500 Mw Turbine Design Data

TURBINE & AUXILIARIES

1.0 TURBINE & AUXILIARIES 1.1 MAIN TURBINE 1.1.1

SPECIFICATIONS (a) (b) (c) (d)

Make Design Type Stages

BHEL KWU, West Germany Three Cylinder Reheat Condensing Turbine. HPT 17 Reaction stages. IPT 12 X 2 Reaction stages. LPT 6 X 2 Reaction stages.

(e)

Valves

HPT -2 Main Stop and Control Valves. IPT -2 Reheat Stop and Control Valve. CRH line – 1 Swing Check Valve. LPBP – 2 Bypass Stop and Control Valves.

(f) (g)

Direction of Rotation Load (i) Rated load (ii) MaxM load

Speed (i) (ii) (iii) (iv) (v)

1.1.1.1

500 MW 524.9 MW (valve wide open condition)

Rated Speed 50 C/Sec MaxmSpeed 51.5 C/Sec ( No Time Limitation) m Min Speed 47.5 C/S ( No Time Limitation) Speed Exclusion Range (without load) 7 to 47.5 C/Sec Standard Over Speed Trip Setting 55.5 C/Sec

Extraction Valves (i) (ii) (iii) (iv) (v) (vi) (vii)

1.1.1.2

Anti Clockwise (Viewed from front pedestal towards Generator).

Extraction 1 Extraction 2 Extraction 3 Extraction 4.1 Extraction 4.2 Extraction 5 Extraction 6

No valve 1 check valve with actuator and 1 check valve without actuator. 1 check valve with actuator and 1 check valve without actuator. 2 check valves with actuator. 2 check valves with actuator. 1 check valve with actuator and 1 check valve without actuator. No valve.

Steam Pressure And Temperatures (Rated)

Initial steam Before 1st stage of HPT HP cylinder exhaust IP cylinder stop valve Inlet Extraction 6 Extraction 5 Extraction 4 Extraction 3 Extraction 2 Extraction 1 LP cylinder exhaust 1.1.1.3

Turbine Extractions

Extractions

1.1.2

Temperatures (oC) 537 537 336.4 537 336.7 412.8 290.8 185.2 126.0 65.4 46.4

Pressure (bar) 166.7 154.4 44.0 39.6 44.0 17.3 7.16 2.56 1.323 0.255 0.1026

Source

1

LPT – 5th stage

2 3 4 5 6

LPT – 3rd stage LPT – 2nd stage IPT Exhaust IPT –7th stage CRH

CASING TEMPERATURE LIMITING VALUES

Going To LPH-1

LPH-2 LPH-3 Deaerator (4.1) and TDBFP-A/B (4.2) HPH – 5A/5B HPH – 6A/6B, TDBFP – A/B

HP turbine casing exhaust Outer casing of LP cylinder (Spray water to L.P. turbine must be switched on at 90oC).

Alarm

M/C must be shut down at

485oC 90oC

500oC 110oC

 90oC  30oC  30oC

 100oC  45oC  45oC

Temperature difference

Between upper & lower casing of HPT. (Middle) IPT Top / Bottom Diff. temp. (Front) IPT Top / Bottom Diff. temp. (Rear) Permissible temperature difference between parallel steam supply lines No time limitation Short time period (15 min) 1.1.3

FEED HEATER OUT OF SERVICE

Operation with Feed Heater out of service Extraction A6=0 Extraction A5=0 Extraction A3=0 Extraction A2=0 Extraction A1=0 Extraction A6 , A5=0 1.1.4

17 oC 28 oC

Main Steam flow, Kg/s 395 421 423 425 423 400

Load MW 500 500 500 500 500 526.6

OUT PUT LIMIT WITH ATT

Out put Limit during the testing with Automatic Turbine Tester Testing of the Main Steam Stop & Control Valves Testing of the HRH Steam Stop & Control Valves 1.1.5

400 MW 200 to 500 MW

MOTORING

Motoring must not be allowed to continue beyond one minute. If the condenser low vacuum limit of 0.3 bar is exceeded, motoring must not be allowed to continue beyond 4 sec.

1.1.6

LOW VACUUM TRIP STANDARD SETTINGS Hydraulic Low Vacuum Trip Electrical Low Vacuum Trip Hydraulic Low Vacuum Trip Bypass Operation

1.1.7 (a)

TURBINE SEAL STEAM SYSTEM

Seal steam supply header pr. (Above Atmospheric) (b) Condenser Vacuum (c) Seal Steam Exhauster Fans

0.035 bar 0.1045 ata

Make No. of Fans Speed Type Motor Make Type Volt Connection Power rating

S.K. System Pvt. Ltd., Sonepat 2 X 100 % 2900 RPM SHSH Bharat Bijlee Ltd. ILA 3050-2 (Induction Motor) 415 V Delta KW

1.1.8 BARRING GEAR (a) (b) (c)

0.3 bar 0.3 bar 0.6 bar

Speed Drive Cut in / Cut out speed

80 to 120 RPM Turbine Lub Oil (Hydraulic Turbine) 210 / 240 RPM

(d)

Location

Front Bearing Pedestal

1.1.9 TURBOVISORY 1.1.9.1

1.1.9.2

Alarm

Trip

Axial Shift

 0.5 mm

 1 mm

Differential Expansions (i) HPT (ii) IPT Overall Expansion of IP + LP Rotor

-5.0 to +3.5 mm -1.0 to +5.5 mm -3 to + 30 mm

Vibration

Absolute Brg. housing Vibn

Absolute Shaft Vibn.

Standard Alarm setting

25m above normal level

Maximum Alarm setting

42m (85-MMI)

100m (200 MMI)

Limit Value for Tripping

53m (106-MMI)

160m (320-MMI)

Alarm

Trip

90 to 115oC (depending on operating temp. of bearing)

130oC

Bearing Temperatures Fixed Points

Turbine bearing pedestal - 2

For HP casing

Turbine bearing pedestal - 2

For IP casing

Turbine bearing pedestal - 3

For LP casing

Thrust bearing.

For Turbine Rotor

All HP, IP & LP Turbine Bearing Pedestals are Fixed. 1.1.10 WEIGHTS (TONS) HP

IP

LP

(a) Cylinder Assembly

94.6 T

41.2 T

79.6 T

(b) Rotor (with Blading)

16.3 T

23.1 T

90T

(c) Stop and C.V.

20.9 T

32.2 T

-

Turbine overall length

19.94 M

Turbine overall width

15.1 M

1.1.11 SIZE OF BEARING 1 250

Diameter (mm) 1.1.12 MATERIAL OF CONSTRUCTION 1.1.12.1 Turbine Casings HP IP

GS17 Cr MOV 515 GS22 MO 4

2 380

3 450

4 500

LP

St. 37-2N (Outer)

1.1.12.2 Blades (Moving) HP (First stage) HP (Other stage) IP LP

X22 Cr MOV 121 X20 Cr 13/X22 Cr MOV 121 X20 Cr MO13/X20 Cr 30 X20 Cr13

1.1.12.3 Rotors HP IP LP

28 Cr MON I 59 30 Cr MON IV 511 26 Ni Cr. MOV 145

1.1.13 TURBINE LOAD SHARING CAPACITY HP turbine IP turbine LP turbine

26 % 34 % 40 %

1.1.14 HEAT BALANCE DATA Rating Vacuum (mmHg)

500 MW

400 MW

300 MW

250 MW

77

77

77

77

(0.927mmWc)

DM Make-Up (%)

0

0

0

0

Turbine Gross Output (MW)

508.489

407.068

306.076

255.734

Turbine Net Output (MW)

500

400

300

250

Heat Rate (Kcal / KW-Hr)

1944.4

1987.2

2059.5

2129.3

Mechanical

1.444

1.444

1.444

1.444

Gen

6.895

5.474

4.482

4.140

TG Auxiliary

0.15

0.15

0.15

0.15

Efficiency (%)

98.33

98.26

98.01

97.757

Losses

1.2 TURBINE LUB OIL SYSTEM 1.2.1 LUB OIL SPECIFICATIONS (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) (q)

Kinematic viscosity Viscosity index Flash point Pour point Neutralisation No.(total Acidity No Emulsion char Air release capacity Rust preventing characteristic Water content % by wt. Solid particles content Foaming tendency at 25oC Foaming stability Ash (% by weight) Particle distribution Specific gravity Copper corrosion Water release

41.4 – 50 CST at 40 oC,28 CST at 50 oC Min 98 200oC (min.) -6oC (max.) Max. 0.2 mg of KOH per gm of Oil. 40-40-0 (20 minutes) 4 minutes (max.) 0-B max. 0.01 % 0.05 % max. by weight. (Max.) 400 Cm3 (Max.) 450 Sec. Max. 0.01 % Min. 17/14 Code. 0.85 g/cm2 at 50oC Not worse than No.1 300 S (Max.)

1.2.2 MAIN OIL TANK

(f)

1.2.3

(a) MOT capacity (b) 1st oil filling (c) Flushing oil quantity (d) Highest oil level from top of tank (e) Lowest oil level from top of tank Filtration particle size of tank filter element

250 m

OIL REQUIREMENT OF BEARINGS (dM /S) 3

(a) (b) (c) (d) (e) (f) (g) (h)

1.2.4

25/40 m3 47.5 m3 28.5 m3 750 mm 750 mm

Bearing 1 Bearing 2 Bearing 3 Bearing 4 Gen. bearing Front Gen. bearing Rear Exciter bearing Estimated oil requirement for the Hydraulic Barring Gear

0.8 15.4 4.55 9.29 7.92 7.92 0.70 57.4

DUPLEX OIL FILTER (FOR BRG. OIL SUPPLY HEADER) (a) (b) (c) (d) (e)

Number Type Size Make Filtration particle size

2 X 100 % 2.68.2 355 / 750 Boll & Kirch 37 m

1.2.5 JACKING OIL SYSTEM (a)

Safety valve setting

200 bar

(b) Pressure regulating valve setting 180 bar (c) Duplex oil filter (Type 400 D 140 Make K&H Eppensteiner, Germany 2x100 % (d) Filtration particle size of filter element 37 m JACKING OIL PUMPS CUT IN AND CUT OUT SPEEDS Jacking oil pumps must be in operation at turbine speeds below 510 RPM. Jacking oil pumps should be cut out at speeds above 540 RPM.

1.2.6 OIL PUMPS SPECIFICATION MOP

AOP

DC EOP JACKING OIL PP

Number

1

2

1

AC : 2 DC : 1

Make Type

BHEL 350 m³/hr

Capacity (dm3/s) Disch. Pr. (bar) Speed (RPM) Drive

87.48 8.4 3000 Turbine

MOTOR MAKE

-

Voltage (V) Motor Power (KW) Rated Current (Amp.)

-

DOR

from top

KSB ETA-15050VL 48 6.7 1470 AC Motor

KSB ETA-10033VL 30 2.3 1410 DC Motor

Crompton Greaves 415V 100 157 Clockwise

Crompton Greaves 220V 13 97 Clockwise

1.2.7 LUB OIL COOLERS (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p)

Number Cooling Surface Area Oil Flow Heat Dissipating Capacity Oil Inlet Temp. Oil Outlet Temp. Oil Side Pr. Drop CW Inlet Temp. CW Outlet Temp. CW Flow CW Side Pr. Drop Test Pr. – Oil Side Test Pr. – CW Side Tube Material Tube Plates Material Casing And Water Boxes Material

2 X 100 % 640 M2 186.2 M3/Hr. 1771 KW 65 oc 45 oc 4 Mwc 38 oc 39.7 oc 900 M3 1.0 Mwc 13.5 Kg/Cm2 15 Kg/Cm2 Admiralty Brass Carbon Steel Carbon Steel

1.2.8 TURBINE OIL CENTRIFUGE SYSTEM 1.2.8.1 Motor Make Crompton Greaves Rating (HP) 11/(15) RPM 1470 Duty S1 Volts 415 Type 3Ø Induction motor Insulation class F Efficiency 89% Bearings DE/NDE 6309-C3(2RS) 1.2.8.2 Centrifuge (a) No. of units One (b) Make Alfa Laval (c) Type MAB 206 S-24 (d) Speed of Bowl (Max.) 8423 RPM 1.2.8.3 Centrifuge Feed Pump (i) Capacity 8.54 M3/Hr (ii) Suction lift 4 M Wtr (g) (iii) Delivery head 15 M Wtr(g) Process temperature(min/max) 0/100 °C Max density of the feed 1100Kg/m³ Max density of the sediment 1600kg/m³ 1.2.8.4 Centrifuge Materials (i) Bowl spindle Steel (ii) Frame, lower and upper parts Cast Iron (iii) Collecting cover Aluminium (iv) Bowl body, hood, disc. stack, gravity disc. Stainless steel (v) Sludge basket Stainless steel (vi) Other bowl parts Tinned steel, bronze, brass 1.2.9 MOT OIL VAPOUR EXHAUST FANS

Make

S.K. System Pvt. Ltd.

Tushako T3 SA 38/46

Tushako T3 SA 38/46

1.84 178 2898 AC & DC Motor Crompton Greaves 415V 45 76 Clockwise

1.84 178 2898 AC&DC Motor Crompton Greaves 220V 45 234 Clockwise

Type Size Speed No. of Fans Motor Make Type Voltage Power rating

SHSH 10 C1 2825 RPM 2x100% Bharat Bijlee Ltd. 1 MJ 3903-2 415 V 0.75 KW

Location No. of PPs. DOR Discharge Pr. Motor Make Rating Volt Current Speed

C.F.T. room (T.G. ‘0’m) 1x100% CCW from DE 2.5 kg/cm2 Siemens 0.69 KW 415 V 1.67 Amps. 1400 RPM

1.2.10 LEAKAGE OIL PUMP

1.3 TURBINE CONTROL SYSTEM (Control Fluid System) 1.3.1 FIRE RESISTANT FLUID SPECIFICATION (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n)

Flash Point Pour Point Neutralisation No. Ignition temp. Air release capacity Water content (by weight) Particle distribution Foaming tendency at 25oC Foaming stability Kinematic viscosity (at 40oc) Solid particles content Density (at 15oC) Oxidation stability Electrical Resistivity

>235oC < -18oC Max. 0.1 mg KOH/g >550oC 5 min. (Max.) < 1000 mg/Kg 17/14 min code < 100 ml 450 Sec. (max.) 41.4 to 50.6 CST 0.05 % (by weight) 1250 Kg/m³ (max.) 2.0 mg KOH/gm (max.) >50 MΩm

1.3.2 CONTROL FLUID TANK (a) (b) (c) (d) (e) 1.3.3 (a)

(b)

Tank capacity 1st fluid filling Flushing fluid quantity Highest fluid level from top of tank Lowest fluid level from top of tank

10/16 m3 15 m3 10 m3 650 mm 750 mm

REGENERATIVE SYSTEM (C.F. PURIFICATION) FILTERS (Filters Philipp, France)

Type of Filters

Purpose

Dry (F2.6) Fuller Earth (HFB12) Fine filter(F2.6)

To take off water Neutralization of acidity Fine filtration and security

REGENERATIVE PUMPS (C.F. Recirculation PP) (i) Number of PPs 2 x 100 % (ii) Make (Pump) Gebr Steimel (Germany) (iii) Type BGK2-24R (iv) Fluid flow 0.28 dm³/s (v) Direction of rotation Anti clockwise from DE (vi) Discharge pr. 3.06 ata (at 55oC) (vii) Speed 1500 RPM (viii) Drive A.C. Motor (c) (ix) (x) (xi) (xii)

Motor Make Motor Power Rated current Voltage

Siemens (Germany) 0.75KW 1.67 Amps. 415 V

1.3.4 CONTROL FLUID PUMPS 1.3.4.1 Pump (a) Number of Pumps (b) Make (c)

Type (d) (e) (f) (g)

Discharge pr. Fluid flow Speed Drive

2 x 100 % KSB WKVM80-1 + 3 11.5 / 38.5 bar 12.1 / 9.33 dm3/s 2975 RPM A.C. Motor

1.3.4.2 Motor (h) (i) (j) (k) (l) (m) (n)

Make Type Voltage Motor rating Rated current Starting current Speed

Siemens ILA63162 AC 415 V 160 KW 256 Amp. 1792 Amp 2975 RPM

No. of cartridges / type

6 throwaway / PD71803C 12 throwaway / HT`11800CR 6 throwaway / PL71812C

Control Fluid Pumps Operating Characteristics

Fluid flow dm³/s

Discharge pressure

Low pressure leakage fluid

12.1

11.5

High pressure leakage fluid

9.33

38.5

Operating point II (during start & opening of the stop valve servo motor) Low pressure leakage fluid & low pressure control fluid High pressure leakage fluid

25.1

10.8

9.33

37.8

Operating point III (during opening of the control valve /LP bypass operation after the load throw off) Low pressure leakage fluid

12.1

10.6

High pressure leakage fluid

24.36

31.6

Operating point I (normal operation)

1.3.5 C.F. VAP. EXTRACTION FANS (a) (b) (c) (d) (e)

Number of Fan Make (Fan) Make (Motor) Speed Current

2 x 100 % Pillar (Germany) Siemens 3000 RPM 0.6 Amps.

1.3.6 CONTROL FLUID COOLER (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) (q) (r)

(a) Number of coolers Cooling surface area Fluid Flow Heat dissipating capacity Fluid inlet temp. Fluid outlet temp. Fluid side pr. drop CW inlet temp. CW outlet temp. CW flow CW side pr. drop Design pr. – CW side Test pr. – CW side Design pr. – Fluid side Test press – Fluid side Tubes material Casing (shell) Water box

2 x 100 32 m2 3 43.2 m /hr. 147 KW 55 oC 49 oC 3.5 MWC 38 oC 40.1 oC 60 M3/Hr. 2.1 MWC 10 Kg/Cm2 15 Kg/Cm2 13 Kg/Cm2 19.5 Kg/Cm2 Stainless steel Stainless steel Carbon steel

1.4 CONDENSER 1.4.1 CONDENSER SPECIFICATIONS Type

Double Pass, Single Shell

Total Surface Area Of Heat Transfer

356034 M2

No. Of Cooling Tubes

22688 Condensing Zone,1710 Air Cooling Zone

Length Of Each Tube

14.73 M

Size Of Tubes (OD X Th.) (For Top Row Tubes) Tube Material

31.75 x 0.7112 mm x mm 31.75 x 0.889 mm x mm Welded titanium B 338 Gr. II

Tube Wall Thinning

7 to 10 %

Design C.W. Temp.

33 oC

CW Temp. Rise

10.45 oC

CW Flow Quantity

54300 M3/Hr.

CW Side Pressure Drop

4.15 MWC

No. Of CW Passes

2

Condensate Back Pressure

0.1045 ata

Water Box Design Pr.

5.0 Kg/cm2

Water Box Hydraulic Test

7.5 Kg/cm2

No. Of Tube Support Plates

2 x 16

Total Empty Wt. Of Condenser (Without LPH-1)

650000 Kg.

1.5 CONDENSATE EXTRACTION PUMP 1.5.1

1.5.2

1.5.3

1.5.4

SPECIFICATIONS Make Type Of First Impeller Number Of Stages Design Flow Rate Inlet – Temperature Inlet – Specific Gravity NPSH Required (3% Head Break Down) Discharge Pressure Total Dynamic Head Shut Off Head Pump Speed No. Of Pumps / Model No. DOR (As Viewed From DE Side) CONSUMPTION AT DESIGN CONDITION Power Input At The Motor Losses In The Motor Power Input To The Pump Efficiency Of The Pump Alone Overall Efficiency Of Pump & Motor ADDITIONAL DATA Minimum Condensate Flow For Continuous Stable Operation Suction Strainer Size Axial Fluid Vel. In Eye (M/Sec.) Critical Speeds (RPM) Sealing Water Requirement Flow Pressure Temperature Bearings Lubrication No. Of Brg. Type Design Load MOTOR SPECIFICATION Make Rating Type Voltage Number Of Poles Speed Frequency Starting Current Full Load Current Insulation Class Motor Winding Cooling Motor Brg. Type Motor Bearing Lubricated

1.6 LP HEATERS SPECIFICATION 1.6.1 GLAND STEAM CONDENSER 1.6.1.1 GSC 1.6.1.2 Gland Steam Exhauster (2 Per Unit) Make SK Systems Pvt Ltd Type SHSH Size 15 ½ Speed 2855 RPM Capacity M3/Hr Motor

BHEL – Hyderabad Double suction 6 800 M³/hr. 49.2oC 0.988 3.1 meter (4.2-1%,4.4-0%) 275 MLC 275 Meters 390 Meters 1486 RPM 3 (50 % duty) / EN6J40/500 CCW 763 KW 32 KW 731 KW 81% 77.6 % 300 M3/Hr. 400 µ 2.85 3380, 5798 0.55 M3/Hr. 3 to 4 ata 48-65 oC Radial Bearings Condensate 10 nos., 100mm Cutless rubber ---

Thrust Bearings Sump Oil 1 Michell Type 8DN1, Tilting Pad 2732 kg. , Maxm Load-6038 Kg

BHEL – Bhopal 763 KW Induction Motor (Squirrel cage) 3.3 KV 4 1489 RPM 50 Hz 600 Amps. 244.0 Amps. F Self Air-Cooled. Anti Friction IOC Servo Gem-3/EQV.

Make Type Rating Bearing

ABB HX 15 2 S 1421 3Φ Ind , 415 V , 50 Hz , 6.7 Amp , 3.7 KW , 2885 RPM DE-6308 ZZ C3 , NDE-6307 ZZ C3

1.6.2 DRAIN COOLER Type Quantity Drain (Kg/Hr.) Pressure of Drain (ata) Temp. of Drain (oC) Quantity of Condensate (Kg/Hr.) Pressure of Condensate (Ata) Condensate Inlet Temp. (oC) Condensate Outlet Temp. (oC) Surface area (M2) Size of tubes OD X Thk Number of tubes Velocity of Condensate (M/Sec.) Number of tube side passes Number of shell side zones Design pressure on shell side (Atg) Design temp. on shell side (oC) Design pressure on tube side (Atg) Design temp. on tube side (oC) Test pressure on shell side (Atg) Test pressure on tube side (Atg) Materials Shell, Channels Tube plate & Channel end covers Flanges Support plate Tubes Condensate Inlet / Outlet pipe Drain Inlet / Outlet pipe Weights Dry Operational Flooded

1.6.3 LP HEATER Type

Heatr-1

Quantity of Extraction steam (Kg/Hr.) Pressure of Extraction steam (Ata)

Straight Tube / Horizontal 155.945 0.2517 In = 64.7 Out = 51.7 1177.636 39 46.9 48.7 145 ¾” x 20 BWG 675 21.5 1 1 3 & Full vacuum 120 39 144 4.5 58.5 C.S. SA 516 GR 70 C.S. SA 516 GR 70B CS SA 105 C.S. IS 2062 S.S. SA TP 304 688 C.S. SA 106 GR “B” C.S. SA 106 GR “B” Kgs. 5400 Kgs. 7200 Kgs. 7200

Heater-2 U-Tube / Horizontal 295.90

Heater-3 U-Tube / Horizontal 124.08

U-Tube / Horizontal 40.702

0.2517

1.30324

2.5174

Temp. of Extraction steam ( C)

64.7

126.7

216

Quantity of Condensate (Kg/Hr.)

1180468

1177.66

1177.66

Pressure of Condensate (Ata)

34

39

32

48.4

61.9

103.8

Condensate Outlet Temp. ( C)

61.9

103.8

124.2

Surface area (M2)

876

1326

838

Size of tubes OD X Thk

¾” x 20 BWG

¾” x 1 mm (Min)

¾” x 1 mm(Min)

Number of tubes

718 ‘U’

917 ‘U’

718 ‘U’

Velocity of Condensate (M/Sec.)

1.99

1.57

199

Number of tube side passes

2

2

2

Number of shell side zones

1

2

2

3 & Full vacuum

3 & Full vacuum

4 & Full vacuum

Design temp. on shell side ( C)

120

155

216

Design pressure on tube side (Atg)

47

39

39

Design temp. on tube side ( C)

144

152

152

Test pressure on shell side (Atg)

4.5

4.5

6

Test pressure on tube side (Atg)

70.5

58.5

58.5

C.S. SA 516 GR 70

C.S. SA 516 GR 70

C.S. SA 516 GR 70

o

o

Condensate Inlet Temp. ( C) o

Design pressure on shell side (Atg) o

o

Materials Shell, Channels

Tube plate & covers

C.S. SA 516 GR 70

C.S. SA 516 GR 70

C.S. SA 516 GR 70

Flanges

***

C.S. SA 106 GR B

C.S. SA 105

Support plate

C.S. IS 2062

C.S. IS 2062

C.S. IS 2062

Tubes

S.S. SA 688 TP 304

S.S. SA 688 TP 304

S.S. SA 688 TP 304

Condensate Inlet / Outlet pipe

C.S. SA 106 GR “B”

C.S. SA 106 GR “B”

C.S. SA 106 GR “B”

Steam inlet pipe

C.S. SA 106 GR “B”

C.S. SA 106 GR “B”

C.S. SA 106 GR “B”

Impingement plate

S.S. SA 240 TP 304

S.S. SA 240 TP 304

S.S. SA 240 TP 304

LP Heater dry

Kgs. 21500

Kgs. 26000

Kgs. 18000

LP Heater in operation

Kgs. 25000

Kgs. 33000

Kgs. 24000

LP Heater flooded

Kgs. 37000

Kgs. 43000

Kgs. 31500

Lift Pr (Kg/Cm2) 9.15 8.7 8.25 9.25 9.0 8.5

Reset Pr (Kg/Cm2) 7.5 7.0 6.25 7.25 7.25 6.75

Weights

1.7 DEAERATOR & FST 1.7.1 DEAERATOR SPECIFICATION Design Pressure (Kg/cm2) Capacity Design Temperature (oC) Operating Pressure Kg/cm2(g) Operating Temp. (oC) Test Pressure (Kg/cm2) Condensate inlet Qty. (Kg/Hr.) Number of trays Number of Spray valves Dissolved Oxygen in feed water (cc/Ltr) Materials Header & Dished End Trays Tray Support Tray removal openings & Internal pipes Packing

9.0 170 M³ 0 / 360 6.8 168.3 13.5 1197.64 576 108 0.005 CS SA 516 GR 70 SS SA 240 TP 304 SS SA 240 TP 304 CS SA 106 GR B CAF – 9

1.7.2 FEED WATER STORAGE TANK 1.7.2.1 FST

Design Pressure (Kg/cm2) Operating Pressure Kg/cm2(g) Operating Temperature (oC) Test Pressure Kg/cm2(g)

Full Vacuum & 9.0 6.8 168.3 13.5

Storage Tank Shell & Dished End Internal Nozzles Cover for Manholes

CS SA 516 GR 70 CS SA 106 GR B CS SA 105

Storage Tank & Header Dry Storage Tank & Header in operation Storage Tank & Header flooded

Kgs. 110000 Kgs. 318000 Kgs. 490000

1.7.2.2 Materials

1.7.2.3 Weights

1.7.3 DEAERATOR SAFETY VALVES Safety Valve SV-1 (On FST / DM Plant Side) SV-2 (On FST) SV-3 (On FST) SV-4 (On FST) SV-5 (On Dea / Turbine Side) SV-6 (On Dea / Boiler Sie)

Design Lift Pr (Kg/Cm2) 9.0 8.5 8.0 9.0 9.0 8.5

1.8 BOILER FEED PUMP AND AUXILIARIES 1.8.1 BOILER FEED PUMP(MAIN)

1.8.1.1 Specifications

Manufacturer Model No. No. of Pumps No. of Stages Casing type Direction of Rotation Suction temp. oC Suction pr. (bar) Discharge pr. (bar) NPSH at 3% head break down (bar) Sp. gravity Flow rate (T/Hr.) Speed (RPM) Efficiency (%) Power consumption KW Total dynamic head (M) for pump Recirculation required for cont. minm flow (T/Hr.) Discharge pressure for the kicker stage(bar) Shut off head(M) 1.8.1.2 Bearings (A)

MDBFP

TDBFP

BHEL / Hyderabad FK 4E36 1 X 50% 4 + 1 kicker stage Outer - Barrel Inner -Radially split. CCW from BP NDE. 164 26.4 202.5 50 0.904 990 5465 81 6223 2390 400 255.02 3000

BHEL / Hyderabad FK 4E36 2 X 50% 4 + 1 kicker stage Outer - Barrel Inner -Radially split. CW from BP NDE. 164 25.7 202.5 50 0.904 990 5465 81 6223 2390 400 255.27 3000

THRUST BEARING

Type Manufacturer Size

Tilting pad (8 + 8 Pads) Glacier MB269 / 2P / 2P

Type Manufacturer Size

Thick Wall Babbit Glacier 110KBA 080 (for NDE)

Type

Burgmann Mech. seal. SHF2/162-E5 (for DE) SHF2/135-E5 (for NDE) 35 bar Pump jacket cooling. Closed loop recirculation via pumping ring through a heat exchanger. < 55oC

(B) JOURNAL BEARING

1.8.1.3 Mechanical Seal

Seal pr. Stuffing box cooling Seal cooling Temperature at seal outlet 1.8.1.4 Suction Relief Valve Make Size Set Pr. Cold Set Pr. Temperature Capacity Type Back Pr.

BHEL ¾” 33.0 Kg/Cm2 33.2 Kg/Cm2 163 0C 42.5 Ltr/Min ¾” 1990 SW 2.1 Kg/Cm2

1.8.2 BOOSTER PUMP 1.8.2.1 Specifications

Manufacturer Model No. No. of Pumps Casing type Direction of rotation (from driver end) Suction temp. (oC) Suction pr. (bar) NPSH at (3% head break down) M Discharge pr. (bar) Pump speed RPM Power consumption, KW Efficiency (%)

MDBFP

TDBFP

BHEL / Hyderabad FA1B75 1 x 50% Horizontal CW 164 9.06 4.5 20.3 1494 608 81.5

BHEL / Hyderabad FA1B75 2 x 50% Horizontal CCW 164 8.3 4.5 20.3 1494 608 81.5

Journal brg.

Thrust brg.

1.8.2.2 Bearings

Type Size Manufacturer

Thick Wall Babbit 080KSA060 Glacier

Tilting pad (8 + 8 Pads) M-8/134/2P-2P Glacier

1.8.2.3 Mechanical Seal

Type Seal pr. Seal cooling

1.8.2.4 Suction Relief Valve Make Size Set Pr. Cold Set Pr. Temperature Capacity Type Back Pr.

Burgmann Mech. Seal 09-H75F2/100-EX1 (for DE) 09-H75F2/100-EX2 (for NDE) 25 bar Closed loop recirculation via pumping ring through a heat exchanger.

BHEL ¾” 11.0 Kg/Cm2 11.1 Kg/Cm2 163 0C 82.3 Ltr/Min ¾” 1990 SW 2.1 Kg/Cm2

1.8.3 BFP DRIVE - MOTOR 1.8.3.1 SPECIFICATIONS

Type Manufacturer DOR from BP side Rated voltage Power rating Full Load Current Starting Current Rated Speed

Cage Rotor Asynchronous Motor BHEL, Bhopal CCW 11 KV 10 MW 601.5 Amps. 2720 Amps. 1500 RPM

1.8.3.2 BEARINGS

Type Lubrication

Sleeve Forced Oil.

1.8.3.3 MOTOR COOLING

Type of Cooler No. of Cooler Cooling water required Cooling water Inlet temp. Cooling water pr. (bar) Outlet temp. of cooling water Temp. of Cold air (Outlet) 1.8.4 HYDRAULIC COUPLING FOR MDBFP Manufacturer Type Journal brg. type Thrust brg. type Direction of rotor

Gear ratio U1 U2 Primary speed Secondary speed Full load slip

CACW (Circulating Air Circulating Water) 2 x 50% 24 M3/hr. 38 oC 6 (Max.) 43 oC 50 oC M/s. VOITH, Germany Hydrodynamic (Geared variable speed) R18KGS-14(API) Plain Tilting pad Input shaft

Hydr. circuit

CCW

CW

109 / 32 68 / 53 5206 RPM 5102 RPM 2.0 %

Output shaft

CCW

Max. output speed Regulation range Bearing temp.

6440 RPM 4:1 downwards < 90oC

1.8.5 LUB OIL SYSTEM FOR MDBFP 1.8.5.1 Lubricating Oil Specification

Oil supplier Brand name Capacity of lube oil tank Total lube oil flow rate (for pps, coupling & motor) Lube oil pr. Control oil pr. Working oil pr. Working oil flow rate

Indian Oil Corporation Servo HLP32 2.5 M3 300 l/Min. 2.5 bar 3.5 bar 2.5 bar (Max.) 1300 l/Min.

1.8.5.2 Oil Coolers

Type (Make) Model No. No. of coolers Oil filling for one heat exchanger Oil flow rate Oil temp. Inlet to cooler Oil temp. Outlet of cooler Cooling Water flow Cooling Water Inlet temp. Cooling Water Outlet temp. Oil side Pr. drop (bar)

Working Oil

Lub Oil

Shell/Tube (VOITH) LINI 131713-D 2 X 100% 148 L 78 M3/hr. < 95 oC < 58 oC 132.0 M3/hr. 38 oC 48 oC 0.54

Shell/Tube (VOITH) LINI 091913-D 2 X 100% 91 L 51 M3/hr. < 65 oC < 50 oC 75 M3/hr. 38 oC 42 oC 0.41

Auxiliary Oil Pp

Main Oil Pp

VOITH/Germany Gear One M2P820 AC Motor 4.0 50 M3/hr.

VOITH/Germany Centrifuge One 2PM600 Shaft driven 4.0 -

BFP

Booster Pp

1.8.5.3 Lub Oil Pumps

Manufacturer Type No. of PP. Model No. Pump Drive Rated head (bar) Rated capacity 1.8.5.4 Lub Oil Requirement In Brgs.

Oil Flow (M3/hr.) Oil pr. (bar) Maxm. Bearing temp. (oC) 1.8.5.5 Oil Purifier For MDBFP

Journal

Thrust

Journal

Thrust

0.42 2.5 100

13.44 2.5 80

0.3 2.5 80

0.72 2.5 65

Make Type Motor Make

1.8.6

Alfa Laval Portable / MAB 103 Bharat Bijli Ltd.

BFP DRIVE TURBINE

1.8.6.1 Specification

Type Manufacturer MaxM Output Design.Rating (economical rating) Turbine normal speed Speed range Specified initial Steam pr. Permissible dev. in Static pr. MaxM Wheel chamber pr. Exhaust steam pr. Specified initial steam temp. Permissible deviation without limitation No. of states No. of stop valve No. of Aux. C.V. No. of Control valves Method of Speed sensing Overspeed trip Critical Speed Turning gear speed Direction of rotation Governing system Shaft power Steam consumption

K1401-2 BHEL / Hyderabad 7575 KW 5732 KW 5275 RPM 1494 to 5750 RPM 6.33 Kg/Cm2 12.0 Kg/Cm2 11.0 Kg/Cm2 0.1064 Kg/Cm2 289.6 oC 320.0 oC 14 Nos. 1 No. 1 No. 5 Nos. Ferostatic pick up 6330 RPM (Electrical) 7550 RPM 150 RPM CCW (as viewed from steam admission end / BP NDE) Electro Hydraulic (I / H Converters) 5750 KW 35.792 T/Hr.

1.8.6.2 TDBFP Bearings

(a) Type (b) Nos.

Journal Brg. 2 Lobed 1 at Front Pedestal 1 at Rear Pedestal

Thrust Brg. Tilting pad, double acting

(8 + 8 Pads) Front Pedestal

1.8.6.2 Couplings

Location

Between Turbine and Main Feed Water Pp Between Booster Pp and Gear Box Between Turbine and Gear Box

Type

Make

Disconnect coupling FDEL Size: 104 Class-I GDN-28 Flexible Gear coupling Size: 101.5 Class-II

M/s. Zurn Industries

1.8.7 TDBFP LUB OIL SYSTEM Oil Brand Name Oil Supplier Main Oil tank capacity Lube oil pr. to brg. Lube oil hdr. pr. (at 17m)

Daphne Super Turbine Oil 46 Savita Chemicals 16.84 M3 0.9 to 1.3 bar for Journal brg. 0.3 to 1.3 bar for Thrust brg. 2 to 2.5 bar

M/s. Waclhand Nagar .I.Ltd M/s. Ameri Drives International

1.8.7.1 Lube Oil Coolers

Manufacturer No. of coolers Type Oil flow rate Water flow rate Oil side pr. drop Inlet oil temp. Outlet oil temp.

BHEL 2 X 100% Shell & Tube 46.8 M3/hr. 120 M3/hr. 2.6 bar 60 oC 45 oC

1.8.7.2 Oil Pumps Specification

Aux. Oil PP

DC Oil PP

Jacking Oil Pump

Oil Transfer Pump

Number

2

1

1

1

Make

M/s.IMO, USA

KSB

Delta Corp.

Delta Corp.

Type

Screw

Centrifugal RPKEM50-200

Gear (HPG2A)

R20-DG

Capacity (lpm)

2500

415

9

50

Rated Head (ata)

12.6

5.5

100.0

3.0

Speed (RPM)

1480

2900

1450

1500

Drive

A.C. Motor

D.C. Motor

A.C. Motor

A.C. Motor

Motor Make

Crompton Greaves

Kirloskar Elect. Company Ltd.

Crompton Greaves

Crompton Greaves

Voltage (V)

415

220

415

415

Power (KW)

90

15.0

3.5

1.5

Rated Current (Amps.)

148

86.5

7.5

3.4

DOR

CW from DE side

CW from DE side

CW from NDE side

CW from DE side

1.8.7.3 Oil Purifier (Centrifuge)

Make Type Motor Operating speed Rated capacity 1.8.7.4 Oil Vapor Extractor Fans Nos Mounting Type Rating Make

Alfa Laval MAB 205 5.5KW, 415V, 10.4 Amp., 1445 RPM 8725 RPM 2.4 M3/Hr.

2 per Pump Tank Top Centrifugal , Direct Mounted 0.37 KW , 2800 RPM Crompton Greaves

1.8.8 TDBFP Governing System 1.8.8.1 Governing Rack Input Oil Pressure 8 bar Power Oil Pressure 8 bar Type of Governing I/H Converter (Current / Hydraulic) Type of Sec Oils HP for MCV & LP for ACV O/P Secondary Oil Pr 1.5-4.5 bar (corresponding to 4-20 mA) ESV Test Oil Pr 8 bar Over Speed Test Oil Pr 3.2 bar 1.8.8.2 Emergency Stop Valve (ESV) Type Opening Time Closing Time Operating Oil Pr Open / Close Operation 1.8.8.3 Main Control Valve (MCV) No of Valves Controlling Mechanism Maximum servomotor travel Start of operation Full Open Condition

Latching Type , Fast Closing 1-2 min 60 mSec 8 bar Solenoids 5 Bush Groove Depth 130 mm 1.5 bar of HP Sec Oil Pr 4.5 bar of HP Sec Oil Pr

1.8.8.4 Aux. Control Valve (ACV) No of Valves 1

Controlling Mechanism Maximum servomotor travel Start of operation Full Open Condition 1.8.8.5 Accumulators No of Accumulators Operating Pressure Operating point Capacity

Seat Overlap 70 mm 1.5 bar of LP Sec Oil Pr 4.5 bar of LP Sec Oil Pr 2 per Pump 6.5 bar Governing Oil Line 35 Ltrs

1.9 HP HEATERS SPECIFICATION 1.9.1 HP HEATERS 5A / 5B Type Quantity Extraction steam (Kg/Hr.) Pressure of Extraction steam (Ata) Temp. of Extraction steam (oC) Quantity of Feed Water (Kg/Hr.) Pressure of Feed Water (Ata) Feed Water Inlet Temp. (oC) Feed Water Outlet Temp. (oC) Surface area (M2) Size of tubes OD X Thk Number of Tubes Velocity of Feed Water (M/Sec.) Number of tube side passes Number of shell side zones Design pressure on shell side (Atg) Design temp. on shell side (oC) Design pressure on tube side (Atg) Design temp. on tube side (oC) Test pressure on shell side (Atg) Test pressure on tube side (Atg) Skirt design. temp. (oC) Materials Shell, Channels Tube plate & covers Flanges Support plate Tubes Condensate Inlet / Outlet nozzles Steam inlet nozzle Impingement plate Weights H.P. Heater dry H.P. Heater in operation H.P. Heater flooded Safety Valve Make Size Set Pr. Cold Set Pr. Temperature Capacity Type Back Pr.

6A / 6B U-Tube / Horizontal 42.53 16.88 413 748.075 230 165.5 203.3 1055 3/4” x 2.7 mm 1347 ‘U’ 1.99 2 3 24 & Full Vacuum 224 320 165.5/203.33 36 480 455

U-Tube / Horizontal 78940 42.723 335.5 748.077 226 203.3 253.4 1269 15.88 x 2.77 mm 1347 ‘U’ 2.00 2 3 52.4 & Full vacuum 273 320 273 / 293 78.6 480 371

SA 387 GR 12 cl.1 SA 350 LF 2 SA 106 Gr B C.S. IS 2062 S.S. SA 688 TP 304 SA 106 Gr B A.S. SA 182 F11 S.S. SA 240 TP 304

C.S. SA 516 GR 70 C.S. SA 688 T P 304 CS SA 105 C.S. IS 2062 S.S. SA 688 TP 304 C.S. SA 350 LF 2 C.S. SA 350 LF 2 S.S. SA 240 TP 304

Kgs. 42250 Kgs. 49300 Kgs. 56250

Kgs. 58050 Kgs. 62550 Kgs. 70100

BHEL

BHEL 4X6 52.4 Kg/Cm2 53.1 Kg/Cm2 230 0C 5414.3 Kg/Hr 1912L 2.1 Kg/Cm2

Kg/Cm2 Kg/Cm2 0 C Ltr/Min Kg/Cm2

1.10 LP DOZING SYSTEM 1.10.1 LP DOZING PUMPS No. of Pumps Type

2 Nos. Ammonia dozing Pps. 2 Nos. N2H4 (Hydrazine) dozing Pps. Metering Pump with Diaphragm Heads

Make Model Capacity Disch. Pressure Hydraulic Fluid Gear Box Oil

Metachem Corporation, Bombay MC – 2 / D/R 50 LPH 45 Kg/cm2 SAE 40 oil Servomesh 460 (IOC)

MOTOR SPECIFICATION

Make Power rating (KW) Current Voltage Connection Insulation Type Speed DOR

Crompton Greaves Ltd. 0.75 2.1 Amp. 415  10% Star Class – F Three Phase Motor 1400 RPM Clockwise from NDE

1.10.2 AGITATORS FOR NH3 & N2H4 DOZING TANKS No. Of Agitators Make Type Speed Power Motor Make Type Voltage Current Speed Power Rating Brg. Lubrication

1 no. for each tank REMI Process Plant & Machinery Limited, Mumbai. Portable, 10/4 1400 RPM 1 HP Crompton Greaves Ltd. 3 phase Induction Motor 415 V 2.1 Amps. 1400 rpm 0.75 KW Lithium II Based Grease.

1.10.3 NH3 TRANSFER PUMP No. of Pump Make Flow rating Speed NPSH Motor make Voltage Current Power Rating

2 Khimline Pumps Ltd., Thane 2.4 M3/Hr. 2820 RPM 1.8 M CGL 415 V 2 Amps. 0.75 KW

1.11 VACUUM RAISING SYSTEM 1.11.1 VACUUM PUMP Make Type No. of PPs Pump rated speed No. of stage Operating liquid Direction of rotation (facing DE shaft End) Starting moment of Inertia Motor Make Type Power rating Voltage Current Rating 1.11.2 SEPERATOR TANK Vol. Of Tank Max. Allowable Working Pr.

Siemens AG 2BE1353-OZY4-Z (ELMO-F) 2 X 100 % 590 RPM 01 Water at 15 0C temp. Clock wise 37 KgM2 Siemens (Germany) 11A8 317-3ZZ 90-Z315 (Squirrel Cage Cont. Rating) 135 KW 415 V 255 Amp 1500 Ltr 1.05 bar

Test Pr. Max. Working Temp. 1.11.3 RECIRCULATING PUMP Type Capacity Delivery head Material - Pump casing - Shaft & Impeller Motor Make Type Power Voltage Speed

2.6 bar 60 oC

LM 65-200 32 M3/Hr. 12 M Cast Iron GG 20 S.S. Siemens Rotory Current Motor 2.2 KW 415 V 1400 RPM

1.12 CENTRAL LUB OIL STORAGE & PURIFICATION UNIT Function

Storage & purification of turbine lube oil, Emptying or filling the turbine lube oil system of Unit # 1 and Unit # 2.

Location

Turbine ‘0’m (Unit # 1 , B-C BAY).

1.12.1 EQUIPMENTS 1.12.1.1 Oil Tanks

No. Of Tanks Capacity Of Tanks

Clean oil Tank 1 No. 60 M3

Dirty oil Tank 1 No. 60 M3

Unloading Tank 1 No. 1 M3

1.12.1.2 Oil Transfer Pumps

Clean Oil Transfer PP Dirty Oil Transfer PP Pump Pump Make Type Speed Flow Disch. Pr. Motor Motor Make Type Speed Voltage

1 no. for transferring oil from Clean oil tank to any of unit oil Tank. 1 no. for transferring oil from Dirty oil tank to Central oil Purifier. Reliable Engg. Company, Rakhial, Ahmedabad UM2 / Positive displacement (Gear Type) 1440 RPM 8250 Ltr / Hr. 2 Kg/cm2 Bharat Bijlee Three phase Induction Motor (ILA 3054) 1480 RPM 415 V

1.12.1.3 Central Oil Purifier

Separator type Max. speed Max. Density of feed Max. Density of sediments Rated capacity Built on Feed pump suction lift Delivery head Delivery head at built in pump outlet Running up / Stopping time Heater Type Voltage Power Make

1.13 HP Bypass System

MAB 2065-24 8423 RPM 1100 Kg/M3 1600 Kg/M3 9500 Ltr/Hr 4 M wg 15 M wg 15 to 25 M 1.2 to 2 min. / 3 minutes with brake applied Indirect 415 V 120 KW Cosmos Engrs., Pune

1.13.1 OIL SUPPLY UNIT Pump Manufacturer

DENISON HYDRAULICS

Model

7-7B-B05-2R00 AIMO

Supply Capacity

24 Ltr /Min.

System Operating Pr.

110 bar

Speed

1440 RPM

Maxm. Oil Pressure

170 bar

Motor Make

Kirloskar

Normal Power

7.5 KW

Voltage

415 V

Speed

1440 RPM

Oil Tank Volume

70 Ltr

Useable Volume

50 Ltr

Hydraulic Accumulator Volume

30 Ltr

Pressure Rating

210 bar

Operating Gas

Nitrogen only

Bladder Material

Nitrile (Synthetic rubber)

Oil Requirement For Initial Filling In 2 X OV32 Oil Supply Units Annual Consumption (Including Initial Filling) Oil Brand Name

250 Ltr 275 Ltr Servo Conval 46 (IOC)

1.13.2 VALVE DATA FOR HP BYPASS SYSTEM BD

BPE1, BPE2

BP-1, BP2

No. Of Valve

1

2

2

Valve Type

E45S

E45S

ARS140A

321

321

187.6/53.4

185

185

540 / 500

Design Pr. Kg/Cm2 O

Design Temp. C