
i) Type Axial flow propeller type
ii) Design exit air temperature 39oc
iii) Air flow rate / cell 31978 m3/min.

Flow Control Valves

i) No. 4 per cell
ii) size 500 Nb
iii) Drive 48 KW, 415V, 3-ø, 50 Hz, Insulation
Class F
Chlorinators
i) No. 2 nos
ii) Capacity 112.5 kg/hr
iii) Type ‘V’ notch vacuum feed
 - 92 -

Chlorinator Booster Pump

i) No. 2 nos
ii) Capacity 9 m3/hr
iii) Head 50 mwc

5.3 BEARING COOLING WATER SYSTEM

5.3.1 BCW PUMP

i) Make KBL
ii) No. 6 for both units (4 working, 2 standby)
iii) Type BHR 42-30 (2 stage)
iv) Rated capacity 930 m3/hr
v) Total dynamic head 80.2 mwc
vi) Size 350 mm
vii) Pump input 238.492 KW
viii) Speed 1450 rpm
ix) Motor Details:
Duty Continuous
Rating 6.6 KV, 3-ø, 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)

Size Flow (m3/hr)
i) Boiler BCW Header 250 NB 294
ii) Turbine BCW Header 500 NB 1070
iii) Air conditioning plant 250 NB 330
(common for both units)

BCW Sump
i) Capacity 1500 m3
ii) Size 24.0 m x 15.0 m 4.0 m
iii) Bottom level 195.00 mtr RL

BCW Overhead Tank

i) Nos 1 for each unit
ii) Type Rectangular
iii) Capacity 210 m
 - 93 -

iv) Size 17.0 m x 4.5 m x 3.25 m

5.3.2 PLATE HEAT EXCHANGER

Primary side Secondary side

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

5.4 SERVICE WATER SYSTEM

Service Water Pump

i) No. Three (1 working, 2 standby)
ii) Type Single stage horizontal centrifugal pump
iii) Capacity 60 m3/hr
iv) Total head 90 m
v) Motor detail 415V, 3-ø, 50Hz, 30 KW, 52A, 2955 rpm,
Insulation Class F.

Service Water Overhead Tank

i) No. 1 for each unit
ii) Type Rectangular, vertical
iii) Capacity 75 m3
iv) Size 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 7.5-8.5
ii) TDS, mg/l 200
iii) Permanganate value 02 ppm
iv) Iron as Fe, mg/l 1.5
v) P. Alkalinity as CaCo3 Nil
vi) M. Alkalinity as CaCo3 90.0
 - 94 -

TREATED WATER QUALITY

Constituent As Analysis

i) Calcium (ca) CaCo3 90 ppm

ii) Magnesium CaCo3 40 ppm
iii) Sodium & Potassium (mg) CaCo3 40 ppm
vi) Sulphate (So4) CaCo3 60 ppm
v) Chloride (Cl) CaCo3 15 ppm
Total Anions CaCo3 172 ppm

vi) Iron Fe 0.2 ppm

vii) Free carbon dioxide CO2 Not traceable
viii)Silica SiO2 9 ppm (colloidal)
6 ppm (reactive)
ix) pH value ---- 7.5 to 8.5
x) Turbidity NTU ---- Not to exceed 10
xi) Organic matter, ppm ---- Traces
xii) Manganese content, ppm ---- Not traceable

FLASH MIXER
i) No of units 2 (one for each clariflocculator)
ii) Material of construction RCC
iii) Size 2.5 m2X 4.1 mswd
iv) Rated flow to each unit 1200 m3/hr
v) Agitator One, 7.5 HP, 1500 rpm

CLARIFLOCCULATOR
i) No of units 2
ii) Material of construction RCC
iii) Rated flow of each ccf 1200 m3/hr
iv) Overall size 31 m2 X 2.7 mswd
v) Detention time (for rated flow)
Flocculator zone 30 min
Clarification zone 158 min (approx)

FILTER BEDS
i) No of units 5
ii) Material of construction RCC
iii) Capacity (each) 500 m3/hr
iv) Size 7.2 m X 4.375 m
v) Rate of filtration 500 m3/hr

FILTER BACK WASH

i) Duration of air scouring 3 to 5 min
 - 95 -

ii) No of air blowers 2 (1 working + 1 stand by)

iii) Capacity 1350 m3/hr
iv) Backwashing By backwash pump
No of pumps 3 (2 working + 1 stand by)
Make/ model Worthington, C18 TC
Capacity (each) 610 m3/hr
Motor 55 kw/ 4 pole
CHLORINATION SYSTEM (PT)
i) No of chlorinator 3
ii) Make/ model V-711
ii) Capacity (each) 10 kg/hr
iv) Booster Pumps
No 2
Capacity 9 m3/hr at 50 mwc
Motor 5.5 Kw

5.5 .2 D. M. PLANT

EFFLUENT QUALITY
a) Activated carbon filter outlet
Free chlorine & iron Not detectable
Turbidity Not to exceed 0.5 NTU
b) Cation exchanger outlet
Sodium as Na < 0.05 ppm
c) Degasser outlet
Free carbon dioxide as CO2 < 5 ppm
d) Anion outlet
Silica as SiO2 (reactive) Not to exceed 0.1 mg/l
Chloride BDL
Conductivity at 250C Not to exceed 2 micro mho/cm
Organics Nil
e) Mixed bed outlet
Total electrolyte Not to exceed 0.1 mg/l
Silica as SiO2 (reactive) Not to exceed 0.02 mg/l
Free CO2 as CO2 Not detectable
Iron as Fe < 0.01
Total hardness Not detectable
PH value 6.8 – 7.2
Conductivity at 250C < 0.2 micro mho/cm
 - 96 -

ACF & EXCHANGER DATA

Activated Strong acidic Strong basic Mixed bed

carbon filter cation anion exchanger
exchanger exchanger
i)No. of units 3 3 3 3
ii)Normal flow rate 75 75 75 75
m3/hr
iii)Max. flow rate m3/hr 90 90 90 90
iv)Regeneration 20 20 20 160
interval hours
v)Net output between 1500 1500 1500 12000
two regeneration, m3
vi)Filling media Activated T-42 Thermax A-27 (MP) A-27 (MP)
Thermax & T-42,
Thermax
vii)Quantity of
Operating Media (m3)
Operating -- 5.38 4.46 1.27 & 1.27
Inert -- 0.318 0.312 --

RELEVANT DATA FOR REGENERATION

1. Chemical Required Cation Anion MB MB

for Regeneration group group cation Anion

a) 100% HCl, kg 215.2 -- 88.9 --

b) 30% HCl, kg 718 -- 296 --
c) 30% HCl, litres 624 -- 257 --
d) 100% NaOH, kg -- 156.1 -- 88.9
e) 45% NaOH, kg -- 347 -- 198
f) 45% NaOH, litres -- 240 -- 136

2. Acid dilution water 21.5 -- 6.0 --

flow rate, m3/hr
3. Alkali dilution water -- 15.0 -- 4.0
flow, rate m3/hr
 - 97 -

MISCELLANEOUS PUMPS

TDH, Drive
No Make Type/stage Operation mwc Motor,
KW
3 Worthington Vertical/ Continuous 20 55
Filter Back Single
Wash Pump

4 Worthington Centrifugal/ Intermittent 30 18.5

DM Plant Single
Pump

3 Centrifugal/ Continuous 75 18.5

Potable Worthington Single
Water Pump

BCW Make 3 Centrifugal/ Intermittent 30 22

Up Pump Worthington Single

Degassed 5 Centrifugal/ Continuous 50 30

Water Pump Kirloskar Single

DM Water 3 Centrifugal/ Intermittent 40 22

Transfer Kirloskar Single
Pump
Acid Transfer 2 Centrifugal/ Intermittent 20 3.7
Pump Antico Single

Caustic 2 Centrifugal/ Intermittent 20 7.5

Transfer Kirloskar Single
Pump
Waste Water 4 ------- Centrifugal/ Intermittent 30 11
Disposal Single
Pump
Filter Air 2 Kay Centrifugal --------- Discharge 18.5
Blower International Pressure
3.55 psi
 - 98 -

Degassed Air 4 Rotary/ ---------- Suction 2.2

Blower Universal Single 2200m3/hr
Mixed Bed 2 Kay Rotary/ --------- Suction -------
Blower International Single 480m3/hr

LIMITING VALUES OF BOILER WATER CHEMISTRY

Sample pH CONDUCTIVIT SiO2 PO4 N2H4 TH Cl- DO NH3 Fe Cu

Y As
In micro siemens NaCl
DC ACC ppb ppm ppb ppm ppm ppb ppb ppb
Boiler Drum 9.2-9.8 <50 <300 1 to 6 0 <2

Sat. Steam 8.8-9.2 <6 <0.3 <20 0 BDL

Main Steam 8.8-9.2 <6 <0.3 <20 0 BDL

Condensate 8.8-9.1 <6 <0.3 <20 0 BDL <20 <0.5
Feed Water 8.8-9.2 <6 <0.3 <20 20 0 BDL <7 <0.5 <10 <5

DM-Make 6.8-7.2 <0.2 <0.2 <20 0 BDL

up
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.

5.6 STANDARD LIMITS OF ENVIRONMENTAL EMISSION

(CONSENT REQUIREMENT)

STACK EMISSION
Quantity of Flue Gas 90×104 Nm3/hr/unit
Suspended Particulate Matter <150 mg/Nm3

AMBIENT AIR QUALITY STANDARDS

Pollutant Time Weighted Concentration in Ambient Air

Average Industrial Residential
Area Area
1 2 3 4
 - 99 -

Sulphor Dioxide Annual avg. 80 g/m3 60 g/m3

(SO2) 24 hours 120 g/m3 80 g/m3

Oxides of Nitrogen Annual avg 80 g/m3 60 g/m3

As NOX 24 hours 120 g/m 80 g/m
Suspended Particulate Annual avg. 360 g/m3 140 g/m3
Matter (SPM) 24 hours 500 g/m 200 g/m

Respirable Particulate Annual avg. 120 g/m3 60 g/m3

Matter (Size less 24 hours 150 g/m3 100 g/m3
than 10 g/m3) (RPM)

Lead (Pb) Annual avg. 1.0 g/m3 0.75 g/m3

24 hours 1.5 g/m3 1.0 g/m3

Carbon Monoxide 8 hours 5.0 mg/m3 2.0 mg/m3

(CO) 1 hour 10.0 mg/m3 4.0 mg/m3

COMBINED INDUSTRIAL EFFLUENT

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

5.7 COAL TRANSPORTATION AND COAL HANDLING SYSTEM

5.7.1 COAL TRANSPORTATION SYSTEM

i) Source of coal Ib Valley Lakhanpur mine

ii) Means of transportation Merry Go Round System
iii) No. of wagons 36 (including 6 standby)
iv) No. of rakes required per day 4
v) Total cycle time of one rake 4 hours 32 minutes
vi) Total distance 19.3 km
vii) Total cycle length 25.25 km
viii) Track length 33.6 km
ix) Track gauge 1676 mm
x) Type of wagon & make Bottom discharge type, Texmaco make
 - 100 -

xi) Tare weight of wagon 27.5 T

xii) Locomotive:
Make Diesel Locomotive Works, Varanasi
Nos. 2
Model / type WDM2/ Co-Co
Horsepower 2400 hp
Max speed 120 kmph
Gear ratio 65/18
Max. Radius of curvature 73.2 m

FILLING STATION FOR DIESEL LOCOMOTIVE

Location MGR Workshop panel building

Capacity 270 KL

5.7.2 COAL HANDLING SYSTEM

Track Hopper
i) No. of hoppers 50
ii) Type of hopper RCC underground
iii) Length of track hopper 200 m
iv) Breadth of track hopper 6.8 m
v) Height of track hopper 7.15

Paddle Feeder
i) Location Underneath Track hopper
ii) No. of paddle feeder 4
iii) Type of paddle feeder Rotary type
iv) Design/Rated capacity 1200 / 1000 T/hr
v) Range of travel 210 m

Vibration Grizzle Feeder

i) Location At crusher house
ii) No. of vibrating grizzly feeder 4 nos
iii) Capacity rated / design 1000 / 1200 T/hr
iv) Frequency 1000 rpm (nominal)
v) Motor 25KW, 415V, 3-ø, 50 Hz, KEC make

Crusher House
i) No. & make of crusher 4, Elecon Engineering Co.
ii) Type & size Ring granulator, EKK 48” x 114”
iii) Main crusher capacity 1000 TPH each
iv) Max. coal size before crusher 300 mm
v) Coal size after crusher 20 mm
 - 101 -

vi) Motor rating KEC make, 825 KW, 6.6 KV, 3-Ø,
50 Hz, 720 rpm, 92 A, Insulation Class F

Conveyor
i) No. of belt conveyors 26
ii) Design / rated capacity 2200 TPH / 2000 TPH

Main belt TRH1A/ 1A/1B 2A/2B 3A/3B 5A/5B 7A/7B 8A/8B SR1
conveyor 1B
iii)Belt speed 2.9 3.02 3.02 2.97 3.02 3.02 2.97 3.02
(m/sec)
iv)Belt width ← 1600
(mm) →
v)No. of plies 4 4 4 4 4 4 4 4
vi)Top cover 5 5 5 5 5 5 5 5
thickness (mm)
vii)Bottom cover 3 3 3 3 3 3 3 3
thickness (mm)
viii)Cover grade ←----------- Fire resistant (FR) ------------------------→

ix)Conveyor
motor:
Rating (KW) 200 330 330 157 400 520 165 300
F.L. Current, (A) 23 34 35 26 43.5 66 19 34
Power supply ←……….. ←…… 6.6KV, 3ø, 50Hz …..→ …..→ …→

x) No. of metal detectors 5 (on conveyor 2A/2B, 7A/7B & SR-1)

xi) No. of belt weigher 6 (on conveyor 1A/1B, 2A/2B, 7A/7B)
xii) No. of sampling unit 4
xiii) No. & type of magnetic separators 5, suspended type
xiv) No. of suspended magnet 2

Tripper
i) Type Travelling type
ii) No. 2
iii) Capacity 2200 t/hr
iv) Travel speed 14.5 m/min.
v) Motor for tripper 11 KW
vi) Brake Thruster operated

Stacker / Re claimer
i) No. 1
ii) Model ASK 965
iii) Stacking capacity (rated/design) 2000 / 2200 TPH
 - 102 -

iv) Reclaiming capacity 2000 TPH

v) Travel Motor Reversible slip ring motor, 6 nos,
10 KW each
vi) Bucket motor Squirrel cage, 125 KW, 415 V, 3ø, 50 Hz
vii) Boom conveyor speed 3 m/sec
viii) Boom conveyor motor
Type & Rating Squirrel cage reversible type,110
KW, 415V, 3ø, 50 Hz
ix) Slew speed 6 m/min. to 32 m/min. (step less)
x) Slew motion motor D.C. type, 2 x 14 KW

Dust Extraction System

i) Total No. of units DE-1 to 6 for section-I & DE-7 to 13 for
Section-II
ii) Fan Centrifugal
iii) Dust velocity 4 m/sec. (at hood)
iv) Cyclone collecting efficiency 85% (base on 10 microns)

Stock Yard
i) Capacity 45 days, coal storage requirement
450000 m3 of coal approx
ii) Length/height of each pile 505 m / 9.5 m

5.8 ASH HANDLING SYSTEM

5.8.1 BOTTOM ASH HOPPER

i) Quantity One
ii) Shape W type
iii) Capacity 200 m3 (effective)
iv) No. of outlet opening Four
v) Maximum level up to which 300 mm below hopper overflow nozzle
ash can be stored elevation.

5.8.2 CLINKER GRINDER

i) Location Feed Gate housing

ii) Capacity 75 TPH
iii) Quantity Four per unit
iv) Hopper evacuation time 70 minutes

FEED GATE HOUSING

No. 4 per unit
 - 103 -

HYDROEJECTOR
No. 4 per unit

5.8.3 HORIZONTAL ASH WATER PUMPS

Fly Ash Pump Fly Ash Pump Bottom Ash Seal Water
(HP) (LP) Pump Pump
i)Location Ash Water Pump House
ii)Type Horizontal, Centrifugal
iii)Quantity 3 3 3 3
iv)Fluid Handled Clear Water
v)Capacity(m3/hr) 250 600 400 60
vi)Total Dynamic 75 55 75 180
Head (mwc)
vii)Speed (rpm) 1480
viii)Suction Flooded
condition
ix)Duty Continuous
x)Coupling Flexible
xi)Drive Details: 415 V, 3-ø, 50 Hz
Supply
Rating (KW/A) 75/132 125/213 120/204 50/88

5.8.4 ASH DISPOSAL PUMP

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

5.8.5 ASH COLLECTION RATE

 - 104 -

Collection point No. of Collection rate of Ash

Hoppers each hopper (kg/hr) Temp. 0C

i) Furnace bottom hopper One 19200 1000

ii) Economizer hopper 4 4800 361
iii) Air heater hopper 6 4800 144
iv) Duct hopper 2 2400 144
v) ESP hopper:
First field 8 61440 144
Second field 8 11212.8 144
Third field 8 2611.2 144
Fourth field 8 998.4 144
Fifth field 8 307.2 144
Sixth field 8 88.32 144
Stack 1 Balance 144

For two units at full load

i) Bottom ash collection 36.8 TPH
ii) Coarse ash collection 18.4 TPH
iii) Fly ash collection 147.2 TPH
iv) Total collection 202.4 TPH maximum

5.9 ASH POND AND ASH WATER RECYCLE SYSTEM

POND‘A’ POND‘B’

i) Gross area, acres/m2 150/6,07,040 242/9,80,000

ii) Top elevation of dyke, m (RL) 197.00 202.00
iii) Average base level, m (RL) 187.00 189.00
iv) Average height of dyke, m 10.00 13.00
v) Max. level of ash deposit, m (RL) 197.00 200.50
vi) Minimum freeboard, m 1.50 1.50
vii)Available depth of ash deposition, m 8.50 11.50
viii)Area covered by bund, m2 2,47,760 2,94,000
ix) Net area (excluding settling tank), m2 3,41,280 6,86,000
x) Capacity, m2 29,00,880 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.
 - 105 -

Transfer Water Pump

i) Nos. 3
ii) Manufacturer Voltas Ltd
iii) Type Vertical Turbine Pump
iv) Model BK 450-022
v) No. of stages 4
vi) Rated capacity, m3/hr 1000
vii) Total dynamic head, mwc 180
viii)Recommended min./max.
flow through the pump, m3/hr 700/1400
ix) Thrust bearing Antifriction type, SKF/FAG 29428E
x) Coupling Pin & Bush type, NBCB (Fenner)
xi) Material
Suction bell Cast steel, WCB, ASTM A-216
Impeller CF8M, ASTM A-743
Motor
i) Manufacturer BHEL, Hardwar
ii) Rating 6.6 KV, 50 Hz, 78.9 A, 1485 rpm
Insulation class-F
iii) Driven equipment demand
Normal / Maximum, KW 609.21 / 620.86

33KV / 6.9KV, 450 KVA Transformer

i) Manufacturer K.E.C. Ltd, Bangalore
ii) Continuous rating 4.5 MVA, 50 Hz, 3-
iii) Rated no load voltage
HV winding 33KV
LV winding 6.9KV
iv) Connection
HV winding Star
LV winding Star
v) Vector group Ynyno
vi) On load/off circuits On-load tap changer
vii) No. of steps 8 steps – 9 positions
viii)Type of cooling ONAN

150 KVA AUX. Transformer

i) Continuous rating 150 KVA
ii) Type Dry
iii) Type of cooling AN
iv) Rated voltage
HV 6.6 KV
LV 433 V
v) Vector group Dyn11
vi) Type of taps Off circuit
 - 106 -

vii) No. of taps 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

Area Type Of Detectors Used

i) Cable trench, cable gallery. ISD, PSD, LHS cable, Quatrozoid bulb.

ii) Generator seal oil unit, oil

tank, oil purification unit. HVW, Quatrozoid bulb

iii) Boiler burner fronts. Manual Call Point

iv) Generator Transformer,

Station Transformer, UAT HVW, Quatrozoid bulb

v) HT/LT switchgear, battery

room, MCC room ISD, Heat Detector

vi) MCR, DAS room, UPS room ISD, PSD

vii) SWAS room ISD
 - 107 -

viii) CHP control room & building ISD

ix) Coal conveyor LHS cable, ROR (Thermocouple type)
x) Switch yard ISD
xi) Service Building ISD, Heat Detector

5.10.2 FIRE SUPPRESSION SYSTEM

FIRE HYDRANT PUMP

i) No. 3
2 Electrical driven, 1 diesel engine driven
ii) Location circulating water pump house
iii) Make Warthington Pump India Ltd
iv) Area where used Total plant area, bunkers, track hoppers

Electric driven Diesel engine driven

v) Rated capacity (m3/hr) 273 273
vi) Total dynamic head (mwc) 90.84 90.84
vii) Size of pump discharge (mm) 200 NB 200 NB
viii) Speed 1470 rpm 1500 rpm
ix) Power required at coupling 88.57 87.62
at duty point (kw)
x) Drive detail:
Make KEC Kirloskar Cummins Ltd
Rated Power 110 KW, 415 V 173 bhp
3-Ø, 50Hz, 182A,
Insulation class B,
Speed 1482 rpm 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

Electrical driven Diesel driven

vi) Rated capacity (m3/hr) 410 410
vii) Total head (mwc) 91.4 91.4
viii) Size of pump discharge (mm) 250 250
ix) Speed (rpm) 1470 1500
x) No. of stages 5 5
 - 108 -

xi) Drive detail:

Make NGEF Ruston & Hornsby
(India) Ltd

Power 160KW, 415V, Rated bhp 230 at

3-Ø, 50Hz,1500 rpm 1500 rpm

JOCKEY PUMP
i) No. of pump 2
ii) Stage 7 stages
iii) Rated capacity (m3/hr) 11
iv) Total dynamic head (mwc) 92.8
v) Drive 7.5 KW, 415V, 3-Ø, 50Hz, 2900 rpm

HYDRO PNEUMATIC TANK

i) Type Vertical cylindrical
ii) Capacity 10 m3
iii) Design pressure 192 psi
iv) Working pressure 175 psi

AIR COMPRESSOR
i) Make Ingersol Rand
ii) Type Single stage, single cylinder, reciprocating
iii) Quantity 1
iv) Capacity 0.56m3/min
v) Head 10 Kg/cm2
vi) Air receiver capacity 225 litre
vii) Working pressure 175 psi

FOAM SYSTEM
i) Area where used HFO/LDO system
ii) Type of system Fixed foam low expansion delivered gently
in oil surface
iii) Application rate 5 lpm/m2 liquid surface area
iv) Foam concentration 30% profein based
v) Type Foam maker with vapour
vi) Foam delivery rate 393 & 768 LPM
vii) Foam compound consumption 3%

HALON SYSTEM
i) Make Cerberus Guinard
ii) Area where used Main control room, Instrumentation pane
rooms, UPS, DAS & excitation rooms
iii) Extinguishing agent Halon1301 gas
iv) Concentration 5% at design temperature
v) Gas discharge duration 30 sec.
 - 109 -

5.11 AIR COMPRESSOR

Manufacturer : Kirloskar Pneumatics Ltd

Type : Reciprocating, horizontal, balance opposed,
oil free type
No. of compressors : 4 per unit

CONSTRUCTION FEATURES
i) No. of stages Two
ii) Cylinder arrangement Balanced opposed
iii) Cylinder bore
LP 1 x 355 mm
HP 1 x 215 mm
iv) Stroke 150 mm
v) Cooling water pressure 2.5 ksc – 3.5 ksc
vi) Inter cooling water pressure 3.5 ksc
vii) Type of drive Direct through belt drive
viii) Main bearing type Split sleeve
ix) Method of lubrication Forced feed by gear pump
x) Max. allowable lube oil temp. 80oc
xi) Cross head lubrication HPC/LPC By gear pump/splash type
xii) Lube oil pressure 2 to 4 kg/cm2(g)

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. 3 for both units
ii) Desiccant Silica gel as per IS 4301
iii) Duty Continuous
iv) Drying cycle 6 hours
v) Type of drying Absorption
vi) Type of reactivation Open thro-system
Type of change Automatic with provision for manual

Motor
i) Manufacturer KEC Ltd., Bangalore
 - 110 -

ii) Rated output 125 KW

iii) Frame size LD 315 MMK 11
iv) Class of insulation B
v) Rated speed 1484 rpm
vi) Power supply 415 V, 3-Ø, 50 Hz

REGENERATION CYCLE
i) Depressurisation 10 min
ii) Heating 3 hours
iii) Cooling 1 hour
iv) Re pressurising 15 min

5.12 AIR CONDITIONING PLANT

Description Main chilling plant Switchyard A.C. plant

Control room/Service bldg. (Direct expansion AHU)

Capacity (tons) 704 702 302(condensing units)

Refrigerant used R-22 R-22 R-22

Compressor
No. 4 2 2
Make ----------------------Kirloskar Pneumatic Ltd---------------------------
Model AC-880 AC-880 AC-470
No. of cylinders 8 8 4
Cylinder bore(mm) 95 95 85
Stroke (mm) 70 70 70
Direction of rotation ----------------------Both directions permitted----------------------------
Max. operating
pressure (bar) 21 21 21
Capacity control(%) ----------------------25, 50, 75, 100-----------------------------------------
Lube oil ----------------------Servofiz F-57 (10C )---------------------------------
Motor GEC make, 415 volt, 3-Ø, 50Hz GEC make, 415 volt, 3- Ø,
93 kw, 169A, 1485 rpm 50Hz,37kw,69A,1470rpm

Shell And Tube Condenser

Make ---------------------------------Blue star Ltd--------------------------------

Model CDS-1686 CDS-1686 CDS-1260
No. 4 2 2
No of tubes 172 172 110
No of passes 3 3 4
Tube material Copper Copper Copper
Max Working pressure
i) Water side (kg/cm2) 7 7 7
ii) Refrigerant side
 - 111 -

(kg/cm2) 21 21 21
Mode of flow -------------------------Water through tubes-------------------------------
Heat rejection rate ------265313 kcl/hr----------------- 110185 kcl/hr

Chiller
Make --------Blue star Ltd---------------- No chiller as direct
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
Water outlet temp (0C) 7.22 7.22
Total water flow (m3/hr) 38 38

Air Handling Unit

Make -------------------------- Blue star Ltd----------------------------------

No 4 4 1
Model Size-12 Size-9, 11 Size-11
Fan type --------------------Centrifugal forward curved------------------------
Air quantity (m3/hr) 40,000 21367 (size-9) 22700
31600 (size-11
Electric strip heaters 318kw 39kw 29kw
Motor ------------------GEC make, 415 volt, 3-Ø, 50Hz---------------------
Rating 15kw 7.5/5.5 kw 7.5 kw

Packaged Air Conditioners

Location ESP control room U#1 & 2 (3 Nos. each)

Capacity 7 ton each
Make Blue star Ltd
Model PWC-711
Electric strip heater 26kw
Condenser cooling Water cooled (shell & tube type)
Compressor Hermatically sealed, Copeland make, 3- motor
Compressor speed 2900 rpm
Suction /
condensing temp 4.4/ 42 0C

SPLIT AIR CONDITIONER

Location Annunciation panel room of unit –2 and Halon cylinder room
No 3
Capacity 7.5 ton
Make Blue star Ltd
Model SAC 711A
Condenser type Air cooled fan coil type
 - 112 -

Compressor Hermatically sealed, Copeland make, 3- motor.

5.13 MAIN PLANT DG SET

Total Nos. 3
Diesel Engine:
i) Make Kirloskar Cummins
ii) Model KTA-2300 G
iii) No. of cylinders 12
iv) Displacement, cub inch(litres) 2300 (37.8)
v) HP at 1500 rpm 890
vi) Engine breathing Turbocharged after cooled
vii) Method of cooling of
engine & lube oil Radiator water cooled / forced air blast
Alternator:
i) Make Kirloskar Electric Co. Ltd.
i) Rated capacity at 40oc 750 KVA
ii) Rated terminal voltage & frequency 433 V, 50 Hz
iii) Rated stator current 1000 A
iv) Class of insulation F
v) Excitation current & voltage
at rated output & power factor 20A, 64.1 V

Diesel Tank:
Capacity 900 litres
- 113 -

SECTION – 6

ANNEXURE
 - 114 -

ANNEXURE - 1

TURBINE ROLLING CURVE-1

DT (HP ESV1 – HP CASING) >5.1

STEP / CRITERIA 11/4

 - 115 -

TURBINE ROLLING CURVE-2

DT (HP ESV2 – HPSHAFT) >5.2

STEP / CRITERIA 11/5

 - 116 -

TURBINE ROLLING CURVE-3

DT (HP BP1 – HP SHAFT) < X6

STEP / CRITERIA 14/2

 - 117 -

TURBINE ROLLING
CURVE-4
DT (LP BP1 – IP SHAFT) < X7

STEP / CRITERIA 19/2

 - 118 -

TURBINE ROLLING CURVE -5

STEAM BEFORE ESV1 S/H > X 4.1

STEAM BEFORE ESV2 S/H > X 4.2

STEP / CRITERIA 11/2

 - 119 -

11/3

TURBINE ROLLING CURVE-6

DT (HP BP1 –HPCV1) < X1.1

DT (HP BP2 –HPCV2) < X1.2

STEP / CRITERIA 4/6

4/7
 - 120 -

TURBINE ROLLING CURVE-7

DT (WET STEAM – HP CV1) <X2.1

DT (WET STEAM – HP CV2) < X2.2

STEP / CRITERIA 4/9

4/10
 - 121 -

ANNEXURE - 2

GENERATOR OPERATING LIMITS

DESIGN POINT

OUT PUT 147 MVA

OUT PUT 210 MW
POWER FACTOR 0.85 LAG
 - 122 -

STATOR VOLTAGE 15.75 KV

STATOR CURRENT 9050 AMP
SPEED 3000 RPM
H2 PRESSURE 3.5 KG/CM2

-------Leading MVAR Lagging MVAR ---------------

Series 1 Turbine Limit (210MW)

Series 2 Rotor Heating Limit
Series 4 Rotor Angle Limiter
Series 5 Rotor Current Limiter

ANNEXURE -3

UNLOADING SCHEDULE DUE TO HIGH DISTILLATE TEMPERATURE

 - 123 -

Series 1 POWER OUTPUT

Series 2 NORMAL TEMP OF DISTILLATE – 450C
Series 3 RATED STATOR CURRENT 9050A
Series 4 STATOR CURRENT
Series 5 RATED OUTPUT
Series 6 MVA OUTPUT

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

ANNEXURE - 4

STATUTORY CLEARANCES
 - 124 -

Subject Clearance Authority

1. Certificate of Incorporation as Registrar of Companies,

OPGC under Companies Act. Orissa.

2. Generating Company under Govt. of Orissa in I & P

Electricity (supply) Act, 1948 Deptt.

3. Orissa river board clearance for Director of Industries,

Effluent discharge. Orissa.

4. Water availability from Hirakud E.I.C. Irrigation, Govt. of Orissa,

Reservoir I & P Deptt.

5. Environmental Clearance State Prevention & Control

Pollution Board, Orissa.

6. Forest Clearance Ministry of Forest, Fisheries &

Animal Husbandry, Govt. of
Orissa.

7. Principle Clearance Govt. of India, Deptt. of I & P.

8. In principle Clearance Planning Commission,

Govt. of India.

9. Techno-Economic Clearance Central Electricity Authority,

Govt. of India.

10. Power Evacuation Central Electricity Authority,

Govt. of India.

11. Civil Aviation Clearance National Airport Authority, India

12. Coal Linkage Deptt. of Coal & Mines, Govt.

of India.

13. Financing by Financial

Institutions Govt. of India.
 - 125 -

ANNEXURE - 5

LICENCES

License License No.

1. Factory Registration under JH 78

Factories Act

2. Boiler Registration under U # 1 - 512

Indian Boiler Act U # 2 – 516

3.Registration under Contract 3199

Labour (R&A) Act

4. Fuel Oil Tank inside Main Plant P-12 (14) / OR-1551

5. Filling Station for Diesel Locomotive P-12 (14) 442

6. Storage of Chlorine Cylinder GC- (OG) S-138/OR

7. Consumer Pump OR- 1616

8. Waste Management Authorization

under Hazardous Waste Management
Handling Rule, 1989 Ind/TV/HW/187(70)/10531

9. E.P.F. Coverage under

EPF (MP) Act. SRO/RKL/7395/292/19-01-98

ANNEXURE – 6

STEAM TABLE
 - 126 -

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
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
 - 127 -

---------------------------------------------------------------------------------------------------
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 1.2583
170.0 350.66 1.750 0.00868 400.4 211.0 611.4 0.9045 1.2427
180.0 355.35 1.812 0.00780 410.1 192.7 602.8 0.9192 1.2258
190.0 359.82 1.889 0.00697 420.2 172.7 592.9 0.9347 1.2075
200.0 364.08 1.99 0.00618 431.4 149.7 581.1 0.9515 1.1864
210.0 368.16 2.13 0.00535 444.6 121.4 566.0 0.9713 1.1606
220.0 372.1 2.39 0.00438 463.0 79.3 542.3 0.9993 1.1222

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 0.1352 0.1436 0.1550 0.1624 0.1731 0.1800 0.1901 0.1970 0.2070
0.2234 0.2397 0.2559 0.2720 0.2880
(197.4) h 668.4 681.1 698.0 708.8 724.7 735.2 751.2 761.8 777.5
803.5 829.6 855.8 882.3 909.0
s 1.5445 1.5699 1.6036 1.6241 1.6527 1.6709 1.6970 1.7137 1.7375
1.7748 1.8098 1.8427 1.8739 1.9038

20.0 v 0.1043 0.1138 0.1197 0.1281 0.1334 0.1412 0.1465 0.1542

0.1667 0.1790 0.1913 0.2035 0.2156
(211.4) h 674.4 693.1 704.6 721.3 732.4 748.8 759.4 775.5
801.9 828.3 854.7 881.3 908.2
s 1.5280 1.5645 1.5863 1.6166 1.6354 1.6621 1.6791 1.7035
1.7414 1.7767 1.8100 1.8415 1.8715
 - 128 -

25.0 v 0.0891 0.0940 0.1010 0.1055 0.1120 0.1162 0.1225

0.1328 0.1426 0.1527 0.1624 0.1722
(222.9) h 687.9 700.2 717.8 729.1 746.1 757.1 773.4
800.4 827.0 853.7 880.5 907.5
s 1.5325 1.5556 1.5874 1.6071 1.6345 1.6518 1.6767
1.7152 1.7509 1.7844 1.8160 1.8462

30.0 v 0.0123 0.0768 0.0829 0.0868 0.0924 0.0960 0.1013

0.1101 1.1185 0.1269 0.1350 0.1432
(232.8) h 682.1 695.5 714.2 726.1 743.5 754.8 771.4
798.7 825.7 852.6 879.6 906.7
s 1 .5038 1.5289 1.5624 1.5827 1.6112 1.6290 1.6542
1.6934 1.7295 1.7632 1.7950 1.8254

40.0 v 0.0510 0.0550 0.0602 0.0634 0.0678 0.0707 0.0749

0.0816 0.0882 0.0946 0.1008 0.1071
(249.2) h 669.7 685.7 706.6 719.6 737.9 749.7 767.2
795.4 823.0 850.4 877.7 905.1
s 1.4530 1.4825 1.5201 1.5423 1.5729 1.5914 1.6177
1.6583 1.6953 1.7296 1.7617 1.7924

50.0 v 0.0416 0.0465 0.0493 0.0531 0.0555 0.0590

0.0646 0.0700 0.0752 0.0803 0.0853
(262.7) h 674.2 698.4 712.5 732.2 744.7 762.9
792.0 820.3 848.2 875.8 903.4
s 1.4410 1.4842 1.5087 1.5412 1.5609 1.5885
1.6302 1.6681 1.7029 1.7356 1.7666

------------------------------------------------------------------------------------------------
---------------
ata 300 320 350 370 400 420 450 470 500
550 600 650 700 750
t,
------------------------------------------------------------------------------------------------
---------------

60.0 v 0.0371 0.0399 0.0432 0.0454 0.0485 0.0505 0.0533 0.0551 0.0579
0.0623 0.0666 0.0708 0.0749 0.0791
(27403) h 689.0 705.1 726.4 739.7 758.7 770.9 788.5 800.1 817.5
845.8 873.8 901.7 929.9 958.3
s 1.4512 1.4788 1.5140 1.5349 1.5635 1.5813 1.6065 1.6225 1.6453
1.6809 1.7138 1.7451 1.7750 1.8035

80.0 v 0.0250 0.0276 0.0308 0.0326 0.0351 0.0367 0.0390 0.0405 0.0427
0.0461 0.0494 0.0527 0.0559 0.0590
(293.6) h 667.0 688.0 713.9 428.8 749.5 762.6 781.5 793.8 811.8
841.1 869.8 898.4 927.1 956.0
 - 129 -

s 1.3875 1.4239 1.4665 1.4902 1.5217 1.5408 1.5676 1.5844 1.6082

1.6449 1.6788 1.7107 1.7411 1.7700

100.0 v 0.0199 0.0231 0.0248 0.0271 0.0285 0.0305 0.0317 0.0335

0.0364 0.0392 0.0418 0.0444 0.0470
(309.5) h 666.0 669.0 716.5 739.8 754.4 774.4 787.3 806.1
836.3 865.8 895.0 925.3 953.5
s 1.3688 1.4231 1.4508 1.4858 1.5065 1.5353 1.5532 1.5781
1.6161 1.6509 1.6835 1.7142 1.7434

120.0 v 0.0178 0.0195 0.0217 0.0229 0.0247 0.0258 0.0274

0.0299 0.0323 0.0346 0.0368 0.0289
(309.5) h 681.5 703.0 729.5 745.5 766.9 780.4 800.1
831.5 861.8 891.7 921.5 951.1
s 1.3798 1.4137 1.4537 1.4765 1.5074 1.5261 1.5522
1.5916 1.6273 1.6606 1.6917 1.7211

150.0 v 0.0120 0.0140 0.0161 0.0173 0.0189 0.199 0.0213

0.0234 0.0254 0.0273 0.0291 0.0309
(340.6) h 6 47.6 678.0 712.2 731.2 754.8 769.7 791.0
824.1 855.6 886.6 917.0 947.4
s 1.3083 1.3567 1.4083 1.4364 1.4698 1.4905 1.5188
1.5604 1.5976 1.6319 1.6639 1.6941

200.0 v 0.0746 0.0103 0.0116 0.0131 0.0139 0.0151

0.169 0.0185 0.0201 0.0215 0.0229
(364.1) h 610.5 676.0 702.2 732.7 750.6 775.0
811.4 845.3 878.2 910.1 941.3
s 1.2320 1.3327 1.3710 1.4140 1.4385 1.4709
1.5168 1.5567 1.5930 1.6265 1.6578