Technical Diary: STAGE-I (2 X 500 MW)

STAGE-I (2 X 500 MW)
TECHNICAL DIARY
MOUDA SUPER THERMAL POWER PROJECT

N T P C LT D
MOUDA, DIST.NAGPUR
MAHARASTRA, PIN-441 104
Preface
Technical Diary for the equipments of 2X500MW Units Mouda STPP
has been prepared by the team P.Suresh Babu(E4), Md. Mohiuddin
Amer(E3), K.Balaji(E2A) and Ankit Shrimankar(E2A). They have gone
through the technical diaries of NTPC Sipat, Simhadri, Ramagundam. Data for
MSTPP dairy has been collected from BHEL O&M manuals, Equipment data
from T&S site, Contract agreement between BHEL/NTPC for MSTPP,
Manufacturer’s specification plates on equipments , manufacturer’s
manuals for some offsite equipments.
The diary contains the important technical data and specification

details of Boiler, Turbine, Generator and offsite equipments with their
associated auxiliaries. More than 200 equipments/ systems have been
covered in this volume. For the remaining equipments mainly in offsite area
data is not available or is not complete. They will be added to the diary after
completion.
Earnest effort has been made by the team to incorporate correct data.
However suggestions are welcome from users for improvements/
corrections if any. Data may be tallied with name plate data on equipments if
required.
The team is grateful to GM (Mouda), AGM (O&M) for their guidance

and support.
Thank you
DGM (O)
4.7.12
S.No Description Page No.
1 BOILER
1.1 General Specification 1
1.2 Furnace Specification 1
1.3 Water walls 1
1.4 Drum 2
1.5 Super heaters 3
1.6 Re-heaters 3
1.7 Super heater & Re-heater Temperature Control 4
1.8 Economizer 4
1.9 Safety Valves 5
1.10 Predicted Performance 5
1.11 Mill & Burner performance 8
1.12 O2, CO2, (Dry Vol.) & Excess Air 8
1.13 Heat Balance 9
1.14 Fuel Characteristics 9
2 BOILER AUXILIARIES
2.1 Boiler Water Circulating Pumps 10
2.2 Mill System 11
2.3 Coal Piping & Burners 13
2.4 Igniters & Scanners 13
2.5 Seal Air Fan 14

2.6 Mill Reject System 15
2.7 I.D. Fan 15
2.8 F.D. Fan 19
2.9 P.A. Fan 21
2.10 Scanner Air Fan 23
2.11 Air Heater (Primary & Secondary) 24
2.12 Steam Coil Air Preheater 27
2.13 Electrostatic Precipitator 27
2.14 Soot Blower 30
2.15 Blow Down Vessels 31
2.16 Bottom Ash System 32
2.17 Fly Ash System 34
3 TURBINE
3.1 Specification of Main Turbine 37
3.2 Limiting Values 38
3.3 Material of Construction 41
3.4 Lube Oil System 42
3.5 Control Fluid System 45
3.6 Condenser 49
3.7 Condenser Extraction Pump 49

3.8 Drain Cooler 50
3.9 LP Heaters 51
3.10 Deaerator & FST 52
3.11 Boiler Feed Pump & Auxiliaries 53
3.12 HP Heaters 60
3.13 Vacuum Raising System 61
3.14 Central Oil Purification Unit 62
3.15 HP Bypass System 62
3.16 LP Bypass System 63
3.17 LP Dosing System 65
3.18 Equipment cooling water system 66
4 GENERATOR
4.1 General information 68
4.2 Rated data 68
4.3 Excitation
a) Main exciter 68
b) Rectifier wheel 68
c) Pilot exciter 69
4.4 Torque and Critical speeds 69
4.5 Generator volume & filling quantities 69

4.6 Voltage Regulating Station 70
4.7 Generator Protection Relays 70
4.8 Seal Oil System 72
4.9 Primary Water System 74
4.10 Gas System 76
5 TRANSFORMERS
5.1 Generator Transformer(GT) 78
5.2 Station Transformer(ST) 78
5.3 Unit Transformer( UT) 78
5.4 Unit Auxiliary Transformer(UAT) 79
5.5 Unit Service Transformer(UST) 79
5.6 Station Service Transformer(SST) 80
5.7 Offsite transformers 80
5.8 Inter Connecting Transformer(ICT) 82
6 MAIN PLANT DG SET
6.1 Main plant DG set 83
7 SWITCH YARD OVERVIEW
7.1 Bus bar 83

7.2 Feeders 84
7.3 400KV Circuit Breaker, Isolator 84
7.4 400KV CT,CVT, Surge Arrestor 85
7.5 220V Battery, Battery Charger 87
7.6 48V PLCC Battery 87
8 HT and LT Switchgear
8.1 11KV Circuit Breaker 87
8.2 3.3KV Circuit Breaker 88
8.3 220V DC Battery, Battery Charger 88
9 Circulation Water System 89
10 Water Treatment Plant
10.1 Pre-Treatment Plant 91
10.2 DM Plant 94
10.3 Chlorination Plant 100
11 Ash Handling System
11.1 Ash Water Pump House 102

11.2 Ash Slurry Pump House 104
11.3 Dry Ash System 107
12 Compressed Air System 111
13 Fire Fighting System
13.1 Fire Hydrant System 112
13.2 Inert Gas System 115
13.3 Foam System 116
13.4 Fire Detector 117
14 Cooling Tower 119
15 Make up water pump house 120
16 Station Auxiliary cooling water(SACW) 121
17 Submersible Sludge Pump 123

1.1 BOILER GENERAL SPECIFICATION
Manufacturer M/s. BHEL (C.E.Design.)
Controlled Circulation With Rifled Tubing, Dry-
Bottom, Radiant Reheat, Single Drum, Top
Type Supported, Balanced Draft Furnace.
Type of Firing Tilting Tangential.

Minimum Load At Which Steam Generator Can Be
Operated Continuously With Complete Flame Stability 30% to 40% BMCR with adjacent coal elevations
Without Oil Support (%BMCR) when firing coal alone in service & 50% min mill loading
Designation 19177 301-51 CC +

16115 235-51
1.2 FURNACE SPECIFICATION

Type Balanced draft furnace with fusion welded
water walls, Single Radiant, Dry Bottom,
Controlled Circulation.
Wall Water steam cooled
Tube arrangement Membrane
Explosion/implosion with stand capacity at 67% +/- 660 wc
yield point
Residence time for fuel particles in the furnace 1.78 Secs.
Effective volume used to calculate the residence 5598 M3
time
Height from furnace bottom ring header to furnace 65.576 m
roof
Depth 16115 mm
Width 19177 mm
Furnace Volume 17599 M3
Drum elevation 76.552 M
Fuel Heat input 1234.2 X 106 KCal/hr @ BMCR DC
Furnace bottom opening 1.151 m
Total water wall area 4099 m2
Total water wall tube 1072
1.3 WATER WALLS
A) FRONT WALLS
OD 51.0 mm
No. of Tubes 291
Pitch 63.5 mm
MWT (Actual Thickness) 5.6 mm
Material SA 210 Grc
Method of joining long tube Butt Welded
Total Wt. of Walls 185320 kg.
Design Pr. of tubes 214.7 kg/cm2
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Max. pressure of tubes 201.2 ksc
Design temp. 397 oC
B) SIDE WALLS, REAR WALLS

Side Walls Rear Walls Extended SW, Corner
Arch, Screen And Hanger
No. of Tubes 490 291

OD 51 mm 51 and 63.5 mm
Pitch 63.5 mm 63.5 and 76.2 mm
Minimum Wall thickness (MWT) 5.6 mm 5.6/7.1 mm
Method of joining long tubes Butt weld Butt Weld

Design Pressure of tubes 214.7 kg/cm2 (g) 214.7 kg/cm2 (g)
Design temp. 397oC 397oC

Material SA210 Grc SA 210 Grc
C) WATER WALL HEADERS

Lower drum WW Outlet Headers
Number 1 5
Outside dia 914.4 mm 273.0 mm
Thickness 92 mm 40.0 mm
Total Wt. of headers(In+out) 185 T
Design Pressure of headers 214.7 kg/cm2(g) 209.5 kg/cm2(g)
Max working pr of headers 201.2 ksc 195.5 ksc
Material specification SA-299 SA-106Gr.C
Design temperature 370oC 370oC
1.4 DRUM
Material Specification SA-299
Design Pressure 210 kg/cm2(g)
Design metal temp. 368 oC
Operating Pressure 196 kg/cm2 (g)
Actual thickness for straight portion 185/155 mm.
Overall length of drum (with dish ends) 22078 mm
Internal dia 1778 mm
Corrosion allowance 0.75 mm
No. of distribution headers 6 nos.
No. of Cyclone Separators 92
No. of secondary driers 92
No. of antivortex spiders 6
Shroud material Carbon Steel
Max. permissible temp. difference between any two 50 deg c
parts of the drum
Water capacity at MCR conditions (in sec) between 10
normal & lowest water level permitted
2|Page
Boiler Drum Wt. (without internal) 221000 (Kg)
Boiler Drum Wt. (with internals) 231000 (Kg)
1.5 SUPERHEATERS
LTSH Divisional Panel (Stage # Platen
(Stage # I) II) (Stage # III)
Material SA 213 T11 SA 213 T11,T22,T91 SA 213 T22,T91,TP347H
Type Convective Radiant Radiant
Drainable / Non- Drainable Non-drainable Non-drainable
drainable
Effective Heating Surface 8650 M2 1700 M2 1733 M2
area
Gas flow path area (m2) 183.5 Radiation section 327.4
Max steam gas side 450 deg c 525 deg c 600 deg c
metal temp
Max gas side metal temp 460 540 620
(0C)
Type of flow Counter Parallel Parallel
OD 47.63 mm 44.5 mm 51.0 mm
Gross length (/one tube) 84 42.4 42.4
(m)
Tube pitch
a) Parallel to gas flow 101 mm 54 60.3
b) Across gas flow 152.4 3048 762
mm
Total no. of assembly 124 6 25
Total no. of tubes 744 432 400
Temperature 0C 493 513 592
1.6 REHEATERS:
Reheater-1 Reheater-2
Type Radiant front platen Convective rear pendant
Total heating surface area 4390 m2 4680 m2
Design pressure (abs) 53.4 ksc -
Max operating pressure 46.5 ksc -
Max steam side metal temp 534 deg c 587 deg c
Max gas side metal temp 575 deg c 628 deg c
No. of assembly 74 74
No of element 1036 888
Tube OD 54 mm 63.5 mm
Gross length (per one tube) 36.1 34
A) HEADERS
Superheater Reheater
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Location Outside Outside
Max. operating pr(abs) 179 SHO (ksc) 43.8 RHO (ksc)
Length (m) 20 20
Total weight (kg) 167,000 95,000
1.7 SUPER HEATER AND RE HEATER TEMP. CONTROL

Manufacturer: BHEL, Trichy
A) SUPER HEATER ATTEMPERATOR
Type Spray type pressure atomised.

Stage One
Position in steam circuit Between LTSH and Divisional Panel S/H
Specification of material SA 335P12
Control temperature 540+/-5oC
Control Range 910 – 1675 T/Hrr.
Maximum Water Flow 45 Tons/hr. at 165oC, Max spray flow 8% of
BMCR flow
B) RE HEATER EMERGENCY TEMP. CONTROL ATTEMPERATOR
Type Spray type pressure atomised.

Manufacturer BHEL, Trichy
Position in steam circuit CRH Line
Material SA106 GrC
Control temp. Range 568+/-5oC
Control Range 827 – 1393 T/Hr.
R/H Normal temp. control Burner tilting and Excess air.
1.8 ECONOMIZER
Type Plain Tube Non-steaming,Drainable,Inline tube
arrangement(Horizontal)
Effective Heating Surface Area 19000 M2(gas side),12800 m2 (water side)
Design Pr. of tubes 216 kg/cm2(g)
OD of tubes 38.1 mm
Minimum thickness tubes 6.2 mm
Length of tubes 158700 M (approx) vol3 pg 205
Pitch 76.2 mm (SL)
103 mm (ST)
No. of blocks 3 Nos.
Assembly 184
Element 552
Max. metal temp 336oC (steam side), 342 deg c (gas side)
Min temp of feed water that economizer can handle 172 deg c
safely
ASME Specification SA210 Gr A1
Gas flow Path area 168 M2 (free gas area)
4|Page
HEADERS INLET OUTLET
Length 18.6 m 19.8 m
Design pr (abs,ksc) 215 210.8
Max working pr (abs,ksc) 201.7 197.8
1.9 SAFETY VALVES

Location Type of Make No. Valve Set Pr. Kg/cm2 (g) Size in/out (mm)
Safety Valve
BOILER 1750 WB BHEL 4 209.0, 76.2/152.4
DRUM 211.1,
213.2, 213.2
1740 WB BHEL 2 215.3, 215.3 76.2/152.4
SUPER 1740 WD BHEL 2 188.5, 188.5 76.2/152.4
HEATER (SV)
OUTLET 1538 VX- BHEL 5 185.5, 185.5, 63.5/101.6
10W 186.6, 186.6, 186.6
(ERV)
COLD 1786 WB BHEL 4 52.4, 52.4, 152.4/254
REHEAT 54.0, 54.0
LINE
HOT 1786 WE BHEL 4 48.4, 48.4, 152.4/203.2
REHEAT 49.9, 49.9
LINE 1525 VX BHEL 4 47.4, 47.4, 152.4/203.2
47.9, 47.9
1.10 PREDICTED PERFORMANCE DATA (DESIGN COAL-Constant Pressure)
A) FLOW
DESCRIPTION Unit HP HEATERS IN SERVICE HP

BMCR 500 400 300 250 HEATERS
MW MW MW MW OUT
Steam
SH Outlet T/Hr 1590.0 1457.9 1167.3 887.6 755.4 1385.5
Reheater Outlet T/Hr 1358.0 1302.1 1052.2 808.3 656.8 1379.0
Water
Feed Water T/Hr 1590.0 1432.9 1087.3 796.6 678.4 1297.5
SH Spray T/Hr 0 25 80 91 77 88
RH Spray T/Hr 2 0 0 0 0 13
Air
PAH Outlet T/Hr 652 582 460 363 357 626
Tempering Air T/Hr 15 4 26 23 10 41
SAH Outlet T/Hr 1155 1067 841 610 464 1157
Total Combustion T/Hr 2024 1855 1529 1198 1033 2026
Air
Fuel
Coal (HHV=3300 T/Hr 374 347 285 224 193 376
kcal/kg)
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Gas
Flue Gas at RAPH T/Hr 2245 2057 1695 1329 1145 2247
Inlet (Pri & Sec)
Flue Gas at RAPH T/Hr 2444 2253 1882 1508 1318 2443
Outlet (Pri & Sec)
Inlet PAH T/Hr 820 737 614 506 501 800
Inlet SAH T/Hr 1425 1320 1081 823 644 1447
Outlet PAH T/Hr 930 847 722 611 603 909
Outlet SAH T/Hr 1514 1406 1160 897 715 1534
B) TEMPERATURE
HP HEATERS IN HP HEATERS
DESCRIPTION Unit BMCR 500 400 MW 300 250 OUT
MW MW MW
Steam
Sat. Temp. in Drum o
C o
C 362 361 358 355 354 360
LTSH Inlet o
C 365 364 363 362 362 365
LTSH Outlet o
C 397 395 399 398 400 406
SH Panel Inlet o
C 397 389 378 367 365 383
SH Panel Outlet o
C 467 464 455 444 439 456
SH Platen Inlet o
C 467 464 455 444 439 456
SH Platen Outlet o
C 540 540 540 540 540 540
RH Stage-1 Inlet o
C 338 337 329 322 311 351
RH Stage-1 Outlet o
C 487 492 494 499 502 502
RH Stage-2 inlet o
C 487 492 494 499 502 502
RH Stage-2 outlet 568 568 568 568 568 568
Water
Economiser Inlet o
C 255 253 243 230 219 169
Economiser Outlet o
C 318 315 309 305 297 286
Air
Ambient o
C 27 27 27 27 27 27
PAH Outlet o
C 313 309 294 275 262 269
SAH Outlet o
C 311 305 294 275 262 266
Gas
SH Panel Inlet o
C 1378 1377 1383 1400 1392 1379
SH Platen Inlet o
C 1128 1115 1091 1067 1043 1125
RH Front Inlet o
C 1029 1013 981 944 914 1027
RH Rear Inlet o
C 852 836 799 756 726 855
LTSH Inlet o
C 673 658 626 590 567 678
Economiser Inlet o
C 549 537 513 486 470 554
Air-Heater Inlet o
C 339 332 314 293 279 289
Air-Heater Outlet o
C 126 125 120 117 114 110
6|Page
C) PRESSURE (STEAM & WATER)
HP HEATERS INSERVICE HP
DESCRIPTION Unit BMCR 500 400 300 250 HEATERS
MW MW MW MW OUT
Pressure
SH Outlet kg/cm2(g) 178 176.6 174 171.9 171.1 175.9
LTSH Outlet kg/cm2(g) 190 186.9 180.9 176.1 174.3 185.3
Drum kg/cm2(g) 195 191.2 183.9 177.9 175.6 189.3
Eco Inlet kg/cm2(g) 200.7 196.4 188.1 181.4 178.8 194.2
Reheater Stage-2 kg/cm2(g) 42.4 40.7 32.7 25.0 20.2 44.1
O/L
Reheater Stage-1 kg/cm2(g) 45 43.2 34.8 26.6 21.5 46.7
Inlet
Pressure Drop
SH system
RH system kg/cm2 17 14.6 9.9 6.0 4.5 13.4
Economiser kg/cm2 2.6 2.5 2.1 1.6 1.3 2.6
including static kg/cm2 5.7 5.2 4.2 3.5 3.2 4.9
head
D) PRESSURE & DRAFTS (AIR & GAS)
HP HEATERS IN HP HEATERS OUT

DESCRIPTION Unit BMCR 500 400 300 250
MW MW MW MW
Primary Air
PA Fan Inlet mmwc -11 -9 -6 -4 -4 -11
PA Fan O/L mmwc 871 885 856 830 783 853
Air heater I/L mmwc 858 875 848 825 778 840
Air heater o/l mmwc 807 832 816 801 754 793
Mill Inlet mmwc 686 712 700 687 644 672
Mill Outlet mmwc 306 323 312 302 277 292
Sec Air
FD Fan Inlet mmwc -14 -12 -8 -5 -3 -14
FD Fan O/L mmwc 177 164 131 105 91 177
Air-Heater I/L mmwc 160 149 121 99 87 160
AirHeater o/l mmwc 113 108 94 83 78 115
Wind Box Pr mmwc 70 70 70 70 70 70
GAS
Furnace mmwc -5 -5 -5 -5 -5 -5
SH Platen Inlet mmwc -5 -5 -5 -5 -5 -5
Reheater Inlet mmwc -6 -6 -6 -6 -6 -6
LTSH Inlet mmwc -15 -13 -11 -9 -8 -15
Economiser Inlet mmwc -31 -29 -24 -19 -16 -30
Economiser o/l mmwc -58 -54 -44 -34 -28 -56
Air-Heater Inlet mmwc -74 -68 -56 -44 -37 -71
Air heater outlet mmwc -166 -149 -115 -90 -82 -154
E.S.P. Inlet mmwc -181 -163 -128 -101 -93 -169
I.D. Fan Inlet mmwc -236 -213 -165 -128 -115 -222
I.D. Fan Outlet mmwc +31 +28 +23 +19 +17 +30
7|Page
1.11 MILL & BURNER PERFORMANCE
(Design Coal-Constant Pressure)
HP HEATERS IN HP Heaters
DESCRIPTION Unit BMCR 500 400 300 250 out
MW MW MW MW
MILL
No. of Mills Top 7 Top 6 Top5 Top4 Top 4 Top 7
in operation (D-K) (E-K) (F-K) (G-K) (G-K) (D-K)
Mill loading % 82.2 89.0 87.7 86.2 74.2 82.6
Air flow/Mill T/Hr 95.3 97.7 97.2 96.5 91.7 95.3
Air Temp. at o
C 307 307 280 261 256 254
Mill Inlet
66
Mill Outlet o
C to
Temperature 100
Fineness % %
(Thro’200 70
mesh)
-30
Burner Tilt Deg to
+30
1.12 O2, CO2 (DRY VOL.) AND EXCESS AIR
(Design Coal- Constant Pressure)

HP HEATERS IN HP HEATERS OUT
DESCRIPTION Unit BMCR 500 400 300 250
MW MW MW MW
Oxygen in
Gas at Eco % 3.58 3.58 3.58 3.58 3.58 3.58
O/L
Carbon-Di-
oxide in Gas % 15 15 15 15 15 15
at Eco O/L
Excess air in
Gas at Eco % 20 20 20 20 20 20
O/L
8|Page
1.13 HEAT BALANCE
(Design Coal – Constant Pressure)

HP HEATERS IN HP HEATERS
DESCRIPTION Uni BMCR 500 400 300 250 OUT
t MW MW MW MW
LOSSES
Dry Gas % 4.238 4.21 4.507 4.287 4.479 3.533
H2O on fuel, % 1.752 1.751 1.749 1.738 1.732 1.732
surf and
inherent
H2O from % 4.698 4.694 4.689 4.66 4.644 4.644
comb. of H2
H2O in Air % 0.104 0.103 0.111 0.106 0.110 0.087
Radiation % 0.221 0.239 0.288 0.369 0.427 0.224
Un burnt % 1.500 1.500 1.500 1.500 1.500 1.500
Carbon
Unaccounted % 0.639 0.642 0.654 0.663 0.674 0.617
Manufacture’s % 0.150 0.150 0.150 0.150 0.150 0.150
Margin
Total Losses 13.302 13.289 13.64 13.473 13.716 12.487
8
EFFICIENCY % 86.7 86.71 86.35 86.53 86.28 87.51
1.14 FUEL
Proximate Analysis
Fixed Carbon % 24
Volatile matter % 21
Moisture % 14
Ash % 41
Grind ability Index HGI 55
Higher Heating value kcal/kg 3300
Size of Coal to Mill mm 50 (approx.)
Ultimate Analysis
Carbon % 31.70
Hydrogen % 3.30
Sulphur % 0.28
Nitrogen % 0.83
Oxygen % 8.54
Carbonates % 0.30
phosphorous % 0.05
Moisture % 14
Ash % 41.0
9|Page
2.1 BOILER WATER CIRCULATING PUMP
Number 3 (2W + 1S )
A) CHARACTERISTICS
Make Torishima Pump, Japan

Type & Size Single Suction double discharge , H1AV2X300-460/1C
Total head 31.26 m
Design Pressure 214 kg/cm2
Test pressure 321 kg/cm2
Design Temperature 370oC
B) NORMAL OPERATING DUTY (BMCR)
No. of pumps operating 2

Suction Pressure 197.43 kg/cm2
Saturation temp. at suction pressure 363.4oC
Flow per pump 2987 m³/hr
Minimum NPSH required
1) Cold 16 m
2) Hot 13 m
Pump efficiency 81%
Power absorbed by pump-mechanical 176.7 KW
C) Motor characteristics
Type Wet Stator squirrel Cage induction

motor.
Motor rating 350 KW. 3300 V. 3 Phase. 50 Hz
Service Factor 1.0
Winding Insulation XLPE extruded insulation
Motor Case design. Temperature 370oC
Hot duty Cold duty
Motor efficiency 89.1 % 92 %
Motor Power Input 198.3 KW 341.3 KW
Power factor 56.3 % 71.2 %
Pump efficiency 81 % 81 %
Rated Full load speed 1470 RPM
Rated Full load current 88.7 Amps.
Rated full load power factor 75%
Starting current 532 A
Insulation class Y
Method of cooling IC8W1W7
Motor cavity fluid to cooler 63 deg c
a) Max recommended operating temp
(alarm)
b) Max allowable operating temp (trip) 66 deg c
Minimum Time interval between starts 1200 sec
No Load current Approx 35 amp
DOR CW from Motor NDE (Bottom)
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D) COOLER
Make BHEL Tiruchirapalli

Type Straight Tube
No. of coolers One/Motor
Water pressure drop through cooler 0.5 bar
Max permissible pressure at water outlet 28 Kg/cm2
Water requirement per cooler 150 l/min
Max. Permissible temp of cooling water at inlet 39 deg c
Max. Permissible temp of cooling water at outlet 42.1 deg c
LP Cooling water flow to Heat barrier 30 l/min
F) BEARING
1) Number 1) 2
2) Type 2) Tilting pad
3) Lubrication system 3) Self (boiler water)
4) Max. permissible temp of bearing 4) 90 deg c
2.2 MILL SYSTEM

A) Mill/Pulveriser (BHEL Hyderabad)
Type of Mill Vertical spindle type XRP1003 size bowl mill
No. of Mills / Unit 10
Max. input coal size 50mm
Coal fineness through 200mesh 70%
Type of Drive Transmission Planetary Gear Box
Type of coupling Flexible gear coupling
For Design coal--
1) Design capacity of mill 65 Tons/hr max capacity for Pulverised fuel with a
Raw coal of Grindability Index=55 HGI and Total
moisture of 14%.
2) No. of mills working at
100% BMCR 7
3) Qty of coal/boiler at
100% BMCR T/hr 374
4) % of mill loading at 100%
BMCR 82.2
Speed of Pulveriser 42 rpm
Motor rating 525 KW, 984 rpm
Mill reject rate
Avg 0.5% of max. coal i/p qty to mill
Max 1.0% of max. coal i/p qty to mill
Estimated life of grinding elements (Sintered carbide 7300 HRS
insert type) :
B) Mill Motor
Manufacturer BHEL, BHOPAL
Type SCIM
Direction of rotation as viewed from Motor NDE CW

Type of mounting Horizontal (B3)
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Standard continuous rating at 40oC ambient temp 561 KW
Derated rating for specified normal condition i.e at 525 KW

50oC ambient temp
Rated Voltage/freq 3300 V/50 Hz
Permissible variation of
Voltage (%) +/- 6.0
Frequency (%) +3 -5
Combined Voltage & Frequency 10% (Abs)
Minimum permissible starting Voltage 85%
Rated speed at rated voltage and frequency 984 rpm
At Rated Voltage and Frequency
Full load current 129 Amp
No load current(A) 55 Amp
Starting current at 100% voltage 600
No. of permissible starts from HOT condition 2
C) Construction Features
1) Stator winding insulation
a) Class & type F/Epoxy Mica resin poor
b) Temp rise over specified 70
ambient
of 50 deg c.
c) Stator winding Star
connection
d) No. of terminals brought 6
out
2) For bearing
a) Type Antifriction
b) Lubricant IOC SERVOGEM-3/EQV.GREASE
c) Lub. Type Self

3) Total weight (Stator+Rotor) 5750 kg
4) Speed switch Yes (240V,1 phase,50Hz)
D) Mill External Lubrication System

Pumps
Qty 2X 100%
Make Tushaco
Type Screw
Capacity 150 LPM
Speed 1450 RPM
Pressure 6 ksc
Motor
Manufacturer CGL
Rating 3 ph induction, 415 V, 50 Hz,
5.5Kw
Speed 1450 rpm
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Efficiency 86 %
Full load current 10.35 A
DOR CW from Motor NDE
Tank Capacity 750 L
Liquid ISO VG-320
Cooler Twin oil cooler, Shell & Tube type
Design pr 15 ksc(shell), 7.5 ksc(tube)
Design temp 80 (both shell & tube)
Surface area 19.24 m2
2.3 COAL PIPING & BURNERS

A) COAL PIPING
Material of Straight pipe Carbon Steel
Internal diameter of straight portion 632 mm
Thickness of straight portion 14.2 mm
Material of bends & liners Ceramic liners
Inside dia of bends 614 mm
Thickness of bends & liners base 8mm, liner 15mm
Provision made for equalizing the Orifice
Coal+air mixture flow in the pulverized
Coal piping
B) COAL BURNERS
Type Tilting tangential
Make BHEL
No. of coal burners 4 Nos per elevation
(Total = 4x10=40)
Temp. of coal Air mixture in PF Pipes 66 to 100 oC
Max allowable temp of burners (deg c) 850
Turn down ratio 1:2
Capacity of each burner at MCR Limited to 55 MKcal/h heat
input
2.4 IGNITERS
Make Unison Industries / USA
Service To light off oil burner
Type High Energy Arc Igniter, Retractable
Location At same elevation of oil burner,one per

Number burner
20 (5 per corner)
Stored energy 12 Joules/Spark nominal
Spark rate 5 sparks/sec nominal
Duty Intermittent 15 min on with 30 min off
Input 3 Amps@220 V AC, 50 Hz.
Scanners
13 | P a g e
Type Visible light, safe flame type
1) Safe flame-1 24 (6 per corner), At aux air/end air compartment
(Fire ball)
2) Safe flame-2 20 (5 per corner), At the same elevations of oil burner
(Discriminating
+ Fire ball)
2.5 SEAL AIR FAN
Manufacturer BHEL
Type NDFV 12.5 H (radial single suction overhung)
No. of fans per boiler 2
Medium handled Air from PA Cold Header
Location Outdoor
Orientation Right Horizontal suction, Top left vertical delivery.
A) Fan
Capacity 8.4 m3/sec.
Total head developed 508 mmWC

Temp. of medium 50oC
Density 1.022 kg/m3
B) Drive Coupling
Type: Pin type Flexible
C) Fan Drive Motor
Make CGL
Rating 75kw, 3 phase, 415 V, 50Hz
Speed 1480 RPM
Current 123 A
D) Lubrication
Fan Oil-ISO VG 68 SUMPOIL

Motor Grease
2.6 MILL REJECT SYSTEM

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A) Compressor
Make Ingersoll Rand (India)

Ltd
Quantity 1w+1s
Type Reciprocating,Horizontal,Two stage,Double
Acting,Water cooled & non lubricating
Capacity 1620 m3/hr at 4.5 ksc

Motor rating 160 Kw, 1500 rpm
Compressor speed 725 rpm
Type of drive V-belt
Oil pump type & no 1 no. pump driven by
compressor shaft
Sump capacity 26 ltr
Lubricant type Ingersoll Rand Recip
Prime
B) Coolers
Inter Cooler After Cooler
Shell Tube Shell Tube
Pressure (Kg/Cm2) 9.75 3.87 9.75 5.97
Temperature (0C) 54.45 148.9 54.5 154.45
Medium Water Air Water Air
MOC SA106Gr.B Copper SA106Gr.B Copper
Water inlet/outlet (0C) 38/42.5 38/42.3
Water inlet /outlet (ksc) 7.5/5.5 7.5/5.5
Air inlet pr 1.45 4.5
Water flow lpm 185 250
No. of tubes 190 186
2.7 INDUCED DRAFT FAN (ID FAN)

A) FAN
Type NDZV 47 SIDOR (Radial double suction simply supported
bearing)
Make BHEL
Orientation Inclined (60 deg top left) Suction, Bottom Horizontal

Delivery (right)
Medium Handled Flue gas
No. per Boiler 2
Location Out door
B) FAN DESIGN RATING
Capacity (design) 609 m3/sec.
Total head developed (design) 490 mm WCl
Temp. of Medium 150oC
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Specific Wt. of Medium 0.764 kg/m3
Speed Variable RPM, 560 max
C) FAN RESERVE
Flow 49.4 %
Pressure 82.1 %
D) COUPLING
Type SOFT
Type of Fan Regulation Inlet damper and variable Frequency Drive.
E) FAN BEARINGS
Fan fixed bearing 10 RTL(Water cooled)
Fan free bearing 10 RTL(Water cooled)
F) VARIABLE FREQUENCY DRIVE (VFD)
(F1)MOTOR
Manufacturer BHEL, BHOPAL

Frame size 1DQ 4344
Type of motor Brushless Synchronous CACW cooled designed to
operate with power fed from Load commutated
Invertor
Rated voltage per channel 2300 V (L-L) RMS
Max continuous demand of ID fan 3701KW (both channels together)
Speed variation 20% to 100% of Dual channel range
PF 0.85 Lead
Insulation Class F
Connection Double star (300 electrically displaced)
Winding Temp Rise 80 deg c over inlet water temp of 390 c by wdg
resistance. 900 c over inlet water temp of 390 c by
wdg RTD.
Type of construction Horizontal,Unidirectional
Cooling Top mounted CACW heat exchanger(2 Ns)
RTS’s settings 1) Alarm=125, Trip= 130
1) Motor stator windings 2) Alarm=85, Trip=90
2) Motor bearings
Rating(KW) Speed(RPM) Freq (Hz) Poles PF (lead) Volts (L-L)

KV
12 Pulse 4075 560 46.6 10 0.85 2.3
6 Pulse 1510 390 31.67 10 0.9 1.593
(F2)VFD Motor Exciter
Make BHEL
Type Brushless
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Stator/Rotor turns ratio 6.01
Exciter stator rated voltage, Frequency, current & 316V, 96.7 Hz, 59A, 3 phase, Star Connection
phase
Exciter rotor
1) Poles 8
2) RPM 660
3) KW 30
4) Volts 98 V DC
5) Amps 334 A DC
Exciter Data at Rotor(V,I,P) Stator(V,I,P)
Motor stand still 70 V 245 A(DC) 17.15 KW 390 V RMS 56.5 A 38.17KVA
condition (DC) (L-L) (RMS-LINE)
12 Pulse(560 92.4 311 28.75 316 59 32.11

rpm,2300 V,4075
KW)
6 Pulse (380 64.7 218 14.09 256 41 18.24

rpm,1511 V,
1431 KW)
(F3) Motor Rating Data (Name plate)
6 Pulse 12 Pulse
Speed (RPM) 380 560
Current (Amp,Line) 629 A 629 A
Voltage (V,L-L) 1511 2300 V
Power (KW) 1431 KW 4075 KW
Power Factor (Ratio) -0.9 -0.9
Exciter voltage (RMS) 256 V 316 V

(Stator 3 ph L-L)
Exciter stator line current RMS 41 A 59 A
(F4)VFD Transformers
Channel # 1 Channel # 2
Rating (KVA) 3250 3250
Voltage Transformation 11000 / 2300 V 11000 / 2300
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Vector Group Dyn1 Dd0
(F5) VFD Reactors (Both Channel 1 & 2)
Qty 8 Nos.
Name Air Core DC Reactor, DRY type, self cooled,
Smoothing type
Voltage rating 3600 V, DC
Rated Current 1000 Amp DC
Inductance 10 milli Henry+ 10%--0%
(F6) ID fan LUBE OIL SYSTEM
1) Pump
Oil tank capacity 600 liters

Pump type Screw Pump
No of pumps 2
Motor Rating 3 Phase, 415V,5 HP, 50 Hz.
Speed 2855 RPM
Amp 6.7
HP 5
Normal Design Pressure 5.0 kg/cm2
Flow rate 80 lpm
Lube Oil Quality ISO-VG-68
DOR CW From Motor NDE
2) Lube Oil Coolers
Qty 2 (1 Working + 1 Standby)

Type Shell & Tube type
Oil inlet/outlet temp 64/54 deg c
Water inlet/outlet temp 38/39.9 deg c
Water flow rate 165 lpm
Heat load 21600 kcal/hr
3) Oil filters
Type Basket type, duplex

Mesh material SS Rating 60 microns
Flow Capacity 160 lpm
4) ID LUBE OIL HEAT EXCHANGER
Shell Tube
Design Pr 14 8
Test Pr 24 12
Design Temp 100 °C 100 °C
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Capacity 80 LPM
Model T7.274.01
2.8 FORCED DRAFT FAN (FD FAN)

A) FD FAN MOTOR
Make BHEL Bhopal

Duty Continuous
Frame Size 1LA7802-6
Mounting Horizontal(B3)
Direction of rotation viewed from DE CW
Permissible variation of V, F, combined V & F +/- 10%, +3/-5 %, 10% (abs)
Minimum permissible starting voltage 85 %
Starting time with min permissible voltage
a) Without driven eqpt coupled 2 sec
b) With driven eqpt coupled 13 sec
KW 1425 (at 50 deg c), 1523 (at 40 deg )
Stator voltage 3300 V
Full load current 307 A
RPM 994
Phase 3
Hz 50
Insulation F
Amb. Temp. 50°C
Connection Star
Deg. Of protection IP 55
Rotor type Sq. Cage
DOR CCW from Motor NDE
B) Construction Features
Stator winding insulation
Class & type F/Epoxy Mica resin poor(VPI)
Temp rise over specified ambient Of 50 deg c. 70
Stator winding connection Star
No. of terminals brought out 6
For bearing
Type Antifriction
Lubricant IOC SERVOGEM-3/EQV.GREASE
Lub. Type Self
Type of cooler NA
Total weight (Stator+Rotor) 9500 kg
Max permissible Temp of rotor 350 deg c
C) FAN DATA
Type AP1 26/16 (Axial Profile-Stage 1)
No. per Boiler Two
Total head developed (design) 410 mmWC
Medium handled Atmospheric Air
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Location Out door
Orientation Vertical Suction Horizontal Delivery.
Specific wt. of medium (design) 1.021 kg/m3
Fan Speed 980 RPM
Fan Regulation Blade pitch control
D) FAN RESERVE
Flow 80.0%
Fan Pressure 212.4%
E) FAN DRIVE COUPLING

Type Spacer Type
F) FAN BEARINGS
Fan Fixed bearing Cylindrical Roller Brg 7248C3
Fan Free bearing Cylindrical Roller Brg NU248C3
G) LUBE OIL SYSTEM

G1) FD FAN LUBE OIL PUMP
Oil Tank capacity 900 Litters

Pump type Triple Screw Pump
Make Tushaco/Alekton
Capacity 175 lpm
Working pressure 12 ksc
Coupling Flexible (Lovejoy)
Fluid ISO VG 68
G2)FD FAN LUBE OIL MOTOR
Make ABB
Amb. Temp 50°C
Voltage 415±10 %
Hz 50±5%
Phase 3
RPM 2870
kW 9.3
Amp 16
G3) Lube Oil Filter
Type Duplex
Filtration 60 micron
Element type SS Mesh
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G4) Lube Oil Coolers
Qty 2
2.9 PRIMARY AIR FAN (PA FAN)

A) FAN
Type AP2 20/12 (Axial profile fan-2 stage)

No. per boiler 2
Orientation Vertical Suction Horizontal Delivery
Medium Handled Atmospheric Air
Location Out door
Type of Regulation Blade Pitch Control
B) FAN DESIGN RATING

Total head developed (design) 1195 mm WCl
Specific Wt. of Medium 1.021 kg/m3
Speed 1480 RPM
C) FAN RESERVE
Fan Flow 94.36 %

Fan Pressure 35.18%
D) FAN DRIVE COUPLING

Type of coupling Spacer type
E) FAN BEARINGS
Fan Fixed bearing 7040 C3

Fan Free bearing NU 236 C3
F) MOTOR
Make BHEL Bhopal

Motor type SCIM
Frame ILA7 905-4
Duty Continuous
kW 2950 (at 50 deg c)
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Stator Volts 11000
Stator Amp 180
RPM 1494
Ph 3
Hz 50
Insulation Class F
Connection Star (Stator) - (Rotor)
Starting time with min permissible voltage
a) Without driven equipment coupled 5.5 sec
b) With driven equipment coupled 10.5 sec
Power Factor 0.89 (100% load)
Efficiency 96.7 % (100% load)
Ambient Temp. 50° C
Temp Rise 70° C
Permissible variation of V, F, combined V & F +/- 6%, +3/-5 %, 10% (abs)
Minimum permissible starting voltage 80 %
Degree of Protection IP55
Total Weight 14500
Max permissible temp of rotor 400 deg c
G) Motor Bearing
DRIVE END NON-DRIVE END

Type Ball and Roller Roller
Recommended Lubricant Grease IOC Servogem – 3
H) PA LUB OIL SYSTEM
1) Pump
Oil tank capacity 400 liters
Pump Screw Pump
Design Pressure 12 kg/cm2
Lube Oil Quality ISO VG 68
Pump discharge 80 LPM
Motor Rating 3 Phase, 415V, 7.5 HP, 50 Hz,11 A
Speed 2870 RPM
2) Lube Oil Filter
Type Basket type, duplex

Mesh material SS Rating 60 microns
Capacity 160 lpm
3) Lube Oil Coolers
Qty 2 (1 Working + 1 standby)

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2.10 SCANNER AIR FAN

A) FAN
No. 2 (One is AC driven + One D.C. driven , 100% standby)

Type of Fan Radial Backward curved Blade Single Suction C.F
Manufacturer DOCTAIRE MAKE, SB 80 II M3
Static Pressure 200 mm H2O at Ɣ=1.09 ksc
Efficiency of the fan 79.5 %
Power absorbed 6.76 KW Ɣ=1.20 ksc
Fan Speed 1480 RPM
Capacity 8000 m3/hr
B) A.C. MOTOR
Make Kirloskar Electric Co. Ltd.

Type & Frame Size TEFC,Squirrel Cage Induction Motor
Rated o/p & rated speed 7.5 KW, 1440 RPM
Rated voltage, frequency & phase 415 V +/- 10%, 50 Hz +/- 5%, 10% absolute sum-3 phase
Full load current 14.3 A
Efficiency & power factor at 100% load 87%, 0.82
Duty cycle S1
Max permissible starting T 15 sec
Class of insulation F
Direction of rotation CW from Motor NDE
Stator winding connection Delta
C) D.C. MOTOR
Make M/s Crompton Greaves Ltd.

Type & Frame Size TEFC, SOLID YOKE, shunt, Frame: AFS 225M
Duty S1 (continuous)
Insulation F Class
Rated output & speed 7.5 KW, 1450 RPM
Armature rated voltage 220 V DC (+10% to -15%)
Full load armature current 40 A DC
Starting current in % of FLC 200 % FLC
Full load efficiency 84 %
No. of terminals brought out 4 (Armature=2, Field=2)
DOR
CW from Motor NDE
2.11 AIR HEATERS

A) PRIMARY AIR PREHEATER (PAPH)
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Make BHEL
Type Ljungstrom Bisector (Regenerative)
Air heater size 27.5 VIM 2000
No. of Air Pre-heater 2 per Boiler
Material specification,thickness:
Cold end elements 1.214 mm- NF6 profile
Intermediate elements 0.8 mm-DU profile
Hot end elements 0.8 mm-DU profile
A1)ELEMENTS
END HEIGHT OF MATERIAL DESCRIPTION OF No. of baskets Effective

ELEMENT ELEMENTS heating
area (m2)
HOT 850 mm Carbon Steel Double Corrugated 240 17525
INTER 850 mm Carbon Steel Double Corrugated 240 17525
COLD 300 mm Corten steel Notched Flat 288 5020
A2) MAIN DRIVE
Electric Motor Make-Kirloskar, Squirrel Cage, induction motor, 11KW, 415V,20 A, 3, 50Hz,
1440 RPM, Frame size 160-L, Insulation Class-F
Speed Reducer Ratio 110 : 1
Speed Reducer Type-1D,3 input ,down shaft
Couplings Fluid coupling for main drive & resilient coupling for aux drive
10 m3 capacity
Air receiver
A3) AUXILIARY DRIVE
Air Motor 5 KW, 540 RPM, with gear box , Air consumption 5.95 NM 3/min.
at 6.33 kg/cm2 from air receiver
A4) BEARINGS
1) Support Bearing (Cold end)
Type Spherical Roller thrust bearing, No.294/500E

Lubrication IOC SERVOCYL C- 680
Drive Motor Make- NGEF, 0.75KW, 415V, 3, 50Hz, 1.7 A. Speed 1400
RPM
Pump Screw Pump (15 liter/Min.)
Couplings Lovejoy coupling L-095
2) Guide Bearing (Hot end)
Type Spherical Roller bearing, No.23060

Lubrication SERVOCYL C-680
Drive 0.75KW, 3, 50Hz 415V,1400 RPM,1.7 A
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Pump Screw Pump (15 liter/min.)
DOR CW From Motor NDE
A5) Set points
LOS (Guide & Support)

1) Oil flow switch 7 lpm
2) Relief V/v set pr 5 ksc
3) RTD- start temp of LOS 40 deg c
4) RTD-Alarm temp 70 deg c
Pr switch- before solenoid v/v 5 ksc
Pr switch- after solenoid v/v 3 ksc
Fire sensing device alarm temp 450 deg c
A6) COOLERS
Guide bearing Oil Cooler Flow 1 M3/Hr./system at 5 ksc

Support bearing Oil Cooler Flow 1 M3/Hr./system at 5 Ksc
B) SECONDARY AIR PRE-HEATER (SAPH)

Make BHEL
Type Ljungstrom Bisector (Regenerative)
No. of Air Pre-heater 2 per Boiler
Material specification,thickness:
Cold end elements 1.214 mm-NF6 profile
Intermediate elements 0.8 mm-DU profile
Hot end elements 0.8 mm-DU profile
Size 30 VIM 2000
B1) ELEMENTS
END HEIGHT OF MATERIAL DESCRIPTION OF No. of baskets Effective

ELEMENT ELEMENTS heating
area (m2)
HOT 850 mm Carbon Steel Double Corrugated 336 27406
INTER 850 mm Carbon Steel Double Corrugated 336 27406
COLD 300 mm Corten Steel Notched Flat 384 7930
B2) MAIN DRIVE
Electric Motor Make-Laxmi Hydraulics Ltd, Squirrel Cage, induction motor,

18.5KW, 35 A, 415V, 3, 50Hz, 1460 RPM
Speed Reducer Ratio 130 : 1
Speed Reducer Type 2D, 3 input, down shaft
Couplings Fluid coupling for main drive & resilient coupling for aux drive
15 m3 capacity
Air receiver
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B3) AUXILIARY DRIVE
Air Motor 5 KW, 540 RPM, with gear box , Air consumption 8 NM3/min. at 6.33 kg/cm2
from air receiver
B4) BEARINGS
1) Support Bearing (Cold end)
Type Spherical Roller thrust bearing, SKF 294/750E

Lubrication IOC SERVOCYL C- 680
Drive Make-NGEF, 0.75KW, 415V, 3, 50Hz, 1400 RPM, 1.7 A
Pump Screw Pump (15 liter/Min.)
2) Guide Bearing (Hot end)
Type Spherical Roller bearing, No.23072/CCK/C3/W33

Lubrication IOC SERVOCYL C-680
Drive Make-Tushaco, 0.75KW, 3, 50Hz 415V, 1400 RPM, 1.7 A
Pump Screw Pump (15 liter/min.)
B5) Set points
LOS (Guide & Support)

Oil flow switch 7 lpm
Relief V/v set pr 5 ksc
RTD- start temp of LOS 40 deg c
RTD-Alarm temp 70 deg c
Pr switch- before solenoid v/v 5 ksc
Pr switch- after solenoid v/v 3 ksc
Fire sensing device alarm temp 450 deg c
B6) COOLERS
Guide bearing Oil Cooler Flow 1 M3/Hr./system at 5 ksc.

Support bearing Oil Cooler Flow 1 M3/Hr./system at 5 ksc
2.12 STEAM COIL AIR PREHEATER (SCAPH)
A) PRIMARY STEAM COIL APH
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No. of Steam Coil APH 2 Nos. per boiler
Supplier M/s C Doctor & Co Pvt Ltd
Size of steam coil Air Preheater 3150 X 4700 X 350 mm
Installed Position Horizontal
Design Pressure 15 kg/cm2 (ata)
Design temp. 210oC
Hydraulic Test Pressure 30 kg/cm2
Weight of one steam coil APH 4850 kg.
B) SECONDARY STEAM COIL APH
No. of Steam coil APH 2 Nos. per boiler

Supplier M/s. Patel Air Temp. Ltd.
Size of steam coil APH 6000 X 3200 X 350 mm
Installed Position Horizontal
Design Pressure 15 kg/cm2 (ata)
Design Temp. 210oC
Hydraulic Test Pressure 30 kg/cm2
Weight of one steam coil APH 5581 kg.
2.13 ELECTROSTATIC PRECIPITATOR (ESP)

A) DESIGN CONDITION (TMCR-Design coal) Guaranteed Point
Gas flow rate 834

m3/sec.
Temperature 125oC
Inlet dust concentration 59.1
g/Nm3
Required Outlet dust concentration 19
mg/Nm3
Type 4xFAA-9x45M-2x92150-2
ESP efficiency 99.968%
No. of precipitator offered per Boiler Four
No. of bus sections Two
No. of Fields along the flow Nine
Pressure drop across the 20.0
Precipitator for Design condition
mmWC
Velocity of gas inside ESP 0.76
m/sec.
Treatment Time 53.29 sec
B) COLLECTING ELECTRODES
No. of rows of Collecting Electrodes per field 47

No of collecting electrodes per field 282
No of collecting electrodes arrangedin each row 6
Total no. of Collecting Plates per Boiler 10152
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Nominal height of collecting plate (m) 15.0
Nominal length of collecting plate (mm) 750
Specified Collecting Area 268.03 m2/m3/sec.
C) EMITTING ELECTRODES
Type Spiral with hooks

Size 2.7 mm dia
No. of electrodes in the frame forming one row 54
No. of electrodes in each field 2484
Total no. of electrodes per Boiler 89424
Total length of electrodes per field 15749 m
Plate / Wire spacing 200 mm (400 mm pitch)
D) GAS DISTRIBUTION SYSTEM

1) Inlet
Type & Quantity Perforated Plate-(3 screen arrangement) with GD rapping

system 1 set
Location Inlet of precipitator
2) Outlet
Type & Quantity Thin sheets formed to a shape of ‘U’, Located with 600 mm pitch- one set
Location Outlet of precipitator
E) HV RECTIFIER (By BHEL BHOPAL/JHANSI)
Rating 95 KV DC (Peak)
1000 mA DC (mean)
Quantity/ESP 18
Type Silicon Oil, Silicon diode, Full Wave Bridge connection
Location Mounted on the top of ESP
F) MOTOR FOR RAPPING EMITTING & Collecting ELECTRODES
Emitting electrode Collecting electrode

rapping motor rapping motor
Rated output (HP) 0.5 0.5
Output speed (RPM) 2.5 1.1
Gear ratio 550.18:1 1246.32:1
Full load current 1.12 A 1.12 A
Location Outdoor/V1 Outdoor/B3
Total weight 109 kg 220 kg
Lub oil Sevomash SP-460 Sevomash SP-460
Oil qty 8.5 litr/gear box 8.75 ltr/gear box
Total qty of geared 72 72
motor
G) MOTOR FOR RAPPING GAS DISTRIBUTION SYSTEM
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Quantity per ESP 8
Rating Geared motor, 0.5HP, 1.1 RPM,3 , 415V, 50Hz, AC
Location On the ESP side panel/ GD housing.
H) RAPPERS FOR COLLECTING ELECTRODE
No. and Type of Rappers One drop hammer per row of collecting
Electrodes having a collecting surface of
135 m2
Rapper Size 4.9 kgs
Frequency of Rap Varying from 12 raps per hour at the inlet field to 0.1 rap/hour at the exit
field.
The frequency of rapping at intermediate fields can be adjusted between
12 and 0.1 per hour according to the requirement.
Drive Geared Electric motor.
Location At the bottom of collecting electrodes.
I) RAPPERS FOR EMITING ELECTRODES
No. and Type of Rappers Approximately one drop hammer for two rows
of Electrodes.
Rapper Size 3.0 kgs

Frequency of rapping 10 raps/hr.
Drive Geared electric motor.
Location On middle frames of emitting system frame work
J) HOPPERS
1) Hopper Specification
Type Pyramidal
No. of hoppers per boiler 144 (36/ESP)
Heating Electrical heating provided at the bottom of the hopper.
Baffling Arrangement 2 sets of deflector plates for each hopper.
K) Heating Elements for Hopper
Quantity per ESP 36 set

Type Panel type
Rating 10kw,1 phase,415 V AC, 50 Hz
Location At the bottom of the hoppers
Thermostat setting for the
Tripping of the heat 120° C
For Shaft Insulators

Quantity per ESP 18
Type Tubular heaters of breathing type
Rating 1.0 KW 1 phase,415 V AC, 50 Hz,
Location In the shaft insulator housing
L) Support Insulators
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Quantity per ESP 72
Rating 1.0 KW , 1 Ph , 415 V
AC , 50 hZ ,
Type Tubular heaters of breathing type
Location Support Insulator House
Recommended thermostat setting 140 deg c
for support heater trip
2.14 SOOT BLOWER
Source of steam for Soot Blowing Tap off from SH Divisional Outlet Header.
Set Pressure on Pr. Reducing Valve 30 kg/cm2(g)
Set Pressure on Safety valve 40 kg/cm2(g)
Maximum flow rate 20 T/Hr
Temp. after Pr. reducing valve 374oC
Sl. DESCRIPTION TYPE OF SOOT BLOWERS

No. WB 1E LRD IIE (LRSB)
01. Blower Numbers 1 TO 88 105R TO 108L 109R TO 124L 125R TO 138L
(6) (26) (8)
02. Travel In MM 305 9700 9700 9700
03. Dead Travel In MM - 370 370 370
04. Nozzle Size In MM/ No. Off Nozzles  26/1  32/2  25/2  25/2
05. Blowing Pressure In Kg/Cm2(G) 11 12.5 12.5 10.5
06. Speed Of Travel In MPM Rotary / 6.1 – 0.7 1.55 – 5.87 1.55 – 5.87 1.55 – 5.87
RPM
07. Blowing Rate Per Group In Kg/Min 89 152 93 79
08. Blowing Time Per Group In Min 1.4 12.04 12.04 12.04
09. Operating Time Per Group In Min 1.5 12.52 12.52 12.52
10. Operating Time Per Cycle In Min 66 75.12 325.52 100.16
11. Steam Consumption Per Group In Kg 125 1830 1120 951
12. Steam Consumption Per Cycle In Kg 5500 10980 29120 7608
13. Cycles Per Day (Assumed) 3 3 3 3
14. Steam Consumption Per Day In Kg 16500 32940 87360 22824
15. Blowing Angle 360o 360o 360o 360o
TOTAL STEAM CONSUMPTION IN Kgs = 159624 (PER DAY)

NOTE BLOWERS OPERATED IN A GROUP OF TWO. BLOWING RATE IS GIVEN FOR 2 BLOWERS.
LRD IIE LONG RETRACTABLE SOOT BLOWER ELECTRICALLY OPERATED.
WB IE WALL BLOWER ELECTRICALLY OPERATED.
A) PAPH SOOT BLOWER
Type of nozzle Twin

Type of drive Swivel Arm
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Location Gas Outlet Duct
Quantity 2 / APH
Cleaning time 1 cycle is approx 30 min
Motor 0.18 KW, 3, 50Hz, 415V, Insulation Class – F
Speed Reducer Two stage reduction worm gear box, Ratio-4900 :1
Steam Consumption 2100kg/hr per device at 14 ksc & 150 deg c
superheat, max pre=17.6 ksc
Air Consumption 10.75 Nm3/min/device at pressure 6.33ksc
B) SAPH SOOT BLOWER
Type of nozzle Twin

Type of drive Swivel Arm
Location Gas Outlet Duct integral with APH
Quantity 2 / APH
Cleaning time 1 cycle is approx 63 min
Motor 0.18 KW, 3, 50Hz, 415V, 670 RPM, 1.0 A
Speed Reducer Two stage reduction worm gear box, Ratio-4900 :1
Consumption 2100kg/hr per device at 14 ksc & 150 deg c
Steam superheat, max pre=17.6 ksc
Consumption 10.75 Nm3/min/device at pressure 6.33ksc
Air
DOR CCW From Motor NDE
2.15 BLOW DOWN VESSELS
IBD TANK CBD TANK

No. 1 1
Type IBD Tank 2500x16 CBD Tank 2000x16
Design Pr. 1.5 kg/cm2(g) 10 kg/cm2(g)
Operating Pr. 1.1 ksc 8 ksc
Design temp. 111 179
Qty of flashed steam 23.44 T/hr. 42.5 T/hr.
Hydraulic test Pr. 2.25 kg/cm2(g) 15 kg/cm2(g)
Shell thickness 16 mm 16 mm
Shell dia 2500 mm 2000 mm
Wt. when empty 6625.578 kg. 4171.243 kg.
Medium Steam & Water Steam & Water
Material Specification SA 515 Gr.70 SA 515 Gr.70
2.16 BOTTOM ASH SYSTEM
Bottom ash hopper 1) 1 per unit [Top 1100 mm S.S.316x6 THK]

2) water volume-601 m3
3) ash volume-554 m3
4) ash weight-359.5 T
Feed gates 1) For bottom ash hopper
2) gate opening=900 X 900 mm(600)
3) Quantity= 8 (4 for unit 1, 4 for unit 2)
Clinker grinder 1) Below bottom ash hopper
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2) 4 no. for 1 unit(2w+2s)
3) capacity=85 TPH
4) roll rpm=40
5) outlet particle size= 25 mm
6) design pr. of body=2 ksc
Clinker grinder gear box (helical type,1) Model 72P II
foot mounted B3 construction, 2) Service factor- 2.0 (min)
POWER BUILD LTD make) 3) Motor Speed 965, Gear Ratio 15.6
4) Mechanical HP- 15 HP
5) Thermal rating- 33 HP
6) No. of teeth of o/p wheel – 51
7) Oil capacity- 2.5 ltr
8) Method of lubrication- splash type
9) Method of cooling- air cooling
Motor rating- 11 KW
Current 20.8 A
Clinker grinder fluid coupling 1) Model SM-5
(Fluidomat ltd,dewas) 2) Coupling rating- 30 kw @ 1000 rpm
3) Dry wt. of coupling – 40 kg
4) Max oil filling – 4.9 litres
5) Flexible coupling – FFX-2
6) Qty- 4 per unit(2w+2s)
7) Recommended oil- Servo system- IOC 32 (viscosity index-95,
flash point-190 deg c)
8) Motor rating- 11kw @ 965 rpm
Feed sump 1) Below clinker grinder
2) 4 per unit
3) Weight -215 kg approx.
Hydro-pneumatic cylinder (up to 14’’1) Cylinder type- double acting non cushioned
size, NUCON make) 2) Operating pr.= 2-10 ksc
3) Hydraulic pr.= 4-10 ksc
4) Operating temp = +80 ° c
5) Mountings= front flange mtg. style G
6) Quantity = 4 per unit
Gear box for BA overflow 1) Model no- H1-140 with fan cooling
pump(PREMIUM make) 2) Type- parallel shaft, helical, foot mounted
3) Qty- 2 per unit
4) Design KW mech- 267/1500 rpm
5) Design KW therm.-179/1500 rpm at 20 deg c
6) Actual ratio- 1.359/1
7) Lub. type- splash
8) Oil type- greaves traxol-G32
9) Oil qty- 6 ltr (approx.)
10) Motor rating – 110 kw/1485 rpm
11) S.F over motor kw- 2.42
BA overflow pump fluid Model- 430 PST
coupling(PREMIUM make)
Seal box for BA hopper overflow 1) 2 per unit
2) At bottom ash hopper
3) Weight- 550 kgs
32 | P a g e
Air oil convertor tank 500NB 1) Qty- 4 per unit, BA hopper area
2) Working/design pr-7/7.7 ksc
3) Empty weight/weight with oil- 135/325 kgs
4) Volume of empty tank- 0.2 m3 (max.oil level)
BA over flow tank 1 no per unit, capacity- 75.3 cubic meter
EQUIPMENTS
QTY. (Both CAPACITY HEAD MOTOR MAKE /

Units) (T/hr.) (MWC) RATING MODEL No.
(KW)
Jet Pump of B.A.Slurry 8(2 W&2 85 T/hr. 332 M3/hr. N.A. Mahendra
(Hydraulic static test pr=4 ksc, below Standby for inlet water Ash Tech Ltd.
bottom ash hopper) each unit ) at 69 MWC
Clinker grinder [ Roll RPM=40, outlet 8 (2 W& 85 T/hr. N.A. 10 Mahendra

particle size=25 mm, design pressure of 2 Sby for Ash Tech Ltd.
body=2ksc, below bottom ash hopper] each unit )
BA overflow water pump
Supplier SAM TURBO Industry pvt ltd

Type AR 150/510
Size 200 X 150
Rated speed 815 rpm
Capacity 450 m3/hr.
Head 29 m
Total weight 3936 kgs
Direction of rotation CW from drive end
Motor:-
Make Marathon
Frame D 315S
Power 110 KW
Speed 1500 rpm
BA seal water pump
Quantity 2
Manufacturer SAM turbo industry ltd
Description Horizontal centrifugal multistage
Liquid handled Ash water/service water/clarified water
Suction condition Flooded
Capacity 30 m3/hr.
Head 40 mwc
Shut off head in M 47.4
33 | P a g e
Pump type/model 3 MD 80/205
No of stages 3
Size in mm 100 x 80
Critical speed 30% above rated speed
Motor KW/rpm 15/1450
Coupling between motor shaft Pin & Bush
& pump shaft
2.17 FLY-ASH SYSTEM
Flushing apparatus for ECO hopper Below ECO hopper, 4 no. per unit, Capacity-2.5
TPH
Adapter below ECO hopper 4 per unit, total wt.- 46.54 kgs
Adapter below ESP hopper 144 per unit, unit weight-38 kgs
Adapter below APH hopper Below primary & secondary air duct, 8 no per
unit, total weight-36 kgs
Fly ash extraction valve (A) 150NB Dome valve
1) Location- below ESP hopper 1st to 3rd field
2) Qty- 48 nos per unit
3) Total weight- 150 kgs
(B) 100NB Dome valve
1) Location- below ESP hopper 4th to 9th field
2) Qty- 96 per unit
3) Location- below APH hopper
4) Qty- 8 per unit
5) Total weight- 100 kgs
Branch Air-intake valve 100NB 1) At unloading TEE inlet
2) Qty- 80 nos
3) Max working pr- 1 ksc
4) Total weight- 35 ksc
Unloading TEE 1) Below ESP hopper(176 per unit)
2) Below APH hopper (8 per unit)
3) Weight-133 kg
Isolation valve 1) Below APH (16 nos)
2) Below ESP (288 nos)
3) Below buffer hopper (48 nos)
Master PD-Pump (Air lock vessel) 1) Model 40/12/10, Pressure conveying vessel
2) Volume of tank- 4 CuM
3) Location- Below buffer hopper
5) Total weight- 2900 kg
Slave PD-Pump (Air lock vessel) 1) Model 40/12/10, Pressure conveying vessel
2) Volume of tank- 4 CuM
3) Location- Below buffer hopper
5) Total weight- 2800 Kgs
Fluidizing blower for buffer hopper (KAY 1) Model 67AC twin lobe
international ltd) 2) Qty- 2 per unit
3) Capacity- 575 m3/hr
4) Diff pressure- 4500 mmwg
34 | P a g e
5) RPM- 1371
6) BHP-13.66
7) Dynamic load- 1.5 X static load (330 kg approx.)
8) Motor make- marathon (SE. 160L)
9) Motor rating- 1440 rpm/20 HP
Vacuum breaker 100 NB vacuum breaker, Qty- ?
Buffer hopper Qty-4 per unit, Total effective volume- 53 CuM
Vacuum pump (ESP stream) 1) Qty-8 no. per unit
2) Vacuum pump capacity selected per stream-
3050 m3/hr. @ 14” Hg (g)
Bag filter Qty- 4 per unit, filtering area selected for each
buffer hopper- 59 m2
Air heating unit for fluidizing air 1) 22 KW-at silo utility building, Qty- 5 no.(4w+1s)
2) 18 KW-at buffer hopper area, Qty- 2 per unit
Fluidizing pad 1) Buffer hopper, Opening size-150x400, Qty-6
2) Buffer hopper, opening size-150x600, Qty-8
3) ESP hopper 1st to 3rd field, opening size-150x200,
Qty-48
VALVE DATA
Size Location Quantity Weight
1) Switch valve 200 NB At ESP area Dome v/v-8 per 493 kg
(Branch isolation unit
v/v) Unloading
tee-4/unit
2) Switch valve 200 NB At ESP area Dome v/v-8 per 313 kg
(Branch isolation unit
v/v) Unloading
tee-8/unit
3) Segregation v/v 200 NB At vacuum p/p o/l 16/unit 190 kg
line & buffer hopper
bag filter inlet line
4) Segregation v/v 250 NB At buffer hopper inlet Dome v/v-4/unit 802 kg
line Unloading
tee-2/unit
5) Unloading tee - Before buffer hopper 4/unit 202 kg
inlet
6) Switch valve 250NB buffer hopper inlet Dome v/v-8/unit 896 kg
(Branch isolation line from primary & ‘Y’ piece-4/unit
v/v) secondary AH
Knife Gate Valve (KGV) Location Quantity

1) 300 mm KGV with chain wheel Below HCSD silo 12
operated Below fly ash silo 16
2) 80 mm KGV with cylinder Inlet of sludge pump 2
actuator, MOH Outlet of settling tank 1
Outlet of sludge tank 1
3) 80mm Bi-directional KGV with Discharge of sludge pump 2
cylinder actuator, MOH
4) 250mm KGV with chain wheel Below ECO hopper 8
35 | P a g e
operated
5) 250mm Bi-directional KGV with Outlet of BA overflow pump 4 ( 2 per unit)
cylinder actuator, MOG
6) 300mm KGV with cylinder Suction of BA overflow pump 4 ( 2 per unit)
actuator, MOG
7) 300mm KGV with cylinder Below fly ash silo 4
actuator Above unloading spout 7
ESP Ash collection rate 180 TPH

APH Ash collection rate 10 TPH
Total 190 TPH
Ash collection in per shift of 8 hrs. per boiler (Ton) 190 x 8 = 1520 T
Ash transportation time for one shift of 8 hrs. (hrs.) 6 hrs.
Ash conveying rate (per boiler) 253.3 T/hr.
Collection equipment ESP/APH
Total no of streams 4 (1 per pass)
Ash conveying rate (per stream) 63.3 T/hr.
3. MAIN TURBINE
3.1 SPECIFICATIONS
Make BHEL
Design KWU, West Germany
Type Three Cylinder Reheat Condensing Turbine.
Stages Single flow HPT 17 Reaction stages.
Double flow IPT 12 X 2 Reaction stages
36 | P a g e
Double flow LPT 6 X 2 Reaction stages.
Valves HPT -2 Main Stop and Control Valves.
IPT -2 Reheat Stop and Control Valve.
CRH line - 1 Swing Check Valve.
HPBP – 2 Bypass Control Valves
LPBP – 2 Bypass Stop and Control Valves
Direction of Rotation Anticlockwise (Viewed from Front Pedestal towards Generator
LOAD
Rated load 500 MW
MaxM load 525 MW (valve wide open condition)
SPEED
Rated Speed 50 C/Sec
Maxm Speed 51.5 C/Sec (No Time Limitation)
Minm Speed 47.5 C/Sec (No Time Limitation)
Speed Exclusion Range(without load) 7 to 47.5 C/Sec
Standard Over Speed Trip Setting 55.5 C/Sec
Permissible for max. 2hrs during the life of LP Blading Speeds below 47.5 C/Sec
Speeds above 51.5 to 60 C/Sec
EXTRACTION VALVES
Extraction 1 No Valve
Extraction 2 1 check valve with actuator 1 check valve without actuator
Extraction 3 1 check valve with actuator and 1 check valve without actuator
Extraction 4.1 2 check valves with actuator
Extraction 4.2 2 check valves with actuator
Extraction 5 1 check valve with actuator and 1 check valve without actuator
Extraction 6 No valve
STEAM PRESSURE AND TEMPERATURES

Pressure (bar) – Absolute Temperatures (oC)
Initial steam 166.7 537

Before 1st stage of HPT 154.4 537
HP cylinder exhaust 44.0 336.4
IP cylinder stop valve Inlet 39.6 565
Extraction 6 44.0 336.1
LP cylinder exhaust 0.1027 46.4
STEAM PRESSURE
Long time operation (bar)# Short time operation
(bar)##
Initial steam 175.5 200
37 | P a g e
Before1ststage of HPT 169.6 169.6
HP cylinder exhaust 50.6 52.8¤
IP cylinder stop valve
40.0 47.6¤
Inlet
Extraction6 50.6 52.8
LP cylinder exhaust 0.3 0.3
# Long time operation: Upper limit value, permissible without time limit.
## Short time operation: Permissible momentary value. The aggregate duration of such swing
must not exceed 12 hours in any one year
¤ The safety valves must to be set so that all short term values are not exceeded .
All pressures are absolute pressures.
TURBINE EXTRACTIONS
Source Going to
Extraction
1 LPT- 5th stage LPH-1
2 LPT – 3rd stage LPH-2
3 LPT – 2nd stage LPH-3
4 IPT Exhaust Deaerator (4.1) and TDBFP-A/B (4.2)
5 IPT –7th stage HPH – 5A/5B
6 CRH HPH – 6A/6B, TDBFP – A/B
3.2 LIMITING VALUES

CASING TEMPERATURE
Alarm M/C must be shut down at

HP turbine casing exhaust 485oC 500oC
Outer casing of LP cylinder 90oC 110oC
(Spray water to L.P. turbine must be
switched on at 90oC).
Temperature difference
Between upper & lower casing of HPT.  90oC  100oC
(Middle)
IPT Top / Bottom Diff. temp. (Front)  30oC  45oC
IPT Top / Bottom Diff. temp. (Rear)  30oC  45oC
Permissible temperature difference between parallel steam supply lines
No time limitation 17 oC
Short time period (15 min) 28 oC
OUT PUT LIMIT DURING TESTING WITH ATT
38 | P a g e
Testing of the Main Steam Stop & Control Valves < 300 MW
Testing of the HRH Steam Stop & Control Valves 300 MW
MOTORING
Motoring must not be allowed to continue beyond one minute. If the condenser low vacuum limit of
0.3 bar is exceeded, motoring must not be allowed to continue beyond 4 sec.
LOW VACUUM TRIP STANDARD SETTINGS
Hydraulic Low Vacuum Trip 0.3 bar
Electrical Low Vacuum Trip 0.3 bar
Hydraulic Low Vacuum Trip Bypass Operation 0.6 bar
TURBINE SEAL STEAM SYSTEM

Seal steam supply header pr. (Above Atmospheric) 0.035 bar
Condenser Vacuum 0.1027 bar
SEAL STEAM EXHAUSTER FANS

No. of Fans 2 X 100 %
Make S.K. System Pvt. Ltd.
Type SHSH
Speed 2900 RPM
Capacity 1440 m3/hr.
Pressure 434 MMWG
Motor
Make Bharat Bijlee Ltd.
Volt 415 V
Connection Delta
Power rating 3.7 KW
Current 7.05 A
DOR A: CW from Motor NDE
B: CCW from Motor NDE
BARRING GEAR
Drive Turbine Lube Oil (Hydraulic Turbine)
Cut in / Cut out speed 210 / 240 RPM
Location Front Bearing Pedestal
TURBOVISORY
Alarm Trip
Axial Shift  0.5 mm  1 mm
Differential Expansions
39 | P a g e
HPT -5.0 to +3.5 mm
IPT -1.0 to +5.5 mm
Overall Expansion of IP + LP Rotor -3 to + 30 mm
VIBRATION
Absolute Bearing Absolute Shaft Vibration
Housing Vibration
Standard Alarm setting - 50m above normal level
Maximum Alarm setting 84m 200m
Limit Value for Tripping 106m 320m
Alarm Trip
Bearing Temperatures 90 to 115oC (depending on operating 130oC

temp. of bearing)
FIXED POINTS
Turbine bearing pedestal – 2
For HP casing
For IP casing
For LP casing
Thrust bearing.
For Turbine Rotor
All HP, IP & LP Turbine Bearing Pedestals are Fixed.
WEIGHTS
HP Turbine, complete assembled 95 T
IP turbine, top half outer casing 26 T
IP turbine, top half inner casing, complete
16 T
with blading
LP turbine, top half outer casing complete 43 T
LP turbine, top half inner outer casing,
complete with blading, guide blade 37 T
carriers and diffusers
HP turbine rotor, complete with blading 16 T
IP turbine rotor, complete with blading 23 T
LP turbine rotor, complete with blading 100 T
Main Stop and control valve, complete
with servo motors, without bend and pipe 27 T
section
Main Stop and control valve, complete
with servo motors, without bend and pipe 34 T
section
3.3 MATERIAL OF CONSTRUCTION

TURBINE CASINGS MATERIAL
40 | P a g e
HP GS17 CrMo V 511
IP GS22 Mo 4
LP ST 42 W
TURBINE SHAFT
Hp Shaft 28 Cr Mo Ni V 59
IP Shaft 30 Cr Mo Ni V 511
LP Shaft 26 Ni Cr Mo V 145
BLADES MOVING FIXED
HPT (First Stage) X22 Cr Mo V 121 X22 Cr Mo V 121
HPT (Other Stages) X22 Cr Mo V 121 X22 Cr Mo V 121
IPT (First Stage) X19 Cr Mo V Nb N111 (for X19 Cr Mo V Nb N111

few initial stages )
IPT (Other Stages) X22 Cr Mo V 121 X22 Cr Mo V 121
LPT (Last Stage) X10 Cr Mo V 122 X20 Cr13

(last stage) (first stage)
LPT X20 Cr13 GX4 Cr Ni 134 ,
(Other stages) X2 Cr Ni12
(Other Stages)
HEAT BALANCE DATA

Rating 500 MW 400 MW 300 MW 250 MW
Vacuum (mmHg) 77 77 77 77
DM Make-Up (%) 0 0 0 0
Turbine Gross Output (MW) 508.494 407.072 306.081 255.740
Turbine Net Output (MW) 500 400 300 250
Heat Rate (Kcal / KW-Hr) 1944.4 1987.2 2059.5 2129.3
Losses
Mechanical (incl. bearing friction, 1.449 1.448 1.449 1.450

windage& exhaust losses) (MW)
Generator (MW) 6.895 5.474 4.482 4.140
TG Auxiliary (MW) 0.15 0.15 0.15 0.15
Efficiency (%) 98.30 98.23 97.97 97.70
41 | P a g e
3.4 TURBINE LUB OIL SYSTEM
LUB OIL SPECIFICATIONS

Kinematic viscosity 41.4 – 50.6 CST at 40oC, 28 CST at 50 oC
Viscosity index Min 98
Flash point 200oC (min.)
Pour point -6oC (max.)
Colour 2 ( max )
Neutralisation No.(total Acidity ) Max. 0.2 mg of KOH per gm.
Emulsion char Max 20 minutes
Deaeration capacity at 50oC 4 minutes (max.)
Rust preventing characteristic 0-B max
Water content % by wt. 0.01 % max
Solid particles content by wt. 0.05 % max.
Foaming tendency at 25oC 400 Cm3 (Max.)
Foaming stability at 25oC 450 Sec (Max.)
Ash (% by weight) Max. 0.01 %
Particle distribution Min. -/17/14 (Class-8)
Specific gravity 0.85at 50oC , 0.90 at 15oC
Copper strip corrosion test at Not worse than No.1
100oC for 3hrs
Water release 300 s (Max.)
OIL SUPPLY
MOT capacity 25/40 m3
1st oil filling 53 m3
Flushing oil quantity 32 m3
Filtration particle size of tank filter element 250 m
Oil temperature at cooler outlet, unit in 38oC min , 45oC normal , 47oC max
operation
Oil temperature at cooler outlet, unit shut down 75oC max
Temperature rise of oil in bearings 20oC normal , 25oC max
OIL REQUIREMENT OF BEARINGS (dM3/S)

Bearing 1 0.8
Bearing 2 15.4
Bearing 3 4.55
Bearing 4 9.29
Gen. bearing Front 7.92
Gen. bearing Rear 7.92
Exciter bearing 0.70
Estimated oil requirement for the Hydraulic 57.4
Barring Gear
DUPLEX OIL FILTER (FOR BRG. OIL SUPPLY HEADER)
Number 2 X 100 %
42 | P a g e
Type RELDW 4020 ZAV 25 VZ
Size 355 / 750
Make MS HYDAC FILTER TECHNIK GMBH
Filtration particle size 25 m
JACKING OIL SYSTEM

Type DFDK 330 D40 W/Hc/-V-So212
Safety valve setting 200 bar
Pressure regulating valve setting 178 bar
Duplex oil filter 1 x100 %
(Type 400 D 140 )
Filtration particle size of filter element 37 m
Make MS HYDAC FILTER TECHNIK GMBH
JACKING OIL PUMPS CUT IN AND CUT OUT SPEEDS
Jacking oil pumps must be in operation at turbine speeds below 510 RPM.
Jacking oil pumps should be cut out at speeds above 540 RPM
.
OIL PUMPS SPECIFICATION
MOP AOP DC EOP JACKING OIL PP
Number 1 2 1 AC : 1 DC : 1
Make BHEL KBL Mather&platt Tushako Tushako
Type Centrifugal Centrifugal Centrifugal Screw Screw
Capacity (m3/s) 350 360.96 108 6.642 6.642
Disch. Pr. 9.1 bar 78.4 MLC 27.06 MLC 178 bar 178 bar
Speed (RPM) 3000 2965 1425 2955 2900
Drive Turbine AC Motor DC Motor AC Motor DC Motor
MOTOR MAKE - Crompton Crompton Crompton Crompton
Greaves Greaves Greaves Greaves
Voltage (V) - 415V 155 V 415V 220V
(Armature) (Armature)
Motor Power (KW) - 110 13 60 60
Rated Current (Amp.) - 173 97(Armature) 95 310
(Armature)
DOR from top - Clockwise Clockwise Clockwise Clockwise
LUB OIL COOLERS

Number 2 X 100 %
Type Shell and Tube type ( straight tube )
Material of
Tubes Adm. Brass
Cooler Shell Carbon steel, IS:2062
Tube Plates Carbon steel, IS:2062
Water Box Carbon steel, IS:2062
Heat load on cooler 100% 1900 KW
Heat transfer area provided/cooler (m2) 640 (including 30% margin )
Heat transfer co-efficient 260 Kcal/hr-m2 oc
43 | P a g e
Shell (oil) side design pressure 9.4 ksc
Tube (water) side design pressure 10 ksc
Oil Flow/cooler 190.8 M3/Hr.
Velocity of water through cooler tubes 1.54m/s
Oil Inlet Temp. 65 oc
Oil Outlet Temp. 45 oc
Oil Side Pr. Drop 4 Mwc
Water side pr drop 3.5 mwc
CW Inlet Temp. 38 oc
CW Outlet Temp. 41.3 oc
CW Flow/cooler 500 M3
CW Side Pr. Drop 3.5 Mwc
TURBINE OIL CENTRIFUGE SYSTEM

Centrifuge
No. of units One
Make Alfa Laval
Type MAB 206 S-24
Recommended through put for best 7500 lph at 65 oc
performance
Speed of Bowl (Max.) 8423 RPM
DOR CW from top
Motor
Make Crompton Greaves
Type 3Ø Induction motor
Volts 415 V
Rating (KW) 11
Current 21 A
RPM 1460
Duty Continuous
Insulation class F
Centrifuge Feed Pump
Discharge pressure 1.5ksc
Process temperature(min/max) 0/100 °C
Max density of the feed 1100Kg/m³
Max density of the sediment 1600kg/m³
Centrifuge Materials
Bowl body head SS alloy AL 111 2377
Separating disks AISI 316
Bowl nut AISI 316
Oil injection nozzle AISI 316
Drive shaft , worm EN8
Other bowl parts Brass -Bronze
MOT OIL VAPOUR EXHAUST FANS

No of Fans 2x100%
Make S.K. System Pvt. Ltd.
Type SHSH
Capacity 396 m3/hr.
Pressure 220 mmwg
Speed 2830 RPM
DOR CW Motor NDE
Motor
44 | P a g e
Make Bharat Bijlee Ltd.
Voltage 415 V
Power rating 0.75 KW
Current 1.65 A
LEAKAGE OIL PUMP

No. of PPs. 1x100%
Location C.F.T. room (T.G. ‘0’m)
Make Tushaco Pumps
Model No RT -40 BP
Flow 40 lpm
Discharge Pr. 5 kg/cm2
MOTOR
Make CGL
Rating 0.75 KW
Volt 415 V
Current 1.8 Amps.
Speed 1410 RPM
DOR CW from MDE
3.5 CONTROL FLUID SYSTEM
CONTROL FLUID (FIRE RESISTANT FLUID) SPECIFICATION

Flash Point >235oC
Pour Point < -18oC
Neutralisation No. Max. 0.1 mg KOH/g
Ignition temp. >550oC
Air release capacity 3 min. (Max.)
Water content (by weight) < 1000 mg/Kg
Particle distribution <15/12 code
Foaming tendency at 25oC < 100 ml
Foaming stability at 25oC 450 Sec. (max.)
Kinematic viscosity (at 40oc) 41.4 to 50.6 mm2/s
Demulsification < 20 mins
Density (at 15oC) 1250 Kg/m³ (max.)
Oxidation stability 2.0 mg KOH/gm (max.)
Electrical Resistivity >50 MΩm
CONTROL FLUID TANK

Tank capacity 10/16 m3
45 | P a g e
1st fluid filling 15 m3
Flushing fluid quantity 10 m3
REGENERATIVE SYSTEM (C.F. PURIFICATION)
FILTERS
Type of Filters Purpose

Dry (F2.6) To take off water
Fuller’s Earth (HFB12) Neutralization of acidity
Mechanical Superfine filter(F2.6) Fine filtration and security
REGENERATIVE PUMPS(C.F. Recirculation PP)

Number of PPs 2 x 100 %
Make (Pump) Tushaco
Type RT-15 HBC 13L

Fluid flow 0.9 m³/s ( 15 lpm)
Direction of rotation CCW from Motor NDE
Discharge pr. 3.0 ksc
Motor
Make CGL
Motor Power 0.55KW
Rated current 1.52 Amps.
Voltage 415 V
Speed 1410 rpm
CONTROL FLUID PUMPS
Pump
Number of Pumps 2 x 100 %

Make KSB
Type WKVM80/1 + 3
Discharge pr. 11.5 / 38.5 bar
Fluid flow 20.6 l/s
DOR CCW from Top
46 | P a g e
Motor
Make Siemens
Type ILGA-313-2 AB94-Z
Voltage 415 V
Motor rating 121 KW
Rated current 200 Amp
Starting current 1614 Amp
Speed 2984 RPM
Control Fluid Pumps Operating Characteristics

Fluid flow Discharge pressure
dm³/s
Operating point I(normal operation)
Low pressure leakage fluid 7.60 11.5
High pressure leakage fluid 6.16 38.5
Operating point II (during start &

opening of the stop valve servo
motor)
Low pressure leakage fluid & low 20.60 10.8

pressure control fluid
Operating point III (during opening

of the control valve /LP bypass
operation after the load throw off)
Low pressure leakage fluid 7.60 10.0
C.F. VAP. EXTRACTION FANS

Number of Fan 2 x 100 %
Make (Fan) Air link engineers pvt ltd
Type AHBH
Capacity 60CMH
Pressure 50mmwg
DOR CCW from MNDE
Motor
Make CGL
Rating 0.55 KW
Speed 2820 RPM
Voltage 415V
Current 1.29 Amps.
CONTROL FLUID COOLER

Number of coolers 2 x 100 %
47 | P a g e
Type of cooler Shell and tube type ( straight tube )
Material of
Tubes Adm. Brass
Cooler Shell Carbon steel, IS:2062
Tube Plates Carbon steel, IS:2062
Water Box Carbon steel, IS:2062
Heat transfer area provided/cooler 31.4 m2
Fluid Flow 30.09 m3/hr.
Heat load on cooler 100% 90 KW
Fluid inlet temp. 60 oC
Fluid outlet temp. 54 oC
Fluid side pr. drop 2.5 MWC
CW inlet temp. 38 oC
CW outlet temp. 39.29 oC
CW flow 60 M3/Hr.
CW side pr. Drop 2.4 MWC
Max. allowable temp. of cooling water 38 oC

at inlet of cooler
Design pr. – CW side 10 Kg/Cm2
Test pr. – CW side 15 Kg/Cm2
Design pr. – Fluid side 13 Kg/Cm2
Test press – Fluid side 19.5 Kg/Cm2
Pressure of control fluid at cooler inlet 8 bar
Heat transfer coefficient 177 Kcal/hr-m2-oC
3.6 CONDENSER
CONDENSER SPECIFICATIONS
Type Double Pass, Single Shell
Heat load considered for design 546.16 x 106KCal/hr
Design circulating water quantity 54300 M3/Hr.

with inlet temperature of 33 oC and
36 oC
48 | P a g e
Total Surface Area Of Heat Transfer 32367 M2
Total no. Tubes 24398
Length Of Each Tube 13.3 M
Size Of Tubes (OD X Th.) 31.75 x 0.7112 mm x mm

(For Top Row Tubes) 31.75 x 0.889 mm x mm
Tube Material SS 304 (Welded)
Water box material thickness (mm) 40

Corrosion allowance (mm) 3.2
Shell thickness (mm) 16
Tube plate thickness (mm) 40
Design velocity through tubes 1.71m/sec
Pressure drop across condenser 4.05mwc

terminals on CW side
Design C.W. Temp. 33 oC
CW Temp. Rise 10.05 oC
CW Flow Quantity 54000 M3/Hr.
CW Side Pressure Drop 4.05 MWC
No. Of CW Passes 2
Condensate Back Pressure 0.1027 bar
Water Box Design Pr. 5.0 Kg/cm2
Water Box Hydraulic Test 7.5 Kg/cm2
No. Of Tube Support Plates 2 x 16
Total Empty Wt. Of Condenser 685000 Kg.

(Without LPH-1)
Condenser hot well storage capacity 65.0 M3
between the normal water level and
low water level
3.7 CONDENSATE EXTRACTION PUMP
No of Pumps 3x50%
Make BHEL – Hyderabad
Model EN6J40/500
Type of First Impeller Double suction , Radial
Number Of Stages 6
Design Flow Rate 785 M³/hr.
Inlet – Temperature 49.2oC
Inlet – Specific Gravity 0.9884
NPSH Required (3% Head Break 3.05 meter (4.15 for 1% ,4.3 for -0%)
Down)
Discharge Pressure 28 ata
Total Dynamic Head 270 Meters
Shut Off Head 353 Meters
Pump Speed 1486 RPM
DOR (As Viewed From DE Side) CW
49 | P a g e
Minimum Condensate Flow For 300 M3/Hr.
Continuous Stable Operation
Suction Strainer Size 400 µ
Axial Fluid Vel. In Eye (M/Sec.) 2.85
Critical Speeds (RPM) 3380, 5798
Shaft sealing
Method of shaft sealing Mechanical seal
Mechanical seal cooling From CEP common discharge
Method of coupling with adjacent Muff Coupling
shafting
Sealing Water Requirement
Flow 6 M3/Hr.
Pressure 3 to 4 ata
Temperature 48-65 oC
Bearings Radial Thrust Bearings
Bearings
Lubrication Condensate Sump Oil
No. Of Brg. 8 1
Type Cutless Tilting Pad
rubber
Design Load --- 2732 kg. , Maxm Load-
6038 Kg
MOTOR SPECIFICATION
Make BHEL – Bhopal
Type Induction Motor (Squirrel cage)
Rating at 50 deg C 900 KW
Voltage 3.3 KV
Number Of Poles 4
Speed 1489 RPM
Full Load Current 195.0 Amps.
Starting Current 600 Amps.
No Load Current 55 Amps
Insulation Class F/ vacuum pressure impregnated
Motor Winding Cooling Self Air-Cooled.
Motor Brg. Type Anti Friction
Motor Bearing Lubricated IOC Servo Gem-3/EQV.
3.8 DRAIN COOLER

Type Straight Tube / Horizontal
Quantity Drain (T/Hr.) 155.945
Pressure of Drain (ata) 0.2517
Temp. of Drain (oC) In = 64.44 Out = 51.66
Quantity of Condensate (T/Hr.) 1177.636
Pressure of Condensate (Ata) 39.71
Condensate Inlet Temp. (oC) 46.66
Condensate Outlet Temp. (oC) 48.33
Surface area (M2) 154.56
Size of tubes OD X Thk X Len 19.05 x 0.889 x4000
Number of tubes 666/675
Velocity of Condensate (M/Sec.) 2.18
Number of tube side passes 1
Number of shell side zones 1
Design pressure on shell side (Atg) 3 & Full vacuum
50 | P a g e
Design temp. on shell side (oC) 120
Design pressure on tube side (Atg) 40 & Full vacuum
Design temp. on tube side (oC) 144
Test pressure on shell side (Atg) 4.5
Test pressure on tube side (Atg) 52
Materials
Shell SA 516 GR 70
Tube sheets ( including overlay SA 516 GR 70
material)
Flanges CS SA 105 for SRV only
Baffles & Support plate IS 2026
Tubes SA 249 TP 304
Condensate Inlet / Outlet pipe SA 106 GR B
Drain Inlet / Outlet pipe SA 106 GR B
Weights
Dry Kgs. 4800
Operational Kgs. 7200
Flooded Kgs. 7200
3.9 LP HEATER
Heater-1 Heater-2 Heater-3
Type U-Tube / Horizontal U-Tube / Horizontal U-Tube / Horizontal

Quantity of Extraction steam 295.90 124.08 40.702
(Kg/Hr.)
Pressure of Extraction steam (Ata) 0.2517 1.30324 2.5174
Temp. of Extraction steam ( C) o
64.7 126.7 216
Quantity of Condensate (T/Hr.) 1180.468 1177.66 1177.66
o
Condensate Inlet Temp. ( C) 48.4 61.9 103.33
Condensate Outlet Temp. ( C) o
61.9 103.8 123.88
Surface area (M2) 984 1337 847
Size of tubes OD X Thk X len 19*0.889*11300 19*0.889*11940 19*0.889*9560
Number of U-tubes 717 917 725
Velocity of Condensate (M/Sec.) 2.03 1.57 2.0
Number of tube side passes 2 2 2
Number of shell side zones 1 2 2
Design pressure on shell side (Atg) 3 & Full vacuum 3 & Full vacuum 4 & Full vacuum
o
Design temp. on shell side ( C) 120 155 216
Design pressure on tube side (Atg) 39 40 & FV 40 & FV
Design temp. on tube side ( C) o
150 152 152
Test pressure on shell side (Atg) 3.9 3.9 5.2
Test pressure on tube side (Atg) 50.7 52 52
Materials
Shell SA 516 GR 70 SA 516 GR 70 SA 516 GR 70
Tube plate & covers SA 516 GR 70 SA 516 GR 70 SA 516 GR 70
51 | P a g e
Flanges IS : 2002 Gr - 70 SA 105 SA 105
Support plate IS 2062 IS 2026 IS 2026
Tubes SA 688 TP 304 SA 688 TP 304 SA 688 TP 304
Condensate Inlet / Outlet pipe SA 106 GR B SA 106 GR B SA 106 GR B
Steam inlet pipe SA 106 GR B SA 106 GR B SA 106 GR B
Impingement plate SA 240 TP 304 SA 240 TP 304 SA 240 TP 304
Weights
LP Heater dry Kgs. 21500 Kgs. 26000 Kgs. 18000
LP Heater in operation Kgs. 25000 Kgs. 33000 Kgs. 24000
LP Heater flooded Kgs. 37000 Kgs. 43000 Kgs. 31500
3.10 DEAERATOR & FST
DEAERATOR SPECIFICATION
Manufacturer BHEL, Hyderabad
Design Pressure (Kg/cm2) 9.0 & FV
Storage capacity available from normal level to 179 M³
the low – low level
Normal level of tank above centreline 457mm
Low- low level of tank below centreline -990 mm
Steam flow to Deaerator 141.251 T/hr
Design Temperature (min/max) 0 / 360 oC
Operating Pressure 6.59 ata
Operating Temp. (oC) 161.7
Hydrostatic test Pressure (Kg/cm2) 11.7
Condensate inlet Qty. (Kg/Hr.) 1069.11 x 103
Number of trays 576
Arrangement of spray nozzles with in Dearator Staggered down spray
Number of Spray valves 108
Dissolved Oxygen in feed water (cc/Ltr) 0.005
Materials
Header & Dished End CS SA 516 Gr 70
Trays SS SA 240 TP 304
Tray Support SS SA 240 TP 304
Tray removal openings & Internal pipes CS SA 106 Gr B
Packing CAF – 9
FST
Design Pressure (Kg/cm2) Full Vacuum & 9.0
Operating Pressure Kg/cm2(g) 6.59
Operating Temperature (oC) 161.7
Test Pressure Kg/cm2(g) 11.7
Materials
Storage Tank Shell & Dished End CS SA 516 Gr 70
Internal Nozzles CS SA 106 Gr B
Cover for Manholes CS SA 105
Weights
Storage Tank & Header Dry 115.4 T
Storage Tank & Header in operation 367.6 T
Storage Tank & Header flooded 558.7 T
52 | P a g e
3.11 BOILER FEED PUMP & AUXILIARIES
BOILER FEED PUMP
MDBFP TDBFP
Manufacturer BHEL / Hyderabad BHEL / Hyderabad
Model No. FK 4E36 FK 4E36
No. of Pumps 1 X 50% 2 X 50%
No. of Stages 4 + 1 kicker stage 4 + 1 kicker stage
Casing type Outer - Barrel Outer - Barrel
Inner -Radially split. Inner -Radially split.
Direction of Rotation from DE CW. CCW
Suction temp. oC 163 163
Suction pr. (bar) 27.8 27.8
Discharge pr. (bar) 213.2 213.2
NPSH at 3% head break down (bar) 50 50
Sp. Gravity 0.9043 0.9043
Flow rate (T/Hr.) 895 895
Speed (RPM) 5465 5465
Efficiency (%) 81 81
Power consumption KW 6171 6171
Total dynamic head (M) for pump 2255 2255
Normal Recirculation flow (m3/hr) 400 400
Discharge pressure for the kicker stage (mlc) 2255+209 2255+209
Shut off head(M) 2864 2864
BEARINGS
THRUST BEARING JOURNAL BEARING
Type Tilting pad (8 + 8 Pads) Thick Wall Babbit
Size MB269 / 2P / 2P 130 (for NDE), 110 ( for DE)
MECHANICAL SEAL
53 | P a g e
Type Burgmann Mech. seal.
SHF2/162-E5 (for DE)
SHF2/135-E5 (for NDE)
Seal pr. 35 atg
Stuffing box cooling Pump jacket cooling.
Seal cooling Closed loop recirculation via pumping ring

through a heat exchanger.
Temperature at seal outlet < 55oC
MECHANICAL SEAL HEAT EXCHANGER
Make Burgmann
Model 09-WED3110/A 100-E1
Type Shell and Tube type
Cooling water flow rate 6 m3/hr
Temp of seal water inlet of cooler 95 0C
Temp of seal water outlet of cooler 60 0C
Temp of cooling water inlet of cooler 38 0C
Temp of cooling water outlet of cooler 46 0C
MECHANICAL SEAL MAGNETIC FILTER

Make Burgmann
Model MAF 2000/NPT ½” -00
Type Filter Screen and Magnetic Rod
Max Operating Pressure 63 bar
Test Pressure 82 bar
Maximum Operating Temp 150 0C
Volume 0.3 L
SUCTION STRAINER
Type Conical Strainer
Degree of Filtration 195 Micron
Fluid to Handle Feedwater
54 | P a g e
Flow rate 1240 m3/hr
Design Pressure 35 kg/cm2 (g)
Max allowable pressure drop
Clean condition 0.1 kg/cm2 (g)

50% clogged condition 0.15 kg/cm2 (g)
BOOSTER PUMP
MDBFP TDBFP
Manufacturer BHEL / Hyderabad BHEL / Hyderabad
Model No. FA1B75 FA1B75
No. of Pumps 1 x 50% 2 x 50%
Casing type Horizontal Horizontal
Direction of rotation (from driver end) CW CCW
Suction temp. (oC) 163 163
Suction pr. (bar) 9.292 9.292
NPSH at (3% head break down) M 4.5 4.5
Discharge pr. (bar) 27.80 27.80
Pump speed RPM 1495 1495
Power consumption, KW 613 613
Efficiency (%) 81.5 81.5
BEARINGS
Journal brg. Thrust brg.
Type Thick Wall Babbita Tilting pad (8 + 8

Pads)
Location NDE, DE NDE
Size Dia 80mm , Len Dia 76 mm

60mm
MECHANICAL SEAL
Type Burgmann Mech. Seal
09-H75F2/100-EX1 (for DE)
09-H75F2/100-EX2 (for NDE)
Seal pr. 25 bar
55 | P a g e
Seal cooling Closed loop recirculation via pumping ring through a heat
exchanger.
Seal Temp <55 0C
SUCTION STRAINER
Type Simplex Basket Filter
Degree of Filtration 315 Micron
Fluid to Handle Feedwater
Flow rate 1240 m3/hr
Design Pressure 35 kg/cm2 (g)
Max allowable pressure drop
Clean condition 0.1 kg/cm2 (g)
50% clogged condition 0.15 kg/cm2 (g)
BFP DRIVE - MOTOR
SPECIFICATIONS
Type SCIM
Manufacturer BHEL, Bhopal
DOR from DE side CW
Rated voltage 11 KV
Power rating 10 MW
Full Load Current 605 Amps.
Starting Current 5 times rated current
Rated Speed 1495 RPM
BEARINGS
Type Sleeve
Recommended lubricant IOC SERVOPRIME-32/EQV
Oil quantity 15.4lpm for both bearing
Lubrication Forced Oil.
MOTOR COOLING
56 | P a g e
Type of Cooler CACW (Circulating Air Circulating Water)
No. of Cooler 2 x 50%
Cooling water required 2 x400lpm
Maximum permissible Inlet water temp. 38 oC
Pressure of water at inlet to coolers 6 bar
Outlet temp. of cooling water 43 oC
Cold air temp. at Outlet 50 oC
HYDRAULIC COUPLING FOR MDBFP

Manufacturer M/s. VOITH, Germany
Type Hydrodynamic (Geared variable speed)

R18KGS-14(API)
Journal brg. type Plain
Thrust brg. type Tilting pad
Direction of rotor
Input shaft Hydr. Circuit Output shaft
CCW CW
CCW
Gear ratio U1 109 / 32
U2 62 / 53
Rated output speed 5465 RPM
Motor speed 1495 RPM
Full load slip 2.3 %
Max. output speed 5833 RPM
Regulation range 4:1 downwards
Bearing temp. < 80oC
Oil reservoir Capacity 2500 lit
LUB OIL SYSTEM FOR MDBFP
Oil supplier Indian Oil Corporation

Brand name Servo HLP32
Capacity of lube oil tank ( initial filling 3500 liters
including coolers)
Capacity of working oil cooler 148 L/cooler
Capacity of lube oil cooler 90 L/ cooler
57 | P a g e
Total lube oil flow rate 300 l/Min.
(for pps, coupling & motor)
Lube oil pr. 2.5 bar
Control oil pr. 3.5 bar
Working oil flow rate 1300 l/Min.
Working oil pr. 2.5 bar (Max.)
OIL COOLERS
Working Oil Lube Oil

Type (Make) Shell/Tube (VOITH) Shell/Tube (VOITH)
Model No. LINI 13 17 13-D LI NI 09 19 13-D
No. of coolers 2 X 100% 2 X 100%
Oil filling for one heat exchanger 148 L 90 L
Oil flow rate (shell) 78 M3/hr. 51 M3/hr.
Oil temp. Inlet to cooler < 95 oC < 65 oC
Oil temp. Outlet of cooler < 58 oC < 50 oC
Oil Temp (Max Admissible) 130 oC 120 oC
Cooling Water flow (tube ) 120 M3/hr. 75 M3/hr.
Cooling Water Inlet temp. 38 oC 38 oC
Cooling Water Outlet temp. 48 oC 42 oC
Cooling Water Temparature (Max Admissible) 70oC 70 oC
Max Admissible Oil Pressure 16 bar 16 bar
HYDRAULIC COUPLING OIL FILTER

Type Duplex Oil Filter
Type DU 1001.30303.25G
Filter element Element, cleanable
Grade of filtration 25µm
Max DP 0.6 bar
LUB OIL PUMPS

Auxiliary oil Pp Main Oil Pp
Manufacturer VOITH/Germany VOITH/Germany
Type Gear Centrifugal
No. of PP. One One
Model No. MZP820 KP 144 , MZP 820
Pump Drive AC Motor Shaft driven
Rated head (bar) 4.0 4.0
Rated capacity 50 M3/hr. -
58 | P a g e
Motor make DUTCHINL
Motor rating 30 kw , 420 v , 50.2 A
Speed 2940 rpm
DOR CW from motor NDE
BFP DRIVE TURBINE
LUB OIL REQUIREMENT IN BRGS.
Main Pp Booster Pp
Journal Thrust Journal Thrust
Oil Flow (M3/hr.) 0.42 13.44 0.3 0.72
Oil pr. (bar) 2.5/3 2.5/3 1.6/2.5 1.6/2.5
Maxm. Bearing temp. (oC) 100 80 80 80
LUBE OIL COOLERS

Manufacturer BHEL
Type Twin Oil Cooler ( shell and tube )
Surface Area 85 M2
Oil Quantity 47.6 M3/hr.
Water Quantity 100 M3/hr.
Oil Side Temp(Inlet/Outlet) (oC) 60/45
Water Side Temp(Inlet/Outlet) (oC) 38/41
Heat Duty 281688 Kcal/hr
Heat Transfer Coefficient 356 Kcal/hrm2oC
OIL PUMPS SPECIFICATION

Aux. Oil Pp DC Oil Pp
Number 2 1
Make Tushaco pumps Kirloskar Ebara
pumps ltd
Model T3S140/40LHS 50x40 UCWM25
Type Centrifugal Centrifugal
Capacity 2500 lpm 24.9m3/hr
Rated Head (11.6 kg/cm2) (51.14m)
Speed (RPM) 1450 2900
Drive A.C. Motor D.C. Motor
Motor Make Crompton Crompton
Greaves Greaves
59 | P a g e
Voltage (V) 415 Field : 220
Armature: 220
Power (KW) 90 11.0
Rated Current (Amps.) 147 Armature:59
Field: 0.44
DOR CW from motor N CW from
DE Motor N DE
OIL PURIFIER (Centrifuge)

Make Alfa Laval
Separator Type MMB 305-11
Motor 3KW, 415V, 5.92 Amp., 2865 RPM
Maximum bowl speed 9510 RPM
Rated capacity 3000lph.
DOR of bowl CW from top
OIL VAPOR EXTRACTOR FANS

Nos 2x100%
Make PAF ( Patels air flow ltd )
Mounting Tank Top
Type Centrifugal , Direct Mounted
Rating 0.22 BHP
DOR CW from motor NDE
Current 0.81 A
Speed 2850 RPM
3.12 HP HEATERS
HP HEATERS SPECIFICATION 5A / 5B 6A / 6B
Type U-Tube / Horizontal U-Tube / Horizontal
Quantity Extraction steam (T/Hr.) 42.53 78.94
Pressure of Extraction steam (Ata) 16.826 41.34
Temp. of Extraction steam (oC) 444.46 331.5
Quantity of Feed Water (T/Hr.) 728.496 728.496
Pressure of Feed Water (Ata) 193.99 198.88
Feed Water Inlet Temp. (oC) 164.05 204.77
Feed Water Outlet Temp. (oC) 204.77 253.38
Surface area (M2) 1018 1200
Size of tubes OD X len mm2 15.875*8650 15.875*10200
Number of U- Tubes 1181 1181
Velocity of Feed Water (M/Sec.) 2.15 2.17
Number of tube side passes 2 2
Number of shell side zones 3 3
Design pressure on shell side (Atg) 24 & Full Vacuum 57 & Full vacuum
Design temp. on shell side (oC) 224 273
Design pressure on tube side (Atg) 330 & Full Vacuum 330 & Full Vacuum
Design temp. on tube side (oC) 224/244 273 / 293
60 | P a g e
Test pressure on shell side (Atg) 36 78.6
Test pressure on tube side (Atg) 460 460
Skirt design. temp. (oC) 455 371
Materials
Shell C.S.SA 516 GR 70 C.S.SA 516 GR 70
Tube plate & covers SA 350 LF 2 SA 350 LF 2
Flanges ( for SRV only) SA 105 SA 105
Support plate SA 516 GR 70 &IS 2062 SA 516 GR 70 &IS 2062
Tubes SA 688 TP 304 SA 688 TP 304
Impingement plate S.S. SA 240 TP 304 S.S. SA 240 TP 304
Weights
H.P. Heater dry (Kgs) 44500 54000
H.P. Heater in operation(Kgs) 49000 59300
H.P. Heater flooded(Kgs) 59080 70700
3.13 VACUUM RAISING SYSTEM
VACUUM PUMP
Make Edwards Ltd
Type Liquid ring pump
No. of PPs 2 X 100 %
No. of stage 02
Seal & Ring Fluid Water
Direction of rotation (from Clock wise
motor NDE)
Moment of Inertia 45 KgM2
Capacity 6961 m3/hr
Motor Make ABB
Type Three phase Induction motor
Power rating 132 KW
Voltage 415 V
Current Rating 267 Amp
Speed 590 RPM
SEPERATOR TANK
Vol. Of Tank 1.75 M3
RECIRCULATING PUMP
Type SHS 40-125/15 SP
Capacity 21 M3/Hr.
Delivery head 10 M
Motor Make AMTECS
Power 1.5KW
Voltage , current 415 V , 3.26A
3.14 CENTRAL OIL PURIFUCATION UNIT (COPU)

OIL TANKS
Clean oil Tank Dirty oil Tank Unloading Tank
61 | P a g e
No. Of Tanks (common for two units) 1 No. 1 No. 1 No.
Capacity Of Tanks 60 M3 60 M3 1 M3
OIL TRANSFER PUMPS

Clean Oil Transfer PP 1 no. for transferring oil from Clean oil tank
to any of unit oil Tank.
Dirty Oil Transfer PP 1 no. for transferring oil from Dirty oil tank
to Central oil Purifier.
Pump
Pump Make Tushaco Pumps Pvt. Ltd.
Speed 1440 RPM
Motor
Motor Make CGL
Power Rating 3.7 KW
Type Three phase SCIM
Speed 1440 RPM
Voltage 415 V
Current 7.6 Amps
3.15 HP BYPASS SYSTEM
OIL SUPPLY UNIT

Pump Manufacturer DENISON HYDRAULICS
Model 7-7B-B05-2R00 AIMO
Supply Capacity 24 Ltr /Min.
System Operating Pr. 110 bar
Speed 1440 RPM
Maxm. Oil Pressure 170 bar
Motor Make Kirloskar
Normal Power 7.5 KW
Voltage 415 V
Speed 1440 RPM
Oil Tank
Volume 70 Ltr
Useable Volume 50 Ltr
Hydraulic Accumulator
Pressure Rating (Max) 210 bar
Operating Gas Nitrogen only
Oil Requirement
Oil Brand Name Servo Conval 46 (IOC)
VALVE DATA FOR HP BYPASS SYSTEM

BD BPE1, BPE2 BP-1, BP2
No. Of Valve 1 2 2
Valve Type E45S E45S ARS140A
Design Pr. Kg/Cm2 321 321 189.5/55
Design Temp. OC 185 185 545 / 500
62 | P a g e
3.16 LP BYPASS SYSTEM
VALVES
ISOLATING VALVE CONTROL VALVE WATER
INJECTION
VALAVE
No per unit 2 2 2
Manufacturer CCI CCI CCI
Valve Model NA 60-700 NB 60-600 840 H
Design Pressure (Inlet) 50.5 kg/cm² 50.5 kg/cm² 40 barg
Design Pressure (Outlet) 50.5 kg/cm² 25.76 kg/cm² 40 barg
Design Temp (Inlet) 568 °C 568 °C 100 °C
Design Temp (Outlet) 568 °C 568 °C 100 °C
Actuator
Model GHZ125 GHZ100 GHZ 63
Type Hydraulic/Spring Hydraulic Electro Hydraulic
Fail Mode Valve Close Valvein place Valvein place
Power UnitPressure
Supply 16 MPa Max 16MPa Max 11.5 160 barg (Max)
Manufacturer CCI 11.5 MPaMin MPa Min 115 barg (Min)
TypeOpen Time (s) HV350AHF-P spez
<2 sec <2 sec < 3 sec
System Pressure
Close Time (s)P1 160 bar <1 sec <1 sec < 3 sec
System Pressure P3 160 bar HPSU UNIT
Pressure Relief Valve P1 170 bar
Pressure Relief Valve P3 170 bar
Accumulator Charging ON 216 bar
Accumulator Charging OFF 240 bar
Standby Pump ON 201 bar
Standby Pump OFF 216 bar
Pressure Too Low 150 bar
Pressure Too High 250 bar
Level Low 200 mm
Level Too Low 170 mm
Fan ON 50 °C
Fan OFF 45°C
Heater ON 30 °C
Heater OFF 35°C
Temperature Too High 60°C
Hydraulic Fluid /ISO VG Fyrquel EHC-N
Tank Capacity 560 lit
Usable Capacity 350 lit
Control Fluid Pump
Pump Discharge 17.4 lit/min
Power 7.5 kW
Speed 1450 rpm
Fan
Power 0.18 kW
Speed 1350 rpm
Filter
Power 0.37 kW
Speed 1390 rpm
Regeneration Pump
Discharge 0.35 lit/min
Power 0.08 KW
Accumulator
No of Accumulator 2
Manufacturer Olaer 63 | P a g e
Type IHV50/330
Nominal Capacity 50 lit
Gas Filling pr at room temp 12 MPa
Admissible Operating Pressure 33 MPa
LP DOZING SYSTEM
Make Marsh automation pvt ltd
3.17 LP DOZING PUMPS

No. of Pumps 2 Nos. Ammonia dozing Pps.
2 Nos. N2H4 (Hydrazine) dozing Pps.
Type Plunger, Simplex , positive Displacement
continuous
Make Metachem Corporation, Bombay
Model MC – 2RL
Capacity 0-53 LPH
Disch. Pressure 45 Kg/cm2
MOTOR SPECIFICATION
Make Crompton Greaves Ltd.
Power rating (KW) 0.75
Current 1.81 Amp.
Voltage 415 V
Connection Star
Insulation Class – F
Type 3 ph . SCIM
Speed 1410 RPM
DOR CW from motor NDE ( for pump A )
ACW from motor NDE ( for pump B )
AGITATORS FOR NH3& N2H4 DOZING TANKS

No. Of Agitators 1 no. for each tank
Make CGL
Type 3 ph, sq TEFC Induction Motor
Voltage 415 V +/- 10 %
64 | P a g e
Current 4.1 Amps.
Speed 930 rpm
Power Rating 1.5 KW
NH3 TRANSFER PUMP

No. of Pump 2
Make Sulzer
Flow rating 2.4 M3/Hr.
Speed 2830 RPM
NPSH 2.3 m
Seal Type Mechanical Seal
Bearing/ Lubrication A.F/ Oil
Motor make CGL
Voltage 415 V
Power Rating 1.5 KW
3.18 EQUIPMENT COOLING WATER SYSTEM
SG- ECW PUMP

PUMP
Make WPIL Ltd
Quantity 2
Discharge 575 m3/hr
Size 8LN18C
Head 65m
MOTOR
Make MARATHON ELECTRIC
Quantity 2 (1W+ 1S)
Type 3-phase Squirrel Cage Δ connected
Stator IM
Rating 180 KW
Voltage 415V
Current 310 A
Speed 1485 RPM
TG- ECW PUMP

PUMP:
Make WPIL Ltd
Quantity 3
Discharge 1250 m3/hr
Size 12LN14A
Head 38m
MOTOR:
Make BHEL
Quantity 3 (2 W+1S)
65 | P a g e
Type 3-ɸ Squirrel Cage Δ connected
Stator IM
Rating 180 KW
Voltage 3.3KV
Current 40 A
Speed 1481 RPM
PHE-SG
Make : IMDC LTD

Quantity 2
Total Surface Area 455.648 m2 clean/fouled
PHE type PHE of water cooler S188
Hot fluid side Cold fluid side
Flow Rate (m3/hr) 510 750

Pressure Drop 7MWC 7MWC
Inlet temp 43.8 deg C 36 deg C
Outlet temp 38 deg C 39.94 deg C
Design pressure 12 Ksc 12 Ksc
Hydrotest Pressure 18 Ksc 18 Ksc
TG PHE
No 3
Manufacturer IDMC Ltd
Total Surface Area 915.224 m2 clean/fouled
PHE Type PHE of water cooler S188
Hot fluid side Cold fluid side
Flow Rate (m3/hr) 1100 1100
Pressure Drop 7MWC 7MWC
Inlet temp 43.4 deg C 36 deg C
Outlet temp 38 deg C 41.4 deg C
Design pressure 10 Ksc 10 Ksc
Hydrotest Pressure 15 Ksc 15 Ksc
ACW SYSTEM
ACW PUMPS & MOTOR

No of pumps 3 ( 2W + 1S )
Make WPIL Ltd
Model no. 14 LN 19 A
Total dynamic head at rated 17 Meters
capacity
Discharge 1700 m3/hr
Speed 987 RPM
Motor
Make Marathon Electric
Type 3-ɸ Squirrel Cage Δ connected
Stator IM
Volts 415
Rating 125 KW
Speed 987 RPM
66 | P a g e
Current 215.6 Amp
SELF CLEANING STRAINER

Number 2 (1W + 1S)
Make GEA BGR INDIA
Normal/max flow rate 3400 / 4080 m³/Hr
Operating pressure 3 to 4.5 bar
Design/ Test pressure 7 / 10.5 Ksc
Design differential pressure for filter 1.5 bar (min.)
section/screen
Design temperature 60 0C
Fluid handled Clarified Water
4 GENERATOR
4.1GENERAL
Make BHEL
Type THDF 115/59
Duty S1
Insulation class F
Cooling of stator winding Directly water cooled
Cooling of stator core & rotor Directly hydrogen cooled
4.2 RATED DATA

Apparent Power 588 MVA
Active power 500 MW
Current 16166 Amps.
Voltage 21 KV  1.05 KV
Speed 3000 rpm
Frequency 50 Hz
Power Factor 0.85 (lag)
H2 pressure 3.5 bar (g)
Cont. perm. unbalance load 8%
Rated Field current for rated output 4040 A
Rated Field Voltage 340 V
Inner connection of stator wdg YY
Stator winding resistance at 25oC U-X = 0.0014747 ohms
V-Y = 0.0014747 ohms
67 | P a g e
W-Z = 0.0014747 ohms
Rotor winding resistance at 25 C
o
F1–F2 = 0.067873 ohms
4.3 EXITATION SYSTEM
A)Main Exciter
Type ELR 70/90-30/6-20
Active Power 3780 KW
Current 6300 Amp.
Voltage 600 V
Speed 3000 rpm
Stator winding resistance at 25oC F1-F2 = 0.6036 ohms
Rotor winding resistance at 20oC U-V = 0.000469 ohms
U-W =0.000469 ohms
V-W = 0.000469 ohms
B)Rectifier Wheel
No. of wheels 2 (one positive and one
negative)
No. of Fuses per rectifier wheel 30
Fuse resistance/Voltage/current Approx. 150 Micro
ohms/800V/800A
No. of diodes per rectifier wheel 60
No. Of RC networks per rectifier 6 Nos.
wheel
No. Of fuses blown per bridge arm 1) 2 fuses- Switch off field
& rectifier wheel forcing
2) 3 fuses- Shutdown
turbine-generator,
replace fuses and diodes
C) Pilot Exciter
Apparent Power 65 KVA
Current 195 A
Voltage 220 V  22 V
Speed 3000 rpm
Frequency 400 Hz
Stator winding resistance at 25oC U-O = 0.002579 ohms
V-O = 0.002579 ohms
W-O = 0.002579 ohms
D) Exciter Air Dryer

Make M/S BRYAIR
Type BA-1.5 A
Rating 4.6 KW
Voltage 230 V
Frequency 50 Hz
Adsorption air Flow rate 120 m3/h
68 | P a g e
Regeneration air Flow rate 35 m3/h
No. of dryer 1 No.
4.4 TORQUE / CRITICAL SPEEDS

Max. short circuit torque of 14585 KNm
stator at line to line single
phase short circuit.
Moment of inertia of generator 10000 kgm2

shaft
Critical speed (calculated) h1 864 RPM
Generator + Exciter coupled h2 2388 RPM
h3 4680 RPM
4.5 Generator volume and Filling quantities
Generator volume (gas volume) 80 m3
CO2 Filling quantity 160 m3 (S.T.P.)*
H2 Filling quantity (To 3.5 bar) 480 m3 (S.T.P.)*
 S.T.P. =Standard temp. and Pressure, 0oC and 1.013 bar to DIN 1343
4.6 Voltage Regulating System

Type AVR Thyristor controlled
(Digital)
Max. output voltage 270V with unloaded
Thyristors
Output current of Field Forcing 158 A
Output current for rated generator 86 A
load
Accuracy of control Better than  0.5%
Setting range of voltage set point +10% to -10% nominal
Potentiometer generator voltage
Aux. voltage from pilot exciter for 3 220V, 400 Hz
thyristor sets
D.C. voltage from station battery for 220V
control
Rated secondary voltage of PT 110V
Power input of voltage transformer 20 VA
per phase
Rated secondary current CT 5A
4.7 GENERATOR PROTECTION RELAYS

CT RATIOS FOR ALL PROTECTIONS: 20000A/5A
PT RATIOS FOR ALL PROTECTIONS: 21KV/110V
69 | P a g e
Nomenclature GRP 1A GRP 1B
SIPROTEC
REG 670 7UM62
Make ABB Siemens
Differential ptn(87G1,87G2)
95% Stator Earth flt trip(64G2) X
100% stator Earth ft trip(64G1) X
Negative seq. protn(46G1,G2)
Dead m/c trip(50GDM1,2)
Inter turn fault trip(95G2)
Rotor earth fault trip(64F) X
Over voltage trip(59G1,G2)
Under freq. trip(81G3,G4)
Over frequency (81G1,G2)
20 Hz relay faulty X
Loss of excitation(40G1,G2)
Back up impedance(21G1,G2)
Low forward power(37G1,G2)
Reverse power(32G1,G2)
Pole slip(98G1,G2)
AVR trouble X
Under Volt. Protn(27G1,G2) X
ST/CB logic X
PT-1 fuse fail(97-1,97-3,97-2) X
RET 670 RET 670
87T1 87T2
GT Differential trip
GT-A HV/LV WTI trip X
GT-A PRD –A trip X
GT-B HV/LV WTI trip X
GT-B PRD trip X
GT-C HV/LV WTI trip X
GT-C PRD trip X
GT-A OTI alarm X
GT-A buchholz alarm X
GT-B OTI alarm X
GT-B buchholz alarm X
GT-C OTI alarm X
GT-C buchholz alarm X
GT tap change opd X
Overhang diff.on HV (87OH) X
Stand by earth fault(51NGT) X
Over excitation(99T) X
COL trouble trip X
GT-A OTI trip X
GT-B OTI trip X
GT-C OTI trip X
GT-A LOL/WTI alarm X
GT-B LOL/WTI alarm X
GT-C LOL/WTI alarm X
GRP 1C
FIRE PROTECTION
RET 670 87GT
OVERALL Diff.(87GT)
GT-A PRD-B TRIP
GT-A BUCHHOLZ TRIP
70 | P a g e
GT-A FIRE PROTN TRIP
GT-B PRD-B TRIP
GT-B BUCHHOLZ TRIP
GT-B FIRE PROTN TRIP
4.8 SEAL OIL SYSTEM
A) SEAL OIL PUMP AIR SIDE
No. 2 X 100 %
Make Tushako
Type Screw Pump
Model T3S-52/54
Capacity 258LPM
Discharge pressure 12 kg/cm2
Pump Motor – Type CGL, ND132M
Rating 7.5 KW
Voltage / frequency 415V, 3 Ph. AC 50 Hz
Current 13.79 A
Speed 1455 RPM
DOR Clockwise (Motor NDE)
B)SEAL OIL PUMP AIR SIDE (DC)
No. 1 X 100%
Make Tushako
Type Screw Pump
Model T3S-52/54
Capacity 258 LPM
71 | P a g e
Motor – Type CGL- AFS 225L
Rating 8.5 KW
Armature Voltage 150 V DC
Armature Current 67 A
Field Voltage 150 V DC
Field Current 1.4 A
Speed 1450 RPM
DOR Clockwise from Motor NDE
C)SEAL OIL PUMP H2 SIDE
No. 1 X 100%
Make Tushako
Type Screw Pump
Model T3S-52/46
Capacity 130 LPM
Motor – Type CGL -ND132M
Rating 4.0 KW
Voltage / frequency 415V,3 Ph. AC 50Hz
Current 8.38 A
Speed 950 RPM
DOR Clockwise from Motor NDE.
D)SEAL OIL FILTER UNIT, AIR SIDE AND H2 SIDE
72 | P a g e
No. for air side 2 X 100%
No. for H2 side 2 X 100%
Type Strainer type filter
Make M/S Boll & Kirch
Volumetric flow rate 12 m3/hr.
Degree of filtration 100 microns
Pressure drop across 0.3 bar with clean filter*

filter
* 1.2 bar with 100% blockage.
E)SEAL OIL COOLER

Design Data Air side H2 side
No. of coolers 2x100 % 2x100%
Oil flow (m3/hr.) 15 7.8
Heat dissipating capacity 140 90
(KW)
Oil inlet temp. 70oC 70oC
Oil outlet temp. 50oC 50oC
Oil pr. drop (bar) 0.833 0.85
Cooling water flow (m3/hr.) 35 22
C.W. inlet temp. (oC) 38 38
C.W. outlet temp. (oC) 41.4 41.5
C. Water pr. drop (mwc) 6.8 7.1
C.W. side design pr. (kg/cm2) 16 16
C.W. side test pr. (kg/cm2) 24 24
Oil side design pr. (kg/cm2) 16 16
Oil side test pr. (kg/cm2) 24 24
Material of tubes Admiralty Brass Admiralty Brass
Tube sheet material C-Steel C-Steel
Water channels material C-Steel C-Steel
4.9 PRIMARY WATER SYSTEM

A) PRIMARY WATER PUMPS
No. 2 X 100%
Type Centrifugal pump
Make Sulzer Pumps
Model CZ 65-250
Capacity 70 m3/hr.
Discharge head 80 M
Motor : Make- Type (A)CGL- ND220 L (B) Marathon
Electric Ltd
Rating 37 KW 37 KW
Voltage 415V three phase 415V three
AC phase AC
Frequency 50 Hz 50 Hz
Speed 2960 RPM 2950 RPM
Rated Current 64 A 65 A
DOR CW from Motor CW from Motor
NDE NDE
73 | P a g e
B) MAIN FILTER
No 2 X 100%
Kind of filter Strainer type filter with magnet bars
Make M/s Boll & Kirch
Model 1.53.1
Volumetric flow rate 25 dm3/s max.
Degree of filtration 150 µm
Pressure drop across 0.1 bar with clean filter
1.2 bar with 100% fouling
filter
C) FINE FILTER
No 1 X 100%
Make M/s Boll & Kirch
Kind of filter 1 plug, 1 cartridge
Model 1.55.1
Volumetric flow rate 0.42 dm3/s max.
Pressure drop across 0.15 bar with clean filter
1.2 bar with 100% fouling
filter
D) ION EXCHANGER
No 1X 100%
Make Birchoff
Volume 83 litres
Resin Lewatit
Resin Volume 56 litres (45 kg)
E) PRIMARY WATER COOLER
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No. of cooler 2x100%
Primary water flow 65 m3/hr
Heat dissipating capacity 1715 KW
P.W. inlet temp. 71.7oC
P.W. outlet temp. 49oC
P.W. pressure drop 1160 mbar
Cooling water flow 250 m3/hr.
Maxm.C.W. inlet temp. 38oC
C.W. outlet temp. 43.9oC
C.W. pressure drop 2 mwc
C.W. design / Test pr. 10/15 kg/cm2
P.W. design / Test pr. 10/15 kg/cm2
Material of Shell, Tubes, Tube SS
sheets
Material of water channel C-Steel
4.10 GAS SYSTEM
A) CO2 FLASH EVAPORATOR/VAPOURISER
No. 1 X 100 %
Rating 18 KW
Voltage 415V, 3 Ph. AC 50Hz
Heat transfer liquid HYTHERM 500 (M/s HPCL)
Volume of heat transfer 25 dm3

liquid
Hole in orifice 2.8 mm
Relief valve on high 175 bar

pressure side
Relief valve on low pr. 8 bar
side
B) H2 GAS COOLER
75 | P a g e
No. of cooler 4 x 25%
H2 gas pr. (bar) 3.5
Gas flow (m /s) 33

3
Heat dissipating capacity (KW) 4640
Cold gas temp. (oC) 45
Hot gas temp. (Max) (oC) 72
Gas pr. drop (Approx.) (Pa) 700
Cooling water flow (Total for 4 m /hr. 540

3
sections)
Cooling water inlet temp. (oC) 38oC
Cooling water outlet temp. (oC) 45.4oC
Water pr. drop (mwc) 3
Materials
Fins Copper
Tubes 90 / 10 Cu-Ni
Tube sheets C-Steel
Water channel C-steel
Design/Test pressure (Tube side) 10/15 kg/cm2

C) H2 GAS DRIER
No. of Dryers 2x100%
Supplier M/s. Jindal Industries Pvt. Ltd.
Capacity 40 NM3/hr.
Operating Pr. 3.5 kg/cm2
Design Pr. 6 kg/cm2
Operating temp. 60oC
Design temp. 80oC
Outlet Gas dew point +3oC to +5oC
Type Refrigerated type
Refrigerant Freon 22
5 TRANSFORMERS
76 | P a g e
5.1 GENERATOR TRANSFORMER
Manufacturer ABB Limited, Vadodara
Nos. of Units 3 nos. per Unit
Rating HV & LV (MVA) 200 MVA each phase
No Load Voltage, HV 420 / 3 KV
No Load Voltage, LV 21 KV
Winding Connection Star-Delta
Rated Current, HV 824.79 Amps.
Rated Current, LV 9523.81 Amps. (each phase)
No. of Phases 3 X1 phase
Frequency 50 Hz
Type of cooling OFAF
Vector group YNd11
Impedance at principal TAP 13.5% + 5%.
OFF Load TAP changer Tapping in steps of 2.5% each
Variation of High Voltage provided on HV winding to give + 5% to - 5%
Temp. Rise in top oil over an ambient of 50 35 oC

deg c.
Temp. Rise in winding over an ambient of 40 oC
50 deg c.
Grounding HV – Solid
No of Coolers 5 (Main)+ 1(Standby)
No of Cooling Fans 2 Fans per Cooler
No of Oil Pump 1 Pump per Cooler
5.2 STATION TRANSFORMER

Nos per Unit 01
Capacity 80/40/40 MVA
Voltage Ratio 132/11.5/11.5 KV
Winding Connection Star-Star
Vector group YNyn0yn0
Line current HV 349.92Amps.
Line current LV1,2 2008.23 Amps.
Temp. rise :-
Oil 50oC
Winding 55oC
Cooling arrangement ONAN/ONAF
Type of Neutral Grounding HV-solid, LV – NGR:22.13Ω
5.3 UNIT TRANSFORMER

Total nos. 1 no. per unit.
Rating 45 MVA
Winding-Connection Delta-Star
Vector Group Dyn1
Number Phases 3
Voltage Ratio 21/11.5 KV
77 | P a g e
HV Current 1374.64 Amps.
LV Current 2510.22 Amps.
Vector group Dyn1
Cooling Type ONAN/ONAF
Type of Neutral Grounding LV - NGR – 22.13Ω
Impedance at Principal Tap(75 C) 11.5 %
Temp. Rise in top oil over an ambient of 50
50 deg c.
Temp. Rise in winding over an ambient of 55
50 deg c.
No of Coolers and its rating as % of 2 X 50% cooling, 6 radiators per bank
transformer cooling equipment
No of Fans per cooler 2 Fans per bank
5.4 UNIT AUXILIARY TRANSFORMER
Manufacturer AREVA T&D INDIA Ltd

Total nos. 2 nos. per unit.
Capacity 16MVA
Winding Connection Delta/Star
Vector group Dyn1
Impedance between HV& LV at Principal 12.5%
tap at 75 deg c.
HV Current 839.8Amps.
Cooling Type ONAN
Type of Neutral Grounding LV – NGR:6.3 Ω
50 deg c.
50 deg c.
Number of coolers and rating 8 Radiators, 100%
as % of transformer cooling
equipment
5.5 UNIT SERVICE TRANSFORMERS
Manufacturer VOLTAMP T/F LTD VADODARA

Capacity 2000 KVA
Winding Connection Delta-Star
Vector group Dyn1
Cooling Type AN – Dry Type
Grounding LV-Solid
5.6 STATION SERVICE TRANSFORMERS
Manufacturer VOLTAMP T/F LTD VADODARA
78 | P a g e
Capacity 2000 KVA
Voltage Ratio 11KV/0.433 V
Vector group Dyn1
Cooling Type AN – Dry Type
Grounding LV – Solid
5.7 OFFSITE TRANSFORMERS

A) ASH SLURRY/ASH WATER/TAC TRANSFORMER,
B) Admin bldg,CHP serv,CHP WT ,CT
Manufacturer AREVA T&D INDIA LTD.

Quantity 1 no. per unit each
Capacity 2.0 MVA
Voltage Ratio 11KV/433 V
Vector group Dyn1
Cooling Type ONAN
Type of Neutral Grounding LV – Solid
Impedance at Principal Tap(75 deg C) 10%
Temp. Rise in top oil over an ambient of 50 50
deg c.
50 deg c.
B) ESP TRANSFORMERS

Total nos. 4+1 nos. per unit.
Capacity 1600 KVA
Voltage Ratio 11 KV/433 V
Vector group Dyn1
Cooling Type ONAN
Impedance at Principal Tap(75 C) 8%
deg c.
50 deg c.
C) DM/PT, Service water/CW Service, Fire water-Transformer
79 | P a g e
Total nos. 1 no. per unit each
Capacity 1600 KVA
Voltage Ratio 11 KV/433 V
Vector group Dyn1
Cooling Type ONAN
deg c.
50 deg c.
D) RAW WATER ST-1, ASH Extraction, Bunker Service, Fuel Oil, Ash Silo Transformer
Make AREVA T&D INDIA LTD.

Quantity 1 no. per unit each
Capacity 1000 KVA
Voltage Ratio 11KV/433 V
Vector group Dyn1
Cooling Type ONAN
50 deg c.
50 deg c.
E) SWITCHYARD SERV TRANSFORMER, MWPH LT, AUX BLR, WORKSHOP/O&M STORE,

AWRS, LOCO SHED

Total nos. 1 no. per unit each
Capacity 630 KVA
Voltage Ratio 11KV/433V
LV Current 840 Amps.
Vector group Dyn1
Cooling Type ONAN
Type of Neutral Grounding LV –solid
50 deg c.
50 deg c.
F) ASH HANDLING TRANSFORMER
80 | P a g e
Make AREVA T&D INDIA LTD.
Quantity 1 per unit
Capacity 7.5 MVA
Voltage Ratio 11KV/3.45KV
HV Current 393.65Amps.
Vector group Dyn1
Cooling Type ONAN
Type of Neutral Grounding LV – NGR
50 deg c.
50 deg c.
G) MISCELLANEOUS SERVICE TRANSFORMER
Make ABB LTD, VADODARA

Quantity 2 nos.
Capacity 16 MVA
Voltage Ratio 132KV/11.5KV
LV Current 803.29Amps.
Winding Connection Star-Star
Vector group YNyn0
Cooling Type ONAN
50 deg c.
50 deg c.
5.8 INTERCONNECTING TRANSFORMER (ICT)
Make ABB LTD, VADODARA

Quantity 2 nos
Capacity 200MVA/200MVA/67MVA(reactive)/5MVA(active)
Voltage Ratio 400/132/33 KV
Vector group YNa0d11
Cooling Type ONAN (40%)/ONAF(60%)/OFAF(100%)
Winding Connection HV & MV- Auto Star, LV- Delta
Type of Neutral Grounding Solid
Impedance at Principal Tap(75 C) 12.5% (+/- 7.5%)
50 deg c.
81 | P a g e
Temp. Rise in winding over an ambient 40
of 50 deg c.
TAC VFD TRANSFORMER
Make Kirloskar Electric Company.

Quantity 6 no for TAC and 3 no for HCSD
Capacity 750 KVA
Voltage Ratio 3.3KV/720V/720V
HV Current 131.2 Amps
LV1 Current (delta) 300.7 Amps
LV2 Current (star) 300.7 Amps
Vector group Dd0yn11
Cooling Type ONAN
Type of Neutral Grounding LV2 – Solid
50 deg c.
50 deg c.
6 MAIN PLANT DG SET

No of DG sets 2 +1 (stand by)
6.1 ENGINE Make Cummins
Type KTA 50G3
No of cylinders 16 cylinder 60º VEE
Aspiration Turbocharged After cooled
Bore stroke 169mm X 159mm
Displacement 50.3 litrs.
Output prime 1470 bhp (1047KWm)
Fuel consumption with @100% load 258 litr/hr
Guaranteed Fuel Consumption rate 146 gms/bhp/hr at 100% load
The fuel consump. Is +5% tolerance with CV of fuel 10200
kcal/kg and spec. gravity 0.85
Oil consumption with 100% load 0.3 lit/hr
Compression ratio 13.9 : 1
Lubricating oil system capacity 177 litr
Coolant capacity(engine + radidator) 440 litr
Specification of Fuel Oil HSD as per IS1460
Fuel oil tank capacity 990 litr
Specification of Lube oil Grade CF-4, 15W40 Valvoline Cummins
Combustion air intake @100% load 81.6 m3/min.
Fan air flow across radiator 27357 litr/sec
Exhaust temp. 629 ºC
Method of cooling of engine and lub. Oil Radiator cooled and water cooled
Battery capacity/rating 180 AH,4X12V
6.2 Alternator
Make Stamford
Rated KVA at 40 ºC temp. 1550 KVA
82 | P a g e
Derated KVA at 50 ºC temp. 1250 KVA
Rated KW at 40 ºC temp. 1240 KW
Derated KW at 50 ºC temp. 1000 KW
Speed 1500 RPM
Voltage & Frequency 415 V & 50 Hz
Current 1739 A
PF 0.8
Excitation Brushless type(separately excited by PMG),10.3KVA
Overload capacity 110% for 1hr for every 12hrs
7 SWITCHYARD OVERVIEW
7.1 BUS BAR
System 2 Bus , 1½ Breaker

Tubular bus conductor,4 inch IPS tube
Manufacture Hindalco Industries Ltd
Bus Conductor Rating 3000 Amps
Withstand capacity for 1sec. 50KA
7.2 FEEDERS
Type ACSR MOOSE CONDUCTOR

Manufacturer GALAXY TRANSMISSIONS PVT LTD,SANGLI
No Of Feeders 4
Max current rating of conductor at 70ºC at an 980 Amps
ambient of 40ºC
400 KV Two lines to Khaperkheda and Two lines to Wardha
7.3 400 KV CIRCUIT BREAKERS

Make ABB Ltd. & India
Type SF6, outdoor, Single Pressure Type
Rated Voltage (KV) 420
Rated Current under normal condition 4000A
Rated Current under site condition 3150A
Rated Frequency (HZ) 50
Number of Poles 3
Whether 3 poles or single pole unit Single Pole Unit
Whether dead tank or live tank design Live Tank
Short Time Thermal Current With Stand For 1 50
Sec (KA)
No.Of Breaks Per Pole 2
Closing Time (mSec) 150 max
Opening Time (mSec) 25 max
Rated Duty Cycle O - 0.3 sec- CO – 3 Min – CO
Max. period between Closing of first contact 5 ms
and last contact in a pole (mSec)
Maximum pole Discrepancy (mSec) 2.5 ms within pole and 3.3 between poles
Type Of Operating Mechanism for
i) Opening i) Spring
ii) Closing ii) Spring
83 | P a g e
Normal Power Consumption at rated voltage
of i) 200W
i) Trip coil per pole ii) 200W
ii) Closing coil per pole
Time required for motor to charge the closing 30 sec
spring(min)
No. of close-open operations possible 1 OCO
after loss of AC supply to drive motor
Motor Data
Type Universal Series Motor
Rating (KW) 1.1
Rated Voltage (V) 220V-220V AC/DC
Full load Current (A) 10
Arc Quenching Medium SF6
Rated pressure and limits of pressure of 6.5 - 7.5
extinguishing medium
Quantity of SF6 per breaker (KGS) 57.5
SF6 low Alarm set at 6.7 bar
SF6 lock out set at 6.0 bar
Minimum Dead Time 300
for auto- re-close (mSec)
Whether Arcing contacts provided YES
Main Contacts
Type Double flow fixed nozzles
Material Copper (Silver Plated)
Rate Of Contact Travel
OPENING (M/Sec) 6-8
CLOSING (M/Sec) 3-4
Grading Capacitor (pF) 500
Tripping And Closing Coils
No.Of Trip Coils 2
No.Of Closing Coils 1
Power Consumption of Trip Coil (W) 600
Power Consumption of Close Coil (W) 300
400 KV ISOLATORS
Make GR POWER SWITCHGEAR Ltd, HYDERABAD
Rated Voltage (KV) 420
Rated Normal Current (A) 2000/3150
Rated Frequency (HZ) 50
No of poles 3
Pole to pole spacing 700 mm
Short Time Thermal Current With Stand For 1 50 KA rms
Sec (KA)
Short Time Thermal Current With Stand For 3 40 KA rms
Sec (KA)
Short Time Thermal Current With Stand 125 KA
dynamic current (peak)
Opening Time (SEC) <10 sec
Closing Time (SEC) <10 sec
Operating Mechanism
Operating Torque required for 3-pole Gang 45
operation (Kgm)
84 | P a g e
Type of motor SQUIRREL CAGEIND. MOTOR,746 watts
Rating of Motor 415V, 3-phase , 1.0 HP
Full load current (Amp) 1.92
Control Voltage 220 V D.C
Main Contacts Hard drawn electrolytic Copper flat
7.4 400 KV CURRENT TRANSFORMER (CTs)

Make M/S Crompton Greaves Ltd ,India
Rated Voltage (KV) 420 rms line to line
Rated Continuous Normal Current (A) 2000 A
Rated Frequency (Hz) 50
Short Time Thermal Current With Stand For 1 50 KA
Sec
Dynamic current withstand 125 KA peak
No.Of Cores Per CT 5
Quantity Of Oil Per CT (Kgs) 520
Total Weight (Kgs) 1600(+/- 10%)
Whether Hermetically Sealed Yes
CORE CORE-1 CORE-2 CORE-3 CORE-4 CORE-5

Ratio 2000- 2000-1000/1 2000-1000- 2000-1000- 2000-1000-500/1
500/1
1000/1 500/1
Accuracy PS PS 0.2 PS PS
400 KV CAPACITIVE VOLTAGE TRANSFORMER (PTs)

Make ABB LTD,INDIA
Rated Voltage (KV)
400/
No.Of Secondary 3
CORE CORE-1 CORE-2 CORE-3
Rated Output(VA) 75 75 75
Accuracy Class 3P 3P 0.2
Capacitance
Of High Voltage Capacitor(PF) 4362
Of Intermediate Voltage Capacitor (PF) 88000
For Carrier Frequency Coupling (PF) 4400
Quantity Of Oil (Litres) 105
Total Weight (KGS) 950
Whether Hermetically Sealed YES
7.4 C)400 KV CAPACITIVE VOLTAGE TRANSFORMER (PTs)

Make ABB LTD,INDIA
Rated Voltage (KV)
400/
No.Of Secondary 3
85 | P a g e
CORE CORE-1 CORE-2 CORE-3
Rated Output(VA) 75 75 75
Accuracy Class 3P 3P 0.2
Capacitance
Of High Voltage Capacitor(pF) 9263
Of Intermediate Voltage Capacitor (pF) 176000
For Carrier Frequency Coupling (pF) 8800
Quantity Of Oil (Litres) 105
Total Weight (KGS) 950
Whether Hermetically Sealed YES
SURGE ARRESTOR
Type ZO diver
Rated Voltage (KV) RMS 390
Maximum continuous operating voltage (COV) 303
(KV) Rms
Nominal Discharge Current (KA) 10
Pressure Relief Current(KA)RMS 40
Frequency (Hz) 50
Surge Monitor Type CRM
Maximum internal leakage current 3mA
7.5 A) 220 V BATTERY

Make AMCO SAFT INDIA LTD
Type Ni-Cd
Capacity (AH) 265
No.Of Cells 169
No of banks 2 (169 cells in each)
Nominal Cell Voltage 1.40 - 1.42
Specific Gravity At 27 0C 1.20
7.5 B) 220 V BATTERY CHARGER

MAKE AMARA RAJA POWER SYSTEM LTD
AC Input (Volts) 3-Ø,4 wire,415 +/- 10%,50Hz +/- 5%
DC Out Put(Volts) 220V,100A
Float Voltage 220-250 V DC
Boost Voltage 220-300 V DC
Output Voltage & Current Control Automatic / Manual
Regulation Better than +/- 1% of output
Ripple Less than 1% of RMS
7.6 BATTERY FOR PLCC
Type Ni-Cd ,37 KPH 160P

Make AMCO SAFT Limited, India
Capacity (AH) at 5 hour discharge rate. 160
Voltage 48 V
No. of Cells 37
No of banks 2 (38 cells in each)
86 | P a g e
Nominal Cell Voltage 1.4 -1.42
Specific Gravity At 27 0C 1.20 - 1.22
8 HT & LT BREAKERS
8.1 11 KV CIRCUIT BREAKERS (VACUUM TYPE)

Make M/S MEGAWIN SWITCHGEAR PVT LTD INDIA
Type VACUUM TYPE

Rated Voltage (KV) AND Freq. 11 KV, 50HZ
Rated Continuous Normal Current (A) 2750 A (incoming bkrs)/ 1250 A(outgoing bkrs)
Making current 100 KA

One sec. current carrying capacity 40 KA
Power frequency withstand voltage for one 28 KV
min.(KV)
Impulse withstand voltage for 1.2/50 micro 75 KV(peak)
sec. Full Wave (KV peak)
Duty cycle for breaking capacity O-0.3sec-CO-3min-CO

Circuit breaker closing time Not more than 5 Cycles (less than 70 ms @ 100% voltage)
Circuit breaker breaking time Not more than 4 Cycles (less than 60ms @ 100% voltage)
Rated Closing Time 75 +/- 5 m Sec
Rated Operating sequence O - 0.3 SEC- CO – 3 Min – CO
Rated Impulse withstand Voltage 75 KV Peak
Rated 1 Min Power Freq Withstand Volt 28 / 35 KV rms
Type of spring charging Motorized
8.2 3.3 KV CIRCUIT BREAKERS (VACUUM TYPE)

Make M/S MEGAWIN SWITCHGEAR P LTD INDIA
Type VACUUM TYPE
Rated Voltage (KV) AND Freq. 3.3 KV, 50HZ
Rated Continuous Normal Current (A) 2750 A (incoming bkrs)/ 1250 A(outgoing bkrs)
Making current 100 KA
One sec. current carrying capacity 40 KA
Power frequency withstand voltage for one 10 KV
min.(KV)
Impulse withstand voltage for 1.2/50 micro 40KV(peak)
sec. Full Wave (KV peak)
Duty cycle for breaking capacity (O-0.3sec-CO-3min-CO)
Circuit breaker closing time Not more than 5 Cycles (less than 70 ms @ 100% voltage)
Circuit breaker breaking time Not more than 4 Cycles (less than 60ms @ 100% voltage)
Type of spring charging Motorized
8.3 BATTERIES
A)MAIN PLANT 220 V
Type Lead Acid, Plante
Make EXIDE INDUSTRIES LTD
Capacity (AH) 1605 AH
87 | P a g e
No.of Cells 107
No of banks 2 (107 cells in each) per Unit
Nominal Cell Voltage 2.25
Specific Gravity At 27 0C 1.20 +/- 0.005
Maximum electrolyte temperature that cell 50ºC
can withstand continuously without injurious
effects, if applicable
B)MAIN PLANT 220 V CHARGER
No 2 Nos
MAKE CALDYNE AUTOMATICS LTD
TYPE SOLID STATE,FULL WAVE,FULL CONTROLLED
FLOAT CUM BOOST
AC Input (Volts) 3-Ø,3 wire, 415 +/- 10%, 50Hz +3%/- 5%
DC Out Put(Amp) 400 A(max.)
Float Voltage(in auto mode) 240.75 V DC(2.25V/cell)
Boost Voltage(in auto mode) 294.25V DC(2.75V/cell(max))
Boost mode set point 225A up to 2.75v/cell in auto mode
Output Voltage & Current Control Automatic / Manual
Control Configuration 3Ø full wave full controlled thyristorised bridge fed through
3Ø transformer
Float Voltage(in manual mode) 0-241V DC
Output Regulation within +/- 1% for 10% of supply voltage fluctuation
Output Ripple Less than 1% peak to peak at full load of 240.75V dc
9. CIRCULATING WATER SYSTEM

PUMP
Manufacturer HYOSUNG Ebara Co. Ltd/FLOWMORE Ltd
Model No VMF 1650 1480/7520-2370 H
Type of discharge Above floor
Number of pumps (2 from HYOSUNG & 3 from FLOWMORE)
MOTOR
Manufacturer Hyosung Corp. Changwon,
Korea
Nos 5
Type 3Ø SCIM
Rated output 2510KW (Continuous Duty)
Type of mounting Vertical
Class & type of insulation F , VPI ( resin poor) with MICA
Temperature rise at rated 70°C
out put
Degree of protection IP-23
Rated voltage 11000 V
Minimum permissible Starting voltage % 80% of the rated voltage
No load current 76 Amp
Starting current 994 Amps at 100% voltage
Rated current 180.6Amp
Rated speed 371 RPM
Efficiency of the motor 96.0 %
Direction of rotation from the top CCW
88 | P a g e
Bearings
Type (DE/NDE) Antifriction/Tilting pad
Recommended lubricant Alvania RL3
Guaranteed running life 200000 Hrs.
Minimum time required to give a start in case 15 Min
of tripping
PERFORMANCE DATA
Guaranteed design capacity 30000 M³/Hr
Total Dynamic head 23.5 M
Rated speed 371 RPM
Pump efficiency at design 88 %
capacity
Pump energy input at design 2181.8KW
capacity
Power consumption at duty 2272.7 KW
point
Run away speed 480 RPM
Maximum and minimum 36200 / 22000 M3/Hr
capacities at which pump can
be operated
Guaranteed Noise level 85 dBA
Guaranteed vibration level at < 100 µ
motor top
Pump specific speed 5168 US unit
NPSH required at design 8100 mm
capacity
Pumps and motors critical 1st 481 RPM
speeds 2nd 518 RPM
PUMP BEARINGS
No per pump 1 Thrust + 3 Thordon type
Type of lubrication Upper bearing by oil bath (motor thrust brg)
Lower bearing by fluid
Manufacturer of thrust bearing RENK
Cooling water required for thrust bearing oil 23 LPM
bath cooling
Suction draft tube material Concrete
Volute Concrete
IMPELLER
Material ASTM A743 CF8M
Minimum water level in the sump 6.3 m
BUTTERFLY VALVE
Power Pack
Make Rexroth
Quantity 5 (1 Per Valve)
Tank Capacity 200 Ltr
Hydraulic Pump
Make FOURESS India Ltd
Type Gear Pump
Capacity Discharge 23 Ltr / Min
Operating/Design pressure of power pack 140/160 bar
Speed 1500 RPM
89 | P a g e
Motor Rating 3 , 415 V ,9.3 KW
Valve
Make FOURESS India
Size 2400 mm
Type Butterfly (Hydraulically Operated With Dead Weight for Fast
closing)
Valve Timings
Opening 45 - 60 Sec (adjustable )
Closing 30 - 60 Sec (adjustable )
Emergency Close 30 sec ( for 90 % travel) + 30 Sec (for rest 10 % travel)
10.WATER TREATMENT PLANT
10.1 PRE-TREATMENT PLANT

Supplier: McNally BHARAT ENGINEERING CO LTD
RAW WATER PUMPS

No of pumps 3
Make FLOWMORE
Type Vertical , Single stage
Capacity of each pump 2200 M³/ Hr
Pump head 25 Meters
Shut off head 36.5 meters
Pump Efficiency at guaranteed flow 87.5 %
Thrust Bearing 1
Thorden type 6
Motor Make CGL
Rating 200 KW
Speed 990 RPM
DESIGN CLARIFIED WATER ANALYSIS

PARTICULARS Unit Raw water Gravity Filter
(mg/l) water
Calcium As CaCo3 125 150.20
Magnesium As CaCo3 100 100
Sodium &Potassium As CaCo3 70 70
Total cations As CaCo3 295 320.20
Bicarbonates As CaCo3 200 195.70
Sulphate As CaCo3 30 52.50
90 | P a g e
Chloride As CaCo3 65 72
Total anions As CaCo3 295 320.20
Silica As SiO2 15 15
Iron Fe 1.0 < 0.3
pH 7.6 – 8.2 6.8 – 8
Turbidity NTU 700 < 10
Organic Matter As KMnO4 - -
CASCADE AERATOR
Description PT-CW System PT-DM System
No. 1 1
Type Circular Cascade Type Circular Cascade Type
Material of Construction RCC RCC
No. of Steps 4 4
No. of falls 5 5
Total height of fall 1.5 m 1.5
Design flow 4950 M3/Hr. 150 M3/Hr.
STILLING CHAMBER
No. of Units 1 1
Type Rectangular Rectangular
Material of Construction RCC RCC
Design flow 4950 m3/hr. 150 m3/hr
INLET CHANNEL
Nos. 3 1
Type Rectangular Open Rectangular Open
Flow per channel 1650 M3/Hr 150 m3/hr
BYPASS CHANNEL
Nos. 1 1
Flow per channel 1650 M3/Hr 150 m3/hr
PARSHALL FLUME
Nos. 3 1
MOC RCC RCC
CLARIFIERS
Nos. 3 1
Type Circular Reactor Circular Reactor
Design flow 1650 m3/hr. 150 m3/hr.
HP of Motor for Impeller Drive 5.0 HP 1.5 HP
RPM of Impeller 22/60 (min/max) 5/15 (min/max)
No. of Blades 6 6
Impeller Dia. 1372 mm 935mm
HP of Geared Motor for Rake Drive 0.75 HP 0.75 HP
Rake Type Centrally Rotating Centrally Rotating
91 | P a g e
Arm Speed of rake 0.04 rpm 0.13 rpm
MOC of rake mechanism MS MS
GRAVITY FILTRATION
Description PT-DM System PT-Portable Water System
No’s 2 (Twin section) 2 (Twin section)
MOC R.C.C R.C.C
Design capacity. 150 M3/Hr 150 M3/Hr
Surface Medium Sand Sand
Supporting Material Graded Gravel Graded gravel
Rate of filtration 5 m3/m2/hr 5 m3/m2/hr
AIR SCOURING
Description PT-DM System & Portable Water System
No. of Blowers 4 Nos. (2W+2S)
Type Twin lobe
Capacity of each Blower 1500 m3/hr.
Motor Make Marathon Electric Motors Ltd.
Type SCIM
KW/RPM of Blower Rating 22 KW/1468 rpm
Current ( Full load/ No load) 37.4 / 15 amps
BACK WASH WATER PUMP

Nos. 3 (2W + 1S)
Manufacturer SAM TURBO INDUSTRY LTD.
Type Vertical Submerged
Capacity 50 m3/hr.
Head 18 MWC
Motor make Marathon Electric
Motor Rating 5.5 KW/1450 rpm
Current ( Full load/ No load) 10 /5.2 Amps
OVER HEAD FILTERED WATER STORAGE TANK

No. 1
MOC RCC
Capacity 300 m3
FILTER WATER RESERVOIR

No. of Reservoirs One in Two Sections
MOC RCC
Capacity 200 m3
SLUDGE DISPOSAL PUMP

No. 3 (2W + 1S)
Make Sam Turbo Industry Ltd
Type Vertical Submersible
Capacity 75 m3/hr.
Total Head 30 MWC
Motor Make Marathon Electric
Type SCIM
Motor Rating 15 KW/1460 rpm
92 | P a g e
Current ( Full load/ No load ) 27.3 /11.5 Amps
PT PLANT CHEMICAL HOUSE
ALUM DOSING PUMP

Description For PT-DM Sys. For PT-CW Sys. For Tube Settler
Nos. 2 (1W + 1S) 4 (2W + 2S) 2 (1W + 1S)
Make Milton Roy India Ltd.
Type Hydraulically actuated diaphragm type metering pump
Max Capacity 600 l/hr. 1800 l/hr. 600 l/hr.
Max Pressure 10 Ksc 7 Ksc 10 Ksc
Req. Capacity 300 l/hr. 1200 l/hr. 300 l/hr.
Req. discharge Pressure 2 Ksc 2 Ksc 2 Ksc
Motor Rating / Speed 0.75 KW/1405 rpm 1.50 KW/ 935 rpm 0.75 KW/1405 rpm
LIME SLURRY TRANSFER PUMPS

Nos. 2 (1W+1S)
Type Horizontal Centrifugal
Head 6MWC
Capacity 15 m3/hr.
Motor Rating 1.5 KW / 1430 rpm
Current ( full load ) 3.15 Amps
LIME SOLUTION PREPARATION TANKS

Nos. 2
Capacity 5.5 m3
Lime Strength 6% W/V
LIME DOSING PUMPS

Nos. 2 (1W + 1S)
Make Sam Turbo Industry Ltd.
Capacity 36 m3/hr.
Head 25 MWC
Motor Rating/Speed 5.5 KW / 1450 rpm
Current (full load/ No load) 10/5.2 amps
POTABLE WATER PUMPS

Nos. 2(1W + 1S)
Make WPIL Ltd.
Type Vertical multi stage ( 6 stages)
Capacity 150 M3/Hr
Head 80 MWC
Type SCIM
Motor Rating 55 KW / 1480 rpm
Current (Full load/ No load) 94.4 / 36 Amps
93 | P a g e
10.2 DM PLANT
Supplier ION EXCHANGE (India ) Ltd.

No Streams Two
Sequence of stream ACF-WAC-SAC-DGT-WBA-SBA-MB—Storage Tank
Capacity 135 M3/Hr/Stream..
OUT PUT WATER QUALITY

pH 6.8 -7.3
Conductivity at 25oC < 0.1 µ mho/cm
Silica reactive <0.02 ppm
Free chlorine Not detectable
Iron as Fe Not detectable
Total Hardness Not detectable
DM PLANT STREAM
Activated Carbon Filter (ACF)

Number 2(one per stream)
Design Flow /Unit (net) 135 m3/hr.
Period between two successive back washes 24 hours.
Net output between two back washes 3240 m3
Filter media / resin Activated carbon
Design pressure of vessel (min) 8 ksc
Effluent quality :
Free chlorine Not detectable
Turbidity <0.5 NTU
Organic Matter Below detectable level
WEAK ACID CATION EXCHANGER

Number Two (one per stream)
Design Flow rate/ Unit 135m3/hr.
Capacity between regeneration / unit 1620 m3
Period between regeneration / unit 12 hours
Resin Wealky acidic, Carboxylic Group
Quantity (ltr) 4478
Resin Make Ion Exchange
Design Pressure of vessel 8 Ksc
Resin Depth:
Min bed depth of resin for counter current 1000 mm
regenerated vessel over bed plate/header
Min bed depth of resin for co- current 800 mm
Regeneration By HCl (30%)
Capacity of Dosing Tank 2 M3
Back Wash Volume 18 M3
Back Wash time 10 mins
Final Rinsing Flow 135
Final Rinsing Time 30 mins
STRONG ACID CATION EXCHANGER

Design Flow rate/ Unit 135m3/hr.
94 | P a g e
Quantity (ltr) 4502
Resin Strongly acidic, high capacity polystyrene resin in bead form
Resin Make ION EXCHANGE
Design Pressure of vessel 8 Ksc
Resin Depth :
Regeneration By HCl
Effluent Quality
Relative silica < 0.2 ppm
Conductivity at 25 °C < 10 µmhos/cm
DEGASSER TOWER
Number One per stream
Type Forced draft type
Fill material Polypropylene or equivalent
Effluent water quality Free CO2 <5ppm
Sodium leakage < 2 ppm as CaCO3
DEGASSED WATER TANK

Number Off One per stream
Type Horizontal Cylindrical atmospheric with dished ends
Effective normal capacity 50 M3
WEAK BASE ANION EXCHANGER
Design Flow rate/ Unit 135 m3/hr.
Design pressure 8 ksc
Quantity (ltr) 4625
Resin Type Tertiary Ammonia group
Resin Depth :
Regeneration By NaOH
95 | P a g e
STRONG BASE ANION EXCHANGER

Number Two
Design flow rate /Unit 135 m3/hr.
Quantity (ltr) 4338
Resin Strong base type-1, high
capacity polystyrene resin
in bead form
Discharge Pressure 8 Ksc
Regeneration By NaOH
MIXED BED EXCHANGER

Design Flow rate/ Unit 135 m3/hr.
Quantity (ltr) 1886
Resin Strongly acidic and strongly basic type-1 resins.
Regeneration By HCl and NaOH
Effluent Quality
Relative silica < 0.2 ppm as SiO2
Iron as Fe Not detectable
Total Hardness Not detectable
pH Value 6.8 – 7.3
Conductivity < 0.1 µmhos/cm
DM WATER TANK
Type Vertical Cylindrical Atmospheric
Number Two
Diameter 14000 mm
Height 11000 mm
Storage Capacity Tank 1600 m3
96 | P a g e
Shell Material Mild steel
Internal protection Solvent free epoxy coating
External painting Chlorinated Rubber Plant
DRIVES OF DM PLANT AREA
FILTER WATER PUMP

Number 3 ( 2 working +1 standby)
Make FLOWMORE
Capacity 150 m3/hr.
Medium Filtered water
Type Vertical Centrifugal Type
Total Head Guaranteed 50 MWC
Stages 4
Motor Make ABB
Rating/ Speed 37 KW / 1475 RPM
DEGASSER AIR BLOWER

Make CBDOCTOR Ventilators Pvt. Ltd.
Number 4 ; 2 for degasser (1W + 1S)
Capacity 4600 NM3/hr
Discharge Head 50 mmWC
Type Centrifugal
Motor Make CGL
Medium Air
Motor KW / RPM 1.5 /1415
DEGASSER WATER PUMP

Make FLOWMORE Ltd.
Number 3 (2W + 1S)
Capacity 140 m3/min.
Discharge Head 50 mwc
Working Fluid De-cationised Water
Type of shaft sealing Mechanical Seal
Motor Make ABB
Rating/rpm 37 KW/1470
Current 65.5 Amps
EFFLUENT DISPOSAL PUMPS

Number 3 (2W + 1S)
Capacity 300 m3/hr
Suction condition Flooded Suction
Type SCIM
Motor rating/Speed 55 KW /1450 rpm
Current (Full load/No load) 94.4/36 Amps
DM REGENERATION PUMPS
Make FLOWMORE Pvt. Ltd.
Number 2 (1W + 1S)
97 | P a g e
Capacity 40m3/hr.
Motor Make ABB
Type 3 ph., SCIM
Motor rating/rpm 9.3/1455
MB AIR BLOWER
Number Two
Capacity 450 m3/min.
Type Rotary
Medium Air
TDH 400 mmWC
Motor Make ABB
KW / RPM 9.3/1455
Current 17 Amps
ACID UNLOADING PUMP

Number Two ( 1W+1S)
Capacity 15 M3
Type of Sealing Mechanical Seal
Medium 30% HCl
Motor Make ABB
KW / RPM 2.2 / 1405
Current 4.5 Amps
ALKALI UNLOADING PUMP

Number Two
Capacity 15 M3/Hr
Medium 48% NaOH
KW / RPM 2.2 / 1450
Current 4.8 Amps
STORAGE & MEASURING TANK DATA IN DM PLANT AREA
Partic Hot DM Acid Alk. Alk. Primin Acid Alk.

ulars Water Storage Mea Meas Prep. g Storag Storag
Tank Tank s. . Tank Tank e e
Tank Tank Tank Tank
TYPE Vertical Vertical Vertical Cylindrical Atmospheric Horizontal
Dish Cylindric Cylindrical With
Ends al Dish Ends
atmosph
eric
Numbe 1 2 2 2 1 2 3 2
rs
Capacit 6.5 M3 1600 M3 2 M3 0.6 10 M3 0.66 50 M3 50 M3
y
Fluid NA NA 30% 20% 48% NA 33% 48%
strengt HCl NaOH NaOH HCL NaOH
h
Shell Rubber lining of 4.5 mm thickness
lining
Materi
98 | P a g e
al
NEUTRALISING PIT
Number One in two sections
Capacity 200 M3 each section
Material of construction R.C.C lined with Acid/Alkali proof tiles
MISCHELLANEOUS PUMPS IN CLARIFIED WATER PP HOUSE
APH WATER PUMPS

Nos. 2(1W + 1S)
Pump Make SAMTURBO Industry limited
Capacity 400 M3/hr
Head 110 Meters
Type SCIM
Motor Rating 220 KW
Speed 1486 rpm
Current (full load/ no load) 48 Amps / 20 Amps
SERVICE WATER PUMPS

Nos. 3(2W + 1S)
Pump make SAMTURBO Industry limited
Capacity 250 M3/hr
Head 80 Meters
Motor Rating/ Speed 75 KW / 1485 rpm
Current (Full load/ No load) 128/50 AMP
COAL DECANTED WATER PUMPS

Nos. 2(1W + 1S)
Make WPIL Ltd.
Capacity 200 M3/Hr.
Head 30MWC
Type of working fluid Treated effluent from coal slurry settling point
Motor make Marathon Electric
Motor Rating/Speed 30KW / 1474 rpm
Current 50.7 Amps/17 Amps
PLANT POTABLE WATER PUMPS

Nos. 2(1W + 1S)
Make WPIL Ltd
Capacity 150 M3/hr
Head 80 MWC
Motor Rating 55KW / 1480 rpm
Current ( Full load/ No load ) 94.4/ 36 Amps
HVA/C PUMPS
Make SAM TURBO
Nos. 2(1W + 1S)
Type Centrifugal
Capacity 100 M3/hr
99 | P a g e
Head 80 M
Motor Rating/Speed/Current 45 KW / 1450 rpm/76.6Amps
10.3 CLORINATION PLANT

I. PT CHLORINATION
II. CW CHLORINATION
III. CHLORINE GAS ABSORPTION SYSTEM
CHLORINATION SYSTEM
Nos. 3 (2W + 1S)
Make Capital controls
Capacity 15 kg/hr.
Type Vacuum operated solution Feed Type
Chlorine Leak detector Sensor 4 nos
No. of Tonners (Cl2) 12(4 cylinders (2W+2S)per stream).
BOOSTER PUMPS (for PT Chlorination)

Nos. 3 (2W + 1S)
Pump Make Sam Turbo Industry Ltd
Type Horizontal Multistage Centrifugal
Liquid Handled Water
Capacity 16 m3/hr.
Head 50 Meters
Motor Make Seimens
CW CHLORINATION
No OF STREAMS 3 (2W +1S)
Make Capital controls
Capacity 100 kg/hr.
Type Vacuum operated solution Feed Type
No of evaporators 3 (one per stream)
No. of Tonners (Cl2) 12(4 cylinders (2W+2S)per stream).
Motor actuator valve One per stream
Chlorine Leak detector Sensor 7 nos
BOOSTER PUMPS
Nos. 3(2 W+1S)
Pump Make Sam Turbo Industry Ltd
Pump Type Horizontal centrifugal
Capacity 60 m3/hr.
Head 46 Meters
Liquid Handled Clorine Water
Motor Make Siemens
MONORAIL HOIST &TROLLEY

Nos. 1
Type Electrically operated (Travel &Hoisting)
Capacity 2 Ton
CHLORINE GAS ABSORPTION SYSTEM

Nos. One
Operation type Auto(starts by receiving signal from gas leak detectors)
FRP Hood for Cl2 Toners All the 32 Toner were connected to CGAS Through FRP hood
100 | P a g e
externally.
Motorised dampers 2 nos (1W+1S)
Caustic Solution Tank One, 6 M3
Solution 20 % Caustic solution
CHLORINE LEAK ABSORPTION SYSTEM

CAUSTIC PUMPS
Nos. 2(1W + 1S)
Capacity 20 M3/Hr
Head 15 M
Motor Make Siemens
Motor Rating/Speed 2.2 KW / 1435 rpm
AIR BLOWER
Nos. 2(1W + 1S)
Make Fiber Plast Equipment
Type Centrifugal Blower
Capacity 6000 M3/Hr at 225 mmWG
Head 15 M
11. ASH HANDLING SYSTEM

11.1 ASH WATER PUMP HOUSE
BAHP water pump

Quantity 2
Description Horizontal split casing
Capacity 360 m3/hr
Head 90 mwc
Shut off head in M 99
Pump type/model ZM II 530/01
No of stages one
Size in mm 250 x 200
Coupling between motor shaft & Pin & Bush
pump shaft
BALP water pump

Quantity 3
Description Horizontal centrifugal pump
Suction condition flooded
Capacity 601 m3/hr
Head 32 mwc
101 | P a g e
Pump type/model TPS 150/400(3 VO)
No of stages one
Coupling between motor shaft & Tyre spacer
pump shaft
Flushing water pump

Pump type MF 300/320
Make Sam Turbo Industry Ltd.
Size 300X300
Quantity 1 no
Head 20 m
Capacity 1005 m3/hr
Total weight 1240 kgs
DOR from DE Clockwise
Motor make/frame Marathon/.D280S
Motor rating 75 kw/ 4P, 1480 rpm
FAHP water pump

Quantity 3
Description Horizontal

Capacity 205 m3/hr
Head 44 mwc
Pump type/model WP 125/400
No of stages One
Coupling between motor shaft Flexible (Lovejoy)
& pump shaft
ECO water pump

Quantity 2
Type 4 TU 14
Size 125 x 100
Capacity 100 m3/hr
Head 70 m
Motor make Marathon/D225S
& pump shaft
No of stages 2
DOR CW from DE
Total weight 1083 kg
102 | P a g e
Ash conditioner water pump
Quantity 5
Type 4 MD 80/205
Size 100 x 80
Capacity 25 m3/hr
Head 45 m
Motor KW/rpm 7.5/1450
Motor make Marathon/D132M
Coupling between motor shaft Pin & bush type

& pump shaft
DOR CW from DE
Total weight 521 kg
Wash water pump

Quantity 2
Manufacturer SAM turbo
Type WP 65/320
Size 80 X 65
Capacity 40 m3/hr
Head 25 m
Motor KW/rpm 7.5 KW/4P; 1450
Motor make/frame Marathon/ 132M
& pump shaft
No of stages Single
DOR CW from DE
Total weight 268 kg
Settling Tank Area

1) Ash water sump Capacity-1107 CuM
2) Settling Tank Qty-1, Ash water sump area,
Volume- 400 CuM
3) Surge Tank Qty-1, Ash water sump area,
Volume- 400 CuM
4) Sludge pump
Quantity 2 (1w+1s)
Description Horizontal centrifugal twin casing
Liquid handled Highly abrasive slurry
Suction condition flooded
103 | P a g e
Capacity 30 m3/hr
Head 20 mwc
Pump type/model ARS 80/340
No of stages One
Size in mm 100 x 80
Pump speed 995
Motor KW/rpm 5.5/1450
Coupling between motor shaft Belt Drive
& pump shaft
DOR CW from DE
11.2 ASH SLURRY PUMP HOUSE

Seal water pump for BA Slurry pumps
Quantity 2
Description Horizontal centrifugal multistage
Liquid handled Ash water/service water/clarified

water
Capacity 45 m3/hr
Head 115 mwc
Shut off head in M 167.2
Pump type/model 11 MD 80/205
No of stages 11
Size in mm 100 x 80
Critical speed 30% above rated speed

Motor make/frame size Marathon/D200L
Coupling between motor shaft & Pin & Bush
pump shaft
DOR CW from DE
Total weight 1577 Kg
HCSD pump
Quantity 3 (2W+1S)
Manufacturer GEHO
Description 2 cylinder, double acting,
crankshaft driven piston diaphragm
Liquid handled High concentration slurry of fly ash
Solids in slurry 55%-65% w/w

Slurry viscosity/Temp 600 mPas/max 600C
Slurry flow rate 25/222/251 m3/hr

(min/norm/max)
104 | P a g e
Discharge pressure 2300 kPa/3640 kPa [norm/max]
Pump type/model ZPM 800

Power at pump shaft 156 kW (@222 m3/hr, 2300 kPa)
Installed motor power 400 kW

Bottom ash Slurry disposal pump
Operation range +10%-45% Fixed speed
Quantity 3 3
Description Horizontal centrifugal twin casing
Specific Gravity 1.1 1.1
Capacity m3/hr 872 872
Head in mwc 45 45
Shut off head in M 50 50
Pump type/model AR 300/750A AR 300/750A
Size in mm 300 x 250 300 x 250
Speed in rpm 795 795
Motor output power 177.15
Higher speed 875 N.A
Head at higher speed 55.5 N.A
lower speed 437 N.A
Head at lower speed 10 N.A
Shaft sealing Gland packing
Sealing water requirement @ 1 ksc above discharge pr
Coupling between motor shaft Fluid coupling & gear box Belt drive
& pump shaft
Pump thrust bearing location Drive end
Recommended motor kw 250
Motor speed 1500
Type of drive Direct drive thro fluid coupling Belt drive
& gear box for BA OF & for first
stage for ash slurry pump
Casing test pr./duration 18 ksc/30 min
Total weight of pump 6300 5520
Fluid coupling for BASDP 1) Variable speed fluid coupling

2) Model No- 570 PST
3) Quantity- 2W+2S
4) Make- Premium
Rotary gear pump of fluid coupling 1) Model- RDRN 150L
2) Flow- 125 LPM
3) Pressure- 3 ksc
4) Motor type/make- SCIM/ Reputed
5) Motor rating- 3HP/1450 RPM
Gear box for BASDP 1) Make- Premium
105 | P a g e
2) Model no- H1-200
3) Cooling type- Helical fans
4) Ratio- 1.6/1
5) Qty- 3
Suction v/v for BASDP 1) 350 mm, knife gate v/v with cylinder actuator,
MOG
2) Qty- 4 for U#1&2 + 1 spare
3) Fluid working temp/pr.- 60 deg c/1 ksc
Discharge v/v for BASDP 1) 350 mm, knife gate v/v with cylinder actuator,
MOG
2) Qty- 3 for U#1&2 + 1 spare
3) Fluid working temp/pr.- 60 deg c/9 ksc
Drain pump for ASPH 1) Type- VG 100/400 +TCH+ N
2) Size- 150 X 100
3) Qty- 2
4) Capacity- 80 m3/hr
5) Head-15 mwc
6) Motor make/frame- Marathon/160L
7) Power/speed- 9.3 Kw/ 960 rpm
Jetting nozzle for BA slurry sump Qty- 8, Estimated wt.- 0.5 kg
Plug gate 400 for slurry sump Qty-2, Total lift of plug gate- 300 mm
Ash slurry sump Capacity- 73.9 CuM
11.3 DRY-ASH SYSTEM
VACUUM PUMP HOUSE

Water ring vacuum pump (model-170)
Type Low speed liquid ring type
Qty required 8 Nos. working & 8 standby
Design condition air flow 3020 m3/hr at 60 C gas temp & 36 C seal water
temp
Gas correction factor at 60 C gas temp & 36 C 1.01
seal water temp
Rated vacuum 14’’ HG (minimum)
Operating inlet air temp 60 C
Operating seal water temp 36 C
Operating vacuum range 100-450 mm HG
Exhauster speed 475 rpm
Seal water requirement at 1ksc,36 C 55 LPM up to 300 mm HG vacuum & 65 LPM
above 300 mm HG vacuum
Condensation factor at 60 C gas temp & 36 C seal 4.45%
water temp & 50% RH
Type of drive VEE belt
Recommended electric motor 90 kw x 1480 rpm
Max permissible gas temp 80 C
Guaranteed exhauster input power at rated 54 BKW
capacity & vacuum
Transport Air Compressor
106 | P a g e
Manufacturer Atlas Copco (India) Ltd
Model number ZA 6J (VSD)
Type Oil free screw
Quantity 6
Capacity of each compressor (atm pr.=1 bar, 108 m3/min
ambient temp=50 C, RH 100%)
Discharge pr. compressor outlet 2.65 ksc
Motor rpm for given capacity 1485 rpm
Discharge temp at design condition Approx. 185-195 C
KW input 383 kw
Guaranteed power consumption at motor input 403 kw
terminals
KW rating of motor 500 kw
Cooling water inlet temp 36 deg c
Cooling water outlet temp 44 deg c
Total cooling water requirement with temp rise 2 l/s
of 8 deg c
Minimum cooling water inlet pressure 2.5 ksc
Method of lubrication Forced feed
Noise level Max 85 dB(A)
Motor make Marathon frame:FDC400F3
Male rotor speed 5625 rpm
Total weight 8 ton
Air intake filter type/number per compressor Dry type filter cartridge/3
After cooler 1) Type- shell & tube
2) 690 LPM water(shell); 108 m3/min air(tube)
3) Operating pressure- 3.5 ksc(shell), 3.65
ksc(tube)
4) Qty- 6
Air dryer for TAC 1) Model- SE 800 AW

2) Qty- 6
3) Capacity- 108 m3/min
4) inlet air pr.- 2.65 bar g
5) inlet/outlet temp- 45/40
Air receiver for TAC 1) Qty- 6
2) Volume- 12 CuM
Instrument Air Compressor

Manufacturer Kirloskar Pneumatic Co. Ltd
Model number 2HA2BIST
Type Non-Lubricated
Quantity 4 (1w+1S for 1 unit)
Type of cooling Water cooled
Compressor/Motor 620/1500 rpm
Design temp/Max Relative humidity/Height 50 deg c/100%/271.5 m
above mean sea level
Discharge air temp at outlet of compressor(2 nd 155 deg c
107 | P a g e
stage)
Discharge air temp at outlet of after cooler 45 deg c
Limit of cut off i.e. Cut In & Cut Out pr. Cut In 7.8 ksc & Cut Out 8.2 ksc
Cylinder configuration Horizontal
No. of cylinders Two
No. of stages Two, Double acting
Discharge pressure 8 ksc
Compressor shaft power 57.66 kw
Noise level 85 dB(A) at 1 m distance from compressor
package in free field condition
Water inlet/outlet temp for coolers 36/40 deg c
Water quantity required for intercooler,L.P & H.P 134/100 LPM
cylinders/after cooler
Sump capacity(oil) 22 Ltr
Consumption (oil) 0.06 ltr/hr (approx.)
Drive arrangement Belt driven ‘SPC-5300’
Cooling water flow (total) per compressor 234 LPM
Discharge air temp at outlet of intercooler 45 deg c
Air Dryer 1) Model- SB 035 BM
2) Capacity- 10m3/min
3) Operating pr.- 8 kgf/cm2
4) Qty-
FLY ASH SILO
Silo Capacity- 1000 T, Qty- 4

Silo area drain pumps 1) Type- VG 80/400+TCH+N
2) Size- 100 X 100
3) Qty- 2
4) Capacity- 80 m3/hr.
5) head- 40 mwc
6) Motor make- Marathon/D200L
7) Power/Speed- 30 KW/1450 rpm
Ash conditioner 1) Capacity- 100 TPH
2) Bulk density of fly ash- 0.75 T/m3
3) Water requirement- 20 m3/hr.
4) Qty-4
Gear box for Ash conditioner (U 1200) 1) SF- 2
2) Mech. Capacity- 40.4 kw
3) Thermal capacity- 31 kw
Bag filter 1) Model- TK 144-360 (Thermax Ltd)
2) Qty-7
3) Design gas flow rate- 18000 Am3/hr.
4) Design pr.= +/-500 mmwc
Pressure relief v/v Qty- fly ash silo=4, HCSD silo=3
Rotary feeder 1) Qty- 8
2) Rotor volume- 0.15 m3
3) Filling factor- 0.97
4) Bulk density- 0.75 T/m3
5) Rotor speed- 15.3 rpm
108 | P a g e
6) Capacity- 100 TPH
Fluidizing blower 1) Model 78AC twin lobe (KAY International)
2) Qty- 5
5) RPM- 1383
6) BHP-33.11
8) Motor make- marathon (SE. 200L)
Motor rating- 1440 rpm/40 HP

Vent filter fan (CB Doctor ltd) 1) Capacity- 16800 m3/hr. @ 200 mmwc
2) Qty-4
3) Fan model- KB 27
4) Fan speed- 1609 rpm
Unloading spout 1) Capacity-100 TPH
2) Qty- 4
HCSD SILO
HCSD silo 1) Type- Conical

2) Capacity- 350 T
3) Volumetric capacity- 466.67 m3 [350/0.75]
4) Total height- 12.91 m
Mixing Tank 1) Qty- 3
2) Tank volume- 113 CuM
3) Wt. of mixing tank with slurry- 191.1 T
(10.3+180.8)
4) Wt. of agitator assy. -3.4 T
Rotary feeder 1) Location- Above SFM [ Model-RV60E]
a) Capacity- 190 TPH
b) Bulk density- 0.75 T/m3
c) Rotor RPM- 19
d) Qty- 6
2) Location- Above unloading for HCSD system
[Model-RV60N]
a) Capacity- 100 TPH
b) Bulk density- 0.75 T/m3
c) Rotor RPM- 15
d) Qty- 3
Drain pump 1) Make- SAM turbo industry ltd.
2) Type- VG 80/460 + ARL
3) Size- 100 x 100
4) Qty- 2
6) Head- 25 mwc
7) Motor make/frame- Marathon/200L
8) KW/RPM- 22/960
Ash conditioner (Below HCSD silo) 1) Qty- 6 no.
2) Capacity- 190 TPH
3) Bulk density- 0.75 T/m3
109 | P a g e
4) Water pr.- 3 ksc
Gear box for ash conditioner (U 1400) 1) SF- 2
2) Mech. Capacity- 57.9 kw
3) Thermal capacity- 41 kw
Charge pump 1) Make/Type- SAM turbo/ AR 150/500
2) Size- 200 x 150
3) Speed- 800 rpm
4) capacity- 265 m3/hr.
5) Motor make/frame- Marathon/D280S
6) KW/rpm- 75/1450
7) DOR- CW from DE
Vent filter fan (CB Doctor) 1) Capacity- 16200 m3/hr. @ 200 mmwc
2) Qty-4
3) Fan model- KB 27
4) Fan speed- 1591 rpm
Fluidizing blower
1) Qty- 3
4) RPM- 1167
5) BHP-12.58
7) Heating unit- 18 kw
Density meter 1) Type- Coriolis

2) Make- Endress+Hauser
3) Measured variable- Ash slurry
4) Location- HCSD silo mixing tank (ART) Hose
pump discharge slurry density
5) Total qty- 3
12. COMPRESSED AIR SYSTEM

COMPRESSOR
Population 5 [3 IAC (2W+1S) + 2 PAC(2W)]
Manufacturer Atlas Copco India

Model No ZR 275
Type Oil free Rotary Screw
Type of operation Continuous Load and Unload
Type of cooling Oil free Water Cooled
PERFORMANCE
Capacity 36Nm³/min (at 45°C, and RH of 75%, Elevation +271.5 MSL)
Discharge pressure after cooler outlet 8 kg/cm2 (g)
Discharge pressure of instrument air at 7.5 kg/cm2(g)
ADP Outlet
Capacity considering design ambient condition 46.7 m3/min
of free air discharge (FAD).
Outlet air temperature after high pressure stage 160°C-180°C
of compressor at design capacity
Design ambient temperature 45°C
110 | P a g e
Power input required at compressor shaft at 290 KW
rated condition
Cooling water consumption corresponding to a 7.75 LPS
temperature rise of 10° C
Number of stages 2
LP Safety Valve Setting 3.7 bar
HP Safety Valve Setting 9.3 bar
MOTOR
Manufacturer Marathon
Type of duty Continuous
Direction of rotation when viewed from NDE CW
Rating 320 KW
Rated voltage 3300 V
Rated speed 2980 RPM
Full load current 66 Amps
No load current 21 Amp
AIR FILTER
Air Intake filter Type Dry Type Filter Cartridge
No per Compressor 1
Filtering Media Paper
Particle removing efficiency 99.9% up to particle size of 3 micron
HEAT EXCHANGER
Intercooler After cooler
Type of Cooler Shell and Tube Type Shell and Tube Type
Compressed Air Inlet/Outlet Temp 160-180/45 °C 160-180/45 °C
Cooling Water Inlet/Outlet Temp 35/45 °C 35/45 °C
OIL COOLER
No of Cooler per Compressor 1

Type Plate Heat Exchanger
AIR DRIER
Manufacturer ATLAS COPCO
Total Numbers 5
AIR RECEIVERS
Quantity 5 No
Volume 10 M3
Pressure 8 Kg/Cm2 at 60 °C
Test Pr. 16 Kg/Cm2
13. FIRE FIGHTING SYSTEM

SIREN
Location Mounted at top of TG Building
Make Kheraj Electrical Industries Pvt Ltd
Type Horizontal Double Mounting
Model HDT -325
Range 3.25 KM
Power Supply 3 phase 440 V
111 | P a g e
Motor Rating 2 HP
13.1 FIRE HYDRANT SYSTEM

APPLICATION AREAS
High Velocity Spray System
Transformers
Boiler Burner Fronts
Lube Oil System
Oil Canal
Clean oil and Dirty Oil Tanks
Generator Seal Oil Units
Medium Velocity Spray System
Cable galleries at various locations
Coal conveyors 1A/B, 2A/B, 3A/B, 4A/B, 5A/B, 6A/B, 7A/B, 8A/B, 9A/B, 10A/B, 11A/B, 12A/B, 13A/B, & TPS. 1,
2, 3, 4, 5, 6, 7, 8, 9,10,11,12,13,& Crusher House
F.O. Pressurizing & Unloading pump house
LDO Tanks
Day Oil Tanks
DG Sets
FIRE WATER STORAGE TANKS

Number 2
Capacity 2130 m³
FIRE HYDRANT PUMPS

PUMP
No of pumps 4 (3motor driven + 1 engine driven)
Make FLOWMORE Pumps
Model HSC
Capacity 410 m3/hr.
Head 105 mwc
DOR CCW from Motor NDE,CW from Engine End
MOTOR
Make ABB Ltd
Frame M2BA315MLC4
Rating 200 KW
Speed 1485 RPM
Rated Current 329 A
No Load Current 100 A
Starting Current 1974 A
DIESEL ENGINE
Number 1
Make Greaves Cotton Ltd.
Type HE Cooled
Model TBD3V6MKI
Speed 1500 RPM
No of Cylinders 6
Bore and Stroke (mm) 128x130
BHP at rated speed 253 HP
Turbo charger Air Pressure at rated load 1.72 bar
Fuel High Speed Diesel (IS:1460)
Specific Fuel Consumption 158 Gram/BHP/Hr. + , 5% prod tol
112 | P a g e
Lube Oil Pressure 2.5 bar (min)
Vibration 15 (mm/sec)
Noise Level 85 dB with Acoustic Enclosure
Lube Oil Cooler
Lube oil flow 150 lpm
Lube oil inlet temp. 80-85 0C
Lube oil outlet temp 150 0C (max)
Cooling Water Temp inlet 85-900C
Cooling Water Temp outlet 800C
Cooling Water Flow Engine coolant water pump flow 400 lpm
SPRAY PUMPS
PUMP
Number 2 (1 motor driven , 1 diesel driven)
Make FLOWMORE Pumps
Model HSC
Capacity 410 m³/hr.
Head 120 MWC
DOR CCW From Motor NDE, CW from Engine End
MOTOR
Make ABB Ltd
Rating 200 KW
Speed 1485 RPM
Rated Current 329 A
Frame M2BA315MLC4
DIESEL ENGINE
Number 1
Type HE Cooled
Model TBD3V6MKI
Speed 1500 RPM
No of Cylinders 6
Turbo charger Air Pressure at rated load 1.72 bar
Lube Oil Cooler
Cooling Water Flow Engine coolant water pump flow 400 lpm
JOCKEY PUMPS
113 | P a g e
PUMP
Number 2
Make FLOWMORE Pumps
Model HES
Capacity 75 m³/hr.
Head 105 MWC
MOTOR
Make ABB Ltd
Rating 55 KW
Speed 2960 RPM
Rated Current 91.4 A
Frame EHX250MA2
Starting Current 639.8 A
BOOSTER PUMP(In hydrant line)

PUMP
Number 2 (1 Motor driven , 1 Diesel driven)
MOTOR
Make ABB Ltd
Rating 37 KW
Speed 1470 RPM
Rated Current 65.5 A
Frame EHX225SMB4
DIESEL ENGINE
Number 1
Type HE Cooled
Model 4G11NA
Speed 1500 RPM
No of Cylinders 4
Lube Oil Cooler
Cooling Water Flow 90 lpm
13.2 INERT GAS (ARGON) SYSTEM
114 | P a g e
DESIGN CRITERIA
Standard NFPA 2001 (2008 edition)
Type of System Total Flooding System, Single Area System
Room Temp (Hazard) Considered 24 0C (Air Conditioned)
Design Concentration at 200C 36.2 % by volume
Discharge Time 60 sec
Duration of Protection 10 min
Argon Storage Cylinder 80L 30.0 Mpa (300 bar)
CO2 Pilot / Actuating Cylinder 5.4L 6.0 Mpa (60 bar)
APPLICATION AREAS
Control Equipment Room Unit #1&2( EL +16.0 M)
Central Control Room at ( EL +16.5 M)in main plant
UPS & Battery Charger Room Unit #1 & 2( EL +8.5 M)
CER for Unit 1 & 2 at 8.5M.
ARGON IG-01 SPECIFICATION

Purity 99.9 % m/m min (m/m: molecule/molecule)
Acidity 0
Water Content 0.005% by weight maximum
Non Volatile Residue None
Suspended matter (sediment) Non visible
13.3 FOAM SYSTEM
DESIGN CRITERIA
Standard NFPA –11
Type of Foam Compound AFFF
Concentration of Foam 3%
Design Density / Rate of Application 6.1 ltr / Min / M2 of Fuel
MinM Pr.reqd. at Foam Maker / Pourer 3.5 Kg/Cm2 g
Proportionating Device Ratio Controller
Pressurising Method Foam Pumps
Type of Foam Outlets Aspirating Type Foam Makers with Vapour seal
APPLICATION AREAS
LDO and HFO Tanks
FOAM PUMPS
Quantity (No’s) 2 (1 No Motor Driven + 1 No Engine Driven)
Make Edwards Pentair Water :USA
Fluid 3% AFFF Foam Concentrate
Temperature 10C to 480C
Viscosity >7 cst
Discharge Pressure 12 bar
Flow 11.47 m³/hr.
MOTOR
Make CGL
Rating 20.11 KW
Speed 1475 RPM
Rated Current 33 A
115 | P a g e
Frame ND 180M
Starting Current 500A
DIESEL ENGINE
Number 1
Make Kirloskar Oil Engines Ltd
Type Compression Ignition
Model DM-20
Speed 1500 RPM
No of Cylinders 2
BHP at rated speed 19.2 HP
Compression Ratio 17.5:1
No of Strokes 4
Governor Type Mechanical
DOR Counter Clockwise looking at Flywheel
end
Lubrication Forced Feed Lubrication as well as
Splash Lubrication
Engine Cooling system Water Cooled
Engine Cooling Arrangement Radiator
Capacity of Fuel Oil Tank 40 lit (capable of 12 hrs. continuous
operation)
FOAM TANKS
Tank
Quantity 2
Outside Dia x Overall Length 1816 mm x 4014 mm
Capacity 8 M3
FOAM PROPERTIES
Make KV Fire Chemicals (India) Pvt Ltd
Type of Concentrate AFFF
Rate of Induction 3%
Appearance Amber Liquid
PH 7-8.5
Specific Gravity 1.00 – 1.03
With Water Miscible
Viscosity < 5 CSt
Sludge Content 0.1 % Max
Freezing Point 0 0C
25% Drainage Time > 2 min
Expansion “7-12
Shell Life 15 Years
13.4 FIRE DETECTORS

Area Fire Extinguishing Fire Detectors
System
Cable Galleries MVW Spray System Multi Sensor
Photo Electric
Conveyors and TP MVW Spray System Digital Type LHS Cable
Q.B. Detector
IR Detector
116 | P a g e
LDO and HFO Tank Foam System Probe Type
Conventional heat
detector
CCR,CER Argon Gas System
Infra-Red Fire Detector

Make Patol UK
Type Series 5000
Application Detection of moving fire on coal
conveyor belt.
Principle Temperature dependent black body
radiation detection
Sensitivity 10 to 40 microwatt adjustable ( 4 Levels )
Temperature -20 0C to +70 0C
Power IR detectors 24 V DC
Air Purging unit 230 V AC, 50 VA
Quartzoid Bulb Sprinkler
Make Tyco
Model TY3251
Operation Temp 79 0C
K factor 80
Size ½”
Beam Detector
Make System Sensor
Model BEAM 124(S)
Projection Range 5-100 mts
Power 24 V DC
Multi Sensor Detector
Make Autronica Norway
Model BH 320 with Self Verify
Coverage Area 25 square metre
Principle
Sensor1: Smoke Photoelectric, Operating on light Scatter
principle
Sensor 2: Temperature Temperature measurement by means of
thermistor
Power 10-27 V DC
Probe type heat Detector
Make FENWAL
Model 27121 - 20 / 190 °F (12-X 27121-020-04)
Temperature setting 190 0F
Listed Spacing 50 feet
Type Rate Compensated Type
Power 2A at 24 V DC
Photoelectric (Optical) Detector
Make Autronica Norway
Model BH 300 with Self Verify
Coverage Area 25 square metre
Principle Photoelectric, Operating on light Scatter
principle
Power 10-27 V DC
117 | P a g e
14. COOLING TOWERS
TOWER
Manufacturer NBCC
Number of Cooling Tower per Unit 2
Type of Tower IDCT with Cells inline
Height of the Tower 27 M
Type of Fill DORON V Bar
No of water inlets 2
No of Cells 8W +1SB
No of Air Inlets 2
MOC of Drift Eliminator Virgin PVC
No of Risers 2x9
No of Nozzles per Cell 330
DESIGN DATA
Circulating Water Flow 30000 M3/hr.
Hot Water Temperature 42.5 0C
Cold Water Temperature 32.5 0C
Inlet Design WBT 28 0C
Relative Humidity 50 %
Range 10 0C
Approach 4.5 0C
L/G Ratio 1.71564
Evaporation Loss 493.11m3/hr.
Heat Dissipation by Circulating Water 316026109.6 KCal/hr.
Pumping head above FGL 13 mwc
FAN
No of Fans 9
Manufacturer Aero Tech Engineers
Model HX1/10.00FB6
Blade Profile Aerofoil
No of Blades 6
Fan Diameter 10000 MM
Volume Air Flow 580.8 M3/sec
Fan Speed 107.68 rpm
Static Pressure 9.73 mmwc
Air Density 1.0961 kg/m3
Design Blade pitch angle (Tip) 9.90
Degree of Pitch adjustment 40 to 230
Total Efficiency 83.84 %
Static Efficiency 62.91 %
Axial Thrust Load 15873.73 N
Radial Load per Blade 12272 N
GD2 6593.57 kg-m2
Type of Drive Shaft Single Span Tubular Floating Type
Type of Coupling Flexible Bush Type S.S 304
GEARBOX
Manufacturer Premium Transmission Ltd
118 | P a g e
Model B-235
Reduction Ratio 13.959/1
Rating 111 KW/1500 rpm
Temperature rise of oil during continuous run at 95 0C
designed condition
MOTOR
Manufacturer Crompton Greaves Limited
Power rating 119.57 KW
Speed 1485 rpm
Full Load Current 175 A
15. Make Up Water Pump House
General
Pump fig./size Fig. 7000 Size 32H/3 stage
Manufacture FLOWMORE
Type of discharge ABOVE FLOOR
Type of Discharge Forced Water
Type Non pull-out type, Mixed flow type
PUMP PERPORMANCE
No of pumps 3
Guaranteed Flow CuM/Hr. 3000
Total Head at Guaranteed 105
flow(MWC)
Shutoff Head(MWC) 146
Pump speed R.P.M 990
Pump efficiency at Guaranteed flow, 87.5
%
Pump input power at guaranteed 980.4
flow, in KW
Power consumption at guaranteed 1042.98
flow at motor terminals, KW
Max.power consumption at motor 1093.6
terminals in the pump operating
range
Guaranteed Noise level(dBA) 85 DBA at a distance of 1Mtr. From
Surface.
Vibration Level As per HIS
Minimum Submergence required
above suction bell inlet(in Milli
Meter)
a) Minimum flow 1600
b) Guaranteed flow 1650
c) Maximum Flow 2000
NPSH required(in Milli Meters)
a) Minimum Flow 6700
b) Guaranteed Flow 8000
NPSH available(in Milli Meters) 13600
Pump specific speed(In US units) 3243
System suction speed(based on 6391
NPSH available)
Pump suction specific speed(based 9707
119 | P a g e
on NPSH required)
Pump drive combined critical speed
a) 1st(in rpm) 3300
b) 2nd(in rpm) 5200
Rotor over speed NA
Motor Rating (at 50° C)in KW 1200
TECHNICAL PARTICULARS
Impeller type & Design
Number of Bearings
a) ‘Thorden’ type 13
b)Thrust bearing(in pump) ONE
c)radial bearing in thrust stand of ONE
pump
Heaviest component to be handled
by the care during
a)Erection(KG) 16500
b)Maintenance(KG) 16500
Capacity of EOT crane(tons) 25
provided in the pump house
Type of Coupling (Pump & Motor) Flexible
PUMP DIMENTIONS(Approx.)
Impeller shaft diameter(mm) 114.3
Line shaft diameter(in mm) 114.3
Size of pump suction bell 930
mouth(mm)
Size of pump discharge flange(mm) 600
Impeller diameter at inlet(mm) 384
Impeller diameter at outlet,(mm) 528.6
MOTOR DETAILS
Manufacturer Crompton Greaves LTD
Motor type Squirrel cage induction motor
Frame size & Type Designation VTPC1080 & CACA
Type of duty S1(continuous)
Direction of rotation ( from NDE) CCW
Standard continuous rating at 40°C 1282
ambient temp.(KW)
Derated rating for specified normal 1200
condition i.e. at 50°C(KW)
Rated voltage, frequency 11000V,50Hz
Rated speed 987
Full load current(Amp) 81
No load current(Amp) 31(indicative only)
Power factor 100% load 0.81
16. Station Auxiliary Cooling Water Pump
General SACW PUMP

Pump fig. /size Fig. 7000 Size 21M/ 1 Stage
Manufacture FLOWMORE
Type of discharge ABOVE FLOOR
Type of Lubrication of Line Shaft SELF WATER LUBRICATED
Type Vertical Turbine - Non pull-out type
PUMP PERPORMANCE
120 | P a g e
No of pumps 3
Guaranteed Flow CuM/Hr. 1000
Total Head at Guaranteed 50
flow(MWC)
Shutoff Head(MWC) 64
Pump speed R.P.M 1480
Pump efficiency at Guaranteed flow, 89.23
%
Pump input power at guaranteed 152.6
flow, in KW
Power consumption at guaranteed 162.34
flow at motor terminals, KW
Max.power consumption at motor 177
terminals in the pump operating
range
Guaranteed Noise level (dBA) 85 DBA at a distance of 1Mtr. From
Surface.
Vibration Level As per HIS
Minimum Submergence required
above suction bell inlet (in mm)
a) Minimum flow 1300
b) Guaranteed flow 1600
NPSH required (in mm)
a) Minimum Flow 6500
b) Guaranteed Flow 10000
NPSH available (in mm) 12200
Pump specific speed (In US units) 2140
System suction speed (based on 6170
NPSH available)
Pump suction specific speed(based 7163
on NPSH required)
Pump drive combined critical speed
a) 1st(in rpm) 2190
b) 2nd(in rpm) 3500
Rotor over speed (rpm) NA
Motor Rating (at 50° C) in KW 200
TECHNICAL PARTICULARS
Impeller type & Design Closed
Number of Bearings
a) Bronze Bush NIL
b) Cut less-rubber type NIL
b) ‘Thorden’ type 6
c) Thrust bearing (in pump) ONE
Heaviest component to be handled
by the care during :
a) Erection(KG) 2600
b) Maintenance(KG) 2600
Capacity of EOT crane (tons) 10
provided in the pump house
Type of Coupling (Pump & Motor) Flexible
PUMP DIMENTIONS (Approx.)
Impeller shaft diameter(mm) 80.96
Line shaft diameter (mm) 49.21
121 | P a g e
Size of pump suction bell mouth 540
(mm)
Size of pump discharge flange(mm) 350
Impeller diameter at inlet (mm) 225.5
Impeller diameter at outlet (mm) 393
MOTOR DETAILS
Manufacturer Crompton Greaves LTD
Motor type 3-Phase Squirrel cage induction
motor
Frame size & Type Designation ND315LX & CACA
Type of duty / Enclosure & Cooling S1 / TEFC safe area IC411
Degree of protection IP55
Direction of rotation Bi-directional viewed from Motor DE
Standard continuous rating at 40°C 217.39
ambient temp.(KW)
Derated rating for specified normal 200
condition i.e. at 50°C(KW)
Rated voltage, frequency 415V ±10% , 50Hz +3% & -5% and
10% (ABS) in combined
Rated speed 1488
Full load current (Amp) 322
No load current (Amp) 75 to 80
Power factor 100% load 0.90
Efficiency at 100% Load 96
17. Submersible Sludge Pump
Make Aqua Machineries Pvt. Ltd.
No. Of Pump 9
Rated Capacity 150 m3 / hr. at 10 m head
Size & Type Of Pump DN 100 & Submersible
No. Of Stage Single
Head / Stage 10 mtr.
Weight of Pump-set with Motor 210 Kg (approx.)
Max. Hydraulic Thrust 1 Ton (approx.)
Speed Of Pump Motor Set 1440 rpm
Head
a) Max Shut off Pressure 18.5 m
b) Dynamic Rated Head 10 m
c) Range of Head 16 m to 7 m
Type Of Impeller Non Clog Type
MOC
a) Discharge Casing C.I. IS 210Gr FG 260
b) Foundation Bolt SS
c) Shaft SS 410
d) Impeller SS CF8M
e) Bearings Anti-friction
f) Discharge Elbow C.I. FG 260 IS 210
g) Suction Bell C.I. FG 260 IS 210
h) Shaft Coupling / Fasteners Mechanical Seal / SS
Max BHP required by the Pump 6 KW
MOTOR Details
Make AQUA Machineries Pvt. Ltd.
Type 3-ɸ Squirrel cage Full Submersible
122 | P a g e
Air Filled Y-Δ connected Stator
Induction Motor
Motor HP 10
Max. Starting Current 250 % FL
Temp. rise of Motor above ambient 80° C
Thrust Bearing Anti-friction
KW Rating 7.5
Rated Voltage 415 V ± 10%
Rated Frequency 50 Hz ± 5%
Min. voltage for starting up to rated 370 V
speed
Stator Resistance / ɸ 1.28 Ω
FL Speed 1440 rpm
FL Current 15 A
No Load Current 6A
Starting Torque 150%
Max. Torque 200%
FL Efficiency 87 %
FL Power Factor 0.82
Insulation Class F
DOR CCW from NDE
Degree of Protection ,Enclosure & IP68
ventilation
123 | P a g e

Technical Diary: STAGE-I (2 X 500 MW)

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STAGE-I (2 X 500 MW)

MOUDA SUPER THERMAL POWER PROJECT

The diary contains the important technical data and specification

The team is grateful to GM (Mouda), AGM (O&M) for their guidance

1.1 General Specification 1

1.2 Furnace Specification 1

1.3 Water walls 1

1.5 Super heaters 3

1.7 Super heater & Re-heater Temperature Control 4

1.9 Safety Valves 5

1.10 Predicted Performance 5

1.11 Mill & Burner performance 8

1.12 O2, CO2, (Dry Vol.) & Excess Air 8

1.13 Heat Balance 9

1.14 Fuel Characteristics 9

2.1 Boiler Water Circulating Pumps 10

2.2 Mill System 11

2.3 Coal Piping & Burners 13

2.4 Igniters & Scanners 13

2.5 Seal Air Fan 14

2.7 I.D. Fan 15

2.8 F.D. Fan 19

2.9 P.A. Fan 21

2.10 Scanner Air Fan 23

2.11 Air Heater (Primary & Secondary) 24

2.12 Steam Coil Air Preheater 27

2.13 Electrostatic Precipitator 27

2.14 Soot Blower 30

2.15 Blow Down Vessels 31

2.16 Bottom Ash System 32

2.17 Fly Ash System 34

3.1 Specification of Main Turbine 37

3.2 Limiting Values 38

3.3 Material of Construction 41

3.4 Lube Oil System 42

3.5 Control Fluid System 45

3.7 Condenser Extraction Pump 49

3.10 Deaerator & FST 52

3.11 Boiler Feed Pump & Auxiliaries 53

3.13 Vacuum Raising System 61

3.14 Central Oil Purification Unit 62

3.15 HP Bypass System 62

3.16 LP Bypass System 63

3.17 LP Dosing System 65

3.18 Equipment cooling water system 66

4.1 General information 68

4.2 Rated data 68

4.4 Torque and Critical speeds 69

4.5 Generator volume & filling quantities 69

4.7 Generator Protection Relays 70

4.8 Seal Oil System 72

4.9 Primary Water System 74

4.10 Gas System 76

5.1 Generator Transformer(GT) 78

5.2 Station Transformer(ST) 78

5.3 Unit Transformer( UT) 78

5.4 Unit Auxiliary Transformer(UAT) 79

5.5 Unit Service Transformer(UST) 79

5.6 Station Service Transformer(SST) 80