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M/S KALYANI GERDAU STEELS LTD

1 X 6MW BLAST FURNACE GAS BASED POWER PLANT


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Sl.No. 8.0 GUARANTEE SCHEDULE Unit Remarks

8.01 Steam parameters and flow conditions with 10 TPH Extraction

a Steam pressure at the inlet of turbine stop valve ata 64

Steam temperature at the inlet of turbine stop


b valve Deg.C 480

c Exhaust parameters ata 0.22

d Normal steam flow condition

- Inlet flow at turbine ESV TPH 34.36

8.02 Guarantee parameters

a Net Power output at generator terminals kW 6000

b Power consumption of auxiliary equipment kW

c Auxilary cooling water flow Cu.M/Hr

Maximum temperature rise in the generator


d windings Deg.C Stator 85
above max. inlet temperature of cooling air of 400c

e Turbine cycle heat rate kcal / kw h 3860

f Vibration limits mm/sec

g Noise level at 1 mtr. distance dB(A) As per OSHA

BIDDER'S SIGNATURE:------ II.8.1 AVANT-GARDE


M/S KALYANI GERDAU STEELS LTD
1 X 6MW BLAST FURNACE GAS BASED POWER PLANT
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Sl.No. 8.0 GUARANTEE SCHEDULE Unit Remarks

8.01 Steam parameters and flow conditions without Extraction

a Steam pressure at the inlet of turbine stop valve ata 64

Steam temperature at the inlet of turbine stop


b valve Deg.C 480

c Exhaust parameters ata 0.22

d Normal steam flow condition

- Inlet flow at turbine ESV TPH 26.91

8.02 Guarantee parameters

a Net Power output at generator terminals kW 6000

b Power consumption of auxiliary equipment kW

c Auxilary cooling water flow Cu.M/Hr

Maximum temperature rise in the generator


d windings Deg.C Stator 85
above max. inlet temperature of cooling air of 400c

e Turbine cycle heat rate kcal / kw h 3025

f Vibration limits mm/sec

g Noise level at 1 mtr. distance dB(A) As per OSHA

BIDDER'S SIGNATURE:------ II.8.2 AVANT-GARDE


M/S KALYANI GERDAU STEELS LTD
1 X 6MW BLAST FURNACE GAS BASED POWER PLANT
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3.0 TURBOGENERATOR DESIGN INPUT AND MINIMUM


REQUIRMENTS.
Sl.N. Description Unit Requirement Acceptance

3.1 Design Input

3.1.1 Number of Turbogenerator No. 1.0 Yes

Turbogenerator Capacity (at 100%


3.1.2 MW 6.0 Yes
MCR)
Steam pressure at the inlet of turbine kg/cm2(a)
3.1.3 64 Yes
ESV
Steam temp. at the inlet of turbine
3.1.4 °C 480 Yes
ESV.

Deaerator outlet Temeprature / BFP


3.1.5 °C 130 Yes
discharge feed water temperature.

Process steam requirements at process 10000kg/hr,


3.1.6 Yes
point VD (Approx. 200m form turbine) 14 ata, 225°C

3.1.7 Process returen condensate quantity kg/hr Nil Yes

3.1.8 Exhaust steam pressure kg/cm2(a) 0.22 Yes

3.1.9 Cooling system Air cooled Yes

3.1.10 Economic steam rate % load 80 to 100 Yes

Minimum expected load at which TG


3.1.11 % MCR 15 Yes
is expected to operate
Maximum noise pressure level at
3.1.12 As per OSHA
1.0mts distance from any equipment
Bidder to
3.1.13 Generator Rating MVA indicate the 7.5
value.

3.1.14 Power factor (Lagging) 0.8 Yes

3.1.15 Generation Voltage KV 6.6 ± 10% Yes

Submitted by Arani Power Systems,


II.3.3 AVANT-GARDE
Updated on 26-12-2009
M/S KALYANI GERDAU STEELS LTD
1 X 6MW BLAST FURNACE GAS BASED POWER PLANT
------------------------------------------------------------------------------------------------------------------------------------------

Sl.N. Description Unit Requirement Acceptance

3.1.16 System Frequency Hz 50 ± 5% Yes

Ambient temperature for performance


3.1.17 °C 30 Yes
design.
Ambient temperature for electrical
3.1.18 °C 50 Yes
design.

3.2 Steam Turbine

TG vendor to
Inlet steam quantity at the inlet of furnish the
3.2.1 34.36 TPH
Turbine ESV details along
with HMBD.

TG vendor to
3.18 tph,
Bleed steam quantity, pressure and furnish the
3.2.2 5.98 ata,
temperature for Deaerator. details along
222.7 ºC
with HMBD.

TG vendor to
10 tph,
Bleed steam quantity, pressure and furnish the
3.2.3 14 ata,
temperature for Process requirement. details along
225 ºC
with HMBD.

Fixed pressure Constant Pr.


3.2.3 Type of Deaerator considered
type Deareator
1.5 times
3.2.4 Turbine casing hydraulic test pressure Yes
design pr.

3.2.5 Turbine Exhaust Orientation Down ward Yes

3.3 Gland Sealing System


Labyrinth type
Labyrinth type
3.3.1 Type of gland packing sealed with
sealed with steam.
steam.
13 Chromium, 13 Chromium,
3.3.2 Gland packing material
Stainless steel Stainless steel
Condensate
3.3.3 Gland steam condenser Yes
cooled

AC motor driven exhauster for gland


3.3.4 2x100% Yes
steam condenser

Submitted by Arani Power Systems,


II.3.4 AVANT-GARDE
Updated on 26-12-2009
M/S KALYANI GERDAU STEELS LTD
1 X 6MW BLAST FURNACE GAS BASED POWER PLANT
------------------------------------------------------------------------------------------------------------------------------------------

Sl.N. Description Unit Requirement Acceptance

HEI / ASME
3.3.5 Design standard for GVC HEI
SecVIII Div.1
SA 106
3.3.6 Shell material Gr.B /SA 515 SA 106 Gr. B
Gr.70

3.3.7 Tube material SA 213 TP 304 Yes

19.05 / 18
3.3.8 Tube size OD x THK Ok
BWG

3.3.9 Water velocity through the tubes m/s not less than 1 Yes

Hr.sq.m.deg.C
3.3.10 Fouling resistance /kcal 0 Yes

Corrosion allowance for the


3.3.11 mm 3.0 Yes
components other than the tubes

3.3.12 Tube side pressure drop kg/Sq.cm 0.5 Yes

3.4 Gear Box

3.4.1 Type Double helical Double helical

3.4.2 Service factor Min. 1.3 1.3

3.4.3 Gear Box noise level As per OSHA Yes

3.5 Oil System

2 X 100 %
3.5.1 No. of Oil coolers Nos Yes
(1W+1S)
2 X 100 %
3.5.2 No. of Oil filters Nos Yes
(1W+1S)

3.5.3 Tube side fouling factor for oil coolers m²h°C/kcal 0 Yes

3.5.4 Water velocity in oil coolers m/s >1.0 Yes

3.5.5 Oil cooler tube material Stainless steel Yes

Submitted by Arani Power Systems,


II.3.5 AVANT-GARDE
Updated on 26-12-2009
M/S KALYANI GERDAU STEELS LTD
1 X 6MW BLAST FURNACE GAS BASED POWER PLANT
------------------------------------------------------------------------------------------------------------------------------------------

Sl.N. Description Unit Requirement Acceptance

3.5.6 Oil cooler shell and tube sheet material IS2062 Yes

3.5.7 Plugging margin for oil cooler % 20 Yes

Corrosion allowance for the


3.5.8 mm 3.0 Yes
components other than the tubes
Capacity of oil purifier with respect to
3.5.9 normal rate of flow through the % 2.0 Yes
reservoir

3.5.10 Minimum filter grade for lube oil Microns 40 Yes

3.5.11 Minimum filter grade for control oil Microns 10 Yes

Minimum filter grade for the common


3.5.12 filter if used for both control and lube Microns 10 Not applicable
oil circuits.

3.5.13 Oil piping material up to filter Carbon Steel Yes

Oil piping material including valves


3.5.14 Stainless Steel Yes
(all wetted parts) from filter to bearings

3.5.15 Return oil piping material Carbon Steel Yes

3.5.16 Oil reservoir material IS2062 Yes

3.5.17 Corrosion allowance for the reservoir mm 3.0 Yes

3.5.18 Overhead emergency oil tank material Stainless steel Yes

3.5.19 Settling oil tank capacity m³ Min. 3.0 Yes

3.5.20 Capacity of oil transfer pump m³/hr Min.1.0 Yes

3.5.21 Settling oil tank material IS2062 Yes

3.6 Insulation

Submitted by Arani Power Systems,


II.3.6 AVANT-GARDE
Updated on 26-12-2009
M/S KALYANI GERDAU STEELS LTD
1 X 6MW BLAST FURNACE GAS BASED POWER PLANT
------------------------------------------------------------------------------------------------------------------------------------------

Sl.N. Description Unit Requirement Acceptance

3.6.1 Bounded Mineral Wool IS 8183 Yes

3.6.2 Hexagonal wire netting IS 3150 Yes

3.6.3 Cladding Aluminium Yes

3.7 Electrical system

6.6 kV, 6.6 kV,


3.7.1 Generation Voltage
3 phase 3 phase

3.7.2 Generator phase rotation Clock Wise Clock Wise

3.7.3 Generator winding connection Star Star

3.7.4 Short circuit ratio > 0.5 0.5

Three phase short circuit withstand


3.7.5 Sec. 3.0 3
time

Saturated rated direct axis sub-transient Between 12% As per TDPS


3.7.6 %
reactance to 18% generator specs

Maximum continuous negative As per TDPS


3.7.7 % 10.0
sequence current generator specs

Negative sequence withstand As per TDPS


3.7.8 Secs 15.0
underfault generator specs

3.7.9 Stator winding insulation Class-F Class-F

3.7.10 Rotor winding insulator Class-F Class-F

Temperature rise of stator and rotor at


maximum continuous rating at 0.8 pf at Limited to
3.7.11 Yes
working voltage and frequency class-B
stipulated.

IP-54 for Generator


3.7.12 Enslosure for alternator and exciter IP-54 & Exciter

Suitable for
3.7.13 Terminal box Yes
cables

Submitted by Arani Power Systems,


II.3.7 AVANT-GARDE
Updated on 26-12-2009
M/S KALYANI GERDAU STEELS LTD
1 X 6MW BLAST FURNACE GAS BASED POWER PLANT
------------------------------------------------------------------------------------------------------------------------------------------

Sl.N. Description Unit Requirement Acceptance

Brush less with Brushless


3.7.14 Excitation type
PMG Excitation

415 V, 3 phase,
3.7.15 Auxiliary Voltage Yes
4 wire

230 V, 1phase,
231 V, 1phase, AC
3.7.16 Control supply AC and 110V
and 110V DC
DC

3.7.17 Voltage variation % ± 10 ± 10

3.7.18 Frequency variation % ±5 ±5

Combined voltage and frequency


3.7.19 % ± 10 Yes
variation

3.7.20 System fault level at 6.6 kV System kA 31.5 Yes

3.7.21 Fault duration for 6.6 kV System Sec 3.0 Yes

Fault level & duration for 415V switch 50kA & 1


3.7.22 Sec Yes
gear Second

3.7.23 Fault duration for 6.6kV Cables Sec 3.0 Yes

3.7.24 Earthing system of 6.6kV NGR grounded Yes


RTDs quantity

3.7.25

12 (4 Nos. per
a) Winding Nos. 2 per phase
phase)

b) Stator core Nos. 4.0 Yes

4 (2 Nos. per
c) Bearing Nos. Yes
bearing)
4 (2 Nos. per
d) Air Cooler Cold & Hot air circuits Nos. Yes
bearing)

e) Exciter Field Nos. 2.0 Yes

3.7.26 AVR PANEL

Submitted by Arani Power Systems,


II.3.8 AVANT-GARDE
Updated on 26-12-2009
M/S KALYANI GERDAU STEELS LTD
1 X 6MW BLAST FURNACE GAS BASED POWER PLANT
------------------------------------------------------------------------------------------------------------------------------------------

Sl.N. Description Unit Requirement Acceptance

a) AVR Type Digital Digital

Two Auto & Two auto & One


b) No. of Channels of AVR
One manual Manual

3.8.27 LAVT Panel

a) Enclosure IP 52 IP 52

Submitted by Arani Power Systems,


II.3.9 AVANT-GARDE
Updated on 26-12-2009
M/S KALYANI GERDAU STEELS LTD
1 X 6MW BLAST FURNACE GAS BASED POWER PLANT
------------------------------------------------------------------------------------------------------------------------------------------

Sl.N. Description Unit Requirement Acceptance

b) No. of PTs (Dual Core) Nos Yes

c) Excitation PT No. As per SLD Yes

d) No. of LAs & SCs Nos Yes

Suitable for
e) Terminal Arrangement Yes
Cables

3.7.28 NGR

a) Enclosure IP 52 Yes

b) Metering CTs Nos Yes

c) Protection CTs Nos Yes


As per SLD
d) Differential CTs Nos. Yes

e) Neutral link No Yes

Suitable for
f) Terminal Arrangment Yes
Cables

Shall be
stainless steel
g) Resistors Yes
edge wound
type.

3.7.29 Protection, Metering & Control Panel

a) Enclosure IP 42 Yes

Microprocessor
based multi -
b) Protection relay with RS 485 interface. functional Yes
relay with
standby relay.
c) Additional discrete relay Yes

Submitted by Arani Power Systems, As per SLD


II.3.10 AVANT-GARDE
Updated on 26-12-2009 and
specification
M/S KALYANI GERDAU STEELS LTD
1 X 6MW BLAST FURNACE GAS BASED POWER PLANT
------------------------------------------------------------------------------------------------------------------------------------------

Sl.N. Description Unit Requirement Acceptance

d) Panel indicating meters Yes

e) Energy Mesurement As per SLD Yes


and
specification

f) Transducer (4-20mA). Yes

3.7.30 LT Cables

1.1 kV Grade,
a) PVC Cable Yes
Al. conductor
1.1 kV copper
b) Control Cables conductor, 2.5 Yes
Sq.mm

3.7.31 Motors

a) Degree of Protection IP 55 Yes

415 Volts +
b) Voltage Yes
10%
Energy
c) Type Yes
efficient

d) Insulation Class F Yes

VFD / DOL /
e) Starting Yes
S/D

f) Duty Continuous Yes

g) Cooling TEFC Yes

Rotatable 4 in
h) Terminal Box Yes
to 90 Deg.

3.7.32 DC Motor

Submitted by Arani Power Systems,


II.3.11 AVANT-GARDE
Updated on 26-12-2009
M/S KALYANI GERDAU STEELS LTD
1 X 6MW BLAST FURNACE GAS BASED POWER PLANT
------------------------------------------------------------------------------------------------------------------------------------------

Sl.N. Description Unit Requirement Acceptance

a) Protection IP 54 Yes

4 Deg. in to 90
b) Terminal Box Yes
Deg.
One No. with
c) Starter No. two stage Yes
resistors.

d) Insulation Class F Yes

3.7.33 HT Cable

6.6 kV XLPE
a) Type Yes
(UE)

b) Conductor Aluminium Yes

As specified in
c) Rating A Yes
SLD

Submitted by Arani Power Systems,


II.3.12 AVANT-GARDE
Updated on 26-12-2009