SIMHADRI

1.0 TURBINE & AUXILIARIES

1.1 MAIN TURBINE
1.1.1 SPECIFICATIONS
(a) Make BHEL
(b) Design KWU, West Germany
(c) Type Three Cylinder Reheat Condensing Turbine.
(d) Stages 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) Direction of Rotation Anti Clockwise (Viewed from front pedestal towards
Generator).
(g) Load
(i) Rated load 500 MW
(ii) MaxM load 524.9 MW (valve wide open condition)

Speed
(i) Rated Speed 50 C/Sec
(ii) MaxmSpeed 51.5 C/Sec ( No Time Limitation)
(iii) Minm Speed 47.5 C/S ( No Time Limitation)
(iv) Speed Exclusion Range (without load) 7 to 47.5 C/Sec
(v) Standard Over Speed Trip Setting 55.5 C/Sec

1.1.1.1 Extraction Valves

(i) Extraction 1 No valve
(ii) Extraction 2 1 check valve with actuator and 1 check
valve without actuator.
(iii) Extraction 3 1 check valve with actuator and 1 check
valve without actuator.
(iv) Extraction 4.1 2 check valves with actuator.
(v) Extraction 4.2 2 check valves with actuator.
(vi) Extraction 5 1 check valve with actuator and 1 check
valve without actuator.
(vii) Extraction 6 No valve.

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1.1.1.2 Steam Pressure And Temperatures (Rated)

Pressure (bar) Temperatures (oC)
Initial steam 166.7 537
Before 1st stage of HPT 154.4 537
HP cylinder exhaust 44.0 336.4
IP cylinder stop valve Inlet 39.6 537
Extraction 6 44.0 336.7
Extraction 5 17.3 412.8
Extraction 4 7.16 290.8
Extraction 3 2.56 185.2
Extraction 2 1.323 126.0
Extraction 1 0.255 65.4
LP cylinder exhaust 0.1026 46.4
1.1.1.3 Turbine Extractions

Extractions Source Going To

1 LPT – 5thstage LPH-1
2 LPT – 3rd stage LPH-2
3 LPT – 2nd stage LPH-3
4 IPT Exhaust Deaerator (4.1) and TDBFP-A/B (4.2)
5 IPT –7th stage HPH – 5A/5B
6 CRH HPH – 6A/6B, TDBFP – A/B

1.1.2 CASING TEMPERATURE LIMITING VALUES

Alarm M/C must be
shut down at
HP turbine casing exhaust 485oC 500oC
Outer casing of LP cylinder 90oC 110oC
(Spray water to L.P. turbine must be switched on at 90oC).
Temperature difference
Between upper & lower casing of HPT. (Middle)  90oC  100oC
IPT Top / Bottom Diff. temp. (Front)  30oC  45oC
IPT Top / Bottom Diff. temp. (Rear)  30oC  45oC
Permissible temperature difference between parallel steam
supply lines
No time limitation 17 oC
Short time period (15 min) 28 oC

1.1.3 FEED HEATER OUT OF SERVICE

Operation with Feed Heater out of service Main Steam flow, Kg/s Load MW
Extraction A6=0 395 500
Extraction A5=0 421 500
Extraction A3=0 423 500
Extraction A2=0 425 500
Extraction A1=0 423 500
Extraction A6 , A5=0 400 526.6

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1.1.4 OUT PUT LIMIT WITH ATT

Out put Limit during the testing with Automatic Turbine Tester
Testing of the Main Steam Stop & Control Valves 400 MW
Testing of the HRH Steam Stop & Control Valves 200 to 500 MW

1.1.5 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 0.3 bar

Electrical Low Vacuum Trip 0.3 bar
Hydraulic Low Vacuum Trip Bypass Operation 0.6 bar

1.1.7 TURBINE SEAL STEAM SYSTEM

(a) Seal steam supply header pr.
(Above Atmospheric) 0.035 bar
(b) Condenser Vacuum 0.1045 ata
(c) Seal Steam Exhauster Fans
Make S.K. System Pvt. Ltd., Sonepat
No. of Fans 2 X 100 %
Speed 2900 RPM
Type SHSH
Motor Make Bharat Bijlee Ltd.
Type ILA 3050-2 (Induction Motor)
Volt 415 V
Connection Delta
Power rating KW

1.1.8 BARRING GEAR

(a) Speed 80 to 120 RPM
(b) Drive Turbine Lub Oil (Hydraulic Turbine)
(c) Cut in / Cut out speed 210 / 240 RPM
(d) Location Front Bearing Pedestal

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1.1.9 TURBOVISORY
1.1.9.1
Alarm Trip

Axial Shift  0.5 mm  1 mm

Differential Expansions
(i) HPT -5.0 to +3.5 mm
(ii) IPT -1.0 to +5.5 mm
Overall Expansion of IP + LP Rotor -3 to + 30 mm
1.1.9.2 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

Bearing Temperatures 90 to 115oC (depending on 130oC

operating temp. of bearing)
Fixed Points
For HP casing Turbine bearing pedestal - 2
For IP casing Turbine bearing pedestal - 2
For LP casing Turbine bearing pedestal - 3
For Turbine Rotor Thrust bearing.

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

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1.1.11 SIZE OF BEARING

1 2 3 4
Diameter (mm) 250 380 450 500

1.1.12 MATERIAL OF CONSTRUCTION

1.1.12.1 Turbine Casings
HP GS17 Cr MOV 515
IP GS22 MO 4
LP St. 37-2N (Outer)

1.1.12.2 Blades (Moving)

HP (First stage) X22 Cr MOV 121
HP (Other stage) X20 Cr 13/X22 Cr MOV 121
IP X20 Cr MO13/X20 Cr 30
LP X20 Cr13

1.1.12.3 Rotors
HP 28 Cr MON I 59
IP 30 Cr MON IV 511
LP 26 Ni Cr. MOV 145

1.1.13 TURBINE LOAD SHARING CAPACITY

HP turbine 26 %
IP turbine 34 %
LP turbine 40 %

1.1.14 HEAT BALANCE DATA

Rating 500 MW 400 MW 300 MW 250 MW
Vacuum (mmHg) 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
Losses
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

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1.2 TURBINE LUB OIL SYSTEM

1.2.1 LUB OIL SPECIFICATIONS

(a) Kinematic viscosity 41.4 – 50 CST at 40 oC,28 CST at 50 oC
(b) Viscosity index Min 98
(c) Flash point 200oC (min.)
(d) Pour point -6oC (max.)
(e) Neutralisation No.(total Acidity No Max. 0.2 mg of KOH per gm of Oil.
(f) Emulsion char 40-40-0 (20 minutes)
(g) Air release capacity 4 minutes (max.)
(h) Rust preventing characteristic 0-B max.
(i) Water content % by wt. 0.01 %
(j) Solid particles content 0.05 % max. by weight.
(k) Foaming tendency at 25oC (Max.) 400 Cm3
(l) Foaming stability (Max.) 450 Sec.
(m) Ash (% by weight) Max. 0.01 %
(n) Particle distribution Min. 17/14 Code.
(o) Specific gravity 0.85 g/cm2 at 50oC
(p) Copper corrosion Not worse than No.1
(q) Water release 300 S (Max.)

1.2.2 MAIN OIL TANK

(a) MOT capacity 25/40 m3
(b) 1st oil filling 47.5 m3
(c) Flushing oil quantity 28.5 m3
(d) Highest oil level from top of tank 750 mm
(e) Lowest oil level from top of tank 750 mm
(f) Filtration particle size
of tank filter element 250 m

1.2.3 OIL REQUIREMENT OF BEARINGS (dM3/S)

(a) Bearing 1 0.8
(b) Bearing 2 15.4
(c) Bearing 3 4.55
(d) Bearing 4 9.29
(e) Gen. bearing Front 7.92
(f) Gen. bearing Rear 7.92
(g) Exciter bearing 0.70
(h) Estimated oil requirement for the 57.4
Hydraulic Barring Gear

1.2.4 DUPLEX OIL FILTER (FOR BRG. OIL SUPPLY HEADER)

(a) Number 2 X 100 %
(b) Type 2.68.2
(c) Size 355 / 750
(d) Make Boll & Kirch
(e) Filtration particle size 37 m

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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 BHEL KSB KSB Tushako Tushako
Type 350 m³/hr ETA-150- ETA-100- T3 SA 38/46 T3 SA 38/46
50VL 33VL
Capacity (dm3/s) 87.48 48 30 1.84 1.84
Disch. Pr. (bar) 8.4 6.7 2.3 178 178
Speed (RPM) 3000 1470 1410 2898 2898
Drive Turbine AC Motor DC Motor AC & DC AC&DC
Motor Motor
MOTOR MAKE - Crompton Crompton Crompton Crompton
Greaves Greaves Greaves Greaves
Voltage (V) - 415V 220V 415V 220V
Motor Power (KW) - 100 13 45 45
Rated Current (Amp.) - 157 97 76 234
DOR from top - Clockwise Clockwise Clockwise Clockwise

1.2.7 LUB OIL COOLERS

(a) Number 2 X 100 %
(b) Cooling Surface Area 640 M2
(c) Oil Flow 186.2 M3/Hr.
(d) Heat Dissipating Capacity 1771 KW
(e) Oil Inlet Temp. 65 oc
(f) Oil Outlet Temp. 45 oc
(g) Oil Side Pr. Drop 4 Mwc
(h) CW Inlet Temp. 38 oc
(i) CW Outlet Temp. 39.7 oc
(j) CW Flow 900 M3
(k) CW Side Pr. Drop 1.0 Mwc
(l) Test Pr. – Oil Side 13.5 Kg/Cm2
(m) Test Pr. – CW Side 15 Kg/Cm2
(n) Tube Material Admiralty Brass
(o) Tube Plates Material Carbon Steel
(p) Casing And Water Boxes Material Carbon Steel

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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.
Type SHSH
Size 10 C1
Speed 2825 RPM
No. of Fans 2x100%
Motor Make Bharat Bijlee Ltd.
Type 1 MJ 3903-2
Voltage 415 V
Power rating 0.75 KW

1.2.10 LEAKAGE OIL PUMP

Location C.F.T. room (T.G. ‘0’m)
No. of PPs. 1x100%
DOR CCW from DE
Discharge Pr. 2.5 kg/cm2
Motor Make Siemens
Rating 0.69 KW
Volt 415 V
Current 1.67 Amps.
Speed 1400 RPM

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1.3 TURBINE CONTROL SYSTEM (Control Fluid System)

1.3.1 FIRE RESISTANT FLUID SPECIFICATION

(a) Flash Point >235oC
(b) Pour Point < -18oC
(c) Neutralisation No. Max. 0.1 mg KOH/g
(d) Ignition temp. >550oC
(e) Air release capacity 5 min. (Max.)
(f) Water content (by weight) < 1000 mg/Kg
(g) Particle distribution 17/14 min code
(h) Foaming tendency at 25oC < 100 ml
(i) Foaming stability 450 Sec. (max.)
(j) Kinematic viscosity (at 40 oc) 41.4 to 50.6 CST
(k) Solid particles content 0.05 % (by weight)
(l) Density (at 15oC) 1250 Kg/m³ (max.)
(m) Oxidation stability 2.0 mg KOH/gm (max.)
(n) Electrical Resistivity >50 MΩm

1.3.2 CONTROL FLUID TANK

(a) Tank capacity 10/16 m3
(b) 1st fluid filling 15 m3
(c) Flushing fluid quantity 10 m3
(d) Highest fluid level from top of tank 650 mm
(e) Lowest fluid level from top of tank 750 mm

1.3.3 REGENERATIVE SYSTEM (C.F. PURIFICATION)

(a) FILTERS (Filters Philipp, France)
Type of Filters Purpose No. of cartridges / type
Dry (F2.6) To take off water 6 throwaway / PD71803C
Fuller Earth (HFB12) Neutralization of acidity 12 throwaway / HT`11800CR
Fine filter(F2.6) Fine filtration and security 6 throwaway / PL71812C

(b) 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) Motor
(ix) Make Siemens (Germany)
(x) Motor Power 0.75KW
(xi) Rated current 1.67 Amps.
(xii) Voltage 415 V

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1.3.4 CONTROL FLUID PUMPS

1.3.4.1 Pump
(a) Number of Pumps 2 x 100 %
(b) Make KSB
(c) Type WKVM80-1 + 3
(d) Discharge pr. 11.5 / 38.5 bar
(e) Fluid flow 12.1 / 9.33 dm3/s
(f) Speed 2975 RPM
(g) Drive A.C. Motor

1.3.4.2 Motor

(h) Make Siemens

(i) Type ILA63162 AC
(j) Voltage 415 V
(k) Motor rating 160 KW
(l) Rated current 256 Amp.
(m) Starting current 1792 Amp
(n) Speed 2975 RPM

Control Fluid Pumps Operating Characteristics

Fluid flow dm³/s Discharge pressure
Operating point I (normal operation)

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 25.1 10.8
control fluid
High pressure leakage fluid 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

1.3.5 C.F. VAP. EXTRACTION FANS

(a) Number of Fan 2 x 100 %
(b) Make (Fan) Pillar (Germany)
(c) Make (Motor) Siemens
(d) Speed 3000 RPM
(e) Current 0.6 Amps.

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1.3.6 CONTROL FLUID COOLER

(a) Number of coolers 2 x 100

(b) Cooling surface area 32 m2
(c) Fluid Flow 43.2 m3/hr.
(d) Heat dissipating capacity 147 KW
(e) Fluid inlet temp. 55 oC
(f) Fluid outlet temp. 49 oC
(g) Fluid side pr. drop 3.5 MWC
(h) CW inlet temp. 38 oC
(i) CW outlet temp. 40.1 oC
(j) CW flow 60 M3/Hr.
(k) CW side pr. drop 2.1 MWC
(l) Design pr. – CW side 10 Kg/Cm2
(m) Test pr. – CW side 15 Kg/Cm2
(n) Design pr. – Fluid side 13 Kg/Cm2
(o) Test press – Fluid side 19.5 Kg/Cm2
(p) Tubes material Stainless steel
(q) Casing (shell) Stainless steel
(r) Water box Carbon steel

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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.) 31.75 x 0.7112 mm x mm

(For Top Row Tubes) 31.75 x 0.889 mm x mm
Tube Material 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 650000 Kg.

(Without LPH-1)

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1.5 CONDENSATE EXTRACTION PUMP

1.5.1 SPECIFICATIONS
Make BHEL – Hyderabad
Type Of First Impeller Double suction
Number Of Stages 6
Design Flow Rate 800 M³/hr.
Inlet – Temperature 49.2oC
Inlet – Specific Gravity 0.988
NPSH Required 3.1 meter (4.2-1%,4.4-0%)
(3% Head Break Down)
Discharge Pressure 275 MLC
Total Dynamic Head 275 Meters
Shut Off Head 390 Meters
Pump Speed 1486 RPM
No. Of Pumps / Model No. 3 (50 % duty) / EN6J40/500
DOR (As Viewed From DE Side) CCW
1.5.2 CONSUMPTION AT DESIGN CONDITION
Power Input At The Motor 763 KW
Losses In The Motor 32 KW
Power Input To The Pump 731 KW
Efficiency Of The Pump Alone 81%
Overall Efficiency Of Pump & Motor 77.6 %
1.5.3 ADDITIONAL DATA
Minimum Condensate Flow For 300 M3/Hr.
Continuous Stable Operation
Suction Strainer Size 400 µ
Axial Fluid Vel. In Eye (M/Sec.) 2.85
Critical Speeds (RPM) 3380, 5798
Sealing Water Requirement
Flow 0.55 M3/Hr.
Pressure 3 to 4 ata
Temperature 48-65 oC
Bearings Radial Bearings Thrust Bearings
Lubrication Condensate Sump Oil
No. Of Brg. 10 nos., 100mm 1
Type Cutless rubber Michell Type 8DN1, Tilting Pad
Design Load --- 2732 kg. , Maxm Load-6038 Kg

1.5.4 MOTOR SPECIFICATION

Make BHEL – Bhopal
Rating 763 KW
Type Induction Motor (Squirrel cage)
Voltage 3.3 KV
Number Of Poles 4
Speed 1489 RPM
Frequency 50 Hz
Starting Current 600 Amps.
Full Load Current 244.0 Amps.
Insulation Class F
Motor Winding Cooling Self Air-Cooled.
Motor Brg. Type Anti Friction
Motor Bearing Lubricated IOC Servo Gem-3/EQV.

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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
Make ABB
Type HX 15 2 S 1421
Rating 3Φ Ind , 415 V , 50 Hz , 6.7 Amp , 3.7 KW , 2885 RPM
Bearing DE-6308 ZZ C3 , NDE-6307 ZZ C3
1.6.2 DRAIN COOLER
Type Straight Tube / Horizontal
Quantity Drain (Kg/Hr.) 155.945
Pressure of Drain (ata) 0.2517
Temp. of Drain (oC) In = 64.7 Out = 51.7
Quantity of Condensate (Kg/Hr.) 1177.636
Pressure of Condensate (Ata) 39
Condensate Inlet Temp. (oC) 46.9
Condensate Outlet Temp. (oC) 48.7
Surface area (M2) 145
Size of tubes OD X Thk ¾” x 20 BWG
Number of tubes 675
Velocity of Condensate (M/Sec.) 21.5
Number of tube side passes 1
Number of shell side zones 1
Design pressure on shell side (Atg) 3 & Full vacuum
Design temp. on shell side (oC) 120
Design pressure on tube side (Atg) 39
Design temp. on tube side (oC) 144
Test pressure on shell side (Atg) 4.5
Test pressure on tube side (Atg) 58.5
Materials
Shell, Channels C.S. SA 516 GR 70
Tube plate & Channel end covers C.S. SA 516 GR 70B
Flanges CS SA 105
Support plate C.S. IS 2062
Tubes S.S. SA TP 304 688
Condensate Inlet / Outlet pipe C.S. SA 106 GR “B”
Drain Inlet / Outlet pipe C.S. SA 106 GR “B”
Weights
Dry Kgs. 5400
Operational Kgs. 7200
Flooded Kgs. 7200

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1.6.3 LP HEATER - Heatr-1 Heater-2 Heater-3

Type U-Tube / U-Tube / U-Tube /
Horizontal Horizontal Horizontal
Quantity of Extraction steam (Kg/Hr.) 295.90 124.08 40.702
Pressure of Extraction steam (Ata) 0.2517 1.30324 2.5174
Temp. of Extraction steam (oC) 64.7 126.7 216
Quantity of Condensate (Kg/Hr.) 1180468 1177.66 1177.66
Pressure of Condensate (Ata) 34 39 32
Condensate Inlet Temp. (oC) 48.4 61.9 103.8
Condensate Outlet Temp. (oC) 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
Design pressure on shell side (Atg) 3 & Full vacuum 3 & Full vacuum 4 & Full vacuum
Design temp. on shell side (oC) 120 155 216
Design pressure on tube side (Atg) 47 39 39
Design temp. on tube side (oC) 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

Materials
Shell, Channels C.S. SA 516 GR 70 C.S. SA 516 GR 70 C.S. SA 516 GR 70

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

Weights
LP Heater dry Kgs. 21500 Kgs. 26000 Kgs. 18000
LP Heater in operation Kgs. 25000 Kgs. 33000 Kgs. 24000
LP Heater flooded Kgs. 37000 Kgs. 43000 Kgs. 31500

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1.7 DEAERATOR & FST

1.7.1 DEAERATOR SPECIFICATION
Design Pressure (Kg/cm2) 9.0
Capacity 170 M³
Design Temperature (oC) 0 / 360
Operating Pressure Kg/cm2(g) 6.8
Operating Temp. (oC) 168.3
Test Pressure (Kg/cm2) 13.5
Condensate inlet Qty. (Kg/Hr.) 1197.64
Number of trays 576
Number of Spray valves 108
Dissolved Oxygen in feed water 0.005
(cc/Ltr)
Materials
Header & Dished End CS SA 516 GR 70
Trays SS SA 240 TP 304
Tray Support SS SA 240 TP 304
Tray removal openings & Internal CS SA 106 GR B
pipes
Packing CAF – 9

1.7.2 FEED WATER STORAGE TANK

1.7.2.1 FST

Design Pressure (Kg/cm2) Full Vacuum & 9.0

Operating Pressure Kg/cm2(g) 6.8
Operating Temperature (oC) 168.3
Test Pressure Kg/cm2(g) 13.5

1.7.2.2 Materials

Storage Tank Shell & Dished End CS SA 516 GR 70

Internal Nozzles CS SA 106 GR B
Cover for Manholes CS SA 105

1.7.2.3 Weights

Storage Tank & Header Dry Kgs. 110000

Storage Tank & Header in operation Kgs. 318000
Storage Tank & Header flooded Kgs. 490000

1.7.3 DEAERATOR SAFETY VALVES

Safety Valve Design Lift Pr Lift Pr Reset Pr
(Kg/Cm2) (Kg/Cm2) (Kg/Cm2)
SV-1 (On FST / DM Plant Side) 9.0 9.15 7.5
SV-2 (On FST) 8.5 8.7 7.0
SV-3 (On FST) 8.0 8.25 6.25
SV-4 (On FST) 9.0 9.25 7.25
SV-5 (On Dea / Turbine Side) 9.0 9.0 7.25
SV-6 (On Dea / Boiler Sie) 8.5 8.5 6.75

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1.8 BOILER FEED PUMP AND AUXILIARIES

1.8.1 BOILER FEED PUMP(MAIN)

1.8.1.1 Specifications
MDBFP TDBFP
Manufacturer BHEL / Hyderabad BHEL / Hyderabad
Model No. FK 4E36 FK 4E36
No. of Pumps 1 X 50% 2 X 50%
No. of Stages 4 + 1 kicker stage 4 + 1 kicker stage
Casing type Outer - Barrel Outer - Barrel
Inner -Radially split. Inner -Radially split.
Direction of Rotation CCW from BP NDE. CW from BP NDE.
Suction temp. oC 164 164
Suction pr. (bar) 26.4 25.7
Discharge pr. (bar) 202.5 202.5
NPSH at 3% head break down (bar) 50 50
Sp. gravity 0.904 0.904
Flow rate (T/Hr.) 990 990
Speed (RPM) 5465 5465
Efficiency (%) 81 81
Power consumption KW 6223 6223
Total dynamic head (M) for pump 2390 2390
Recirculation required for cont. minm flow (T/Hr.) 400 400
Discharge pressure for the kicker stage(bar) 255.02 255.27
Shut off head(M) 3000 3000
1.8.1.2 Bearings
(A) THRUST BEARING

Type Tilting pad (8 + 8 Pads)

Manufacturer Glacier
Size MB269 / 2P / 2P
(B) JOURNAL BEARING
Type Thick Wall Babbit
Manufacturer Glacier
Size 110KBA 080 (for NDE)

1.8.1.3 Mechanical Seal

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

1.8.1.4 Suction Relief Valve

Make BHEL
Size ¾”
Set Pr. 33.0 Kg/Cm2
Cold Set Pr. 33.2 Kg/Cm2
Temperature 163 0C
Capacity 42.5 Ltr/Min
Type ¾” 1990 SW
Back Pr. 2.1 Kg/Cm2

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1.8.2 BOOSTER PUMP

1.8.2.1 Specifications
MDBFP TDBFP
Manufacturer BHEL / Hyderabad BHEL / Hyderabad
Model No. FA1B75 FA1B75
No. of Pumps 1 x 50% 2 x 50%
Casing type Horizontal Horizontal
Direction of rotation (from driver end) CW CCW
Suction temp. (oC) 164 164
Suction pr. (bar) 9.06 8.3
NPSH at (3% head break down) M 4.5 4.5
Discharge pr. (bar) 20.3 20.3
Pump speed RPM 1494 1494
Power consumption, KW 608 608
Efficiency (%) 81.5 81.5

1.8.2.2 Bearings
Journal brg. Thrust brg.
Type Thick Wall Babbit Tilting pad (8 + 8 Pads)
Size 080KSA060 M-8/134/2P-2P
Manufacturer Glacier Glacier

1.8.2.3 Mechanical Seal

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

1.8.2.4 Suction Relief Valve

Make BHEL
Size ¾”
Set Pr. 11.0 Kg/Cm2
Cold Set Pr. 11.1 Kg/Cm2
Temperature 163 0C
Capacity 82.3 Ltr/Min
Type ¾” 1990 SW
Back Pr. 2.1 Kg/Cm2

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1.8.3 BFP DRIVE - MOTOR

1.8.3.1 SPECIFICATIONS
Type Cage Rotor Asynchronous Motor
Manufacturer BHEL, Bhopal
DOR from BP side CCW
Rated voltage 11 KV
Power rating 10 MW
Full Load Current 601.5 Amps.
Starting Current 2720 Amps.
Rated Speed 1500 RPM

1.8.3.2 BEARINGS
Type Sleeve
Lubrication Forced Oil.

1.8.3.3 MOTOR COOLING

Type of Cooler CACW (Circulating Air Circulating Water)
No. of Cooler 2 x 50%
Cooling water required 24 M3/hr.
Cooling water Inlet temp. 38 oC
Cooling water pr. (bar) 6 (Max.)
Outlet temp. of cooling water 43 oC
Temp. of Cold air (Outlet) 50 oC

1.8.4 HYDRAULIC COUPLING FOR MDBFP

Manufacturer M/s. VOITH, Germany
Type Hydrodynamic (Geared variable speed)
R18KGS-14(API)
Journal brg. type Plain
Thrust brg. type Tilting pad
Direction of rotor Input shaft Hydr. circuit Output shaft
CCW CW CCW
Gear ratio U1 109 / 32
U2 68 / 53
Primary speed 5206 RPM
Secondary speed 5102 RPM
Full load slip 2.0 %
Max. output speed 6440 RPM
Regulation range 4:1 downwards
Bearing temp. < 90oC

1.8.5 LUB OIL SYSTEM FOR MDBFP

1.8.5.1 Lubricating Oil Specification
Oil supplier Indian Oil Corporation
Brand name Servo HLP32
Capacity of lube oil tank 2.5 M3
Total lube oil flow rate 300 l/Min.
(for pps, coupling & motor)
Lube oil pr. 2.5 bar
Control oil pr. 3.5 bar
Working oil pr. 2.5 bar (Max.)
Working oil flow rate 1300 l/Min.

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1.8.5.2 Oil Coolers

Working Oil Lub Oil
Type (Make) Shell/Tube (VOITH) Shell/Tube (VOITH)
Model No. LINI 131713-D LINI 091913-D
No. of coolers 2 X 100% 2 X 100%
Oil filling for one heat exchanger 148 L 91 L
Oil flow rate 78 M3/hr. 51 M3/hr.
Oil temp. Inlet to cooler < 95 oC < 65 oC
Oil temp. Outlet of cooler < 58 oC < 50 oC
Cooling Water flow 132.0 M3/hr. 75 M3/hr.
Cooling Water Inlet temp. 38 oC 38 oC
Cooling Water Outlet temp. 48 oC 42 oC
Oil side Pr. drop (bar) 0.54 0.41

1.8.5.3 Lub Oil Pumps

Auxiliary Oil Pp Main Oil Pp
Manufacturer VOITH/Germany VOITH/Germany
Type Gear Centrifuge
No. of PP. One One
Model No. M2P820 2PM600
Pump Drive AC Motor Shaft driven
Rated head (bar) 4.0 4.0
Rated capacity 50 M3/hr. -

1.8.5.4 Lub Oil Requirement In Brgs.

BFP Booster Pp
Journal Thrust Journal Thrust
Oil Flow (M3/hr.) 0.42 13.44 0.3 0.72
Oil pr. (bar) 2.5 2.5 2.5 2.5
Maxm. Bearing temp. (oC) 100 80 80 65

1.8.5.5 Oil Purifier For MDBFP

Make Alfa Laval
Type Portable / MAB 103
Motor Make Bharat Bijli Ltd.

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1.8.6 BFP DRIVE TURBINE

1.8.6.1 Specification
Type K1401-2
Manufacturer BHEL / Hyderabad
MaxM Output 7575 KW
Design.Rating (economical rating) 5732 KW
Turbine normal speed 5275 RPM
Speed range 1494 to 5750 RPM
Specified initial Steam pr. 6.33 Kg/Cm2
Permissible dev. in Static pr. 12.0 Kg/Cm2
MaxM Wheel chamber pr. 11.0 Kg/Cm2
Exhaust steam pr. 0.1064 Kg/Cm2
Specified initial steam temp. 289.6 oC
Permissible deviation without 320.0 oC
limitation
No. of states 14 Nos.
No. of stop valve 1 No.
No. of Aux. C.V. 1 No.
No. of Control valves 5 Nos.
Method of Speed sensing Ferostatic pick up
Overspeed trip 6330 RPM (Electrical)
Critical Speed 7550 RPM
Turning gear speed 150 RPM
Direction of rotation CCW (as viewed from steam admission end / BP NDE)
Governing system Electro Hydraulic (I / H Converters)
Shaft power 5750 KW
Steam consumption 35.792 T/Hr.

1.8.6.2 TDBFP Bearings

Journal Brg. Thrust Brg.
(a) Type 2 Lobed Tilting pad, double acting
(8 + 8 Pads)
(b) Nos. 1 at Front Pedestal Front Pedestal
1 at Rear Pedestal

1.8.6.2 Couplings
Location Type Make
Between Turbine and Main Disconnect coupling FDEL M/s. Zurn Industries
Feed Water Pp Size: 104 Class-I
Between Booster Pp and Gear Box GDN-28 M/s. Waclhand Nagar .I.Ltd
Between Turbine and Gear Box Flexible Gear coupling M/s. Ameri Drives
Size: 101.5 Class-II International

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1.8.7 TDBFP LUB OIL SYSTEM

Oil Brand Name Daphne Super Turbine Oil 46
Oil Supplier Savita Chemicals
Main Oil tank capacity 16.84 M3
Lube oil pr. to brg. 0.9 to 1.3 bar for Journal brg.
0.3 to 1.3 bar for Thrust brg.
Lube oil hdr. pr. (at 17m) 2 to 2.5 bar

1.8.7.1 Lube Oil Coolers

Manufacturer BHEL
No. of coolers 2 X 100%
Type Shell & Tube
Oil flow rate 46.8 M3/hr.
Water flow rate 120 M3/hr.
Oil side pr. drop 2.6 bar
Inlet oil temp. 60 oC
Outlet oil temp. 45 oC

1.8.7.2 Oil Pumps Specification

Aux. Oil PP DC Oil PP Jacking Oil Oil Transfer
Pump
Pump
Number 2 1 1 1

Make M/s.IMO, USA KSB Delta Corp. Delta Corp.

Type Screw Centrifugal Gear (HPG2A) R20-DG

RPKEM50-200
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 Kirloskar Elect. Crompton Crompton

Greaves Company Ltd. Greaves 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 CW from CW from CW from

DE side DE side NDE side DE side

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1.8.7.3 Oil 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.

1.8.7.4 Oil Vapor Extractor Fans

Nos 2 per Pump
Mounting Tank Top
Type Centrifugal , Direct Mounted
Rating 0.37 KW , 2800 RPM
Make 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 Latching Type , Fast Closing
Opening Time 1-2 min
Closing Time 60 mSec
Operating Oil Pr 8 bar
Open / Close Operation Solenoids

1.8.8.3 Main Control Valve (MCV)

No of Valves 5
Controlling Mechanism Bush Groove Depth
Maximum servomotor travel 130 mm
Start of operation 1.5 bar of HP Sec Oil Pr
Full Open Condition 4.5 bar of HP Sec Oil Pr

1.8.8.4 Aux. Control Valve (ACV)

No of Valves 1
Controlling Mechanism Seat Overlap
Maximum servomotor travel 70 mm
Start of operation 1.5 bar of LP Sec Oil Pr
Full Open Condition 4.5 bar of LP Sec Oil Pr

1.8.8.5 Accumulators
No of Accumulators 2 per Pump
Operating Pressure 6.5 bar
Operating point Governing Oil Line
Capacity 35 Ltrs

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1.9 HP HEATERS SPECIFICATION

1.9.1 HP HEATERS 5A / 5B 6A / 6B
Type U-Tube / Horizontal U-Tube / Horizontal
Quantity Extraction steam (Kg/Hr.) 42.53 78940
Pressure of Extraction steam (Ata) 16.88 42.723
Temp. of Extraction steam (oC) 413 335.5
Quantity of Feed Water (Kg/Hr.) 748.075 748.077
Pressure of Feed Water (Ata) 230 226
Feed Water Inlet Temp. (oC) 165.5 203.3
Feed Water Outlet Temp. (oC) 203.3 253.4
Surface area (M2) 1055 1269
Size of tubes OD X Thk 3/4” x 2.7 mm 15.88 x 2.77 mm
Number of Tubes 1347 ‘U’ 1347 ‘U’
Velocity of Feed Water (M/Sec.) 1.99 2.00
Number of tube side passes 2 2
Number of shell side zones 3 3
Design pressure on shell side (Atg) 24 & Full Vacuum 52.4 & Full vacuum
Design temp. on shell side (oC) 224 273
Design pressure on tube side (Atg) 320 320
Design temp. on tube side (oC) 165.5/203.33 273 / 293
Test pressure on shell side (Atg) 36 78.6
Test pressure on tube side (Atg) 480 480
Skirt design. temp. (oC) 455 371
Materials
Shell, Channels SA 387 GR 12 cl.1 C.S. SA 516 GR 70
Tube plate & covers SA 350 LF 2 C.S. SA 688 T P 304
Flanges SA 106 Gr B CS SA 105
Support plate C.S. IS 2062 C.S. IS 2062
Tubes S.S. SA 688 TP 304 S.S. SA 688 TP 304
Condensate Inlet / Outlet nozzles SA 106 Gr B C.S. SA 350 LF 2
Steam inlet nozzle A.S. SA 182 F11 C.S. SA 350 LF 2
Impingement plate S.S. SA 240 TP 304 S.S. SA 240 TP 304
Weights
H.P. Heater dry Kgs. 42250 Kgs. 58050
H.P. Heater in operation Kgs. 49300 Kgs. 62550
H.P. Heater flooded Kgs. 56250 Kgs. 70100
Safety Valve
Make BHEL BHEL
Size 4X6
Set Pr. Kg/Cm2 52.4 Kg/Cm2
Cold Set Pr. Kg/Cm2 53.1 Kg/Cm2
Temperature 0C 230 0C
Capacity Ltr/Min 5414.3 Kg/Hr
Type 1912L
Back Pr. Kg/Cm2 2.1 Kg/Cm2

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1.10 LP DOZING SYSTEM

1.10.1 LP DOZING PUMPS
No. of Pumps 2 Nos. Ammonia dozing Pps.
2 Nos. N2H4 (Hydrazine) dozing Pps.
Type Metering Pump with Diaphragm Heads
Make Metachem Corporation, Bombay
Model MC – 2 / D/R
Capacity 50 LPH
Disch. Pressure 45 Kg/cm2
Hydraulic Fluid SAE 40 oil
Gear Box Oil Servomesh 460 (IOC)

MOTOR SPECIFICATION
Make Crompton Greaves Ltd.
Power rating (KW) 0.75
Current 2.1 Amp.
Voltage 415  10%
Connection Star
Insulation Class – F
Type Three Phase Motor
Speed 1400 RPM
DOR Clockwise from NDE

1.10.2 AGITATORS FOR NH3 & N2H4 DOZING TANKS

No. Of Agitators 1 no. for each tank
Make REMI Process Plant & Machinery Limited, Mumbai.
Type Portable, 10/4
Speed 1400 RPM
Power 1 HP
Motor Make Crompton Greaves Ltd.
Type 3 phase Induction Motor
Voltage 415 V
Current 2.1 Amps.
Speed 1400 rpm
Power Rating 0.75 KW
Brg. Lubrication Lithium II Based Grease.

1.10.3 NH3 TRANSFER PUMP

No. of Pump 2
Make Khimline Pumps Ltd., Thane
Flow rating 2.4 M3/Hr.
Speed 2820 RPM
NPSH 1.8 M
Motor make CGL
Voltage 415 V
Current 2 Amps.
Power Rating 0.75 KW

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1.11 VACUUM RAISING SYSTEM

1.11.1 VACUUM PUMP
Make Siemens AG
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 temp.
Direction of rotation Clock wise
(facing DE shaft End)
Starting moment of Inertia 37 KgM2
Motor Make Siemens (Germany)
Type 11A8 317-3ZZ 90-Z315
(Squirrel Cage Cont. Rating)
Power rating 135 KW
Voltage 415 V
Current Rating 255 Amp

1.11.2 SEPERATOR TANK

Vol. Of Tank 1500 Ltr
Max. Allowable Working Pr. 1.05 bar
Test Pr. 2.6 bar
Max. Working Temp. 60 oC

1.11.3 RECIRCULATING PUMP

Type LM 65-200
Capacity 32 M3/Hr.
Delivery head 12 M
Material - Pump casing Cast Iron GG 20
- Shaft & Impeller S.S.
Motor Make Siemens
Type Rotory Current Motor
Power 2.2 KW
Voltage 415 V
Speed 1400 RPM

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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
Clean oil Tank Dirty oil Tank Unloading Tank
No. Of Tanks 1 No. 1 No. 1 No.
Capacity Of Tanks 60 M3 60 M3 1 M3

1.12.1.2 Oil Transfer Pumps

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

1.12.1.3 Central Oil Purifier

Separator type MAB 2065-24
Max. speed 8423 RPM
Max. Density of feed 1100 Kg/M3
Max. Density of sediments 1600 Kg/M3
Rated capacity 9500 Ltr/Hr
Built on Feed pump suction lift 4 M wg
Delivery head 15 M wg
Delivery head at built in pump outlet 15 to 25 M
Running up / Stopping time 1.2 to 2 min. / 3 minutes with brake applied
Heater
Type Indirect
Voltage 415 V
Power 120 KW
Make Cosmos Engrs., Pune

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1.13 HP Bypass System

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 250 Ltr

Supply Units
Annual Consumption 275 Ltr
(Including Initial Filling)
Oil Brand Name 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
Design Pr. Kg/Cm2 321 321 187.6/53.4
Design Temp. OC 185 185 540 / 500

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