Condensate extraction pump

10/09/12 6:00 PM

TABLE OF CONTENTS

1 MAIN BOILER
1.1 GENERAL SPECIFICATION
1.2 DESIGNATION
1.3 FURNACE SPECIFICATION
1.4 WATER WALLS
1.4.1
FRONT WALLS
1.4.2
SIDE WALLS, REAR WALLS
1.4.3
WATER WALL HEADERS
1.5 DRUM
1.6 SUPERHEATERS
1.7 RE HEATERS
1.8 SUPER HEATER AND RE HEATER TEMP. CONTROL
1.8.1
SUPER HEATER ATTEMPERATOR
1.8.2
RE HEATER EMERGENCY TEMP. CONTROL ATTEMPERATOR
1.9 ECONOMISER
1.10 BOILER WATER CIRCULATING PUMP
1.10.1 CHARACTERISTICS
1.10.2 NORMAL OPERATING DUTY
1.10.3 MOTOR CHARACTERISTICS
1.10.4 WEIGHTS (APPROXIMATE)
1.10.5 CC PUMP OVERHEAD TANK
1.10.6 CC BOOSTER PUMP

2 MILL SYSTEM
2.1 MILL
2.2 MILL MOTOR
2.3 MILL BEARINGS
2.4 MILL EXTERNAL LUBRICATION SYSTEM
2.5 RAW COAL FEEDER
2.5.1
Feeder
2.5.2
Motor
2.5.3
Clean out conveyor
2.6 MILL REJECT SYSTEM
2.7 COAL PIPING & BURNERS
2.7.1
COAL PIPING
2.7.2
COAL BURNERS
2.7.3
OIL FIRING

3 INDUCED DRAFT FAN (ID FAN)

3.1 FAN
3.2 FAN DESIGN RATING
3.3 FAN RESERVE
3.4 VARIABLE FREQUENCY DRIVE (VFD)
3.4.1
Channel Rating
3.4.2
VFD Transformers
3.4.3
VFD Reactors (Both Channel 1 & 2)
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Condensate extraction pump

3.4.4
3.4.5
3.4.6
3.4.7
3.4.8

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VFD Motor Exciter

COUPLING
FAN BEARINGS
MOTOR
LUBE OIL SYSTEM

4 FORCED DRAFT FAN (FD FAN)

4.1 FAN
4.2 FAN DESIGN RATING
4.3 FAN RESERVE
4.4 COUPLING
4.5 FAN BEARINGS
4.6 MOTOR
4.6.1
Motor Bearing
4.7 LUBE OIL SYSTEM
4.7.1
Pump
4.7.2
Lube Oil Filter
4.7.3
Lube Oil Coolers

5 PRIMARY AIR FAN (PA FAN)

5.1 FAN
5.2 FAN DESIGN RATING
5.3 FAN RESERVE
5.4 FAN DRIVE COUPLING
5.4.1
FAN BEARINGS
5.4.2
MOTOR
5.4.3
Motor Bearing
5.5 PA LUB OIL SYSTEM
5.5.1
Pump
5.5.2
Lube Oil Filter
5.5.3
Lube Oil Cooler

6 SCANNER AIR FAN

6.1
6.2
6.3

FAN
A.C. MOTOR
D.C. MOTOR

7 PRIMARY AIR PREHEATER (PAPH)

7.1 ELEMENTS
7.2 MAIN DRIVE
7.3 AUXILIARY DRIVE
7.4 BEARINGS
7.4.1
Support Bearing
7.4.2
Guide Bearing
7.4.3
SOOT BLOWERS
7.4.4
BEARING HOUSING OIL CAPACITY
7.4.5
COOLERS

8 SECONDARY AIR PRE-HEATER (SAPH)

8.1
8.2

ELEMENTS
MAIN DRIVE

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8.3 AUXILIARY DRIVE

8.4 BEARINGS
8.4.1
Support Bearing
8.4.2
Guide Bearing
8.5 SOOT BLOWERS
8.6 BEARING HOUSING OIL CAPACITY
8.7 COOLERS

9 STEAM COIL AIR PREHEATER (SCAPH)

9.1
9.2

PRIMARY STEAM COIL APH

SECONDARY STEAM COIL APH

10 ELECTRO STATIC PRECIPITATOR

10.1 DESIGN CONDITION
10.2 COLLECTING ELECTRODES
10.3 EMITTING ELECTRODES
10.4 GAS DISTRIBUTION SYSTEM
10.4.1 Inlet
10.4.2 Outlet
10.5 HV RECTIFIER
10.6 MOTOR FOR RAPPING EMITTING ELECTRODES
10.6.1 MOTOR FOR RAPPING COLLECTING ELECTRODES
10.6.2 MOTOR FOR RAPPING GAS DISTRIBUTION SYSTEM
10.6.3 RAPPERS FOR COLLECTING ELECTRODE
10.6.4 RAPPERS FOR EMITING ELECTRODES
10.7 HOPPERS
10.7.1 Hopper Specification
10.7.2 Heating Elements for Hopper
10.7.3 Heating Elements For Shaft Insulators
10.7.4 Support Insulators

11 SOOT BLOWER
12 H.P. DOSING PUMP
12.1 MIXING TANK
12.2 METERING TANK
12.3 DOSING PUMPS

13 BLOW DOWN VESSELS

14 PRESSURE REDUCING AND DESUPERHEATING STATION (PRDS)
14.1 PRDS STATION
14.1.1 HT & LT PRDS
14.1.2 MS & CRH PRDS
14.1.3 7.2 PRDS STATION SAFETY VALVES

15 EXPRESS LAB (SWAS)

15.1
15.2
15.3
15.4
15.5

SPECIFIC CONDUCTIVITY
CATION CONDUCTIVITY
PH
DISSOLVED OXYGEN
SILICA

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Condensate extraction pump

15.6
15.7
15.8
15.9

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PHOSPHATE
HYDRAZINE
SODIUM
CHLORIDE

16 CONDENSATE EXTRACTION PUMP

16.1 MOTOR SPECIFICATION
16.2 PUMP SPECIFICATION
16.3 CONSUMPTION AT DESIGN CONDITION
16.4 CEP SUCTION STRAINER
16.4.1 Operating Condition
16.4.2 Performance Condition
16.4.3 Design Condition
16.5 SEALING WATER REQUIREMENT

17 TURBINE DRIVEN BOILER FEED PUMP

17.1 BOOSTER PUMP
17.2 MAIN PUMP
17.2.1 Direction of rotation from Booster Pump to BFP
17.3 TURBINE
17.4 TDBFP- GEAR BOX
17.5 OIL SYSTEM
17.6 OIL VAPOR EXTRACTOR FANS
17.7 OIL PUMPS SPECIFICATION
17.8 OIL PURIFIER (CENTRIFUGE)
17.9 TDBFP GOVERNING SYSTEM
17.9.1 Governing Rack
17.9.2 Emergency Stop Valve (ESV)
17.9.3 Main Control Valve (MCV)
17.9.4 Aux. Control Valve (ACV)
17.9.5 Accumulators
17.9.6 Hydraulic Pressure Accumulator
17.9.7 Material
17.10 TDBFP TWIN OIL COOLER
17.10.1 Design Data
17.10.2 Weights
17.10.3 Materials
17.11 FLEXIBLE COUPLING
17.11.1 Specification
17.11.2 Coupling capacity
17.12 POWER PACK ASSEMBLY
17.13 OPERATING CONDITION

18 MOTOR DRIVEN BOILER FEED PUMP

18.1 BOOSTER PUMP
18.2 MAIN PUMP
18.3 MOTOR
18.4 HYDRAULIC COUPLING
18.5 FLEXIBLE COUPLING (91069-00) MOTOR HC
18.5.1 Specification
18.5.2 Coupling Capacity
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18.6 OIL PUMP

18.7 LUBRICATING OIL SPECIFICATION
18.8 OIL COOLERS
18.9 LUB OIL REQUIREMENT IN BRGS
18.10 OIL PURIFIER FOR MDBFP
18.11 OPERATING PARAMETER
18.12 BFP CONICAL STRAINER
18.12.1 Operating Condition
18.12.2 Performance Condition
18.12.3 Design Condition

19 DEAERATOR AND FST

19.1 DEAERATOR HEADER ASSEMBLY
19.1.1 Materials
19.2 FEED WATER STORAGE TANK
19.2.1 Materials
19.2.2 Weights
19.3 DEAERATOR SAFETY VALVES

20 SEAL OIL SYSTEM

20.1 AC SEAL OIL PUMP (AIR SIDE) 2NO FULL CAPACITY
20.1.1 Pump specification
20.1.2 Motor specification
20.2 DC SEAL OIL PUMP (AIR SIDE)
20.2.1 Pump specification
20.2.2 Motor specification
20.3 SEAL OIL COOLER (AIR SIDE)
20.4 SEAL OIL COOLER (GAS SIDE)
20.5 AS SEAL OIL FILTER
20.6 H2 SEAL OIL FILTER

21 TG LUBE OIL SYSTEM

21.1 LUBE OIL PUMPS SPECIFICATION
21.1.1 Pumps specification
21.1.2 Motor specification
21.2 MATERIALS

22 HP HEATERS
22.1 HPH-5A & 5B
22.1.1 Weight (kg)
22.1.2 Details (stand Pipe)
22.2 HPH-6A & 6B
22.2.1 Weight (kg)
22.2.2 Details (stand Pipe)
22.3 HP HEATERS SPECIFICATION
22.4 MATERIALS
22.5 SAFETY VALVE

23 CONTROL FLUID
23.1 FIRE RESISTANT FLUID SPECIFICATION
23.2 CONTROL FLUID TANK
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23.3 CONTROL FLUID PUMPS

23.3.1 Pump specification
23.3.2 Motor specification
23.4 CONTROL FLUID COOLER
23.4.1 Design pressure
23.4.2 Hydraulic test
23.4.3 Weight
23.5 CONTROL FLUID PUMP MOTOR SET
23.5.1 Low Pressure Pump
23.5.2 High Pressure Pump
23.6 CHANGE OVER DOUBLE FILTER
23.6.1 Design requirement
23.6.2 Flow across Filter
23.6.3 Pressure Drop across filter
23.7 REGENERATIVE SYSTEM (C.F. PURIFICATION)
23.7.1 Filters (Filters Philipp, France)
23.7.2 Heating unit
23.7.3 Regenerative pumps (C.F. Recirculation PP)
23.7.4 Pump specification
23.7.5 Motor specification

24 MAIN TURBINE
24.1 MAIN TURBINE
24.1.1 Specifications
24.1.2 Weights (tons)
24.1.3 Size of bearing
24.2 MATERIAL OF CONSTRUCTION
24.2.1 Turbine Casings
24.2.2 Blades (Moving)
24.2.3 Rotors
24.3 IP TURBINE CASING
24.3.1 Outer casing
24.3.2 Chamber-2
24.4 IP TURBINE ROTOR
24.5 LP SHAFT
24.5.1 Material
24.6 TURBINE EXTRACTIONS
24.7 OPERATING PARAMETER
24.7.1 Steam Pressure And Temperatures (Rated)
24.7.2 Casing temperature limiting values
24.7.3 Permissible temperature difference between parallel steam supply lines
24.7.4 Feed heater out of service
24.7.5 Out put limit with ATT
24.7.6 Motoring
24.7.7 Low vacuum trip standard settings
24.7.8 Barring gear
24.8 TURBOVISARY PARAMETER
24.8.1 Axial Shift
24.8.2 Differential Expansions
24.8.3 Vibration
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24.8.4 Bearing temperature

24.8.5 Fixed Points
24.9 HEAT BALANCE DATA
24.10 TURBINE LOAD SHARING CAPACITY

25 TURBINE SEAL STEAM SYSTEM

25.1 SEAL STEAM
25.1.1 Exhauster Fans specification
25.1.2 Motor specification
25.1.3 Seal stem pressure control valve

26 CENTRAL LUB OIL STORAGE & PURIFICATION UNIT

26.1 CLEAN OIL TANK
26.1.1 Material
26.2 DIRTY OIL TANK
26.2.1
26.3 OIL TRANSFER PUMPS
26.3.1 Pump specification
26.3.2 Motor specification
26.4 CENTRAL OIL PURIFIER
26.4.1 Centrifuge
26.4.2 Centrifuge Feed Pump
26.4.3 Centrifuge Motor
26.4.4 Centrifuge Materials

27 FLASH TANKS
27.1 HP FLASH TANK
27.1.1 Material
27.2 STEAM DRAIN FLASH TANK
27.3 FEED WATER HEATER SAFETY V/V DISCHARGE FLASH TANK

28 EQUIPMENT COOLING WATER SYSTEM

28.1 ECW TANK (TG)
28.2 EQUIPMENT COOLING WATER PUMP
28.2.1 ECW (SG)
28.2.2 ECW (TG)
28.3 PLATE HEAT EXCHANGER
28.3.1 TG
28.3.2 SG

29 AUXILIARY COOLING WATER SYSTEM

29.1 AUXILIARY COOLING WATER PUMP
29.2 GA & CROSS SECTION SELF CLEANING STRAINER (SCS)
29.2.1 Design Data
29.2.2 Details of Flushing Pump Skid SCS

30 VACUUM RAISING SYSTEM

30.1 VACUUM PUMP
30.1.1 Pump specification
30.1.2 Motor specification
30.2 RECIRCULATING PUMP
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30.2.1 Pump specification

30.2.2 Motor specification
30.2.3 Material
30.3 SEPARATOR TANK

31 PRIMARY WATER SYSTEM

31.1 PRIMARY WATER PUMP
31.2 PRIMARY WATER FILTER

32 OFF SITE AREAS

32.1 PTCW SYSTEM
32.1.1 Raw water transfer pump
32.1.2 Electric motor
32.1.3 Booster pump (For Raw water pump lubrication)
32.1.4 Electric motor- Raw water booster pump
32.1.5 Reactor clarifier
32.1.6 CLARIFIED WATER SYSTEM
32.2 FIRE HYDRANT SYSTEM
32.2.1 SPRAY SYSTEM
32.2.2 JOCKEY PUMP
32.2.3 BOOSTER PUMP HYDRANT LINE
32.2.4 AIR COMPRESSOR ( 2 NO)

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Condensate extraction pump

1.1 GENERAL SPECIFICATION

10/09/12 6:00 PM

1 MAIN BOILER

Manufacturer
Type

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

Type of Firing

Tilting Tangential.

Minimum Load At Which Steam

Generator Can Be Operated
Continuously With Complete Flame
Stability Without
Oil Support
(%MCR)

30%

Controlled Circulation With Rifled Tubing,

Dry-Bottom, Radiant Reheat, Single
Drum, Top Supported, Balanced Draft
Furnace.

1.2 DESIGNATION
19177

301-51 CC +

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15797

1.3 FURNACE SPECIFICATION

Type

Wall
Tube arrangement
Residence time for fuel particles in
the furnace
Effective volume used to calculate
the residence time
Depth
Width
Furnace Volume
Drum elevation
Fuel Heat input

230-51

Balanced Draft Furnace with Fusion Welded

W/W.
Water steam cooled
Membrane
3 Secs.
16900 M3
15.797 M
19.177 M
16900 M3
76.38 M
1231.3 X 106 KCal/hr.

1.4 WATER WALLS

Total heating surface area

Total Water wall Tube

1.4.1 FRONT WALLS

OD
Pitch
MWT
Material
Method of joining long tube
Total Wt. of Walls
Design Pr. of tubes
Design temp.

4837 M2
1062 Nos.

51.0 mm
63.5 mm
5.6 mm
SA 210 Grc
Fusion Welded
185320 kg.
217.8 kg/cm2
398 oC

1.4.2 SIDE WALLS, REAR WALLS

Side Walls
OD
Pitch
Minimum Wall thickness (MWT)
Method of joining long tubes
Design Pressure of tubes
Design temp.
Material

51 mm
63.5 mm
5.6 mm
Butt weld
217.8 kg/cm2 (g)
398oC
SA210 Grc

Rear Walls Extended SW, Corner

Arch, Screen And Hanger
51 and 63.5 mm
63.5 and 76.2 mm
5.6, 7.6 and 11 mm
But Weld
217.8 kg/cm2 (g)
398oC
SA 210 Grc

1.4.3 WATER WALL HEADERS

Number
Outside dia
Thickness
Total Wt. of headers
Design Pressure of headers
Material specification
Design temperature

Lower drum
1
914.4 mm
95 mm
172.0 (T)
217.8 kg/cm2(g)
SA-515 Gr.70
370oC

WW Outlet Headers
5
273.0 mm
40.0 and 50.0 mm
31.0 (T)
213.0 kg/cm2(g)
SA-106Gr.C
370oC

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Condensate extraction pump

1.5 DRUM

10/09/12 6:00 PM

Material Specification
Design Pressure
Design metal temp.
Operating Pressure
Actual thickness
Overall length of drum (with dish
ends)

SA-299
207 kg/cm2(g)
368 oC
193 kg/cm2 (g)
210/175 mm.
24216 mm

Internal dia
Corrosion allowance
No. of Down Comers
No. of Cyclone Separators
No. of driers
Shroud material
Boiler Drum Wt. (without
internal)
Boiler Drum Wt. (with internals)

1778 mm
0.75 mm
6 nos.
92
124
Carbon Steel
233.3 (MT)

1.6 SUPERHEATERS
Material
Type
Drainable / Non-drainable
Effective Heating Surface area
OD
Total no. of assembly
Total no. of tubes
Temperature 0C

1.7 RE HEATERS

Type
Total heating surface area
Design Pressure
No. of assembly
No. of element
Tube OD

243.292 (MT)

Ltsh
(Stage # I)
SA 213
Convective
Drainable
6018 M2
44.5 mm
124
744
493

Divisional Panel
(Stage # II)
SA 213
Radiant
Non-drainable
1319 M2
44.5 mm
48
432
513

Platen
(Stage # III)
SA 213
Radiant
Non-drainable
1385 M2
51.0 mm
25
400
592

Radiant Front Platen, Convective Rear Pendant.

6864 M2
52.4 kg/cm2(g)
74
888
54.0 mm

1.8 SUPER HEATER AND RE HEATER TEMP. CONTROL

1.8.1 SUPER HEATER ATTEMPERATOR
Type
Stage
Position in steam circuit
Specification of material
Control temperature
Control Range
Maximum Water Flow

Spray type pressure atomized.

One
Between LTSH and Divisional Panel S/H
SA 335P12
540oC
910 1675 T/Hr.
45 Tons/hr. at 174oC

1.8.2 RE HEATER EMERGENCY TEMP. CONTROL ATTEMPERATOR

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Type
Manufacturer

Spray type pressure atomized.

BHEL, Trichy

Position in steam circuit

Control temp. Range
Control Range
R/H Normal temp. control

CRH Line
540oC
827 1393 T/Hr.
Burner tilting and Excess air.

1.9 ECONOMISER
Type
Horizontal Heating Surface Area
Design Pr. of tubes
OD of tubes
Minimum thickness tubes
Length of tubes
Pitch
No. of blocks
Assembly
Element
Design temp.
ASME Specification
Gas flow Path area

Plain Tube Non-steaming.

18200 M2
217.8 kg/cm2(g)
51.00 mm
6.2 mm
296.4 M
101.6 mm (SL)
136.0 mm (ST)
3 Nos.
130
276
334oC
SA210 Gr A1
131 M2

1.10 BOILER WATER CIRCULATING PUMP

Number
1.10.1

3 (2W + 1S)
CHARACTERISTICS

Type
Size
Design Pressure
Design Temperature
1.10.2

1.10.3

Single Suction double discharge.

(2x13) X 16 X 19 H
212 kgf/cm2
370oC

NORMAL OPERATING DUTY

Suction Pressure
191.6 kgf/cm2
Pumping temp.
365oC
Quantity Pumped
3018 m/hr
Differential Pressure
3.12 kgf/cm2
Minimum NPSH required
Above Vapor Pressure
19 m (3% head drop)
Pump efficiency
84% Hot Duty
Power absorbed
195 KW Hot duty
347.8 KW Cold Test.
MOTOR CHARACTERISTICS

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Type
Wet Stator squirrel Cage induction.
Output
350 KW
Service Factor
1.0
Winding Insulation
XLP
Motor Case design. Temperature 343oC
Hot Duty
Cold Test
Motor efficiency
88.6%
90.5%
HP input
315
522.7
Power factor
0.69
0.810
Overall efficiency
74.4%
76%
Full load speed
1450 RPM
Full load current
84 Amps.
Motor starting current
240 Amps.
1.10.4
WEIGHTS (APPROXIMATE)
Pump casing
4600 kg.
Motor complete
6700 kg.
Heat exchanger
9000 kg.
Total
12000 kg.
1.10.5
CC PUMP OVERHEAD TANK
Type
2500 X 12
Make
Trichy, BHEL
Capacity
19.0 m3
Temp.
50oC
Working Pressure 7 kg/cm2
Test Pressure 10.5 kg/cm2
1.10.6
CC BOOSTER PUMP
Pump
Head
50 m
Speed
2900 RPM
Flow
9 m3/hr.
Motor
Frame
ND 150 L
Speed
2920 RPM
Current
26 Amp.
Rating
15 to 20 KW
Insulation Class
F

2.1 Mill
Type of Pulverizer
No. of Mills / Boiler
No. of Mills for Design Coal
at 100% BMCR
Design capacity of mill

2 MILL SYSTEM
Bowl Mills XRP 1003
10
7
66.3 Tons/hr. for Pulverized fuel fineness 70% through 200
mesh with a Raw coal of Grindability. Index 55 HGI and
total moisture of 14%.

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Speed of Pulveriser
Motor rating

600
525 KW

2.2 Mill Motor

Manufacturer
Motor type
Direction of rotation as viewed
from NDE
Standard continuous rating at
40oC ambient temp. as per Indian
standard
Rated Voltage
Speed
Full load current
No load current(A)

BHEL, BHOPAL
Cage Rotor a synchronous Motor
525 KW

3300 V
600 RPM
137 Amp
75 Amp

2.3 Mill Bearings

(a) Type
(b) Recommended Lubricant

Drive End
Non-Drive End
NU 236
NU 236
62 36MC3
Grease IOC Servogem - 3

2.4 Mill External Lubrication System

Pumps
Make
Type
Capacity
Speed
Coupling
Motor Manufacturer

2X 100%
Alekton
Screw
70 LPM
970 RPM
Lovejoy
ABB

Rated out put & speed

Bearing make & type
Full load current

3.7 KW, 960 RPM

DE 6308ZZC3, NDE 6307ZZC3
8.3 A

2.5 RAW COAL FEEDER

2.5.1 Feeder
Type
Capacity
Supplier
Quantity per Boiler
Gear Ratio (main Drive)
Gear Ratio (COC Drive)
Bulk density of coal.
Working pressure.

36 Gravimetric Feeder
Minimum - 16.4 T/Hr , Maximum - 82
T/Hr
BHEL
10
138.24:1
1059.43:1
55lbs/ft3
500mmwc

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2.5.2 Motor
Rating

5.5 KW TEFC

Duty cycle

Continuous

Speed

1440 RPM

Current

11 .0 Amp.

Insulation Class

Duty

SI

2.5.3 Clean out conveyor

Rating & type

Duty
Voltage rating
Speed
Full load current
Insulation Class
Method of starting
Type of wt sensor
Type of speed sensor

0.25 KW AC geared motor

Continuous S1
415 V , 3 phase , 50 HZ
930 RPM
1.0 amp
F
DOL
Strain gauge type load cell(2 nos per feeder )
Tachogenerator (2 nos per feeder)

2.6 MILL REJECT SYSTEM

Bulk density T/ m3
Temperature
Total mill reject rate t/hr

1.6
200
0.7

Vessel vol cft

Air receiver, m3
Conveying air m3 /min
Motor Make

6
10
15.5
NGEF

Rating

415 V+_6%50HZ Through transformer feeder

2.7 COAL PIPING & BURNERS

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2.7.1 COAL PIPING

Material of Straight pipe
Carbon Steel
Fuel Pipe diameter
658.8 mm
Fuel Pipe thickness
14.2 mm
2.7.2 COAL BURNERS
Type
Make
No. of coal burners feed by each mill
No. of elevation of burners
Temp. of coal Air mixture in PF Pipes

Tilting Tangential
BHEL
4 (Total no. of coal burners-40)
10
75 oC

2.7.3 OIL FIRING

2.7.3.1 HEAVY OIL BURNERS

Burner
Oil Gun
Atomiser
Air Nozzle
Atomiser Designation
Atomiser spray angle
Fuel
Capacity Maximum

Tilting tangential; Corner fired.

Parallel pipe design, steam atomized.
External mixed; const. Pressure; steam atomized.
Rectangular
Spray plate 90J24
90oC
Fuel oil to IS1593; 1971, LSHS oil, HPS oil.
7.5% MCR heat input per elevation.
30% MCR total.
No. of oil guns
20 (4 per elevation).
Location of oil guns
Auxiliary air nozzles, AB, CD, EF, FG & HJ.
Oil Firing rate maximum
2662 kg/hr/gun
Minimum oil Firing rate
885 kg/hr/gun
Oil pressure at maximum Rating
9.5 kg/cm2 (g)
Minimum allowable HFO pressure 3.0 kg/cm2 (g)
205 kg/hr/gun
Atomising steam flow at MaxM
rating
Atomising steam flow at minimum 257 kg/hr/gun
rating
Oil viscosity at the gun
15 to 30 CST
Steam quality
10 to 15oC super heat.
Atomising steam pressure
5.25 kg/cm2(g)

2.7.3.2 LIGHT DIESEL OIL BURNERS

Service
Atomiser
Fuel
Capacity (Max.)
No. of oil guns
Location of oil guns
LDO flow/gun(max/min Kg/hr)
Atomising air flow/gun(Max,
Min,Scale)
Maximum Rating LDO Pressure

Initial start up and warm up.

External Mixed, Constant Pressure, Compressed
Air Atomised.
LDO to IS1460/1974
7.5% MCR heat input and total 7.5% MCR.
4
In Auxiliary air nozzle AB.
2190/750
165 / 210 / 245
9.0 kg/cm2(g)

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Minimum Rating LDO Pressure

3.0 kg/cm2(g)

Atomising air pressure

.25 kg/cm2(g)

2.7.3.3 IGNITERS
Make

Unison Industries / USA

Service

Oil burner light off.

Type

High Energy Arc Igniter

Location

Burner Mounting Panel

Output

Min 4 Spark / Second, 12 Joules/Spark

Input

110V AC, 50 Hz.

3 INDUCED DRAFT FAN (ID FAN)

3.1 FAN

Type

NDZV 47 SIDOR

Make

BHEL

Orientation

Inclined Suction Bottom Horizontal Delivery

Medium Handled

Flue gas

No. per Boiler

Location

Out door

3.2 FAN DESIGN RATING

Capacity

Total head developed

593.32 m3/sec.
485 mm WCl

Temp. of Medium

153oC

Specific Wt. of Medium

0.780 kg/m3
560 RPM

Speed

3.3 FAN RESERVE

Flow

44.9 %

Pressure

79.9 %

3.4 VARIABLE FREQUENCY DRIVE (VFD)

3.4.1 Channel Rating
Single Channel

Dual Channel

Speed (RPM)

400

560

Current (Amp)

400

2 X 560

Motor Voltage (V)

1796

2 X 2300

Power (KW)

1465

4021

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Condensate extraction pump

Power Factor (Ratio)

10/09/12 6:00 PM

0.9

0.9

Channel # 1

Channel # 2

Rating (KVA)

3000

3000

Voltage Transformation

11000 / 2300 V

11000 / 2300

Vector Group

Dd0

DYN11

3.4.2 VFD Transformers

3.4.3 VFD Reactors (Both Channel 1 & 2)

Name
Air Core Reactor
Rated Current

900 Amp

Inductance

10 milli Henry

3.4.4 VFD Motor Exciter

Make

BHEL

Rating

34 KW

Excitation Voltage

342 V

Excitation Current

64 Amp

Connection

Star

Volts

100 V

Current

340 Amp

Speed

530 RPM

Frequency

85 Hz

Specification

IS : 4722

3.4.5 COUPLING
Type
Type of Fan Regulation

SOFT
Inlet damper and variable Frequency Drive.

3.4.6 FAN BEARINGS

Fan fixed bearing

10 RT

Fan free bearing

10 RT

Permissible bearing clearances

Oil clearance

0.250 mm to 0.430 mm

Side clearance

0.230 mm to 0.315 mm

Axial thrust clearance

0.380 mm to 0.760 mm

Cooling water flow for the fan

4.0 m3 per hour / Brg.

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Brgs
Note :- Cooling Water Flow Is Based On 32oc Ambient And 32oc Water Inlet
Temperature.
3.4.7 MOTOR
Manufacturer
Frame size
Type Max
Rating
Speed
PF
Insulation Class
Connection
Max. Stator Voltage
Max. Stator Current
Type of Duty
Type of Exciter
Exciter Rotor Voltage
Exciter Rotor Current
Exciter Stator Current
Exciter Stator Voltage

BHEL, BHOPAL
1DQ 4342
Synchronous Motor 2 X 2300 V
4021 KW (both channels together)
56 RPM to 560 RPM
0.9 Lead
F
Double star
2 X 2300 V
2 X 5807A
Continuous
Brushless
116 V D.C.
300 Amp. D.C.
80 A (3j)
415V AC (3j)

Stator Winding Connection

Y (Star)

3.4.8 LUBE OIL SYSTEM

3.4.8.1 Pump
Oil tank capacity
Pump type
No of pumps
Motor Rating
Speed
Normal Design Pressure
No. of Lube Oil Cooler / Boiler
Quantity of Cooling Water / Boiler
Lube Oil Quality
Relief Valve Setting

80 liters/min
Screw Pump
2
3 Phase, 415V,2.2KW, 50 Hz.
2900 RPM
5.0 kg/cm2
4 (2 Working + 2 Standby)
265 LPM
ISO-VG-68
6.0 kg/cm2

3.4.8.2 Oil filters

Type
Mesh material
Working pressure
Capacity

Basket type
SS Rating 60 microns
5 ksc
150 Lpm

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3.4.8.3 Heat Exchanger

Design pressure
Shell side 8 ksc, Tube side 7 ksc
Capacity
80 Lpm
Heat exchange capacity
21600 Kcal/Hr

4.1 FAN

4 FORCED DRAFT FAN (FD FAN)

Type
No. Per Boiler
Make

AP1 26/16 Axial fan, constant speed, aerofoil,

single stage with silencer & aerofoil assembly in
suction ducting.
Two
BHEL Ranipet

4.2 FAN DESIGN RATING

Capacity
Total head developed
Medium handled
Location
Orientation
Temp. of medium
Specific wt. of medium
Fan Speed
Fan Regulation
Fan Weight

261.6 m3/sec.
391 mmwc
Atmospheric Air
Out door
Vertical Suction Horizontal Delivery.
50oC
1.0334 kg/m3
980 RPM
Blade pitch control
27 Tonnes

4.3 FAN RESERVE

Flow
Fan Pressure

68.6%
96.5%

4.4 COUPLING
Type

Regiflex Coupling.

4.5 FAN BEARINGS

Fan Fixed bearing
Fan Free bearing

Cylindrical Roller Brg NU 248C3 + 7248

Cylindrical Roller Brg NU 248C3

4.6 MOTOR
Manufacturer
Motor type
Frame size
Fan Speed

M/s. BHEL, BHOPAL

SCIM,IS 325:1978 standards.
1LA7803-6,Continous duty.
980 RPM

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Direction of rotation as viewed

from
Non-driving end

Clockwise

Standard continuous rating at

40oC
Ambient temp. as per Indian
Standard
Standard continuous rating at
50oC
Rated Voltage (Volts)
Permissible Variation of
(a) Voltage (Volts)
(b) Frequency (Hz)
Combined Voltage and
frequency

1300 KW

MinM Permissible Starting

Voltage (V)
Speed at Rated Voltage and Freq.
At Rated Voltage and Frequency
Full load current
No load current
Without driven equipment coupled
With driven equipment coupled

8800 (80 % RV)

4.6.1 Motor Bearing

Type
Recommended Lubrications
Lubrication

3300 KW
11 KV
10 %
50 + 3 %, -5%
10 % (Abs)

995 RPM
84.2 Amps.
34 Amps.
1.5 Seconds.
15 Seconds.
Antifriction
OIL -IOC servogem-3 or equivalent
lubricated(grease0
Self

4.7 LUBE OIL SYSTEM

4.7.1 Pump
Oil Tank capacity

1300 Litters

Pump type

Screw Pump

Motor Rating

3j, 415V, 9.3KW, 50 Hz

Speed

2870 RPM

Design Pressure

12 kg/cm2
3 (2 working + 1 standby)

No. of Oil Cooler / Boiler

Quantity of Cooling Water /
Boiler
Relief v/v setting
System discharge capacity

430 LPM
13.5 kg/cm2
175.0 LPM

4.7.2 Lube Oil Filter

Type
Basket type
Mesh material
SS Rating 60 microns
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Condensate extraction pump

Working pressure
Capacity

10/09/12 6:00 PM

12 ksc
350 Lpm

4.7.3 Lube Oil Coolers

Design pressure
Shell side 15 ksc, Tube side 8.75 ksc
Capacity
175 Lpm
Heat exchange capacity
Kcal/Hr
Temperature limits
Shell-80 0C , Tube-80 0C

5.1 FAN

5 PRIMARY AIR FAN (PA FAN)

Type
No. per boiler
Orientation
Medium Handled
Location
Type of Regulation

AP2 20/12
2
Vertical Suction Horizontal Delivery
Atmospheric Air
Out door
Blade Pitch Control

5.2 FAN DESIGN RATING

Capacity
Total head developed
Temp. of medium
Specific Wt. of Medium
Speed

170 .5m3/sec.
1183 mm WCl
50oC
1.0508 kg/m3
1480 RPM

5.3 FAN RESERVE

Fan Flow
Fan Pressure

84.5 %
35.2%

5.4 FAN DRIVE COUPLING

Type of coupling

Rigiflex coupling

5.4.1 FAN BEARINGS

Fan Fixed bearing
Fan Free bearing
Fan weight
5.4.2 MOTOR
Type
Manufacturer
Type of Duty
Direction of rotation as viewed
from
Non-drive end
Rated Voltage
Standard continuous rating at

7040 C3
NU 236 C3
1300 Tons

SQ Cage
BHEL, BHOPAL
S1
Anti clockwise
11,000 Volts
1817 KW

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10/09/12 6:00 PM

40oC ambient temp. as per Indian

Standard
Derated rating for specified
2450 KW
o
normal condition i.e. 50 C ambient
temp.
Permissible Variation of
Voltage
Frequency
Rated Speed at Rated Voltage and
Frequency
At rated Voltage and Frequency
Full Load current
No Load current
Starting time with minimum
Permissible Voltage of 80% RV
Without Fan
With Fan

10% Volts
5% Hz
1494 RPM
107 Amps.
30 Amps.
2.0 sec.
18.0 sec.

5.4.3 Motor Bearing

Bearing
Type
Recommended Lubricant

DRIVE END
NON-DRIVE END
Ball and Roller
Roller
Grease IOC Servogem 3

5.5 PA LUB OIL SYSTEM

5.5.1 Pump
Oil tank capacity
Pump
Motor Rating
Speed
Design Pressure
Lube Oil Quality
Relief Valve Setting
Pump discharge
No. of Lube Oil Cooler / Boiler
Quality of Cooling Water / Boiler
5.5.2 Lube Oil Filter
Type
Mesh material
Working pressure
Capacity

600 liters
Screw Pump
3 Phase, 415V, 7.5KW, 50 Hz
2870 RPM
12 kg/cm2
150 VG 68
13.5 kg/cm2
80 LPM
4 (2 Working + 2 standby)
265 LPM

Basket type
SS Rating 60 microns
12 ksc
160 Lpm

5.5.3 Lube Oil Cooler

Design pressure
Shell side 15 ksc, Tube side 8.75 ksc
Capacity
80 Lpm
Heat exchange capacity
xxxx Kcal/Hr
Temperature limits
Shell-80 0C , Tube-80 0C
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6 SCANNER AIR FAN

6.1 FAN
No.
Type of Fan
Manufacturer
Boosting Pressure
Efficiency of the fan
Power consumption
Fan Speed
Capacity
Density

2 (One is AC driven + One D.C. driven , 100%

standby)
Radial Backward curved Blade Single Suction
DOCTAIRE HPSC 315 SWSI
200 mmWC
72 %
6.08 KW
1455 RPM
8000 CMH
1.09

6.2 A.C. MOTOR

Make
Type & Frame Size
Rating
Full Load Current
Efficiency
Speed

Crompton Greaves Ltd.

TEFC, Squirrel Cage Induction Motor
9.3 KW
17.5 Amp.
88%
1460 RPM

6.3 D.C. MOTOR

Make
Frame Size
Duty
Insulation
Rating
Current
Speed

Kirloskar Electric Co. Ltd.

TDC 225 L
S1
F Class
9.30 KW
51 Amp.
1450 RPM

7 PRIMARY AIR PREHEATER (PAPH)

Make
Type
Air heater size
No. of Air Pre-heater

BHEL
Ljungstrom Bisector (Regenerative)
30 VIM 2000
2 per Boiler

7.1 ELEMENTS
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Condensate extraction pump

END
HOT
INTER
COLD

10/09/12 6:00 PM

HEIGHT OF
ELEMENT
850 mm
850 mm
300 mm

MATERIAL
Carbon Steel
Carbon Steel
Carbon Steel

DESCRIPTION OF
ELEMENTS
Double Corrugated
Double Corrugated
Notched Flat

7.2 MAIN DRIVE

Electric Motor
Speed Reducer Ratio
Speed Reducer
Final Speed

Squirrel Cage, induction motor, 11KW, 415V, 3j,

50hZ, 1450 RPM, Frame size 160-L, Insulation
Class-F
110 : 1
Type-IA (3 in put) ;up shaft
1.42 RPM

7.3 AUXILIARY DRIVE

Air Motor

3KW, 3020 RPM, Air flow 0.18 NM3/Sec. at inlet

Pressure of 6.33 kg/cm2

7.4 BEARINGS
7.4.1 Support Bearing
Type
Lubrication
Drive
Pump

7.4.2 Guide Bearing

Type
Lubrication
Drive
Pump
7.4.3 SOOT BLOWERS
Type of nozzle
Type of drive
Location
Quantity
Medium
Motor
Reduction Ratio

Spherical Roller thrust bearing, No.294/500 SKF /

FAG.
SERVOCYL C680
0.75KW, 415V, 3j, 50Hz, 1425 RPM, Class - F
Insulation.
Screw Pump (15 liter/Min.)

Spherical Roller bearing, No.23060 CCK C3 / W33

SKF/FAG.
SERVOCYL C680
0.55KW, 3j, 50Hz 415V, 910 RPM, Insulation
Class - F
Screw Pump (15 liter/min.)

Twin
Sweep
Gas Outlet
2 / APH
Steam at 340oC and 14 kg/cm2(g) and 2100 kg/hr.
0.18 KW, 3j, 50Hz, 415V, 1380 RPM, Insulation
Class F
4900 :1

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10/09/12 6:00 PM

7.4.4 BEARING HOUSING OIL CAPACITY

Guide Brg. Housing
25 liters
Support Brg. Housing
90 liters
7.4.5 COOLERS
Guide bearing Oil Cooler Flow
Support bearing Oil Cooler Flow

2 M3/Hr./Blr.
2M3/Hr./Blr.

8 SECONDARY AIR PRE-HEATER (SAPH)

Make
Type
Size

BHEL
Ljungstrom Bisector (Regenerative)
30.5 VIM 2000

8.1 ELEMENTS
END
HOT
INTER
COLD

HEIGHT OF
ELEMENT
850 mm
850 mm
300 mm

MATERIAL
Carbon Steel
Carbon Steel
Carbon Steel

DESCRIPTION OF
ELEMENTS
Double Corrugated
Double Corrugated
Notched Flat

8.2 MAIN DRIVE

Electric Motor
Speed Reducer Ratio
Speed Reducer
Final Speed

Squirrel Cage induction motor, 18.5KW, 415V, 3j,

50hZ, 1475 RPM, Insulation Class-F
130.36 : 1
Type-2, input Down Shaft.
1.12 RPM

8.3 AUXILIARY DRIVE

Air Motor

3KW, 4070 RPM, Air flow 0.22 NM3/Sec. at Inlet

Pressure of 6.33 kg/cm2(g).
IEC DUSTERLOH-IPM 400/8:1
COUPLING BIBBY

8.4 BEARINGS
8.4.1 Support Bearing
Type
Lubrication
Drive
Pump

8.4.2 Guide Bearing

Type
Lubrication

Spherical Roller thrust bearing. 294/750E

Forced Oil Servocyl C680
0.75KW, 415V, 3j, Class - F Insulation.
Screw Pump (15 liter/min.)

Spherical Roller bearing.23072 CCK

Forced Oil Servocyl C680

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Condensate extraction pump

10/09/12 6:00 PM

Drive

0.55KW, 3j, 50Hz 415V, Insulation Class - F

Pump

Screw Pump (15 litre/min.)

8.5 SOOT BLOWERS

Type of nozzle
Type of drive
Location
Quantity
Medium
Motor

Twin
Sweep
Gas outlet
2 / APH
Steam at 340oC and 14 kg/cm2(g) and 2100 kg/hr.
0.18 KW, 3j, 50hZ, 415V, 750 RPM, Insulation
ClassB
Speed Reduction-4900:1

8.6 BEARING HOUSING OIL CAPACITY

Guide Brg. Housing
Support Brg. Housing

30 liters

8.7 COOLERS
Guide bearing Oil Cooler Flow
Support bearing Oil Cooler Flow

2 M3/Hr./Blr.
M3/Hr./Blr.

STEAM COIL AIR PREHEATER (SCAPH)

9.1 PRIMARY STEAM COIL APH

No. of Steam Coil APH
Supplier
Size of steam coil Air Preheater
Installed Position
Design Pressure
Design temp.
Hydraulic Test Pressure
Weight of one steam coil APH

2 Nos. per boiler

M/s. Patels Air Temp. Ltd.
2500 X 5200 X 250 mm
vertical
20kg/cm2 (ata)
210oC
30 kg/cm2
3700 kg.

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9.2 SECONDARY STEAM COIL APH

No. of Steam coil APH
Supplier
Size of steam coil APH
Installed Position
Design Pressure
Design Temp.
Hydraulic Test Pressure
Weight of one steam coil APH

2 Nos. per boiler

M/s. Patels Air Temp. Ltd.
3700 X 6000 X 250 mm
Vertical
20kg/cm2 (ata)
210oC
30 kg/cm2
5200 kg.

10
10.1

Electro Static Precipitator

DESIGN CONDITION

Gas flow rate 821.5 m3/sec.

Temperature 125oC
Inlet dust concentration
63.1 g/Nm3
Outlet dust concentration
35.8 mg/Nm3
Type
FAA-8 X 45-2X90130-2
ESP efficiency
99.925%
No. of precipitator offered per Boiler
Four
No. of Gas Path per ESP
One
No. of Fields in series
in each gas Path
Eight
Pressure drop across the
Precipitator for Design condition
15.0 mmwc
Velocity of gas inside ESP 0.87 m/sec.
Treatment Time
41.4 Secs.

10.2

COLLECTING ELECTRODES

No. of rows of Collecting Electrodes

per field
61
No of collecting electrodes per field 366
No of collecting electrodes arranged
in each row 6
Total no. of Collecting Plates per Boiler
11,712
Nominal height of collecting plate 13.0 M
Nominal length of collecting plate 750 mm
Specified Collecting Area
273.45 m2/m3/sec.

10.3

EMITTING ELECTRODES

Type
Spiral with hooks
Size
2.7 mm dia
No. of electrodes in the frame
forming one row
54
No. of electrodes in each field
3,240
Total no. of electrodes per Boiler 103680
Total length of electrodes per field 13478.45
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Condensate extraction pump

10/09/12 6:00 PM

Plate / Wire spacing 150 mm (300 mm pitch)

10.4

GAS DISTRIBUTION SYSTEM

10.4.1
Inlet
Type & Quantity
Perforated Plate 2 sets
Location
Inlet of precipitator
10.4.2
Outlet
Type & Quantity
Thin sheets formed to a shape of U
Located with 600 mm pitch- one set
Location
Outlet of precipitator

10.5

HV RECTIFIER

Rating

70 KV DC (Peak)
1200 mA DC (mean)
Quantity per Boiler 16
Type
Silicon diode, Full Wave Bridge Connection.
Location
Mounted on the top of ESP

10.6

MOTOR FOR RAPPING EMITTING ELECTRODES

Quantity
Rating
Location

16 per ESP Pass

Geared motor, 0.33Hp, 2.5 RPM,3j , 415V, 50Hz.
At the Roof of ESP.

10.6.1

MOTOR FOR RAPPING COLLECTING ELECTRODES

Quantity
Rating
Location

16 per ESP Pass

General motor, 0.33Hp, 1.1 RPM,3 j, 415V, 50Hz, AC
On the side panels of the casing.

10.6.2
Quantity
Rating
Location

MOTOR FOR RAPPING GAS DISTRIBUTION SYSTEM

8 Total
Geared motor, 0.33hP, 1.1 RPM,3 j, 415V, 50Hz, AC
On the GD housing.

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Condensate extraction pump

10.6.3

10/09/12 6:00 PM

RAPPERS FOR COLLECTING ELECTRODE

No. and Type of Rappers

One drop hammer per row of collecting

electrodes having a collecting surface of

117 m2.

Rapper Size

4.9 Kgs

Frequency of Rap

Varying from 20 raps per hour at the inlet field to 1

rap/hour at the exit field. The frequency of rapping at
intermediate fields can be adjusted between 20 and 1 per
hour according to the requirement.

Drive
Location

10.6.4

Geared Electric motor.

At the bottom of collecting electrodes.

RAPPERS FOR EMITING ELECTRODES

No. and Type of Rappers:

Approximately one drop hammer for two rows of Electrodes.

Rapper Size:
Frequency of rapping:
Drive:
Location:

10.7

3.0 Kgs
10 raps/hr.
Geared electric motor.
On middle frames of emitting system frame
work.

HOPPERS

10.7.1
Hopper Specification
Type
Pyramidal
No. of hoppers/ESP
32 per Pass
Heating
Electrical heating provided at the bottom of the hopper.
Baffling Arrangement
2 sets of deflector plates for each hopper.
10.7.2
Heating Elements for Hopper
Quantity per boiler
128 sets(18 Nos per hopper)
Type
Panel type 10kw/hopper
Rating
10kw/hopper,1 phase,V, 50 Hz,AC
Location
At the bottom of the hoppers
Thermostat setting for the
Tripping of the heat

120 C

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10.7.3
Heating Elements For Shaft Insulators
Quantity per
ESP 16
Rating
1.0 KW 1 phase,415V, 50 Hz,AC
Location
In the shaft insulator housing
10.7.4
Nos
Rating
Location

Support Insulators
641 Per Boiler
1.0 KW , 1 Ph , 415 V , 50 hz , AC
Support Insulator House

11
Source of steam for Soot Blowing
Set Pressure on Pr. Reducing
Valve
Set Pressure on Safety valve
Maximum flow rate
Temp. after Pr. reducing valve

Sl.
No.

DESCRIPTION
Blower Numbers

SOOT BLOWER
Tap off from SH Divisional Outlet Header.
30 kg/cm2(g)
40 kg/cm2(g)
20 T/Hr.
374oC

TYPE OF SOOT BLOWERS

WB 1E
LRD IIE
1 TO 88
105R TO
109R TO
108L
118L

119R TO
129L

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Condensate extraction pump

10/09/12 6:00 PM

Travel In MM

305

9700

127R TO
138L
9700

Dead Travel In MM

350

350

350

Nozzle Size In MM/ No. Off

Nozzles
Blowing Pressure In Kg/Cm2(G)
Speed Of Travel In MPM Rotary /
RPM
Blowing Rate Per Group In
Kg/Min
Blowing Time Per Group In Min

j 26/1

j 32/2

j 25/2

j 25/2

11

12.5

12.5

10

6.1 0.7

1.55 5.87

1.55 5.87

1.55 5.87

89

303.2*

185

151

1.4

12.06

12.06

12.06

Operating Time Per Group In Min 1.5

12.5

12.5

12.5

Operating Time Per Cycle In Min

66

25

137.5

87.5

Steam Consumption Per Group In

Kg
Steam Consumption Per Cycle In
Kg
Cycles Per Day (Assumed)

125

3657

2231

1821

5500

3657

24542

7584

Steam Consumption Per Day In

Kg
Blowing Angle

16500

10971

73626

21852

360o

360o

360o

360o

9700

(PER DAY) TOTAL STEAM CONSUMPTION IN Kgs = 122949

NOTE
LRD IIE
WB IE

BLOWERS OPERATED IN A GROUP OF TWO. BLOWING RATE IS GIVEN FOR

BLOWERS.
LONG RETRACTABLE SOOT BLOWER ELECTRICALLY OPERATED.
WALL BLOWER ELECTRICALLY OPERATED.

12
12.1

MIXING TANK
Capacity
Weight
Design temp.
Design Pr.
Mixing Motor
Speed
Manufacturer

12.2

H.P. DOSING PUMP

2200 Liters
800 kg.
60oC
1.5 kg/cm2
1.5 hp
925 RPM
Power Piping Company, Madras

METERING TANK

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Condensate extraction pump

12.3

10/09/12 6:00 PM

Capacity

2200 liters

Weight
Temp.
Motor capacity
Speed
Manufacturer

750 kg.
60oC
1.5 hp
925 RPM
Power Piping Company, Madras

DOSING PUMPS
Make
Type
Capacity
Pressure
No. of Pumps per boiler
Fluid handled
Motor Rating
Motor Speed
Volt
Insulation
Current

M/s. V.K. Pumps Industries Pvt. Ltd.

Reciprocating Plunger type.
207 liter/hr.
230 kg/cm2
2
Trisodium Phosphate
5.5 K.W.
1500 RPM
415V, 50 Hz, 3 Phase
F Class
11 Amp.

13
No.
Type
Design Pr.
Design temp.
Hydraulic test Pr.
Shell thickness
Shell dia
Wt. when empty
Medium
Material Specification

14

14.1

14.1.1

BLOW DOWN VESSELS

IBD TANK
1
IBD Tank j2500x16
1.5 kg/cm2(g)
111Oc
2.25 kg/cm2(g)
16 mm
2500 mm
6625.578 kg.
Steam & Water
SA 515 Gr.70

CBD TANK
1
CBD Tank j2000x16
10 kg/cm2(g)
179Oc
15 kg/cm2(g)
16 mm
2000 mm
4171.243 kg.
Steam & Water
SA 515 Gr.70

PRESSURE REDUCING AND DESUPERHEATING STATION (PRDS)

PRDS Station

HT & LT PRDS
Pressure
Temperature
Volume of Steam
Application

HT PRDS
16 ata
320oC
115 T/Hr
TG Gland Sealing
BFP Turbine
AH Soot blowing
Mill Inerting

LT PRDS
16 ata
210 oC
75 T/Hr
Deareator Pegging
HFO Automisation
SCAPH

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Condensate extraction pump

14.1.2

10/09/12 6:00 PM

MS & CRH PRDS

Pressure
Temperature
Volume of Steam
Spray Required

14.1.3

7.2

10.6 T/Hr (200bar & 185

oC)

8 T/Hr (200bar & 185

oC)

3
All at 18 bar

15

EXPRESS LAB (SWAS)

SPECIFIC CONDUCTIVITY
DM Makeup Water
Condensate Discharge after CPU
Feed water at Economiser Inlet
Drum water
Saturated Steam
Superheated Steam

15.2

CRH
52.4 to 20.0 ata
360 to 350 oC
10 T/Hr

PRDS STATION SAFETY VALVES

Nos
Rating

15.1

MS
186.6 to 20.0 ata
540 to 350 oC
92.5 T/Hr

Instrument
Make
Conductivity Polymetron
Transmitter

Model
8311
(K=0.1) /
9125

Range
0-10 s / Cm
0-10 s / Cm
0-10 s / Cm
0-10 s / Cm
0-10 s / Cm
0-10 s / Cm

Instrument
Make
Conductivity Polymetron
Transmitter

Model
8310
(K=0.01) /
9125

Range
0-1 s / Cm
0-1 s / Cm
0-1 s / Cm
0-1 s / Cm
0-1 s / Cm
0-1 s / Cm

Instrument
PH
Transmitter

Model
HA-425-60T-S7 / 9135

Range
0-14 s / Cm
0-14 s / Cm
0-14 s / Cm
0-14 s / Cm
0-14 s / Cm
0-14 s / Cm

CATION CONDUCTIVITY
DM Makeup Water
Condensate Discharge
Condensate Discharge after CPU
Feed water at Economiser Inlet
Saturated Steam
Superheated Steam

15.3

PH
DM Makeup Water
Condensate Discharge
Condensate Discharge after CPU
Feed water at Economiser Inlet
Saturated Steam
Superheated Steam
Drum water

Make
Polymetron

0-14 s / Cm

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Condensate extraction pump

15.4

10/09/12 6:00 PM

DISSOLVED OXYGEN
Condensate Discharge
Deaerator Outlet
Feed water at Economiser Inlet

15.5

Instrument
Oxygen
Analyser

Make
Polymetron

Model
9182

Range
0-50 ppb
0-20 ppb
0-20 ppb

Instrument
Silica
Analyser

Make
Polymetron

Model
Range
SILKOSTAT 0-20 ppb
8891
0-500 ppb
0-20 ppb

Instrument

Make
Polymetron

Model
Range
PHOSPHAMAT 0-2000 ppb
8892

Instrument
Hydrazine
Analyser

Make
Polymetron

Model
Range
HYDROSTAT 0-100 ppb
9186

Instrument
Sodium
Analyser

Make
Polymetron

Model
SODIMAT
9073

Instrument
Chloride
Analyzer

Make
PABB

Model
Range
CHLORIDE 0-2000 ppb
8234

SILICA
Condensate Discharge after CPU
Drum Water (CBD)
Superheated Steam (MS)

15.6

PHOSPHATE
Drum Water

15.7

HYDRAZINE
Feed water at Economiser Inlet

15.8

SODIUM
Condensate Discharge
Condensate Discharge after CPU

15.9

Range
0-50 ppb
0-50 ppb

CHLORIDE
Drum Water

16
16.1Motor specification
Make
Rating
Type
Voltage
Number Of Poles
Speed
Frequency
Stator Current

CONDENSATE EXTRACTION PUMP

BHEL Bhopal
900 KW continuous duty
Induction Motor (Squirrel cage)
11 KV 3 phase
4
1492 RPM
50 Hz
58.5 Amps.

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Condensate extraction pump

10/09/12 6:00 PM

Insulation Class
Degree of protection

F
IP55

Motor Winding Cooling

Motor Brg. Type
Motor Bearing Lubricated
DOR
Space Heater rating
Lube

Self Air-Cooled.
Anti Friction
IOC Servo Gem-3/EQV.
Clockwise view from top
800W, 240 V
Grease, 50 gm for 4000 running hr

16.2Pump specification

Manufacture
BHEL, Hyderabad
Pump designation
EN6J 40/500
No. Of Pumps
3 (50 % duty)
Type
Vertical canister
Number of Stages
6
Type of first impeller
double suction
NPSH Required
3.1 meter (4.2-1%, 4.4-0%)
DOR (As Viewed From DE Side)
CCW
Design flow rate
800m3/hr
Inlet temperature
49.2 0c
Specific gravity
0.9884
Total discharge head
275mwc
Shut off head
361 m
Pump Speed
1492 rpm
Power input to motor
763 kw
Efficiency of Pump
81 %
Minimum flow for continuous operation 300 m3 /hr
Radial Bearing
Cut less rubber, 8 Nos. 100 mm size
Critical Speeds (RPM)
3380, 5798

16.3

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

763 KW
32 KW
731 KW
81%
77.6 %

16.4CEP Suction Strainer

Make
Hole size
16.4.1
NB
Fluid
Temp
Flow rate

Multiplex
400

Operating Condition
503
Condensate
50C
970

16.4.2
Performance Condition
Alteration rating
315 Max.
Clean Pr. Drop
0.03 Ksc
Dirty Pr. Drop
0.05 Ksc (50% Clogged condition)
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Condensate extraction pump

10/09/12 6:00 PM

16.4.3
Design Condition
Design code
ASME Sec-VII Div. 14
Pr.
8.0 + FV
Temp
65C
Hyd. test
12 Ksc 30 min
Empty/flooded wt
1350/2210 Kg
Basket (OD+Length+Area)
730*780 & 29417 cm2

16.5Sealing water requirement

0.55 M3/Hr.
3 to 4 ata
48-65 oC

Flow
Pressure
Temperature

17

TURBINE DRIVEN BOILER FEED PUMP

17.1Booster pump
Manufacturer
Type
Direction of rotation (Viewed on NDE)
Liquid pumped
S.G. at suction temperature
Suction temperature
NPSH
Differential Head (design)
Flow rate
Efficiency
Speed
Power absorbed

17.2Main pump

Manufacturer
Type
Suction Flow
Kicker Flow
Suction pressure
Design Head
Kicker Head
Speed
Efficiency
Thrust Bearing
Manufacturer
Type
Mechanical seal
17.2.1
Turbine
BFP
BP

BHEL
FA IB 75
Anticlockwise
DM Water
0.9045
162.7 Dec C
4.5 KSC
205 M
990.0 m3/hr
81.50%
1495 rev/m
613 KW
BHEL
FK 4E 36
990 cum/hr
150cum/hr+ 30cum/hr
6.85 kg/cm2
205.0 kg/cm2
209.0 kg/cm2
5465 rpm
81%

Mitchell Bearing
Double thrust.
Bergman

Direction of rotation from Booster Pump to BFP

CCW
CCW
CW

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Condensate extraction pump

10/09/12 6:00 PM

17.3
Turbine
Equipment

Turbine
Maximum output
Design rating
Speed
Speed range
Max Initial Steam Pr
Pemissible steam pr
(without deviation)
Initial steam Temperature
Max Initial steam Temperature
(without limitation)
Exhaust pressure
0.105 ata
Trip Speed
6012
Critical Speed
7550

7504 KW
5748 KW
5260 RPM
1494-5750 RPM
6.32 ata.
11.3 ata
288.4 0 C.
320.0 0 C.

17.4TDBFP- Gear Box

(Ref. 0-311-01-02121)

Sr. No
30/5875 to 30/5879
Input Speed
5465 rpm
Output Speed
1495 rpm
Ratio
3.655
Power transmission
822 HP/613 KW
Normal power torque @ LS Shaft
3916 mN
Exceptional torque@ LS Shaft
7832 mN
Recommended Lube Oil
ISO VG 46
Max. Oil flow
30 LPM at KPA & 50 CHeat rejection rate
17.6KW
Turbine lube oil strainer size
250
Turbine lube oil Strainer Mat.
Stainless Steel

17.5Oil system
Lube oil pump
Emergency Oil pump
Jacking Oil Pump
Oil vapour extractor fans

2 Nos
1 No
1 No
2 Nos

17.6Oil Vapor Extractor Fans

Nos
Mounting
Type
Rating
Make
Full load current

2 per Pump
Tank Top
Centrifugal, Direct Mounted
0.37 KW , 2800 RPM
Crompton Greaves
0 .79 A

17.7Oil Pumps Specification

Aux. Oil PP

DC Oil PP

Jacking Oil Pump

Oil Transfer

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Condensate extraction pump

10/09/12 6:00 PM

Number

Pump
1

Make

Tushako, india

KSB

Delta Corp.

Delta Corp.

Type

Screw

Centrifugal

Gear (HPG2A)

R20-DG

Capacity (lpm)

2500 lpm

24.9 m3/hr

Rated Head
(Ksc)
Speed (RPM)

11.6

50.8 at 40C
58 at 70C
3.0

1440

51.2 m
disch pr-4.5
2900

9
suc pr-7.0 Ksc
100.0
1440

1400

Drive
Motor Make

A.C. Motor
Crompton Greaves

D.C. Motor
Crompton Greaves

A.C. Motor
Crompton Greaves

A.C. Motor
NGEF

Voltage (V)

415

220 (armature)

415

415

Power (KW)

90

15.0

3.7

1.1

Rated Current

147

79

7.6

2.5

DOR
Motor
Speed (rpm)

CW from
DE side
1480

CW from
DE side
2900

CW from
NDE side
1440

CW from
DE side
1400

Motor bearing

6318-C3

6311-2RS

Efficiency

94.5

6306ZZ
6205ZZ
-

17.8Oil Purifier (Centrifuge)

Make
Alfa Laval
Type
MAB 205
Motor
5.5KW, 415V, 10.4 Amp., 1445 RPM
Operating speed
8725 RPM
Rated capacity
2.4 M3/Hr.
Indirect oil heater
415 V, 3 phase, 50 Hz
Heater capacity
60 KW
Feed pump motor make Bharat Bijlee
Motor specification
2.2 KW, 415 V, 4.6 Amp
Running up time
1.5-2.5 min
Stopping time
2 min with break applied

17.9TDBFP Governing System

17.9.1

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

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Condensate extraction pump

17.9.2

10/09/12 6:00 PM

Emergency Stop Valve (ESV)

Type
Opening Time
Closing Time
Operating Oil Pr
Open / Close Operation

17.9.3

Latching Type, Fast Closing

1-2 min
60 mSec
8 bar
Solenoids

Main Control Valve (MCV)

No of Valves
Controlling Mechanism
Maximum servomotor travel
Start of operation
Full Open Condition

17.9.4

Aux. Control Valve (ACV)

No of Valves
Controlling Mechanism
Maximum servomotor travel
Start of operation
Full Open Condition

17.9.5

1
Seat Overlap
70 mm
1.5 bar of LP Sec Oil Pr
4.5 bar of LP Sec Oil Pr

Accumulators
No of Accumulators
Operating Pressure
Operating point
Capacity

17.9.6

5
Bush Groove Depth
130 mm
1.5 bar of HP Sec Oil Pr
4.5 bar of HP Sec Oil Pr

2 per Pump
6.5 bar
Governing Oil Line
35 Ltrs

Hydraulic Pressure Accumulator

Ref no 3-11430-02000

Designation
Hydraulic Pr. Accumulator (2 lit)
Gas Pressure
2 Bar
Filling Gas
Nitrogen
Normal operating Pr.
2.5 Bar to 6 Bar
Max. Operating Pr.
8 Bar
Working Medium
Turbine oil of 21 to 31 centistokes at
50C Or Fire
Resistance Fluid
21 to 27 centistokes at 50C
Max. Allowable operating Pr
100 Bar
Normal working Temp.
65C
Allowable Range of operation
0C to 80 C

17.9.7
Membrane

Material
VITON

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Condensate extraction pump

10/09/12 6:00 PM

Accumulator-Body

17.10

C22.8N

TDBFP Twin Oil Cooler

(Drg no3-165-01-00277)

17.10.1

Design Data
Design Data

Shell

Make
Design Pr. Ksc
Test Pr.
Ksc
Pr drop
0.65 0.8
Design Temp.
C
Corrosion allow mm
Stress Relieving
Radiography
No. of Passes
Medium
Joint efficiency
Surface area/cooler Sq.m
No. of Tubes Per Cooler
Tube Length mm
Tube Size of OD*Thk mm
Pitch/Type
mm
No. of Baffles per cooler
Baffle Pitch mm
Heat Duty Kcal/hr
Oil Qty.
m3/hr
Water Qty. m2/hr
Oil Side Temp
C
Water side Temp C
Over all Heat

17.11

Materials
shell
tubes

BHEL
10
13.0

13.5
17.55
100

BHEL

100

1.6

1.6
NO

NO

NIL

NIL
4

1
Oil
0.7

Water
0.7

85
436
4000
15.875*1.24
19.05/
25
141
281688
47.6
100
60/45
38/41
356 Kcal/hr m2 C

17.10.2
Weights
Empty Weight
Kg (Both code)
Working Weight
do
Flooded weight
do
17.10.3

Tube

5700
6800
7200

CS, SA 106Gr B
SS(SA 249 TP 304)

Flexible Coupling

(Drg no8GBL-219)

17.11.1
Specification
Power
KW
Speed
rpm
Operating Torque Kgm
Max. Torque Kgm
623

900
1486
502

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Condensate extraction pump

Max. Inst. Torque

10/09/12 6:00 PM

Kgm

1246

17.11.2
Coupling capacity
Continuous Torque Kgm
Peak Torque
Kgm
Short circuit Torque Kgm
Inertia (WK2)
kgm2
Torsional Stiffness Kgm/rad
(1/3 shaft penetration)
Balance

17.12

17.13

1061
2122
3925
0.55
0.281*10
G 2.5 ISO 1940

Power pack assembly

Make
Specification
HP
Volts
Amps
Rpm
Frame

Baldor, USA
M35A03X419
2
220/380/415-440
5.6/3.2/2.9-2.8
2850
145TC

Operating condition

TDBFP
Capacity
Head
Temp.
Sp Gr.
Efficiency
Power
(KW)
Speed
(rpm
NPSHR
M/c

855
1982
161
0.9062
81%
5229

Design
capacity
990
2025
162.7
9045
81
6098

BOOSTER P/P
Emergency
Run
Condition
Out
970
1100
227
198
161.1
146.6
0.9062
.9198
81
81.5
671
670

5430

5260

5465

1570

56

43

50

4.6

Emergency
Condition
970
2308
161.1
0.9062
81%
6823

Run
Out
1100
1787
146.6
0.9198
81%
6080

Best eff

5740
52

18

Best eff
855
193
161.0
0.9062
79.5
512

Design
capacity
990
205
162.7
0.9045
81.5
613

1486

1439

1495

5.1

3.8

4.5

MOTOR DRIVEN BOILER FEED PUMP

18.1Booster pump
Manufacturer
BHEL Hyderabad 2003
Type
FA IB 75
Pump no
P2002-040
Direction of rotation (Viewed on NDE)
Anticlockwise
Liquid pumped
DM Water
S.G at suction temperature
0.9045
Suction temperature
162.7 Dec C
NPSH
4.5 KSC
Differential Head (design)
205 M
Flow rate
990.0 m3/hr
Efficiency
81.50%
Speed
1495 rev/m
Power absorbed
613 KW

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Condensate extraction pump

10/09/12 6:00 PM

18.2Main pump

Manufacturer
Frame
Pump no
Suction Flow
Kicker Flow
Suction pressure
Design Head
Kicker Head
Speed
Efficiency
Temperature
Thrust bearing
Manufacturer

BHEL Hyderabad 2003

FK4E 36
P2002-052
990 cum/hr
150cum/hr+ 30 cum/hr
6.85 ata
2025 m
209.0 ata
5465 rpm
81%
162.7
Mitchell Bearing
Double thrust.

Mechanical seal
Manufacturer

18.3

Eagle Poonawala, Pune

Motor

Manufacturer
Type
Power
Voltage
Current
Speed

BHEL
3 phase synchronous
10 MW
11 kv
601.5 amps
1495 rpm

18.4Hydraulic coupling
Manufacturer
Type
Code
Hydraulic oil type

M/s. VOITH, Germany

R 18 KGS 14 API
Bharat S 138 RIHAND
HLP32 to DIN 51524

Journal brg. Type

Plain
Thrust brg. Type
tilt
Rotation seen in direction of power flow
Input shaft
CCW
Output shaft
CCW
Gear ratioU1
109/32
Gear ratio U2
62/53
Full load slip
2.3%
Primary Speed
5092 rpm
Secondary speed
5102 RPM
Max. Output speed
5820 rpm
Oil tank filling
2.50 cum.
Power Required
6945 KW
Lube oil flow
300 l/min at 2-2.5 KSC pr
Full load slip
2.0 %
Max. Output speed
6440 RPM
Regulation range
4:1 downwards
Bearing temp.
< 90oC

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Condensate extraction pump

10/09/12 6:00 PM

18.5Flexible coupling (91069-00) Motor HC

18.5.1
Specification
Make
Power
Speed
Operating Torque
Max. Torque (Kg-m)
Max. Ins. Torque
18.5.2

Euro flex Transmission Pvt. Ltd.

10000 KW
1494 rpm
5249
6650
13300

Coupling Capacity

Continuous torque
Peak torque
Short cut torque
Inertia

91.7 KN-m
183
311
10.35

18.6Oil Pump
Manufacturer
Type
No. of PP.
Pump Drive
Rated head (bar)
Rated capacity
Motor type
Power
Rated speed
Voltage
Protection

Auxiliary Oil Pp
VOITH/Germany
Gear
One
AC Motor
4.0
2950 lpm
DE 200LA2
30 KW
2950 rpm
415 V
IP55

Main Oil Pp
VOITH/Germany
Centrifuge
One
Shaft driven
4.0
-

18.7Lubricating 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.

18.8Oil Coolers
Type (Make)
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

Working Oil
Shell/Tube (VOITH)
2 X 100%
148 L/32L

Lub Oil
Shell/Tube (VOITH)
2 X 100%
91 L/63L

78/120 M3/hr.
95 /38oC
58/48 oC
120 M3/hr.

51/75 M3/hr.
65/38 oC
50/42 oC
75 M3/hr.

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Condensate extraction pump

10/09/12 6:00 PM

Cooling Water Inlet temp.

Cooling Water Outlet temp.
Oil side Pr. drop (bar)
Maximum allowable pr

18.9

38 oC
48 oC
0.54
16/10

38 oC
42 oC
0.41
16/10

Lub Oil Requirement In Brgs

BFP
Journal
0.42
2.5
100

(M3/hr.)

Oil Flow
Oil pr. (bar)

Maxm. Bearing temp (oC)

18.10

Thrust
13.44
2.5
80

Equip.

Alfa Laval
Portable / MAB 103
Bharat Bijlee Ltd.

Operating parameter
Operating Speed
Design
Best eff

BFP
Booster Pump
Motor
HC I/P Shaft
HC O/P Shaft

18.12
18.12.1

Thrust
0.72
2.5
65

Oil Purifier For MDBFP

Make
Type
Motor Make

18.11

Booster Pp
Journal
0.3
2.5
80

5465
1495
1495
1495
5465

5245
1495
1495
1495
5245

Run
out

Emer.

5425
1495
1495
1495
5425

5775
1495
1495
1495
5775

Critical Speed
First
New
Worn
out
9124
8118
4632
4523
-------------

Second
New Worn
out
12093 11926
8530 8490
-------------

BFP Conical Strainer

Operating Condition
BFP
400
Feed water

NB
Fluid
Flow (m3/hr)

1240

BP
450
--1240

18.12.2

Performance Condition
BFP
Alteration rating
195
Clean Pr. Drop
0.03
Dirty Pr. Drop
0.05
18.12.3

BP
315
0.15
0.15 (50% Clogged)
Condition)

Design Condition

NB
Design code
Temp
Basket (OD*L)
Gross area

BFP
BP
400
450
ASME Sec-VII Div. 14
190C
190C
420*2280m
570*760m
30390 cm2
22067 cm2

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Condensate extraction pump

Empty/flooded wt

10/09/12 6:00 PM

1200/1725

19

2350/2875

DEAERATOR AND FST

19.1Deaerator Header Assembly

Type
Diameter x Thickness
Header length
Design pressure
Design Temperature
Operating pressure
Operating Temperature
Test Pressure
Test Temperature
Condensate inlet Qty
No Of Trays
No. Of spray valves
Spray valve capacity
Dissolved Oxygen in Feed water
Cond. Temp/enthalpy/pr
19.1.1

Spray cum Tray

ID3000X 16 mm
10564 mm
9 ksc & full vacuum
O
360 C
6.59 KSC
167.5 OC
11.5 KSC
Ambient
1272.885 tph
576
108
15 T/hr
0.005 cc/lit
124.7/125.3/6.9

Materials
Header & Dished End
Trays
Tray Support
Tray removal openings & Internal pipes

SA 516 GR 70
SA 240 TP 304
SA 240 TP 304
SA 106 GR B

Packing

CAF 9

19.2Feed water storage Tank

Inside dia x thickness

3600 X 20 mm
Total Length
Steam inlet quantity 84.774 T/hr
Inlet steam pr/temp 6.9 Ksc/288 C
Safety valve set pr 6.9 Ksc
Inlet steam enthalpy 725.7 Kcal/Kg
Design Pressure
9 ksc & full vacuum
O
Design Temperature
360 C
Feed water out pressure/temp
6.8 ksc/163
Feed water enthalpy
164.5Kcal/kg
Feed water quantity
1625.334 T/hr
Test Pressure
11.7 KSC
Test Temperature
Capacity (NWL to LWL)
170
19.2.1

19.2.2

Materials
Storage Tank Shell & Dished End
Internal Nozzles
Cover for Manholes

32425 mm

Ambient

SA 516 GR 70
SA 106 GR B
SA 105

Weights

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Condensate extraction pump

10/09/12 6:00 PM

Storage Tank & Header Dry

Storage Tank & Header in operation
Storage Tank & Header flooded

Kgs. 110000
Kgs. 318000
Kgs. 490000

19.3DEAERATOR SAFETY VALVES

Safety Valve

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

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 Side)

20
20.1
20.1.1

Reset Pr
(Kg/Cm2)
7.5
7.0
6.25
7.25
7.25
8.5

SEAL OIL SYSTEM

AC Seal oil pump (Air side) 2no full capacity

Pump specification

Kind of pump
Type
Capacity
Discharge pr
20.1.2

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

Screw pump
3-52/54-IBSCS 1X2 (DELTA)
258 lpm
12 ksc

Motor specification

Make
Rating
Voltage/frequency
Current
Speed
Type of insulation

CGL
7.5 KW
415 V/50 hz
15.6 A
1440 rpm
P55

20.2 DC Seal oil pump (Air side)

20.2.1

Pump specification

Kind of pump
Type
Capacity
Discharge pr
20.2.2

Screw pump
3-52/54-IBSCS 1X2 (DELTA)
258 lpm
12 ksc

Motor specification

Motor
Rating
Voltage/frequency
Current
Speed

TDC 225L (KEC)

8.5KW
220 V DC
67 A
1450 rpm

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Condensate extraction pump

10/09/12 6:00 PM

Type of insulation
No of pump No of gas side

20.3

IP55
2 no full capacity

Seal oil cooler (Air side)

Type
Make
Surface area (m2)
Oil flow
Heat dissipating capacity
Oil inlet temp
Oil outlet temp
Oil pr drop
Cooling water flow
Cooling water inlet temp
Cooling water outlet temp
Water pr drop

surface
BHEL-HARDWAR

19.1
1.16 dm3/s
140 KW
70 C
50 C
0.833 bar
35 m3 /hr
36 C
39.4 C
6.8 mWC

20.4Seal oil cooler (Gas side)

Type
Make
Surface area (m2)
Oil flow

surface
BHEL-HARDWAR
19.1m3
2.17dm3/s
Heat dissipating capacity
90 KW
Oil inlet temp
70 C
Oil outlet temp
50 C
Oil pr drop
0.85 bar
Cooling water flow
22 m3 /hr
Cooling water inlet temp
36 C
Cooling water outlet temp
39.5 C
Water pr drop
7.1 mWC
Tube side deign pressure
16ksc
Shell side deign pressure
16ksc

20.5AS seal oil filter

Filter-1

Make
F (m)

BOLL & Kirch

BOLL & Kirch
100
100

20.6H2 seal oil Filter

Filter-1

Make
F (m)

Filter-2

BOLL & Kirch

BOLL & Kirch
100
100

21

TG LUBE OIL SYSTEM

21.1

Lube Oil pumps specification

21.1.1

Pumps specification
MOP
AOP
1
2

Number

Filter-2

DC EOP
1

JOP
AC: 2

DC: 1

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Condensate extraction pump

10/09/12 6:00 PM

Make

BHEL

Mather+platt

Mather+platt

All weiler

Type

350 m/hr

5/6 EHLG

4/9KL-70

361

1800

SDF/A80R466-9- SDF/A80R466W112
9-W112
111-158
111-158

8.4

75.7m

2.76

178

178

3000

2970

1425

2900

2900

Turbine

AC Motor

DC Motor

AC Motor

DC Motor

Capacity
(LPM)
Disch. Pr.
(bar)
Speed
(RPM)
Drive
21.1.2

All weiler

Motor specification
-

Make
Voltage (V)
Motor Power (KW)
Rated Current (Amp.)
DOR from top

Crompton
Greaves
415V
110
173
Clockwise
F

Insulation

21.2

Crompton
Greaves
220V
13
97
Clockwise
IP55

ABB
415V
76
122
Clockwise
IP55

Crompton
Greaves
220V
50
315
Clockwise
F

Materials

Shell, Channels
Tube plate & covers
Flanges
Support plate
Tubes
Condensate Inlet / Outlet
pipe
Steam inlet pipe
Impingement plate

C.S. SA 516 GR 70
C.S. SA 516 GR 70
***
C.S. IS 2062
S.S. SA 688 TP 304
C.S. SA 106 GR B

C.S. SA 516 GR 70
C.S. SA 516 GR 70
C.S. SA 105
C.S. IS 2062
S.S. SA 688 TP 304
C.S. SA 106 GR B

C.S. SA 516 GR 70
C.S. SA 516 GR 70
C.S. SA 105
C.S. IS 2062
S.S. SA 688 TP 304
C.S. SA 106 GR B

C.S. SA 106 GR B
S.S. SA 240 TP 304

C.S. SA 106 GI B
S.S. SA 240 TP 304

C.S. SA 106 GR B
S.S. SA 240 TP 304

22

HP HEATERS

22.1HPH-5A & 5B

(1230-001-04HY-PVM-B-026)

Shell

Design Temp
No. Of passes
No. Of U tube
22.1.1
Empty
Flooded
Operating

Design Pr.
224
3 zone
reg-1171,

Tube
24 & vacuum
224/244
two
provided- 1181

330 & vacuum

Weight (kg)
44500
49000
59080 Kg

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Condensate extraction pump

10/09/12 6:00 PM

22.1.2
Details (stand Pipe)
High High level (HHL)
High level (HL)
Normal level (NWL)
Internal dia (ID)
Low low (LL)

110 mm below vessel CL

390 mm
525 mm
1500 mm
605 mm

22.2HPH-6A & 6B

(1230-001-04HY-PVM-B-028)

Design Pr
Design Temp
No. of passes
No. of U tube
22.2.1
Empty
Flooded
Operating

Shell
57 & vacuum 330 & vacuum
273
273/293
3 zone
two
reg-1171
provided- 1181

Tube

Weight (kg)
54000
59300
70700

22.2.2
Details (stand Pipe)
High high level (HHL)
110 below vessel CL
High level (HL)
390 mm
Normal level (NWL)
525
Internal dia (ID)
1500 mm
Low low (LL)
605 mm

mm

22.3HP Heaters Specification

HP HEATERS
Type
Quantity Extraction steam (T/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)

5A / 5B
U-Tube / Horizontal
42.210
16.89
413
264
230
165.2
203.4
964
5/8 x 12 mm
1181 U
2.0
2
3
24 & Full Vacuum
224
330
224/330
31.2
429

6A / 6B
U-Tube / Horizontal
78.7825
42.76
335.5
748.037
264
203.4
253.5
1145
5/8 x 12 mm
1181 U
2.00
2
3
57& Full vacuum
273
330
273 / 293
74.1
429

455

360/440

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Condensate extraction pump

10/09/12 6:00 PM

Skirt design. temp. (oC)

22.4

Materials

Shell, Channels
Tube plate & covers
Flanges
Support plate
Tubes
Condensate Inlet / Outlet nozzles
Steam inlet Pipe
Impingement plate

22.5

C.S. SA 516 GR 70
CS SA 350 LF 2
CS SA 105
C.S. IS 2062
S.S. SA 688 TP 304
CS SA 350 LF-2
A.S. SA 335 P11
S.S. SA 240 TP 304

SA 387 GR 12 cl.1
CS SA 350 LF 2
CS SA 105
C.S. IS 2062
S.S. SA 688 TP 304
C.S. SA 350 LF 2
C.S. SA 106 GRB
S.S. SA 240 TP 304

Safety Valve

Make

BHEL

Size
Set Pr.
Cold Set Pr.
Temperature
Capacity
Type
Back Pr.

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

23

CONTROL FLUID

23.1Fire resistant fluid specification

Flash Point
>235oC
Pour Point
< -18oC
Neutralization No.
Max. 0.1 mg KOH/g
o
Ignition temp.
>550 C
Air release capacity
< 3 min
Water content (by weight)
< 1000 mg/Kg
Particle distribution
<15/12 code
o
Foaming tendency at 25 C
< 100 ml
Foaming stability
450 Sec. (max.)
o
Kinematic viscosity (at 40 c)
41.4 to 50.6 mm2/s
Solid particles content
0.05 % (by weight)
o
Density (at 15 C)
1250 Kg/m (max.)
Oxidation stability
2.0 mg KOH/gm (max.)
Electrical Resistivity
>50 Mm
Demulsification
< 20 min
Chlorine content
<50 mg/Kg

23.2Control fluid tank

Tank capacity
1st fluid filling

10/16 m3
15 m3

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Condensate extraction pump

10/09/12 6:00 PM

10 m3
650 mm
750 mm

Flushing fluid quantity

Highest fluid level from top of tank
Lowest fluid level from top of tank

23.3Control fluid pumps

23.3.1

Pump specification
Number of Pumps

Make

2 x 100 %
KSB

Type
Discharge pr.
Fluid flow
Speed
Drive

WKVM80-1 + 3
11.5 / 39.3 bar
12.1 / 9.33 dm3/s
2975 RPM
A.C. Motor

Motor specification
Make
Type
Voltage
Motor rating
Rated current
255 Amp.
Starting current
Speed

20.30 LPS

23.3.2

23.4

Siemens
ILA63162 AC
415 V
160 KW
1792 Amp
2982 RPM

Control Fluid cooler

(Refer DRG. 2-165-08-70004C80)

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
23.4.1

2 x 100
31.4 m2
43.2 m3/hr.
147 KW
55 oC
49 oC
3.5 MWC
38 oC
40.1 oC
60 M3/Hr.
2.4 MWC

Design pressure
Shell side=10.0ksc
Tube side=13.0ksc

23.4.2

Hydraulic test
Test pressure
Tube side=19.5ksc
Test fluid
Test duration

shell side=15.0 ksc

water
30 min

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Condensate extraction pump

10/09/12 6:00 PM

23.4.3
Weight
Empty weight
Flooded/operating weight
Total surface area provided

1355.0kg
1850.0kg
31.4 m3

23.5Control Fluid Pump Motor set

(Ref no3-11924-25000)

23.5.1
Sl.
No.

Low Pressure Pump

Operating
Condition

Total flow through LP

pump
Section (dm3/sec)
12.1+9.36=21.46
25.1+9.36=34.46
12.1+24.36=36.46

I
II
III

23.5.2

Disch. PR at Ex. the

pump after LP pump
(bar)
11.5
10.8
10.10

Disch. Flow
(dm3sec)
12.1
25.1
12.1

High Pressure Pump

Sl. No. Operating

Condition

Total flow through LP

pump sec (dm3sec)

I
II
III

9.36
9.36
24.36

Operating point I
Operating point II
Operating point III

Disch. PR at Ex. the

pump after LP pump
(bar)
27
27
21

Disch. Flow
(dm3sec)
38.5
37.8
31.1

(normal operation)
(during start & opening of the stop valve servo motor)
(during opening of the control valve /LP bypass operation
After the load throws off)

23.6Change Over Double Filter

(Ref no 2-11445-41000)

23.6.1

Design requirement

Max. Operating Pr.

Test Pressure
Working Pr. & Temp.
Medium
23.6.2
Design flow
Max. Flow

100 Ksc
150 Ksc
36 Ksc, & 65C
FRF, Viscosity 33-48 mm2/S at 40 C

Flow across Filter

0.6 dm3/Sec
1.16 dm3/Sec

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Condensate extraction pump

23.6.3

10/09/12 6:00 PM

Pressure Drop across filter

Pr. Drop for design flow

Pr. Drop for Max. Flow

<0.1 Ksc in clean condition

<0.2 Ksc in clean condition

The change over to the other, the pressure drop across the of 0.8 Ksc :

23.7 Regenerative system (C.F. purification)

23.7.1
Make
Design pr

Filters (Filters Philipp, France)

Rander & co.
3 bar
Operating temperature
80 C
Hydraulic test pr
4.5 bar
Medium
oil
Type of Filters
Dry (F2.6)
Fuller Earth (HFB12)
Fine filter (F2.6)

Purpose
To take off water
Neutralization of acidity
Fine filtration and security

23.7.2
Make
Capacity
Volts

Heating unit
DAPASS SALES COR.
27kW
220-440

23.7.3

Regenerative pumps (C.F. Recirculation PP)

No of cartridges / type
6 throwaway / PD71803C
12 throwaway / HT`11800CR
6 throwaway / PL71812C

23.7.4
Pump specification
Number of PPs
2 x 100 %
Make
Gebr Steimel (Germany)
Type
BGK2-24R
Fluid flow
0.28 dm/s
Direction of rotation
Anti clockwise from DE
Discharge pr.
3.06 ata (at 55oC)
Speed
1500 RPM
Drive
A.C. Motor
23.7.5

Motor specification

Make
Motor Power
Rated current
Voltage

24.1
24.1.1
Make
Design
Type

Siemens (Germany)
0.75KW
1.79 Amps.
415 V

Main Turbine

24

MAIN TURBINE

Specifications
BHEL
KWU, West Germany
Three Cylinder Reheat Condensing Turbine

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Page 54 of 72

Condensate extraction pump

Stages
IPT 12 X 2 Reaction stages
LPT 6 X 2 Reaction stages
Valves

10/09/12 6:00 PM

HPT 17 Reaction stages.

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
Direction of Rotation
Towards Generator)
Rated load
MaxM load

Anti Clockwise (Viewed from front pedestal

500 MW
524.9 MW (valve wide open condition)

Rated Speed
50 C/Sec
m
Max Speed
51.5 C/Sec (No Time Limitation)
m
Min Speed
47.5 C/S (No Time Limitation)
Speed Exclusion Range
7 to 47.5 C/Sec
(Without load)
Standard Over Speed Trip Setting 55.5 C/Sec
24.1.2

Weights (tons)
HP

IP

LP

Cylinder Assembly

94.6 T

41.2 T

79.6 T

Rotor (with Blading)

16.3 T

23.1 T

90T

Stop and C.V.

20.9 T

32.2 T

Turbine overall length

Turbine overall width

24.1.3

24.2
24.2.1
HP
IP
LP

Size of bearing
Brg no
Diameter (mm)

19.94 M
15.10 M

1
250

2
380

3
450

4
500

Material of construction
Turbine Casings
GS17 Cr MOV 515
GS22 MO 4
St. 37-2N (Outer)

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Condensate extraction pump

24.2.2

Blades (Moving)

HP (First stage)
HP (Other stage)
IP
LP
24.2.3

10/09/12 6:00 PM

X22 Cr MOV 121

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

Rotors

HP
IP
LP

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

24.3IP turbine casing

(Ref. 0-10601-41000)

24.3.1

Outer casing

Max. Working Pr.

Test Pr.
Time Duration
24.3.2

8.1 bar
11 bar
30 min.

Chamber-2

Max. Working Pr.

Test Pr.
Time Duration

19.1 bar
25 bar
30 min.

24.4IP Turbine Rotor

(Ref. 0-10201-41000)

Data for over speed test

Over Speed frequency
Duration of Over Speed
Critical Speed
Operation Speed
DOR
(When seen in direction of Generator)

62.5 Hz (3750 rpm)

20 min
3372 rpm
50 Hz
Anti Clock

24.5LP Shaft

(Ref 0-10301-41000)

Over speed Frequency

Duration of over speed
Original speed of rotor
Operating Speed
DOR of rotor when seen
in direction of the generator

62.5 Hz (3750 rpm)

2 min
1134 (18.9 Hz)
50.0 Hz (3000 rpm)
Anti clock wise

Before Balancing and over speed test, the assembly of rotor should be
complete in all respect.
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Weight of Bladed rotor

24.5.1

89850 Kg

Material

Top, Bottom & side plate

Nozzle pipe
Stiffener, Gusset, Rib, Stray
Channel & Nozzle
Elbow
Bolts & Nut

24.6

IS 2062 Gr-A
IS 20 SA106 Gr-B
IS 2062 Gr-A
SA 234 Gr- WPB
El 4.6 & 8.0

Turbine extractions
Extractions Source
1
LPT 5th stage

Going To

2
3
4
5
6

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

LPT 3rd stage

LPT 2nd stage
IPT Exhaust
IPT 7th stage
CRH

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

LPH-1

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.

24.7Operating parameter
24.7.1

Steam Pressure And Temperatures (Rated)

Parameter
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

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

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

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Condensate extraction pump

10/09/12 6:00 PM

LP cylinder exhaust
24.7.2

0.1027

46.4

Casing temperature limiting values

Alarm

Parameter
HP turbine casing exhaust
Outer casing of LP cylinder
(Spray water to L.P. turbine must be switched on
at 90oC).
Between upper & lower casing of HPT.
(Middle)
IPT Top / Bottom Diff. temp. (Front)

485oC
90oC

IPT Top / Bottom Diff. temp. (Rear)

24.7.3

500oC
110oC

90oC

100oC

45oC

60oC

45oC

60oC

Permissible temperature difference between parallel steam supply lines

No time limitation
Short time period (15 min)
24.7.4

M/C must be
shut down at

17 oC
28 oC

Feed heater out of service

Operation with Feed Heater out Main Steam flow,

Kg/s
of service
Extraction A6=0
395
421
Extraction A5=0
Extraction A3=0
423
Extraction A2=0
425
Extraction A1=0
423
Extraction A6, A5=0
400
24.7.5
Out put limit with ATT
Testing of the Main Steam Stop & Control Valves
Testing of the HRH Steam Stop & Control Valves
24.7.6

Load MW
500
500
500
500
500
526.6

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.
24.7.7

Low vacuum trip standard settings

Hydraulic Low Vacuum Trip
Electrical Low Vacuum Trip
Hydraulic Low Vacuum Trip Bypass
Operation

24.7.8

0.3 bar
0.3 bar
0.6 bar

Barring gear

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Condensate extraction pump

10/09/12 6:00 PM

Speed
Drive
Cut in / Cut out speed
Location

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

24.8Turbovisary parameter
24.8.1

Axial Shift
Alarm

Trip

0.5 mm

24.8.2

1 mm

Differential Expansions

HPT

-5.0 to +3.5 mm

IPT

-1.0

Overall Expansion of IP + LP Rotor

-3

24.8.3

to

+5.5 mm

to + 30 mm

Vibration
Absolute Brg housing Vib

Absolute Shaft Vib

Standard Alarm setting

Maximum Alarm
setting
Limit Value for
Tripping
24.8.4

25mm above normal level

42mm (85-MMI)

100mm (200 MMI)

53mm (106-MMI)

160mm (320-MMI)

Bearing temperature
Alarm

Bearing Temperatures

Trip

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

24.8.5
Fixed Points
For HP casing
For IP casing
For LP casing
For Turbine Rotor

130oC

Turbine bearing pedestal -2

Turbine bearing pedestal -2
Turbine bearing pedestal -3
Thrust bearing

v All HP, IP & LP Turbine Bearing Pedestals are Fixed.

24.9Heat balance data

Rating

300 MW
77

250 MW
77

DM Make-Up (%)

500 MW
400 MW
77
77
(0.927mmWc)
0
0

Turbine Gross Output (MW)

508.489

306.076

255.734

Vacuum (mmHg)

407.068

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Condensate extraction pump

10/09/12 6:00 PM

Turbine Net Output (MW)

500

400

300

250

Heat Rate (Kcal / KW-Hr)

1944.4

1987.2

2059.5

2129.3

Mechanical
Gen

1.444
6.895

1.444
5.474

1.444
4.482

1.444
4.140

TG Auxiliary

0.15

0.15

0.15

0.15

Efficiency (%)

98.33

98.26

98.01

97.757

Losses

24.10

Turbine load sharing capacity

HP turbine
IP turbine
LP turbine

26 %
34 %
40 %

25
25.1

Turbine seal steam system

Seal steam

Seal steam supply header pr.

(Above Atmospheric)
Condenser Vacuum

0.035 bar
0.1045 ata

25.1.1
Exhauster Fans specification
Make
S.K. System Pvt. Ltd., Sonepat
No. of Fans
2 X 100 %
Speed
2900 RPM
Type
SHSH
25.1.2
Motor specification
Motor Make
Bharat Bijlee Ltd.
Type
ILA 3050-2 (Induction Motor)
Volt
415 V
Connection
Delta
25.1.3
Seal stem pressure control valve
Type
HAS-1-K-02
Oil control
10kg
Thrust
10KN
Oil pressure
35 bar
Type of oil
BPB100K
Stroke
40mm

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Condensate extraction pump

26

10/09/12 6:00 PM

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 0m (Unit # 3, B-C BAY).

26.1Clean Oil Tank

(Ref. 1230-001-03BH-PVM-B012)

Design Pr.
Design temp.
Operating Pr.
Operating Temp.
Storage medium
Net Capacity
Empty wt.
Flooded wt.
26.1.1

atm.
70C
Static
Ambient
Turbine lube oil
60 m3
9.5 ton.
63.5 ton

Material

Top, Bottom & side plate

Nozzle pipe
Stiffener, Gusset, Rib, Stray
Channel & Nozzle
Elbow
Bolts & Nut

IS 2062 Gr-A
IS 20 SA106 Gr-B
IS 2062 Gr-A
SA 234 Gr- WPB
El 4.6 & 8.0

26.2Dirty Oil tank

(1230-001-03-BH-PVM-B013)

Design Pr.
Design temp.
Operating Pr.
Operating Temp.
Storage medium
Net Capacity
Empty wt.
Flooded wt.

atm.
70C
Static
Ambient
Turbine lube oil
60 m3
9.5 ton.
63.5 ton

26.2.1

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Condensate extraction pump

10/09/12 6:00 PM

26.3Oil Transfer Pumps

Clean Oil Transfer PP1 no.

For transferring oil from Clean oil tank

to any of unit oil Tank.
Dirty Oil Transfer PP1 no.
For transferring oil from Dirty oil tank
to Central oil Purifier.
Specification for both the pumps
26.3.1
Make
Type
Speed
Flow
Disch. Pr.

Pump specification
Delta corporation
UM2 / Positive displacement (Gear Type)
1440 RPM
8250 Ltr / Hr.
2 Kg/cm2

26.3.2

Motor specification

Make
Type
Speed

Crompton Greaves
Three phase Induction Motor (ILA 3054)
1440 RPM
Voltage
415 V
3.7 KW/7.6 A

Rating

26.4

Central Oil Purifier

26.4.1
Centrifuge
Make
Type
No. of units
Maximum speed bowl (rpm)
Speed motor shaft (rpm)
Electrical current frequency (Hz)
26.4.2

On
8423
1500
50

Centrifuge Feed Pump

Capacity
Suction lift
Delivery head
Process temperature (min/max)
Max density of the feed
Max density of the sediment
26.4.3

Alfa level
MAB 206 S-24

8.54 M3/Hr
4 M Wtr (g)
15 M Wtr (g)
0/100 C
1100Kg/m
1600kg/m

Centrifuge Motor

Make
Rating kW/(HP)
RPM
Duty
Volts
Current
Type
Insulation
Efficiency

Bharat Bijlee
11/(15)
1450
S1
415
20.5 amp
3 Induction motor
class F
89%

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Condensate extraction pump

26.4.4

10/09/12 6:00 PM

Centrifuge Materials

Bowl spindle
Frame, lower and upper parts
Collecting cover
Bowl body, hood, and disc, Stack, gravity disc.
Sludge basket
Other bowl parts

27.1HP Flash tank

27

Steel
Cast Iron
Aluminum
Stainless steel
Stainless steel
Tinned steel, bronze, brass

FLASH TANKS

(1230-001-03-BH-PVM-B008)

Design & Const. Code

ASME B & PV Code section
VIII Div. N-1, 2001
Design Pr.
3.5 KSC & full vacuum
Design Temp.
210C
Hydraulic test Pressure
5.25 Ksc 30 min.
Joint efficiency
0.7
Dry. Wt/flooded wt
7250/35400 Kg
Weight of tank with water
up to NWL
12050 Kg
27.1.1

Material

Shell & dished end

Nozzle N1, N14
Nozzle N2-10 & 13, 15, 16
Plate/SA 106 Gr. B
Nozzle NIL
Support
Holding down bolt (M 30 X 120LG)
Nuts & washer for holding down bolts

Steel Plate/SA 516 Gr. 60

Steel Plate/SA 516 Gr. 60
Seam less Carbon St.
Alloy steel/SA 335 Gr. P22
angle/IS 2062 Gr. A
Steel Bar/4.6
Steel Bar/4.0

27.2Steam drain flash tank

(1230-001-03-BH-PVM-B005)

Design & Const. Code

ASME B & PV Code section

VIII Div. N-1, 2001
Design Pr.
3.5 KSC & full vacuum
Design Temp.
210C
Hydraulic test Pressure
5.25 Ksc 30 min.
Joint efficiency
0.7
Dry Wt/flooded wt
3700/14300 Kg
Weight of tank with water up to NWL 7850 Kg

27.3Feed water heater safety v/v discharge Flash Tank

(1230-001-03-BH-PVM-B006)

(Same as HPFT)

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Condensate extraction pump

10/09/12 6:00 PM

Design & Const. Code

VIII Div. N-1, 2001
Design Pr.
Design Temp.
Hydraulic test Pressure
Joint efficiency
Dry/Flooded weight
Wt of tank with water up to NWL

28

ASME B & PV Code section

3.5 KSC & full vacuum
210C
5.25 Ksc 30 min.
0.7
1800/4500 Kg
2500 Kg

EQUIPMENT COOLING WATER SYSTEM

28.1ECW tank (TG)

(1230-001-03-BH-PVM-B015)

Design Code
Design Pr
Design temp.
Operating Pr.
Storage medium
Capacity of tank
Empty wt
Wt flooded/tank
Normal water level (NWL)
Low (L)
Low- Low (LL)
High (H)
Over flow

ASME Sec-VIII Div.-1, 2001

atm
70C
Static
cooling water
10m3
6.8 Ton
27.45 ton
200 mm above GCL
400 mm below GCL
575 mm below GCL
720 mm above GCL
870 mm above GCL

28.2Equipment cooling water pump

28.2.1

ECW (SG)

Make
Model
Sl no
Flow (m3/hr)
Head
(m)
Speed (rpm)
28.2.2

VOLTAS-thane
H300M2
05/02/2047/A2/A3
1400
60
1484

ECW (TG)

Make
Model
Sl no
Flow (m3/hr)
Head
(m)
Speed (rpm)

VOLTAS-thane
H350L1
05/02/2046/A8
1500
35
1484

28.3Plate heat exchanger

28.3.1

TG

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Condensate extraction pump

10/09/12 6:00 PM

A
B
S.No.
30107-79-533 30107-79-535 30107-79-534
Type
M-30FG
M-30FG
0
Maximum work temperature
60 C
600C
Design pressure (Ksc)
10
10
28.3.2

SG
A

B
30107-79-537
M-30FG
0
60 C
10

S.No.
Type
Maximum work temperature
Design pressure (Ksc)

29

M-30FG
600C
10

30107-79-536
M-30FG
0
60 C
10

AUXILIARY COOLING WATER SYSTEM

29.1Auxiliary cooling water pump

A

Flow (m3/hr) 2350

Head
(m)
Speed (rpm)
988

C
2350

2350

15

15
988

15
988

29.2GA & Cross Section self cleaning strainer (SCS)

Ref no G1-1252-201-02-006

29.2.1
Design Data
Design Code
Design Temp.
Operating Pressure
Design Pr.
Test Pr.
Design differential Pr. For Screen
Normal Water flow
Max. water flow
Empty weight
Working Weight
Installation position
29.2.2

ASME SEC
60C
3 Ksc
7.0 Ksc
14 Ksc
1.5 Bar
4700 cum /Hr
5640 cum/Hr
2200 Kgs
4600 Kgs
Horizontal

Details of Flushing Pump Skid SCS

Ref no G1-1252-204-02-007

Design code
Design Temp
Operating Pr.
Design Pr.
Test Pr.
Flushing Pump skid weight
Fluid handled
Flushing P/P flow
Flushing P/P Head
Flushing P/P shut off head
Fluid handled

ASME Sec VIII Div-I (latest)

60 C
3 Ksc
7 Ksc
14 Ksc
450 Kgs
clarified water
90m3/hr
15 MWC
17.5 MWC
Clarified water

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Condensate extraction pump

10/09/12 6:00 PM

Pr. Drop across filter

Clean condition
100 mbar
In 50% chocked condition

30
30.1

130 mbar

VACUUM RAISING SYSTEM

Vacuum pump

30.1.1
Pump specification
Type
2BE1353-OZY4-Z (ELMO-F)
No. of PPs
2 X 100 %
Pump rated speed
590 RPM
No. of stage
01
Operating liquid Water at
15-0C temps.
Direction of rotation
(facing DE shaft End) Clock wise
Starting moment of Inertia
37 KgM2
30.1.2
Make
Type

Motor specification

Power rating
Voltage
Current Rating

30.2

Siemens (Germany)
11A8 317-3ZZ 90-Z315
(Squirrel Cage Cont. Rating)
135 KW
415 V
255 Amp

Recirculating pump

30.2.1
Type
Capacity
Delivery

Pump specification

30.2.2

Motor specification

LM 65-200
M3/Hr.

33.1
Head 12.9 M

Make
Type
Power
Voltage
Speed
30.2.3

Siemens
Rotary Current Motor
2.2 KW
415 V
1400 RPM
Material

Pump casing
Shaft & Impeller

30.3

Cast Iron GG 20
S.S

Separator tank
Type
Make

Abscheider

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Condensate extraction pump

10/09/12 6:00 PM

Froling
Vol. Of Tank
Max. Allowable Working Pr.
Test Pr.
Max. Working Temp.

1500 Ltr
1.05 bar
2.6 bar
60 oC

31

PRIMARY WATER SYSTEM

31.1Primary water Pump

Pump-1
MKF 12 AP 001
Make
Model
SL no
Flow (m3/hr)
NPSH (m)
Speed rpm
Head (m)
N (kw)

Pump-2
MKF 12 AP 001
sulzer pump India
07 65-250
103685-01
70

sulzer pump India

07 65-250
10368-04
70

2
2950

2
2950
80

80

23.37

23.37

31.2Primary water filter

Make
Type
Fab no
Size
Year

32.1

Boll & kirch

1.53.1.270.750 DN 100
3759040/3A
150 m
2003

PTCW SYSTEM

Boll & kirch

1.53.1.270.750 DN100
3759040/3B
150 m
2003

32 OFF SITE AREAS

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Condensate extraction pump

32.1.1

Raw water transfer pump

Make
Type
Nos
Capacity (Cu m/hr)
Guaranteed Head at rated capacity
Speed (RPM)
Rage of pump operation
Minimum submergence reqd.above edge of
suction bell.
Bearings-pump shaft (4 nos)
Designed life (continuous operation)
Bearings- thrust (1 no), pump DE
Designed life (continuous operation)
Shaft sealing
Coupling -line shaft
Coupling between pump & Motor

32.1.2

Electric motor
Make
Type
Rating
RPM
Full load/No load current
Rated voltage
Voltage variations
Frequency variations
Combined voltage & frequency variations.
Direction of rotation (viewed from DE)
Power factor

32.1.3

10/09/12 6:00 PM

Mather & platt pump.

Vertical turbine, single stage.
3(2 working & 1 standby)
Normal 2750 Cu M/hr
Maximum 3300 Cu M/hr
Minimum 825 Cu M/hr
20 MWC
990 rpm
40-120 %
1300 (at rated flow)
1500 (at maximum flow)
Thordon, external forced water
lubricated
20,000 hrs
Spherical roller, self oil cooled
40,000 hrs
Gland packing(braided Teflon
impregnated)
Solid muff coupling (3 nos)
Flexible (Pin & Bush type)

ABB-India
Squirrel cage induction motor,
fan cooled.
200 KW
990
343/125 A
415 V
10 %
5%
10 %
Bi-directional

Bearings (2 no)

0.85 (Full load), 0.5 (No load)

0.125(starting)
Ball type,FAG/SKF, self
lubricated, Lithium based
grease.

Guaranteed life in hours

30,000 hrs.

Booster pump (For Raw water pump lubrication)

Make
Mather & platt pump
Type
End suction, radially split
Nos
Capacity
Guaranteed Head at rated capacity
Speed (RPM)
Range of pump operation
Bearings

casing. (Axial entry radial

discharge)
6( 3 working & 3 standby)
3.5 M3/hr
40 MWC
2830

40-120 %
Ball type, 2 Nos (DE & NDE)

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Condensate extraction pump

Designed life (continuous operation)

Coupling between pump & Motor
Shaft sealing

32.1.4

32.1.5

10/09/12 6:00 PM

grease lubricated, circulating

air-cooled.
40,000 hrs
Spacer type Pin bush
Gland packing Teflon
impregnated white
asbestos,TIWA)

Electric motor- Raw water booster pump

Make
ABB-India
Type
Squirrel cage induction motor,
fan cooled.
Rating
3.7 KW
Speed (RPM)
2830
Full load/No load current
7.2/3.4 A
Rated voltage
415 V
Voltage variations (Volts)
Frequency variations (Hz)
Combined voltage & frequency variations.
Direction of rotation (viewed from DE)

10 %
5%
10 %
Bi-directional

Power factor
Bearings (___no)

0.87 (Full load), 0.5 (No load)

0.12(starting)
Ball type, FAG/SKF, selflubricated, Lithium based
grease.

Guaranteed life in hours

30,000 hrs.

Reactor clarifier
Type & manufacturer
Number
Design output (each)
Size
Effluent turbidity
Retention time at rated capacity (in
clarification zone)
Mean velocity of flow (at rated capacity)
Cu.m/sq. m/hr
Turbine in reaction zone
Number
Speed of rotation of turbine
Turbine drive
Rake drive turbine motor

Solid contact type reactor

clarifier; EIMCO-KCP
2
2600 Cu. M/Hr.
35 m dia x 4.9 SWD
Less than 10 NTU
90 minutes
3.0 Cu.m/sq.m/hr
One
4 feet /sec (Max)
7.5 Kw
0.75 Kw

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Condensate extraction pump

32.1.6

32.1.6.1

CLARIFIED WATER SYSTEM

Clarified water transfer pump

Make
Model
Type

Mather & Platt pump.

400/500 AST
Horizontal split casing, axial
suction & axial discharge

Nos
NPSH reqd
Rated Capacity (Cu m/hr)
Guaranteed Head at rated capacity
Speed (RPM)
Rage of pump operation
Bearings-pump shaft 2 no (thrust collar at
pump NDE provided)

3(2 working & 1 standby)

4.2 M
1900 Cu M/hr
18 MWC
988 rpm
40-120 %
Single row deep groove,
grease lubricated, circulating
air-cooled.
40,000 hrs
Gland packing (Teflon
impregnated asbestos)
Flexible Pin & Bush type with
180 mm spacer.

Designed life (continuous operation)

Shaft sealing
Coupling between pump & Motor

32.1.6.2

Electric motorMake
Type
Rating
RPM
Full load/No load current
Rated voltage
Voltage variations
Frequency variations
Combined voltage & frequency variations.
Direction of rotation (viewed from DE)
Power factor

32.2

10/09/12 6:00 PM

ABB-India
Squirrel cage induction
motor, fan cooled.
132 KW
988
228/79 A
415 V
10 %
5%
10 %
Bi-directional

Bearings (2 no)

0.85 (Full load), 0.5 (No load)

0.21(starting)
Ball type, FAG/SKF, selflubricated, Lithium based
grease.

Guaranteed life in hours

30,000 hrs.

FIRE HYDRANT SYSTEM

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Condensate extraction pump

10/09/12 6:00 PM

Pump Main
Make

-- Motor driven (3 nos.)

-- KBL ;horizontal split
casing type
Model
-- UP 150/53
Capacity
-- 410 Cu.m/hr
Head
-- 107 MWC
Speed
-- 1488 (FLS)
Pump Standby -- Diesel driven (1 nos.)
Make
-- KBL ;horizontal split
casing type
Model
-- UP 150/53
Capacity
-- 410 Cu.m/hr
Head
-- 107 MWC
Speed
-- 1500
32.2.1

32.2.2

SPRAY SYSTEM
Pump Main
-- Motor driven (1nos.)
Make
-- KBL ; horizontal split
casing type
Model
-- UP 150/53
Capacity
-- 410 Cu.m/hr
Head
-- 107 MWC
Speed
-- 1488 (FLS)
Pump Standby -- Diesel driven (1 nos.)
Make
-- KBL ;horizontal split
casing type
Model
-- UP 150/53
Capacity
-- 410 Cu.m/hr
Head
-- 107 MWC
Speed
-- 1500

-- Crompton Greaves
-- SQ.CG- TEFC
-- ND 315L
-- 190 Kw (HT motor)
-- 1488(FLS)

Motor
Type
Frame
Rating
RPM

-- Cummins India Ltd.

-- Compression ignition
-- NT 743 F1
-- 255 HP
-- 1500

Motor
Type
Frame
Rating
RPM

-- Crompton Greaves
-- SQ.CG- TEFC
-- ND 315L
-- 190 Kw (HT motor)
-- 1488(FLS)

Motor
Type
Frame
Rating
RPM

-- Cummins India Ltd.

-- Compression ignition
-- NT 743 F1
-- 255 HP
-- 1500

Motor
Type
Frame
Rating
RPM

-- Crompton Greaves
-- SQ.CG- TEFC
-- ND 200L
-- 30 Kw
-- 2900

Motor
Type
Frame
Rating
RPM

-- Crompton Greaves
-- SQ.CG- TEFC
-- ND 225S
-- 33 Kw
-- 1450

JOCKEY PUMP

Pump Standby -- Motor driven (2 nos.)

Make
-- KBL ;horizontal split
casing type
Model
-- CPHM 50-32
Capacity
-- 40 Cu.m/hr
Head
-- 107 MWC
Speed
-- 2900

32.2.3

Motor
Type
Frame
Rating
RPM

BOOSTER PUMP HYDRANT LINE

Pump Main
Make
Model
Capacity
Head

-- Motor driven (1nos.)

-- KBL ; horizontal split
casing type
-- UP 100/38
-- 171 Cu.m/hr
-- 45 MWC

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Condensate extraction pump

10/09/12 6:00 PM

Speed
-- 1500
Pump standby -- Diesel driven (1nos.)
Make
-- KBL ; horizontal split
casing type
Model
-- UP 100/38
Capacity
-- 171 Cu.m/hr
Head
-- 45 MWC
Speed
-- 1500

32.2.4

Motor
Type
Frame
Rating
RPM

-- KOEL
-- Compression ignition
-- 4R 1040
-- 42 HP
-- 1500

Motor
Type
Frame
Rating
RPM

-- Crompton Greaves
-- SQ.CG- TEFC
-- ND
-- 7.5 Kw
-- 750

AIR COMPRESSOR ( 2 NO)

Make
Type
Model
Capacity
Pressure

-- INERSOLL RAND
-- Reciprocating
-- 2545D10
-- 40Cu.m/hr
-- 17.6 Ksc

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Page 72 of 72