CFAS Enterprises Inc.
After Market Utility Power Equipment Brokerage
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GTG_1627GR_Fm6CC_50Hz.doc
GEC Fm6 35Mw Simple Cycle 11Kv Diesel OR 50 MW Combined Cycle Plant
Asking Price:
Fuel:
Voltage:
Frequency:
Simple Cycle US $6MM as is.
Combined Cycle US $ 9.75MM as is
Diesel
11.500 KV
50 Hz
Page 2 of 130
Page 3 of 130
INDEX
PROJECT OVERVIEW
1.
14
PROJECT OVERVIEW
14
1.1.
SITE CONDITIONS AND CLIMATOLOGICAL DATA ............................................... 14
1.2.
FUEL ANALYSIS ...................................................................................................... 14
1.2.1. NAPHTHA ANALYSIS ......................................................................................... 14
1.2.2. ANALYSIS OF HSD (TYPICAL) ........................................................................... 15
1.3.
PROJECT MILESTONES .......................................................................................... 15
1.3.1. OPEN CYCLE ...................................................................................................... 15
1.3.2. COMBINED CYCLE ............................................................................................. 16
1.3.3. AUXILIARY SYSTEMS - COMBINED CYCLE ..................................................... 16
MECHANICAL
1.
17
GAS TURBINE GENERATOR
17
1.1.
GENERAL ................................................................................................................. 17
1.1.1. SPECIFICATION ................................................................................................. 17
1.1.2. GAS TURBINE RATING (GUARANTEED) .......................................................... 17
1.2.
COMPRESSOR SECTION ........................................................................................ 17
1.3.
TURBINE................................................................................................................... 18
1.3.1. TURBINE SECTION ............................................................................................ 18
1.3.2. COMBUSTION SYSTEM ..................................................................................... 18
1.3.3. BEARING ASSEMBLY ......................................................................................... 18
1.4.
STARTING SYSTEM ................................................................................................. 18
1.5.
FUEL SYSTEM.......................................................................................................... 18
1.5.1. FUEL PUMP ........................................................................................................ 18
1.5.2. FLOW DIVIDER ................................................................................................... 19
1.5.3. HITEC DOSING SYSTEM.................................................................................... 19
1.6.
LUBRICATION SYSTEM .......................................................................................... 19
1.6.1. LUBE OIL COOLER ............................................................................................. 19
1.6.2. FILTER (LUBE OIL) ............................................................................................. 20
1.7.
HYDRAULIC SUPPLY SYSTEM ............................................................................... 20
1.7.1. HYDRAULIC SUPPLY FILTERS .......................................................................... 20
1.7.2. CONTROL OIL FILTERS ..................................................................................... 20
1.8.
COMPRESSOR WASH SYSTEM.............................................................................. 20
1.8.1. DETERGENT PUMP............................................................................................ 20
1.8.2. DM WATER PUMP .............................................................................................. 20
1.9.
INLET AIR FILTER .................................................................................................... 21
1.10. ATOMIZING AIR SYSTEM ........................................................................................ 21
1.11. OIL MIST SEPERATOR ............................................................................................ 21
1.12. GENERATOR ............................................................................................................ 22
1.12.1. LOAD GEAR ........................................................................................................ 22
1.13. FIN FAN COOLER .................................................................................................... 22
1.13.1. PERFORMANCE DATA ....................................................................................... 22
1.13.2. HEAT EXCHANGER ............................................................................................ 23
1.13.3. FANS ................................................................................................................... 23
1.14. NOX CONTROL SYTEM ........................................................................................... 23
1.14.1. GENERAL............................................................................................................ 23
1.14.2. GUARANTEED PERFORMANCE........................................................................ 23
1.14.3. DESIGN & CONSTRUCTION FEATURE ............................................................. 23
Page 4 of 130
2.
GT EXHAUST SYSTEM
24
2.1.
GENERAL ................................................................................................................. 24
2.2.
PROCESS DESIGN DATA ........................................................................................ 24
2.3.
THERMAL DESIGN DATA ........................................................................................ 24
2.4.
GT EXHAUST DIVERTER & GUILLOTINE DAMPER............................................... 24
2.4.1. DIVERTER DAMPER........................................................................................... 24
2.4.2. GUILLOTINE DAMPER ....................................................................................... 24
2.4.3. EXPANSION JOINT ............................................................................................. 25
2.4.4. BYPASS STACK.................................................................................................. 25
2.4.5. BYPASS STACK SILENCER ............................................................................... 25
2.4.6. SEAL AIR FAN (DIVERTER DAMPER) ............................................................... 25
2.4.7. SEAL AIR FAN (GUILLOTINE DAMPER) ............................................................ 25
3.
HRSG AND AUXILIARIES
26
3.1.
HEAT RECOVERY STEAM GENERATOR ............................................................... 26
3.1.1. GENERAL............................................................................................................ 26
3.1.2. DESIGN CONDITION OF GT EXHAUST GAS DETAILS..................................... 26
3.1.3. MAXIMUM CONTINUOUS RATING IN UNFIRED MODE .................................... 26
3.1.4. MAXIMUM CONTINUOUS RATING IN AUXILIARY FIRED MODE ..................... 27
3.2.
HRSG COMBUSTION SYSTEM ............................................................................... 27
3.2.1. BURNER.............................................................................................................. 27
3.2.2. SCANNER & AUXILIARY COOLING FANS ......................................................... 28
3.2.3. NAPHTHA BOOSTER PUMP .............................................................................. 29
3.2.4. NAPHTHA FILTER .............................................................................................. 30
3.2.5. NAPHTHA COOLERS ......................................................................................... 30
3.3.
HRSG - AIR SYSTEM FOR AUXILIARY FIRING ...................................................... 31
3.3.1. FD FAN ................................................................................................................ 31
3.3.2. FD FAN MOTOR.................................................................................................. 31
3.3.3. FD FAN SUCTION FILTER .................................................................................. 32
3.3.4. MULTILOUVER DAMPER ................................................................................... 32
3.4.
HP / LP STEAM SYSTEM ......................................................................................... 33
3.4.1. HP RECIRCULATION PUMP............................................................................... 33
3.4.2. LP RECIRCULATION PUMP ............................................................................... 34
3.4.3. HP BOILER ASSEMBLY ...................................................................................... 35
3.4.4. LP BOILER ASSEMBLY ...................................................................................... 35
3.4.5. SAFETY VALVE SETTING VALUES ................................................................... 35
3.4.6. HRSG DESUPERHEATER .................................................................................. 36
3.5.
BOILER BLOWDOWN SYSTEM .............................................................................. 36
3.5.1. CONTINUOUS BLOW DOWN (CBD) TANK ....................................................... 36
3.5.2. INTERMITTENT BLOW DOWN (IBD) TANK....................................................... 36
3.5.3. BLOWDOWN COOLER ....................................................................................... 37
3.6.
PHOSPHATE DOSING SYSTEM .............................................................................. 37
3.6.1. DOSING PUMPS ................................................................................................. 37
3.6.2. TANKS ................................................................................................................. 37
3.6.3. AGITATOR .......................................................................................................... 37
4.
HRSG FEED WATER SYSTEM
38
4.1.
DEAERATOR ............................................................................................................ 38
4.1.1. NORMAL OPERATING CONDITIONS ................................................................ 38
4.1.2. MAX. OPERATING CONDITIONS ...................................................................... 38
4.1.3. CONSTRUCTION DETAILS ................................................................................ 38
4.2.
HP BOILER FEED PUMP ......................................................................................... 38
4.2.1. POWER CONSUMPTION .................................................................................... 39
4.2.2. COOLING WATER REQUIREMENTS ................................................................. 39
Page 5 of 130
4.2.3. COUPLING .......................................................................................................... 39
4.3.
HP BFP MOTOR ....................................................................................................... 39
4.4.
BFP SUCTION STRAINER ....................................................................................... 40
4.5.
LP BOILER FEED PUMP .......................................................................................... 40
4.5.1. POWER CONSUMPTION .................................................................................... 40
4.5.2. COOLING WATER REQUIREMENTS ................................................................. 40
4.5.3. COUPLING .......................................................................................................... 41
4.6.
LP BFP MOTOR........................................................................................................ 41
4.7.
BFP SUCTION STRAINER ....................................................................................... 41
5.
CONDENSATE SYSTEM
41
5.1.
CONDENSATE EXTRACTION PUMP ...................................................................... 41
5.2.
CEP MOTOR ............................................................................................................. 42
5.3.
STRAINER ................................................................................................................ 43
5.4.
CONDENSATE STORAGE TANK ............................................................................ 43
5.5.
STEAM JET AIR EJECTOR ...................................................................................... 43
5.5.1. MAIN EJECTOR .................................................................................................. 43
5.5.2. HOGGING EJECTOR .......................................................................................... 43
6.
STEAM TURBINE GENERATOR & ACCESSORIES
44
6.1.
STEAM TURBINE ..................................................................................................... 44
6.1.1. GENERAL............................................................................................................ 44
6.1.2. DESIGN & PERFORMANCE DATA ..................................................................... 44
6.1.3. GLAND SEAL SYSTEM ....................................................................................... 45
6.1.4. HYDRAULIC CONTROL OIL SYSTEM ................................................................ 46
6.1.5. LUBRICATING OIL SYSTEM............................................................................... 46
6.1.6. NOISE HOOD (ACOUSTIC ENCLOSURE) ......................................................... 48
6.1.7. STEAM TURBINE PROTECTION SYSTEM ........................................................ 49
6.2.
STEAM TURBINE GENERATOR .............................................................................. 49
6.2.1. GENERATOR PROTECTION RELAY PANEL ..................................................... 50
6.2.2. GENERATOR EXCITATION SYSTEM ................................................................ 52
6.2.3. LA, SC, PT, CT CUBICLE .................................................................................... 53
6.2.4. NEUTRAL GROUNDING CUBICLE ..................................................................... 54
6.3.
TURBINE OIL PURIFICATION SYSTEM .................................................................. 56
6.3.1. CENTRIFUGE...................................................................................................... 56
6.3.2. FEED PUMP ........................................................................................................ 56
6.3.3. DISCHARGE PUMP ............................................................................................ 56
6.3.4. HEATER .............................................................................................................. 57
6.3.5. POLISHING FILTER ............................................................................................ 57
6.3.6. TURBINE LUBE OIL COLLECTION TANK .......................................................... 57
7.
LIQUID FUEL SYSTEM
57
7.1.
NAPHTHA STORAGE AND HANDLING SYSTEM ................................................... 57
7.1.1. NAPHTHA FORWARDING PUMPS ..................................................................... 57
7.1.2. NAPHTHA UNLOADING PUMP .......................................................................... 58
7.1.3. NAPHTHA STORAGE TANK ............................................................................... 58
7.2.
HSD STORAGE AND HANDLING SYSTEM ............................................................. 58
7.2.1. HSD FORWARDING PUMP ................................................................................ 58
7.2.2. HSD UNLOADING PUMP .................................................................................... 59
7.2.3. HSD STORAGE TANK ........................................................................................ 59
7.2.4. CENTRIFUGE...................................................................................................... 59
8.
DM WATER SYSTEM
60
8.1.
GENERAL ................................................................................................................. 60
8.2.
DM PLANT DESAL WATER SUPPLY PUMP (PAW PUMPS) .................................. 60
Page 6 of 130
8.3.
8.4.
8.5.
8.6.
8.7.
8.8.
8.9.
8.10.
8.11.
8.12.
8.13.
9.
EFFLUENT DISPOSAL PUMPS ............................................................................... 61
ACID / ALKALI UNLOADING CUM TRANSFER PUMPS ......................................... 61
DM WATER TRANSFER PUMP ............................................................................... 61
BLOWERS ................................................................................................................ 62
DM WATER PUMPS FOR REGENERATION............................................................ 62
MIXED BED EXCHANGER ....................................................................................... 62
ACID STORAGE TANK ............................................................................................ 62
ACID MEASURING TANK ........................................................................................ 63
ALKALI STORAGE TANK ........................................................................................ 63
ALKALI MEASURING TANK .................................................................................... 63
DM WATER TANK .................................................................................................... 63
COOLING WATER SYSTEM
63
9.1.
COOLING WATER PUMPS ...................................................................................... 63
9.2.
CONDENSER ............................................................................................................ 64
9.3.
INDUCED DRAFT COOLING TOWERS ................................................................... 65
9.3.1. FAN ..................................................................................................................... 65
9.3.2. FAN MOTOR ....................................................................................................... 65
9.4.
PLATE HEAT EXCHANGER..................................................................................... 66
9.5.
SEA WATER INTAKE PUMPS ................................................................................. 66
9.6.
CW PIPING ............................................................................................................... 67
9.7.
SEA WATER RETURN PIPING ................................................................................ 67
9.8.
SEA WATER INTAKE PIPING .................................................................................. 68
9.9.
STRAINERS .............................................................................................................. 68
10. EQUIPMENT COOLING WATER SYSTEM
69
10.1. ECW PUMP ............................................................................................................... 69
10.2. ECW MAKE UP TANK .............................................................................................. 69
10.3. LUBE OIL COOLERS ............................................................................................... 69
10.4. GENERATOR HEAT EXCHANGER.......................................................................... 69
11. CW CHLORINATION SYSTEM
ERROR! BOOKMARK NOT DEFINED.
11.1. BOOSTER PUMPS .......................................... ERROR! BOOKMARK NOT DEFINED.
11.2. CHLORINATOR ............................................... ERROR! BOOKMARK NOT DEFINED.
11.3. CHLORINE ANALYSER .................................. ERROR! BOOKMARK NOT DEFINED.
11.4. VACUUM REGULATOR & CHECK UNIT ........ ERROR! BOOKMARK NOT DEFINED.
11.5. TONNER .......................................................... ERROR! BOOKMARK NOT DEFINED.
11.6. INJECTOR ....................................................... ERROR! BOOKMARK NOT DEFINED.
11.7. CHLORINE GAS FILTER ................................. ERROR! BOOKMARK NOT DEFINED.
11.8. BLOWER.......................................................... ERROR! BOOKMARK NOT DEFINED.
11.9. GAS LEAK DETECTER ................................... ERROR! BOOKMARK NOT DEFINED.
11.10. GAS FEEDER .................................................. ERROR! BOOKMARK NOT DEFINED.
11.11. CHLORINATOR FOR SEA WATER INTAKE CHLORINATION.ERROR! BOOKMARK
NOT DEFINED.
12. CW ACID DOSING SYSTEM
ERROR! BOOKMARK NOT DEFINED.
12.1. DOSING PUMPS .............................................. ERROR! BOOKMARK NOT DEFINED.
12.2. ACID UNLOADING PUMP ............................... ERROR! BOOKMARK NOT DEFINED.
12.3. MEASURING TANKS....................................... ERROR! BOOKMARK NOT DEFINED.
13. HP / LP DOSING SYSTEM
70
13.1. HP DOSING SYSTEM ............................................................................................... 70
13.1.1. DOSING PUMP ................................................................................................... 70
13.1.2. SOLUTION PREPARATION AND FORWARDING TANK .................................... 70
13.1.3. AGITATOR .......................................................................................................... 71
Page 7 of 130
13.2. LP DOSING SYSTEM ............................................................................................... 71
13.2.1. DOSING PUMPS ................................................................................................. 71
13.2.2. AGITATORS ........................................................................................................ 71
13.2.3. MEASURING TANKS .......................................................................................... 72
14. SERVICE & POTABLE WATER SYSTEM
72
14.1. SERVICE & POTABLE WATER TANK ..................................................................... 72
14.2. SYNTEX MAKE TANKS ............................................................................................ 72
14.3. SERVICE & POTABLE WATER PUMPS .................................................................. 73
15. COMPRESSED AIR SYSTEM
73
15.1. AIR COMPRESSOR .................................................................................................. 73
15.2. INLET AIR FILTER .................................................................................................... 74
15.3. INTER COOLER AND AFTER COOLER .................................................................. 74
15.4. MOISTURE SEPARATOR ........................................................................................ 75
15.5. AIR RECEIVER ......................................................................................................... 75
15.6. AIR DRYER ............................................................................................................... 75
16. FIRE DETECTION & PROTECTION SYSTEM
75
16.1. HYDRANT PUMP ...................................................................................................... 76
16.2. SPRAY PUMPS......................................................................................................... 76
16.2.1. HVW SPRAY SYSTEM ...................................................................................... 76
16.2.2. HVW SPRAY PUMP ............................................................................................ 76
16.2.3. MVW SPRAY SYSTEM ..................................................................................... 76
16.2.4. MVW SPRAY PUMP ............................................................................................ 77
16.2.5. MVW SPRAY PUMP (DG OPERATED) ............................................................... 77
16.3. JOCKEY PUMP......................................................................................................... 77
16.4. FIRE FIGHTING & GAS DETECTION SYSTEM FOR GAS TURBINE ..................... 77
16.5. FIRE ALARM SYSTEM ............................................................................................. 78
17. AC & VENTILATION SYSTEM
78
17.1. GENERAL ................................................................................................................. 78
17.2. RECIPROCATING (SEMI HERMATIC TYPE) COMPRESSOR ................................ 78
17.3. SHELL & TUBE TYPE CONDENSER ....................................................................... 78
17.4. AIR HANDLING UNIT ............................................................................................... 78
17.5. HORIZONTAL END SUCTION TYPE, CF CW PUMP ............................................... 79
17.6. INDUCED DRAFT FRP COOLING TOWER .............................................................. 79
17.7. CF BLOWER (VENTILATION SYSTEM)................................................................... 79
18. MISCELLANEOUS HOISTS & CRANE
79
18.1. SINGLE GIRDER EOT CRANE (NAPHTHA PUMP HOUSE) ................................... 79
18.2. ELECTRIC WIRE ROPE HOIST ................................................................................ 80
18.3. ELECTRIC WIRE ROPE HOIST FOR S/G CRANE ................................................... 80
18.4. MANUAL HOIST WITH TROLLEY ............................................................................ 80
18.5. TURBINE HALL EOT CRANE (15/3T D/G EOT CRANE) ......................................... 81
18.6. SINGLE GIRDER SEMI EOT CRANE (BFP AREA) .................................................. 82
18.6.1. HOIST .................................................................................................................. 82
ELECTRICAL
1.
83
GENERATOR TRANSFORMER (40/50 MVA)
83
1.1.
GENERAL ................................................................................................................. 83
1.2.
TYPE OF COOLING .................................................................................................. 83
1.3.
TAP CHANGING EQUIPMENT ................................................................................. 83
1.4.
INSULATION LEVEL ................................................................................................ 84
Page 8 of 130
1.5.
1.6.
1.7.
BUSHINGS................................................................................................................ 84
BUSHING CT ............................................................................................................ 84
TRANSFORMER OIL ................................................................................................ 85
2.
220 KV SWITCH YARD EQUIPMENT (OPEN CYCLE)
85
2.1.
GENERAL ................................................................................................................. 85
2.2.
CIRCUIT BREAKER ................................................................................................. 85
2.3.
ISOLATORS .............................................................................................................. 85
2.4.
GROUND SWITCHES ............................................................................................... 85
2.5.
INSTRUMENT TRANSFORMERS ............................................................................ 85
2.5.1. CURRENT TRANSFORMERS ............................................................................. 85
2.5.2. VOLTAGE TRANSFORMERS ............................................................................. 86
2.6.
LIGHTNING ARRESTERS ........................................................................................ 86
2.7.
RELAY & CONTROL PANEL ................................................................................... 86
2.7.1. IMPORTANT RELAYS ......................................................................................... 86
3.
220 KV SWITCHYARD EQUIPMENT (COMBINED CYCLE)
86
3.1.
GENERAL ................................................................................................................. 86
3.2.
CIRCUIT BREAKER ................................................................................................. 87
3.3.
ISOLATOR ................................................................................................................ 87
3.3.1. GENERAL............................................................................................................ 87
3.3.2. EARTHING SWITCH (NOT PROVIDED FOR BUS ISOLATOR) .......................... 87
3.4.
CURRENT TRANSFORMER..................................................................................... 88
3.5.
ELECTROMAGNETIC VOLTAGE TRANSFORMER (EVT) ...................................... 88
3.6.
CONTROL AND RELAY PANEL .............................................................................. 88
3.6.1. SYSTEM PARTICULARS .................................................................................... 88
3.6.2. CONTROL AND RELAY PANEL .......................................................................... 89
3.6.3. IMPORTANT RELAYS ......................................................................................... 89
3.7.
LIGHTNING ARRESTER .......................................................................................... 89
3.8.
PLCC EQUIPMENT ................................................................................................... 90
3.9.
REMOTE SYNCHRONISING PANEL ....................................................................... 90
4.
STATION LIGHTING
90
4.1.
ILLUMINATION LEVELS AND TYPES OF LUMINAIRE........................................... 91
4.2.
TECHNICAL DATA FOR STATION LIGHTING ........................................................ 92
4.2.1. SYSTEM DESIGN DATA ..................................................................................... 92
4.2.2. LUMINAIRES, LAMPS AND ACCESSORIES ...................................................... 92
4.2.3. DESIGN PARAMETERS OF MAIN EQUIPMENT ................................................ 92
OPEN CYCLE POWER PLANT
93
5.
STATION AUXILIARY TRANSFORMER & LT TRANSFORMER
94
5.1.
2 MVA TRANSFORMER ........................................................................................... 94
5.2.
500 KVA TRANSFORMER........................................................................................ 94
6.
415V SWITCH GEAR (PCC) & LV BUS-DUCT
95
6.1.
415V SWITCH GEAR (PCC) ..................................................................................... 95
6.1.1. GENERAL............................................................................................................ 95
6.1.2. SYSTEM .............................................................................................................. 95
6.1.3. RATED CURRENT .............................................................................................. 95
6.1.4. A.C. / D.C. POWER SUPPLY .............................................................................. 95
6.1.5. CIRCUIT BREAKER ............................................................................................ 95
6.2.
LV BUS-DUCT .......................................................................................................... 96
7.
DC SYSTEM (BATTERIES, BATTERY CHARGER, DCDB)
Page 9 of 130
96
7.1.
7.2.
7.3.
8.
9.
BATTERY.................................................................................................................. 96
BATTERY CHARGER ............................................................................................... 96
DC DISTRIBUTION BOARD ..................................................................................... 97
415V MCC
97
8.1.
GENERAL ................................................................................................................. 97
8.2.
CONTACTOR ............................................................................................................ 98
8.3.
THERMAL OVERLOAD RELAYS ............................................................................. 98
8.4.
CURRENT TRANSFORMERS .................................................................................. 98
8.5.
CIRCUIT BREAKER ................................................................................................. 98
HT CABLE
98
COMBINED CYCLE POWER PLANT
99
10. HT/LT TRANSFORMERS AND NGR
99
10.1. TRANSFORMERS .................................................................................................... 99
10.2. NEUTRAL GROUNDING RESISTOR (NGR) FOR 6.5 MVA TRANSFORMER (LV
SIDE) 100
10.2.1. GENERAL.......................................................................................................... 100
10.2.2. CURRENT TRANSFORMER ............................................................................. 100
11. 12 KV & 6.6 KV SWITCHGEAR
101
11.1. 12 KV SWITCH GEAR ............................................................................................ 101
11.1.1. GENERAL.......................................................................................................... 101
11.1.2. CIRCUIT BREAKERS ........................................................................................ 101
11.1.3. CURRENT TRANSFORMERS ........................................................................... 101
11.1.4. VOLTAGE TRANSFORMERS ........................................................................... 101
11.1.5. RELAYS (NUMERICAL) .................................................................................... 102
11.2. 6.6 KV SWITCH GEAR ........................................................................................... 102
11.2.1. GENERAL.......................................................................................................... 102
11.2.2. CIRCUIT BREAKERS ........................................................................................ 102
11.2.3. CURRENT TRANSFORMERS ........................................................................... 102
11.2.4. VOLTAGE TRANSFORMERS ........................................................................... 103
11.2.5. RELAYS (NUMERICAL) .................................................................................... 103
12. 415V SWITCH GEAR (PCC) & LV BUS-DUCT
103
12.1. 415V SWITCH GEAR (PCC) ................................................................................... 103
12.1.1. GENERAL.......................................................................................................... 103
12.1.2. SYSTEM ............................................................................................................ 103
12.1.3. RATED CURRENT ............................................................................................ 103
12.1.4. A.C. / D.C. POWER SUPPLY ............................................................................ 103
12.1.5. CIRCUIT BREAKER .......................................................................................... 104
12.1.6. AUXILIARY VOLTAGE ...................................................................................... 104
12.2. LV BUS-DUCT ........................................................................................................ 104
13. SUPERVISORY, CONTROL & ANNUNCIATION PANEL (SCAP)
104
14. 415V MCC, ACDB , DCDB
105
14.1. GENERAL ............................................................................................................... 105
14.2. AIR CIRCUIT BREAKER ........................................................................................ 105
14.3. CONTACTOR .......................................................................................................... 105
14.4. THERMAL OVERLOAD RELAYS ........................................................................... 106
14.5. CURRENT TRANSFORMERS ................................................................................ 106
15. DC BATTERY & BATTERY CHARGER
Page 10 of 130
106
15.1.
15.2.
220 V DC BATTERY ............................................................................................... 106
220V BATTERY CHARGER.................................................................................... 107
16. HT CABLES
107
16.1. GENERAL ............................................................................................................... 107
16.2. TYPE DESIGNATION.............................................................................................. 107
16.3. VOLTAGE GRADE ................................................................................................. 107
16.4. CONDUCTOR ......................................................................................................... 108
16.5. INSULATION ........................................................................................................... 108
16.6. OTHER PROPERTIES ............................................................................................ 109
17. ELECTRICAL LABORATORY EQUIPMENT
109
17.1. ELECTRIC MOTOR CHECKER .............................................................................. 109
17.2. MEGGAR ................................................................................................................ 110
17.3. HIGH VOLTAGE INSULATION TESTER ................................................................ 110
17.4. OIL DIELECTRIC STRENGTH TEST KIT (MOTORISED)....................................... 110
17.5. RELAY TESTING KIT ............................................................................................. 110
17.6. DIGITAL MICRO-OHMMETER ................................................................................ 110
CONTROL & INSTRUMENTATION
1.
111
GT CONTROLS
111
1.1.
SYSTEM ARCHITECTURE ..................................................................................... 111
2.
PLC 111
3.
GAS DETECTION SYSTEM
112
4.
STG CONTROL SYSTEM
112
4.1.
STG PLC ................................................................................................................. 112
4.2.
IO MODULES .......................................................................................................... 112
4.3.
TURBINE SUPERVISORY SYSTEM....................................................................... 113
4.3.1. VIBRATION MONITORING SYSTEM ................................................................ 113
4.3.2. RESISTANCE TEMPERETURE DETECTOR (RTD) ......................................... 114
4.3.3. SPEED SENSOR ............................................................................................... 114
4.3.4. ALARM AND TRIP POINT SETTINGS .............................................................. 114
5.
DISTRIBUTED CONTROL SYSTEM (DCS)
115
5.1.
SYSTEM CONFIGURATION ................................................................................... 115
5.2.
FIELD CONTROL STATION (FCS) ......................................................................... 115
5.3.
INFORMATION COMMAND STATION (ICS) .......................................................... 116
5.4.
ENGINEERING WORK STATION (EWS)................................................................ 116
5.5.
DATA HIGHWAY .................................................................................................... 116
5.5.1. V NET ................................................................................................................ 116
5.5.2. E NET ................................................................................................................ 116
5.5.3. RIO BUS ............................................................................................................ 117
5.6.
GENERAL ............................................................................................................... 117
5.7.
IO MODULES .......................................................................................................... 117
5.7.1. RTD INPUT MODULE........................................................................................ 117
5.7.2. T/C INPUT MODULE ......................................................................................... 117
5.7.3. ANALOG INPUT MODULE ................................................................................ 117
5.7.4. ANALOG OUTPUT MODULE ............................................................................ 118
5.7.5. DIGITAL INPUT MODULE ................................................................................. 118
5.7.6. DIGITAL OUTPUT MODULE ............................................................................. 118
5.7.7. COMMUNICATION MODULE ............................................................................ 118
5.8.
SEQUENCE OF EVENT RECORDER (SER) .......................................................... 118
Page 11 of 130
6.
FIELD INSTRUMENTS
119
6.1.
PRESSURE / DIFFERENTIAL PRESSURE GAUGE .............................................. 119
6.2.
TEMPERATURE GAUGE ....................................................................................... 119
6.3.
PRESSURE / DP SWITCH ...................................................................................... 119
6.4.
LEVEL SWITCH ...................................................................................................... 119
6.5.
THERMOCOUPLE AND RTD ................................................................................. 119
6.6.
TRANSMITTERS..................................................................................................... 120
6.7.
DISPLACEMENT TYPE LEVEL TRANSMITTER.................................................... 120
6.8.
ORIFICE PLATES ................................................................................................... 120
6.9.
ANNUBAR .............................................................................................................. 120
6.10. FLOW NOZZLES .................................................................................................... 120
6.11. ELECTRONIC DRUM LEVEL INDICATOR (EDLI) ................................................. 120
6.12. BI- COLOUR LEVEL GAUGE ................................................................................. 121
6.13. MASS FLOW METER ............................................................................................. 121
7.
STEAM & WATER ANALYSIS SYSTEM (SWAS)
121
7.1.
VARIOUS STREAMS & RANGE OF MEASUREMENT: ......................................... 121
7.2.
SAMPLE HANDLING SYSTEM: ............................................................................. 122
7.2.1. PRIMARY COOLER........................................................................................... 122
7.2.2. ISOLATION VALVE (IV51/IV32) ........................................................................ 122
7.2.3. SAMPLE COOLER (PSC1) ................................................................................ 122
7.2.4. VARIABLE PRESSURE REDUCING ELEMENTS (VREL) ................................ 122
7.2.5. PRESSURE GAUGES (PGG2) .......................................................................... 122
7.2.6. TEMPERATURE GAUGES ( TG03)................................................................... 122
7.2.7. BACK PRESSURE REGULATOR / RELIEF VALVE (PRB/RV) ........................ 122
7.2.8. CATION COLUMN (CNT1) ................................................................................ 123
7.2.9. STREAM SELECTOR ........................................................................................ 123
7.2.10. SOLENOID VALVE ............................................................................................ 123
7.3.
SENSORS & ANALYSERS:.................................................................................... 123
7.3.1. PH MEASUREMENT ......................................................................................... 123
7.3.2. CONDUCTIVITY MEASUREMENT .................................................................... 123
7.3.3. IN SITU CONDUCTIVITY MEASUREMENT ...................................................... 123
7.3.4. DISSOLVED OXYGEN MEASUREMENT .......................................................... 123
7.3.5. HYDRAZINE MEASUREMENT .......................................................................... 124
7.3.6. SILICA MEASUREMENT ................................................................................... 124
8.
CONTINUOS EMISSION MONITORING SYSTEM (CEMS)
124
8.1.
ANALYSER ............................................................................................................. 124
8.2.
SAMPLING PROBE ................................................................................................ 124
8.3.
CALIBRATION GAS CYLINDERS .......................................................................... 124
8.4.
OXYGEN ANALYSER ............................................................................................. 124
9.
UNINTERRUPTED POWER SUPPLY (UPS) SYSTEM
125
9.1.
RECTIFIER.............................................................................................................. 125
9.2.
BYPASS SUPPLY ................................................................................................... 125
9.3.
INVERTER .............................................................................................................. 125
9.4.
INTERMEDIATE DC CIRCUIT ................................................................................ 125
9.5.
BYPASS TRANSFORMER AND SERVO CONTROLLED VOLTAGE STABILISER
125
9.6.
STATIC SWITCH..................................................................................................... 125
9.7.
BATTERY................................................................................................................ 125
10. CONTROL VALVES
126
11. PLANT COMMUNICATION SYSTEM
127
Page 12 of 130
11.1.
11.2.
EPABX .................................................................................................................... 127
PA SYSTEM ............................................................................................................ 127
12. IMPORTANT SETTINGS
128
12.1. TRIP CONDITIONS ................................................................................................. 128
12.2. AUTO START CONDITIONS .................................................................................. 129
Page 13 of 130

1.
PROJECT OVERVIEW
PROJECT OVERVIEW
EPC Power has set up a Combined Cycle Power Plant of 53.5 MW capacity. The
combined cycle operation of the plant has commenced from January 2000 after the
successful commissioning of Steam Turbine.
The plant consists of one Gas Turbine Generator (Frame 6 B) of 35 MW capacity, one
Heat Recovery Steam Generator (HRSG) and one Steam Turbine Generator (STG) of
18.5 MW capacity. The fuel for continuous operation is Naphtha and start up fuel is
HSD. The plant uses a 220 KV switchyard for power evacuation. The DM water
requirement for the plant is sourced through a DM plant/ Desalination Plant. Sea water is
used for condenser cooling which involved 4.0 km long intake piping and 4.0 km long
return water piping.
The Gas Turbine, which was supplied by EGT was commissioned during August 98.
While the HRSG was supplied by GTFB (Group II), the Steam Turbine was supplied by
Alstom - France.
The total life cycle hrs of the gas turbine package is 61134 hrs, and total hrs since last
overhaul 324 hrs
1.1. SITE CONDITIONS AND CLIMATOLOGICAL DATA
Max. 42 0C
Min. 11 0C
Max. 32 oC
Max. 100%
Min. 25%
3 M above Mean Sea Level (MSL)
Zone III as per IS: 1893
80 kmph (Average)
160 kmph (Max)
Ambient dry bulb temperature :
Ambient wet bulb temperature :
Relative Humidity
:
Site elevation
Seismic Zone
Wind speed
:
:
:
1.2. FUEL ANALYSIS
1.2.1. NAPHTHA ANALYSIS
Kinetic viscosity at 15 oC, cst (max):
Specific Gravity at 15oC
:
Flash Point, oC (min)
:
Initial BP oC (min)
:
Final BP oC (max)
:
Aromatics, % v/v (max)
:
Olefins, % v/v (max)
:
Reid VP, kg/cm2 (max)
:
Sulphur, % w/w
:
0.5
0.73 - 0.75
- 10.0
45
170
16
1
0.5
0.02 - 0.15
Page 14 of 130
Vanadium, ppm (max)
Na + K, ppm (max)
Lead, ppm (max)
Calorific value (HHV), kcal/ kg
Calorific value (LHV), kcal/ kg
C/H Ratio
Water, % volume
Ca, ppm (max)
:
:
:
:
:
:
:
:
1.0
1.0
0.022
11200 – 11390
10615 – 10860
5.6
NIL
1.0
1.2.2. ANALYSIS OF HSD (TYPICAL)
Acidity, inorganic
: Nil
Acidity total, mg of KOH/g
: Max 0.50
Ash, percent by mass
: Max 0.01
Carbon residue (rams bottom
percent mass)
: Max 0.20
Octane number
: Min 42
Pour Point
: Max 6 o C
Copper strip corrosion for 3 hours
at 100 oC
: Not worse than 0.1
Distillation percent recovery
at 366 oC
: Min 90
Flash point Pensky-Martnes (closed) :
Min 32 oC
o
Kinematic viscosity CS at 38 C : 2.0 - 7.5
Sediment, percent by mass
: Max 0.05
Total Sulphur, percent by mass : Max 1.0
Water content, percent by vol
: Max. 0.05
Total sediments mg per 100 ml : Max 1.0
Density at 15oC
: 0.86 g/cc
LHV
: 10,000 Kcal/Kg
1.3. PROJECT MILESTONES
1.3.1. OPEN CYCLE
Sr.N
o
1
2
3
4
5
6
7
8
9
10
DESCRIPTION
Project Zero date
Plot plan finalisation
Start of civil works
Receipt of Gas Turbine
Generator at site
Release of Gas Turbine
foundations
Start of Gas Turbine erection
Release of Naphtha - HSD
tank foundations
Liquid fuel system (HSD)
commissioning
Gas turbine commissioning
on HSD
Fire
Protection
and
PLAN
ACTUAL
22.05.97
26.08.97
18.09.97
21.03.97
12.11.97
27.09.97
16.12.97
14.10.97
20.12.97
15.10.97
21.10.97
03.01.98
31.01.98
17.06.98*
12.08.98
27.06.98
27.08.98
16.06.98
21.12.98
Page 15 of 130
Sr.N
o
DESCRIPTION
Detection
system
commissioning
11
Liquid fuel system (Naphtha)
commissioning
12
Gas Turbine commissioning
on Naphtha
* Revised commissioning date (Target 2)
PLAN
ACTUAL
23.06.98
08.01.99
30.06.98
26.01.99
PLAN
14.04.98
14.07.98
01.04.99
01.04.99
30.07.99
21.08.99
21.08.99
30.09.99
-
ACTUAL
14.04.98
25.09.98
09.04.99
17.04.99
06.11.99
02.12.99
09.12.99
18.12.99
04.01.2000
25.02.2000
1.3.2. COMBINED CYCLE
S.No
1
2
3
4
5
6
7
8
9
10
DESCRIPTION
Project Zero Date
Start of civil works
Start of HRSG erection
Start of STG erection
Hydro test of HRSG
Alkali Boil Out
Steam Blowing
Safety Valve floating
Synchronisation
Reaching of full load
1.3.3. AUXILIARY SYSTEMS - COMBINED CYCLE
SYSTEM
DM Water system
Cooling Water system
Equipment Cooling Water system
Power Evacuation system
Sea Water Intake system
Power cycle piping system
Condensate and Feed water
system
COMMISSIONING DATE
22.09.99
19.10.99
13.10.99
30.09.99
30.10.99
30.10.99
30.09.99
Page 16 of 130

1.
MECHANICAL
GAS TURBINE GENERATOR
1.1. GENERAL
1.1.1. SPECIFICATION
Make
Model
Gt Application
Cycle
Shaft Rotation
Rated shaft speed
Type of Operation
Control
:
:
:
:
:
:
:
Important Protections
:
Cooldown Mechanism
Sound attenuation
:
European Gas Turbine
Pg 6551 (B)
Generator Drive
Simple
Counter Clockwise
:5100 rpm
Continuous
Mark V Speedtronic Solid-State
(Electronic Control System)
Overspeed, Overtemperature, Vibration And Flame
Detection, Low lub oil pressure
:Ratchet device integral with torque converter.
Inlet and exhaust silencers to meet site
requirements.
1.1.2. GAS TURBINE RATING (GUARANTEED)
ISO
SITE (32 DEG C)
Without water injection:
Base load
Peak load
Base
load
Peak load
Rating Open cycle mode
:
38390 KW
42370 KW
34090
KW
37770 KW
Rating Combined cycle mode:
38110 KW
42090 KW
33760 KW
37440 KW
With water injection:
Rating Open cycle mode
:
42040 KW
44610 KW
35520
KW
39550 KW
Rating Combined cycle mode:
39970 KW
44360 KW
35200 KW
39230 KW
Site condition
ISO condition
1.2. COMPRESSOR SECTION
No. of Compressor stage
Compressor type
Casing split
Inlet guide vanes type
:
:
32 deg C, 60% RH
15 deg C, 60% RH
:
:
:
:
17
Axial flow, heavy duty
Horizontal flange
Variable
Page 17 of 130
1.3. TURBINE
1.3.1. TURBINE SECTION
No. of Turbine stage
Casing split
Nozzles three-stage
:
:
:
3
Horizontal
Fixed area
1.3.2. COMBUSTION SYSTEM
Type
Chamber arrangement
Fuel Nozzle
Spark Plugs
Flame detectors
:
:
:
:
:
10 Multiple combustors, reverse flow design
Concentrically located around the Compressor
Dual fuel nozzles pressure atomizing, 1 / chamber
2, electrode type, spring-injected self-retracting
4, ultra-violet type
1.3.3. BEARING ASSEMBLY
Quantity
:
Lubrication
:
No.1 bearing assembly
:
(located in inlet casing assembly):
Journal
:
Active thrust
:
Inactive thrust
:
No.2 bearing assembly
:
(located in exhaust frame
assembly)
Thrust Bearings
:
2
Pressure Lubricated
Active and inactive thrust and journal,
all contained in one assembly
Elliptical (Supplier GE)
Tilting pad, self-equalizing (Supplier GE)
Tilting pad, non-equalizing (Supplier GE)
Elliptical journal
Supplier (Kingsbury)
1.4. STARTING SYSTE
Starting Device
Manufacturer
Type
Rating
Speed
Torque Converter Type
:
:
:
:
:
:
Diesel engine
Detroit Diesel
12V 71T
470 kW
2300 rpm
Hydraulic with integral reversing gear
and ratchet and manual actuation.
1.5. FUEL SYSTEM
Operating type
:
:
Starting/ Stopping on HSD
Continuous Operation on Naphtha / HSD
Speedtronic* MK V - Turbine control
:
:
:
Screw pump
Allweiler, Germany
303 ltr./min, 62 bars, 1884 rpm
:
:
:
Siemens, Germany
58 KW, 415 V, 50 Hz, Explosion proof - EEx e IIC T3
2900 rpm
Fuel Manual signal
1.5.1. FUEL PUMP
Type
Supplier of fuel pump
Capacity
MOTOR
Supplier
Rating
Speed
Page 18 of 130
1.5.2. FLOW DIVIDER
Flow divider
Make
Model No.
Nominal Out put
Operational Pressure range
:
:
:
:
:
1.5.3. HITEC DOSING SYSTEM
Hitec Storage tank capacity :
Dosing Pump
Make
:
Quantity
:
Capacity
:
Type
:
Motor for Dosing Pump
Make
:
Rating
:
Explosing proof design
:
Controls for pump/motor
:
Compressor Water Wash System
System Supplier
:
1.6. LUBRICATION SYSTEM
Lubricant
:
Total Capacity
:
Bearing header pressure
:
Main lube pump (MOP)
:
MOP Capacity
:
Auxiliary lube pump (AOP) :
sump type
Supplier of AOP
:
AOP Capacity
:
AOP Motor
:
Supplier of AOP motor
:
Emergency lube pump (EOP) :
sump type
Supplier of EOP
:
EOP Capacity
:
Supplier of EOP Motor
:
EOP Motor
:
1.6.1. LUBE OIL COOLER
Type
:
Supplier
:
Quantity
:
Cooling Water Required
:
Pressure drop across the cooler:
Water side design pressure :
Oil side design pressure
:
In-line, free wheeling, 10 elements
Electrohydraulic servo control
Scherzinger
106186M/N
12.87 lpm per element at 2400 rpm
7 - 84 bars
3000 ltr.
Bran & huebbe
2 Nos. (2 x 100%)
1.6 ltr / hr, 8 bars
Positive displacement, diaphragm type, EP 31
CEMP
0.55 kW, 415 V, 50 Hz., Speed-1400 rpm (variable)
Eex de IICT4
PLC with two frequency converter.
Rotring Engineering
Mineral lube oil, ISO VG 32
Approx. 6400 ltrs.
1.73 bar
Shaft-driven, integral with accessory Gear.+
1742 lpm, Pressure - 6.3 bar
AC Motor-driven, vertical, submerged, centrifugal,
Allweiler, Modle - NSS 65-250 W8
104.4 cu.m/hr, Pressure - 4.5 bar
30 kW, Model - FLS 200
Leroy Somer France
DC Motor-driven, vertical, submerged, centrifugal,
Allweiler, Model - NSS 50-160 W8
57 cu.m/hr, Pressure - 2.1 bar
CEB Alsthom
7.5 kW D.C., Model - LPA 112L
U-tube bundle, Oil heat to closed cycle water
Quiri France
One
2330 lpm
0.6 bar appx. (Water Side)
6.5 bar
2.7 bar
Page 19 of 130
1.6.2. FILTER (LUBE OIL)
Type
Supplier
Quantity
Cartridge type
:
:
:
:
Full flow
Filters Philippe
Double unit with transfer valve
5-micron filtration, pleated paper
1.7. HYDRAULIC SUPPLY SYSTEM
Supplier
:
Main hydraulic supply pump :
Capacity
:
Speed
:
Hartmann, USA
Accessory gear-driven, Positive displacement type.
68.4 ltr./min, 82.7 bars
1424 rpm
1.7.1. HYDRAULIC SUPPLY FILTERS
Supplier
:
Type
:
Quantity
:
Custom Comp. USA
Full flow
Double unit with transfer valve
1.7.2. CONTROL OIL FILTERS
Supplier
Type
Quantity
Filter Philippe
Full flow
Double unit with transfer valve
:
:
:
1.8. COMPRESSOR WASH SYSTEM
1.8.1. DETERGENT PUMP
Supplier
Model
No. of pumps
Type
Nominal Head
Nominal Capacity
Speed
No. of stages
Motor
Supplier
Rating
Insulation Class
Degree of Protection
1.8.2. DM WATER PUMP
Supplier
Model
No. of pumps
Type
Nominal Head
Nominal Capacity
Speed
No. of stages
Motor
Supplier
:
:
:
:
:
:
:
:
KSB
Movichrom 3/10 CN
1 No.
Multistage, vertical high-pressure centrifugal
90.0 - 40.0 m
0.6 - 4.4 m3/h
2900 rpm
10
:
:
:
:
KSB
2.2 kW, 415 V, 2900 rpm
F
IP 55
:
:
:
:
:
:
:
:
KSB
Movichrom 9/8 CN
1 No.
Multistage, vertical high-pressure centrifugal
109.0 - 50.0 m
2.2 - 14.0 m3/h
2900 rpm
8
:
KSB
Page 20 of 130
Rating
Insulation Class
Degree of Protection
:
:
:
4.0 kW, 415 V, 2900 rpm
F
IP 55
1.9. INLET AIR FILTER
Design airflow (GT air)
Design airflow (Ventilation air)
Filter number
:
Element type
:
:
7110m3/min (ISO)
:
335 m3/min (ISO)
GDX77-1895
KYX77-0202-606797
KYX77-0228-606797
Number of modules
:
3
Number of element pairs (GT air)
:
170
Number of element pairs (Vent. air) :
10
Number of pressure switches
:
1 photohelic pressure switch for cleaning
installed in the control box
1 mechanical pressure switch for high pressure drop
alarm : 1.0 kPa.
1 mechanical pressure switch for high pressure drop
turbine stop alarm : 1.8 kPa.
1 pressure switch for low compressed air alarm : 5.5
bar
Number of program control cards
:
1
Number of valves
:
90
Number of manifolds
:
3
Cleaning cycle start
:
5.5 mbar
Cleaning cycle stop
:
3.5 mbar
Pulse interval
:
30 sec
Pulse length
:
0.10 sec
Compressed air pressure
:
7 bar eff.
Max. temp. of compressed air
:
80°C
Quantity of compressed air reqd.
:
1.13m3/min free air delivery
Electrical Requirement
:
3 x 415 V AC - 50 Hz - 5 kVA
230 V AC - 50 Hz - 2.5 kW
1.10. ATOMIZING AIR SYSTEM
Supplier
Main Compressor
Starting compressor
driven by
Air precooler (HX-1)
Supplier for HX-1
1.11. OIL MIST SEPERATOR
Make
Type
Fan with motor
Make
Rating
Capacity
Max. Pressure
:
:
:
Atlas Copco, USA
Accessory gear-driven, rotary centrifugal
Rotary lobe, axial flow, positive displacement, belt
:
:
starting
diesel motor.
Shell and tube air-to-water heat exchanger.
American Stand., USA
:
:
Frank Filter Systems
SG600/4080/140-2V(GT)
:
:
Siemens
7.5 KW/415V/ 14.3A/ IP55
:
2910 lit/min.
(-) 140 mbar
:
Page 21 of 130
1.12. GENERATOR
Manufacturer
Type
Rated output
Voltage and frequency
Power Factor
Current
Class of insulation
Speed
Air gap
Cold resistance at 20 oC
Stator
Rotor
Ambient air temp. /
Cooling water temp.
Lubrification source
Excitation:
Excitation System
Nominal excitation values
Ceiling excitation values
MV frame details:
CT
:
:
:
:
:
:
GEC Alsthom, France
T600 C, Closed air-cooler circuit
41.500 MW / 48.824 MVA
:
11.500 KV / 50 Hz / 3000 rpm
0.85
:
2,451 A
F
3,000 rpm
42.5 mm
:
:
:
0.00373 ohm/ phase
0.364 ohm
26 deg. C / 34 deg. C
:
Gas turbine lubrification system
:
A.C. Exciter with rotating diodes
(Brushless system)
:
267 V, 533 A
:
460V, 960 A
:
:
3000/1 A, CL5P10, 15VA, 3 nos.
3000/1 A, CL5P20, 10VA, core 2&3, core 1 CL0.5, 3
:
:
:
:
:
:
:
3000/1 A, CL0.5, 30VA, 3 nos.
(11.5/3)/ (100/3) V, CL0.5, 100VA, 3 nos.
(11.5/3)/ (100/3) V, CL3P, 15VA, 3 nos
11.5KV/ 2x180V, 26kVA
(11KV/3)/127V, 12.7kVA
0.27 ohm at 30 0C
12 KV, 3 nos.
:
:
:
:
:
:
Flender - Graffenstaden
TRL 65 CV
54,000 KW
5,114 rpm
3,000 rpm
ISO VG 32
:
:
160.2 cu. m/hr.
CW inlet temp. (design) - 65 deg. C
CW outlet temp. (design) - 50 deg. C
980,000 kg/hr
Inlet Air temp. = 42 deg. C
Outlet Air temp. = 52.2 deg. C
10.25 mm WC
:
nos
PT
Excitation transformer
NGT
NGR
LA
1.12.1. LOAD GEAR
Manufacturer
Type
Capacity (nominal)
Input speed
Output speed
Lubrication oil
1.13. FIN FAN COOLER
1.13.1. PERFORMANCE DATA
Cooling Water Flow
Water side temperature
Total Air Flow
Air side temperature
Fan Static pressure
:
:
:
:
Page 22 of 130
1.13.2. HEAT EXCHANGER
Manufacturer
Heat Exchange capacity
No. of bundles
No. of tubes per bundle
No. of header passes
Tube Diameter /thickness
Tube length
Pitch (Trans / Longi)
Arrangement of Bundles
Fin Type
:
:
:
:
:
:
:
:
:
:
Paharpur Cooling Tower Ltd.
160% (60% spare) of duty heat load.
3 x 50%
192
Four
25 mm / 2.4 mm
10350 mm
67 / 61
Parellel
Embedded 'G' type
1.13.3. FANS
Manufacturer
Fan Capacity
No. of Fans
Fan Diameter
Number of Blades
Speed
Pitch
Motor rating per fan
:
:
:
:
:
:
:
:
Moore
150% (50% spare)
6 (4 Working + 2 standby)
3.05 M
6
318 rpm
Adjustable
15 KW
:
:
:
:
Kirloskar Brothers Ltd.
RKB 40-14H
Horizontal Centrifugal
2 x 100%
1.14. NOX CONTROL SYTEM
1.14.1. GENERAL
Manufacturer
Model No.
Type of Pump
Number of Pumps
1.14.2. GUARANTEED PERFORMANCE
Rated Capacity
:
11 cu. meter/hr.
Total head at rated cap.
:
265 mLC
Shut-off head
:
283 mLC
Pump rated speed
:
2900 rpm
Pump efficiency at rated
:
61%
Capacity w/o any -ve tolerance
limit NPSHR
:
1.26M
Pump input power at rated capacity : 13.01 kW
Drive motor rating
:
18.5 kW
1.14.3. DESIGN & CONSTRUCTION FEATURE
Minimum flow
:
3 cu.m/hr
Number of stages
:
Nine
Shaft sealing arrangement :
Gland packing
Page 23 of 130
2.
GT EXHAUST SYSTEM
2.1. GENERAL
Manufacturer
2.2. PROCESS DESIGN DATA
Fluid
Flow(Nor/Max)
Temp (Nor/Max)
Pressure Drop Max.
2.3. THERMAL DESIGN DATA
Max. Temp
Thermal Insulation
Internal
of Ceramic Wool
External
Surface Temp.
:
M/s. GRAND PRIX FAB PVT. LTD
:
GT Exhaust Gas
:
133.9 / 148.6 Kg/Sec.
:
547 / 564 / 583 deg. C
90 mm WC (Open Cycle)
40 mm WC (Closed Cycle)
:
:
:
583 deg. C
For Bypass stack & Silencer
:
125 mm Mineral Wool Lined with
25 mm
:
NIL
:
60 deg C at Amb. 42 deg. C & Full
load condition (Gas temp. 564 deg C)
2.4. GT EXHAUST DIVERTER & GUILLOTINE DAMPER
2.4.1. DIVERTER DAMPER
Manufacturer
Size
Operating time
Pressure
Max. Flow
Weight of Isolator
Pressure drop
When closed to boiler
When closed to bypass
Sealing efficiency
Sealing air diff. Pressure
Electric Actuator
Make
Motor
Worm reduction gearbox
Make
Supply
Command Signal
:
:
:
:
:
:
Fouress Engg. India Ltd.
3048 x 3048 mm
60 Seconds
500 WC
148.6 Kg/Sec
16,000 Kg (Approx.) With Operator
:
90 mm WC
:
40 mm WC
Duplex 100%
:
500 mmWC
:
:
:
AUMA (model - SA50 E 180)
4KW, speed - 2800 rpm, 415 V
:
:
:
AUMA (model - GSD 315 + GZ 30), ratio - 424 : 1
415V, 3Ph, 50Htz
4 to 20 mA
2.4.2. GUILLOTINE DAMPER
Manufacturer
:
Size
:
Operating time
:
Function
:
Pressure
:
Max. Flow
:
Weight of Isolator with operator
Fouress Engg. India Ltd.
3048 mm x 3048 mm
6.3 +/- 0.2 Minutes
On/Off
500 WC
148.6 Kg/Sec
:
10,000 Kg (Approx.)
Page 24 of 130
Electric Actuator
Make
:
Motor
:
Worm Reduction gearbox
Make
:
2.4.3. EXPANSION JOINT
Make
Type and quantity
Design Temperature
Internal Pressure
2.4.4. BYPASS STACK
Height
Inside Diameter
Material
Insulation details
wool
AUMA (model : SA25 E 180)
2.2 KW, speed - 2800 rpm, 415V
AUMA (model - GSD 160 + GZ 14), ratio -
216 : 1
:
:
:
:
Keld Ellentoft India
Non-metallic and 3 Nos.
600 deg. C
300 mmWC
:
:
:
:
30m
3850 mm
IS 2062
125mm mineral wool lined with 25mm of ceramic
Insulation Cladding with SS 409 - 3 mm thick plate
2.4.5. BYPASS STACK SILENCER
Make
:
Shell Thickness
Shell Material
:
Splitter thickness
Perforated sheet thickness
Grand Prix
:
6mm
Steel to IS 2062
:
2 mm
:
1.6mm
2.4.6. SEAL AIR FAN (DIVERTER DAMPER)
Quantity
:
2 Nos. (2 x 100%)
Make
:
C. Doctor & Co.
Model
:
UMPR - 230 (70%)-SWSI
Capacity
:
56 m3/min
Pressure
:
650mm WC
Speed
:
2920rpm
Motor
Make
:
Crompton Graeves Ltd.
Rating
:
15 HP, 2-Pole, 415 V, 3 Phase AC, 3000 rpm
Frame size
:
160M
2.4.7. SEAL AIR FAN (GUILLOTINE DAMPER)
Quantity
:
1 No
Make
:
C. Doctor & Co.
Model
:
UMPR - 230-SWSI
Capacity
:
70 m3/min
Pressure
:
600mm WC
Speed
:
2920rpm
Motor
Make
:
Crompton Graeves Ltd.
Rating
:
20 HP, 2-Pole, 415 V, 3 Phase AC, 3000 rpm
Frame size
:
160L
Page 25 of 130
3.
HRSG AND AUXILIARIES
3.1. HEAT RECOVERY STEAM GENERATOR
3.1.1. GENERAL
Manufacturer
Type
No. of HRSG
Design Std
Location
Auxiliary / Supplementary
firing fuel
:
:
:
:
:
:
GTFB, L&T
Unfired with an option of firing, vertical (CMI design),
forced circulation, dual pressure
1 No.
IBR
Outdoor
Naphtha
3.1.2. DESIGN CONDITION OF GT EXHAUST GAS DETAILS
Air temp. at GT inlet
:
32 0C
GT load: 40 - 100 %
Mass flow
:
392 - 484 TPH
Temperature
:
417 - 547 0C
Oxygen content
:
16.2 - 13.4 % (volume dry)
3.1.3. MAXIMUM CONTINUOUS RATING IN UNFIRED MODE
Operating mode
:
Sliding Pressure & Temperature
Duty
:
Continuous base load / Part load operation and also
capable of cyclic and low load operation.
HP HRSG Section
Performance
Steam Capacity
:
62.5 TPH
Superheater outlet Steam Pressure :
88.9 Kg/cm2 (g)
Superheater outlet Steam Temp. :
Peak
70.0 TPH
79.2 Kg/cm2 (g)
508 + 5 0C
508 + 5
0
C
LP HRSG Section
Steam Capacity
:
4.3 TPH
Superheater outlet Steam Pressure :
4.4 Kg/cm2 (g)
Superheater outlet Steam Temp. :
4.81 TPH
4.4 Kg/cm2 (g)
194 + 5 0C
Steam to Deaerator from LP Drum
Steam Capacity
:
9.6 TPH
Steam Pressure
:
4.4 Kg/cm2 (g)
Steam Temp.
:
154.7 0C
10.4 TPH
4.4 Kg/cm2 (g)
154.7 0C
Feed water inlet conditions to HP section
Feed water temperature
:
127 0C
Feed water flow
:
62.5 TPH
127 0C
70.0 TPH
Feed water inlet conditions to LP section
Feed water temperature
:
125 0C
Feed water flow
:
13.9 TPH
125 0C
15.21 TPH
Page 26 of 130
197.1 0C
Max. gas side pressure drop from
Gas Turbine exhaust flange through
HRSG Stack
:
255 mm of WC
Max. allowable gas side pressure
Drop in HRSG
:
200 mm of WC
Exhaust NOx concentration :
75 ppmvd at 15 % excess O2
3.1.4. MAXIMUM CONTINUOUS RATING IN AUXILIARY FIRED MODE
Operating mode
:
Constant Pressure and Temperature. Superheater
Temperature control range 40% to 100%MCR
Duty
:
Continuous base load / Part load operation and also
capable of cyclic and low load operation.
HP HRSG Section
Steam Capacity
:
70.0 TPH
Superheater outlet Steam Pressure :
79.2 Kg/cm2 (g)
Superheater outlet Steam Temp.
:
508 + 5 0C
LP HRSG Section
Steam Capacity
:
3.6 TPH
Superheater outlet Steam Pressure :
4.4 Kg/cm2 (g)
Superheater outlet Steam Temp. :
201 + 5 0C
Steam to Deaerator from LP Drum
Steam Capacity
:
10.4 TPH
Steam Pressure
:
4.4 Kg/cm2 (g)
Steam Temp.
:
154.7 0C
Feed water inlet conditions to HP section
Feed water temperature
:
127 0C
Feed water flow
:
70 TPH
Feed water inlet conditions to LP section
Feed water temperature
:
125 0C
Feed water flow
:
14.0 TPH
Max. gas side pressure drop from
Gas Turbine exhaust flange through
HRSG Stack
:
255 mm of WC
Max. allowable gas side pressure
Drop in HRSG
:
200 mm of WC
Exhaust NOx concentration :
75 ppmvd at 15 % excess O2
3.2. HRSG COMBUSTION SYSTEM
3.2.1. BURNER
3.2.1.1. MAIN GAS BURNER
Manufacturer
Number
Burner type
:
:
:
Rodenhuis & Verloop B.V.
4 Nos
MG-15
3.2.1.2. MAIN OIL BURNER
Manufacturer
Number
:
:
Rodenhuis & Verloop B.V.
4 Nos
Page 27 of 130
Burner type
3.2.1.3. IGNITOR BURNER
Number
Burner type
Norm. duty
Turn down ratio
:
TTL-15
:
:
:
4
Gas / Electric
100-200 MW
:
Fixed load
3.2.1.4. IGNITOR FLAME SUPERVISORY SYSTEM
Make
:
Kromshroder
Type
:
IFW - 15T
Power supply
:
240 V - 50 Hz
Flame rod
:
Belpa
3.2.1.5. HIGH TENSION TRANSFORMER
Make
:
Belpa
Type
:
HE5-TIC7
Secondary voltage
:
1x6500 V / 20 mA
3.2.1.6. COMBUSTION AIR
No. of FD air fans
:
Air temperature
Air flow
Pressure drop over burners
1
:
:
:
3.2.1.7. AUXILIARY AIR SYSTEM
Air flow to main burners during
Oil firing
:
Combustion air flow to ignitor :
Required static pressure for firing:
0.41 Kg/s
0.02 Kg/s
11.1 Kpa
3.2.1.8. FUEL SUPPLY SYSTEM
Fuel type
Net heating value
Eff. Supply pressure
Supply temperature
Max. fuel flow
a) for TEG mode
b) for FD mode
:
Ambient
399.6 TPH
600 Pa (max)
:
:
Light fuel oil (naphtha)
:
44.4 MJ/ Kg
1000 Kpa
Ambient
:
:
0.71 Kg/s (GT load at 40%, four burners)
1.80 Kg/s (four burners)
3.2.2. SCANNER & AUXILIARY COOLING FANS
3.2.2.1. AUXILIARY FAN
Manufacturer
Fan model
Size
Wheel dia
Number of fans
Capacity
Static pressure
:
:
:
:
:
:
:
Patels Airtemp (Temp) India Ltd.
HP-03
75
31.3/4”
2
5157 m3/ hr
13.42 kPa
Page 28 of 130
Motor
Manufacturer
Type
Duty
Output
Voltage
Full load current
Full load speed
Insulation class
Efficiency at 100%
Bearings type no
Type of lubrication
3.2.2.2. SCANNER FAN
Manufacturer
Fan model
Size
Wheel dia
Number of fans
Capacity
Static pressure
Motor
Manufacturer
Type
Duty
Output
Voltage
Full load current
Full load speed
Insulation class
Efficiency at 100%
Bearings type no
Type of lubrication
:
:
:
:
:
:
:
:
:
:
:
Crompton Greaves Ltd.
3Ph Squirrel cage induction motor
S1
37 KW
415 V + 10%
61 A
2940 rpm
F
92.5 %
6312 (DE & NDE)
Lithium soap base grease Gr 3
:
:
:
:
:
:
:
Patels Airtemp (Temp) India Ltd.
HP-02
50
20”
2
736 m3/ hr
4.68 kPa
:
:
:
:
:
:
:
:
:
:
:
Crompton Greaves Ltd.
3Ph Squirrel cage induction motor
S1
3.7 KW
415 V + 10%
7.3 A
2865 rpm
F
84.0 %
6206 (DE & NDE)
Grease Grade II
3.2.3. NAPHTHA BOOSTER PUMP
Manufacturer
:
Size & Type
:
No. of pumps
:
Fluid
:
Capacity
:
Discharge pressure
:
Pr. at suction nozzle
:
Total head
:
Shut off head
:
Pump efficiency
:
NPSH available
:
NPSH required
:
Stuffing box sealing
:
Lub oil
:
Bearings
a) Radial - Type/ number
:
b) Thrust – Type/ number
:
Sulzer Pumps India Ltd., Thane
ZE 25-2315
2 (1-working, 1- standby)
Naphtha
10.5 m3/ hr
11.77 Bar a
3.0 Bar a
133.85 MWC
139 MWC
22.0%
>35 MWC
0.6 MWC
Mechanical seal of Durametallic
ISO VG 36 (Servo 36)
1xNU308
2x7308
Page 29 of 130
Motor
Manufacturer
:
Frame size
:
Applicable standard
:
Duty
:
Type
:
Rated continuous o/p kW at 40 C
ambient
:
Rated speed
:
Rated voltage & % variation :
Rated frequency & % variation:
Full load current
:
Degree of protection of enclosure:
Method of cooling
:
Insulation class
:
Bearings
a) Make
:
b) Type
Drive end
:
Non drive end
:
3.2.4. NAPHTHA FILTER
Manufacturer
Type
Quantity
Flow rate (max)
:
:
:
:
Crompton Greaves, Mumbai.
E160L
IS 2148/ IS 325/ IS 1231
S1
Flameproof
14 kW
2910 rpm
415V + 10%
50 Hz +
5%
26 A
IP55 as per IS 4691
IC0141 as per IS 6362
Class F
SKF/ FAG/ NTN
Ball
Ball
Ravi Techno Systems
Simplex Basket
2 Nos (1 Working + 1 Standby)
6.85 MT/ Hr
3.2.4.1. SUCTION FILTER
Inlet Pressure
:
3-4 Bar
Temperature
a) Design
:
65 0C
b) Operating
:
10 - 42 0C
Max Particle size
:
100 Micron
Pressure drop at clean condition:
0.1 Kg/ cm2
Pressure drop at 50% clogged cond.:0.2 Kg/ cm2
Material of Construction
:
SS304
3.2.4.2. DISCHARGE FILTER
Inlet pressure
:
10 bar
Max Particle size
:
10 Micron
Pressure drop at clean condition:
0.1 Kg/ cm2
Pressure drop at 50% clogged cond.:0.2 Kg/ cm2
Material of Construction
:
SS304
3.2.5. NAPHTHA COOLERS
Manufacturer
:
Type / Model
:
Quantity
:
No. of Tubes/ Length per tube:
Heat Transfer Area
:
Fluid
:
Praj Industries Ltd.
Corrugated Tube Heat Exchangers / K12, Hard
1 No.
12 Nos. / 3000 mm
2.036 m2
Tube side
Shell side
Naphtha
Cooling water
Page 30 of 130
Flow rate
Temperature Inlet/ Outlet
Actual pressure drop
Heat Load
Viscosity in/ out
:
:
:
:
:
7100 Kg/ hr
48 / 43.7 0C
0.1 bar.g
0.749 cP
7987 Kg/ hr
25 / 37 0C
0.1 bar.g
16216 Kcal /hr
0.755 cP
3.3. HRSG - AIR SYSTEM FOR AUXILIARY FIRING
3.3.1. FD FAN
Manufacturer
:
M/s ABB
Type
:
Centrifugal (ABB Ref. no. IAHHWEB 8005)
Number of Fans
:
One
Fan Capacity Rating
Capacity
:
414000 Kg/ hr
Medium handled
:
Fresh air
Temp. of medium
:
42 C
Rotational speed
:
740 rpm
Static pressure at fan inlet (design): - 15 mmWg
Static pressure at fan outlet (design):335 mmWg
Mechanical design temp.
:
70 C
Bearings
Drive end
:
SOFN 226 BF
22266 CC/C3/W33
Non-drive end
:
SOFN 230 BL
22230 CC/C3/W33
3.3.2. FD FAN MOTOR
Manufacturer
Type
:
:
Frame size
:
Application standard
:
KW rating (nominal)
:
Type and Rating
Duty
:
Rated voltage & variation
:
Rated frequency & % variation:
Full load current (amp)
:
No load current (amp)
:
Rated Continuous Output
a) At 42 0 C ambient
:
b) At 500 C ambient
:
Performance
Starting Current at rated voltage
%FL current
:
Starting time (Damper closed)
a) with load
:
b) No load (driven equipment
uncoupled)
:
Crompton Greaves
3 Ph SQ Cage Motor
DY TSR 241 TS&A
TPC 450E
IS 325, 1978
510
S1
6.6 KV+ 10%
50 Hz+ 5%
59 A
28 A
540 KW
510 KW
500 % (incl of IS tolerance)
80% voltage 100% voltage
27 sec
17.5 sec
3 sec
Construction
Page 31 of 130
1.5 sec
Degree of protection of enclosure:
Method of cooling
:
Insulation class
IP55
IC0161
:
Class 'F'
Bearings
a) Make
b) Type and Catalogue no.
:
:
c) Recommended lubricant
:
DE
NDE
SKF/ FAG/ EQV or EQUI
Antifriction type
NU226C3
NU221C3 & 6221C3
Lithium base grease - Servogem -3
3.3.3. FD FAN SUCTION FILTER
Manufacturer
Type
Construction
Size
Efficiency
Pressure drop (design)
Separators
Quantity
:
:
:
:
:
:
:
:
Dyna Filters
HDPE 3 Ply Air filters (Washable)
3 Layers of High Density polythene mesh.
510 x 610 x 150 mm
90 % down to 10 microns.
5 mm W.G.
Aluminium
118 Nos.
3.3.4. MULTILOUVER DAMPER
Manufacturer
:
Quantity
:
Size
:
Operating torque
:
Operating / Design Temperature:
Operating Pressure
:
Sealing Efficiency
:
Orientation duct/ damper
:
Drive
Type
:
Pneumatic cylinder
:
Operating Pressure
:
Operating Time
:
Solenoid Valve
Type
:
Control supply
:
3.3.4.1. SEAL AIR FAN
Make
Quantity
Capacity
Static pressure
Motor
Make
Raing
Frame
Duty
Rated voltage
Full load current
Protection and insulation
Bachmann Industries
2 Nos.
1700 x1700 mm (Inside insulated)
273 Kg-m
548 0C / 595 0C
300 mm WC
100 % with seal air.
Vertical / Horizontal
Double acting
8" Bore x 20" (500 mm) Stroke
4 Kg / cm2 (Min)
5 Secs
4 Way dual sol.
220 V AC
:
:
:
:
Patel Air Temp ( I ) Ltd.
2 x 100 %
1.11 Cub. M / Sec
646.3 mmWC at 42 degC
:
:
:
:
:
:
:
CGL
18.5 KW
ND 160 L
S1
3 ph, 50 Hz, 415 V
32 A
IP-55 / F
Page 32 of 130
Bearing
Speed
Lubrication
:
:
:
6309
2920 rpm
Lithium soap based grease Gr-2
3.4. HP / LP STEAM SYSTEM
3.4.1. HP RECIRCULATION PUMP
Manufacturer
:
Type
:
No. of pumps
:
Medium delivered
:
Capacity
:
Minimum capacity
:
Differential head
:
NPSH – R
:
Differential head
:
Suction pressure max.
:
Pumping Temperature (PT) :
Specific gravity at PT
:
Pump input
:
Lubrication
Oil (according to DIN 51 524) :
Oil temperature
:
Cooling
Seal)
Cooling water
Pressure normal/ max
Temperature outlet max
Sulzer Pumps, Germany.
ZU 100-4200
2 x 100%
feed water
180 m3/ hr.
25 m3/ hr.
51.5 m FS
3.3 m
3.6 bar
81.0 bar
296.1 C
719 Kg/ m3
22.7 kW
ISO VG 46
>40-65 C
Shaft Seal Housing
:
:
:
0.6 m3/ hr
2/ 10 bar
40 C
Safety Technical Limit Data
Max. allowable working pressure:
116.8 bar
Max. allowable working temperature: 322.6 C
3.4.1.1. HP RCP MOTOR
Manufacturer
Motor type
KW rating (nominal)
Frame size
Application standard
Type and Rating
Duty
Rated Continuous Output
a) At 42 0 C ambient
b) At 500 C ambient
Rated speed at full load
Voltage, Frequency
Full load
:
:
:
:
:
Crompton Greaves Ltd.
3 Ph SQ Cage Motor
37 KW
ND2258
IS 323: 1996, IS1231:1974
:
S1
:
:
:
:
:
40 KW
37 KW
2950 rpm
415 V + 10% , 50 + 5% Hz
60 A
Construction
Page 33 of 130
Cooler (Mech.
0.5 m3/ hr
2/ 10 bar
40 C
Degree of protection of enclosure:
Method of cooling
:
Insulation class
:
Temperature rise over 500 C
Ambient
:
Bearings
a) Make
b) Type and Catalogue no.
:
:
70 0C
SKF/ EAG/ NTN/ EQUI
Ball berg 6313
3.4.2. LP RECIRCULATION PUMP
Manufacturer
:
Type
:
No. of pumps
:
Fluid
:
Capacity
:
Discharge pressure
:
Pr. at suction nozzle
:
Total head
:
NPSH available
:
NPSH required
:
Rotation
:
Casing
Type
:
Pressure (design)
:
Temperature
:
Lubrication
Lub oil
:
Coupling
Type
:
Make/ model
:
Bearings
Radial type/ number
:
Thrust – Type/ number
:
Suction Strainer
Make
Material: body/ wire gauge
Mesh size
IP55
IC0141, Fan cooled
Class 'F' (Temp rise limited to Class B)
Kirloskar Ebara Pumps Ltd., Pune.
100 x 80 UCWM 25
2 x 100%
Boiler circulation water
50.67 m3/ hr
7.84 Bar a
6.64 Bar a
13.47 MLC
6.30 MLC
1.0 MLC
Clockwise from drive end
Volute
9.9 kg/cm2 a
160 C
ISO VG 46
Carden shaft (universal joint)
Unique
BALL 6311 C3
BALL 2x7312 BECB
:
:
:
L&T supply
A 105/ SS 304
40
3.4.2.1. LP RCP MOTOR
Manufacturer
:
Frame size
:
Applicable standard
:
Rating
:
Type/ model of motor service :
Duty
:
Rated continuous o/p kW at 50 C
ambient
:
Rated speed
:
Voltage, Frequency
:
Crompton Greaves, Mumbai.
ND 112 MX
IS 325
3.7 kW
SCR
S1
3.7 kW
1430 rpm
415V + 10%, 50 Hz + 5%
Page 34 of 130
Full load current
:
7.50A
Construction
Degree of protection of enclosure:
Method of cooling
:
Insulation class
:
Temp. rise over 50 C ambient:
Bearings
Make
Type Drive end
Non drive end
Recommended
Lubricant
IP55
TEFC/ IC0141
Class F
Class B
70 C
:
:
:
SKF or equivalent
6306
6206
:
Lithium base grease Grade
3.4.3. HP BOILER ASSEMBLY
HP
Superheater-II
HP
Superheater-I
HP Evaporator
1458.0
Design
temp.for
tubes
0
C
547
1000.0
505
105.0
110.0
165.0
5793.0
374
105.0
110.0
165.0
HP
Economiser-II
HP
Economiser-I
HP Drum
5578.0
311
137.5
165.7
249.0
2597.0
170.0
137.5
165.7
249.0
41.9
318
105.0
110.0
165.0
Design
temp.for
tubes
0
C
251.0
188.0
168.0
179.88
Working
Pressure
(Kg/ cm2
g)
8.1
8.1
15.5
8.1
Design
Pressure
(Kg/ cm2
g)
8.9
10.0
20.10
9.2
Hydrotest
pressure
(Kg/ cm2
g)
13.35
15.0
30.15
13.8
Module
Heating
Surface
Area (m2)
Working
Pressure
(Kg/ cm2
g)
104.5
Design
Pressure
(Kg/ cm2
g)
105.0
Hydrotest
pressure
(Kg/ cm2
g)
165.0
3.4.4. LP BOILER ASSEMBLY
Module
Heating
Surface
Area (m2)
LP Superheater
LP Evaporator
LP Economiser
LP Drum
47.0
5150.0
503.0
38.24
3.4.5. SAFETY VALVE SETTING VALUES
Location
Set Pressure
( Kg/Sq cm gauge)
Page 35 of 130
Reset pressure
( Kg/Sq cm gauge)
HP Drum
HP Drum
HP main steam
LP Drum
LP Drum
LP main steam
CBD tank
As required
Actual
As required
Actual
103.5
104.5
102
8
8.1
7.55
9
103.5
104
102
8
8.1
7.6
9.1
100.4
101.4
98.9
7.8
7.9
7.3
8.7
99.5
101
99
7.65
7.8
7.4
8.6
3.4.6. HRSG DESUPERHEATER
Manufacturer
:
Type
No. of Nozzle(s)
Kv sel
Full stroke
Actuating force
Shut off deltaP
:
:
:
:
:
:
BTG (System design/supply by Chemtrols)
DESH1
DESH2
DA46 – D
1
2.5 m3/ hr
1.6 m3/ hr
19 mm
4 KN
166.0 Kg/ cm2 (a)
Actuator Type
Model
Stroke
Positioner
Air Supply
Input Signal
Increasing signal
Power Supply failure
:
:
:
:
:
:
:
:
Valtek
Pneumatic Piston
38 mm
Pneumatic – Beta
5 Kg/ cm2 (g)
0.2 – 1.0 kp/ cm2
Valve opens
Valve closes
3.5. BOILER BLOWDOWN SYSTEM
3.5.1. CONTINUOUS BLOW DOWN (CBD) TANK
Manufacturer
:
W.P. Engineering Works.
Design code
:
I.B.R.
Pressure (Design)
:
13.5 Kg/ cm2 (a)
Temperature (Design)
:
179.58 0C
Corrossion allowance
:
3.0 mm
Capacity
:
2.6 m3
3.5.2. INTERMITTENT BLOW DOWN (IBD) TANK
Manufacturer
:
W.P. Engineering Works.
Design code
:
ASME Section VIII Div -1
Pressure (Design / Operating):
2.5 Kg/ cm2 (a) / Atmospheric
Temperature (Design / Operating): 328 0C / 150 0C
Corrossion allowance
:
3.0 mm
Capacity
:
1.7 m3
Page 36 of 130
3.5.3. BLOWDOWN COOLER
Manufacturer
:
Type / Model
:
Quantity
:
No. of Tubes/ Length per tube:
Heat Transfer Area
:
Fluid
Flow rate
Temperature Inlet/ Outlet
Actual pressure drop
Heat Load
Viscosity in/ out
:
:
:
:
:
:
3.6. PHOSPHATE DOSING SYSTEM
Skid mounted unit supplied by:
Praj Industries Ltd.
Corrugated Tube Heat Exchangers / K36, Hard
1 No.
36 Nos. / 3000 mm
6.107 m2
Tube side
Condensate
4000 Kg/ hr
100 / 60 0C
0.1 bar.g
0.363 cP
Shell side
Cooling water
5333 Kg/ hr
35 / 65 0C
0.1 bar.g
160030 Kcal /hr
0.565 cP
ENPRO Engineering.
3.6.1. DOSING PUMPS
Manufacturer
Type
Number of pumps
Capacity (Normal / Design)
Pressure
Motors
Make
Type
71
Design/ Mfg. Std.
Rating/ speed
:
:
:
:
:
LP Boiler
HP Boiler
V.K. Pumps
Reciprocating simplex plunger
2 x 100%
2 x 100%
5 / 6 LPH
15 / 17 LPH
10.9kg/ cm2 (g)
110kg/ cm2 (g)
:
:
Crompton Greaves
3 ph., AC, squirrel cage induction motor
TEFC, F Cl insul. IP-55, Foot mounting, Frame AD
:
:
IS 325
0.37 kW
/ 1440 rpm
3.6.2. TANKS
Solution preparation tank & Solution Forwarding tank.
Sr.
No
1
2
Description
3
Design code
Type
Size
3.6.3. AGITATOR
Make
Type
Agitator Motor
Make
Solution Preparation
tank
Vertical Cylindrical
ID 1000 x ht 1200 x
thk 3
IS 803
Solution Forwarding
tank
Vertical Cylindrical
ID 1000 x ht 1200 x
thk 3
IS 803
:
:
Enpro Engineer
High speed, direct coupled with bearing arrangement
:
Crompton Greaves
Page 37 of 130
4.
Type
:
Design/ Mfg. Std.
Rating/ speed
:
:
3 Ph., AC, Squirrel cage induction motor
TEFC, F Cl insul. IP-55, Flange mounting,
Frame AD 80
IS 325
0.37 kW
/ 1440 rpm
:
:
:
:
:
:
PPE & S - UE Gr II, L&T
Stork sprayer type
1x100 T/hr boilers
2180 ID x 6190 Tan to Tan length
1 No. 100 TPH spring type sprayer
7 PPB
HRSG FEED WATER SYSTEM
4.1. DEAERATOR
Manufacturer
Type
Service
Size
Sprayer
Dissolved oxygen guarantee
4.1.1. NORMAL OPERATING CONDITIONS
Process fluid
Flow rate
(T/hr)
Pressure
(Kg/cm2 a)
66.8
9.6
62.5
13.9
2.37
5.45
2.37
2.37
Condensate
Heating Steam
HP Feed water
LP Feed water
4.1.2. MAX. OPERATING CONDITIONS
Process fluid
Flow rate
(T/hr)
Condensate
Heating Steam
HP Feed water
LP Feed water
4.1.3. CONSTRUCTION DETAILS
Design code
Operating Pressure
Design Temp
Corrosion allowance
Storage Capacity
a) Gross
b) Net
c) Active
4.2. HP BOILER FEED PUMP
Manufacturer
Pressure
(Kg/cm2 a)
76.9
10.9
72.1
15.7
2.37
5.45
2.37
2.37
Temperatur
e
0
C
48.9
155.1
125.1
125.1
Enthalpy
KJ/ Kg.
Temperatur
e
0
C
50.1
155.1
125.1
125.1
Enthalpy
KJ/ Kg.
-
209.71
2747.932
524.6
524.6
:
:
:
:
ASME SEC VIII DIV-1 & HEI
2.37 Kg/cm2 a
205 0C
Shell & D'End - 3.2mm, Nozzles - 1.6 mm
:
:
:
25 m3
16.6 m3
15.6 m3
:
KSB AG, Germany.
Page 38 of 130
Model No.
Type
Type of Operation
No. of pumps
Direction of rotation from DE
Medium delivered
Design Capacity
Duty point capacity
Total dynamic head
:
:
:
:
:
:
:
:
:
NPSH – Requried
:
Range of Operation
:
HGC 3/14
Multistage, Horizontal, Centrifugal Pump
Continuous
2 X 100%
Clockwise
Feed water (125.1 0C, 0.9388 sp gravity, pH >=8.5)
85 m3/ hr.
65 m3/ hr.
1220 MLC (at design capacity)
1294 MLC (at duty point capacity)
1370 MLC (shut off head)
4.4 MLC (at design capacity)
3.8 MLC (at duty point capacity)
30 m3/ hr to 110 m3/ hr
4.2.1. POWER CONSUMPTION
a) Guaranteed pump input power
At duty point capacity
:
b) Pump input power at design
Capactiy
:
Maximum allowable working
Pressure for casings
:
Critical speed for pump & assembly
Excluding drive
:
337.5 KW
380 KW
170 Kg/ cm2
7440 rpm
4.2.2. COOLING WATER REQUIREMENTS
Cooling water required for
a) Lube oil cooler
:
N.A.
b) Sealing and flushing
:
60 Ltr/min
Cooling water pressure at terminal
Point
:
3 to 4 kg/cm2
Pressure drop across the coolers: Max 0.05 kg/cm2
4.2.3. COUPLING
a) Type & make
b) Service factor
c) Spacer length
:
:
:
4.3. HP BFP MOTOR
Manufacturer
:
Type
:
Model Type
:
Total Numbers
:
Rated output
:
Voltage
:
Rated current
:
Rated speed
:
Thermal with stand time at 100%
of rated voltage
:
Protection
:
Gear type with spacer, HICLIFF
2.0
210 mm
NGEF Ltd., Bangalore
Horizontal foot mounted
AUT 400-1120/ 2
2
450 KW
6.6 KV, 3ph, 50 Hz
46 A
2975 rpm
20 sec (Hot)/ 30 sec (Cold)
IPW 55
Page 39 of 130
Load torque at rated speed
Starting time
a) at 110% of rated voltage
b) at 100% of rated voltage
c) at 80% of rated voltage
:
0.56 TR
:
:
:
3 sec
4 sec
8 sec
Method of cooling
Bearing
DE
NDE
Lubricant
:
As per IC 0161
:
:
:
NU 218 P63
6218 P63
Grease spheerol –AP2
4.4. BFP SUCTION STRAINER
a) Type
:
Y type
b) Mesh Size
:
50 microns
c) Pressure drop during clean cond.: 0.1 kg/cm2
d) Press. Drop during 50% clogged: 0.3 kg/cm2
4.5. LP BOILER FEED PUMP
Manufacturer
Model No.
Type
Type of Operation
No. of pumps
Direction of rotation from DE
Medium delivered
Design Capacity
Duty point capacity
Total dynamic head
:
:
:
:
:
:
:
:
:
:
NPSH – Requried
:
Range of Operation
:
KSB Pumps Ltd., India
WK 40/ 6 DSB
Multistage, Horizontal, Ring section
Continuous
2 X 100%
Clockwise
Feed water (125.1 0C, 0.94 sp gravity, pH 8 to 9)
18 m3/ hr.
16 m3/ hr.
137 MLC (at design capacity)
142.86 MLC (at duty point capacity)
155 MLC (shut off head)
2.9 MLC (at design capacity)
2.7 MLC (at duty point capacity)
5 m3/ hr to 23 m3/ hr
4.5.1. POWER CONSUMPTION
a) Guaranteed pump input power
At duty point capacity
:
Pump input power at design
Capactiy
:
Maximum allowable working
Pressure for casings
:
Critical speed for pump & assembly
Excluding drive
a) First critical speed
:
b) Second critical speed
:
10.74 KW
11.57 KW
25 Kg/ cm2
3750 rpm
5427 rpm
4.5.2. COOLING WATER REQUIREMENTS
Cooling water required for
a) Lube oil cooler
:
N.A.
Page 40 of 130
b) Sealing and flushing
:
Cooling water pressure at terminal
Point
:
4.5.3. COUPLING
a) Type & make
b) Service factor
c) Spacer length
:
:
:
2 to 3 kg/cm2
DB2-C/ Unique Transmit
1.5
140 mm
4.6. LP BFP MOTOR
Manufacturer
:
Type
:
Total Numbers
:
Frame size
:
Applicable standard
:
Duty
:
Rated continuous o/p kW at 50 C
ambient
:
Rated speed
:
Rated voltage & % variation :
Rated frequency & % variation:
Full load current
:
Construction
Degree of protection of enclosure:
Method of cooling
:
Insulation class
:
Temp. rise over 50 C ambient:
4.7. BFP SUCTION STRAINER
a) Type
:
b) Mesh Size
:
c) Pressure drop during clean cond.
d) Press. Drop during 50% clogged
5.
50 to 60 Ltr/min
Kirloskar Electric Co. Ltd.
Squirrel cage
2
PM160M
IS 325
S1
15 kW
2920 rpm
415V + 10%
50 Hz +
25.8 A
5%
IP55
TEFC-IC4111
Class F
70 C
Y type
50 microns
:
0.6 kg/cm2
:
1.0 kg/cm2-
CONDENSATE SYSTEM
5.1. CONDENSATE EXTRACTION PUMP
Manufacturer
:
KSB Pumps Ltd., India
Model No.
:
WKT125/5
Type
:
Vertical canister
Type of Operation
:
Continuous
No. of pumps
:
2 x 100%
Direction of rotation from DE :
Counter Clockwise
Medium delivered
:
Condensate (47.1 0C, 0.989 sp gravity, pH 8 to 9)
Design Capacity
:
86 m3/ hr.
Duty point capacity
:
70 m3/ hr.
Total dynamic head
a) At design capacity
:
122 MLC
b) At duty point capacity
:
126.48 MLC
c) Shut off head
:
135.5 MLC
Page 41 of 130
NPSH – Requried
a) At design capacity
:
b) At best efficiency point
:
Minimum continuous flow at
design speed
:
Power consumption
c) Guaranteed pump input power
At duty point capacity
:
d) Pump input power at design
Capactiy
:
Maximum allowable working
Pressure for casings
:
a) Suction casing
:
b) Stage & discharge casing :
Critical speed for pump & assembly
Excluding drive
a) First critical speed
:
b) Second critical speed
:
Cooling Water
a) Pressure
:
b) Quantity
:
Coupling
Type & make
:
1.5 MLC
2.0 MLC
51 m3/ hr
40.058 KW
42.85 KW
15 Kg/ cm2
20 Kg/ cm2
1810 rpm
2330 rpm
0.5 to 1.0 Kg/ cm2 (g)
3-5 Ltr/ min
Flexible spacer/ Unique
5.2. CEP MOTOR
Manufacturer
:
Kirloskar Electric Co. Ltd.
Type
:
Squirrel cage
Frame size
:
VSC250M
Applicable standard
:
IS 325
Duty
:
S1
Rated continuous o/p kW at
a) 50 C ambient
:
55 KW
b) 40 C ambient
:
57 KW
Rated speed
:
1478 rpm
Rated voltage & % variation :
415V + 10%
Rated frequency & % variation:
50 Hz +
5%
Full load current
:
94 A
Performance
Starting current at rated volt. (FLC): 600% FLC
Starting torque at rated voltage:
200% (72.5 Kgm)
Starting time with load at
80 % voltage
:
4 sec approx
100 % voltage
:
2.5 sec approx
Safe stall time at 110% rated voltage
Cold
:
33 sec
Warm
:
20.6 sec
Permissible running time at full load
At minimum permissible volt (75%): 5 Min
Minimum possible voltage % of
Rated voltage during starting :
80%
Construction
Degree of protection of enclosure: IPW55
Page 42 of 130
Method of cooling
:
Insulation class
:
Temp. rise over 50 C ambient:
TEFC-IC4111
Class F/ Ltd to class B
70 C
5.3. STRAINER
a) Make & Type
:
Multitex-make/ conical
b) Mesh size
:
100 mm
c) Material of mesh
:
SS304
g) Pressure drop during clean cond.: 0.6 kg/cm2
h) Press. Drop during 70% clean:
0.7 kg/cm25.4. CONDENSATE STORAGE TANK
Manufacturer
:
Design & Fab code
:
Capacity Net/ Total
:
Dimension of the tank
:
Design temperature
:
Corrosion Allowance
:
Erection weight
:
Weight filled with water
:
Suyog Engineers Ltd.
IS 10987
23 / 33.08 m3
2.65 m dia x 6.0 m height
65 0C
1.5 mm
6900 Kg
38750 Kg
5.5. STEAM JET AIR EJECTOR
Manufacturer
:
Mazada Controls
5.5.1. MAIN EJECTOR
Description
:
2 Stage Main SJAE (2 x100 %) with 2 nos
inter & after condenser (Surface type)
5.1 Kg/cm2 A
152 °C
10 SCFM (Total)
20.4 Kg/hr (dry air)
44.9 Kg/hr (Water Vapour)
21.5 TPH at 16.0 Kg/cm2 A, 46.1 °C
Steam Pressure
Stream Temperature
Capacity
:
:
:
Minimum Condensate Flow :
5.5.2. HOGGING EJECTOR
Type
No. of Unit
Steam Pressure
Steam Temperature
Vacuum Attainable
:
:
:
:
:
Single stage
1 x 100 %
5.1 Kg / cm2 A
152 °C
66% of Condenser Vacuum in 10 minutes
Page 43 of 130
6.
STEAM TURBINE GENERATOR & ACCESSORIES
6.1. STEAM TURBINE
6.1.1. GENERAL
Manufacturer
Type
:
:
SIMENCE INDIA
Axial Flow, Impulse type, Nozzle governed
6.1.2. DESIGN & PERFORMANCE DATA
Turbine Output
Rated
:
18.00 MW
Max :
20.00 MW
Turbine Type
:
V45A
Rated conditions
:
Steam pressure before turbine
Stop valve
:
76 ata
Steam temperature before turbine
Stop valve
:
505 C
Steam flow through turbine
Stop valve
:
62.5 TPH
LP (Injection) steam pressure :
4.5 Kg/ cm2 (a)
LP (Injection) steam temperature:
191 0C
LP (Injection) steam flow
:
4.5 TPH
Turbine exhaust pressure
:
0.101 Kg/ cm2 (a)
Turbine rated speed
:
Rated speed
:
6800 RPM
Direction of rotation
:
C.C.W ( seen turbine-Generator)
Trip speed
:
110 % of rated
Critical speed
:
3480 RPM ( 50 % speed )
Operating frequency range of
Turbine auxiliaries
:
47.5 - 52.5 Hz
Maximum allowable turbine
Exhaust pressure at rated condition: 0.300 atm
Minimum allowable turbine
Exhaust pressure at rated condition: 0.106 atm
Weight of heaviest piece to be
handled during erection
:
Turbine skid - 40000 Kgf
Critical speed of turbine rotor - :
3500 RPM ( Approx 50 % speed )
Max. allowable temperature at
Turbine exhaust hood
:
110 0C
Exhaust sprayhood system provided:Yes
Run-down time after turbine trip out
With vacuum
- To stand still
:
15 min (approx.)
Steam purity
Specific electric conductivity :
Less than 0.2 #S/Cm
Silica
:
Less than 20 #g/Ltr
6.1.2.1. BLADING
Stage Blading
a)Control stage ( Impulse blade)
: One Stage
Page 44 of 130
b)Reaction stages
Type of Governing
First Nozzle group
Seond nozzle group
: 19 Stage
: Nozzle control governing.
: 19 Nozzle
: 9 Nozzle.
6.1.2.2. TURBINE STOP VALVES
HP
Nos
:
Size of each valve connection
Full closure time
LP (Injection steam)
Nos
:
Size of each valve connection:
Full closure time
:
1
:NB 150 ANSI 1500 lbs
:0.3 sec
1 - External to turbine
NB 200 ANSI 150 lbs
1 sec
6.1.2.3. TURBINE CONTROL VALVES (HP)
Steam control valve
:
Steam control valve actuator :
Operating time
Open :
Close :
Total Valve movement :
:
First control valve open at
:
Second control valve opening :
6.1.2.4. GOVERNING SYSTEM
Type of governor
Mode of Governing
Make
Type
6.1.2.5. BEARINGS
Type of bearings
Journal diameter
Type of Oil
Front Bearing Clearance
Rear Bearing clearance
6.1.3. GLAND SEAL SYSTEM
HP Gland sealing
Pressure
Steam flow
Temp
Valve actuator
LP Gland sealing
Pressure
2 Nos
1 Nos.
1 to 5 sec
0.2 to 0.5 sec
36 MM
22 MM
23 to 36 MM
:
:
:
Digital Electro hydraulic
Digital
Wood ward
Wood ward 505
:
:
:
:
:
Tilting pad
180 MM
ISO VG 46
34 to 39 MM
34 to 39 MM
:
:
:
1.1 Ata
:0.04 TPH
505 deg C
Pneumatic.
:
1.1 Ata
Page 45 of 130
Steam flow
Temp
Valve actuator
:
:
:
0.126 TPH
191 Deg C
Pneumatic.
6.1.4. HYDRAULIC CONTROL OIL SYSTEM
Type of control fluid
:
Mineral oil
Specification of control fluid :
ISO VG 46
Manufacturere
:
SLPL:
Tank capacity
:
400 Ltr
Required flow
:
60 LPM
Oil cooler inlet temp
:
50 degC
Oil cooler outlet temp
:
45 degC
Cooling Water
:
45 LPM
Heater rating
:
3 KW / 415 AC / 3 phase
6.1.4.1. CONTROL FLUID PUMPS
a) No. of pumps
b) Type
c) Capacity
d) Discharge pressure
e) Motor rating
:
:
:
:
:
2
Positive displacement
12 ltr/ min
110 Kg/ cm2 (a)
5.5KW
6.1.4.2. FILTERS FOR CONTROL FLUID SYSTEM
Manufacturere
:
SLPL
Tppe
:
Paper Mesh
Flow at DP 0.3 Bar
:
60 LPM
Filterationlevel
:
10#m
Filter insert material
:
Micro organic paper.
6.1.4.3. CONTROL FLUID COOLERS
No. of coolers in service
:
Cooling water requirement
per cooler
:
- Flow
:
- Pressure
:
- Temp rise
:
Water slide pressure drop of
Each cooler
:
Tube material
:
1
0.46 (Nor) / 1.0 (Max) m3/ hr
2.2 kg/cm2
1.5 0C
<0.5 Kg/ cm2
SS
6.1.5. LUBRICATING OIL SYSTEM
6.1.5.1. LUBRICATING OIL SUPPLY
Tank Capacity
:
Initial oil filling
:
Retention time
:
10000 Litres
5600 Litres
6 min
Page 46 of 130
1.5 Kg/ cm2 (a)
300 Litres
Mineral Oil
ISO VG46 Servo Prime 46
Lubrication oil system pressure:
Lub. Oil quantity in the system:
Type of Lube oil
:
Specification of Lube oil
:
Level of cleanliness to be maintained
For the lube oil for satisfactory
Operation of the system
a)
Permissible suspended particle
Size
:
Class 9 NAS 1638
b) Permissible water content by
volume
:
0.05 %
6.1.5.2. MAIN OIL PUMP
Numbers
Make
Type
Drive
Capacity
Delivery head
Speed
:
:
:
:
:
:
:
1
All Weiler
SNFG 660 R54QW1
Turbine shaft
890 Ltr/ min
35 MLC
1500 RPM
6.1.5.3. AUXILIARY OIL PUMP
Numbers
Make / model
Type
Drive
Capacity
Delivery head
Speed
Bearings - Nos/ Type
Absorbed / rated power
:
:
:
:
:
:
:
:
:
1
ROTO / RI111
Twin screw
AC Motor
810 Ltr/ min
4.0 bar (g)
1440 RPM
2 / Antifriction
15 KW
6.1.5.4. EMERGENCY OIL PUMP - DC
Numbers
:
Make / Model
:
Type
:
Drive
:
Capacity
:
Delivery head
:
Speed
:
Rated voltage/ power
:
Bearing quantity/ type
:
1
ROTO / RI 95
Twin screw
DC Motor
570 ltr/ min
1.1 bar (g)
1440 RPM
220V DC/ 5.5 KW
2/ Antifriction
6.1.5.5. OIL VAPOUR EXTRACTION FAN
Numbers
:
Make / Model
:
Type
:
Capacity
:
Drive
:
Absorbed / rated power
:
Speed
:
1
PHILIPPE / E205-9
Aercology
450 m3/ hr
AC motor
1.1 KW
3000 RPM
Page 47 of 130
Bearings type
:
Antifriction
6.1.5.6. OIL COOLERS
Numbers
:
Installation
:
Cooling surface area required:
Cooling surface area provided:
Cooling water inlet temperature:
Cooling water outlet temperature:
Oil outlet temp.
:
Oil inlet temp
:
Cooler dia X Height
:
Pressure drop of oil slide
:
Pressure drop of water slide :
Fouling factor water slide
:
Number of tubes
:
Line change over facility provided:
2 x 100%
Horizontal
70.86 m2
75.1 m2
35 0C
42 0C
45 0C
66 0C
600x3925 mm
0.85 bar
0.5 bar
0. 0614 milli m2Hr 0C/ kCal (overall)
426
Yes
6.1.5.7. LUBRICATING OIL FILTER
Type
:
Flow rate per filter
:
Filtration particle size
:
Bursting pressure
:
Online change facility provided:
Twin
100 %
10 micron (nominal)
10 Kg/ cm2s
Yes
6.1.5.8. GEAR BOX
Gear make
Type:
Rated power
Input speed ( turbine)
Output speed (generator )
Lubrication
Oil type
Filtering
Inlet pressure
Inlet temp Normal
Inlet temp Max
Oil flow :
:
TRIVENI
Reducertype
21000 KW
6800 RPM
1500 RPM
:
:
:
:
:
:
ISO VG 46
25 microns.
1.7 Bar ( g )
49 Deg C
60 Deg C
450 LPM.
:
:
NOISE HOOD (ACOUSTIC ENCLOSURE)
Location of the machine
No. of Exhaust fans
Location of exhaust fans
Heat Load inside enclosure
:
:
:
:
:
On a pedestal
2
On top
29KW at 40 deg C Ambient
62KW at 15 deg C Ambient
Noise Spectrum of Steam Turbine
Frequency
(Hz)
Level (dB)
63
125
250
500
1000
2000
4000
8000
57
78
79
81
86
85
76
69
Page 48 of 130
1600
0
59
Global (dBA)
90
Noise Spectrum of GearBox based on No Load Test is
Frequency
(Hz)
Level (dB)
Global (dBA)
31.
5
40
63/ 250
500
1000 2000
125
52/ 70
80
73
74
62
85 (10 dBA to be added for the load)
4000
8000
79
79
1600
0
74
6.1.5.9. ACOUSTIC HOOD FAN MOTOR
Make
:
NGEF
Type
:
Squirrel Cage Induction Motor,
Class F Insulation,
IP55 Protection
Numbers
:
One
Voltage
:
415V, 3ph, 50Hz
Power Output
:
1.5 KW
Speed
:
1400 rpm
6.1.6. STEAM TURBINE PROTECTION SYSTEM
Over speed trip
:
110 % of rated speed
Low lubrication oil pressure trip:
0.6 Kg/ cm2 (a)
High lub. oil temperature trip :
125 0C
High exhaust hood temp alarm:
120 0C
Low vacuum trip for steam turbine: 0.2 Kg/ cm2 (a)
Thrust bearing excessive wear trip: + 0.3 mm
High Vibration Alarm Trip
a) Shaft
:
b) Bearing housing
Control oil pressure low
High babbit temp trip
HP 36 / 48 microns -check for corrected valus??
LP 50 / 67 microns
70 bar (g)
120 C
:
:
:
Weights
Name & Wt. of heaviest piece to:
Be handled during erection :
Name & Weight of heaviest piece to
Be handled during maintenance:
Minimum required distance between
Center line of TG & main hook of
EOT crane for handling of TG
Component
:
Generator - 45000 Kgf
Turbine skid - 45000 Kgf
Generator rotor 13600 - Kgf
4m
6.2. STEAM TURBINE GENERATOR
A.C. Generator, frame size & poles: DG1000N3150E, 4Pole
Serial no.
:
P140723-10
Specification
:
IEC34
Page 49 of 130
Rating kVA
Voltage and frequency
Rated power factor
Rated line current
Speed
Enclosure IP and in words
Cooling IC and in words
Air gap
Winding resistance at 20 0C
Stator
Rotor
:
:
:
:
:
:
:
:
:
Bearings
Make
Type
Size
Float
:
:
:
:
:
24058
11500V, 50 Hz
0.85
1208 A
1500 rpm
IP55 CACW
IC 8A1W7\
20 mm
0.0206 ohms/ phase
0.0989 ohm
Exciter – frame size
:
Rotating armature resistance
at 200C between terminals :
Field resistance at 200C
:
Air gap
:
Excitation for
1. Rated full load on the
Generator
:
2. Rated voltage on no load :
Rectifier diode ref. and quantities:
Permanent-magnet generator for
AVR power supply O/p voltage/
Current / Hz
:
Generator noise level
Mean sound power level
:
Mean sound pressure level :
Maximum sound pressure
level measured at 1m from
the machine surface
:
DE
RENK
EMZLB
22-280
Min 3mm
:
:
:
:
:
:
:
EMZLQ
22-280
Max 13mm
MAJ39M20
0.00467 (line-line)
7.65 ohms
1.5mm
7.3A, 70V
2.43A, 19V
WESTCODE 6 OFF SW15PH40
6 OFF SW15PH400R
220V/ 5.1A/ 275Hz
100db (A)
78db (A)
82db (A)
6.2.1. GENERATOR PROTECTION RELAY PANEL
6.2.1.1. LGPG RELAY
Type
Model No.
Sr.No.
Make
Rated Voltage
Auxiliary Voltage
Frequency
NDE
RENK
LGPG111
LGPG11101P55LEE
127245K
CEGELEC
100/120V AC
220V DC
50 Hz
Page 50 of 130
Sr.
No.
Protection
Relay Settings
Alarm
Setting
Trip Setting
Differential
IEC
Cod
e
87G
1
Current Settings
Nil
2
Over Voltage
59V
Voltage Settings
Timer Settings
Nil
3
Under Voltage
27G
Nil
4
Protection For
AVR Sensing PT
Stator Earth Fault
60
1&2
51N
Voltage Settings
Timer Settings
Voltage Balance
Is1=0.07 KA
K1= 0%
Is2=1.40 KA
K2=150 %
V>12.5kV
T>3.0 S
V>>12.5kV
T>>4.0 S
V<9.2kV
T=3.0 S
Vs>5 V
5
6
7
8
9
10
11
12
Over Current
51V
Stator Over
Current
51N
Stag
e-2
Under Freq.
81U
(Alarm)
1
Under Freq. (Trip) 81U
2
Negative
46
Sequence
Stag
e1
Negative
46
Sequence
Stag
e1
Field Failure
40G
Nil
Characteristic:
Standard Inverse
Current Setting
Timer Multiplier
Setting
IDMT Operating
Characteristics
Reset Time Setting
Functions:
Voltage Restrained
Characteristic
Standard Inverse
Current Settings
Time Multiplier
Reset Time Setting
Voltage Settings
Current Setting
Timer Setting
Ie>1.0 A
TMS : 0.20
Ie>>0.10 A
tReset=1.0 S
I >1.4 KA
Nil
YMS = 0.3 S
tReset=1.0 S
Vs1:11.5 KV
Vs2 :3.4 KV
K : 0.45
Ie>>0.1
T>>0 S
Frequency Setting
Time Setting
Frequency Setting,
Time Setting
Current Setting
Timer Setting
F1<48.5 Hz
t1:2.0 S
F2<47.5 Hz
t2:1.0 S
I2 > 0.08kA
t > 2S
Current Setting
Heating Costant
Cooling Constant
Max. Operating T
Min Operating T
Mho Offset
Mho Diameter
Delayed Pickup T
Delayed Drop Off
I2 >> 0.10kA
K: 14S
Kreset : 14S
tMax : 500S
tMin : 3.0S
Xa : 821.0
Ohm
Xb : 13.36
Ohm
t : 1.0 S
Page 51 of 130
Sr.
No.
Protection
IEC
Cod
e
Relay Settings
13
Reverse Active
Power
32P
Power Setting
Delayed Pickup T
Delayed Drop Off
14
Low Forward
Power
32L
Power Setting
Delayed Pickup T
Delayed Drop Off
6.2.1.2. KBCH 140 RELAY
Type
Model No.
Sr.No.
Make
Rated Voltage
Auxiliary Voltage
Frequency
:
:
:
:
:
:
:
Sr.
No.
Protection
1
Overall
Differential
IEC
Cod
e
87G
T
2
Overfluxing
24
3
Transformer Ref
64G
T
Alarm
Setting
Trip Setting
tDO : 2.0 S
(-) P > 37.0
KW
t :0.5 S
tDO : 2.0 S
P < 0.25W
t : 1.0 S
tDO : 2.0 S
KBCH140
KBCH14001H15LED
127246K
CEGELEC
100/120V AC
220V DC
50Hz
Relay Settings
Alarm
Setting
Trip Setting
Diff Current Setting,
High Set,
Transformer Conf,
HV Ratio Cor, LV1
Ratio Cor, LV2 Ratio
Cor
Overfluxing Alarm,
Time Setting,
Overfluxing Trip,
Time Setting, 5th
Harmonics Setting
Current Setting
Nil
Id > 0.2 PU,
Id >> 10.0
PU, HV +
LV1(X2)
+LV2, 1.2,
1.11, 0.32
V/F = 2.31,
tV/F = 5 S,
V/F = 2.42,
tV/F = 1.0,
Iof = 10 %
Io > HV
0.100 PU
Nil
6.2.2. GENERATOR EXCITATION SYSTEM
The excitation system is designed for a brushless generator (with rotating exciter and
rotating diodes) with permanent magnet generator.
6.2.2.1. AUTOMATIC VOLTAGE REGULATORModel No.
:
Alspa AVR820
Make
:
CEGELEC
Sr.
No.
1
2
3
Item Description
Qty.
Power Supply Module PWR325
CPU Model 351
Input module MDL645
Page 52 of 130
1No.
1No.
1No. (16logic input)
4
5
6
7
8
9
Output module MDL940
1No. (16relays output)
Input module ALG221
2Nos. (4 analog input)
Output module ALG391
1No. (2 analog output)
Communication module N80 link CMM305
1No.
Electrical measurements module IP142/IP144
1No.
Thyristor trigger unit GENI
1No.
AVR Function:
1. Generator voltage regulation according set point.
2. Reactive power control.
3. Rotor current limitation.
4. Flux limitation (U/F).
5. Generator line current limitation.
6. Underexcitation limitation.
7. Internal fault detection & measurement monitoring.
8. Automatic follow up of the set point when manual control operating.
9. Auto switching to standby channel ( MCR) in case of failure of AVR.
6.2.2.2. MANUAL CURRENT REGULATOR
Model No.
:
Alspa MCR820
Make
:
CEGELEC
Sr.
No.
1
2
3
4
5
6
7
Item Description
Qty.
Power Supply Module PWR325
CPU Model 341
Input module MDL645
Output module MDL940
Input module ALG221
Output module ALG391
Thyristor trigger unit GENI
MCR Function
1No.
1No
1No. (16logic input)
1No. (16relays output)
1No. (4 analog input)
1No. (2 analog output)
1No.
:
1) Regulation of exciting current according to set point.
2) Automatic follow up of the manual set point according to AVR
output providing a bumples transfer from primary chanel to stand
by chanel.
3) Internal fault detection
4) Control of starting and stopping logic sequences.
5) Control of generator voltage building.
6.2.3. LA, SC, PT, CT CUBICLE
6.2.3.1. CUBICLE
Make
:
Rated voltage
:
Rated frequency
:
Dry power frequency withstand
Voltage
:
Impulse withstand Voltage :
Continuous current rating of Main
Bus bar
:
Momentary current
:
POWER GEAR LIMITED, Banglore
11.5KV
50HZ
28KV rms
75KV peak
1250A
40KA rms for 1sec.
Page 53 of 130
Reference standard
:
IS - 3427
6.2.3.2. POTENTIAL TRANSFORMER
PT-1
Make
Type
Ratio
110/Ö3
Acc. Class
Burden
Insulation Class
Ref. Standard
PT-2
Kappa Electrical
Resin Cast
Resin Cast
11500/Ö3 / 110/Ö3 / 110/Ö3
11500/Ö3 /
:
:
:
:
:
:
:
3P/0.5
100/200VA
PT Primary protection fuse
Make
Type
Rated Voltage
Breaking capacity
:
:
:
:
Alstom
VTF11
11KV
52.4KA
Lightning Arrestor
Make
Type
Rated Voltage
Insulation level of housing:
Frequency
Nominal Discharge Current:
:
:
:
:
:
:
ELPRO International - India
Station
12KV
28KV rms
50Hz
10KA
Surge Capacitor
Make
Rated Voltage
Insulation level of housing
Rated Capacitance
Frequency
:
:
:
:
:
Madhav Capacitors - India
12KV
28KV rms
0.25 micro farad
50Hz
:
:
:
:
:
:
:
:
Kappa Electrical
Resin Cast
1400/1-1A
5/0.5
15/15VA
28/75KV
E
IS -2705
6.2.3.3. CT
Make
Type
Ratio
Acc. Class
Burden
Insulation level
Insulation class
Ref. Standard
0.5
50VA
E
IS 3156
6.2.4. NEUTRAL GROUNDING CUBICLE
6.2.4.1. CUBICLE
Make
:
Rated voltage & Frequency :
1 Min. Power frequency withstand
Emform Power Projects Private Limited, Bangalore
12KV, 50HZ
Page 54 of 130
Voltage
Impulse withstand Voltage
:
:
28KV rms
75KV peak
6.2.4.2. OTHER EQUIPMENT
Sr. Description
Specification
1
CT for
Metering, IS2705
2
CT for
Protection, IS2705
3
CT for
Generator
Diffrential
Protection, IS2705
4
CT for
Generator
Transformer
over all
Diffrential
Protection, IS2705
CT for Earth
Fault, IS - 2705
5
6
Neutral
Grounding
Transformer
IS-2028
7
Neutral
Grounding
Resistor IEEE32
Neutral
Grounding
Isolator IS 1818
8
Make
1400/1A, Class-0.5,
Burden-50VA, Insulation
class- E, Short time
rating- 40KA for 1 second
1400/1A, Class-5P20,
Burden-40VA, Insulation
class- E, Short time
rating- 40KA for one
second
1400/1A, Class-PS,
Vkp>300, Im<15Ma at Vk
, RCT<4.5 Ohm at 75 °C,
Insulation class-E, Short
time rating- 40KA for 1
second
1400/1A, Class-PS,
Vkp>600, Im<15Ma at Vk
, RCT<6 Ohm at 75deg.C
, Insulation class- E,
Short time rating- 40KA
for one second
Pragat
i
Qty
.
03
Pragat
i
03
Pragat
i
06
Pragat
i
03
10/1A, Class- 5P10,
Burden- 15VA, Insulation
class- E, Short time
rating- 1.5KA for one
second
Ratio- 15KV / 20V,
Rating- 20KVA
Continuous,
Type- Dry Type,
Insulation- Class F with
class B temp. rise.
Rated Voltage- 1100V,
Resistance - 0.245 Ohms,
Pragat
i
01
Kappa
01
Essen
01
Rated Voltage- 12KV,
Single Pole, 200A
Continuous, 2NO + 2NC
DP
01
Page 55 of 130
Remarks
3 used for
generator ckt.
breaker panel
6.3. TURBINE OIL PURIFICATION SYSTEM
6.3.1. CENTRIFUGE
Manufacturer
:
Model
:
Capacity
:
Location
:
Speed
:
CENTRIFUGE MOTOR
Manufacturer
:
Type
:
Quantity
:
Frame size
:
Duty
:
Rated Output
:
Voltage
:
Full load current
:
Speed
:
Insulation class
:
Enclosure/ Protection
:
Bearing Number (DE & NDE) :
Lubrication
:
6.3.2. FEED PUMP
Manufacturer
Type
Max suction lift permissible
Capacity
Speed
Discharge pressure
Internal built in relief valve
6.3.3. DISCHARGE PUMP
Manufacturer
Type
Location
Discharge pressure
Capacity
Speed
Internal built in relief valve
PUMP MOTOR
Manufacturer
Type
Quantity
Frame size
Duty
Rated Output
Full load current
Speed
Pennwalt India Ltd.
AS 12 VHC
1000 ltr/ hr
Indoor
15000 rpm
Crompton Greaves Ltd.
3 Ph Squirrel cage Induction
1 No.
ND 90L
S1
1.10 KW
415V , 50Hz , 3 ph
2.5 A
2830 rpm
Class F
TEFC / IP 55 as per IS:4691 - 1985
6205
Lithium soap base Grease Grade 2
:
:
:
:
:
:
:
Master Services
Positive displacement gear pump
3m
1100 ltr/ hr
1440 rpm
1.5 kg/cm2
Provided
:
:
:
:
:
:
:
Master Services
Positive displacement (Rotary ear)
After centrifuge
3 kg/ cm2
1200 ltr/ hr
1440 rpm
Provided
:
:
:
:
:
:
:
:
Crompton Greaves Ltd.
3 Ph SQ, TEFC / IP 55 , Class F
1 No.
ND 90L
S1
1.50 KW, 415V, 50Hz , 3 ph
3.4 A
1405 rpm
Page 56 of 130
6.3.4. HEATER
Manufacturer
Type
Quantity
Heater rating
:
:
:
:
Pennwalt India Ltd.
Direct
1 No.
24 KW
6.3.5. POLISHING FILTER
Manufacturer
Type
Quantity
Capacity
Pressure drop
:
:
:
:
:
Pennwalt India Ltd.
Edge
1No.
1000 Ltr /hr
0.5 Kg/cm2
6.3.6. TURBINE LUBE OIL COLLECTION TANK
Manufacturer
:
Suyog Engineers Ltd.
Design & Fab code
:
IS 803 / API - 650
Capacity Net/ Total
:
7.5 / 8.5 m3
Sp. Gravity of product
:
0.875
Operating temperature
:
65 0C
Design temperature
:
80 0C
Design pressure & vacuum :
Hydrostatic head and Vacuum
Operating Weight
:
7965 Kg
7.
LIQUID FUEL SYSTEM
7.1. NAPHTHA STORAGE AND HANDLING SYSTEM
7.1.1. NAPHTHA FORWARDING PUMPS
Manufacturer & Model No. :
Ingersoll-Rand (India) Ltd.
(1.5 HPX x 12A-1b-2
No. of Pumps
:
2 x 100%
Type of Pumps
:
Horizontal Centrifugal
Operating Conditions
Hazardous Area
:
Class : 1
Classification
Group : D, Division :1
Performance
Rated Capacity
:
20 cu.m/hr
NPSH Required
1.73 mLC
Total head at rated Capacity :
95 mLC
Efficiency
:
39.5%
Shut-off head
:
98.2 mLC
Min. Continuous Flow
:
8.9 cu.m/hr
Rated Speed
:
2910 rpm
Drive Motor
Manufacturer
Rated Out put
Type of construction
Supply voltage
Frequency
:
:
:
:
:
KEC
15 kW
Flame proof construction
415 +/- 10% V AC
50 +/- 5% Hz
Page 57 of 130
Type of enclosure
Type of insulation
Degree of Protection
:
:
:
7.1.2. NAPHTHA UNLOADING PUMP
Manufacturer & model No. :
Type of Pumps
:
No. of Pumps
:
Operating Conditions
Hazardous area Classification:
Performance
Rated Capacity
:
NPSH Required
:
Total head at rated cap.
:
Guaranteed power Consumption:
by pump At max. viscosity
Efficiency
:
Rated Speed
:
Drive Motor
Manufacturer
Rated output
Type of construction
Supply voltage
Frequency
Type of enclosure
Degree of protection
Class of insulation
:
:
:
:
:
:
:
:
7.1.3. NAPHTHA STORAGE TANK
Manufacturer
:
No. of Tanks
:
Type
:
Size
:
Capacity / tank
:
TEFC
Class F with temperature rise limited to class B.
IP 55
Tushaco Pumps Ltd.
(TDSH 118/064.100.40.5BK)
Twin Screw external Bearing
3 (2 Working + 1 standby)
Class 1, Group D, Division 1
50 cu.m/hr
2 mLC
30 mLC
11.2 kW
37%
1470 rpm at full load
Crompton Greaves
18.5 kW
Flame proof construction
415 +/- 10% V AC
50 +/- 5% Hz.
TEFC
IP 55
Class F with temperature rise limited to ClassB.
Sai Engineering Works
Two (2)
Vertical floating roof-single deck with rolling ladder
24M Dia. x 16M Ht.
6334 m3
7.2. HSD STORAGE AND HANDLING SYSTEM
7.2.1. HSD FORWARDING PUMP
Manufacturer & Model No. :
No. of Pumps
:
Type of Pumps
:
Operating Conditions
Liquid handled
:
Temperature
:
Hazardous Area Classification:
Performance
Rated Capacity
:
NPSH Required
:
Ingersoll-Rand (India) Ltd.
1HP x 11A - 1B2
3 (2 working + 1 standby)
Horizontal Centrifugal
HSD
Ambient temperature
Class 1, Group D, Division 1
5 cu.m/hr
2.01 mLC
Page 58 of 130
Total head at rated cap.
Efficiency
Shut-off head
Min. continuous flow
Rated speed
Drive Motor
Manufacturer
Rated Output
Type of construction
Supply voltage
Frequency
Type of enclosure
Type of insulation
7.2.2. HSD UNLOADING PUMP
Manufacturer & Model No.
:
:
:
:
:
90 mLC
14.2%
97.9 mLC
3.0 cu. m/hr
2910 rpm
:
:
:
KEC
9.3 kW
Flame proof construction
:
415 +/- 10% V AC
50 +/- 5% Hz.
TEFC
Class F with temperature rise limited.
To class B
:
:
:
:
Type of Pumps
:
No. of Pumps
:
Operating Conditions
Hazardous Area Classification:
Performance
Rated Capacity
:
NPSH Required
:
Total head at rated cap.
:
Guaranteed power Consumption:
by pump At max. viscosity
Efficiency
:
Rated Speed
:
7.2.3. HSD STORAGE TANK
Number
Type
Size
Capacity
:
:
:
:
7.2.4. CENTRIFUGE
Make
:
Type
:
Number
:
Liquid handled
:
Capacity
:
Guaranteed discharge Pressure:
Moisture content at the Inlet of
Centrifuge
:
Guaranteed residual Moisture:
at the outlet of Centrifuge
Guaranteed solid particle
:
Size at the outlet of c.f.
Guaranteed power
:
Tushaco pumps Ltd.
(TS 135/060.000.40.5K)
Twin screw external bearing
3
Class 1, Group D, Division 1
30 cu.m/hr
3 mLC
25 mLC
7.7 kW
26%
1470 rpm at full load
One (1)
Vertical Conical Roof
5.2M Dia. x 6M Ht.
100 m3
ALFA LAVAL
Manual cleaning type centrifuge
Three
HSD
6 m3/hr
1.5 kg/sq. cm
1.5 % v/v (15000 ppm)
0.05 % v/v (500 ppm)
5 microns
6.5 kW
Page 59 of 130
Consumption by motor
Accessories
Feed pump with drive
:
Motor and suction strainer
Pump make
:
Motor make
:
Motor rating
:
Strainer
:
Strainer make
:
Strainer type
:
Sludge and water Collecting Tank:
8.
Three (3)
ALIL
CGL
7.5 kW, 415 V, 50 Hz, 3ph, IP55, B5, Flame proof
40 NB screwed conn., SS screen, Mesh size 12
SKILT
' Y ' Type
Three
DM WATER SYSTEM
8.1. GENERAL
Normal Flow rate
:
Peak flow rate
:
Run length between successive
regeneration
:
Net productive output between
regeneration
:
15 m3/hour
30 m3/hour (with both stream in service)
68 hours
900 m3
8.2. DM PLANT DESAL WATER SUPPLY PUMP (PAW PUMPS)
Description
Manufacturer
:
WPIL Limited.
Model No.
:
B7TC
Type of pump
:
Vertical turbine
Design / testing code
:
IS : 1710
Number of pumps
:
3 (2 working + 1 standby)
Performance Data
Rated capacity
Total head at rated cap.
Bowl head
Shut-off head
Range of operation
Rated speed
Efficiency at rated cap.
Bowl efficiency
Input power at rated cap.
:
:
:
:
:
:
:
:
:
15 cu.m/hr
35 mLC
35.02 mLC
42 mLC
50% - 150%
1460 rpm
63.82%
64%
2.23 kW
Design & Constructional Features
No. of stages
:
8
Min. submergence req.
:
0.2 M
at rated capacity
Drive Motors
Page 60 of 130
Make
Motor rating at 50 deg. C
Application standard
Type of motor
Degree of protection of
Insulation class
:
:
:
:
:
:
8.3. EFFLUENT DISPOSAL PUMPS
Make
:
Model
:
Mark
:
Type
:
Capacity
:
Head
:
Discharge Pressure
:
Qty
:
Efficiency
:
Max. Rated speed
:
Supply Voltage
:
Supply Frequency
:
MOTOR
Make
Frame
:
:
KEC
3.7 kW
IS 325
TEFC
IP-55
Class B insulation
KIRLOSKAR BROTHERS LTD.
CPHM 32/13
PEF1/2
Horizontal Centrifugal
15 cu.m/hr
20 mWC
2.0 kg/sq. cm
Two (2)
49.5%
2900 rpm
415 V, 3 ph
50 Hz.
KIRLOSKAR ELECTRIC CO. LTD
PM 90L
8.4. ACID / ALKALI UNLOADING CUM TRANSFER PUMPS
Make
:
ANTICORROSIVE EQUIPMENT
Model
:
EXP - 55 - AG
Mark
:
PHL / PAK -1/2
Capacity
:
10 cu.m/hr
Head
:
15 mWC
Qty
:
Two (2)
8.5. DM WATER TRANSFER PUMP
No. of Pumps
:
Type
:
Rated Capacity
:
NPSHA
:
Total Head Development at rated
capacity
:
Shut-off Head
:
PUMP MOTOR
Type
Rated Voltage
Duty
Type of Cooling
Degree of Protection
Insulation Class
:
:
:
:
:
:
2 x 100 %
Horizontal, Centrifugal (Radially split casing)
17 m3 / hr
8 MLC
38 MLC
120% of pump rated head
Squirrel Cage Induction Motor
415 V
S1
TEFC
IP 55
F
Page 61 of 130
Voltage Variation
:
Frequency Variation
:
Combined Voltage & frequency
variation
:
8.6. BLOWERS
Type
Size
Manufacturer
Speed
Capacity
Pressure
Motor power
Motor make
:
:
:
:
:
:
:
:
±10%
± 5%
10%
KG
53 AC
Kay Engineering Works
970 rpm
73.62 CFM
6.70 psi
7.5 HP
Kirloskar, 3ph induction motor, 11 amp.
8.7. DM WATER PUMPS FOR REGENERATION
Make
:
KIRLOSKAR BROTHERS LTD.
Model
:
CPHM 32/16
Mark
:
PDMR1/2
Type
:
Horizontal Centrifugal
Capacity
:
10 cu.m/hr
Head
:
25 mWC
Discharge Pressure
:
2.5 kg/sq.cm
Efficiency
:
40%
Impeller dia
:
145 mm
Qty
:
Two
Max. Rated Speed
:
2900 rpm
Supply Voltage
:
415 V, 3 ph, 50 Hz
MOTOR
Make
Frame
:
:
KIRLOSKAR ELECTRIC CO. LTD
PM 90L
8.8. MIXED BED EXCHANGER
MAKE
Mark
Size / Capacity
Qty
Design Temperature
Design Pressure
Test Pressure
:
:
:
:
:
:
:
Thermax Culligan Water Technologies Ltd.
MB1/2
1200 mm dia. x 2800 mm HOS
2
40 deg. C
5.0 kg/sq. cm
7.5 kg/sq. cm
8.9. ACID STORAGE TANK
Make
Size / Capacity
Qty
Design Pressure
Design Temperature
:
:
:
:
:
Thermax Culligan Water Technologies Ltd
1800 mm dia. x 4200 mm LOS
One
Atmospheric
40 deg. C
Page 62 of 130
8.10. ACID MEASURING TANK
Make
Mark
Size / Capacity
Qty
Design Temperature
Design Pressure
Test Pressure
Net Weight
:
:
:
:
:
:
:
:
Thermax Culligan Water Technologies Ltd.
MHL
800 mm dia. x 800 mm ht.
One (1)
40 deg. C
Atmospheric
Full of Water
181 kg
8.11. ALKALI STORAGE TANK
Make
Size / Capacity
Qty
Design Pressure
Design Temperature
:
:
:
:
:
Thermax Culligan Water Technologies Ltd
1800 mm dia. x 4200 mm LOS
One (1)
Atmospheric
40 deg. C
8.12. ALKALI MEASURING TANK
Make
Mark
Size / Capacity
Qty
Design Temperature
Design Pressure
:
:
:
:
:
:
Thermax Culligan Water Technologies Ltd
MAK
800 mm dia. x 800 mm ht.
One (1)
40 deg. C
Atmospheric
8.13. DM WATER TANK
Type
Capacity
Number
Diameter
Height on straight
Design & testing code
:
:
:
:
:
:
Vertical, conical roof type
250 cu.m. each
Two (2)
7.5 M
6.0 M
IS 803
:
:
:
:
:
:
:
:
:
:
Voltas Ltd, India
BS 550-022/ 2 stage
2 x 100%
Sea water (10 0C approx, 1.03 sp gravity)
3m
4400m3/ hr
26.23 MLC
90 %
359.7 KW
1.5KW
9.
COOLING WATER SYSTEM
9.1. COOLING WATER PUMPS
Manufacturer
Type
Numbers
Medium
NPSH [R]
Capacity
Bowl head
Bowl efficiency
Power absorbed
Mechanical loss
Page 63 of 130
Total power absorbed
Pump rotation
MOTORS
Manufacturer
Frame No.
Rating
Speed
Voltage
Insulation class
Protection
Bearings
DE
NDE
Lubrication
:
:
361.2 KW
Clockwise ( viewed from above)
:
:
:
:
:
:
:
NGEF Ltd., Bangalore
AVM 630 L8 TEFC
450 KW
745 rpm
6.6 KV + 10 %, 3 ph, 50 Hz
F
IPW 55
:
:
:
NU 326
2 x 7324 BUO
Grease : Spheerol AP2 (Lithium based)
9.2. CONDENSER
Manufacturer
:
Type
:
Effective heat transfer area :
No. of Shells
:
Steam condensed
(Rated):
Steam pressure
:
Condensing temperature
:
Cooling water type
:
Cooling water flow rate
:
Cooling water temperature :
C.W. Pressure drop
:
No of passes
:
Heat duty
:
Cleanliness factor
:
Heat transfer coefficient
:
Log Mean Temp. Difference :
PPE & S - UE Gr II, L&T
Single Pressure, Divided
2024.34 m2 (Provided heat transfer area - 2032 m2)
One
66.5 TPH
0.1010 bar (a)
45.98 0C
Sea water through Cooling Tower
3567.294 TPH
Inlet - 33.0 0C, Outlet - 43.011 0C
Allowable-0.49 bar, Calc - 0.481 bar
2
3.41 x 107 kCal/ hr
0.80
2609.3 kCal/ hr-m2-0C
6.79 0C
Shell features:
Design Pressure (Shell / Tube):
1.10 Kg/ cm2 / 6.00 Kg/ cm2
Design Temperature (Shell / Tube): 120 0C / 80 0C
Tubes
Material
O.D. (mm) BWG
Length
Qty
(mm)
(nos)
Condensing
Titanium
19.05
22
8000
3895
Air cooling
Titanium
19.05
22
8000
339
zone
Support Plates Per Bundle
Qty
Spacing
Thickness
Tube Sheets Per Bundle
Quantity
Pitch
:
:
:
12
614 mm
13mm
:
:
2
25.4 mm
Page 64 of 130
Total
4244
Hotwell capacity
Design tube velocity
:
:
3532 litres for 3 minutes
1.98 M/S
Nozzles
Cooling water
Condensate outlet
Turbine exhaust area
:
:
:
Inlet- 22 inch, Outlet-22 inch (2 Nos.)
9 inch (1 No)
2.69 m2
9.3. INDUCED DRAFT COOLING TOWERS
Manufacturer
:
Paharpur Cooling Towers Ltd.
Type
:
Cross flow
No. of cooling towers
:
1
Cell per cooling tower
:
2
Total cooling tower capacity :
5400 m3/hr
No. of operating cells
:
2
Flow per cell
:
2700 m3/hr
Hot / Re-cooled water temp :
43.5 / 33 0C
Design ambient wet bulb temperature
(exclud. recirculation allowances): 28 C
Tower operation
:
Continuous
Type of water handled
:
Sea water
Type of fill
:
Splash
Basin type
:
Under ground in compartments (one per cell)
9.3.1. FAN
Manufacturer
Total Static Pressure
No. of Blades
Diameter of fan
Fan Speed
Total fan dynamic head
Mechanical efficiency
Bearing Quantity
Bearing Type
:
:
:
:
:
:
:
:
:
Paharpur
6.78mm
8
8.534 M
114 rpm
3.38 mmWC
82.70 %
Six (6)
Timken for equal tapered roller
9.3.2. FAN MOTOR
Make
Type
:
:
NGEF Ltd.
Squirrel cage rotor (Pole changing type),
Twin speed with two separate windings
:
:
:
:
:
:
:
:
:
:
AMW280S4/6
S1
415 10%V, 50  5%Hz, 3ph
75 / 30 KW
142 / 58 A
1478 / 984 rpm
0.81 / 0.77
Class F
IPW 55
Bi-directional
Frame size
Duty
Voltage
Output at 50C
Rated Current
Rated speed
Rated Power Factor
Insulation
Protection
Direction of Rotation
Page 65 of 130
9.4. PLATE HEAT EXCHANGER
Make
:
Type
:
PPE & S - UE Gr II, L&T
TL 500 KBGL
General
PRIMARY
SECONDARY
Fluid
:
DM Water
Sea Water
Temp. In/Out
:
42 / 35 deg. C
33 / 38.3 deg. C
Mass flow rate (kg/hr)
:
146917.5
174298.5
Design Temp.
:
50 Degree C for Calculation
Normal Working Pressure
:
6.5 kg/sq. cm
6.0 kg / sq. cm
H. TR. Area (Effective)
:
88.3 sq. cm
Design Pressure
:
8 bar
8 bar
Pressure drop (Max) at 1.1 capacity: 0.5 kg/sq. cm
0.5 kg/sq. cm
9.5. SEA WATER INTAKE PUMPS
Make
:
Model
:
Type of Pump
:
Design & Testing std.
:
Duty
:
Location
:
No. of pumps
:
Rated Capacity
:
Total Head
:
Bowl Head
:
Shut off Head
:
Range of Operation
:
Pump Efficiency at rated capacity:
Power consumption at rated :
condition
Constructional feature
Pullout type
:
Impeller type
:
No. of stages
:
Min. submergence required :
At rated capacity
Bearing span
:
Shaft Dia.
:
Coupling bet. Pump & drive :
No. of column pipes and max.:
Length of single piece
No. of shaft pieces & max. :
Length of single piece
Type of Shaft Coupling
Between impeller and line shaft:
Between line and head shaft :
Impeller and Line shaft bearing
Type of bearing
:
Type of lubrication
:
WPIL LIMITED
E18TC
Vertical turbine mix flow
HIS Level A
Continuous
Outdoor
One
945 cu.m/hr
23.5 mLC
23.95 mLC
37 mLC
70 - 130%
83.66%
79.05 kW
No
Closed
Two
0.89 m
3.0 m
43 mm
Pin and bush type
3 Nos. (3 m)
3 Nos. (3 m)
Sleeve Type
Sleeve type
Thordon
Self Water
Page 66 of 130
Thrust Bearing(s)
Location
:
No. provided
:
Type
:
Manufacturer
:
Design Axial Load
:
Design life at pump duty point:
Type of lubricant
:
On Pump
One
Anti friction
SKF / FAG
1850 kg
20,000 hrs.
Oil
DRIVE MOTOR
Make
Frame Size
Application std.
SIEMENS
280M
:
IS 325
:
:
Type and Rating
Type of Motor
:
Service
:
Rated Output at 50 deg. C amb.:
Rated speed in rpm
:
Rated voltage
:
Full load current in amp
:
No load current in amp
:
Over load capacity & duration:
ILAO 283-4YA80 Squirrel cage induction motor
Out door
90 kW
1480
415 V, 50 Hz, 3 ph
156
57
160 % for 15 sec
Construction
Connection of stator winding :
Degree of protection of enclosure:
Method of cooling
:
Insulation class
:
Delta
IPW 55
IS 6362 IC 0141
F
Bearings
Make
Recommended lubricant
:
:
SKF ON 6317C3 (DE), 6317C3 (NDE)
Servo GEM - 3
Direction of rotation (NDE)
:
Anti clock wise
:
:
:
1219 mm, spiral rolled (SAIL make)
10 mm
Internal Cement mortar of 25 mm thick & External
Cement mortar coating of 40 mm thick for
underground piping & coal tar epoxy coat
9.6. CW PIPING
Pipe Diameter
Pipe Thickness
Special Coating
9.7. SEA WATER RETURN PIPING
HDPE PIPES
Piping designation
:
Codes & standards for design &
manufacture
:
Size
:
Return water pipe line (after ‘Y’ junction)
ISO 4427
DN 630 mm, 24 to 28 mm thick
Page 67 of 130
Class
Wall series
Raw material
Standard length
Joints
:
:
:
:
:
Total maximum flow through the
HDPE pipe
:
9.8. SEA WATER INTAKE PIPING
DI PIPES
Piping designation
:
System
:
Design pressure
:
PIPES
Material
:
Size
:
Method of manufacture
:
Joints
:
PN 4.0
S-12.5 (SDR 26)
PE 80
6 meter
Butt fusion welding for the pipe
Extrusion welding for the diffuser ports
1560 m3/hr (approx.)
Sea Water Pipeline
Cooling water make-up system
5.0 kg/cm2(g)
Ductile Iron as per IS-8329 / ISO-2531, Class-K9
450 mm, 8.5 mm thick (major portion)
Casting
Push-on Spigot - Socket joint with SBR gasket as
per IS - 12820 for underground pipes and Flange
Joints complete with nuts, bolts and SBR gaskets
for overgroun pipes
PROTECTION
Internal protection
External protection
:
:
Mortar lining 3-5 mm, conforming to ISO-4179
Zinc spray over oxide surface as per ISO-8179
followed by cold applied bitumen coating as per BS3416, Type-II
Air Valves
:
Double Kinetic type
9.9. STRAINERS
Make
:
Type
:
Quantity
:
Size
:
Mesh Size
:
Dia of wire Mesh
:
Minimum thickness of Screen:
Fluid
:
Operating Capacity (flow thro’
strainer)
:
Acceptable pressure drop at 50%
clogging
:
Operating Pressure
:
ACW System
CT Makeup
(at I/L to PHE)
(at I/L to CT Basin)
Multitex, Delhi
Simplex Basket Type
2 Nos.
2 Nos.
300 NB
450 NB
20 microns
500 microns
24 SWG, SS
1.5 mm
Seawater with
Sea water
COC of 1.3
400 M3/hr
26 MWC
Page 68 of 130
625 M3/hr
1.0 MWC
24 MWC
10. EQUIPMENT COOLING WATER SYSTEM
10.1. ECW PUMP
Manufacturer
:
Type
:
Quantity
:
Capacity
:
Head
:
Run out capacity
:
NPSH required at rated capacity:
Efficiency
:
Range of Operation for guaranteed
Performance
:
Shut of head
:
Rotation viewed for DE
:
Bearings
:
Lubricant
:
MOTOR
Make
Power
Speed
Frame
Sam Turbo Industry Ltd.
WP 150/400
2 Nos.
327 m3/hr
38 mLC
460 m3/ hr
2 mLC
79%
280 - 460 m3/hr
42.5 mLC
Clockwise
SKY / FAG
Oil immersed Servo system
:
:
:
:
Crompton
55 kW
1450 rpm
250M
10.2. ECW MAKE UP TANK
Manufacturer
Design & Fab code
Capacity Net/ Total
Design temperature
Design pressure & vacuum
Corrosion Allowance
Operating Weight
Erection weight
Weight filled with water
:
:
:
:
:
:
:
:
:
Suyog Engineers Ltd.
IS 10987
3 / 5.53 m3
50 0C
As per IS 10987
1.5 mm
5050 Kg
2050 Kg
7580 Kg
10.3. LUBE OIL COOLERS
Manufacturer
Type
Quantity
Oil flow capacity
Oil in / outlet temp
Water flow capacity
Heat Exchange Capacity
Tube Material
:
:
:
:
:
:
:
:
Reynolds.
Shell and Tube
2 Nos./system
730 Lit/min
66.57 / 45 0C
1400 lit/ min
478 KW
SS304
10.4. GENERATOR HEAT EXCHANGER
Manufacturer
:
Oeltecthnik France
Type
:
Heat Exchanger with bare tubes / OKG 12/80
Operating Data
Shell Side
Page 69 of 130
Tube Side
Fluid circulated
Heat exchanged
Liquid flow
Temperature in
Temperature out
Fouling factor (x 10E4)
Design
Design pressure
Design Temperature
Tube diameter / thickness
Number of Passes
Tube length
Number of Tubes
:
:
:
:
:
:
Oil VG 46 (4.0 grd E) Water
0.80 KW
0.36 m3 /hr
0.46 m3 /hr
0
54.73 C
39.00 0C
50.00 0C
40.50 0C
2
2
0.00 m K/W
1.72 m K/W
:
:
:
:
:
:
6.00 bar
80 0C
10.00 x 1.00 mm
2
800.00 mm
40
8.00 bar
60 0C
11. HP / LP DOSING SYSTEM
11.1. HP DOSING SYSTEM
11.1.1. DOSING PUMP
Manufacturer
Model
Type
Number of pumps
Capacity (Normal / Design)
Pressure
Plunger dia/ speed
Gear ratio
:
:
:
:
:
:
:
:
Turn down ratio
Performance/ design std.
Volumetric efficiency
Linear/ Metering Accuracy
Motors
Make
Type
:
:
:
:
71
Design/ Mfg. Std.
Rating/ speed
LP Boiler
HP Boiler
V.K. Pumps
PR-10 Head A1
Reciprocating simplex plunger
2 x 100%
2 x 100%
5 / 6 LPH
15 / 17 LPH
10.9kg/ cm2 (g)
110kg/ cm2 (g)
24mm / 25 spm
14mm / 100 spm
60:1
15:1
Worm & Worm wheel
10:1
API 675 with deviations
90%
+ 3% / + 1%
:
:
Crompton Greaves
3 ph., AC, squirrel cage induction motor
TEFC, F Cl insul. IP-55, Foot mounting, Frame AD
:
:
IS 325
0.37 kW
/ 1440 rpm
11.1.2. SOLUTION PREPARATION AND FORWARDING TANK
Type
:
Vertical cylindrical with dishend & bolted hinged top
Cover.
Size
:
ID 1000x 1200ht x 3 thk
Capacity
:
Working 800 ltrs
Design code
:
IS 803
Operation Pressure
:
Atmospheric
Page 70 of 130
Accessories
Tank)
11.1.3. AGITATOR
Make
Type
Application
Impeller type
Impeller diameter
Agitator speed
Mounting
Coupling
Drive Motor rating
:
Dissolving basket, removable type (for Preparation
:
:
:
:
Enpro Engineer
High speed, direct coupled with bearing arrangement
For solution preparation and forwarding tank
3 Bladed propeller
:
125 mm
1440 rpm
Top entry, centre mounted
Rigid, Muff type
0.75 kW/ 1440 rpm
:
:
:
:
Agitator Motor
Make
Type
:
:
Design/ Mfg. Std.
Rating/ speed
:
:
Crompton Greaves
3 Ph., AC, Squirrel cage induction motor
TEFC, F Cl insul. IP-55, Flange mounting,
Frame AD 80
IS 325
0.37 kW
/ 1440 rpm
:
Ammonia dosing
Pump
Swellore
Hydrazine dosing pump
LP
HP
Swellore
:
:
:
WH-1125/14
71
Plunger
WH-1125/8 WH-1125/8
71
71
Plunger
:
:
:
:
:
:
:
2
12.2 L/ hr
25 Kg/ cm2
SS316
0.37 KW
1440 rpm
IP-55
2
2
3L/ hr
3 L/hr
7.5 Kg/ cm2 7.5 Kg/ cm2
SS316
SS316
0.37 KW
0.37 KW
1440 rpm
1440 rpm
IP55
IP55
11.2. LP DOSING SYSTEM
11.2.1. DOSING PUMPS
Manufacturer
Swellore
Model
Frame size
Type
Plunger
Number
Flow
Head
Material
Rated Output
Rated speed
Protection
11.2.2. AGITATORS
Manufacturer
Model
Mark number
Client mark no.
Type
Numbers
:
:
:
:
:
For Ammonia
For Hydrazine
Dosing tank
Dosing tank
Swellore
Swellore
WH-1125/8
WH-1125/8
Agitator-1 A/B
Agitator-2 A/B
:
1CF01K-A/B
1CF02K-A/B
High speed
High speed
2
2
Page 71 of 130
Material
Rated output
Rated speed
:
:
:
SS316
0.37 KW
1000 rpm
SS316
0.37KW
1000 rpm
Motors
Manufacturer
:
Type
:
Duty Cycle
:
Tag No.
:
Frame size
:
Quantity
:
Voltage
:
Method of Starting
:
Rated Output
:
Full/ No load current
:
Rated Speed (rpm) / Poles (Nos):
Class of Insulation
:
Protection
:
Bearing No DE / NDE
:
Lubricant
:
Ammonia
Hydrazine
Agitators (Both)
NGEF Ltd.
NGEF Ltd.
NGEF Ltd.
Squirrel cage Induction Type
Continuous S1
P1 A/B
P2 A/B & P3 A/B AG1, AG2 A/B
AMW 71 K4 AMW 71 K4 AMW80 K6
2 Nos
4 Nos
4 Nos
415 V + 10% , 50 Hz + 5%
DOL
0.37 KW
1.05 / 0.955 A 1.3 / 0.92 A 1.05 / 0.955 A
1440 / 4
1440 / 4
940 / 6
Class F
IP-55
6203 2RS C3
Speerol AP2
11.2.3. MEASURING TANKS
Ammonia dosing tank
Hydrazine
dosing tank
Mark number
Clients Mark No.
Numbers
Diameter
HOS/ LOS
Material
Design pressure
Design code
Chemical/ concentration
:
:
:
:
:
:
:
:
(LP)
CM-1 A/B
:
1CF01T-A/B
2
600mm
1200mm
SS316
Atmospheric
GEP
Ammonia, 5%
12. SERVICE & POTABLE WATER SYSTEM
12.1. SERVICE & POTABLE WATER TANK
Capacity
:
15 cu.m.
Number
:
One (1)
Diameter
:
3.0 M
Height on straight
:
2.5 M
12.2. SYNTEX MAKE TANKS
Size & Qty
:
:
2 cu.m , Five (5)
1 cu.m, One (1)
Page 72 of 130
(LP)
CM-2 A/B
1CF02T-A/B
2
600mm
1200mm
SS316
Atmospheric
GEP
Hydrazine, 1%
12.3. SERVICE & POTABLE WATER PUMPS
IN NAPHTHA AREA
Manufacturer
Model
Type of pump
Numbers
GUARANTEED PERFORMANCE
Rated Capacity
Total head at rated capacity
Shut -off head
Range of operation of pump
Rated Speed
Pump Efficiency
Power Consumption
NPSH required at rated capacity
DRIVE MOTOR
Make
Frame size
Applicable standard
Type of motor
Duty
Rated output at 50 deg. C amb.
Rated speed in rpm
Rated Voltage
Full load current in amp
Sam Turbo Ind. Ltd
Wp 32/200
Horizontal
2
IN POWER PLANT
AREA
Sam Turbo Ind. Ltd
Wf 32/160
Centrifugal
2
5 cu.m
10 mLC
10.8 mLC
2-11 cu.m/hr
1450 rpm
33 %
0.41 kW
0.6 m
7 cu.m
25 mLC
27 mLC
3-20 cu.m/hr
2900 rpm
36 %
1.33 kW
1.0 m
Crompton
90 L
IS 325
TEFC, Sq. Cage, Flame
Proof
S1
1.1 kW
1410
415 V, 50 Hz, 3 ph
2.7
Crompton
100 L
IS 325
TEFC, Sq. Cage Ind.
Motor
S1
2.2 kW
2830
415 V, 50 Hz, 3 ph
5
13. COMPRESSED AIR SYSTEM
13.1. AIR COMPRESSOR
Manufacturer
Model No.
Type
Numbers
Duty
Location
Type of control
:
:
:
Chicago Pneumatic India Ltd.
2H x 2T 31 - 18.P
Reciprocating, oil less, horizontal, water cooled,
2 stage, balanced mounted on skid.
2 x 100%
Continuous
Indoor
Electropneumatic
:
:
:
:
Guaranteed performance
Capacity
:
Discharge pressure
:
Design ambient temp.
:
Design ambient press.
:
Design amb. RH
:
Free air cap. Considering
worst amb. Conditions
:
Air temp. at compressor discharge:
Compressed air outlet
:
500 / 615 (N cu.m/hr & cu.m/hr) FAD
8.1 kg/sq. cm
42 deg. C
1.033 kg/sq. cm
100%
10.25 cu.m/min.
165 deg. C
40-45 deg. C
Page 73 of 130
Power input required
:
Crankshaft speed
:
Total cooling water req.
:
Pressure required
:
Press. drop within the battery limit:
Noise level near comp.
:
Vibration limit
:
(measured at top & bottom
of main bearing)
Construction Features
Type of compressor
Type of drive (v belt /
Gear box, etc.)
Number of stages
Single acting/double acting
Number of cylinders
Cylinder arrangement
64.25 (+/- 4%) kW
700 rpm
10.5 cu.m/hr (including I/C & A/C)
2.5 kg/sq. cm
3.5 kg/sq. cm
85 dBA @ 1 M
500 
:
:
Reciprocating, Horizontal balanced opposed.
V - Belt
:
:
:
:
Two (2)
Double acting
Two
Horizontal
MAIN BEARING
No. per compressor
Main Bearings Type
:
:
Three (3)
Copper - Lead Alloy
Drive Data
Details of drive
:
Electric Motor 100 HP IP-55 SQ. Cage TEFC
415 V , 50 Hz , 3 ph
:
:
:
:
:
Indoor
Dry I.I Filters
One
Integral
85 dBA (A)
:
:
:
:
19.11 cu.m/min
99%
5 micron
10 mm of WC
13.2. INLET AIR FILTER
Location
Type & Make
Number per compressor
Silencer
Silencer outlet noise
Performance
a) Air flow rate
b) Filtering efficiency
c) Particle size
d) Max. pressure drop at
design air flow rate
13.3. INTER COOLER AND AFTER COOLER
No. per compressor
:
1 No. Each
Design and fab. Code
:
TEMA 'C' & ASME SEC VIII DIV 1/IS:2825 CL-II
Type of cooling
:
Water cooled
Cooling water rate
:
6 cu.m/hr
Design pressure
a) shell (water)
b) Tube (air)
:
:
5/5 kg/sq.cm (g)
4/10.125 kg/sq.cm (g)
Page 74 of 130
Temperature
a) Compressed air inlet
b) Compressed air outlet
c) Cooling water inlet
d) Cooling water outlet
:
:
:
:
135 - 140 / 165 - 170 deg. C
40 - 45 / 40 - 45 deg. C
32/32 deg. C
39 - 42 / 39 - 42 deg. C
Pressure drop
a) Cooling water side
b) Compressed air side
:
:
Total 0.7 to 1 kg/sq.cm
0.2 / 0.2 kg/sq.cm
:
:
:
Volume bottle type
1 No. per cooler
SQ-CAGE TEFC 415 V. 3PH, 50Hz, IP-55, 50
DEG AMBIENT
:
:
:
:
:
:
:
:
:
:
Vertical
3 Nos.
IS : 2825 CL. II / ASME sec VIII
10.125 kg/sq.cm (g)
1600 mm
4550 mm
8 mm
Torispherical
10
4.5 cu.m
13.4. MOISTURE SEPARATOR
Make & type
No. per compressor
Air compressor with drive
Motors as per specification
13.5. AIR RECEIVER
General
Type
Numbers
Design and testing code
Design Pressure
Inside diameter
Height / length on straight
Shell thickness
Type of dished end / dim.
Thickness of dished end
Capacity (water)
13.6. AIR DRYER
Type & model
:
No. of drying plants
:
Capacity
:
Guaranteed dew point at outlet:
Operating pressure
:
Air pressure drop between
the terminal points of air dryer:
Quantity of air required
per regeneration
:
Type of desiccant
:
Heatless purge type
One
615 cu.m/hr (FAD)
- 40 deg. C
8.1 kg/sq.cm
0.3 - 0.4 kg/sq.cm
12.5%
Activated alumina
14. FIRE DETECTION & PROTECTION SYSTEM
Area covered
Pipe line size
Main header
:
STG Building, Admn. Building, Security/ gate house
:
150 NB
Page 75 of 130
Branches
:
80 NB
Hydrant valves
Pressure in lines
:
:
65 NB
8.8 Kg/ cm2
:
:
:
:
Fairbanks
One
13 H
:
273 cu.m/hr
88 mWC
:
:
:
:
:
Kirloskar
Vertical Flange Mounted Solid Shaft Design
110 kW
1481 rpm
VSC 315
:
ST Generator Transformer, Naphtha tanks
SAT 2&3, SST1&2
14.1. HYDRANT PUMP
Make
Numbers
Model
Capacity
Head
MOTOR
Make
Type
Rating
Speed
Frame Size
14.2. SPRAY PUMPS
14.2.1. HVW SPRAY SYSTEM
Areas covered
Sizes
Fire detection line
:
25 NB
Fire QBD's
:
25 NB (79 °C)
Spray line
:
50 NB
It is operated though release valve with the detection signal available in the control room.
14.2.2. HVW SPRAY PUMP
Make
Numbers
Model
Capacity
Head
MOTOR
Make
Type
Rating
Speed
Frame Size
:
:
:
:
Fairbanks
One
13 H
:
273 cu.m/hr
88 mWC
:
:
:
:
:
Kirloskar
Vertical Flange Mounted Solid shaft design
110 kW
1481 rpm
VSC 315
14.2.3. MVW SPRAY SYSTEM
Areas covered
:
UAT, Cable gallery
Sizes
Fire detection line
:
25 NB
Fire QBD's
:
25 NB (79 °C)
Spray line
:
60 NB
It is operated though release valve with the detection signal available in the control room.
Page 76 of 130
14.2.4. MVW SPRAY PUMP
Make
Numbers
Model
Capacity
Head
MOTOR
Make
Type
Rating
Speed
:
:
:
:
Fairbanks Morse (I) Ltd.
One
13 H
:
25 cu.m/hr
88 mWC
:
:
:
:
Kirloskar
Vertical Flange Mounted Solid shaft design
110 kW
1481 rpm
14.2.5. MVW SPRAY PUMP (DG OPERATED)
Make
:
Fairbanks
Model
:
13 H
Capacity
:
273 cu.m/hr
Head
:
88 mWC
DIESEL ENGINE
Make
:
Kirloskar Cummins
Model
:
NTA 495 F1
Type
:
Compression ignition
Rating
:
173 H.P.
Speed
:
1500 rpm
14.3. JOCKEY PUMP
Make
Model
Capacity
Head
MOTOR
Make
Type
Rating
Speed
Frame Size
:
:
:
Fairbanks Morse (I) Ltd.
6H
:
25 cu.m/hr
88 mWC
:
:
:
:
:
Kirloskar
Vertical Flange Mounted Solid shaft design
15 kW
2920 rpm
BPM 160M
14.4. FIRE FIGHTING & GAS DETECTION SYSTEM FOR GAS TURBINE
Supplier
:
Minimax Windhorst
No. of CO2 cylinders
:
25 Nos. capacity 67 ltr.
1 No. capacity 10.7 ltr.
Type of discharge
:
Initial - 60 Sec
Extended - 30 min
Fire Detectors
a. In accessory compartment :
4 Nos. (316°C)
Type - Ex- Proof, NEC Class 1, Group - C,D, Div 1
b. In Load Gear Compartment:
4 Nos. (316°C)
Type - Ex- Proof, NEC Class 1, Group - C,D, Div 1
c. In Turbine Compartment :
6 Nos. (316°C)
Type - Ex- Proof, NEC Class 1, Group - C,D, Div 1
Page 77 of 130
14.5. FIRE ALARM SYSTEM
Fire alarm system is provided in CCR, CW MCC Room, Administration building, Naphtha
MCC room and Electrical Annex. Building.
It comprises of
1. Ionization type smoke detectors
2. Photoelectric smoke detectors
3. Heat detectors
4. Response indicators
5. Manual call points
15. AC & VENTILATION SYSTEM
15.1. GENERAL
A/C Sys
Capacity
Temperature
Relative Humidity
:
:
:
55 TR
24 ± 1.5 °C
50 ± 5 %
15.2. RECIPROCATING (SEMI HERMATIC TYPE) COMPRESSOR
Make
:
BLUE STAR LIMITED
Model
:
JS 43F - N50B
Quantity
:
2
Type
:
Semi Hermatic Reciprocating
Capacity
:
55TR
Refrigerant
:
R 22
RPM
:
1440
Suction temp
:
6 deg. C
Condensing temp
:
42 deg. C
Capacity control
:
Automatic
Oil charge in crank case
:
16 ltrs.
Recommended oil
:
York Oil 'C'
Type of lubrication
:
Forced
15.3. SHELL & TUBE TYPE CONDENSER
Make
:
BLUE STAR LIMITED
Type
:
Shell and Tube
Model
:
YCD 61
Water flow rate
:
220 USGPM
Water in temp
:
91.4 deg. F
Water out temp
:
98.6 deg. F
Nos of passes
:
3
Length of tubes
:
2134 mm
Nos. of tubes
:
80
Dia. of tubes
:
11 3/4"
Pump down capacity
:
104 Kgs.
15.4. AIR HANDLING UNIT
Make
Quantity
:
:
BLUE STAR LIMITED
2
Page 78 of 130
Type
Model
Type of Fan
Capacity
Static Pressure
Fan speed
Construction
No. of Blower
:
:
:
:
:
:
:
:
Vertical Discharge
CS - 578
DIDW FORWARD CURVED
25900 CFM
65 mm WC
461 rpm
Heavy gauge zinc coated steel
One
15.5. HORIZONTAL END SUCTION TYPE, CF CW PUMP
MAKE
:
MATHER AND PLATT
Type
:
Horizontal end suction
Model
:
ET 17L 100 X 65
Flow
:
50 cu.m/h
Total Head
:
30 M
RPM
:
1460
Quantity
:
2
15.6. INDUCED DRAFT FRP COOLING TOWER
Make
:
MIHIR ENGINEERS LIMITED
Type
:
Induced Draft
Model
:
CM 4-6E-3
Water Flow
:
220 USGPM
Water temp in
:
98.6 deg. F
Water temp out
:
91.4 deg. F
RPM
:
960
Motor HP
:
3 HP
Quantity
:
2
15.7. CF BLOWER (VENTILATION SYSTEM)
Make
:
PATEL AIR - TEMP LTD.
Fan Type
:
PA - 27
Size
:
100, SISW, CL-1
Capacity
:
75000 CMH
Static Pressure
:
55 mm WC
RPM
:
863
BHP
:
22.65
Quantity
:
One
16. MISCELLANEOUS HOISTS & CRANE
16.1. SINGLE GIRDER EOT CRANE (NAPHTHA PUMP HOUSE)
Capacity
(MH/AH)
:
2.0 Tonne
Span
:
8.7 M
Lift MH
:
5.0 M
Hoist (MH)
Speed (MH/CREEP/AH)
:
Motor details (MH/CREEP/AH)
Type of Motors (MH)
:
4 MPM
SCR
Page 79 of 130
Rated speed (MH)
KW/HP
(MH)
:
:
1425 rpm
2.2 / 3.0
Wire Rope
Constructions (MH/AH)
Type of Core (MH/AH)
:
:
6 X 36
1 MC
16.2. ELECTRIC WIRE ROPE HOIST
Location
:
Type & Duty
:
Capacity
:
Height of Lift
:
Hoisting speed
:
CT Speed
:
Control
:
Rope / No. of falls
:
Rope Drum / Length
:
Travel length
:
Hoist Weight
:
Hoist Motor
:
C.T Motor
:
Hoist Brake
:
C.T Brake
:
Fire Water & Misc. Pumps
EWRH CL - II, As per IS : 3938
3T
6.0 M
4.0 MPM
16.0 MPM
By Pendant
10 mm / 4
220 mm / 600 mm
30.0 M
350 kg
3.7 kW, Sq. Cage, 4 Pole Reversible
0.18 kW, Sq. Cage, 4 Pole Reversible
DC EM Disc Type / AC EM Shoe
AC EM Disc Type
16.3. ELECTRIC WIRE ROPE HOIST FOR S/G CRANE
Location
:
Store
Type & Duty
:
EWRH CL. - II. As per IS : 3938
Capacity
:
2.0 T
Height of Lift
:
5.0 M
Hoisting speed
:
4.0 MPM
CT Speed
:
16.0 MPM
Control
:
By Pendant
Runway Beam size
:
ISMB - 300
Rope / No. of falls
:
8 mm / 4
Rope drum / Length
:
170 mm / 600 mm
Travel Length
:
8.7 M
Hoist weight
:
300 kg
Hoist Motor
:
2.2 kW, Sq. Cage Induction, 4 Pole Reversible
Hoist motor make
:
Crompton Greaves Ltd.
CT Motor
:
0.18 kW, Sq. Cage Induction, 4 Pole Reversible
CT Motor make
:
Crompton Greaves Ltd.
Hoist Brake
:
DC EM DISC TYPE/ AC EM SHOE
CT Brake
:
AC EM DISC TYPE
16.4. MANUAL HOIST WITH TROLLEY
Make
:
Location
:
Type of Hoist
:
Reva Industries Ltd.
DM Plant Bldg. / Non Hazardous Area /
Liquid Fuel Pump House / Hazardous Area.
Triple Spur Geared
Page 80 of 130
Type of hook with depress
Type safety latch
Type of Mechanism Brake
Method of actuation for
Brake
Type of Bearing for trolley
Wheel
Brake Lining
Trolley wheel
:
EN-3A, IS: 8610 or Equivalent
:
:
Screw & Disc
Automatic self-actuation
:
Deep Groove Ball Bearing
:
:
Asbestos Base
4 Nos. (Each Trolley)
16.5. TURBINE HALL EOT CRANE (15/3T D/G EOT CRANE)
Manufacturer
:
Anupam Industries Limited
Type
:
Double Girder Box Type E.O.T. Crane
Operation
:
Floor By Pendant
S.W.L for M.H.
:
15 T
S.W.L for A. H.
:
3T
Span of Crane
:
14000 mm
Power Supply
:
415V, +/- 10%, 50Hz, +/- 3%
Control Supply
:
110V A.C.
Motor type (M.H./A.H.)
:
10 hp Slipring / 6.75 hp Slipring
C.T. Rail Size
:
40 mm Sq. Bar
L.T. Rail Size
:
60 lbs/Yrd.
C. T. Acceleration
:
10 cm/sq. sec
L.T. Acceleration
:
10 cm/sq. sec
Motor type (C.T / L.T)
:
4.0 hp Slipring / 4.0 hp Slipring
Class of Crane
:
II - Mechanical , III - Electrical
IS for Mechanism
:
IS - 3177 & IS - 807
Ambient Temperature
:
50 deg. C
Service Condition
:
Indoor
Location
:
STG Building
Bay Length
:
28 M
Height of Lift (M.H.)
:
9200 mm
Height of Lift (A. H.)
:
9900 mm
Head room clearance
:
2000 mm
Over all width
:
4800 mm
Crane Weight
:
17.5 T
Crab Weight
:
5.55 T (Approx.)
Speed (M/min)
:
MAIN
MICRO
Main Hoist
:
1.2
0.12
Auxiliary Hoist
:
2.4
0.24
Cross Travel
:
10
1.0
Long Travel
:
25
2.5
L. T. Drive provided
:
Central Drive
Platform & Hand railing
:
Both side
Type of control
:
Floor operated
DSL Type
:
M.S. Angle
C.T. Wheel Base
:
2455 mm
L.T. Wheel Base
:
3370 mm
Rail Gauge
:
2220 mm
Buffer Type (CT / LT)
:
Spring / Spring
Right
Left
End Clearance
:
135
153
Page 81 of 130
M.H. Hook Approach
A. H. Hook Approach
:
:
1900
1100
1100
1900
16.6. SINGLE GIRDER SEMI EOT CRANE (BFP AREA)
Manufacturer
:
Safex Electromech Pvt. Ltd.
S. W. L. (Capacity)
:
5000 Kgs.
Class
:
II, Medium Duty, IS 3177, IS 3938
III - For Electrical
Span
:
5.6 M
Lift
:
5.7 M
Speed (M/Min)
:
Hoisting
C.T.
4.0
Manual
Motor
Power consumption
:
5.5 kW
----Speed
:
1440 rpm
----Type
:
Sq. Cage
-----
L.T.
Manual
Brake
Size
Type
:
:
7"
--Electro Magnetic
Power Supply
Location
Operation
Bay Length
Gantry Rail
Wire Rope
DSL
Crane Weight
L.T. Wheel Size
:
:
:
:
:
:
:
:
:
415+/- 10%, 50Hz +/- 5%, 3 ph, A.C.
Indoor
Floor Operated
15.0 M
40 Sq. Bar
12, 6 x 37, Steel, Fibre Core IS : 2266
4 SWG, 3 Wire Bare Copper Conductor
4500 Kgs.
200
:
:
:
:
:
:
:
:
:
:
:
:
:
:
:
110V
:
Safex Electromech Ltd.
7500 Kgs.
6M
Pendant Push Button for Hoisting
II As per IS 3839
CW Pump House
14, 6 x 36 / 6 x 37, Length - 40M, No. of fall - 4
272, Pitch-16.5mm, Length - 1105 mm
7500 Kgs.
Disc type, Safex make
Hoisting
C.T.
4.0
Manual
Sq. Cage Class B, Tesc, 3 ph, A.C., IS 325
9.3 kW
--415V +/- 10%, 50Hz +/- 5%, 3 ph, A.C
16.6.1. HOIST
Make
Capacity
Lift
Type
Class
Location
Wire Rope
Rope Drum
Hook
Brake
Speed
MPM
Motor
Power Consumption
Power Supply
Control Voltage
:
Travel
10M
Page 82 of 130
-----
---

1.
ELECTRICAL
GENERATOR TRANSFORMER (40/50 MVA)
1.1. GENERAL
Manufacturer
GEC-ALSTHOM
Standard
Service
MVA Rating:
With ONAN cooling
With ONAF cooling
Rated Voltage :
HV Winding (KV)
LV Winding (KV)
Connections:
HV Winding
LV Winding
Vector Group
IS:2026, 3639
Outdoor
40
50
235
11.5
Star
Delta
Ynd1
1.2. TYPE OF COOLING
a) No x Capacity of Cooling Unit furnished
b) No of Cooling Units required for full load operation
Each cooling unit is provided with :
a) No x kW rating of fan motor
b) No of Standby fans
Rating of fan motors – Voltage, Phase and frequency
Automatic operation of cooling fans provided (Y/N)
Insulation
Class of insulation
Type of insulation
1.3. TAP CHANGING EQUIPMENT
Manufacturer
Type
No of steps
% Voltage at each step
Control
a) Manual/ Local Electrical / Remote Electrical
Guaranteed positive sequence impedance at 75 C with
100% rating , 
Principal Tap 
Zero Impedance at 75 C with 100% rating , 
Temperature – rise over an ambient of 50C
Top oil in C
Windings (by resistance measurement method) C
Losses at rated voltage and frequency on principal tap
kW
No load loss . kW
Copper loss at full load at 75C kW
Page 83 of 130
2 x 50%
10 radiators
2 x 0.5 kW
1
415V, 3  50 Hz.
Yes
Class A
Paper/Press Board
BHEL
OLTC
18
1.25%
Provided
12.5%
10.6%
50
55
31 kW
155 kW
Cooler losses
Withstand time (sec ) without damage for :Three phase dead short circuit at terminal with rated
voltage maintained on the other side.
Single phase short circuit at terminal with rated voltage
maintained on other side.
3.5 kW
No load current at rated voltage and rated frequency
1% of rated full load
current
1.4. INSULATION LEVEL
Separate source power frequency voltage withstand
a. HV Winding (kVp/kVrms)
b. LV Winding (kVp/kVrms)
c. HV Neutral (kVp/kVrms)
Over Excitation without Continuous rating (%)
Overfluxing withstand time
a) For overfluxing factor 1.10 (sec)
b) For overfluxing factor 1.25 (sec)
c) For Overfluxing factor 1.40 (sec)
Overload rating withstand time considering initial load as
100% of rated load at site conditions
a) 110% overload hours/day
b) 120% overload hours/day
c) 140% overload hours/day
d) 160% overload hours/day
e) 200% overload hours/day
3 sec
3 sec
950/395
75/28
38 kVr.m.s
CONTINUOUS
60 sec
5 sec
11/32C/ 42C
cont/ 8/4
cont/6/3
6/1/30 min
2/5 min /1 min
20 min/60 sec/10 sec
1.5. BUSHINGS
Manufacturer
Type
Minimum creepage distance in mm
Rating kV
HV LV/HV – Neutral
BHEL/GEC-ALSTOM
COND/Oil Filled
7595/372/372.
7595/372/372
Reference Standard
As per IS:2099
1.6. BUSHING CT
Restricted E/F/standby
E/F
KAPPA
Ring
IS- 2705
 300 V (Knee Point)
150/1
5P20/PS
660V
15
CLASS A
Make
Type
Reference standard
Voltage rating
CT ratio
Class
Insulation level
Burden VA
Insulation class
Page 84 of 130
1.7. TRANSFORMER OIL
Standards to which it conforms
IS 335
The Details of STG GENERATOR TRANSFORMER are identical to above supplied
transformer.
2.
220 KV SWITCH YARD EQUIPMENT (OPEN CYCLE)
2.1. GENERAL
Total No of Bays
Generator Bay
Outgoing Line Bay
Main Bus
Droppers
System Voltage
:
:
:
:
:
:
2
1
1
3” IPS Al . Tube
Moose Conductor
245 KV
2.2. CIRCUIT BREAKER
Make & Type
Rated short circuit current for 3 sec (kA rms)
Rated closing & Latching capability ( kA rms)
Rated interrupting time (ms)
Rated reclosing time (ms)
Rated operating duty cycle
Type of operating mechanism
Breaker operating time (ms)
2.3. ISOLATORS
Make & Type
Rated full wave impulse withstand across the open gap
(kV)
Rated 50Hz, 1min. withstand across the open gap (kV rms)
Range of control voltage (Vdc)
Current, start/run (A)
Control data for operating mechanism
Operating time (s)
Maximum charging current interrupting (A)
2.4. GROUND SWITCHES
Rated close & latch current
Number of closing operations into energised bus without
damage
CGL
200-SMF-40A
40
100
<60
Not more than 200.
O- 0.3s- CO-3 min-CO
Spring (closing) /
pneumatic (opening)
<160 ms.
ELPRO.
1050 kV peak
530 kV (rms)
190 V to 240 V DC
5.6 A / 1.6 A
10 to 12 sec
10A at 220V DC.
40 kA for 3 sec.
one ( 1 )
2.5. INSTRUMENT TRANSFORMERS
2.5.1. CURRENT TRANSFORMERS
Make & Type
Continuous thermal current rating factor
Page 85 of 130
CGL IOSK 245/460/1050
120% of rated primary
current
Secondary winding insulation class
Accuracy classification
Class A
PS / 5P20 / 0.5
2.5.2. VOLTAGE TRANSFORMERS
Make & Type
Name of Manufacturer
Power frequency field test voltage with VT connected (kV
rms)
Nos. & ratio of high voltage to low voltage winding
Thermal rating of each secondary winding (VA)
Accuracy classification
List of burdens for which above accuracy classification
apply
2.6. LIGHTNING ARRESTERS
Name of Manufacturer
Type
Model number
Voltage rating (kV)
CVE 245 / 1050 / 50
CGL
460 kV (rms)
Line CVT : 245kV/1.73//
110V/1.73 // 110V/1.73
Bus CVT : 245kV/1.73//
110V/1.73 // 110V/1.73
300VA for each winding.
Line CVT : 0.5/3P
Bus CVT : 0.5/3P
Line CVT : 100/50
Bus CVT : 100/50
CGL
Gapless Zinc oxide
ZLAx25C
198 kV
2.7. RELAY & CONTROL PANEL
Make & Type
Make and type of each relay
Make & Type of each meter
Make & Type of push buttons/switches
Other System Particulars
Annunciator
Make
Elpro
Gec-Alstom
AE/ABB
Kaycee
Same as shown in items
nos 14.6.1,14.6.2
Minilec
2.7.1. IMPORTANT RELAYS
Type
HORM
CAG-34
VTX31
VAJHM23,53
MCTGM11
METIM11
Pilot wire protection
Differential
Busbar Supervision
Trip
Static O/C
Directional unit for O/C Relay
3.
220 KV SWITCHYARD EQUIPMENT (COMBINED CYCLE)
3.1. GENERAL
Total No. of Bays
:
2
Page 86 of 130
STG Bay
Outgoing Line Bay
Main Bus
Droppers
System Voltage
:
:
:
:
:
1
1
3” IPS Al. Tube
Moose Conductor
245 KV
3.2. CIRCUIT BREAKER
Make & Type
Rated short circuit current for 3 sec (kA rms)
Rated closing & Latching capability ( kA rms)
Rated interrupting time (ms)
Rated reclosing time (ms)
Rated operating duty cycle
Type of operating mechanism
Breaker operating time (ms)
CGL, 200-SMF-40A
40
100
<60
Not more than 200.
O- 0.3s- CO-3 min-CO
Spring (closing) /
pneumatic (opening)
<160 ms.
3.3. ISOLATOR
3.3.1. GENERAL
Make,Type
Service
Pole
Rated Voltage
System neutral earthing
Insulation level
Impulse withstand voltage across isolating distances
Impulse withstand voltage to earth & between poles
Rated current
Continuous at 500C
Short time current for 3 Sec
Rated dynamic short circuit withstand current of Isolator &
earth switch
Creepage distance
Operating Mechanism
Main Blade
Earth Switch
Auxiliary Voltage
Motor
Control and Interlock
Heater / lamp / socket
S&S,
Double
break
switch
Outdoor
3
245 kV, 50 Hz
Effectively earthed
1050 kV Peak
1200 kV Peak
1250A
40 kA
100 kA Peak
7595 mm
Motor Operated spring
charge
AC Motor operated as
well as manual
Manual
415V, 3-Ph, 50 Hz
220 V DC (80%-110%)
240 V, 1-Ph, 50Hz
3.3.2. EARTHING SWITCH (NOT PROVIDED FOR BUS ISOLATOR)
General
Make, Type
Elpro,Vertical break
Service
Outdoor
Poles
Three
Rating
245kV
Short time for 3 Sec.
40kA
Page 87 of 130
Peak short time
Operating Mechanism
Mounting
Number of auxiliary contacts on each earth switch
Rating of Auxiliary contacts
100kA Peak
Manual operating handle.
Vertical
6
NO
+
6
NC
(Convertible)
10 A at 220V DC with
breaking capacity of 2 A
DC.
3.4. CURRENT TRANSFORMER
General
Make
Type
ABB
Oil filled, self cooled,
Dead tank type
Outdoor, Upright
220kV
Service
Rated voltage class
Nos. of Poles
Frequency
System Neutral
Insulation level
1 minute 50 Hz withstand
Impulse withstand
Insulation class
Short time rating
Rated 1-Second current
Rated dynamic current
Creepage distance (Minimum)
3
50 Hz
Effectively earthed
460 kV rms
1050 kV (peak)
Class-A
40 kA rms
100 kA peak
7595 mm
3.5. ELECTROMAGNETIC VOLTAGE TRANSFORMER (EVT)
General
Make
System Details
Rated System continuous current
System Neutral
Insulation level
1 min. 50 Hz withstand kV
Impulse withstand
Insulation Class
Creepage distance
System fault level
Over voltage factor
Continuous
30 Second
CGL
1250A
Effectively earthed
460 kV rms
1050 kV Peak
A
7595 mm
40 kA
1.2
1.5
3.6. CONTROL AND RELAY PANEL
3.6.1. SYSTEM PARTICULARS
Make
Neutral Earthing
ALSTOM
Effectively earthed
Page 88 of 130
Basic impulse withstand voltage (peak)
Power frequency withstand voltage (rms)
Fault level on 220kV bus
3.6.2. CONTROL AND RELAY PANEL
Reference Standard
Type of Panel
Control voltage (Nom / Max.)
Degree of protection
Type of mounting of all Relays
Wiring
1050kV
460kV
40kA (rms) for 1Sec
IS 2147
Vertically mounted
220 / 240 V DC
IP 54
Flush type
650 / 1100V grade
stranded
copper
conductor with FRLS
PVC insulation
3.6.3. IMPORTANT RELAYS
TYPE
HORM
CAG-34
VTX31
VAJHM23,53
MCTGM11
METIM11
Pilot wire protection
Differential
Busbar Supervision
Trip
Static O/C
Directional unit for O/C Relay
3.7. LIGHTNING ARRESTER
Make
Rated arrester voltage
No Discharge current
Minimum discharge capability
Continuous operating voltage at 500C
Max. / Min. switching surge residual voltage (1kA)
Max. residual voltage at
i) 5kA
ii) 10kA nominal discharge current
High current short duration test value (4/10S wave)
Current for pressure relief test
Low current long duration test value-2000 S
Prospective symmetrical fault
Pressure relief
RIV at 156 kV rms
Partial discharge at 1.05 cov
Terminal connector
Page 89 of 130
CGL
198kV
10kA of 8/20S wave
As per long duration
discharge Class:3
156kV
420 / 400 KVp
480 kVp
510 kVp
40 for 0.2 Sec
40kA (rms)
1000A
40kA (rms)for 0.2 Sec
Class-A of table VII of IS:
3070 or IEC requirement.
less than 500 V
Not more than 50%
Bimetallic clamp type,
suitable for MOOSE
ACSR
3.8. PLCC EQUIPMENT
Make
Mode of transmission
Carrier frequency range in kHz
Carrier frequency in kHz
Nominal carrier frequency band in either direction of
transmission in kHz
Allowable frequency difference between pair of PLC
terminals
Supply voltage
Rated Voltage in kV
Highest system voltage in kV
Rated continuous current at 500C in Amp
Rated short time current for 1 sec in kA
Nominal discharge current of protective device in kA
Type of tuning
Rated blocking bandwidth
Min. resistive component of impedance within the rated
blocking bandwidth in Ohm
Rated inductance of main coil in mH
Partial Discharge level at 1.05 cov
Return loss of coupling device
Band width for coupling device
48V DC battery along with suitable battery charger
Inductance of wave trap
ABB
AM single side band with
suppressed carrier or
reduced carrier
40 to 500
308(Receiving);
320(Transmission)
4
Should not exceed 2 Hz
with suppressed carrier
and with reduced carrier
frequency difference
shall not be zero.
48V DC
220kV, 50 Hz
245
1250
40
10
Broad Band
100-160kHz and 150500kHz with R min. 600
Ohm
600
0.5
Not more than 50%
Not less than 12 dB
Suits the frequency plan
120Ah lead acid battery :
Standard make
Battery Charger : AFCO
make
0.5mH
3.9. REMOTE SYNCHRONISING PANEL
Supplier
:
ALSTOM
 Remote operation of breakers of CCPP and some breakers of MRSS is envisaged
from Remote Control Panel.
 Mimic of 220 KV system is provided in this panel.
 Alarm and trip annunciation are provided in this panel.
 Important Relays:
1 Check Synchronising Relay
SKE11
2 Guard Relay for Synchronising
VAA21
3 Dead Line Charging Relay
VAA21
4.
STATION LIGHTING
Page 90 of 130
Package Supplier
:
L&T-ECC
4.1. ILLUMINATION LEVELS AND TYPES OF LUMINAIRE
AREA DESCRIPTION
TYPE OF LUMINAIRE
Flood light (on poles)
2
3
4
Gas Turbine area
(Outdoor)
HRSG
Switch yard
Naphtha pump house
5
Naphtha Storage
6
Transformer yard
7
Roads
8
9
10
11
Fin fan cooler area
HSD pump house
Battery room
Switchgear room
12
13
Control room
DM Plant and misc.
pump house
Administration block –
façade outdoor area
Administration block –
Entrance
Administration block and
offices
Blended water storage
tank , DM Tank Area,
chemical Storage Area,
Cooling tower
Transformer yard
1
14
15
16
17
18
19
20
21
22
23
24
Floodlight and well glass
Flood light (on poles)
Flameproof
fluorescent/bulkhead/wellgl
ass
Floodlight (On poles
outside the Naphtha
storage fence)
Floodlight /Street light and
bulkhead for local lighting.
Streetlights
Floodlights
Medium bay
Corrosion proof fluorescent
Industrial vitreous
enamelled fluorescent
Recessed mirror optic
Medium bay
ILLUMINATION LEVEL
(LUX)
100
70
50
100
50
50
20 for main approach road
and 10 for plant aux road.
50
100
100
200
300
100
Floodlight with metal
halide, CFL ballast
Post top lanterns
50/100
Mirror optic, CFL wall
bracket downlighter.
Floodlight
300
Floodlight on electrical
annex Building
CW pump house/BFP
Medium bay/High bay
Battery room
Corrosion proof fluorescent
Switchgear room / SWAS Industrial vitreous
room
enamelled fluorescent
STG Hall & control
High Bay , Ind Vitreous
Building
Enamelled , Decorative
Mirror Optic (Recess
Mounted) & Well glass
CW Chlorination &
Corrosion resistant
Treatment Building
Fluorescent
Deaerator Area
Wellglass
Page 91 of 130
10
Functional
50
150
100
200
-
100/150
-
25
26
HSD Tank Area
HSD Pump house
Flp Floodlight
Flp well glass
-
4.2. TECHNICAL DATA FOR STATION LIGHTING
4.2.1. SYSTEM DESIGN DATA
Design Ambient
Details of operating parameters
AC Supply
Rated voltage
Rated frequency
Voltage variation (permissible)
Frequency variation (permissible)
Combined voltage and frequency variation (sum of
absolutes permissible )
System fault level at rated voltage
DC Supply
Rated voltage
Voltage variation (permissible)
4.2.2. LUMINAIRES, LAMPS AND ACCESSORIES
Degree of protection for drip proof luminaries.
Flame proof luminaries
Hazardous area classification
Degree of protection
Mounting type for well glass
Non – integral control gear box
Degree of protection
Type of lamp holder for incandescent luminaries
Tap setting for Ballasts
HPMV
HPSV
Lamps
Type of fluorescent Lamps
Type of lamp cap for incandescent lamp
Type of lamp cap for HPMV & HPSV lamps
Emergency Lighting Unit
Wattage and No of lamp
Battery voltage
Type of battery
AH capacity of battery
Lumen output of lamp at rated voltage
Emergency duration of unit
50 degree C
415V 3PH 4 WIRE
50 Hz.
+/-10%
+/- 5%
+/- 10%
50KA (RMS)
220V, 2 WIRE
191 to 240 V
IP 55 for outdoor
luminaires
Zone IIA & IIB
IP 55
Eye Bolt
IP 55
E-27
200,220,240
220,240
Tri-phosphor coated
G-13
E27/E40
King Deluxe
21W
6V
Sealed maintenance free
lead acid battery
20 AH
970
6 hours
4.2.3. DESIGN PARAMETERS OF MAIN EQUIPMENT
4.2.3.1. LIGHTING PANEL (OF MDS/HAVELLS)
Application
Degree of protection
Indoor
Page 92 of 130
Indoor/Outdoor
IP 52
Outdoor
Type of incomer
MCB type for lighting panel
Busbar material
Fault level of Busbar
Lighting Poles
Type as per IS
Degree of protection
Degree of protection
Miniature Circuit Breaker
Short time rating
IP 55
ELCB + MCB
SP MCB
Aluminium
10 kA (R.M.S)
2713
IP 55
IP 55(I) IP 20(D)
9 KA
4.2.3.2. LIGHTING DISTRIBUTION BOARDS
Degree of protection
Main panel
Transformer Cubicle
Type of Incomer
Type of outgoing Feeder
Fault current and duration
IP 54
IP 42
TPN Switch fuse
TPN Switch fuse
50KA for 1 Sec
4.2.3.3. LIGHTING TRANSFORMER
kVA Ratings
Type of cooling
Rated Current
Primary
Secondary
Rated voltage
Primary
Secondary
Temperature rise above ambient in winding by resistance.
Vector Group
Insulation class
100/50 kVA
AN
139.2A/69.6 A
139.2A/69.6 A
415V
433V
70 DEG C
D yn 11
F
4.2.3.4. CURRENT TRANSFORMERS
Type
Secondary Rating
Output
Accuracy class
Cast resin
5A
5VA
1
4.2.3.5. ELECTRONIC TIMERS
Time Switch
Type
Range
TSQT, 240 V AC
1-24 hours
-: OPEN CYCLE POWER PLANT :-
Page 93 of 130
5.
5.1.
STATION AUXILIARY TRANSFORMER & LT TRANSFORMER
2 MVA TRANSFORMER
General
Make
KVA Rating
Voltage Ratio
Installation (Service)
Type of cooling
Winding connection
HV Side
LV Side
Vector Group
Type of Insulation of winding
Tap changer
Range - No. of taps x % variation
Impedance
Temp. Rise above 50 0 C Ambient
In Oil
In Winding
Type
System fault level
Voltamp , Vadodara
2000 kVA
6.6 / 0.433 kV
Outdoor
ONAN
Delta
Star
Dyn11
Class A
Off Circuit Tap Changer
 5% - 5 taps x 2.5%
7.15%
50 C
55 C
Oil immersed
HV
40 kA(rms)
Insulation level
6.6 kV
Power frequency level (KV rms)
Basic impulse level (kV peak)
System earthing
20
60
Non effectively
earthed
Continuous
Duty
5.2. 500 KVA TRANSFORMER
General
Make
LV
50 kA
(rms)
0.433
kV
3
Effectivel
y earthed
Voltamp,Vadodara
kVA Rating
Voltage Ratio
Installation (Service)
Type of cooling
Winding connection
HV Side
LV Side
Vector Group
Type of Insulation of winding
Tap changer
Range - No. of taps x % variation
Impedance
Temp. Rise above 50 0 C Ambient
In Oil
In Winding
Page 94 of 130
500 kVA
6.6 / 0.433 kV
Outdoor
ONAN
Delta
Star
Dyn11
Class A
Off Circuit Tap Changer
 5% - 5 taps x 2.5%
5%
50 C
55 C
General
Type
System fault level
Oil immersed
HV
40 kA (rms)
6.6 kV
Insulation level
Power frequency level (kV rms)
Basic impulse level (kV peak)
System earthing
20
60
Non effectively
earthed
Continuous
Duty
6.
LV
50 kA
(rms)
0.433 kV
3
Effectively
earthed
-
415V SWITCH GEAR (PCC) & LV BUS-DUCT
6.1. 415V SWITCH GEAR (PCC)
6.1.1. GENERAL
Make
Type
L&T, Gr.III
Metal clad, Only Breaker
modules are drawout
Indoor
IP - 54.
Service
Enclosure
6.1.2. SYSTEM
Voltage
Combined Voltage & Frequency variation
System
6.1.3. RATED CURRENT
(At 50 C)
Bus bar
Circuit Breaker
Switches
Short Circuit Rating
Short time Rating for 1 sec.
Insulation Level
415V, 50 Hz, 3 ph
10% (Absolute Sum)
Effectively earthed
3200 A
3200 /1600/1000 A
------100A to 630A----50kA.
2.5 kV for 1 min.
6.1.4. A.C. / D.C. POWER SUPPLY
Control Voltage for Circuit Breaker & Relays
Control Voltage for other modules
Service Voltage
A.C. Fault Level
6.1.5. CIRCUIT BREAKER
Rating
Duty Cycle
Breaking Current
A.C. Symmetrical
A.C. Asymmetrical
Making Current
220 V D.C.(190 - 240V)
240V A.C. , 1 Ph
240V A.C. , 1 Ph
50 kA (Symm)
3200 /1600/1000 A
0-3’ -CO-3’ –CO
50 kA for 1 sec.
1.2 x 50 kA.
2.1 x 50 kA Peak
Page 95 of 130
Auxiliary Voltage
Closing
Tripping
Spring Charging
6.2. LV BUS-DUCT
Supplier
General
Type
System
Voltage
220 V D.C.(85 – 110%)
220V D.C. (70 – 110%)
220V D.C. (190 – 240V)
:
L&T, SWTC, GR - III
Non segregated
Rated Current at 50 Deg. C ambient
Short time current rating for 1 sec.
Insulation Level
One (1) minute power frequency withstand voltage
Temperature rise – maximum ( over 50 Deg. C ambient)
a) Bus conductor
b) Bus enclosure & structure
7.
415 V , 50 Hz,, 3 ph &
neutral
3200A
50 kA
2.5 kV
40 Deg. C.
20 Deg. C
DC SYSTEM (BATTERIES, BATTERY CHARGER, DCDB)
7.1. BATTERY
General
Manufacturer
Type
Type of Battery positive Plates
Guaranteed AH capacity at 10 hrs discharge rate
AH capacity at half-hour discharge rate at min site ambient
of 11 deg C
No of Cells /Battery
Applicable Standard
Recommended range of floating/trickle charging voltage
Nominal Cell voltage for Boost Charging
Intermediate Tapping
Trickle charging current
Maximum Electrolyte temperature that cell can withstand
continuously without injurious effects
Internal Resistance of each cell
7.2. BATTERY CHARGER
Manufacturer
Exide Industries Ltd.
220V, 650AH, Lead-Acid
Battery
Tubular
650AH
211AH
110
IS: 1651 of 1991
2.15-2.18 V/ cell
2.70 V
83rd cell
325/1300 milliamps
45 deg C
0.330 milliohms
Chhabi Electricals Pvt.
Ltd.
Charger rated output current
i. Float charging mode
ii. Trickle charging mode
20A
1-2mA/AH
Load limiter current setting range (Trickle mode)
Automatic voltage regulator
i. Type
Page 96 of 130
1-2A / 20A
Solid state SCR control
ii. Percentage stabilisation of the output DC voltage
iii. Voltage setting range
iv. Response time of Automatic voltage regulator
Manual voltage regulator
i. Type
ii. Voltage setting range
Boost charging current setting range
Boost charging voltage limit setting range
Degree of protection for charger
Rectifier Assembly
Rated direct voltage
Double wound
Rated
6.78 kVA (Float)
38.5 kVA (Boost)
IS-4540
Standard Applicable
7.3. DC DISTRIBUTION BOARD
Make
Nominal Voltage
Type of bus conductor
Temp. rise of bus bar over 500C
Sr.
No.
1
2
3
4
Solid state by
potentiometer
0-100%
25% to 100%
1.85 V / Cell to 2.7 V /
Cell
IP 42
240/220V (Float)
300V (Boost)
415V AC
Rated input voltage
Rectifier Transformer
Type
8.
1%
2.16V-2.23 / Cell V
Less than 100 ms
Chhabi Electricals
220V DC
Copper
limited to 30 0C
415V MCC
Name of
MCC/Board
HSD MCC (D/O)
DM Plant
MCC(D/O)
FW & misc. P/H
MCC
LFS MCC (D/O)
Local Dol Starters
Local Push Buttons
Main Bus
Rating
125 A
400A
Incomer type & rating
No. of Incomers
125 FSU
400FSU
2
2
1000A
1000 ACB(M)
2
800A
800A ACB(E)
1
:
:
Eighteen ( 18 ) nos.
Twenty two ( 22 ) nos.
8.1. GENERAL
Make
Type
Reference Standard
HRS Fuses
Type
Reference Standard
L&T
Heavy duty/motor duty
IS:4064
Cartridge type
IS: 9224
Page 97 of 130
8.2. CONTACTOR
Rated service voltage
System earthing
Short circuit level
415V, 50 Hz, 3 poles
Solidly earthed
50 kA (rms) at 415 V for
1 Sec.
240V AC
As per IS: 2959
Control circuit Voltage
Limits of Temperature
8.3. THERMAL OVERLOAD RELAYS
Type
Ambient temperature
compensated bimetal
operated hand reset type
IS: 8544
Built in
Reference Standard
Single phasing protection
8.4. CURRENT TRANSFORMERS
Service
System
Indoor
415V , 3 phase, 4 wire,
50 Hz, solidly earthed
Cast Resin
IS: 2705
Class- 1.0 for metering ,
ISF <=5
Class 5P10 for
Protection
Type
Reference Standard
Accuracy
8.5. CIRCUIT BREAKER
Make & Type
Duty cycle
Breaking current
AC symmetrical
AC Asymmetrical
Making Current
Auxiliary Voltage
Closing, Tripping, Spring Charging
9.
HT CABLE
General
Make
L & T/ CNCS
0.3-CO-3’-CO
60 kA
50kA for 1 sec
1.2 x 50kA
2.1 x 50kA Peak
240 V AC
220V AC
Universal Cables, Satna,
M.P.
2XWaY
IS:7098 Pt(2)/85
1/C x 500 mm2
12.7kV/22kV
Type designation
Applicable standard
Cable size & no. of cores
Rated voltage
Conductor
i ) Material
ii) Max. D.C. resistance at 20C
iii) Aprox. A.C. resistance at 90C
Insulation
Page 98 of 130
Annealed Plain Copper
IS:8130/84 rm/v
compacted circular
0.0366 /km
0.052 /km
i) Material
XLPE to IS:7098/II/85
Over all dia cable (in mm)
Short circuit capability of conductor
55.0 mm (approx)
41.2 kA for 3 seconds
-:
COMBINED CYCLE POWER PLANT
:-
10. HT/LT TRANSFORMERS AND NGR
10.1. TRANSFORMERS
Particulars
Make
MVA Rating
Frequency in Hz
Voltage Ratio in kV
Service / Duty
Type of cooling
No. of cooler banks x
capacity
Winding connection :
( i ) HV Side
( ii ) LV Side
Vector Group
Type of Insulation of
winding
Tap changer
( i ) Type
( ii ) Voltage range
( iii ) No. of taps x %
variation
Impedance
Design ambient
temperature
Temp. rise above
50C ambient
( i ) Top Oil
( ii ) Winding (as
measured by
resistance method)
System earthing
( i ) HV side
Voltamp
6.5
50
11.5/6.9
Outdoor /
continuous
ONAN
2 x 50% of
full load
Voltamp
2
50
6.6/0.433
Outdoor /
continuous
ONAN
2 x 50% of full
load
Voltamp
1.25
50
6.6/0.433
Outdoor /
continuous
ONAN
2 x 50% of
full load
Voltamp
0.5
50
6.6/0.433
Outdoor /
continuous
ONAN
2 x 50% of
full load
Delta
Star
Dyn11
Class A
Delta
Star
Dyn11
Class A
Delta
Star
Dyn11
Class A
Delta
Star
Dyn11
Class A
Off circuit
5 %
5 taps 2.5%
Off circuit
5 %
5 taps 2.5%
Off circuit
5 %
5 taps 2.5%
6.25%
50C
7.15%
50C
6.25%
50C
Off circuit
5 %
5 taps
2.5%
5.0%
50C
50C
55C
50C
55C
50C
55C
50C
55C
Non
effectively
earthed
Non-effectively
earthed
Noneffectively
earthed
Non
effectively
earthned
Page 99 of 130
( ii ) LV side
System fault level
( i ) HV side
( ii ) LV side
Rated power
frequency withstand
voltage for
bushing/winding:
( i ) HV side
( ii ) LV side
Rated lightning
withstand voltage for
bushing/winding:
( i ) HV side
( ii ) LV side
Minimum creepage
distance (mm)
Noneffectively
earthed
Effectively
earthed
Effectively
earthed
Effectively
earthed
40 kA (rms) /
3 sec
40 kA (rms) / 1
sec
40 kA (rms) /
1 sec
40 kA
(rms) / 1
sec
50 kA
(rms) / 1
sec
40 kA (rms) /
1 sec
50 kA (rms) / 1
sec
50 kA (rms) /
1 sec
28 kV (rms)
20 kV (rms)
20 kV (rms)
20 kV (rms)
3 kV (rms)
3 kV (rms)
20 kV
(rms)
3 kV (rms)
75 kV
60 kV
25 mm/kV
60 kV
-25 mm/kV
60 kV
-25 mm/kV
60 kV
-25 mm/kV
10.2. NEUTRAL GROUNDING RESISTOR (NGR) FOR 6.5 MVA TRANSFORMER (LV SIDE)
10.2.1. GENERAL
Make
Standards (National / International)
Type
Voltage Grade
Enclosure class
Resistor type
Current rating at 40°C
Resistance
Highest system voltage
Power frequency voltage
S.R.Narkhede
IEEE-32
Outdoor, self supported
6.9 kV
IPW-55
Punched stainless steelAISI 430
300 A for 10 sec.
13.28 ohms
7.2 kV
20 kV
10.2.2. CURRENT TRANSFORMER
For REF
Type
Standards (National / International)
Ratio
Class
Quantity
Page 100 of 130
Epoxy
resin cast
IS 2705
630 / 1 A
PS
1 No.
For
Standby
Epoxy
resin cast
IS 2705
300 / 1 A
5P20
1 No.
11. 12 KV & 6.6 KV SWITCHGEAR
11.1. 12 KV SWITCH GEAR
11.1.1. GENERAL
Manufacturer
Type designation
Applicable standards
Rated voltage (kV)
Short circuit withstand current and duration at rated voltage
of the switchgear cubicle
Dynamic current withstand rating kA (peak)
Degree of protection provided for the Cubicle
VT/Relay Compartments
Circuit Breaker Compartments
11.1.2. CIRCUIT BREAKERS
Manufacturer
Type designation
Conforming Standard
Type ( SF6)
Rated voltage & frequency (kV HZ)
Maximum system voltage (kV)
Continuous current rating
Three (3) second current carrying capacity (kA rms.)
Asymmetrical Breaking current (kA)
Rated making capacity
Circuit breaker closing time (ms)
Circuit breaker breaking time (ms)
Max. temp. rise over ambient
Breaking capacity
Rated capacitive breaking current
a) Nominal current
b) Breaking current
Insulators
Manufacturer
11.1.3. CURRENT TRANSFORMERS
Manufacturer
Type designation
STC rating for 3 seconds
Voltas Switchgear Ltd.
Belledonne
IEC 298, IEC694, IS:
12729
12 kV
40 kA for 3 sec.
110 kAp
IP54
IP44
Voltas Switchgear Ltd.
FG2
IEC 56/ IS 13118
SF6 type
11.5 kV, 50 Hz
12.075 kV
3000A/1600A/630A at
50C
40 kA
43.5 kA
110 kAp
70-90 ms
60-80 ms
40C
40kA
a)3000A/1250A/ 630A
b)2200A/1120A/500A
Baroda Bushing
Voltas Switchgear Ltd.
TCR
40 kA for CT more than
200A. CT less than 200A
is provided with STC
rating of 40kA for 1 sec.
Class E
Insulation Class
11.1.4. VOLTAGE TRANSFORMERS
Manufacturer
Type designation
Voltas Switchgear Ltd.
TPRS
Page 101 of 130
11.1.5. RELAYS (NUMERICAL)
Manufacturer
Auxiliary supply
ABB
220V DC
11.1.5.1.TYPES OF NUMERICAL RELAYS
a) Under voltage Relay
b) Differential Relay
c) Combined O/C & E/F Relay
SPAU130C
SPAD346C
SPAJ 140C
11.2. 6.6 KV SWITCH GEAR
11.2.1. GENERAL
Manufacturer
Type designation
Applicable standards
Rated voltage (kV)
Maximum system voltage (kV)
Short circuit withstand current and duration at rated
voltage of the switchgear cubicle (kA peak)
Degree of protection provided for the Cubicle
VT/Relay Compartments
Circuit Breaker Compartments
11.2.2. CIRCUIT BREAKERS
Rated voltage & frequency (kV HZ)
Maximum system voltage (kV)
Continuous current rating
Rated making capacity
Max. temp. rise over ambient
Rated capacitive breaking current
a) Nominal current
b) Breaking current
Other Parameters
Insulators
Manufacturer
Voltas Switchgear Ltd.
Belledonne
IEC 298/ IS: 3427
6.6
7.2
40 kA for 3 sec
IP54
IP44
6.6 kV, 50 Hz
7.2 kV
1250A/ 630A at 50C
100 kAp
35C
a)1250A/ 630A
b) 875A/ 500A
Same as for the one
shown in item no.11.1.2
Baroda Bushing/
Approved Equivalent.
11.2.3. CURRENT TRANSFORMERS
Manufacturer
Type designation
STC rating for 3 seconds
Insulation Class
Temperature rise over 50 deg C
Page 102 of 130
Voltas Switchgear Ltd.
TCR
40 kA for CT more than
200A. CT less than 200A
is provided with STC
rating of 40kA for 1 sec.
Class E
As per IS 2705
11.2.4. VOLTAGE TRANSFORMERS
Manufacturer
Type designation
Voltas Switchgear Ltd.
TPRS
11.2.5. RELAYS (NUMERICAL)
Manufacturer
Auxiliary supply
ABB
220V DC
11.2.5.1.TYPES OF NUMERICAL RELAYS
a) Under voltage Relay
b) Motor Protection Relay
c)Combined O/C & E/F Relay
d)REF Relay
SPAU130C
SPAM 150C
SPAJ 140C
SPAJ 115C
12. 415V SWITCH GEAR (PCC) & LV BUS-DUCT
12.1. 415V SWITCH GEAR (PCC)
12.1.1. GENERAL
Make
Type
L&T, Gr.III
Metal clad, Only Breaker
modules are drawout
Indoor
IP - 54.
Service
Enclosure
12.1.2. SYSTEM
Voltage
Combined Voltage & Frequency variation
System
12.1.3. RATED CURRENT
(At 50 C)
Bus bar
Circuit Breaker
Switches
Short Circuit Rating
Short time Rating for 1 sec.
415V, 50 Hz, TPN
10% (Absolute Sum)
Effectively earthed
3200 A
3200 /1600/1000 A
100A to 630A
50kA.
Insulation Level
2.5 kV for 1 min.
12.1.4. A.C. / D.C. POWER SUPPLY
Control Voltage for Circuit Breaker
Control Voltage for other modules
Service Voltage
A.C. Fault Level
Page 103 of 130
220 V D.C.(190 - 240V)
240V A.C, 1 Ph, 50 Hz
240V A.C, 1 Ph, 50 Hz
50 kA (Symm)
12.1.5. CIRCUIT BREAKER
Rating
Duty Cycle
Breaking Current
A.C. Symmetrical
A.C. Asymmetrical
Making Current
3200 /1600/1000 A
0-3’ -CO-3’ -CO
50 kA for 1 sec.
1.2 x 50 kA.
2.1 x 50 kA Peak
12.1.6. AUXILIARY VOLTAGE
Closing, Tripping, Spring Charging
12.2. LV BUS-DUCT
Supplier
Manufacturer
220 V D.C.
L&T, SWTC, GR – III
Star Drive
:
:
General
Type
Material : Enclosure
: Conductor
Non segregated
Sheet steel / Aluminium
Aluminium / Aluminium
Alloy
2 mm for sheet steel and
3 mm for aluminium
Thickness of enclosure(minimum)
System
Voltage
Rated Current at 50 Deg. C ambient
Short time current rating for 1 sec.
Insulation Level :
One (1) minute power frequency withstand voltage
Temperature rise – maximum ( over 50 Deg. C ambient)
a) Bus conductor
b) Bus enclosure & structure
415 V , 50 Hz, TPN
3200A
50 kA
2.5 kV
40 Deg. C.
20 Deg. C
13. SUPERVISORY, CONTROL & ANNUNCIATION PANEL (SCAP)
Supplier
:
Maktel Systems
Description of important componenets :
MVAR meter, MW meter, Frequency Meter
3 Phase digital load manager,type 3480 with RS-485 serial
port aux. supply , 110vac PT supply ( CT Ratio : 200/1 , PT
Ratio : 6.6KV/110V
3 Phase digital load manager,type 3480 with RS-485 serial
port aux. supply , 110vac PT supply ( CT Ratio : 630/1 , PT
Ratio : 6.6KV/110V
Breaker Control Switches – Descripency type
Automatic Semaphore for breaker & isolator
Annunciator –static type (220 vdc, 48 /60way) with hooter
Synchroscope meter for 110v PT supply, 360 deg rotation
type
Page 104 of 130
MAKE
AE
Enercon
Enercon
ABB
DAV
Minilec
AE
14. 415V MCC, ACDB , DCDB
Make
1
2
3
4
5
Name of
MCC/Board
HRSG/STG MCC
(D/O)
CW MCC(D/O)
SeaWater Intake
MCC(Extension)
HVAC MCC (D/O)
FLS MCC
(Extension)
:
L&T
Main Bus
Rating
1000 A
Incomer type &
rating
1000 ACB(E)
No. of Incomers
1000A
1000A
1000 ACB(E)
___
2
__
600A
800A
600A FSU
800ACB(E)
2
--
2
14.1. GENERAL
MCC,ACDB,DCDB
Metal Clad, Double/
Single front, free
standing, floor mounted.
Degree of Protection
LT Compartment
Breaker Compartment
Drawout/ Fixed
IP-54 (IP42 for DCDB)
IP-54
Fully drawout for MCC/
Fixed type for ACDB &
DCDB
50 kA for 1 sec
Fault withstand capability
14.2. AIR CIRCUIT BREAKER
Electrically/ Manually Operated
Electrically operated
having close and trip coil.
11NO +11NC
No of Aux. Contacts
Load break switches
Type
Reference Standard
HRC Fuses
Type
Reference Standard
Heavy duty/ motor duty
IS : 4064
Cartridge type
IS : 9224
14.3. CONTACTOR
Rated service voltage
System earthing
Short circuit level
415V ,50 Hz, 3 pole
solidly earthed
50 kA (rms.) at 415V for
1 sec
240VAC
AC 3 for unidirectional
motors
AC 4 for bi-directional
motors
85% to 110%
minimum pickup voltage
is 85%of rated voltage.
Control circuit
Utilisation category
Limits of operation
Closing (pickup)
Drop out
Page 105 of 130
Limits of temperature Rise over 50C ambient
14.4. THERMAL OVERLOAD RELAYS
Type
Reference standard
Rated current-adjustable setting
minimum drop out
voltage is 65%of rated
voltage.
35 deg C without silver
plating and 40 deg C with
silver plating at the joints.
BMR
IS : 8544
0.7 to 1.2 times full load
current of the drive.
Built in.
Single phasing protection
14.5. CURRENT TRANSFORMERS
Service
System
Type
Rated voltage
Accuracy
Power frequency withstand voltage
Rated short time current
Short time withstand current
Indoor, Cast resin type
415V, 3 phase, 4 wire,
50 Hz, solidly earthed
Cast resin
415V  10%
Class-1.0 for metering,
ISF  5, 15VA and 5P20,
15 VA for protection and
10VA for metering CT in
the outgoing circuit.
2.5kV (rms.) for one
minute
the maximum let through
fault current
15. DC BATTERY & BATTERY CHARGER
15.1. 220 V DC BATTERY
(Same as of Open Cycle)
General
Manufacturer
Type
Type of Battery positive Plates
Guaranteed AH capacity at 10 hrs discharge rate
AH capacity at half-hour discharge rate at min site ambient
of 11 deg C
No of Cells /Battery
Applicable Standard
Recommended range of floating/trickle charging voltage
Nominal Cell voltage for Boost Charging
Intermediate Tapping
Trickle charging current
Maximum Electrolyte temperature that cell can withstand
continuously without injurious effects
Page 106 of 130
Exide Industries Ltd.
220V, 650AH, Lead-Acid
Battery
Tubular
650AH
211AH
110
IS: 1651 of 1991
2.15-2.18 V/ cell
2.70 V
83rd cell
325/1300 milliamps
45 deg C
Internal Resistance of each cell
0.330 milliohms
15.2. 220V BATTERY CHARGER
Charger
Quantity
Float Charger(40A)
2 nos 40A Stand alone
Float Charger.
Solid state, full wave,
fully controlled/ six pulse,
three phase bridge
rectifier type.
Type
AC Input
Supply
Voltage variation
Frequency variation
Combined volt. & frequency variation
Short circuit level
System Earthing
220V DC voltage setting adjustment of AVR for float
charging
Voltage stabilization for constant voltage regulator
Permissible ripple content at rated continuous load
Float Charging voltage/cell
Degree of Protection of Charger Panel
415V, 3ph., 50 Hz, 4
wire,200A
 10 %
5 %
10%
50 kA for 1 sec
Solidly earthed
 10 % of nominal
voltage
a)  1 % of set DC
voltage with 10 %
variation in supply
voltage and 5%
variation in frequency
b)  5 % during
transients
1% max.
2.16V
IP42
16. HT CABLES
16.1. GENERAL
Make
RPG Cables Ltd. (Unit :
Asian cables & Industries
India
Country of Manufacturer
16.2. TYPE DESIGNATION
For 1C-500 mm2 (12.7/22kV)
For 1C-300 mm2 (6.35/11kV)
For 3C-185 mm2 (6.35/11kV)
Applicable standard
2XWaY
A2XWaY
A2XFY
IS:7098 Part (2)
16.3. VOLTAGE GRADE
For 1C-500 mm2 (12.7/22kV)
For 1C-300 mm2 (6.35/11kV)
For 3C-185 mm2 (6.35/11kV)
12.7 / 22 kV
6.35 / 11 kV
6.35 / 11 kV
Page 107 of 130
16.4. CONDUCTOR
I ) Material
For 1C-500 mm2 (12.7/22kV)
Annealed plain copper as
per IS:8130
H2 grade Aluminium as
per IS:8130
H2 grade Aluminium as
per IS:8130
For 1C-300 mm2 (6.35/11kV)
For 3C-185 mm2 (6.35/11kV)
II) Nominal cross section area in sq. mm
For 1C-500 mm2 (12.7/22kV)
For 1C-300 mm2 (6.35/11kV)
For 3C-185 mm2 (6.35/11kV)
III) Max. D.C. resistance at 20C at  / km
For 1C-500 mm2 (12.7/22kV)
For 1C-300 mm2 (6.35/11kV)
For 3C-185 mm2 (6.35/11kV)
IV) Approx. A.C. resistance at operating temp. 90C
For 1C-500 mm2 (12.7/22kV)
For 1C-300 mm2 (6.35/11kV)
For 3C-185 mm2 (6.35/11kV)
Conductor Screen
i) Material
ii) Thickness (in mm)
16.5. INSULATION
i) Material
500 mm2
300 mm2
185 mm2
0.0366
0.1
0.164
0.0499
0.1300
0.2110
Black Extruded Semiconducting compound
0.3 (Minimum)
Extruded XLPE as per IS
: 7098
ii) Nominal thickness (in mm)
For 1C-500 mm2 (12.7/22kV)
For 1C-300 mm2 (6.35/11kV)
For 3C-185 mm2 (6.35/11kV)
iii) Type of curing for XLPE insulation (Gas)
Insulation Screen
i) Material
ii) Minimum Thickness in mm
For 1C-500 mm2 (12.7/22kV)
For 1C-300 mm2 (6.35/11kV)
For 3C-185 mm2 (6.35/11kV)
Metallic screen (wherever applicable)
i) Material
ii) Type
Rating KA, Sec
Inner sheath
i) Type of inner sheath
ii) Minimum thickness of inner sheath
For 1C-500 mm2 (12.7/22kV)
For 1C-300 mm2 (6.35/11kV)
For 3C-185 mm2 (6.35/11kV)
Page 108 of 130
6.0 mm
3.6 mm
3.6 mm
Dry cured dry cooled
Black extruded semicompounded material.
0.30
0.30
0.30
Single layer of copper
tape
Tape (Lapped)
0.3 kA/sec (each core)
Extruded PVC type ST2
0.5 mm
0.4 mm
0.7 mm
Armour Material
i) Type
For 1C-500 mm2 (12.7/22kV)
Al. Round wire of grade
H4 of IS:8130
Al. Round wire of grade
H4 of IS:8130
Galvanized flat steel strip
For 1C-300 mm2 (6.35/11kV)
For 3C-185 mm2 (6.35/11kV)
ii) Nominal dimension
For 1C-500 mm2 (12.7/22kV)
For 1C-300 mm2 (6.35/11kV)
For 3C-185 mm2 (6.35/11kV)
Outer Sheath
i) Type
2.5mm diameter
2.0 mm diameter
4 x 0.8 mm
Extruded PVC type ST2
IS:5831/84 (FRLS)
ii) Minimum thickness of outer sheath
For 1C-500 mm2 (12.7/22kV)
For 1C-300 mm2 (6.35/11kV)
For 3C-185 mm2 (6.35/11kV)
iii) Color of Outer sheath
For 1C-500 mm2 (12.7/22kV)
For 1C-300 mm2 (6.35/11kV)
For 3C-185 mm2 (6.35/11kV)
16.6. OTHER PROPERTIES
Over all dia cable (in mm)
For 1C-500 mm2 (12.7/22kV)
For 1C-300 mm2 (6.35/11kV)
For 3C-185 mm2 (6.35/11kV)
Approx. weight of finished cable (kg/km)
For 1C-500 mm2 (12.7/22kV)
For 1C-300 mm2 (6.35/11kV)
For 3C-185 mm2 (6.35/11kV)
Guaranteed value of minimum oxygen index of outer
sheath
Maximum acid-gas generation by weight (%) of outer
sheath
Minimum light transmission
Short circuit capability of cable
For 1C-500 mm2 (12.7/22kV)
For 1C-300 mm2 (6.35/11kV)
For 3C-185 mm2 (6.35/11kV)
2.04 mm
1.56 mm
2.36 mm
Yellow
Black
Black
58
42
69
7050
2200
5710
29 (min) at room temp
20% max by weight
Max. smoke density
rating=60% as per
ASTM-D-2843
71.5kA for 1 Seconds
28.2kA for 1 Seconds
17.4kA for 1 Seconds
17. ELECTRICAL LABORATORY EQUIPMENT
17.1. ELECTRIC MOTOR CHECKER
Make
Model No.
Insulation Resistance
EMC ELECRONIK
EMC-22
0 to 20 mega ohm
Page 109 of 130
at 500 VDC. Max
current
0 to 60 ohms in 6 ranges
(0.2 ohm F.S.D. in range
6)
0 to 300 mh in 6 ranges
( 1 mh FSD in
range 6)
Resistance
Inductance
17.2. MEGGAR
Supplier / Make
Josts Engg.Co./ Meggar MJ10
0-2000Mega ohms
100V,
250V,250V,500V,100
0V
Insulation Resistance
Nominal test voltage d.c.
17.3. HIGH VOLTAGE INSULATION TESTER
Supplier / Make
:
PCI Ltd. / Edgkumbe
Range
:
100kohms, to 100 Gohms at test voltage of 500V
, 1kv,2.5 kv, 5kv
Accuracy
:
  1.5 %
Supply
:
240 VAC  10%
17.4. OIL DIELECTRIC STRENGTH TEST KIT (MOTORISED)
Supplier / Make
:
PCI Ltd. / HCK
Range
:
0 to 100KV DC
Accuracy
:
 1kv
17.5. RELAY TESTING KIT
Supplier / Make
:
PCI Ltd./ Programma
Range
:
Current from 0 –100A, Voltage up to 220V DC
 Minimum 10 memory storage cells for results and settings.
 Serial port (RS 232) for down loading information to PC.
17.6. DIGITAL MICRO-OHMMETER
Supplier / Make
:
Range
:
Accuracy
:
PCI Ltd./ Programma
0 to 1999micro-ohm and 0to 19.99 m-ohm
 1 %S
Page 110 of 130

1.
CONTROL & INSTRUMENTATION
GT CONTROLS
Supplier
Model
:
:
General Electric
Speedtronic Mark V
1.1. SYSTEM ARCHITECTURE
Primary Operator Interfaces (<I>)
Back up operator Interface(<BOI>)
GT control Panel
:
Enclosure Class
:
Power Supply
:
Configuration
:
:
2 Nos.
IBM compatible PC
Colour Monitor
Key Board
Cursor positioning device
Printer
:
1 No
1 No
NEMA Type 1
125V D.C. & 220V A.C.
TMR (Triple Modular Redundant)
(Software implemented fault tolerance)
Hard Ware
Redundant Control Processor Cores :
<R>, <S>, <T>
Communicator Core
:
<C>
Protective Core
:
<P>
Digital I/O core for control
Processors
:
<QD1>, <QD2>
Communicator Digital I/O Core
:
<CD>
2.
Communication
<I> to Mk V
:
<I> TO DCS
:
STAGE LINK (ARCNET LAN)
Co-axial Cable
MODBUS
PLC
Service
LFS Naphtha pumps control
(LCP1 & LCP3)
LFS, HSD pumps (unloading)
control (LCP2)
DM Plant controls
Compressors controls
Make
AllenBradley
AllenBradley
AllenBradley
Toshiba
Hitec Dosing System
Siemens
Page 111 of 130
Model No
SLC 5/O4
SLC 5/O3
SLC 5/O2
Prosec T1
MDR 28
Display Unit O1S100
SIMATIC
PLC S5 – 90U
with
SIFT
Compressor washing system
controls
3.
SIMATIC
PLC S5 – 90U
GAS DETECTION SYSTEM
Make
Model:
Controller
Sensor
No. of sensors
Calibration gas
High alarm
Hi-Hi alarm (Trip)
4.
Siemens
:
Sieger
:
:
:
:
:
:
5701
780
8
Propane mixed with air to 50% LEL
20% LEL
50% LEL
:
:
CEGELEC
Alspa PLC 820
Central Processor Unit
Model No.
Processor
Memory capacity
Scan Time
Software
:
:
:
:
:
CPU351
80386 EX
80 KB
0.3 mS for 1-KB logic
ALSPA P8 programming package
Power Supply Unit
Model No.
Input Voltage
Output voltage
Rating
:
:
:
:
PWR 325
230 V, AC, 50 Hz, UPS
24 V, DC
30 Watts
STG CONTROL SYSTEM
4.1. STG PLC
Supplier
Model No.
HMI 820 REMOTE OPERATOR STATION
The remote operator station is based on Pentium PC running under Windows NT
workstation with PLC820 communication.
CPU
:
Pentium
FDD
:
3.5”
CRT
:
21”
Printer
:
Dot Matrix, 80 Column
Historical Storage
:
Alarm & Critical events- 5 Days
Curves & Analog Data – 1 Day
4.2. IO MODULES
TYPE
RTD
MODULE
DESCRIPTION
INPUT Model No.
Type of RTD
No of channels
SPECIFICATION
ALG 620 IC670
Pt 100
4
Page 112 of 130
TYPE
ANALOG
MODULE
DESCRIPTION
INPUT Model No.
No of channels
Input Scan Rate
ANALOG
Model No.
OUTPUT
Range of Output
MODULE
Allowable
Load
resistance
No of channels
DIGITAL INPUT Model No.
MODULE
Interrogation voltage
Input current
No of channels
DIGITAL OUTPUT Model No.
MODULE
Output signal
Contact rating
No of channels
COMMUNICATIO Model No.
N MODULE
Interface
Mode
Transmission rate
Transmission code
SPECIFICATION
ALG221
4
2 ms for 4 channels
ALG391
4-20 mA
850 
4
MDL634
24 V DC
7 mA
8
MDL940
Potential free contact
2 Amps
16
CMM311
RS 232
Serial
9600 bytes/s
MODBUS RTU Protocol
4.3. TURBINE SUPERVISORY SYSTEM
4.3.1. VIBRATION MONITORING SYSTEM
Supplier
:
BENTLY NEVADA, USA
System
:
3300
Probes
Shaft side Model No.
:
330171-00-08
Gear side Model No.
:
330105-02
DC Resistance (nominal)
:
Average Scale Factor (ASF) :
Gap Voltage
:
7.3  + 0.28  / m
7.87  0.21 mV/m
9 VDC
Proximitor Sensor
Supply Sensitivity
Supply voltage range
Current drawn
Output resistence
:
:
:
:
< 2 mV change in output V / change in input V
-17.5 Vdc to –26.0 Vdc
12 mA max. with 10K load
50K
Dual Vibration Monitor
Model No.
Signal Input:
Input Impedance
Signal Scale factor
:
:
:
:
3300 / 16
Two-channel proximity input
10 K
200 mV/mil
Signal Conditioning
Monitor Range
:
Full scale meter range selected
Page 113 of 130
Accuracy
Displays
Meter
full scale
Front Panel Control
Internal Control
:
1% of full-scale error maximum at 77 C
:
LCD bargraph, dual scale with resolution of 1.6% of
:
:
Switch for Alert, danger and gap voltage reading
Switches on circuit board for set point adjustment,
danger bypass & channel bypass
External remote control: Reset, Inhibit, Trip Multiply
and set point adjustment
External Control
:
Output
:
4-20 mA
Transducer power
:
-24 Vdc
4.3.2. RESISTANCE TEMPERETURE DETECTOR (RTD)
Make
:
Lufkin
Type
:
Pt100
4.3.3. SPEED SENSOR
No. of speed probes
Manufacturer
Type
Thread length
Output voltage (Standard)
Output volatage (Guarantee)
Dc resistance
Inductance
:
:
:
:
:
:
:
:
Six ( Three for LP turbine & three for HP turbine)
AIRPAX
70085-1010001
1.125” (28.75 mm)
40 V,(P-P)
3.4 V(P-P)
130-Ohm Max.
34 mH
4.3.4. ALARM AND TRIP POINT SETTINGS
Vibration / Tempereture probe
Range
Set points
location
Alarm/ Trip
VIBRATION
HP turbine exhaust / admission / gear 0-100m
36 m /48 m
side shaft vibration X / Y
HP turbine thrust bearing wear
-1.2,
0, -0.6 & 0.3 mm
+0.8 mm
/ -0.9 & 0.6
mm
LP turbine exhaust / admission / gear 0-100m
50 m /67 m
side shaft vibration X / Y
LP turbine thrust bearing wear
-1.2,
0, -0.68 & 0.3
+0.8 mm
mm / -0.98 &
0.6 mm
Generator gear / exciter side shaft 0-100m
56 m /75m
vibration X / Y
TEMPERATURE
HP turbine thrust / admission side /
110 C/120 C
exhaust side bearing temperature
LP turbine thrust / admission side /
110 C/120 C
exhaust side bearing temperature
Page 114 of 130
Gear HP turbine side bearing temp
Gear LP turbine side bearing temp
Gear Generator side bearing temp
Generator gear / exciter side bearing
temp
5.
99 C/107 C
99 C/107 C
99 C/107 C
85 C/90 C
DISTRIBUTED CONTROL SYSTEM (DCS)
Supplier
Model No.
5.1. SYSTEM CONFIGURATION
No. of FCS
No. of ICS
No. of EWS
Associated Systems
printer
:
:
Yokogawa Blue Star Ltd.
Centum CS
:
:
:
:
4 (3 nos for HRSG & BOP, 1 no for BMS)
4
1
Pentium II PC for Historical long term trend with
Peripherals
:
Historical Trend Capacity
:
Pentium II PC for Performance Calculation with
printer
Sequence of Event Recorder (SER) sytem
4 nos Dot matrix printers (Model YPR 120)
1 no Colour Hard copy Unit (Model YPR 520)
256 points with 1 sec update for 30 days
COMMUNICATION
DCS to STG
DCS to GTG (Mk V)
DCS to plant LAN
:
:
:
Redundant RS 485 link
RS 485 link
Ethernet through DDE
PERFORMANCE CALCULATIONS
 Gas turbine efficiency
 Steam turbine efficiency
 HRSG efficiency
 Steam turbine heat rate
 GTG & combined cycle heat rate
 Condenser performance
 HP feed pump efficiency
5.2. FIELD CONTROL STATION (FCS)
Model No.
:
Processor
:
Memory capacity
:
Battery Back up
:
Operating System
:
Battery recharge time
:
Maximum no. of nodes
:
Communication Interface
:
RIO Bus Interface
:
Power Supply
:
AFM10D
R30000 (30 MHz)
12 MB
72 hours
ORKID (real time kernal definition)
Min. 48 hours
8
V net interface - Dual – redundant
Dual – redundant
230 V AC, 50 Hz
Page 115 of 130
5.3. INFORMATION COMMAND STATION (ICS)
Model No.
:
AIH00D-L421/MU/1-R1/1-E2/C20
Processor
:
Motorola MC68040
CRT Display
:
21”
Resolution
:
1280 X 1024 pixels
Mouse
:
Optical three button type
Sounds
:
7 types of loudspeaker sounds
Main Memory
:
96 MB
Hard Disk
:
2 GB Mirrored disk
Peripherals
:
Serial Printer, Colour Hard Copy Unit (CHU),
Magnetic Cartridge Tape Unit
Communication Interface
:
V Net - one duplexed port
E Net - one port
RS 232 Interface - one port (max. 4 ports)
Operation Keyboard
:
Dust-proof semi-stroke key 48 user function keys
Engineering Keyboard
:
For engineering functions through remote login to
EWS
Operating System
:
HP-UNIX
No. of Graphics
:
800
No. of Trend Panels
:
800 each having 8 parameters
No. of control Panels
:
800 each having 8 parameters
Historical Storage
:
Short term / long term storage
Other Facilities
:
4 half size windows; Security of operation and
engineering functions
Screen refresh rate
:
1 sec
5.4. ENGINEERING WORK STATION (EWS)
Model No.
:
HP9000 series 700
Operating System
:
HP-UNIX
Function
:
Maintenance of database and for configuration of
engineering functions both in On-line & off-line mode
Self Documenting Function :
For taking printout of all control drawings, logic
charts etc. configured in system
5.5. DATA HIGHWAY
5.5.1. V NET
Speed
Transmission Path
Access Control
802.4)
Transmission Length
Transmission Cable
5.5.2. E NET
No. of ICS
Transmission Speed
Line Access Control
Transmission Distance
Transmission Cable
:
:
:
10 MBPS
Dual redundant
Master less Token Passing (Conforming to IEEE
:
:
500 m without repeaters
Coaxial Cable as medium
:
:
:
:
:
Max. 16 ICS can be connected
10 MBPS
CSMA-CD Method; Thin Ethernet
185 m
Coaxial Cable
Page 116 of 130
5.5.3. RIO BUS
No. of Nodes
Transmission Speed
Transmission Path
Transmission Distance
Transmision Cable
:
:
:
:
:
Max. 8
2 MBPS
Dual redundant
Max. 750 m
Twisted Pair cable
5.6. GENERAL
Maximum no. of cards
:
640-Single Channel I/O Cards per FCS, 160 - 16
Channel I/O Cards (Digital). The above quantity is
maximum in each variety.
64 stations in one domain and maximum 64 domains
Both On Line & Off line possible
Max. no. of nodes
:
Engineering function changes :
No. of I/O counts & Power Supply
modules installed in the system:
Analog Inputs-241 (single channel card)
Analog Outputs-50 (single channel card)
RTD - 126 (single channel card)
T/C - 63 (single channel card)
Digital Input - 1408 (16 channel card)
Digital Output - 768 (16 channel card)
Communication Module (RS 485) - 6
PW402 - 36
PW302 - 8
5.7. IO MODULES
5.7.1. RTD INPUT MODULE
Model No.
Range of Input
Input conversion accuracy
Input scan rate
Measuring Current
Effect of ambient
No of channels
:
:
:
:
:
:
:
AAM21
0 to 333 
 0.08 
1 sec
1 mA
 0.16  / 10C of change temperature change
Single channel module
5.7.2. T/C INPUT MODULE
Model No.
Range of Input
Input conversion accuracy
Input scan rate
RJC Input
RJC Accuracy
Effect of ambient
No of channels
:
:
:
:
:
:
:
:
AAM21/RJ
-50 to 150 mV
 20 V
1 sec
-10 to 70C
1C
 40 V / 10C of change temperature change
Single channel module
5.7.3. ANALOG INPUT MODULE
Model No.
No of channels
Accuracy
Input Scan Rate
:
:
:
:
AAM10
Single channel
 16 A
100 m sec to 1 sec
Page 117 of 130
5.7.4. ANALOG OUTPUT MODULE
Model No.
:
Range of Output
:
Allowable Load resistance :
Accuracy
:
Effect of ambient
:
Through put time
:
No of channels
:
AAM50
22.5 mA or less
0 – 750 
 48 A
 32 A / 10C temperature change
100 m sec
Single channel module
5.7.5. DIGITAL INPUT MODULE
Model No.
Input signal
:
:
Contact rating
Power consumption
Input Scan Rate
No of channels
:
:
:
:
ADM11C
OFF – 100 K or more
ON – 200  or less
5 V DC, 20 mA min.
600 mA max.
50 m sec to 1 sec
16 channel module
5.7.6. DIGITAL OUTPUT MODULE
Model No.
:
Output signal
:
Contact rating
:
Power consumption
:
Through put time
:
No of channels
:
ADM51C-2
Transistor contact
30 V DC, 100 mA max.
600-mA max.
50 m sec
16 channel module
5.7.7. COMMUNICATION MODULE
Model No.
:
Interface
:
Mode
:
Transmission rate
:
Transmission code
:
ACM12
RS 485
Half duplex
9600 bps
ASCII, binary
5.8. SEQUENCE OF EVENT RECORDER (SER)
Make
:
Hathway, USA
Model No
:
Betalog4100R
No of inputs configured
:
128
No. of Input module
:
4 cards (64 digital inputs per module)
Resolution
:
1 msec
Sequential Memory capability :
>4500 event message per 64 points
Historical memory capability :
Circular buffer with 6000 events
Field contact voltage
:
48 V DC
Clock Synchronisation
:
External Sync pulse once per hour from DCS
PC for archiving
:
Pentium II with 21” colour monitor
Printer
:
Make – TVSE; Model no. – MSP240; speed – 200
cps
Page 118 of 130
6.
FIELD INSTRUMENTS
6.1. PRESSURE / DIFFERENTIAL PRESSURE GAUGE
Manufacturer
:
Pyro Electric Instruments, Goa
Model No.
:
XX/PBB 6 0/X( As per range) AI S6 S4 S6X1/2”
NPT(M)
Sensing Element and Material
:
316SS Bourdon for high pressure
316SS Bellows/ Diaphragm for low pressure
Dial Size
:
150mm
Enclosure
:
IP65
End Connection
:
½” NPT(M) (bottom)
Accuracy
:
1.5 % of span
6.2. TEMPERATURE GAUGE
Manufacturer
:
Body Material
:
Dial Size
:
Accuracy
:
Enclosure
:
Material of Bourdon Movement:
End Connection
:
6.3. PRESSURE / DP SWITCH
Manufacturer
:
Model no.
:
Sensing Element and material:
Material
Accuracy
Enclosure
End connection
:
:
:
:
6.4. LEVEL SWITCH
Manufacturer
:
Model No.
:
Sensing Element and material:
Material
Enclosure
End connection
Differential
:
:
:
:
6.5. THERMOCOUPLE AND RTD
Manufacturer
:
Model No.
:
Calibration and Accuracy
:
Characteristic
span
Enclosure (Head)
Number of Elements
Pyro Electric Instruments, Goa
Die-cast aluminium with epoxy coating
150mm
+/-1% of span
IP65
316SS/304SS
½ “ NPT (M) / M 20 x 1.5
Switzer Instruments
GM-201-02-XX-2 / GB-935-XX
Piston actuated for high pressure,
Diaphragm or Bellows for low pressure/ vacuum
316 SS
 1% of FSD
IP66
½”NPT (M)
Levcon instruments Pvt. Ltd.
MLS series.
Float operated magnetic reed switch for process fluid
with external cage.
316SS
IP66
Flanged
12  2 mm
:
Pyro Electric Instruments, Goa.
2Pt8316D2316LTXXXX / 2K8316D2316LTXXXX
As per ANSI MC-96.1 latest revision for
Thermocouple and IS 2806 latest revision for RTD
Linear with respect to temperature within +/- 0.5% of
:
:
IP65
Duplex
Page 119 of 130
T/C & RTD conn with Thermowell:
6.6. TRANSMITTERS
Manufacturer
Type & Construction
Capacitance
Model No.
Accuracy
Enclosure
Diaphragm
Power Supply
Load Resistance
½ “ NPT (M) /M20x1.5
:
:
Yokogawa
:
Thermax Fuji
Smart & Silicon Resonance :
Smart &
:
:
EJA110A/430A/ 440A
 0.075%
(0.12% for EJA440A)
NEMA 4X
Hestalloy
16.4 to 42 VDC
600  at 24 VDC
:
:
:
:
:
:
FCX series
 0.1 %
:
:
SS316
16.1 to 45 VDC
6.7. DISPLACEMENT TYPE LEVEL TRANSMITTER
Manufacturer
:
Magnetrol
Model No.
:
XE65-2C6B-ESA
Type
:
2 wire- Hart type
Cage Material
:
Carbon Steel
Displacer type
:
316 SS
Enclosure
:
IP66
Linearity
:
±0.5% of span.
Reliability
:
±0.4% of span.
Load Resistance
:
420  at 24 VDC
6.8. ORIFICE PLATES
Manufacturer
Model No. / Type
Material of element
:
Micropricisions, Fariadabad
Concentric Sq. edge / As per ASME PTC-19.5 Part II
or BS-1042
SS316
6.9. ANNUBAR
Manufacturer
Model No. / Type
Material of element
:
:
:
Veries Inc. , USA
Averaging pitot tube
SS316
6.10. FLOW NOZZLES
Manufacturer
Model No. / Type
:
:
:
Micropricisions, Fariadabad
Long Radius, weld neck / As per ASME PTC-19.5
Part III or BS-1042 or ISA 1932
Main Steam Flow
Feed water flow before
:
:
:
:
:
A182 F316
273.00 / 215.84
0.66694921
78000 Kg/Hr.
3000 mmWC
Service
eco. I/L
Material of flow element
Pipe ID /OD in mm
Beta Ratio
Maximum flow
Max. Differential pressure
:
:
6.11. ELECTRONIC DRUM LEVEL INDICATOR (EDLI)
Manufacturer
:
Level State, U.K.
Model No
:
202 - 501 / 12
Page 120 of 130
A182 F316
168.30 / 131.78
0.61138462
85000 mmWC
1000 mmWC
Insertion probes
Enclosure
Power supply
Range
:
:
:
:
12 nos
IP66
2 nos. 230 V AC, 50 Hz
-675mm to 425 mmWC
6.12. BI- COLOUR LEVEL GAUGE
Manufacturer
Product Name
Model No.
Range
:
:
:
:
NARVIK VALVES
DUCO
3000N9
-675mm to 425 mmWC
6.13. MASS FLOW METER
Manufacturer
Application
Sensor Model No.
Transmitter Model No.
Range
Accuracy
Transmitter Output
Transmitter Power Supply
:
:
:
:
:
:
:
:
Micro Motion (Fisher-Rosemount)
Naphtha Flow Measurement
BASIS FT100
IFT9701
0 – 10 TPH
 0.2 %
Self-powered 4-20 mA, 600 
220 VAC
7.
STEAM & WATER ANALYSIS SYSTEM (SWAS)
7.1. VARIOUS STREAMS & RANGE OF MEASUREMENT:
The measurements provided for various streams are listed below:
Stream
Measurement
Range
HP Drum Water
Specific Conductivity
0-300 S/cm
pH
0-14 pH
Silica
0-500 ppb
HP Drum Saturated Specific Conductivity
0-10 s/cm
Steam
HP Main Steam
Specific Conductivity
0-10 s/cm
Cation Conductivity
0-1 s/cm
LP Drum Water
Specific Conductivity
0-300 S/cm
pH
0-14 pH
Silica
0-500 ppb
LP Drum Saturated Specific Conductivity
0-10 s/cm
Steam
Cation Conductivity
0-1 s/cm
LP Main Steam
Specific Conductivity
0-1 S/cm
Hotwell
Specific Conductivity
0-10 S/cm
CEP
Discharge Specific Conductivity
0-10 S/cm
Header
Cation Conductivity
0-1 s/cm
pH
6-14 pH
Deareator Outlet
Specific Conductivity
0-10 S/cm
Cation Conductivity
0-1 s/cm
pH
6-14 pH
Dissolved Oxygen
0-20 ppb
HP BFP Discharge
Hydrazine
0-50 ppb
Page 121 of 130
Stream
LP BFP Discharge
Sea Water
Measurement
Hydrazine
pH
Range
0-50 ppb
4-14 pH
7.2. SAMPLE HANDLING SYSTEM:
7.2.1. PRIMARY COOLER
Supplier
Manufacturer
Model No.
Type
Nominal Heat duty
Sample flow rate
Cooling water flow rate
:
:
:
:
:
:
:
GTFB Gr.II, L&T
Forbers Marshall
V100-18C
Counter flow single pass
48,000 kcal/h
60 lph
4000 lph
7.2.2. ISOLATION VALVE (IV51/IV32)
Type
:
Make
:
Globe, Bar Stock
EXCEL HYDRO
7.2.3. SAMPLE COOLER (PSC1)
Type
:
Make
:
Model no.
:
Coil in Shell, Counter flow
Santry, USA
TLF4225
7.2.4. VARIABLE PRESSURE REDUCING ELEMENTS (VREL)
Make
:
Santry, USA
Type
:
Variable Orifice size
Material
:
SS
Set Pressure
:
1.8 Kg/cm2
Rating
:
500 PSI@300 F
Sample inlet / outlet connection:
¼” OD Tube
7.2.5. PRESSURE GAUGES (PGG2)
Make
:
Range
:
Enclosure
:
GI
0-10 Kg/Cm2
IP65
7.2.6. TEMPERATURE GAUGES ( TG03)
Make
:
Type
:
Range
:
Enclosure
:
GI
Bimetallic
0-100C
IP65
7.2.7. BACK PRESSURE REGULATOR / RELIEF VALVE (PRB/RV)
Make
:
SENTRY, USA
Set Pressure
:
1.5 – 1.8 Kg/cm2
Regulated Range
:
20 Psig.
Inlet / Outlet
:
1/4” NPT (F)
Page 122 of 130
7.2.8. CATION COLUMN (CNT1)
Make
Inlet / Outlet
:
:
Ion Exchange
1/4” NPT (F)
7.2.9. STREAM SELECTOR
Make
Model no.
Quantity
No. of Stream / unit
Main Supply
Analog output
Analog input
:
:
:
:
:
:
:
SAYAMAK INSTRUMENTATION PVT LIMITED
SS-301
2
2
230 V A.C
1 no. 4-20 mA.
3 Channel 4-20 mA.
7.2.10. SOLENOID VALVE
Make
Type
Power Supply
Enclosure
:
:
:
:
ASCO
3 Way, direct
230 V, A.C, and 50 Hz.
Whether Proof
:
:
:
:
:
:
Fisher-Rosemount
399-07-CB99
1500mV
Automatic 0-85 C
1054B
Black, NEMA 4X, IP-65
7.3. SENSORS & ANALYSERS:
7.3.1. PH MEASUREMENT
Make
Sensor model No.
ORP
Temperature Compensation
Analyser model No.
Enclosure
7.3.2. CONDUCTIVITY MEASUREMENT
Make
:
Sensor Model No.
:
Cell Constant
:
Analyser Model No.
:
Current output
:
Enclosure
:
Fisher Rosemount
400-11-54-50 / 400-12-54-50
0.01/0.1
1054B
Isolated, 4-20 ma, 600 Ohm Load.
Black, ABS, NEMA 4X, IP-65
7.3.3. IN SITU CONDUCTIVITY MEASUREMENT
Make
:
Fisher Rosemount
Sensor Model No.
:
400-54
Analyser Model No.
:
1054B
Current output
:
Isolated, 4-20 ma, 600 Ohm Load.
Enclosure
:
Black, ABS, NEMA 4X, IP-65
7.3.4. DISSOLVED OXYGEN MEASUREMENT
Make
:
ORION, USA
Model No.
:
ORION 1816 AO
Signal output
:
Isolated, 4-20 ma, 600-Ohm Load, assignable
Accuracy
:
 2% of reading or 0.1ppb
Page 123 of 130
7.3.5. HYDRAZINE MEASUREMENT
Make
:
Model No.
:
Signal output
:
Accuracy
:
7.3.6. SILICA MEASUREMENT
Make
Model No.
Accuracy
Reagents
8.
ORION, USA
ORION 1818 AO
Isolated, 4-20 mA, 600-Ohm Load, assignable.
Upto range 0-50ppb  2% of reading or 0.1ppb
:
:
:
:
HACH, USA
HACH 60000-40
0.00 to 500 g/L 1.0 g/L or  5 % of reading
2.9L Molybdate 3 (Cat no. 1995-03)
2.9L Citric acid / surfactant (Cat no. 23470-03)
2.9 L Amino acid F (Cat no. 23531-03)
2.9 L Silica Standard Solution, SiO2, 500 g/L (cat
no. 21008-03) 250 ml required for standardisation
CONTINUOS EMISSION MONITORING SYSTEM (CEMS)
8.1. ANALYSER
Make
Model No.
Principal
Feature
Range
SO2
CO
NO
8.2. SAMPLING PROBE
Make
Material
Depth of the probe
Sample filter
:
:
:
:
Maihak
MULTOR 610
NDIR technique
It can measure 4 IR components including H2O
cross sensitivities
:
:
:
0 - 85 ppm
0 - 500 ppm
0 - 300 ppm
:
:
:
:
Chemtrols
SS316
1/3rd to 2/3rd of stack diameter
HOKE
8.3. CALIBRATION GAS CYLINDERS
Make
:
Zero gas cylinder
:
SO2 SPAN GAS Cylinder
:
CO SPAN GAS Cylinder
:
NO SPAN GAS Cylinder
:
SGC
100% N2, 47 litres CS Cylinder
74-PPM SO2 balance N2, 10 Litres, Al Cylinder
403-PPM CO balance N2, 10 Litres, Al Cylinder
230-PPM NO balance N2, 10 Litres, Al Cylinder
8.4. OXYGEN ANALYSER
Make
Model No.
Type
Range
Error
Response Time
Power Supply
Servomex, UK
Xendos, 2700
Zirconia
0 – 25%
<1% of range
10 sec
220V AC, 50 Hz
:
:
:
:
:
:
:
Page 124 of 130
Probe Temperature
Protection
9.
:
:
700C
IP66 / NEMA 4X
UNINTERRUPTED POWER SUPPLY (UPS) SYSTEM
Manufacturer
Type designation
Input supply voltage
:
:
:
DB Power Electronics (P) Ltd.
Parallel redundant with static bypass
415V 3ph +10/-30 %
9.1. RECTIFIER
Line voltage
Input frequency variation
:
:
415 V, 3 phase +10% / -30%
 6%
9.2. BYPASS SUPPLY
Line Voltage
Overload on Bypass
:
:
415 V +10/-30%
10 times rated ‘I’ for 100msec.
9.3. INVERTER
Output Voltage
Output Frequency
Current limiting capability
Load power factor
:
:
:
:
1ph 240V
50 Hz
160%
0.6 to unity
9.4. INTERMEDIATE DC CIRCUIT
Voltage limits of inverter operation:
Voltage stability of the rectifier:
Max. boost charge duration :
Back up duration
:
315 to 438 V
±1%
8 hrs.
120 minutes for a load cycle as follows
For first 30 min., load = 50KVA
From 30 min to 120 min, load = 6 KVA
9.5. BYPASS TRANSFORMER AND SERVO CONTROLLED VOLTAGE STABILISER
Type
:
Dry, two winding
Secondary output
:
240V,1Ph, 50 Hz
Automatic Voltage regulator :
Servo controlled
Synchronising range
:
±2.5Hz
9.6. STATIC SWITCH
Type
Maximum transfer time
9.7. BATTERY
Manufacturer
Model No.
Type of battery
Positive plates
Guaranteed AH capacity at
five hours discharge rate
End cell voltage
Battery load cycle duration
:
:
Static
¼ Cycle
:
:
:
:
:
SABNIFE POWER SYSTEMS
287 KPH 150P
Nickel Cadmium, High discharge type
Pocket plates
150 AH
:
:
1.10 V/cell
50KVA for first 30 min.
Page 125 of 130
No. of cells
:
6 KVA for next 90 min.
287
10. CONTROL VALVES
Tag. No. /
Model No.
1CVAS022
38-41412
Plug / Cage
Characteristics
MIL CONTROLS LTD
Condenser
Lenear
Hotwell High level
Ctrl
Steam press Ctrl Linear
to Ejector
1CVAS006
38-41012
HP steam press Linear
Ctrl to Desal plant
1CVCD002
38-41621
Deaerator
Ctrl
Level Equal
Percentage
1CVAS019
38-41612
Deaerator
Ctrl
press Linear
1CVMC001
38-21714
Hotwell makeup Linear
Ctrl
(Normal
capacity)
CEP
min Linear
recirculation Ctrl
1CVCD045
38-211X5
1CVCD016
38-78103
1CVMC006
38-41012
Tag Description
1PCV FO 002
38-21125
Hotwell makeup Linear
Ctrl
(High
capacity)
HSD Header
Equal
Pressure Control
Percentage
1PCV FO 003
38-21125
Naphtha
header Equal
pressure Control
Percentage
1LCVBB109
1”EZ657 (30)
1PCVNF260
1.5”
EZ667(30)
1FCVFW031A/
B
3”
HPT667
(70)
1FCVFW032
2”
HPT667
(45)
FISHER XOMOX
CBD tank level Equal
Ctrl
percentage
Naphtha flow Ctrl
Equal
percentage
Description
Nominal Cv: 15
Valve Size: 2”
Actuator Size: 11
Nominal Cv: 45
Valve Size: 3”
Actuator Size: 18
Nominal Cv: 30
Valve Size: 4”
Actuator Size: 18
Nominal Cv: 140
Valve Size: 3”
Actuator Size: 15
Nominal Cv: 300
Valve Size: 6”
Actuator Size: 18
Nominal Cv: 20
Valve Size: 2”
Actuator Size: 11
Nominal Cv: 13
Valve Size: 2”
Actuator Size: 15
Nominal Cv: 2.5
Valve Size: 1”
Actuator Size: 11
Nominal Cv: 26
Valve Size: 2”
Actuator Size: 11”
Nominal Cv: 66
Valve Size: 4”
Actuator Size: 15”
Nominal Cv: 8.84
Nominal Cv: 5.18
HP Drum Level Linear
Ctrl
(100%
capacity)
Nominal Cv: 34.4
HP Drum
Ctrl
capacity)
Nominal Cv: 10.5
Level Equal
(30% Percentage
Page 126 of 130
Tag. No. /
Model No.
1FCVFW427A/
B
2” EZ667 (45)
1FCVNF107
1” EZ657 (30)
Tag Description
Plug / Cage
Characteristics
LP Drum Level Equal
Ctrl
(100% Percentage
capacity)
Naphtha
Equal
recirculation
Percentage
press Ctrl
Description
Nominal Cv: 53.8
Nominal Cv: 8.84
11. PLANT COMMUNICATION SYSTEM
11.1. EPABX
Manufacturer
Model No.
:
:
Tata Telecom
Paradigm Plus, 10X-130
Configuration:
 Voice DID card
 4 P&T lines
 64 extensions
The main components:
 'Wizard Plus' operator console
 Wall mounted normal telephones
 Desk top normal telephones
 Weather-proof, wall mounted telephones
 Flame proof, Weather-proof, wall mounted telephones
 'Wizard' Digital Telephone
 Cordless Handset
11.2. PA SYSTEM
Manufacturer
:
Philips India Ltd.
Configuration:
 14 way Central Control Exchange
 Central Processing Unit
 EPABX interface card
 4 channels of communication
The main components:
 Desktop Hand set stations
 Indoor wall mounted hand set stations
 Indoor wall mounted flameproof hand set stations
 Outdoor wall mounted hand set stations
 Outdoor wall mounted flameproof hand set stations
 Indoor loud speakers
 Flame proof / cone type Indoor loud speakers
 Portable hand set stations
Page 127 of 130
12. IMPORTANT SETTINGS
12.1. TRIP CONDITIONS
System
HRSG
Description
Boiler Trip conditions:
HP Drum Level LL
LP Drum Level LL
Condenser Hotwell Level HH
HP Drum pressure HH
LP Drum pressure HH
HP recirculation flow LL
LP recirculation flow LL
Scanner Cooling air DP LL
Furnace pressure High
Burner trip conditions:
Furnace temperature HH
Aux. air DP LL
Instrument air pressure Low
Oil Pressure HH (FD Mode)
Oil Pressure LL
Flame Failure
Equipment
Trip Value
-550 mm from normal level
-550 mm from normal level
825 mm from bottom
condenser
100 Kg/cm2
8 Kg/cm2
68 TPH
11 TPH
0.5 KPa
5 KPa
of
730  C
7.5 KPa
450 KPa
5.5 KPa
0.35 KPa
From scanners
Turbine trip conditions (Process
trip from DCS):
HP Drum Level HH
LP Drum Level HH
400 mm from normal level
Steam pressure Low
400 mm from normal level
Steam temperature Low
30 Kg/cm2
50 C below the saturation
Boiler Trip
steam temperature
As above
HP BFP A/B trip conditions:
Deaerator level LL
200mm from bottom tapping of
standpipe
Motor winding temperature HH
120C
Pump / Motor Bearing temperature Pump - 100C, Motor - 80C
HH
10C
Suction & discharge temperature
Difference Hi
105 Kg/cm2
Discharge pressure LL
Electrical Trip
LP BFP A/B trip conditions:
Deaerator level LL
200mm from bottom tapping of
standpipe
Suction & discharge temperature 10C
Difference Hi
Discharge pressure LL
11 Kg/cm2
Electrical Trip
Page 128 of 130
System
Description
CEP A/B trip conditions:
Condenser Hotwell level LL
Discharge pressure LL
Pump Running & Discharge Valve
closed
Electrical Trip
CW Pump A/B trip conditions:
Sump level LL
Motor winding temperature HH
Pump / Motor Bearing temperature
HH
Pump Running & Discharge Valve
closed
Electrical Trip
FD Fan trip conditions:
Motor winding temperature HH
Fan / Motor Bearing temperature HH
Bearing vibration HH
Electrical Trip
HP RCP A/B trip conditions:
HP drum level LL
RCP discharge flow LL
HP seal water temperature HH
Electrical Trip
LP RCP A/B trip conditions:
LP drum level LL
RCP discharge flow LL
Electrical Trip
CT Fan A/B trip conditions:
Gear box oil level low
Motor Vibration High
Electical trip
HP Bypass Ctrl trip conditions:
Hotwell Level HH
Condenser Vacuum
HP Bypass O/L temp High
CEP Discharge press LL
LP Bypass Ctrl trip conditions:
Hotwell Level HH
Condenser Vacuum
LP Bypass O/L temp High
CEP Discharge press LL
Trip Value
175 - 200 mm from bottom of
condenser
1.5 Kg/cm2
1900 mm below from top of
sump
120C
80C
100C
80C
5.5 mm/s
-550 mm from normal level
68 TPH
85C
-550 mm from normal level
11 TPH
Factory Set
Factory Set
825 mm from bottom
533
180C
7 Kg/cm2
825 mm from bottom
533
158C
7 Kg/cm2
12.2. AUTO START CONDITIONS
System
Equipment
Description
HP BFP- A/B:
Page 129 of 130
Auto start value
System
Description
Standby pump will start if:
 Running pump trips on process
protection or on MCC trip
 Pump running and discharge
pressure Low
LP BFP A/B:
Standby pump will start if:
 Running pump trips on process
protection or on MCC trip
 Pump running and discharge
pressure Low
CEP A/B:
Standby pump will start if:
 Running pump trips on process
protection or on MCC trip
 Pump running and discharge
pressure Low
CWP A/B:
Standby pump will start if:
 Running pump trips on process
protection or on MCC trip
 Pump
Running & Discharge
Valve closed
HP RCP A/B:
Standby pump will start if:
 Running pump trips on process
protection or on MCC trip
 Pump running and discharge flow
low
LP RCP A/B:
Standby pump will start if:
 Running pump trips on MCC trip
 Pump running and discharge flow
Low
ECW A/B:
Standby pump will start if:
 Running pump trips on MCC trip
 Pump running and discharge
pressure Low
Page 130 of 130
Auto start value
110 Kg/cm2
13 Kg/cm2
9 Kg/cm2
125 TPH
20 TPH
3.5 Kg/cm2