Technical Diary 500mw

TECHNICAL DIARY
1X500 MW HTPS, KW
HASDEO THERMAL POWER STATION

CHHATTISGARH STATE POWER GENERATION COMPANY LTD.
1
I. FLOW
HP Heaters In HP
U
Description Heaters
nit BMCR 500MW 400MW 300MW 250MW
out
Steam
t/h 1590.0 1457.9 1167.3 887.6 755.4 1385.5
Superheater outlet
t/h 1358.0 1302.1 1052.2 808.3 656.8 1379.0
Reheater outlet
Water
Feed Water t/h 1590.0 1432.9 1087.3 796.6 678.4 1297.5
SH spray t/h 0 25 80 91 77 88
RH spray t/h 2 0 0 0 0 13
Air
t/h 652 582 460 363 357 626
AH outlet (Primary)
t/h 15 4 26 23 10 41
Tempering air
t/h 1155 1067 841 610 464 1157
AH outlet (Secondary)
t/h 2024 1855 1529 1198 1033 2026
Total Combustion Air
Gas
Flue gas at RAPH inlet
(Primary & Secondary) t/h 2245 2057 1695 1329 1145 2247
Flue gas at RAPH outlet t/h 2444 2253 1882 1508 1318 2443
(Primary & Secondary) t/h 820 737 614 506 501 800
Inlet PAH t/h 1425 1320 1081 823 644 1447
Inlet SAH t/h 930 847 722 611 603 909
Outlet PAH t/h 1514 1406 1160 897 715 1534
Outlet SAH
Fuel
t/h 374 347 285 224 193 376
Coal
2
II. TEMPERATURE
HP Heaters In HP
U
Description Heaters
nit BMCR 500MW 400MW 300MW 250MW
out
Steam
0
Sat. temp. in Drum C 362.0 361.0 358.0 355.0 354.0 360.0
0
LTSH inlet C 365.0 364.0 363.0 362.0 362.0 365.0
0
LTSH outlet C 397.0 395.0 399.0 398.0 400.0 406.0
0
SH Panel Inlet C 397.0 389.0 378.0 367.0 365.0 383.0
0
SH Panel Outlet C 467.0 464.0 455.0 444.0 439.0 456.0
0
SH Platen Inlet C 467.0 464.0 455.0 444.0 439.0 456.0
0
SH Platen Outlet C 540.0 540.0 540.0 540.0 540.0 540.0
0
RH Stage-I Inlet C 338.0 337.0 329.0 322.0 311.0 351.0
0
RH Stage-I Outlet C 487.0 492.0 494.0 499.0 502.0 502.0
0
RH Stage-II Inlet C 487.0 492.0 494.0 499.0 502.0 502.0
0
RH Stage-II Outlet C 568.0 568.0 568.0 568.0 568.0 568.0
Water
0
Economizer Inlet C 255 253 243 230 219 169
0
Economizer Outlet C 318 315 309 305 297 286
Air
0
Ambient C 27 27 27 27 27 27
0
AH outlet (Primary) C 313 309 294 275 262 269
0
AH outlet (Secondary) C 311 305 294 275 262 266
Gas
0
SH Panel Inlet C 1378 1377 1383 1400 1392 1379
0
SH Platen Inlet C 1128 1115 1091 1067 1043 1125
0
RH Front Inlet C 1029 1013 981 944 914 1027
0
RH Rear Inlet C 852 836 799 756 726 855
0
LTSH Inlet C 673 658 626 590 567 678
0
Economizer inlet C 549 537 513 486 470 554
0
Airheater Inlet C 339 332 314 293 279 289
0
Airheater Outlet C 126 125 120 117 114 110
3
4
5
6
MAIN BOILER
7
General Specification
Manufacturer - M/s BHEL (C.E. Design)
Type - Top Supported, Balanced Draft, Dry bottom, Single drum

Controlled Circulation with Rifled tubing, Radiant Reheat.
Type of FIRING - Tilting TANGENTIAL
 Minimum load at which steam generator

Can be operated continuously with
Complete flame Stability without oil
Support (% MCR) -2 adjacent Mill at 50% capacity
 Minimum load at which the steam generator
Can be operated continuously with
Complete flame stability with oil
Support (% MCR) - 20%
 Maximum load for which individual mill
Beyond which no oil support is required - 50%
Furnace Specification
Type - Controlled Circulation
Wall - Water Steam cooled
Bottom - Dry
Draft - Balanced
Tube arrangement - Membrane
Explosion/Implosion
Withstand capacity at 67%
Yield point - +/- 660 mmWC
Residence time for fuel particles
in the furnace - 3 second
Effective volume used to calculate
The residence time (M3) - 14790
Height from furnace bottom ash
Hopper to furnace roof (M) - 62. 735
Depth (M) - 16.115
Width (M) - 19.177
Furnace projected area (M2) - 7610
Furnace volume (M3) - 17599
Attemperator
Type - Spray
No. of Stages - Single Stage
Medium of Spray - Feed Water
8
Re heater
Type -Stage I Pendant Platen
-Stage II Pendant Spaced
Total H.S. - 8620 m2
Control - Burner Tilt & Excess Air
Economizer
Type - Plain Tube
Total H.S. - 15200 m2
No. of Blocks - 3
Air Heater
Type - Bisector PAPH-27.5 VI 2000
Bisector SAPH-30.0 VI 2000
Total H.S - PAPH-40070 m2, SAPH-62740 m2
Motor - PAPH-11.0 KW, SAPH-18.5 KW
Safety Valves
9
Location of
SV Blow
Down S.No. Location Make set pr Value (kg/cm2)
Capacity
KGS/Hr.
1. LHS SV-1 Consol 209.0

235755
1750 WB
2. RHS SV-2 Consol 211.1
239256
1750 WB
BOILER 3. LHS SV-3 Consol 213.2
289192
DRUM 1750 WB
SV 4. RHS SV-4 Console 213.2
289192
1750 WB
293531
1740 WB
293531
1740 WB
SUPER 7. SH SV-7 Consol 188.5

200932
HEATER 1740 WD
SV 8. SH SV-8 Consol 188.5
200932
1740 WD
KGS/Hr.
9. Consol 185.5
129850
1538 VX
ERV 10. Consol 185.5
129850
10
SUPER 1538 VX
HEATER 11. Consol 186.6
129850
1538 VX
12. Consol 186.6
129850
1538 VX
13. Consol 186.6
129850
1538 VX
Location of
SV Blow
Down S.No. Location Make set pr Value (kg/cm2)
KGS/Hr.

212157
1786 WB
214248
REHEATER 1786 WB
INLET 16. LHS SV-16 Consol 54.00
216338
CRH 1786 WB
218427
1786 WB

160910
1786 WE
162496
1786 WE
164265
11
1786 WE
164265
REHEATER 1785 WE
OUTLET 22. R22 Consol 47.4
164265
HRH 1785 WE
23. R22 Consol 47.4
164265
1785 WE
24. R22 Consol 47.9
164265
1785 WE
25. R22 Consol 47.9
164265
1785 WE
MAIN PARAMETERS
FUEL DESIGN COAL
UNIT 100% 100% 50%
BMCR TMCR TMCR
GENERATOR MW - 500 250
Superheat Flow t/h 1590 1457.9 755.4
Reheat Flow t/h 1358 1302.1 656.8
Total Heat Output of System (Q Duty) Mkcal/h 1046.6 969.7 538.6
Pressure at Super heater Outlet Kg/cm2(g) 178 176.6 171.1
0
Temperature at SH Outlet C 540 540 540
Pressure at Re heater Inlet Kg/cm2(g) 45.02 43.19 21.45
0
Temperature at Re heater Inlet C 337.5 337.1 310.7
Pressure at Re heater Outlet Kg/cm2(g) 42.37 40.65 20.17
12
0
Temperature at Re heater Outlet C 568 568 568
0
Feed Water Temperature (ECO Inlet) C 254.5 253.4 219.4
0
Ambient Air Temperature C 27 27 27
0
Combustion Air Temp (secondary) C 311 305 262
Fuel Quantity t/h 374 347 193
Air Quantity (Total Combustion Air) t/h 2024 1855 1033
0
Temp of Flue Gas at Boiler C 126 125 114
Exit(corrected)
0
Temp of Recirculation Gas C - - -
Quantity of Recirculation Gas t/h - - -
Efficiency Based on HHV(BSEN 12953- % 84.84 84.85 84.74
15:2003)
13
CHEMICAL CONTROL LIMITS (WATER/STEAM CYCLE)
Parameters Cond Feed Boiler Steam
Drum
-------------------------------------------------------------------------
 pH at 250C 9.0- 9.0 9.1 9.0
9.2 9.2 9.4 9.2
 Sp. - - <30 -
Conductivity
µs/cm
 Cation Cond. <0.2 <0.2 - -

µS/ CM
 Res. Hydrazine 10-20

as N2H4 (ppb)
 Ammonia as 1.0 1.0

NH3 PPM (Max) (Max)
 Phosphate as <2
PO4 ppm
 Silica as Si02 <10 <10 <100 <10

ppb Max.
 Total Iron as Fe <10 <10 <10

ppb Max.
 Total copper as <3 <3 <3

Cu ppb
 Chloride as CI <500
ppb Max.
 D.O as 02 <40 <5

ppb Max.
 Sodium as Na <5
ppb Max.
 TDS (mg/i) <20

ppm
14
GENERATOR STATOR COOLING
WATER
 pH at 250C 6.5-8.5
 Cond. at 250C <2
µs/cm
 D.O. (ppb) <100
GENERATOR SYSTEM
 Hydrogen Purity >97.0

(%)
 Dew Point (0C) at (-)100 C – (+)100 C
 ECW pH at 250 C
(Controlled by) 8.5-9.0
Dozing Caustic
Solution)
RECOMMENDED LIMIT OF SILICA IN BOILER DRUM
DRUM SiO2 (ppm) DRUM SiO2 (ppm)

PRESSURE PRESSURE
------------------------------------------------------------------------------------------------------
60 155 0.30
80 160 0.20
100 1.9 165 0.15
120 0.90 170 0.10
130 0.75 175 <0.10
140 0.55 180 <0.10
145 0.45 190 <0.10
150 0.35 200 <0.10
15
BOILER AUXILIARIES
BOILER WATER CIRCULATING PUMP
Number off : 3 Nos. (2+1)
Electrical Supply : 6600 Volts - 3 phase - 50 Hz.
Make : Torishima Pumps (India) Pvt Ltd
Type & Size : Single suction-Double Discharge
HLAV 2x300-460/1C
Design pressure : 214 Kg/cm2
Design temp : 3700C
Capacity : 2987 m3/Hr
Total Head : 31.26 m
MOTOR CHARACTERISTICS
Type : Wet Stator-Squirrel Cage-Induction
Frame : HCV-55/40035-665
Output : 350 KW.
Voltage : 6600 V
Current : 47.9 A
RPM : 1470
Connection : Star
ID FAN
Type : Radial fan NDZV 47 S (SIDOR)
Make : BHEL
Suction Orientation : 60o top left
Delivery Orientation : Bottom Horizontal Right
Medium handled : Flue Gas
Location : Outdoor
No per Boiler : 2
Fan Design Rating

Capacity : 609m3/sec
Total head developed : 490 mmWC
Temp. Of medium : 1500C
Density : 0.764 kg/m3
Speed : 580 rpm
ID FAN MOTOR
Manufacturer : BHEL
Frame : 1D04344
Type : Synchronous motor, Continuous duty, VFD Driven
Rated voltage : 6600 V
16
Direction of rotation as viewed
From driving end : Clockwise
KW rating : 4075 KW
RPM : 580 (max)
Stator Volts : 2X2.3 kV
Stator Amp : 2X629 A
Excitation Volts : 98 Volts
Excitation Amp : 334 A
Connection : Double Star.
F.D. FAN
Type : Axial reaction API-26/16
No. per Boiler : Two
Fan design rating
Capacity : 277m3/sec
Medium Handled : Fresh air
Location : Outdoor
Total Head Developed : 410 mmWC
Temp. Of medium : 500C
Specific wt. of medium : 1.046 Kg/m3
Fan speed : 980 rpm
Type of coupling : Flexible
Fan wt. : 25.84Ton
Fan efficiency at 100% MCR : 81%
Lubrication equipment
Fan lubrication : Forced oil circulation
Motor lubrication : Grease lubricated
Type of fan regulation : Blade pitch control
Bearings
Fixed bearings : Cyl Roller Brg NU 248 C3, Angular
Contact Ball Bearing 7248 B
Expansion bearings : Cyl-Roller Brg. NU 248C3
F. D. FAN MOTOR
Manufacturer : M/s BHEL
Motor type : SQ Induction motor
From Non driving end : CCW
Rating for specified
Normal condition i.e. 500C : 1525Kw
Rated voltage : 6600 V
Full load current : 166 A
17
Speed : 980 rpm
PA FAN
Type : Axial reaction AP-2-20/12

Orientation : Horizontal
Medium Handled : Fresh Air
Location : Ground level Outdoor
No. per Boiler : 2
Fan design rating

Capacity : 193M3/sec
Total head developed : 1195mmwc
Temp. Of medium : 500c
Lubricating equipment
Fan Lubrication : Forced Oil circulation
Motor Lubrication : Grease
Type of Fan Regulation : Blade Pitch Control
P.A. FAN MOTOR

Manufacturer : M/s BHEL
Motor type : SQ Induction motor
From non driving end : CCW
Standard Continuous rating at
500C ambient temp : 2950 KW
Rated voltage : 6600
Full load current : 300 A
P.F : 0.89
RPM : 1480
Lube oil circulation system of P. A. fan
Tank capacity : 400 liters
Type of motor : A - 112-MA-4F
Output rating (motor) : 5.5Kw
Supply (motor) : 415 V+/- 10% 3 Ph, Delta-connection
Full load speed : 1425 rpm
Frequency : 50 Hz +/- 5%
Pump
Make : BORNEMANN
TYPE AND CAPACITY : E4V 045 KIF 215/1 363 dm3/s
Speed : 1450 rpm
18
Discharge pressure : 16 bar
SCANNER AIR FAN

Nos. : 2
One is A.C driven
Other is DC driven 100% standby
Make : Primo
Boosting pressure : 254 mmWC
Design capacity of each : 3600 m3/hr
Design temp. : 500C
Motor rating : 7.5 KW - 2 Pole, 415 V, 13.5 Amp
Speed : 2900 rpm
Type : Radial Back ward Curved
Blade Single Suction
Medium to be handled : Dust laden air
Max. Dust concentration : 300 mg/M3
Air Qty. : 1.30 m3/s
Air density considered at 200C : 1.2 kg/M3
Air density at operating : 1.09 kg/M3
Condition
Static pressure developed at
Air density of 1.2 kg/M3 and
At 200C. : 285 MMWC.
Static pressure developed at air : 280 MMWC
Density of 1.09 Kg/m3 and at
200C
Power Consumption at fan shaft
at air density of 1.2 kg/M3
and at 200C : 6.4 HP.
Power Consumption at fan shaft at
Air density of 1.09Kg/M3 & at 200C : 5.78 HP.
Direction of rotation of
Impeller when viewed from drive end: Clockwise.
Discharge Angle : Vertically upward.
AIR HEATER
PRIMARY AIR HEATER
Type : Bisector
Air Heater Size : 27.5 VIM 2000
Rotor Drive Motor : Energy Saver, 11 KW GEC,1460 RPM, 415 V,20 Amp.
Speed Reducer : Type-ID,3 Input, Up shaft, APC (FALK) 110:1
Approx. oil Capacity : 50 Litres
Coupling : 11.5 FCU (Fluid Coupling)
19
Bushings : Taper lock Bush & Adapter
No. per Boiler : 2
Filter Lubricator : Valjan 1 '' BSP
AUXILIARY DRIVE
Air Motor : Pneumatic Air Motor
IR 92RA014, 5.51:1
Coupling : Bibby Coupling 124 - A
Rotor Support Bearing : Spherical Roller thrust Bearing SKF - 294/500E
Rotor Guide Brg : Spherical Roller taper bore, 23060/CCK/C3/W33
RTD : 1” BSP (M) Duplex-Thermo well
Oil Capacity of support brg housing : 100 litres
Oil Capacity or guide brg housing : 50 litres
SECONDARY AIR HEATER
Nos. per Boiler : Two
Heater size : 30 VIM 2000
ROTOR DRIVE
Motor TEFC : 18.5 KW, 1460 RPM, 415 V, 3 PHASE,
50 HZ, 32 Amp (FL)
Speed Reducer : 7 AP, FALK 130.36:1
Oil Capacity : 98 Litres (approx)
Couplings : 12.75 FCU (Fluid coupling)
Bushings : Worthingdon Hub
Filter Lubricator : 1'' BSP
AUXILIARY DRIVE
Air Motor : Pneaumatic Air Motor
IR 92RA022,
Coupling : Bibby Coupling - 124 C
Rotor Support brg : Spherical roller thurst brg. SKF 294/750E
Rotor Guide Brg : Spherical Roller bearing 23072/CCK/C3/W33
RTD : 1” BSP (M) Duplex-Thermo well
Oil capacity of support brg housing : 150 litres
Oil capacity of Guide brg housing : 50 litres.
STEAM COIL AIR PREHEATER

PRIMARY SECONDARY
1. Design pr (Kg/cm )2
15 15
2. Hyd Test pr (Kg/cm2) 30 30
3. Design temp (0c) 210 210
4. Wt. of steam coil air 4850 5589
Pre heater (kg)
5. No. of steam coil air Two Two
Pre heater per boiler
6. Size of steam coil air 3150x4700x350 6000x3200x350
20
Pre heater (mms)
7. Installed Operation Horizontal Horizontal
SEAL AIR FAN

Manufacturer : BHEL
Type : Centrifugal fan NDFV 12.5 H Mounted
No. of Fans per Boiler : 2
Location : Outdoor.
Arrangement : Horizontal Shaft
Fan Weight : 1365 kgs.
Capacity : 8.4 M3/Sec.
Density of Medium : 1.022 Kg/M3
Total head developed : 508 MMWC
Speed : 1480 RPM
Drive Motor
Make : M/S Crompton Greaves
Frame : 280 S
Rating : 75KW
Type : Squirrel cage Induction.
Motor TEFC.
COAL MILL
BOWL MILL
Type of Pulveriser: : 1003 XRP
No. of Mills/Boiler : 10
No. required for full load : 7
Base capacity of Mill : 65 T/hr for a Pulverized
Fuel fines 70% through 200 mesh
with a raw coal of grindability.
Index 55 HGI and a total
moisture of not more than 8%.
Mill motor : M/s. BHEL, 525 KW, 6.6 kV, 600
RPM
Coupling : Gear type flexible coupling with
spacer assembly between mill &
Motor.
Bearings : Antifriction bearings for main
vertical shaft assembly journals
shaft assembly and worm shaft
assembly.
Cooling System : Immersed in oil bath
No. of Oil Coolers/Mill : Two
BOWL MILL MOTOR
21
Manufacturer : M/s Siemens West Germany/BHEL
Frame : 1LA7636-6
Motor Type : SQ - Motor
Standard continuous rating at 500C: 525Kw
Ambient temperature as per Indian
Standard
Rated voltage : 6600 Volts
Rated speed : 985 RPM
At Rated voltage and frequency
Full load Current : 64A
No load Current : 32 A
FOR BEARINGS
DRIVE END NON DRIVE END
a. Type : NU -230 6230 C3 NU - 226
B. Recommended lubricant : Grease - Servo Gem 30 F IOC
RAW COAL FEEDER

Type : SECO - 36'' Gravimetric (with
Mechanical Weighing)
Capacity : Minimum - 11350 Kg/hr.
Maximum - 87820 Kg/hr
Supplier : SECO. U.S.A.
Nuclear Monitor : 2 in No. (Upper and Lower)
Quantity Required : 18 RH
Density of material to be handled
Kg/m3 : 720 to 1280
Drive Motor (KW) : 5.6
Clean out motor (KW) : 0.22
Power supply : 415V, 3A, 50 Hz
Gear reduction : 130.5:1 at 1375 rpm
COAL BURNERS
Type : Tilting tangential
Make : BHEL
No. of Coal Burners feed by each : 4
Pulveriser.
No. of elevation of Burners : 10
Total No of Coal burners : 40
Temp. of Coal Air Mixture : 66- 770C
Max allowable temp. of Burners : 8500 C
Turn down ratio : 4:1
22
PRESSURE REDUCING AND DESUPERHEATING STATION
PRD Valves : One per unit
Flow Capacity of each valve : 110.3 T/hr.
Type of actuator : pneumatic
Body Material : WCB
Trim Material : S4 S420 J2 + H2
Body design pressure : 600 lbs class
Design Temp. : 3550C
De superheating water pressure : 314 kg/cm2
Temp. : 1850C
THERMAL INSULATION
OTHER
H. P. PIPING EQUIPMET TURBINE
-------------------------------------------------------------------
Insulation Material Mineral Wool Mineral Wool Mineral wool
(Rockwool)
Type of Insulation Boded type Boded Type Spray Type
Material (LRB -8183) Mattress Max temp
Insulating
Mat. Can withstand 7500C 750 0C 7500C
Insulating Material IS- 8183/98 IS- 8183/98 IS-8185/98
Standard
Density of
Insulating Material 150 kg/ m 3
Thermal Conductivity as per IS 8183 Kcal/ M/hr /oc at mean temp of

1. 500C 0.43
2. 1000C 0.52
3. 150 C
0
0.62
4. 2000C 0.68
5. 250 0C 0.80
6. 300 C
0
0.90
SOOT BLOWER(Wall)
Blower Nos. : 1 to 88
Travel : 305mm
Blowing Pressure : 11 kg/cm2
Speed (axial) : 6.1 MPM
Speed (rotary) : 0.7 RPM
23
Operating Time : 1.5 min
Cycles per day : 3
Blowing Angle : 3600
Light Diesel Oil

Service : Initial start-up and warm-up
Atomizer : External mixed, constant pressure,
compressed air atomized.
Fuel : LFO to IS 1460
Capacity maximum : Total 7.5% MCR heat input
Number of oil guns : 4 (in one elevation i.e. AB)
Location of oil guns : AB elevation (in auxiliary air nozzle)
LFO flow/gun : 2325 kg/hr (max), 850 kg/hr (min)
LFO pressure : 9.5 kg/cm2 (max), 3.0 kg/cm2 (min)
Atomizing air pressure : 5.25 kg/cm2 (min)
LFO Specifications
Standard : IS 1460
Pumping Temperature : 400C
Firing Temperature : 400C
Viscosity : 2.2 to 15.7 cst @ firing temp.
Total Sulfur : 1.8% by weight
Density at 40oC : 0.830 Kg/liter
High heating value : 10,000 Kcal/Kg approx.
Heavy Fuel Oil

Service : After sufficient warm-up of boiler,
during low loads, Turbine synchronization, Safe shutting down of boiler
Burner : Tilting tangential, corner fired
Oil Gun : Paralled pipe design, steam atomized,
External mixed, Constant pressure atomizer
Air nozzle : Rectangular
Diffuser : 190mm, 10 off 450 vanes with loading
edge with scanner and igniter cuttings
Atomizer spray angle : 900
Fuel : HFO/LSHS/HPS
Capacity : 30% MCR total in 5 elevations
Number of Guns : 20 (04 per elevation)
24
Location of Guns : AB, CD, EF, GH & JK (in Aux. air
nozzle)
HFO flow/gun : 2220 kg/hr (max), 850 kg/hr (min)
HFO pressure : 9.3 kg/cm2 (max), 3.5 kg/cm2 (min)
Minimum allowable HFO pressure : 3.0 kg/cm2
Minimum allowable steam pressure : 5.25 kg/cm2
Oil viscosity at the gun : 15 to 30 cst
Steam quality minimum : 10 to 150C superheat
HFO Specifications
Standard : IS 1593
Pumping Temperature : 570C
Firing Temperature : 1200C
Viscosity : 370 cst @ 500C temp.
Total Sulfur : 4.5% by weight
Specific gravity : 0.925@ 570C
Gross heating value : 10,270 Kcal/Kg approx
ELECTROSTATIC PRECIPITATOR
Design condition
Gas flow rate : 834.1 m3/ Sec
Temperature : 125 0C
Inlet Dust Concentration : 59.1 gm/Nm3
Outlet Dust Concentration : 19 gm/Nm3
ESP efficiency : 99.968 %
Type : 4xFAA - 9x45M2- 2x92150 -2
No of precipitator per boiler : Four
No. of Gas path per ESP : Two
No. of fields in series in each gas : Nine
Path
Pressure drop across the precipitator: 20 mmWC
for design condition
Velocity of gas inside ESP : 0.76 m/Sec
Treatment time : 53.29 Sec.
Specific collection area (M2/M3/sec) : 167.7
Guaranteed collection efficiency (%) : 99.52
Guaranteed air-in-leakage rate (M3/sec) : 2.8
Collecting Electrodes
No. of rows of Collecting electrodes per field : 2340
No. Collecting electrodes per field : 282
25
No. Collecting plates arranged in each row : 06
Total No. collecting plates per boiler : 10152
Nominal height of collecting plate : 15 meters
Nominal length of collecting plate : 750 mm
Specific collecting area : 268.03 m2
Emitting Electrode
Type : Spiral with Hooks.
Size : 2.7 mm Dia.
No. of electrodes in the frame forming one row : 54
No. of electrodes in each field : 2484
Total no. of electrodes per Boiler : 89424
Total length of electrodes per field : 15750 meters
Plate/wire spacing : 200 mm (400MM Pitch)
RAPPERS FOR COLLECTING ELECTRODES
No. and type of Rappers: One drop Hammer per row of collecting electrode having a
Collecting surface of 135 m2
Rapper Size : 4.9 kgs
Frequency of Rap: Varying from 12 raps/ hr at the inlet field to 0.1 rap/ hr at
the exit field. The frequency of rapping at intermediate
fields can be adjusted between 12 and 0.1rap per hour
according to requirements.
Drive : Geared electric Motor
Location : At the bottom of CEs.
Rappers for emitting electrodes

No. and type of rappers : One drop hammer for two
Rows of Electrodes
Rapper Size : 3.0 kgs.
Frequency of Rap : 10 raps/ hr.
Drive : Geared Electric Motor
Location : On middle frames of
emitting system frameworks.
Rapper for Gas Distribution System

Qty : 4
Rating : Geared MOTOR 0.5 HP 1.1RPM at 3 phase 415 V,
50 Hz.
Location : On the G.D. Housing side pan panels of the casing.
Hoppers
26
Type : Pyramidal
No. of hoppers/ ESP : 36
Total No. of hoppers : 144
Heating Element : Panel type, Electric heating provided at the bottom of
hoppers, Rating – 10kW, 1 Phase, 415V AC
Recommended thermostat setting for heater trip –
120oC
Baffling arrangement : 2 Sets of deflector Plates for each hopper across the
gas flow direction underneath the collecting plates
to prevent gas sneakage.
Rectifier
Rating : 95 kV DC (peak), 1000mA DC (mean)
Quantity / ESP : 18
Type : Silicon Oil, Silicon Diode, Full wave bridge
connection
Location : Mounted on the roof of precipitator
Rapping of Collecting Electrodes & Gas Distribution Screens

Quantity per ESP : 18 Nos.
Rating : Geared Motor 0.5 HP, 1.1 RPM, 3-Ph, 415V, 50 Hz AC
Location : On the ESP side panel / GD housing
Rapping of Emitting electrode
No. of rapping gear shafts : 18
Rating : Geared MOTOR 0.5 HP/2.5rpm at 3-ph 415v, 50 Hz
AC
Location : On middle frame of Emitting system frame work
27
TURBINE AND AUXILIARIES
SPECIFICATION OF MAIN TURBINE

a) Make : KRAFTWERK UNION, WEST GERMANY
b) Type : Three Cylinder, reheat, condensing turbine
c) Stages : HP 17 No, IP 12x2 No, LP 6x2 No
d) Nominal rating : 500 MW
e) Peak Loading (VWO) : 524.2 MW
f) Rated Speed : 3000 rpm
g) Max/ Min Speed : 3090 / 2850 rpm
h) Speed exclusion range : 400 to 2850 rpm
i) Direction of Rotation : Anti Clockwise when viewed from Front Pedestal
towards the Generator.
STEAM PRESSURES & TEMPERATURE (RATED VALUES):

Pressure (bar) Temperature (0C)
-----------------------------------------------------------------------------------------------------
a) Initial steam : 166.7 537
b) First Stage Pressure : 154.4 537
c) HP Cylinder Exhaust : 44.03 338.9
d) IP stop valve inlet : 39.63 537
e) Extraction 6 : 44.03 338.9
f) Extraction 5 : 17.32 414.8
g) Extraction 4 : 7.16 290.8
h) Extraction 3 : 2.753 191.4
i) Extraction 2 : 1.470 133.4
j) Extraction 1 : 0.339 70.9
k) L.P. Cylinder exhaust : 0.1013 46.3
WEIGHT (Tones):
HP IP LP
----------------------------------------------------------------------------------------------------
a) Rotor : 16 23 100
b) Cylinder Assembled : 95 42 86.0
c) Main stop & control valve : 22
d) Reheat stop & control valve : 32
Moments of Inertia (kg/m2):

a) Rotor of HP Cylinder : 713.0
b) Rotor of IP Cylinder : 2145.6
C) Rotor of LP Cylinder : 22981.0
28
LIMITING VALUS
® Casing Temperature (0c)

Alarm M/C must be shut down at.
a) HP Turbine Exhaust : 480 500
b) Outer Casing of LP : 90 110
Cylinder
(Spray water to LP cylinder must switched on at 900C)
® Temperature Difference (0K) (Between upper and lower casing section)

Alarm m/c must be shut down at
-------------------------------------------------------------------------------------------------
a) H.P. Turbine middle : +/- 90 +/ - 100
b) I.P. Turbine Front : +/- 30 +/- 45
c) I.P. Turbine Rear : +/- 30 +/- 45
® Steam purity (KWU Recommended Values)

a) Conductivity at 25 0C : < 0.15 Ms/CM
Alkaline method
b) Silica Acid (SiO2) : < 0.010 mg/kg
c) Total iron (Fe) : < 0.005 mg/kg
d) Total copper : < 0.010 mg/kg
e) Sodium (Na) : < 0.02 mg/kg
® Bearing temperatures (0C)

Alarm M/C must be shut down at.
--------------------------------------------------------------------------------------------------------------------------
a) Normal operating temperature : 90 130
Below 75 0C
b) Normal operating temperature : 100 130

Above 750
® Vibration (Absolute Vibration)

Bearing Housing Shaft
a) Nominal valve for Alarm : 50 microns above
Normal level
b) Max. Value for alarm : 84 microns 200 microns
29
c) Limit value for tripping : 106 microns 320 microns
(Manual)
® Differential Expansions
a) H.P. Turbine : + 5mm - 3mm
b) I. P. Turbine : +8mm - 2mm
c) L.P. Turbine : +30mm - 3mm
MATERIAL OF CONSTRUCTION
Casings
H.P. Outer Casing/ Barrel Casing : GS 17 Cr Mov 511
H.P. Blade carrier : GS 17 Cr Mov 511
I.P. Casing : GS 22 MO 4
L.P. Casing : Outer St. 37-2 N
: Inner I- GS M04,H II, 15
M03
: Inner II St. 37- 2N
Shafts
H.P. Shaft : 28 Cr. MONI 59
I.P. Shaft : 30 Cr. MONIV 511
L.P. Shaft : 26 Ni Cr. NOV 145
Moving Blades
H.P. Turbine first stage : x 22 cr Mov 121
H.P. Turbine other stages : x 20 cr 13 / x 22 cr
Mov121
I.P Turbine stages : x 20 cr mo 13 / x
20 cr 30
L.P. Turbine stages : x 20 cr 13
Fixed Blades
H.P Turbine First stage : x 22 Cr MOV 121
H.P Turbine other stage : x 22 Cr MOV 121x20Cr

MO 13
IP : x 22 Cr 13 /x 20 Cr MO 13
LP : x 20 Cr 13 /x 20 Cr MO
1320 Mn5/x 7 Cr MO 13
Casing Joint Bolts
H.P. Cylinder : 21 Cr MOV 57
IP : 21 Cr MOV 57
LP : St. 50/24 Cr. M0 5
Shaft couplings same material as shaft
30
IP/LP cross over/ cross around piping ST. 37/ St 42 W
No. of bearings including Thrust Bearing of Turbine: 4 Journal + 1 Thrust
Size of bearing
I II III IV
------------------------------------------------------------------------------------------
Diameter mm 280 380 560 560
Length mm 140 290 500 560
Antifriction material used in Bearings: Babbit

Type of thrust bearing combined journal: Mitchel thrust bearing.
LUBE OIL SYSTEM

Lube Oil Specification
S/No Properties /Test Numerical Value Unit
--------------------------------------------------------------------------------------------------------------------
1. Forming Characteristics at Max 400 CM3
25 C Foaming
0
Foam Stability (0cm3) Max 450 S

2. Water content Max 0.01 wt%
3. Steam emulsion test Max 300 S
4. Solid foreign Matter Max 0.05 wt %
5. Cleanliness to SAE A - 6D
a) With servo valves Min 3 Filter class
b) Without servo valves Min 3 - do -
6. Flash point Min 200 o
C
7. Pour point Min -6 0
C
8. Demulsibility max 20 Min.
9. Color Max 2 -
10. Copper strip test Max 2-100 A3 Corrosiveness
11. Corrosion resistance to Max 0-A Mg KOH / g
Steel
12. Oxidation characteristics, Max. 2.0 mg KOH/ g
Increase in neutralization
Number
13. Kinematic viscosity at 400C 41.4-50.6 mm2/s (cst)
Kinematic viscosity at 50 C 0
28.8 mm2/s (cst)
14. Density at 15 C 0
Max. 0.900 g/cm3
15. Neutralization Number Max. 0.2 mg KOH/g
16. Air Release at 50 0C Min. 5 Min.
31
Oil Supply System
a) Oil tank rated capacity : 25/40 m3
b) Highest Oil level from top of : 900 mm
Tank
c) Lowest oil level from top of : 950mm
Tank
d) First oil filling : 53 m3
e) Flushing Oil quantity : 25m3
Duplex Oil filter for Jacking Oil

a) Number : 2x100%
b) Filtration Particle Size : 37 Microns
Jacking Oil pump

a) Safety Valve Setting : 200/ 180 ata
b) Pressure limiting valve setting : 180/ 140 ata
c) Pump starts at a turbine speed of : <510 rpm
d) Pump stops at a turbine speed: > 540 rpm
Specification of Oil pumps

Pump MOP AOP DC EOP JOP
------------------------------------------------------------------------
Number 1 2 1 1 AC + 1 DC
Make BHEL M&P M&P TUSHACO
Type - 5/6 4/5SR T 38/46
EHLG 12KL MODEL 70
Capacity (Rated) 87.48 100 30 1.85
Dm3/Sec
Discharge pressure 8.4 6.3 2.3 178
Kg/Cm (Gauge) at
2
Speed (RPM) 3000 2970 1425 2900

Drive Turbine AC Motor DC motor AC & DC Motor
Motor
Make CG CG CG/CG
Voltage 415 220 415/220
Motor Power (KW) 110 13 60
Rated Current (A) 173 97 95
Starting Current (A) 265 420 1140
RPM 2965 1425 2955/2900
Lube Oil Cooler

a) Number : 2x100%
b) Cooling Surface : 640m2
c) Oil flow : 240m3/Hr.
32
d) Heat dissipating capacity : 552.15 K.cal/s.
e) Oil inlet temperature : 65 0c
f) Oil outlet temperature : 45 0C
g) Oil pressure drop (approx) : 0.22 at
h) Cooling water inlet temp. : 38 0C
i) Cooling water outlet temp. : 40.20C
j) Cooling water Pressure drop : 0.1 at
(Approx)
k) Tube material : Admirality Brass
l) Tube sheet material : Leaded Brass (60.40)
m) Permissible gauge Pressure : 9.8 ata
during operating water side.
n) Test gauge pressure water : 14.7ata
side
o) Permissible gauge Pressure : 7.85ata
during operation Oil side
p) Test gauge pressure Oil side : 11.77ata
CONTROL FLUID SUPPLY

A) Fire resistant fluid is used for the control system
a) Control fluid tank rated capacity. : 10/16 M3
B) Highest fluid level from top of tank : 700 mm
c) Lowest fluid level from top of tank : 750 mm
d) First Oil filling : 15 M3
e) Flushing fluid quantity : 12 M3
B) Filters
a) Numbers. : 2 Nos.
b) Earth filling : 30/60 Mesh
c) Fine mesh filter : 1 No.
d) Filtration Particle size : 3 to 5 micron
e) Filter Material : Cotton.
C) Control Fluid Cooler
a) Numbers : 2x100 %
b) Cooling Surface : 19.6 m2
c) Fluid flow : 82.4 M3/Hr.
d) Heat dissipating capacity : 24.55 k.cal /s.
e) Fluid inlet temperature : 55 0C
f) Fluid pressure drop : 0.25 at
g) Cooling water inlet temperature : 38oC
h) Cooling water outlet temperature : 41.8 C 0
i) Cooling water pressure drop : 0.1 at

j) Tube material : Admirality Brass
k) Tube sheet material : Leaded Brass (60:40)
33
l) Permissible gauge pressure : 9.8 at
during operation water side.
m) Test gauge pressure water side : 14.7 at
n) Permissible gauge pressure during : 7.85 at
Operation fluid Oil side
o) Test gauge Pressure fluid side : 11.77 at
D) Barring Gear
a) Type of Drive : Hydraulic turbine
b) Method of engagement : Hydraulic
c) Cut in / cut speed : 210/240 rpm
d) Barring speed : 80-200 rpm
E) Governing
There are two speed controlling devices, Speed Sensor
i) Hydraulic speed Governor : Primary Oil pump
ii) Electro- Hydraulic controller : Hall Generator.
(There are 3 in Nos.
One in spare)
iii) Over Speed Set Value : 10- 11 %
F) Gland Sealing System
a) Electro - Hydraulic, self sealing after : 40% Load
G) Motor
Make- Siemens, 121 KW, 415 V, 200 Amp, 2984 rpm
BOILER FEED PUMPS AND AUXILIARIES
A) Booster Pump Details:
Motor Driven Turbine Driven
Manufacturer Delaval Stork Delaval - stork

Pump type KHTB 50-35/25 KHTB 50-35/25
Rotation (Viewed form DE) C.W C.W

Operating Temperature (0C) 164.6 164.6
Specific gravity at operating 0.901 0.901
Temperature
Flow (m3/Hr.) 1072 1072
Abs.suc. pressure (kg/cm2) 9.25 8.5
Abs disch pressure (kg/cm2) 16.05 18.2
Head (m) 76 108
NPSH 3% (m) 4.9 5.6
NPSH 0% (M) 6.1 7.0
Efficiency (%) 80.1 80.7
34
Shaft power (Kw) 264 345
Speed (rpm) 1495 1720
B) Boiler feed pump- Main pump

Manufacturer Delaval - stork Delaval - Stork
Pump type 5BB 81510 5BB 81510
Rotation (Viewed from DE) CCW CCW
Number of Stages 4 4
Operating temp (oC) 164.6 164.6
Sp. gravity at operating temp 0.901 0.901
NPSH required (M) 31 31
Capacity at suction (m3/hr) 1072 1072
Bleed off (m3 / hr) 42.7 42.7
Kicker stage (m /hr)
3
95.4 95.4
Min. allowable capacity (m3/hr) 256 256
Total dynamic head (m) 2224 2192
Total dynamic head at min 2642 2614
(m) Flow and 5366 rpm)
Speed (rpm) 5395 5366
Power required (Kw) 7002 6908
Efficiency (%) 82.2 82.1
C) Variable speed Geared coupling for M.D. BFP

Manufacturer Voith
Type R18 KGS- 14
Input speed 1420 rpm
Output speed 4886 rpm
Power 7487 KW
Oil tank filling 2500 liters
D) Boiler Feed pump Drive - Motor

Manufacturer BHEL
Type ITE 7538- 8FE72-Z
Rated power 10000 KW
Speed 1495 rpm
Full load current 605 A
Voltage 11000 V
Frequency 50 Hz
E) BFP Turbine
Manufacturer : Delaval - Stork
Type/ : KJ- MV- SF- 7R
Output (KW) : 7262
Max. Cont. Speed (rpm) : 5567
35
Rotation (Seen in Direction of : C.C.W
Steam flow)
Ist Lateral critical speed (rpm) : 3710
Steam Inlet pressure (ata) : 7.486
Auxiliary steam inlet press (ata) : 26.5
Steam inlet temperature, (0C) : 299
Auxiliary steam Inlet Temp (0C) : 340
Exhaust pressure (ata) : 0.1
Over speed Trip at, (rpm) : 5900
F) Gear Box (T.D.)
Manufacturer : Tacke
Type : TNB 200
Input speed, (rpm) : 5406
Output speed, (rpm) : 1740
Power (KW) : 401
Agma Service factor : 2.0
G) Lube and Control Oil for BFP
Tank capacity (Max) 5750 Liters
Capacity (Operating level) 4050 liters
H) Main Lube Oil / control Oil Pump

Make : Alweiler
Type : SNDA 440 -46
Number : 2x100%
Capacity : 855 Liters/ Min.
Discharge press. : 15 kg/cm2 (g)
Power consumption : 27 KW
I) Motor
Make : GEC
Type : D225 MD
Power : 37 KW
Speed : 3000 rpm
Power supply : 240/415 V, 3 ph, 5o Hz
Insulation : Class B
J) Emergency lube Oil pump (D.C)

Make : Allweiler
Type : SNDA 210-46
Number : One
Capacity : 414 Liters/min.
Discharge Press. : 4.5 kg/cm2 (g)
Power cons. : 5.2 KW
36
K) Motor
Make : GEC
Type : YD 200 LAD
Power : 7.5 KW
Speed : 3000 rpm
Power supply : 220 VDC
Insulation : Class B
DEAERATOR
Manufacturer I. A. E.C India Ltd.

Type SPRAY
Design Pressure (internal) 8.8 kg/cm2 &Vac.
Design pressure (external) 1.055 kg/cm2
Design temperature 325 oc
Feed water outlet temperature 164.6 0c
Operating pressure & Temp 7.218 kg/ cm2 (a) & 298.7 0C
Storage capacity 170 M3 at 2/3 CSA (Excluding Heads)
Outlet capacity 1530.375 T/hr
Oxygen Guarantee 0.005 ML/ L (7ppb)
Number of holes on Steam line 5120
Number of condensate 2
Spray valves
Number of safety valves 3 (8.8kg/cm2, 8.4 kg/cm2, 8.0 kg/cm2)
and their set pressures
Number of supports 3 (fixed and 2 roller supports)
Outside dia of shall 3636 mm
Straight length of shell 26660 mm
Overall length of shell 28550 mm
VACUUM RAISING SYSTEM-2 No of 100%EACH
No of stages = One
Pump rated speed = 590 rpm
Rotor/ vane tip Speed = 21.9 m/sec
Motor
160 KW, 50 Hz, 0.415 kV, 3 Phase
a) Type squirrel cage, induction motor
b) Full load current 305 Amps
c) Power factor at rated load 0.78
d) Rated speed 590 rpm
e) Efficiency 93.8%
37
CONDENSATE EXTRACTION PUMP
Supplier BHEL
Type of First Impeller Double Suction
Number of stages 4
Design Flow rate capacity 817. 36 m3 /hr
Inlet - Temperature 43.1 0C
Inlet - specific Gravity (specific wt) 0.991 kg/dm3
NPSH required 3.4 meter
Discharge pressure 32 ata
Total dynamic Head 320 meters
shut off Head 398 meters
pump Speed 1485 rpm
Power Consumption at design condition
i) Power input at the motor Driver H.P 886.1KW
ii) Losses in the motor 34.1 KW
iii) Power input to the pump 852 KW
iv) Efficiency of the pump alone 82.8 %
v) Overall efficiency of the pump motor 79. 6%
Motor of Condensate Extraction pump
Manufacturer BHEL
Motor type ORNVG X 630 ia 4
Direction of rotation as COUNTERCLOCKWISE
Viewed from non- driving end
Standard continuous rating
at 50 0C ambient temperature
as per Indian Standard ( KW) 900 KW
Rated voltage (Volts) 6600 V
CONDENSER
Type Single
Area of Condenser surface Area 26612 sq. meters
Number of cooling tubes 24398
Length of each tube 14630 mm
Size of tubes - 22.225 x 0.7112
(OD X thickness in mm)
Tube material - SS. 304
Weight of empty condenser 600 TE
Weight of tubes 144.8 TE
C.W. flow 54000 M3 /hr
C.W. velocity 1.8288 M/sec.
C.W. design 28oC
C.W. Max Inlet temperature 33oC
C.W. Max outlet temp 43.05 oC
38
Back Pressure at MCR 65.278 mm of Hg
at 28oC
Condenser Temperature rise max 10.050C
Terminal temperature Difference with 3.32oC
C.W. flows with steam
Pressure loss condenser 4050 mmWCl
Fouling factor 90%
Cleanliness factor 0.90
CIRCULATING WATER SYSTEM

C.W. Pumps
1. Name of Manufacturer KIRLOSKAR BRO LIMITED
2. Type Vertical Mixed flow, SEMI Open full out single stage type.
3. Number of pumps 3 Nos.
4. Discharge Capacity 33000M3 /Hr.
5. Guaranteed total head at pump 27.0 m
Discharge flange
6. Rated speed 373 RPM
7. Thurst brg.
Type of thurst brg Tilting pad type
Method of Lubrication & cooling Self lubrication with cooling water tubes.
C.W. Motor
Manufacturer BHEL
Type Squirrel cage Induction MOTOR
Standard Continuous - rating at 400C App 3160 KW
Ambient temp
Rated Voltage & frequency 6.6 KV & 50 Hz
Rated speed at rated Voltage & Frequency 375 RPM
EQUIPMENT COOLING WATER PUMPS
T.G. Side
Number 2(1+1)
Motor 3ph, 50Hz, BHEL, Continuous Duty
K.W. 132
Voltage 6600 V
RPM 1480
Connection Star
S.G. Side
Number 3(2+1)
Motor 3ph, 50Hz, BHEL, Continuous Duty
K.W. 180
Voltage 6600 V
RPM 1480
39
Connection Star
Self Cleaning Strainer
Make BHEL
Normal/Maximum Water Flow 3400 m3/Hr, / 4080 m3/Hr
Operating/Test Pressure 3.0 to 3.5 Bar / 11.25 Bar
Design Pressure 7.5 Kg/cm2
Design Temperature 600C
Fluid Handled Clarified Water
40
GENERATOR & AUXILIARIES
GENERATOR
General
Make BHEL (KWU)
Type THDF 115/59
Code IEC 34-1, VDE 0530
Cooling Stator winding directly water cooled.
Stator core & Rotor directly hydrogen cooled.
RATING
Apparent power 588 MVA
Active Power 500 MW
Power factor 0.85 (lag)
Terminal voltage 21 KV
Permissible variation in + 58 %
Voltage
Speed/ Frequency rpm/Hz 3000/50
Stator current 16200 Amps
Hydrogen pressure kg / cm2 4
Short Circuit Ratio 0.48
Field current (Calculated value) 4040 A
Field Voltage 340V
Class and type of Insulation MICALSTIC (Similar to class F)
No. of terminals brought out 6
Resistance in ohms at 20oC
Stator winding between terminals u-x 0.001414
v-y 0.001417
w-z 0.001420
Rotor winding F1- F 2 0.068293
MAIN EXCITER
Active Power 3780 KW
Current 6300 A
Voltage 600 V
Speed 3000 rpm
Pilot Exciter
Apparent power 65 KVA
41
Current 195A
Voltage 220V (1+ 10%)
Frequency 400 Hz
PF 0.6
CRITICAL SPEEDS
1. Critical speed (Calculated) nk1 14.4 S-1 (VGEN)
nk2 30.1 S-1 (V-EXC)
nk3 39.8 S-1 (S-GEN)
GENERATOR VOLUME AND FILLING QUANTITIES

1. Generator volume (Gas Volume) 80 m3
2. Co2 filling quantity *** 160 M3 (STP) *
3. H2 filling quantity ** (to 4 bar) 520 M3 (STP) *
* STP = Standard temperature and pressure. O 0C and 1.013 bar to DIN 1343.
** Volume required with unit at stand still with the unit on turning gear, the volume will
be higher.
*** Co2 quantity kept on stock must always be sufficient for removal of the existing
hydrogen filling . All values are approximate.
GENERATOR PROTECTIONS
Generators are high quality machines for securing the best possible continuity of power supply.
In addition to a suitable technical design and responsible mode of operation, provision has
therefore been made for automatic protection facility the following protections have been
provided in the 500 MW TG.
1. Generator Differential protection (87G)

2. Generator Low forward power protection (37G)
3. Negative phase sequence protection (46G)
4. Pole slipping protection (98 G)
5. under frequency protection (81 G)
6. L.B.B. Protection (50 G)
7. Gen field failure protection (40G)
8. Stator Earth fault protection (64 G1 & 64G2)
9. Inter turn fault protection (95 G)
10. Overload protection (51g)
11.Over Voltage protection (59G)
12. Gen. Back up impedance protection (21G)
SEAL OIL SYSTEM

Seal Oil pump 1 and 2 air side -
42
Kind of pump screw pump
Make CG
Type SNH 210 - R46 (All Weiler)
Capacity 3.3dm3/sec
Discharge pressure 15 bar
Pump motor type 1 LA 3 133- 4AA90 (Siemens)
Rating 7.5 KW
Voltage /frequency 415v, 50 Hz
Current 13.79 A
Speed 1455 RPM
Type of enclosure IP 54
No. 2 Nos. full-capacities
Seal Oil pump-3, AIR side (DC SOP)

Kind of pump Screw pump
Make CG
Type SNH 210 - R46 (All weiler)
Capacity 3.3 dm3 /s
Pump motor Type I Ha 4165- 50JL20 (Siemens)
Rating 8.5 KW
Voltage 220V DC
Current 67 A
Speed 1450 rpm
No. 1 No. full - capacity,
Seal Oil pump H2 side (AC)

Kind of pump Screw pump
Make CG
Type SNH 210- R46
(ALL Weiler)
Capacity 2.17 dm3 / s
Pump motor type ILA3 133- 6AA90
(Siemens)
Rating 4 KW
Voltage 415V, 50 Hz
Current 8.38 A
Speed 950 rpm
Type of enclosure IP54
No. 1 No. full - capacity.
43
PRIMARY WATER SYSTEM
Primary water pumps 1 and 2 SS11 DOO1/SS11
DOO2
Kind of pump Centrifugal pump
type Cpk -cm 65- 250
( KSB)
Speed 47 S -1
Capacity 19 dm3/s
Discharge head 80 m
pump motor type ILA 4207 - 2AA90
(CG)
Rating 37 KW, 64 Amp
Voltage 415V, three phase AC
Frequency 50 Hz
Speed 2690 rpm
No. 2 Nos. full-capacity
EXCITATION SYSTEM
A- Wheel (negative polarity)
No/type of diodes 60 No/ssi1 12 120

S3 (Siemens)
No./ Type of fuses 30 Nos./3 NC 9 538
Resistance/ Voltage / Current Approx. 150/ 800V,
800 A
Per fuse No. of RC networks 6 Nos.
B- Wheel (Positive Polarity)

No. Type of diodes 60 Nos. /SSil 13 120
D3 (Siemens)
No./ Type of fuses 30 Nos./3 NC 9 538
Resistance/ Voltage / Current approx. 150/ 800V, 800 A
Per fuse No. of RC networks 6 Nos.
SPECIFICATIONS OF TRANSFORMERS
Generator Transformer
1. Manufacturer BHEL
2. Nos. of units 4 Nos.
3. Rating HV & LV (MVA) 200 MVA
4. Rated Voltage, HV 420 KV
5. Rated Voltage. LV 21 KV
6. Rated current, HV 825 Amps
44
7. Rated current, LV 9520 Amps
8. No. of phases 1
9. Frequency 50 Hz
10. Type of cooling OF AF
11. Connection symbol when YD5
formed a bank.
12. Impedance at principal tap 12.5%
(750C)
13. OFF CKT Tap Changer Tapings in 5 equal steps of
2.5% each provided on HV
Winding to give + 5% to - 5%
14. Temperature rises Variation of high voltage
i. Oil by thermometer 500C
ii. Winding by resistance 550C
15. CTI and WTI, auxiliary contacts

Settings
i. OTI Alarm 850C
Trip 900C
ii. WTI Alarm 1050C
Trip 1150C
Station Transformer
2. Nos. off 2
3. Capacity 20/35/50 MVA
4. Voltage Ratio 33/11.5/6.9 KV
5. Vector group DY/nY/n
Unit Auxiliary Transformer

2. Nos. off 2
3. Capacity 20/25
4. Voltage Ratio 21/6.9 KV
5. Vector group DYN
6. Cooling ONAN/ONAF
7. Percentage impedance 8.5%
COMPRESSED AIR SYSTEM & AUXILIARIES
COMPRESSED AIR SYSTEM
Manufacturer : Atlas
Type of compressor : Horizontal Balanced Opposed
45
Numbers : Instrument Air : 2 Nos.
: Service Air : 1 Nos.
Actual capacity of each compressor : 30.0 Nm3/min
Discharge pressure Kg/cm2 gauge : 8.0
Design ambient temperature : 50 deg C
Design ambient pressure : 0.99753 Kg/cm2 abs
Design ambient humidity : 100%
Exact capacity considering worst : 39.05(at45 deg.C&75%RH)
Ambient condition as stated in data
Specification sheet in M3/Min of

the air discharge (F.A.D.)
Air temperature after first stage : 159 deg. C
of compression
Air temperature after last stage of : 160 deg. C
compression (actual)
Outlet air temperature (After : 42 deg. C
cooler) 0C
Compressor efficiency at design condition : 75%
Mechanical efficiency at design : 90%
condition
Air pressure after L.P. stage : 1.9 Kg/cm2 g
KW input required at the compressor : 204.8
shaft in design rated condition
KW input required at the compressor : 212.00
shaft at design rated corresponding
to 103% of the rated speed.
Guaranteed power consumption : 224.56
(Maximum i.e. without any tolerance)
Crankshaft speed, rpm : 591
Total cooling water requirement : 240
M3/hr (For all compressors and its
Accessories located in compressor house)
Number of stage : Two
Single acting or double acting : Double
Type of drive : Direct coupled thro flexible
coupling
Cylinder bore in mm : LP 530. HP 335
Stroke, mm : 200
Clearance in % of volume : LP - 11%, HP - 14.5%
Thickness, mm : LP - 16.5, HP - 14.50
Method of cylinder Lubrication : Non-Lubricated
IA/SA Motor
Make : Marathan
46
Frame : DC 355 F900
Rating : 315 KW, 6.6 KV, 32.5 Amp, 2982 rpm
DIESEL GEN. SET
Engine
Rating at site condition : 750 KVA
Engine type : KTA 3067 G
RPM : 1500 rpm
No. of Cylinders ^ arrangement : 16 cylinders 600 Vee.
Starting time : 30 Sec from Cold
Governor : PSG Motorized
Fuel Oil : HSD as per IS: 1460 grade
Lube Oil : MIL IS2104 C
Guaranteed fuel oil
Consumption at 100% : 150 gms/BHP/hr
Lube oil consumption : 0.62 lit/hr
Mech. Efficiency : 38%
Total Weight : 6 Ton
Alternator
KW : 600
KVA : 750
Pf : 0.8
Stator Current : 1043 A
Speed : 1500 rpm
Frequency : 50 HZ at 1500 rpm

Excitation Current : 2.5A at 47.0 V.
& Voltage
Efficiency
Load 110% : 93.7%
100 % : 94.6%
75% : 94%
50% : 93.5%
25% : 90.5%
Regulation - 30% Thru AVR voltage is maintained within +/- 1%
Fire Hydrant Motor

Make : Jyothi Ltd.
Frame : CWT- 316
Rating : 200 KW, 6.6 KV, 22.8 Amp, 1495 rpm
Back Up ACW Motor

47
Make : BHEL
Frame : 1L-7710-8
Rating : 570 KW, 6.6 KV, 68 Amp, 1495 rpm
INTER LOCK & PROTECTION
48
BOILER & AUXILIARIES
AIR PREHEATER INTERLOCKS :
AIR PREHEATER CAN BE STARTED IF THE FOLLOWING PERMISSIVES

ARE MET:-
- Guide bearing lop is not in off position. Support bearing lop is not in off position
- Air motor air supply available (air supply before solenoid valve/manual valve
- Local push button in released condition.
ID FAN INTERLOCKS :
ID Fan PERMISSIVES
a. ID Fan discharge gate in closed position.
b. Inlet guide vane minimum.
c. Scoop position minimum (<5%).
d. Inlet gate closed.
e. Bearing temp normal, motor NDE/DE. Fan NDE/DE bearing temp normal (<85 0C)
f. Oil temp after cooler adequate. (< 50 Deg. C)
g. Stack Path available. (Any two ESP available)
h. Any APH to ESP available / any ID Fan ON.
- With local push button released, If ID fan is started, ID fan will take start and inlet/out
dampers will open.
- If the dampers fail to open within 180 seconds the running fan will trip.
i. ID Fan Lube Oil Tank Level > minimum (Switch)
j. Fan Either Lube Oil Pump ON.
k. Fan motor & Exciter winding Temp Not High. (Exciter<90 0C, Motor<120 0C)
STACK PATH AVAILABLE CONDITION WILL BE SATISFIED WHEN : -

a. Primary / Secondary APHS’ are in service.
b. All Flue gas dampers of APH open.(Both APH regulating Dampers and isolating Dampers)
ID Fan PROTECTION:
1. Electrical Protection Trip.

2. Emergency push button pressed.
3. Stop command from UCB.
49
4. Bearing temp High-High. (MOTOR/FAN)
(Motor - 90 Deg. C, Fan - 82 Deg. C)
5. Lube Oil pressure Very low < 0.4 kg/cm2
6. Fan running & inlet/outlet gate close.
7. Motor / Fan bearing vibration Hi-Hi (Motor Brg - 9 microns/Sec, Fan Brg – 12.6 mm/sec).
(TD = 10 Sec)
8. Corresponding FD fan trip (for ID fan-A, FD fan-B running and FD
fan-A tripped) (for ID fan-B, FD fan-A running and FD fan-B tripped)
9. Post purge fan trip (FSSS)
10. ID Fan Motor Winding Temp High (>130 Deg C)
11. ID Fan Exciter Bearing Temp High (>120 Deg C)
FD FAN INTERLOCKS:-
FD Fan PERMISSIVES
1. Discharge Damper closed.
2. Blade pitch minimum (<5%).
3. Lube Oil pressure adequate > 0.8 Kg/cm2.
4. Oil tank level adequate.
5. Control oil pressure adequate > 8 Kg/cm2
6. Any Lube oil Pump running.
7. Fan/ motor bearing temp. (Fan < 90 Deg. C, Motor < 85 Deg C)
8. ID Fan permits.
9. Fan Motor winding Temp Not High (< 110 Deg C)
10. FD Fan Lube Oil Tank Level > minimum (Switch)
11. Oil temp after cooler adequate. (< 65 Deg. C)
ID FAN PERMIT WILL BE SATISFIED WHEN -

a. Both the ID Fans are in Service [OR]
b. Any ID Fan is running and FD fan is not running.
When given a start command fan will start and its discharge Damper will open. If the
discharge damper fails to open within 180 Sec, Running fan will trip.
FD Fan PROTECTION:
1. Electrical protections trip.
4. One ID Fan and one FD already in service & corresponding ID Fan not running.
5. Fan bearing temp. High > 110 Deg. C (TD 2 Sec)
6. Motor bearing temp. High > 90 Deg. C (TD 2 Sec)
7. Motor Winding temp. High > 130 Deg C (TD 2 Sec)
8. Outlet Damper fails to open within preset time/fan running and
discharge damper closed for more than. 120 seconds.
9. Vibration more than preset value. (Motor – 15.5 mm/s, Fan – 19.8 mm/s, TD – 10 Sec)
50
10. All ID Fans stopped
11. Post Purge Fan trip
12. Lube Oil pressure Lo < 0.4 Kg/cm2, Control Oil pressure Lo < 4 Kg/cm2, TD – 10 Sec.
PA FAN INTERLOCKS:
PA FAN PERMISSIVES-
1. Blade pitch in minimum position (< 5%).
2. Discharge Damper closed.
3. Lube Oil pressure adequate > 0.8 Kg/Cm2
4. Control Oil pressure adequate > (Set 8 Kg/Cm2).
5. Lube oil tank level adequate (not low).
6. Fan / Motor bearing temp Not high. ( Motor < 80 0C, Fan < 85 0C, TD – 10 Sec)
7. Any one Oil Pump running.
8. Both PAPH ON & Air Path available OR [any PAPH ON] & Air Path available & PAF-B
OFF].
9. PA Fan start permissive available OR other PA Fan ON.
10. Local push button in released condition.
11. Lube Oil cooler outlet temperature not high (< 50 0C).
12. Motor winding temp Not high. ( < 110 0C)
PA FAN PROTECTIONS:
1. Electrical protection trip.
4. Fan/motor bearing temp High (> 90 Deg C), TD- 10 Sec.
5. M.F. T. operated
6. Fan Running & Outlet Damper fails to open After 90 Sec.
7. Motor/Fan Bearing Vibration Hi-Hi (Fan > 19.8 mm/s, Motor > 15.5 mm/s, TD-10 Sec)
8. Motor Winding Temp High (> 130 0C, TD 2 Sec)
9. Lube Oil pressure Lo < 0.4 Kg/cm2, Control Oil pressure Lo < 4 Kg/cm2, TD – 5 Sec.
10. Both FD Fans OFF.
SCANNER FAN LOGICS

AC FAN: -
Scanner fan can be started from FSSS console.
Start in the following conditions
a. Scanner duct to furnace DP is <152. 4mm of WCL
b. Loss of Critical power for > 2 sec
c. Start command AC or DC persisting & neither fan start within 5 sec.
FAN CAN BE STOPPED WHEN
a. No Start command and stop command is given.
b. Scanner duct to furnace DP is > 152.4 mm WCL
51
or
c. Scanner duct to furnace DP High> 600mm WC for 10 secs.
DC SCANNER FAN:-
a. It can he started from FSSS console
FAN STARTS AUTOMATICALY WHEN

a. DP between scanner header & furnace is<152.4 mm of WCL after a time delay of 5
SECS
b. Loss of Critical power for > 2 secs.
c. Start command for AC or DC persists neither fan taking
start within 5 SEC.
FAN CAN BE STOPPED WHEN
a. No start command present and stop command is given
b. DP between scanner header & furnace > 152.4 mm WCL
c. Scanner duct to furnace > 600 mm WCL
SEAL AIR FAN LOGICS:

a. Seal air fan can be started from FSSS console.
b. Seal air fan A or B start command persisting & neither of
them is starting within 5 SEC.
c. Seal air fan A trips after 15 sec if both PA fans trip
d. Seal air fan-A can be stopped manualy if fan - B is in service and stop button is not
operated.
SEAL AIR FAN - A

CAN BE STARTED FROM
1. Start push button
2. Start Command given for any fan & neither of them is running for more than 5 sec.
3. Either PA fan on
4. Either PA fan on & seal air header to cold air duct delta-p Less than 101.6 mm WCL with
a time delay of 10 sec & no stop command.
TRIP CONDITIONS
1. Push button
2. No PA fan is running for more than 15 sec.
3. Fan-B stop push button not pressed.
SEAL AIR FAN – B

1. Start push button.
2. Start command given for any fan & neither of these fan takes start within 5 sec then start
command goes to both fan.
3. Either PA fan ON & seal air header to cold air duct delta- P <101.6mm WCL)
4. No stop command.
52
TRIP CONDITION
1. Neither of the fan discharge damper Open.
2. Stop push button.
3. Neither PA fan is on for more than 15 sec.
SEAL AIR FAN - B

a. It starts automatically when primary air fan is running & seal air header to cold air duct
DP is < 101. 6mMWCl for more than 10 sec.
b. Seal air fan-B trips after 15 sec of PA fan tripping.
c. Fan-B can be stopped only when fan-A is in service.
d. When start command for both fans are there and none of the fans start one more
command goes after 2 second for starting the fans.
PULVERISERS:
PULVERISER START PERMISSIVES:-
PULVERISER START PERMIT

a. No MFT & Any feeder Proven.
b. No MFT & Burner tilt Horizental & airflow less 40%
1. Pulveriser discharge V/V is open
2. Mill outlet temperature is < 93 Deg. C
3. Feeder in remote
4. Cold air gate open
5. No pulveriser auto unsuccessful start
6. Tramp Iron Gate open
7. Feeder inlet gate open
8. Primary air permits available
9. Lube oil temp > 320 F
10. Lube Oil sump level adequate
11. No pulveriser trip.
WHEN ABOVE CONDITIONS ARE FULFILLED PULVERISER READY WILL APPEAR
PRIMARY AIR PERMIT

-For mills A.B.C.D. - Either both PA and both FD on or any one PA and one FD running and four
or less no. of mills running and PA header (A.B.C.D) duct pressure not low or low-low.
-For mills E.F.G.H.J - Either both PA and both FD fans running or any one FD and one PA running
four or less pressure not low or low-low.
FOR PULVERISER START FOLLOWING ARE TO BE FUFILLED

1. Pulveriser ready.
53
2. Seal air to header under bowl DP > 200mm WCL.
3. Pulveriser not on.
4. Ignition permit available (3 out of 4 oil guns in service and boiler load >30% and
adjacent feeder running at>50% loading).
5. Start command given.
IGNITION PERMITS FOR MILLS:-
MILL - A
(a) AB elevation 3 out of 4 guns in service. OR
(b) Feeder B is proven and feeder speed > 50% and boiler load > 30%
MILL - B
a. 3 Out of 4 AB guns in service
OR
b. 3 Out of 4 CD guns in service and feeder C is proven with
feeder speed > 50%
OR
c. Feeder A or C are proven with> 50% feeder speed & boiler load > 30%
MILL - C
a. 3 out of a 4 CD elevation guns in service
OR
b. 3 out of 4 AB elevation guns in service and feeder B speed>50%
OR
c. Feeder B or D proven with feeder speed > 50% and boiler load > 30%
MILL - D
a. 3 Out of 4 CD Elevation guns in service
OR
b. Feeder ''G'' or ''E'' proven with feeder speed>50% and boiler load>30%
MILL - E
a. 3 out of 4 EF elevation guns in service
OR
b. 3 out of 4 elevation guns in sevice with feeder ''D'' proven and speed>50%
OR
c. Feeder 'D' or 'F' in service with speed >50% and boiler load>30%
MILL - F
a. 3 out of 4 EF Elevation guns in service.
OR
b. Feeder 'E' Or 'G' In Service With Speed >50% And Boiler Load>30%
54
MILL - G
a. 3 Out of 4 EF guns in service and feeder 'F' in service with speed>50%
OR
b. Feeder 'F' or ' H' in service with feeder speed > 50% and boiler load > 30%
MILL - H
a. 3 out of 4 HJ guns in service.
OR
b. Feeder 'G' or 'J' in service with feeder speed > 50% and boiler load > 30%
MILL - I
a. 3 out of 4 HJ guns in service
OR
b. 3 feeder ' H' Is proven with speed > 50% and boiler load > 30%
COAL FEEDER STARTING
[A] Feeder can be started when the following are satisfied -

1. Pulveriser is in manual mode.
2. Feeder speed demand is at minimum.
3. Pulveriser in ready.
4. Pulveriser temp. is < 54 deg. & not more than 93 deg C
5. Ignition permit is rejected & igniter permits available.
6. Pulveriser is on.
7. No boiler trip
8. No feeder stops command in manual mode.
[B] After feeder starting within 5 seconds, coal on belt should be established. Otherwise feeder
will trip. Ignition permit should be available for 180 seconds from the moment start command
to feeder is given.
[C] COAL FEDDER PROTECTIONS:

1. Discharge chute is plugged.
2. Once Feeder trips, it can be restarted after 3 seconds
3. Feeder can be stopped from the console when selected to manual.
4. There is no coal in belt.
5. Trips in feed rate error of the demand and supply and Feeding mismatches By more than
20%.
PULVERISERS PROTECTIONS:-
1. Stop button is operated.
2. Primary Air trip command is present
3. Boiler Trip
55
4. Mill Discharge valve not open.
5. Ignition permit required and lost within 180 second.
6. Lube Oil pump trip (a) lube oil pump ON and pressure low with a delay of 10 seconds.
(b) Pulveriser ON and lube oil pump NOT ON for more than 10 seconds.
7. EPB trip.
8. Seal air header/minimum bowl DP< 128 mmWC with a delay of 1 minute.
9. Elevation power not available for > 2 sec
10. Auto stop command is present
11. Pulveriser start command is persisting but pulveriser not on within 10 seconds.
CC PUMP PERMISSIVE & PROTECTIONS

Running CC Pump will trip in the following conditions:-
1 Discharge valve 1 not fully open.
2. Discharge Valve 2 not fully open.
3 Motor cavity Temp high T/C (I.V.M.) and local switch / indicator are in series with set
value % 60o C and 57.2O C respectively.
4. Electrical trips/EPB trip
CC Pumps Permissive:
1. Motor cooling water flow adequate. (> 32 Gallons/ Minute).

2. Casing diff temp Adequate (>15 Deg C)
3. Motor cavity temp adequate (< 57.2 Deg C).
4. Discharge valve -1 Open.
5. Discharge valve - 2 Open
6. EPB Released.
FSSS: LOGICS
MFT CONDITIONS:
Master fuel trip is initiated if any one of the following occurs:
a) All FD fans tripped.
b) All ID fans Tripped.
c) Inadequate water wall Circulation for more than 5 Sec.
d) Both EPB-1, 2 Pressed.
e) Loss of Re heater Protection for More than 10 seconds.
f) Both Secondary APHS Tripped.
g) All Boiler Feed pump tripped (TD-10 Sec)
h) Drum level low-low for > 5 sec (-375 mm)
i) Drum level High-high for> 10 sec (+250 mm)
j) Furnace Pressure high - high (2/3 Logic) (> +150mmwcl)
k) Furnace pressure low-low (2/3 LOGIC) (< -175mmwcl).
l) Loss of all fuel.
56
m) Unit Flame Failure trip.
n) EPB trip of Boiler.
o) Loss of 220 Volts DC supply for> 2 seconds.
p) Loss of 24 V DC.
q) Air flow < 30 % (< 600 TPH)
r) Less than Fire Ball & Loss of 110 V AC in any Elevation in service.
PURGE CYCLE:
Purge Ready signal will appear when:
a. HFO trip valve closed
b. All HFO Nozzle valves are closed
c. All Pulverizes off
d. All Feeders off
e. No Boiler trip
f. All scanners sense No Flame (Fireball AB, BC, DE, FG, GH, HJ AND
DISCRIMINATING AB, CD, EF, & HJ)
g. Air Flow > 30%
h. All Hot Air Gates Closed
i. Drum level Satisfactory
j. All Aux air dampers modulating (AA to JJ).
k. Both PA fans off
l. Wind box/ Furnace delta `p' adequate (25mmWC). (When `push to purge' Button is
Pressed, Purging will Start for five Minutes.)
9.2 SECONDARY AIR CONTROL:

A. All Aux air Dampers AA, AB, BC, CD, DE, EF, FG, GH, HJ,JJ modulate to maintain a
preset Differential Pressure Between Wind box and Furnace Till 30% of Boiler Load.
B. When Boiler load crosses 30% the set point of wind box Pressure is Increased
automatically to another preset value and all aux, air dampers except where there is oil
firing, Start closing from top to bottom in a sequential Manner to Maintain the new delta
p.
C. Aux air dampers associated with oil elevations go to a fixed opening of 35% the setting
of 35 % Has been provided by BHEL during Commissioning.
D. All fuel air dampers A,B,C,D, E,F,G,H&J Modulate according to Feeder speed after the
feeder is proven UP TO 50% of feeder speed the Designated Damper remaining closed
and between feeder speed variation for 50 to 100% fuel air damper modulates from 0 to
20 %
E. Aux. air dampers Associated with oil Elevations closes during HEA Igniter start and
opens after oil Nozzle valves full open, Elevation Started and start time has expired.
57
F. All fuel air dampers close after 50 Seconds of respective Feeder Trip.
G. When Boiler load falls down to < 30% all aux. air dampers (except fuel air) Starts
opening from Bottom to top in a sequential manner at a time interval of 10 sec, each.
COOLING TOWER / CIRCULATING WATER PUMPS
BCW - Pumps permissives

1) BCW Pump motor cavity temp ok >2 0C & <60 0C
2) Drum N2 Filling Isolation Valve Left (B001), (B002); Right (B028), (B029) Closed.
3) BCW LP Cooler flow Lo-Lo (Switch).
4) Cooling Water to BCW not abnormal
5) Heat Barrier flow not Low.
6) BCW Pump Disch. Valve-1 & 2 Open.
7) BCW Protection Criteria Present.
8) Heat Barrier Flow not Low (Switch).
9) BCW Suction Temp Casing not ok <28 0C
PROTECTION:
01) Bearing Temperature Hi-Hi (95 deg. c rising)
02) Suction duct level low-low (283 m)
03) Pump running & discharge valve closed (5 deg. Open from full closed) or 5 % open
from fully closed condition (Sequential Trip )
04) Pump Running & Lube Flow-low (45 Sec) 34 & 30 LPM
05) Hydraulic Emergency trip (push Button)
06) Push Button trip (Local)
DRUM LEVEL PROTECTION

Boiler will be tripped on drum level Protection if drum level goes Hi- Hi (+250mm)> 10 sec
or. drum level goes lo-lo (-375mm)> 5 sec
and
i) Both Hydrasteps are voting
or
ii) Left Hydrasteps & RHS Transmitter are voting
or
iii) RHS Hydrastep & LHS transmitter are voting
INADEQUATE WATER WALL CIRCULATION FOR > 5 SECS
Inadequate water wall circulation tripping for boiler is to act as follows:

All CC pumps tripped
OR
58
All three pumps in service & DP<10 psi
OR
Any one discharge valve of each of the pump is not open. Pump off is sensed From switch
gear service contact, DV- 1/DV-2 discharge valve not open is sensed from valve limit
switches and low diff. Pressure transmitter. Boiler tripping would occur only when all the 6
transmitters sense low DP together.
REHEATER PROTECTION LOGIC STAGE -II
01. Enabling when Boiler is working and main steam pressure > 30 kg/sq. CM
02. Arming when HP bypass BP1 or HP bypass BP2 open >2% and LP bypass V/V open.
03. On Re heater protection tripping for boiler is as follows.
i) Turbine is in tripped condition and boiler is working if BP1 & BP2 are not open boiler
will trip after 15 seconds.
OR
LP bypass Command is > 35% and both LP bypass v/v not open for >35 seconds boiler
will be tripped.
Once the protection is armed the protection will disarm only after boiler Tripping.
REHEATER PROTECTION STAGE -I
ARMING:
1. Boiler lighted up / no MFT
and
2. Boiler Pressure > 25 kg/cm2
and
3. Either BP1 or BP2 open 2% and LP bypass open > 2% once only after that self
Latching.
PROTECTION:
1. Protection arming
And
2. Turbine trip from CH-1 and CH-2
And
3. Either LP bypass close or both HP bypass valves close (<2% open) then boiler will
trip after a time delay of 15 seconds.
MAIN TURBINE PROTECTIONS

MECHANICAL
a. Local trip lever operated axial yes
b. Thrust. BRG Axial shift +/-1mm
c. Over speed bolts 3200 rpm
d. condenser Vacuum low-low
59
ELECTRICAL
a. Emergency trip from UCB Yes.
b. Remote trip during ATT (Prot. program)
c. Fire Prot. I (PB PUSH)
d. Fire protection II (PB PUSH)
e. MOT level low-low 1150 mm from top
f. Generator protection
g. Boiler fire off or boiler trip
h. MCB turbine trip ATRS S/D Program
I. Condenser VAC .low-low 0.3 Kg/cm2 (2 out of 3)
j. Extended turbine protections.

k. Lube oil pr. low- low 1.2 Kg/cm2 at brg end (2 out of 3)
EXTENDED TURBINE PROTECTIONS:

a. Level Gen bushing casing top Level > 90 mm (2 out of 2)
b. Cold Gas temp. Behind cooler > 60 deg. c (2 out of 2)
c. Warm air temp main exciter > 80 deg. c (2 out of 2)
d. Seal oil temp behind cooler > 50 deg. c (2 out of 2)
e. Primary water temp behind cooler > 60 deg c (2 out of 2)
f. Stator water flow low-low < 48 TPH (TD- 5 Sec)
g. Primary water flow main bushing (U/V/W) < 0.37 kg/ sec (2out of 2)
h. HP casing diff temp mid metal top/bottom >100 Deg C, arming load
> 20 %
i. IP casing –diff temp- (Front) > 45 Deg C, arming load > 20%
j. IP casing delta Rear > 45 Deg C, arming load > 20%
k. HP Exhaust temp > 480 Deg C, ( 2 out of 2 )
l. Stator Main Bushing (R) flow low < 1.33 TPH, (TD – 60 Sec)
m. Stator Main Bushing (S) flow low < 1.33 TPH, (TD – 60 Sec)
n. Stator Main Bushing (T) flow low < 1.33 TPH, (TD – 60 Sec)
o. Turbine Trip from Bearing Temperature > 130 Deg C.
FIRE PROTECTION -1 PB PUSH

Fire Protection 1 channel 1, Fire Protection 1 channel 2 can be operated from UCB, MOT
room near LP bypass, near HP Turbine.
When, this is operated:-
1. Turbine Trip
2. SGC - CF pump off
3. SLC CF heater off
4. SLC CF pump off
5. CF Heater 1 & 2 off
6. HPCF pump 1 & 2 off
60
7. HPCF Cir pump 1 & 2 off
8. Vacuum Breaker open
FIRE PROTECTION - II PB PUSH

FP2 channel 1 FP 2 channel 2 can be operated from UCB, HP turbine, MOT room, and LP
Bypass.
When, this is operated:-
1. Same as 1 to 8 of fire protection 1
2. SGC Oil supply off
3. SLC AOP 1 & 2 off
4. SLC EOP ON
5. SLC JOP -1 & 2 off
6. SLC Turning Gear off
7. AOP 1 & 2 off
8. JOP 1 (AC) off
9. JOP-2 (DC) ON
MOT LEVEL LOW-LOW – 1150 MM from Top (2/3 LOGIC)

1. Turbine trip
2. Vacuum Breaker Open
3. SGC Oil supply off
4. SLC AOP 1 & 2 off
5. SLC EOP on
6. SLC JOP 1 & 2 off
7. SLC Turning gear off
8. AOP 1 & 2 off
9. JOP 1 off
10. JOP 2 on
CEP INTERLOCKS
CEP PERMISSIVES
1. Suction valve open 100 %
2. Discharge Valve Closed/Discharge header PR. > 28 kg/cm2 Square
3. Recirculation valve open 100 %
4. Bearing temp < preset value
5. Discharge vent valve 100 % open
6. Hot well level Greater than Preset value
CEP PROTECTIONS:
1. Hot well level low-low (2 out of 2)
2. Suction valve close (0%)
3. Bearing temp high - high (100 0C)
61
4. Discharge pressure low -low (22 kg/ cm2 Falling and CEP running) standby CEP comes
in service at a discharge pressure of 26 ksc CEP discharge header pressure low alarm
comes at 27 KSC
PERMISSIVES FOR CEP AUTO START

1. Suction valve open 100 %
2. Discharge valve closed /discharge header pr. >28 kg /cm2
3. Recirculation valve open 100%
4. Bearing temp. < preset value
5. CEP on auto
6. Other CEP trip
7. Any one CEP running and discharge header pressure < preset Value.
TD BFP
START PERMISSIVE:-
1. Lube Oil pressure normal > 3.5 KSC at O` MTR near oil tank.
2. TD BFP control valve closed.
3. Position controller output 0 %
4. Disconnecting coupling engaged.
5. Pump Delta T low < 25 D.C.
6. Deaerator level normal
7. Pump discharge valve closed (80% Open)
8. Recirculation valve open (100%)
9. Suction valve open (100%)
10. Warm-up valve closed (0%)
PROTECTION:
1. Suction valve not open
2. Exhaust valve not open
3. Main pump bearing temp high-high > 120 Deg. CEL
4. Turbine bearing temp high-high > 120 0C.
5. Trip oil pressure low-low < 2 Kg/cm2 (2/3 logic Switches)
6. Lube oil pressure low- low < 1.0 Kg/cm2. (2/3 logic Switches)
7. Vacuum low-low <0.2 KSC
8. Axial shift of main pump high > +/- 0.70 mm (2/3 logic)
9. Axial shift of turbine high > +/- 0.70 mm (2/2 logic)
10. Over Speed trip at 6300 rpm
11. Seal water temp high for main pump > 85 0C DE/NDE side.
12. Deaerator level low- low <-1650 mm, level switches)
13. Local trip (mech.) -1.
14. Local trip (Elect) (2/2)
15. UCB trip manual (Elect) (2/2)
16. Governing oil pressure low- low < 4.5 Kg/cm2. (2/3 logic Switches)
62
17. TDBFP Exhaust steam temperature very high > 120 Deg C, (2/3 logic Switches)
18. TDBFP Exhaust steam pressure very high > 0.4 Kg/cm2, (2/3 logic Switches)
19. TDBFP Live steam pressure v. high > 12.5 Kg/cm2, (2/3 logic Switch)
20. Turbine Eccentricity very high > 92 mic
21. Turbine GB i/p vibration very high > 70 micron (TD – 5 Sec)
22. Turbine GB o/p vibration very high > 70 micron (TD – 5 Sec)
23. Turbine FJB vibration very high > 70 micron (TD – 5 Sec)
24. Turbine RJB vibration very high > 70 micron (TD – 5 Sec)
25. TDBFP DE vibration very high > 18 micron (TD – 5 Sec)
26. TDBFP NDE vibration very high > 18 micron (TD – 5 Sec)
27. Turbine GB Temperature very high > 120 Deg C, (TD – 30 Sec)
28. Turbine Bearing Temperature very high > 120 Deg C, (TD – 30 Sec)
29. Booster Pump Brg Temperature very high > 95 Deg C for NDE
30. Booster Pump Brg Temperature very high > 105 Deg C for DE
31. Booster Pump Thrust Brg Temp very high > 105 Deg C for NDE, (TD-10 Sec)
32. BFP Bearing Temperature very high > 95 Deg C, (TD – 30 Sec)
33. TDBFP working AND Suction Flow Low < Variable set point as per speed.
34. FW Suction / Discharge DT high > 15 Deg C (Speed>3500 rpm & ESV Open & Control
v/v >2% OR Aux Steam control v/v > 3%)
MD BFP:
START PERMISSIVES:
1. Seal water header pr. normal > 15 ksc.
2. Deaerator level normal (> -20 mm).
3. Pump bearing temp normal < 90O C
4. Motor DE/NDE bearing temp normal < 90O C
5. Hydraulic Coupling bearing temp normal <90O C
6. Discharge valve closed or header pressure not low.
7. Lube oil pressure normal > 2.0 KSC.
8. Recirculation valve open 100 %
9. Pump suction valve open.
10. Warm-up valve closed.
11. Main pump delta T Normal < 250 C
12. Hydraulic coupling scoop in min. position.
13. MDBFP AOP ON.
FOR AUTO START:

1. Seal water header pr. normal 15 ksc.
2. Deaerator level normal.
3. Pump bearing temp normal< 90O C
4. Motor DE/NDE bearing temp. Normal < 90O C
5. Hydraulic Coupling bearing temp. Normal< 90 0C
6. Discharge Valve closed or header pressure not low.
63
7. Lube Oil pressure normal > 1.2 ksc.
8. Recirculation valve open 100%
9. Pump suction valve open 100%
10. BEP "C" on auto
11. BFP ' A ' Tripped or BFP ` B tripped or BEP ` A `Running and suction flow> one pump
capacity or BFP `B` running and suction flow > one pump capacity.
MDBFP PROTECTION:
1. Axial Displacement very high> 7 mm
2. Bearing temp very high > 100 O C.
3. Deaerator level low-low.
4. Lube oil pressure very low< 0. 8KSC.
5. Suction valve not open.
6. Seal water temp (suction side) very high > 85O C.
7. Seal water temp (disch side) very high >85O C
8. Push button stops.
9. UCB manual stop.
Generator & Aux. Data
Rated MW Capacity : 500 MW
Rated MVA Capacity : 588 MVA
Rated Terminal Voltage : 21 KV
Synchronous reactance : 193 %
Transient reactance : 24%
Sub-Transient reactance : 17%
Rated Power Factor : 0.85
NGT Details
Make : FRANCE TRANSFC France
: 21 kV/240V.3.3A/250A. 60kVA
: % Z - 7.5
: Secondary mid pt. earthed
: Secondary earthing resist.
o.4 Ω, 400A, 250 V
Generator I2t : 10
Continuous Neg. Seq.
Withstand capacity : 8%
Generator Transformer
Rated MVA Capacity : 3 x 200 MVA
Voltage Ratio : 420/V3/21kV
Vector Group : Yd5
Cooling : OFAF
64
% Impedance : 12.59
Grounding : Solid
Unit Aux. Transformer

Rated MVA Capacity : 25 MVA
Voltage Ratio : 21 / 6.9 kV
Vector Group : Dy7
Cooling : OFAF
% Impedance : 8.5
Taps : + 5% to- 10% on HV (OLTC)
Grounding Resistance : 12.7Ω, 300A, 10sec
1. Generator Differential 87G
2. Generator & Generator Transformer
Over all differential 87 GT
3. Generator loss of Excitation 40 G
Generator loss of Excitation 2A/40G
Generator loss of Excitation 2B/ 40g
Generator loss of Excitation 40 GX
4. GT over fluxing 99 GT, 2/99GT.
5. Low forward power inter lock A 37 GA
Low Forward Power 2/ 37 GA
6. Low forward power inter lock B 37 GB
Low forward power 2A/37 GB
Motoring Alarm AB/37 GB
7. Back up impedance 21/G
Back up impedance. 2/21G
8. Stator Earth Fault 1 64 G1
Stator earth Fault 2 64 G2
Stator earth Fault Standby 64 G3
9. Inter turn fault 95 G
10. Rotor Earth Fault SIEMENS
11. GT HV Winding differ 87 HV
12. GT Standby E/F 51 NGT
13. Generator over voltage 59 G
Generator over voltage 2/59 G
14. O/H line differential 87 L
15. Negative Phase Seq. 46 G
16. Generator Overload 51 O/L, (51G)
17. Local Breaker Backup 50Z
Local Breaker Backup 2/50Z, 2/50ZX
18. Pole Slipping 98 G
65
Resistive Finder Relay 98 GY
19. Generator under frequency (Alarm) 81 G
Generator Under frequency (Alarm) 2/81 G
20. UAT Differential 87 UTA
UAT Differential 87 UTB
21. UAT Backup over current 51 UTA
UAT Backup over current 51 UTB
22. GT Differential 87 T
23. UAT Back up E/F 51 NUTA, 51 NUTB
24. Gen. VT fuse fail 160/260/360X
GENERATOR PROTECTION 186 G Operates When:-

01. Gen. Diff Protection 87 G
02. Gen Stator 100% E/F Protection 64 G1
03. Gen under Frequency Alarm (Alarm Only) 81 G
04. Gen O/V Alarm (Alarm Only) 59 G
05. Gen Pole slipping protection 98G+98GY
06. Gen. Low forward power interlock 37GAX, 2/37GA
07. Generator Backup IMPEDENCE Protection 21G
08. GT HV Winding diff protection 87 HV
09. GT Standby E/F Protection 51 NGTX
10. GT WTI & OTI (Turbine Trip (TTR)) 30 B
11. UAT-A & R Backup Over current Protection 51 UTA/UTB
12. GT BUCHHOLTZ 30 A
13. UAT A & B Bucholz Flag Relay 30C/30D
14. LBB Protection Trip Flag Relay 30 F
16. UAT’s A & B temperature high flag relay (only)
for tripping UAT in comer) 30L / 30N
17. Generator Stator 95% E/F Protection 64 G3
OPERATION OF 186G TRIP RELAY Leads To The Following -

01. Trip unit bus 'A' 6.6 KV Incomer
02. Trip unit bus 'B' 6.6 KV Incomer
03. Trip Generator Breaker / Transfer Coupler Breaker
04. Trip Field Breaker
05. Trip TTR - A
06. Trip TTR - B
07. TO Arm Main CB LBB Protection
08. To Auto Change Over Ckt. of Unit/STN/TIE
GENERATOR PROTECTION 286G Operates When:-

01. Generator Transformer Block overall differential 87 GT
Protection
66
02. Generator Negative Sequence Protection 46G
03. Generator Overload alarm (Alarm Only) 51 G
04. Generator Inter Turn Fault Protection 95 G
05. Generator Stator Standby Earth Fault Protection 64 G2
06. GT Over Fluxing 99 GT
07. Generator Field Fail Protection 40G
08. Generator low forward power protection 37GBX, 2A/37GB
09. Generator Transformer Diff Protection. 87T
10. L.B.B. Protection 2/50ZX
11. UAT A Differential Protection 87UTA
12. UAT B Differential Protection 87UTB
13. UATA Backup E/F Protection 51NUTA
14. UATB Backup E/F Protection 51NUTB
15. GT Pressure Relief Device Flag Relay 30 P
16. GT Fire Protection 30 J
17. UAT A& B Fire Protection Flag Relay 30H, 30K
18. B/B Protection Trip Flag Relay 30M, 96X
19. UAT A&B UTI & OTI (Only for UAT Incomer Trip) 30L, 30N
OPERATING OF 286G TRIP RELAY Leads To The Following: -

01. Trip Generator Breaker
02. Trip Field Breaker
03. Trip TTR- A
04. Trip TTR- B
05. To ARM Main CB LBB Protection
06. To Trip Circuit of 52 UTA, 52 UTB (6. 6KV UAT I/C)
07. To Auto Change Over CKT of Unit Bus A&B
08. To CC of Generator Field Circuit Breaker (Blocks Permissive)
09. To CC of Generator Circuit Breaker (Blocks Permissive)
BOILER - TURBINE - GENERATOR TRIPPING LOGIC

A. Boiler Problems Troubles Lead To
a. Boiler Trip MFR A
b. Boiler Trip MFR B
B. Operation of MFR A/B Lead to
a. Turbine Trip TTR A
b. Turbine Trip TTR B
C. Operation of Turbine Trip TTR A/B Leads To
a. ESV A/B, IV A/B Closed
D. Trip Oil Pressure <2 KG/CM2
AND
Operation of Low Forward Power Relay A/B 37A/B Leads to
a. Generator Trip through 2/37GA, 2A/37GB & Then 186G/286G
67
b. Trip 400 KV Generator Breaker & 6.6 KV UAT I/C Breaker and field Breaker
TURBINE GENERATOR TROUBLES Lead To:-

a. Operation of turbine trip relay TTR / A/B
b. Operation of low forward power relay A/B 37A/B
c. Generator trip through 2/37 GA, 2A/37GB, 186G, 286G
d. Trip 400 KV generator breakers & 6.6 KV UAT I/C breaker and field breaker
ELECTRICAL FAULTS Lead To:-

a. Generator Trip 186G
b. Generator Trip 286G
c. 186G & 286G Trip all Gen. 400 KV & 6.6 KV breakers & field breaker
d. Operate turbine trip TTR A/B
e. Change over of Unit to station supply at 6.6 KV.
500 MW GENERATOR TRANSFORMER TRIP:

Each Phase GT Has the Following Protection -
01. Bucholz trip
02. Pressure release device at a pressure of 0.35 Kg/cm2
03. Winding Temperature high Alarm At 110 Deg. C
Trip at 120 Deg. C
04. Oil Temperature High Alarm at 90 Deg. C
Trip at 100 Deg. C
GENERATOR TRANSFORMER COOLER CONTROL
 Six numbers of cooler units, each unit consists of a fan and a pump. 1, 3, 5 Cooler units
take start along with closing of field breaker & stop with field breaker off.
 2, 4,6 Cooler units take start at 80O C. Winding temp & Stop at 70 deg C. winding temp.
UAT’S
UAT’S Has The Following Protections:-
01. Bucholz relay
02. On load tap changer Bucholz
03. Winding temperature high Alarm at 90 Deg. C
Trip at 100 Deg. C.
o4. Oil Temperature High Alarm at 80 Deg. C
Trip at 90 Deg. C
***On Temperature high of winding & oil it offloads the UAT.
UAT’S FAN AUTO STARTING
68
There are four fans two auto & two standbys i.e. per radiator one main & one reserve. The
main fan takes start at 65O C winding Temperature and stops at 55 Deg. C. winding
temperature. If the main fan trips due to any reason reserve fan takes start automatically.
Black Out Start-up Procedure

Unit Status immediately after black out
 Failure of all HT and LT electrical AC supply.
 All equipments in tripped condition.
 Loss of normal lighting.
Equipment at risk/ Action Plan –

 Electrical Side:
Step 1: Ensure Generator Breaker is opened, if not then open it from Local.
Step 2: Ensure the availability of 220 Volt DC supply.
Step 3: Ensure DC lighting is in service, if not DC light should be ON manually.
Step 4: Ensure DG set started in auto, if not DG set should be started manually.
Step 5: Take DG set on load and charge DG MCC.
 Turbine Side:
All Bearings of turbine and generator needs proper lubrications and Seal Oil at
the ends of casing (DC EOP, DC SOP & DC JOP must be in running condition).
Step 1: Ensure DC EOP has started on auto, if not, start it from DCS/Local.
Step 2: For healthiness of Seal Oil System, ensure that DC Seal Oil pump had
started in auto. In case it does not start on auto. Start DC SOP from local.
Step 3: Ensure vacuum breaker valve opened in auto.
Step 4: Start DC JOP at 510 RPM, if AC JOP does not came on auto.
Step 5: Turbine rotor needs uniform cooling. Barring should ensured otherwise
hand barring should be done.
Step 6: Safety of LP turbine diaphragm – Entry of steam into the condenser to be
restricted & vacuum breaker should be open and seal steam to be
isolated.
Step 7: Both TDBFPs DC EOP should be started in auto, otherwise start manually.
 Boiler Side :
Step 1: Start DC Scanner Fan for cooling of scanner.
69
Step 2: AH needs uniform cooling. Start APH by Air Motor; if air motor is not
running open the by-pass manual valve.
Step 3: Take diesel hydrant pump is in service.
 After charging DG MCC ensure that :-
 Changeover DC Aux to AC Aux.(i.e., JOP, EOP, Scanner fan etc,)
 Start SOP (H2-side).
 Unit DCDB main charger is in service.
 Start JOP & LOP of both TDBFPs and stop DC EOP.
 Keep MOT vapor extraction fan B in service.
 Start all Air Pre Heaters electrically.
 Start LOPs of ID fans, FD fans, PA fans & Mills.
 If LT supply is restored, then all electrically operated valves should be closed
from control room.
 At 510 RPM of Turbine , start AC JOP if not then start DC JOP and turning gear
motor should be ON. Engage barring gear when turbine come to rest, then
hand barring of turbine is required for uniform cooling of rotor. The rotor
should be rotated by handle intermittently.
70
Unit Start-up Procedure
1. Total no. Of permits issued during shut-down ......................
2. Total no. Of permits cancelled ......................
3. List of pending permits not essential for rolling a. ......................
b. ......................
c. ......................
4. Work still going on
a) Name of Auxiliary ........................
b) Probable time of completion .........................
5. HFO tank level ........................
6. HFO tank temperature ........................

7. Ensure HFO pump running with pump recirculation, if tank heating is continuing
from PH-I auxiliary steam. (Running/Stand By) ........................
8. HSD tank level ........................
9. Ensure one HSD pump in service with minimum recirculation. ........................
10. Ensure clearance from BMD for lit up (for cold start) ........................
11. Inform shift chemist for adequate availability of DM water .......................
12. All guns cleaning and fitting checking ........................
13. Check drum gauge glass/drum level for lit-up. ........................
14. Ensure BCW pump running / stand-by ........................
15. Ensure Deaerator and Hot well level ........................
71
16. Start MD-BFP Time.-.................
17. Inform AHP for LP pump availability and boiler –furnace sealing ...................
18. Ensure all air heaters are in service ...................
19. Check all flue gas path dampers/ gate of Air-heater Inlet/Outlet (should be opened)
A) SAPH A&B flue gas/ air Inlet/Outlet ..................
B) PAPH A&B flue gas Inlet/Outlet ..................
20. Status of Scanner fan (Running/stand-by) ..................
21. All boiler drum vent should be opened if drum pressure < 3Kg/cm2 .................
22. All super-heater drains should be opened if drum pressure < 3Kg/cm2 ..............
23 Start one of set of the ID / FD fan and maintain 30% air flow with balanced draft.
24. Start furnace purging time-....................
Purge completed and boiler reset time-....................
25. Boiler lit-up with 2 HSD guns at AB elevation time-....................
(Take reading of HSD tank level) Mtr/KL-...............
26. Add two more HSD guns after 30minutes Time - .................
27. Check all turbine area drains and MAL drains. (Open/Close) .....................
28. Open all PRDS drains and vent. .....................
29. Open Gland sealing lines drain at 17 mtr and 8.5 mtr near station ....................
30. Check all the turbine running/stand-by auxiliaries .....................
a) TG set on barring (barring speed) .....................
b) CW pump status running/ stand-by .....................
c) Vacuum pump readiness seal tank lvl should be normal .....................
d) DMCW pumps running/ stand-by status .....................
e) CEP pumps running/ stand-by status .....................
f) ACW pumps running/ stand-by status .....................
g) Make sure line and bus isolator connected to reference bus .....................
31. Watch Drum pressure & drum metal temp.
72
32. Close all drum air vents at 3 kg/cm2 of drum pressure time................
33. Close all super-heaters drain/ vent a 5 kg/cm2 at MS pressure time................
34. Open Boiler main steam-stop valve at 6 kg/cm2 MS pressure time................
35. Start PRDS charging time................
36. Ensure HFO heater charging time................
37. Ensure atomising steam charging time................
38. Start Deaerator pegging from PRDS time................
39. Add HFO guns as soon as aux steam ready for heating and atomising.
a) At CD elevation guns .......................

b) At EF elevation guns .......................
40. PRDS charging completed as 14 kg/cm2 and 310 deg C time...............
41. Gland sealing line charging started time...............
42. Gland sealing line charging completed time.............
43. Ensure Re-heater vent should be closed time................
44. Start Gland steam Exhauster time................
45. Start vacuum pump time................
46. Ensure vacuum breaker close time................
47. Turbine gland sealing charged time................
48. Line up of both TDBFP from Feed water line & gland sealing time................
49. Ensure both TDBFP on barring time..................
50. Ensure HPBP/LPBP attemperation line up time.................
51. HP/LP bypass charging started time.................
52. Observe required steam parameter with gradual rising of firing rate for fulfilment of Turbine
criteria
53. Close all PRDS drains and vents. ...........................
54. Start PA fan & maintain PA header to 800 mmWC time...................
54. Start seal air fan time...................
55. Start bottom mill with minimum loading Time: .................
73
(Observe furnace temp then rise gradual loading of mill)
56. Ensure fulfilment of Criteria X1 & X2 (To Open ESV) ...........................
57. Ensure Turbine & Generator reset ...........................
58. Ensure Trip oil pressure ...........................
a. Ensure controller in EHG. Check settings of EHTC & CMC page in DCS.
a. Pressure reference set point should zero at EHTC
b. load reference set point at 50MW & Pr max 525 MW at EHTC
c. Rate of loading should between 10 MW to 25 MW
59. Raise Speeder Gear from 0 to 100% ...........................
60. Raise Starting Device gradually from 0 % to 100% ...........................
b. HP stops valve opening (at 34%) time...................
c. IP stops valve opening (at 35%) time...................
61. Ensure Sec oil pressure (HP, IP and Auxiliary) ...........................
62. Ensure fulfilment of Criteria X3, X4 & X5 (360 rpm) ...........................
63. Send DC to LD on estimated time. Time...................
64. Give command for 360rpm & observe all Turbovisory parameters and observe LPT exhaust
hood temp.
a. HP control valve opening time...................
b. IP control stops valve opening time...................
65. 360 rpm achieved Time...................
66. Soaking started ...........................
67. Ensure for criteria X6 (3000 rpm) ............................
68. Give command 3000 rpm in speed controller & observe all Turbovisory parameters
69. 3000rpm achieved Time...................
70. Start excitation Time...................
71. Start synchronization process Time...................
72. Unit synchronized Time...................
73. Close HP/LP Bypass gradually and mal drains too. ...........................
74
74. Take all fuel oil tank levels (HSD & HFO) ..........................
74. Take in service of second ID & FD Fans, not in service. Time...................
75. Observe the following very important parameters going before 100 MW
a. Condenser vacuum variable set point
b. HP Casing Top Bottom Differential Temperature
c. IP Casing Top Bottom Differential Temperature
d. HP exhaust Temp <500 oC
76. Operate Trim device after 100MW – 120MW load.
77. Raise Load gradually (up to 230MW) with respect of rising of firing rate.
78. Start second PA Fan and Mills one by one according to required parameters.
79. Start charging of LP Heater-2 & 3 at 100MW – 120MW load. Time...................

80. Start charging of Deaerator from extraction steam & ensure closing of pegging valve
from PRDS at 150MW -180MW load. Time...................
81. Feed ctrl v/v change over from 30% to 100 % (at 180Mw). Time...................
82. Supply change over from station to UAT at 100MW. Time...................
83. Start rolling of both TDBFPs
TDBFP-A rolling started at Time...................
TDBFP-B rolling started at Time...................
84. Soaking of TDBFPs completed. Time...................
85. Take TDBFP on load one by one and stop MDBFP.
TDBFP-A loaded at Time...................
TDBFP-B loaded at Time...................
MDBFP stopped at Time...................
86. Start HPHs charging from steam side at 250MW - 275MW. Time...................
87. Take fuel oil tank level after complete oil guns withdrawn. ..........................
88. Raise unit load according to DC up to full load.
75
Shift in Charge
Group...........
1X500 MW
(Extn.)
SHUT-DOWN PROCEDURE
1. Ensure that the Unit is on CMC mode with limit pressure mode (Load Control Active) in
service and Boiler Master in auto mode. ………….…..……..
2. Check the load gradient is set at 5 MW/min on both the consoles and MS Pr Set Pt in auto
mode. ………….…..……..
3. Reduce the load demand to 400 MW & wait till load reduces to 400MW.………….……
4. Take the MS Pr controller in manual and gradually reduce the throttle pressure set point to
about 130Kg/cm². ………….…..……..
5. Drop the MS temperature and RH temperature to cool the turbine (up to 510°C).
………….…..
……..
6. Take Unit on Turbine Follow mode (Pressure Control Mode). ………….…..……..
7. Stop the top most pulveriser to reduce the firing. ………….…..……..
8. Close the extraction block valves of HP heater 6 from steam side. ………….…..……..
9. Further reduce the firing to reduce the steam temp and Unit load up to 375MW.
………….…..
……..
10. Maintain the furnace pressure, boiler drum level and PA header pressure during the transient.
………….…..
……..
11. Check that HP casing temperature and HP shaft temperature drops as per the main steam
temperature. ………….…..……..
76
12. Check that flame intensity at elevations corresponding to running feeders and also the furnace
pressure. ………….…..……..
Unit Load reduced to 75%
13. Select the pulveriser which is at the top most elevation. Reduce the loading of the feeder to
minimum. Stop the feeder. ………….…..……..
14. Wait till the pulveriser grinding current comes to No Load Current. Check that the mill outlet
temp and bowl differential pressure. ………….…..……..
15. Check that the turbine pressure controller is active and Unit is in turbine follow mode from
CMC. ………….…..……..
16. Reduce the fuel input by decreasing the maximum limit (feed rate) of individual running
feeder from CMC console. ………….…..……..
17. Reduce the throttle steam pressure set point gradually by lowering the set point on CMC
console. ………….…..……..
18. When Load approaches 350MW, start MDBFP, take it on load & stop one TDBFP.
………….…..
……..
19. Ensure the Load reduced up to 270 MW, Stop the second TDBFP & ensure MDBFP is
working normal. ………….…..……..
20. Close the extraction block valves of HP heater 5 from steam side. ………….…..……..
21. Transfer the furnace pressure controller to manual mode and reduce the loading on one ID
Fan and load the other fan. ………….…..……..
22. Transfer the FD Fan blade pitch control to manual mode and unload the FD Fan
corresponding to above ID Fan which is unloaded. ………….…..……..
23. Maintain the furnace pressure and air flow during above operation. ………….…..……..
24. Stop one ID Fan and one PA fan. ………….…..……..
25. Ensure the flame stability within the furnace; if necessary Cut-in the oil support (Three
feeders with loading above 75% may not need the oil support). ………….…..……..
Load Reduced below 50% & HP/LP bypass operation
77
26. Adjust the HP bypass pressure set point to match existing throttle pressure.
………….…..
……..
27. Transfer the Initial pressure mode to limit pressure mode and reduce the throttle pressure set
point to keep the deviation positive. ………….…..……..
28. Reduce the target load (load reference) value from the governing console (Pr ref. & Pr limit
comes down at a rate set by the load gradient). ………….…..……..
29. Ensure that LP bypass controller is kept on auto with fixed set point slightly below the sliding
set point. ………….…..……..
30. As the throttle pressure increases on reduction of load the HP bypass valves will open on auto
causing the cold reheat pressure to go up. Once this pressure exceeds the sliding set point, LP
bypass valves will also open. ………….…..……..
31. Further reduce the load set point from the governing console. Check that the opening of HP
by pass valves increases further. The hot reheat temperature can be controlled by controlling
reheat temperature by HP bypass attemperation valves. ………….…..……..
32. Change over from unit supply to station supply for 6.6KV A and B buses using synchroscope.
………….…..
……..
33. Cut-in oil support at AB elevation with minimum oil pressure to stabilize the flame.
………….…..
……..
34. Transfer all the three running feeders to manual mode and reduce the loading in one of the
pulverisers. ………….…..……..
35. Take out top pulveriser. ………….…..……..
36. Close the extraction steam block valves to LPH1,2 &3 once load has come below 20%. Check
that the drain control valves closes. Open the drains of the extraction line.………….….
37. Transfer the low load feed regulation station to auto mode and take the three element feed
water control to manual mode. ………….…..……..
38. Stop one CEP also by giving a stop command from the UCB hand switch after opening the
recirculation valve fully. ………….…..……..
39. Cut in one more oil elevation and maintain the oil pressure & temp.………….…..……..
40. Change over the 16 ata header from existing unit by opening the tie valve.
………….…..
……..
78
41. Reduce the attemperation if the main steam temperature has come to around 380°C
………….…..
……..
42. Maintain the hot well, deaerator level during this transient operation.………….…..……..
43. Ensure that unit status is safe. ………….…..……..
44. Take the HP/LP bypass valves in manual mode and reduce the opening of HP/LP bypass.
………….…..
……..
45. Stop bottom pulveriser as per the instruction given earlier. ………….…..……..
46. Check that all the fuel air dampers close from top to bottom. ………….…..……..
47. Bring the burner tilt to horizontal position. ………….…..……..
48. Check that start permit is available, burner tilt horizontal and air flow less than 40%.
………….…..
……..
49. Remove the oil guns at CD elevation by pressing pair 1-3 and 2-4 stop push buttons.
………….…..
……..
50. Check that 5 min. scavenging operation is complete and gun retracts back.
………….…..
……..
51. Remove the oil guns at AB elevation.
52. The moment oil nozzle valve for 4th corner closes, the boiler will trip and loss of all fuel to
furnace alarm will come. ………….…..……..
53. MFR tripped alarm comes. Both the MFR A/B relays trip red lamp comes.………….…..……
TURBINE ON BARRING GEAR
54. At 2850 RPM, ensure that one AOP cut-in to operation (If AOP fails to start in Auto mode
then start it manually). ………….…..……..
55. At about 540 RPM ensure that jacking oil pump takes start and jacking oil pressure comes to
about 125 Kg/cm². ………….…..……..
56. At about 210RPM check that the barring gear valve starts opening and turbine speed is
maintained to about 190 RPM. ………….…..……..
57. Open the HP casing drain manually after switching off the SLC. ………….…..……..
58. Open the entire four drains upstream interceptor valve at valve seat.………….…..……..
79
59. Open the main steam strainer drain valve. ………….…..……..
60. Open the drains upstream of ESV at valve seat. ………….…..……..
61. Ensure the SLC drain for various drain valve in ‘ON’. ………….…..……..
62. Check the differential expansions of all the three casing within limits.………….…..…..
63. Check the bearing temperature for all the bearing should start coming down.
………….…..
……..
64. Check that the seal steam pressure is maintained and condenser Vacuum satisfactory.
………….…..
……..
65. Reduce the fixed set point of LP bypass to maintain flow through reheater. The opening of the
LP bypass control valve increases. ………….…..……..
66. Reduce the attemperation controllers to minimum for SH and RH. ………….…..……..
VACCUM BREAK
………….…..……..
67. Stop Vacuum Pump.
68. When condenser pressure approaches 0.7 to 0.8 kg/cm², open Vacuum Breaker.
………….…..
……..
69. Break Seal Steam Supply and Stop Seal Steam Exhauster fan. ………….…..……..
BOILER SHUT DOWN
OBJECTIVE
A. To trip the boiler and carry out the purging. ………….…..……..
B. To fill the boiler to highest drum level. ………….…..……..
OPERATIONAL STEPS
80
70. Check that HOTV closes and green lamp comes on. ………….…..……..
71. Bring the air flow to less than 40% by FD fan blade pitch. ………….…..……..
72. Check that all the purge permissive are satisfied and purge ready lamp comes.
………….…..
……..
73. Close that HP/LP bypass manually and increase the set pressure higher than the existing
pressure. ………….…..……..
74. Push the ‘Push to purge’ switch from FSSS consol. The purging light glows and stays for 5
mins. and purge complete light comes once purging is over. The MFR A and B relay reset.
………….…..
……..
75. Wait till the fuel air damper starts closing from top. Maintain the air flow in between 30 to
40%. ………….…..……..
76. Raise the MDBFP discharge pressure by raising the scoop. ………….…..……..
77. Open the low range feed control valve to start the drum filling. Check that the level in drum
which will gradually increases. ………….…..……..
78. Stop the drum filling once all the ports of the hydra step are indicating water (green lamp on).
Ensure that blow down valves are closed including emergency blow down.………….…..……
79. Stop the HP dosing system from local. ………….…..……..
80. Stop the MDBFP. Ensure that barring gear of the BFP turbine engages.………….…..……..
81. Stop the LP dosing pump. ………….…..……..
82. Close the manual isolation valve to HP bypass desuperheating valve from local.
………….…..
……..
83. Check that MDBFP discharge pressure and flow drops to zero. ………….…..……..
84. Close the equipment cooling water to MDBFP motor. ………….…..……..
SHUT DOWN OF AIR & FLUE GAS SYSTEM
85. Check the plant status with boiler in tripped condition and purging carried out.
………….…..
……..
86. In manual mode reduce the FD fan blade pitch to 0%. Check that the air flow reduces and
generates an alarm below 30%. ………….…..……..
81
87. Check that the first cause of trip red flags comes on FSSS console as air flow is less than
30%. Both the MFR trip and red lamp comes on. ………….…..……..
88. Stop the FD fan by turning the switch to OFF position. ………….…..……..
89. Check that the fan current drops down to zero and discharge pressure starts dropping down.
………….…..
……..
90. Check that discharge dampers of both the fans open fully. ………….…..……..
91. Check that scanner fan emergency damper from atmosphere opens. ………….…..……..
92. Stop the ID fan by turning the switch to OFF position. ………….…..……..
93. Check that the fan Amps drops down to zero and inlet/outlet pressure decreases.
………….…..
……..
94. Ensure that the dampers for all three fans open fully on interlock. ………….…..……..
95. Keep the lube oil pumps of the entire fan running till the bearing temp of the fans come down.
………….…..
……..
96. Check that the flue gas temp. entering the air heater goes less than 120°C. Stop secondary
APH A & B motor. ………….…..……..
97. Keep open all the flue gas inlet /outlet dampers on air side as well as flue gas side in order to
allow the natural air circulation for cooling. ………….…..……..
98. Check and close all air preheater cold end temp. controllers. ………….…..……..
99. Close the steam inlet valves to primary and secondary APH. ………….…..……..
100.Ensure that ESP fields are not charged. ………….…..……..
101.Stop the DC scanner air fan, once the furnace is sufficiently cooled.………….…..……..
82

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TECHNICAL DIARY

HASDEO THERMAL POWER STATION

Manufacturer - M/s BHEL (C.E. Design)

Type - Top Supported, Balanced Draft, Dry bottom, Single drum

 Minimum load at which steam generator

1. LHS SV-1 Consol 209.0

SUPER 7. SH SV-7 Consol 188.5

14. LHS SV-14 Consol 52.40

18. LHS SV-18 Consol 48.40

 Cation Cond. <0.2 <0.2 - -

 Res. Hydrazine 10-20

 Ammonia as 1.0 1.0

 Silica as Si02 <10 <10 <100 <10

 Total Iron as Fe <10 <10 <10

 Total copper as <3 <3 <3

 D.O as 02 <40 <5

 TDS (mg/i) <20

 Hydrogen Purity >97.0

 Dew Point (0C) at (-)100 C – (+)100 C

RECOMMENDED LIMIT OF SILICA IN BOILER DRUM

DRUM SiO2 (ppm) DRUM SiO2 (ppm)

Fan Design Rating

Type : Axial reaction AP-2-20/12

Fan design rating

P.A. FAN MOTOR

SCANNER AIR FAN

STEAM COIL AIR PREHEATER

SEAL AIR FAN

RAW COAL FEEDER

Thermal Conductivity as per IS 8183 Kcal/ M/hr /oc at mean temp of

Light Diesel Oil

Heavy Fuel Oil

Drive : Geared electric Motor

Location : At the bottom of CEs.

Rappers for emitting electrodes

Rapper for Gas Distribution System

Rapping of Collecting Electrodes & Gas Distribution Screens

SPECIFICATION OF MAIN TURBINE

STEAM PRESSURES & TEMPERATURE (RATED VALUES):

Moments of Inertia (kg/m2):

® Casing Temperature (0c)

® Temperature Difference (0K) (Between upper and lower casing section)

® Steam purity (KWU Recommended Values)

® Bearing temperatures (0C)

b) Normal operating temperature : 100 130

® Vibration (Absolute Vibration)

H.P Turbine other stage : x 22 Cr MOV 121x20Cr

Shaft couplings same material as shaft

Antifriction material used in Bearings: Babbit

LUBE OIL SYSTEM

Foam Stability (0cm3) Max 450 S

Duplex Oil filter for Jacking Oil

Jacking Oil pump

Specification of Oil pumps

Speed (RPM) 3000 2970 1425 2900

Lube Oil Cooler

CONTROL FLUID SUPPLY

i) Cooling water pressure drop : 0.1 at

BOILER FEED PUMPS AND AUXILIARIES

A) Booster Pump Details:

Motor Driven Turbine Driven

Manufacturer Delaval Stork Delaval - stork

Rotation (Viewed form DE) C.W C.W

B) Boiler feed pump- Main pump