Tech Diary - Ii PDF

TECHNICAL DIARY
COMPILED BY: O&M COMMISSIONING

FOREWORD
Efficient, safe and reliable operation of a thermal power plant mainly
depends upon the awareness of the O&M staff about the plant and its
equipments. A power plant has many inter-related systems and it is necessary on
part of all technical staff to understand the design parameters and limits of the
various systems. With this in mind, Commissioning department has made an
effort to compile technical data of different systems of stage-III in the form of a
technical diary.
I hope this diary will serve as a very useful ready reference to all O&M
personnel in executing their day to day jobs in efficient manner.
While all efforts have been taken to ensure correctness of data, the
possibilities of few errors and anomalies cannot be ruled out as the systems are
constantly under review during operation and maintenance stages also.
Any suggestion for improvement and pointing out of inaccuracies is
welcome and will be incorporated in subsequent editions.
With warm regards.
(P. Ramesh)
Ramesh)
E .D. (Rihand)
FOREWORD
In the present competitive scenario with stringent tariff norms, efficient
& optimized operation of the equipments and fast decision making is most
important to stay ahead. The knowledge of equipment data is very helpful in
this regard.
It gives me immense pleasure that the commissioning team has brought
out the technical diary of Rihand stage-III in print as well as digital formats.
I congratulate the commissioning team for taking out this initiative to
assimilate all technical data related to stage-III.
I am sure that this technical diary will act as a ready reference for the
O&M team to take correct decisions in minimum possible time.
The errors which might have inadvertently crept in should be
brought to the executives concerned, so that they might be corrected quickly.
With warm regards.
(Shivendra Kumar Sinha)

General Manager (O&M)
INDEX
TAB 1 : BOILER & AUXILIARIES
TAB 2 : TG & AUXILIARIES
TAB 3 : ELECTRICAL SYSTEMS
TAB 4 : OFFSITE & COMMON SYSTEMS
N.B.- The schematics are available as PDF documents on

the operation webpage.
CONTENTS (BOILER & AUXILIARIES)
1.0 BOILER Page No.

1.1 GENERAL SPECIFICATION 3
1.2 DESIGNATION 3
1.3 FURNACE SPECIFICATION 3
1.4 WATER WALLS 4
1.5 DRUM 4
1.6 SUPERHEATERS 5
1.7 RE HEATERS 5
1.8 SUPERHEATERS & RE HEATERS TEMP CONTROL 6
1.9 ECONOMISER 6
1.10 PREDICTED PERFORMANCE DATA (DESIGEN COAL) 7
1.11 SAFETY VALVES 12
2.0 BOILER AUXILIARIES
2.1 BOILER WATER CIRCULATING PUMP 13

2.2 MILLING SYSTEM 14
2.3 COAL PIPING & BURNERS 18
2.4 OIL FIRING 18
2.5 INDUCED DRAFT FAN (ID FAN) 20
2.6 FORCED DRAFT FAN (FD FAN) 23
2.7 PRIMARY AIR FAN (PA FAN) 25
2.8 SCANNER AIR FAN 26
2.9 PRIMARY AIR PREHEATER (PAPH) 27
2.10 SECONDARY AIR PREHEATER (SAPH) 29
2.11 STEAM COIL AIR PREHEATER (SCAPH) 31
3.0 ELECTOSTATIC PRECIPITATOR (ESP)
3.1 DESIGN CONDITION 32

3.2 COLLECTING ELECTRODES 32
3.3 EMITTING ELECTRODES 32
3.4 GAS DISTRIBUTION SYSTEM 33
3.5 ESP ELECTRICALS 33
3.6 RAPPING SYSTEM 34
3.7 HOPPERS 35
3.8 HEATING ELEMENTS 35
4.0 SOOT BLOWER 35

5.0 HP DOSING PUMP 36
5.1 MIXING TANK
5.2 METERING TANK
5.3 DOSING PUMPS
6.0 BLOW DOWN VESSELS 37

7.0 PRESSURE REDUCING & DESUPERHEATING STATION (PRDS) 38
8.0 SG EQUIPMENT COOLING WATER SYSTEM 38

8.1 DMCW PUMPS
8.2 MOTOR
8.3 PLATE HEAT EXCHANGERS (PHEs)
9.0 SWAS PARAMETERS 40
9.1 CHEMICAL PARAMETERS LIMIT

9.2 EXPRESS LAB INSTRUMENTS
10.0 FUEL OIL PUMP HOUSE 41
10.1 HFO PUMPS

10.2 LDO PUMPS
10.3 HFO HEATER & DRAIN OIL COOLER
10.4 HFO DRAIN OIL PUMPS
10.5 HFO SUMP PUMP
10.6 LDO UNLOADING PUMP
10.7 DRAIN OIL PUMPS (FOHS)
10.8 SUMP PUMPS (FOHS)
11.0 MILL REJECT SYSTEM 44
11.1 GENERAL
11.2 SYSTEM DESIGN
11.3 DENSEVEYOR
11.4 MILL REJECT COMPRESSORS
12.0 STARTUP CURVES As Annexure
12.1 COMBINED BOILER TURBINE STARTUP CURVES

A) COLD STARTUP
B) WARM STATUP (36 HRS SHUTDOWN)
C) HOT STARTUP (8 HRS SHUTDOWN)
12.2 TURBINE STARTUP CURVES- CONSTANT PRESSURE

12.3 TURBINE STARTUP CURVES- SLIDING PRESSURE
CONTENTS (TURBINE & AUXILIARIES)
1. MAIN TURBINE
1.1 SPECIFICATIONS 49
1.2 TURBINE LUBE OIL SYTEM 53
1.3 GENERATOR 56
1.4 TURBINE CONTROL FLUID SYSTEM 58
1.5 CONDENSER 60
1.6 LP HEATERS 61
1.7 DEAERATOR & FST 62
1.8 HP HEATERS 63
1.9 LP DOSING SYSTEM 64
1.10 CENTRAL LUBE OIL STORAGE & PURIFICATION UNIT 64
1.11 HP BYPASS SYSTEM 65
1.12 LP BYPASS SYSTEM 66
2.0 TURBINE AUXILIARIES
2.1 CONDENSATE EXTRACTION PUMP 67

2.2 BOILER FEED PUMP & AUXILIARIES
2.2.1 BOILER FEED PUMP (MAIN) 68
2.2.2 BOOSTER PUMP 69
2.2.3 HYDRAULIC COUPLING OF MDBFP 70
2.2.4 LUBE OIL SYSYTEM FOR MDBFP 70
2.2.5 BFP DRIVE –MOTOR 71
2.2.6 TDBFP LUB OIL SYSTEM 71
2.2.7 OIL PURIFIER (CENTRIFUGE) 72
2.3 VACCUM PUMP 73
2.4 TG EQUIPMENT COOLING WATER SYSTEM 74
2.6 AUXILIARIES COOLING WATER SYSTEM (ACW) 75
2.7 CONDENSER ON LOAD TUBE CLEANING SYSTEM (COLTCS) 76
3.0 DM MAKEUP & CPU REGENERATION SYSTEM 77
4.0 COMPRESSED AIR SYSTEM 79

CONTENTS (ELECTRICAL)
1.0 Transformers 80
1.1 Generator Transformer (GT)
1.2 Station Transformer (ST)
1.3 Unit Transformer (UT)
1.4 Unit Auxiliary Transformer (UAT)
1.5 Station Auxiliary Transformer (SAT)
1.6 Ash Disposal Pump House Transformer (ADPHT)
1.7 Coal Handling Transformer (CHPT)
1.8 Station Service Transformer (SST)
1.9 Unit Service Transformer (UST)
1.10 ESP Transformer(ESPT)
1.11 Ash Extraction Transformer(AET )
1.12 Fire water Transformer
1.13 Raw water Transformer
1.14 DM/CPU Transformer
1.15 PT Service Transformer
1.16 Fuel Oil Service Transformer
1.17 Ash Water /Ash Slurry Service Transformer
1.18 Bunker Service Transformer
2.0 Breaker 84
2.1 400 KV Switchyard breaker
2.2 11KV and 3.3KV MV Switchgear breaker
2.3 415V LT switchgear Breaker
CONTENTS (OFFSITE)
1. CW system Page No.
1.1 CW pump 88
1.2 CW motor 89
1.3 Electro hydraulic actuator 91
1.4 EOT crane 92
2. SACW system
2.1 SACW pump 93
2.2 SACW motor 94
2.3 EOT crane 95
3. Cooling tower
3.1 Thermal design calculation 95
3.2 Blades 96
3.3 Gearbox 96
3.4 Motor 97
3.5 Sludge pump 98
4. Raw water system
4.1 Pump 98
4.2 Motor 100
4.3 Lube water system 101
5. Fire water system
5.1 General 102
5.2 Diesel engine 102
5.3 Pump 104
5.4 Motor 105
5.5 Foam system 106
5.6 Sprinkler system 108
6. PTCW
6.1 PT Clarifier 108
6.2 Clarifier water system
6.2.1 Clarified water makeup system 109
6.2.2 HVAC makeup system 110
6.2.3 Potable water system 111
6.3 Pressure filter 111
6.4 Sludge disposal system 111
6.5 ETP(Effluent Treatment Plant) system
6.5.1 Waste water pump 112
6.5.2 Treated Effluent Disposable pump 113
6.5.3 ETP clarifier 113
6.6 Service water system
6.6.1 Service water pump 114
6.6.2 APH wash water pump 114
6.7 Chemical dosing system
6.7.1 Alum dosing pumps for PT-clarifier 115
6.7.2 Alum dosing pump for LET-clarifier 115
6.7.3 Lime dosing pump 115
6.7.4 Lime slurry transfer pump 116
6.7.5 Agitator 116
6.8 Chlorination system 116
6.9 Coal settling system(CHP area) 118
7. ADPH
7.1 Ash slurry pumps 119
7.2 BAHP 120
7.3 BALP 121
7.4 FAHP 122
7.5 Flushing water pump 122
7.6 HP seal water pump 123
7.7 LP seal water pump 124
7.8 Drain pump in ASPH 124
7.9 BA seal water pump 125
7.10 Vacuum pump in ESP 125
7.11 Bottom ash overflow pump 126
7.12 Sludge pump for settling tank 127
7.13 Eco booster pump 128
7.14 Clinker grinder 128
7.15 Instrument Air Compressor(IAC) 129
7.16 Instrument Air Drier 130
7.17 Transport Air Compressor(TAC) 130
7.18 Transport Air Drier 131
7.19 Fly Ash Conditioner water pump 131
7.20 Drain pump( Silo area) 132
7.21 Wash Water pump (Silo area) 132
7.22 Silo fluidizing blower 132
7.23 Buffer Hopper Aeration blower 132
7.24 Heaters of Silo & Buffer hopper 133
TECHNICAL DIARY
BOILER AND AUXILIARIES
Prepared By Reviewed By Approved By

S K VISHWAKARMA SUSHIL KUMAR M K SINGH
Asst Manager Manager AGM
STAGE-3 TECHNICAL DIARY (BOILER)
CONTENTS
1.0 BOILER Page No.

1.1 GENERAL SPECIFICATION 3
1.2 DESIGNATION 3
1.3 FURNACE SPECIFICATION 3
1.4 WATER WALLS 4
1.5 DRUM 4
1.6 SUPERHEATERS 5
1.7 RE HEATERS 5
1.8 SUPERHEATERS & RE HEATERS TEMP CONTROL 6
1.9 ECONOMISER 6
1.10 PREDICTED PERFORMANCE DATA (DESIGEN COAL) 7
1.11 SAFETY VALVES 12
2.1 BOILER WATER CIRCULATING PUMP 13

2.2 MILLING SYSTEM 14
2.3 COAL PIPING & BURNERS 18
2.4 OIL FIRING 18
2.5 INDUCED DRAFT FAN (ID FAN) 20
2.6 FORCED DRAFT FAN (FD FAN) 23
2.7 PRIMARY AIR FAN (PA FAN) 25
2.8 SCANNER AIR FAN 26
2.9 PRIMARY AIR PREHEATER (PAPH) 27
2.10 SECONDARY AIR PREHEATER (SAPH) 29
2.11 STEAM COIL AIR PREHEATER (SCAPH) 31
3.0 ELECTOSTATIC PRECIPITATOR (ESP)
3.1 DESIGN CONDITION 32

3.2 COLLECTING ELECTRODES 32
3.3 EMITTING ELECTRODES 32
3.4 GAS DISTRIBUTION SYSTEM 33
3.5 ESP ELECTRICALS 33
3.6 RAPPING SYSTEM 34
3.7 HOPPERS 35
3.8 HEATING ELEMENTS 35
4.0 SOOT BLOWER 35

5.0 HP DOSING PUMP 36
5.1 MIXING TANK
5.2 METERING TANK
5.3 DOSING PUMPS
6.0 BLOW DOWN VESSELS 37
7.0 PRESSURE REDUCING & DESUPERHEATING STATION (PRDS) 38
1

8.1 DMCW PUMPS
8.2 MOTOR
9.0 SWAS PARAMETERS 40
9.1 CHEMICAL PARAMETERS LIMIT

9.2 EXPRESS LAB INSTRUMENTS
10.0 FUEL OIL PUMP HOUSE 41
10.1 HFO PUMPS

10.2 LDO PUMPS
10.5 HFO SUMP PUMP
10.6 LDO UNLOADING PUMP
10.7 DRAIN OIL PUMPS (FOHS)
10.8 SUMP PUMPS (FOHS)
11.0 MILL REJECT SYSTEM 44
11.1 GENERAL
11.2 SYSTEM DESIGN
11.3 DENSEVEYOR
11.4 MILL REJECT COMPRESSORS
12.0 STARTUP CURVES As Annexure
12.1 COMBINED BOILER TURBINE STARTUP CURVES

A) COLD STARTUP
B) WARM STATUP (36 HRS SHUTDOWN)
C) HOT STARTUP (8 HRS SHUTDOWN)
12.2 TURBINE STARTUP CURVES- CONSTANT PRESSURE

12.3 TURBINE STARTUP CURVES- SLIDING PRESSURE
2
BOILER & ITS AUXILLIARIES
1.0 BOILER
1.1 GENERAL SPECIFICATION

Manufacturer M/S BHEL
Type Controlled Circulation with Refilled tubing ,
(CC+) ,Dry bottom ,Radiant Reheat ,Single
drum ,Top supported ,Balanced Draft
Furnace
Type of firing Tilting Tangential
1.2 DESIGNATION
19177 301-51 CC+

16115 235-51
1.3 FURNANCE SPECIFICATION
Type Balance Draft Furnace With Fusion Welded Water

Walls
Wall Water steam cooled
Tube arrangement Membrane
Residence time for fuel 1.84 Sec.
particles in the furnace
Effective volume used to 16424 M3
calculate the residence
time
Depth 16115 mm
Width 19177 mm
Furnace volume 17599 M3
Drum elevation (C.L) 74.977 M
Fuel heat input 1233.6X10b Kcal/hr @ BMCR DC
3
1.4 WATER WALLS
Total water wall tubes 1072 Nos.
1.4.1 WATER WALL RIFLE TUBES
OD 51.0 & 63.5 mm

Thickness 5.6, 6.0 , & 7.1 mm
Materials SA 210 Gr. C
Design Pr. Of tubes 214 & 211.3 Kg/cm2
Design temp 396 °c
1.4.2 WATER WALL SMOOTH TUBES
OD 51.0 & 63.5 mm

Thickness 7.1, 5.6, 6.0, 8.8 mm
Design Pr. Of tubes 211.3 & 214 Kg/cm2 (g)
Design temp 396 & 368 °c
1.4.3 WATER WALL HANGER RIFLE TUBES
OD 63.5 mm
Thickness 12 mm
Design Pr. Of tubes 211.3 Kg/cm2 (g)
Design temp 396 °c
1.4.4 WATER WALL HEADERS
WW bottom ring drum WW top headers

Number 1 5
Outside dia 914.0 mm 273.0 mm
Thickness 85 mm 40.0 & 50.0 mm
Design Pr. Of headers 214 Kg/cm2 (g) 209.0 Kg/cm2 (g)
Material specification SA 299 SA-106 Gr. C
Design temp 368 °c 368 °c
1..5 DRUM
Material specification SA-299

Design pressure 209 Kg/cm2 (g)
Design material temp 368 °c
Operating pressure 195 Kg/cm2 (g)
4
Actual thickness 155/185 mm

Internal dia 1778 mm
Number of down comers 6 nos.
Number of cyclone separators 92
Number of driers 124
Shroud materials CS-IS 2062 Gr. A
1.5.1 WATER LEVEL INDICATOR
Location Boiler Drum Boiler Drum

Type DWLG EWLI
Make Yarway BHEL
Quantity 2 4
21” VISIBILITY BHEL VISION
1.6 SUPERHEATERS
Stage#1 Stage#2 Stage#3

Material SA 213 SA 213 SA 213
Type LTSH Horizontal & SH division SH finish platen
pendant (Convective) panellette (Tube (Tube projected )
projected ) Radiant Radiant
Drainable/Non drainable Drainable Non drainable Non drainable
Effective heating surface 8661 M2 1415 M2 1485 M2
area
Tube OD 47.63 mm 44.5 mm 51.0 mm
Total number of 124 6 (x 8 panelletes) 25
assembly
No. of element 744 432 (9 elements per 400 (16 per
panellete) panel)
ASME Specification SA213 T11 SA 213 T22 & T91 SA213 T22, T91
& TP347H
1.7 RE HEATERS
Stage#1 Stage#2
Type Pendant Platen Pendant Spaced
No. of assembly 74 74
No. of element 1036 888
Tube OD 54.0 mm 63.5 mm
Total heating surface area 8620 m2
Control Burner tilt & excess air
Design Pressure 42.37 Kg/cm2 (g)
5
1.8 SUPER HEATER & REHEATER TEMP CONTROL
1.8.1 SUPER HEATER ATTEMPERATOR
Type Spray type pressure atomized

Stage One
Position in steam circuit Between LTSH & division panel S/H
Specification of material SA 335P 12
Control temp 540 °c
Control range 755.4-1590 T/Hr.
1.8.2 REHEATER EMERGENCY TEMP. CONTROL ATTEMPERATOR
Type Spray type pressure atomized

Manufacturer BHEL Trichy
Position in steam circuit CRH Line
Control temp range 568 °c
Control range 656.8-1358 T/Hr.
R/H Normal temp. control Burner tilting & Excess air
1.9 ECONOMISER
Type Plain tube non steaming

Horizontal heating space area 19000 m2
Design Pressure tube 215.0 Kg/cm2 (g)
OD of tubes 38.1 mm
Minimum thickness of tubes 5.3 mm
Length of tubes 296.4 m
Pitch 103 mm (ST)
76.2 mm (SL)
No. of blocks 3 Nos.
Assembly 184
Element 552
Design temp. 336 °c
ASME Specification SA210 Gr A1
6
1.10 PREDICTED PERFORMANCE DATA (DESIGN COAL-constant pressure)
7
1.10.2 TEMPERATURE
8
1.10.3 PRESSURE (STEAM & WATER )
9
1.10.4 PRESSURE & DRAFT (AIR & GAS)
1.10.5 FUEL
Proximate Analysis
Fixed Carbon % 24
Volatile matter % 22
Moisture % 20
Ash % 34
Grind ability Index HGI 55
Higher heating value Kcal/kg 3500
Size of coal to mill mm 50 (Approx.)
10
Ultimate Analysis
Carbon % 34.20
Hydrogen % 3.00
Sulphur % 0.30
Nitrogen % 0.92
Oxygen % 6.90
Carbonates % 0.65
Phosphorous % 0.03
Moisture % 20.00
Ash % 34.00
1.10.6 MILL & BURNER PERFORMANCE
HP Heaters in service HP
Heaters
DESCRIPTION Unit Out
BMCR 500 400 300 250 MAX O/P
MW MW MW MW
MILL
No. of mills in operation % Top 7 Top 7 Top 5 Top 4 Top 4 Top 7

Mill loading T/Hr 82.8 76.7 88.7 86.6 74.7 83.3
Air flow mill °c 95.1 92.7 97.4 96.8 91.8 95.3
Air temp at mill Inlet 328 324 310 291 279 285
Mill Outlet
Temperature 66 to 100
°c
Fineness %
(Thro’ 200 mesh) % 70
Burner Tilt
Deg -30 to +30
1.10.7 O2, CO2 (DRY VOLUME) AND EXCESS AIR
HP Heaters in service HP Heaters

Out
DESCRIPTION Unit BMCR 500 400 300 250 MW MAX O/P
MW MW MW
Oxygen in gas at Economizer % 3.59 3.59 3.59 3.59 3.59 3.59

Outlet
Carbon di-oxide in gas % 14.78 14.78 14.78 14.78 14.78 14.78

Economizer Outlet
Excess air in gas at Economizer % 20.00 20.00 20.00 20.00 20.00 20.00
Outlet
11
1.10.8 HEAT BALANCE
HP Heaters in service HP Heaters

Out
DESCRIPTION Uni BMCR 500 400 300 250 MW MAX O/P
t MW MW MW
LOSSES
Dry gas % 4.229 4.165 4.157 4.237 4.256 3.668
H2O on fuel, surf & inherent % 3.502 3.496 3.490 3.489 3.485 3.469
H2O from comb. Of H2 % 4.695 4.687 4.679 4.678 4.672 4.651
H2O in air % 0.094
0.109 0.107 0.107 .109 0.109
Unburnt carbon %
1.500 1.500 1.500 1.500 1.500 1.500
Radiation %
Unaccounted % 0.216 0.234 0.283 0.361 0.419 0.215
Manufactures margin % 0.784 0.784 0.791 0.807 0.817 0.760
0.150 0.150 0.150 0.150 0.150 0.150
Total losses % 15.185 15.123 15.157 15.331 15.408 14.507

Efficiency % 84.81 84.87 84.84 84.66 84.59 85.49
1.11 SAFETY VALVES
VALVE SET RELIEVING

SL. VALVE TAG TYPE OF SAFETY PR. CAPACITY
DOWN
BLOW
% OF
LOCATIO NO. NO. VALVE KG/CM2 (G) KG/HR.
N CLOSE
OPEN
1 SV1 CONSOL 1750 WB 209 200.6 4.0 212800
BOILER
DRUM 2 SV2 CONSOL 1750 WB 211.1 200.5 5.0 214928
3 SV3 & SV4 CONSOL 1750 WB 213.2 202.5 5.0 217056
4 SV5 & SV6 CONSOL 1740 WB 215.3 204.5 5.0 261228
SH SV 5 SV7 & SV8 CONSOL 1740 WD 188.5 181.3 3.8 187670
6 SV9 & SV10 CONSOL 1538 VX-10 W 185.5 180.3 2.8 116388
SH ERV 7 SV11, SV12 & CONSOL 1538 VX-10 W 186.6 180.6 3.2 86945
SV13
8 SV14 & SV15 CONSOL 1786 WB 52.40 49.8 5.0 207461
CRH 9 SV16 & SV17 CONSOL 1786 WB 54.0 51.3 5.0 214147
HRH SV 10 SV18 & SV19 CONSOL 1786 WE 48.4 46.0 5.0 157460
11 SV20 & SV21 CONSOL 1786 WE 49.9 47.4 5.0 162457
HRH ERV 12 SV22 & SV23 CONSOL 1525 VX 47.4 46.5 2.0 117191
13 SV24 & SV25 CONSOL 1525 VX 47.9 46.9 2.0 118402
SOOT 14 SV30 CONSOL 1811 LC 6X 40.0 38.4 4.0 29970
BLOWER
12
2.1 BOILER WATER CIRCULATING PUMP

Number 3
2.1.1 CHARACTERISTICS
Make TORISHIMA PUMP MFG. CO. LTD., JAPAN

Type Single suction double discharge (glandless)
2.1.2 NORMAL OPERATING DUTY
Suction Pressure 197.37 kg/cm2

Saturation temperature at suction pressure 363.4 °c
Quantity pumped 2987 m3/hr
Total pump head 1.76 kg/cm2
Minimum NPSH required (Cold) 15 M
Minimum NPSH required (Hot) 15 M
Pump efficiency 81 %
Power absorbed 176.7 KW
2.1.3 MOTOR CHARACTERISTICS
Type (Wet stator squirrel cage induction motor)

Rating 350 KW
Voltage & frequency 3300 V & 50 Hz
Service factor 1.0
Class of insulation “Y” (90 C)
Winding insulation material XLPE
Rated power factor 75 %
Motor case design temperature 368 °c
Full load speed 1470 RPM
Full load current 89.7 Amps.
Starting current 500 % FLC
Hot Duty Cold Test
Motor efficiency 88.2 % 91.00 %
Motor power input (KW) 200.3 340.1
Pump efficiency (%) 81 81
2.1.4 BEARING
Number 2
Type Tilting pad
Lubrication System Self (Boiler water)
Life in hours 30000 hours
Max. permissible temp. of bearing 90 °c
13
2.1.5 CC PUMP OVER HEAD TANK
Type 2500 X 12
Make BHEL Trichy
Capacity 20.0 M3
Temp 50 °c
Working pressure 7 kg/cm2
Test pressure 10.5 kg/cm2
2.1.6 CC BOOSTER PUMP (EMERGENCY COOLING)
MOTOR
Make Marathon Electric Motors (I) Ltd.

Type TEFC SC Eff-2
Frame size D132 S
Degree of protection IP 55
Speed 2850 RPM
Full load current 10.4 Amp.
No load current 4.2 Amp.
Rating 5.5 KW
Rating Insulation class F
PUMP
Make Sam Turbo Industry Limited
Quantity 02
Type/Model WP+C 32/200.
Head 45 mwc/mlc (Discharge Pr.-8 Ksc min)
Speed 2900 RPM
Capacity 10 M3/Hr
2.2 COAL FIRING
2.2.1 MILL SYSTEM
2.2.1.1 PULVERISER
Make BHEL HYADRABAD

Type of Pulveriser Bowl mill XRP 1003 with Planetary Gearbox
No. of Mills/Boiler 9
Speed of Pulveriser in RPM 42
Motor rating KW 525
Mill capacities
Standard condition Design coal Worst coal
Max. capacity T/Hr 68 60.9 55.80
Moisture in raw coal % 12 20 22
HGI of raw coal 55 55 50
No. of mills for Design coal at 7 7 9
100% BMCR
14
2.2.1.2 MILL MOTOR
Manufacturer BHEL, BHOPAL

Motor type SCIM
Standard continuous rating at 40 °c ambient 525 KW
temp. (As per IS)
Rated voltage 3300 V
Permissible variation of
Voltage +/- 6.0
Frequency +3 -5
Combined Voltage & Frequency 10% Abs
Minimum Permissible starting voltage (% ) 85
Rated speed at rated voltage & freq (RPM) 984
Starting time with minimum permissible
Voltage
Without driven equipment 0.5 Sec
With driven equipment coupled 5.7 Sec
At rated Voltage & Frequency
Full load current 129 Amp
No load current (A) 55 Amp
2.2.1.3 MILL MOTOR BEARING
Drive-End Non- Drive-End
(A) Type NU 228M+62283 NU 224M
(B) Recommended Lubricant Grease IOC servo gem -3/Eqv
2.2.1.4 MILL EXTERNAL LUBRICTION SYSTEM
Manufacturer: TA Hydraulics Pvt. Ltd. Hyderabad
2.2.1.4.1 PUMPS
Make
Type Three screw pump
Quantity 2X100 %
Capacity 150 LPM
Speed 1450 RPM
Coupling Love joy
Operating Pressure 3 to 5 Bar
Relief valve setting 8.5 Bar
Filter 25 micron SS mesh, Test Press-22 ksc
Operating fluid ISO VG 320
15
2.2.1.4.2 LUBE OIL PUMP MOTOR
Make Crompton greaves Ltd.

Type , Frame & Duty SCIM, 132S & S1
Rated Output 5.5 KW
Rated Speed 1450 RPM
Rated Voltage 415 V
Full load current 10.4 Amps
DOR from NDE side CW
Bearing type no.DE/NDE 6308 ZZ / 6208ZZ
2.2.2 RAW COAL FEEDER
2.2.2.1 FEEDER
Type of feeder Belt type Gravimetric Feeder

Feeder Size 36’’ Inlet
Capacity Min-16 T/Hr, Max-80 T/Hr
Supplier BHEL
Quantity per boiler 9
Gear Ratio (Main drive) 125 :1 (M/S Shanthi Gears Ltd.)
Gear Ratio (COC drive) 1041:1 (M/S Shanthi Gears Ltd.)
Bulk density of coal 0.88 t/m3
Working pressure 500 mmwc
Purge air requirement 12 m3 / min / Feeder
Application of Purge air To make positive purge air flow, recommended delta ‘p’
between feeder and pulveriser to be adjusted
Service air requirement 1 m3 / hr at 2-3 KSC
Application of Service air For bulls eye cleaning (Intermittent requirement)
Water requirement 1 m3 / hr at 2-3 KSC
Application of Water For fire quenching
Type of weight sensor Strain gauge type load cell (2 Nos/Feeder)
Location of weight sensor Suspended roller in the weigh span
Type of speed sensor Tacho generator (2 Nos/Feeder)
Location of speed sensor Output shaft of Eddy Current Clutch
Output from speed sensor 45 V AC +/-5 % @1000 RPM
Coal on belt switch type Micro switch actuated by a cam & with contact rating
5A @ 240V AC or 0.5A @ 220 DC
Discharge plugged switch Micro switch actuated by a cam & with contact rating
5A @ 240V AC or 0.5A @ 220 DC
2.2.2.2 MAIN MOTOR

Make Laxmi Hydraulics Pvt Ltd. (LHP)
Rated output 5.5 KW
Rated Torque 3.8 Kg.m
Type of Enclosure & ventilation IP 55, TEFC
Type of mounting Vertical flange Mounting
Rated voltage 415 V, 50Hz , 3 Ph
16
Rated speed 1440 RPM

Full load current 11.30 Amp
Insulation class F (Temp rise limited to class B)
Duty S1
Eff. At full load 86%
2.2.2.3 CLEAN OUT CONVEYOR

Make Bharat Bijlee Ltd.
Rated output 0.25 KW
Frame size AD 80 D
Type of Enclosure & ventilation IP 55
Type of mounting Horizontal flange Mounting
Rated voltage 415 V, 50Hz , 3 Ph
Rated speed 915 RPM
Insulation class F (Temp rise limited to 70 degree)
Duty S1
Eff. At full load 69 %
2.2.2.4 EDDY CURRENT CLUTCH

Manufacturer M/S Dynaspede Integrated System Pvt. Ltd .
Type Open ventilated , Drip proof , Round Frame
Mounting Vertical downward flanged
Duty S1
Rating 5.5 KW
Clutch coil voltage 90 V DC (Max)
Current 3 Amp at (Max)
Speed 1200 RPM (Max) / 120 (Min)
2.2.3 SEAL AIR FAN
2.2.3.1 FAN
Manufacturer BHEL Ranipet
Fan Type NDFV 12.5 H (Overhung impeller with IGV)
No. of fans per boiler 2
Medium handled Air from PA cold heater
Location Outdoor
Suction Orientation Right Horizontal
Delivery Orientation Left Top 90 deg.
Total head developed 508 mmwc
Speed 1480 RPM
2.2.3.2 PARAMETER USED

Air temp 50 ° c
Density 1.027 Kg/m3
Volume/Fan 7.5 m3/Sec
Head 508 mmwc
17
2.2.3.3 SEAL AIR FAN DRIVE MOTOR
Make Crompton Greaves

Rating 75 KW
Rated Voltage 415 (+/-) 10%
Frequency 50 Hz +3%/- 5 %
Speed 1480 rpm
Full load current 134 Amps
DOR CW as viewed from DE end
2.2.3.4 BEARING LUBRICATION

Quantity 20 ltrs/fan
Grade Servo prime 68,Bharat turbol 68,turbinol
68,teresso 68
Recommended interval of Lubrication Once in Six months
2.2.3.5 BEARING TYPE
Fixed Bearing NU314/C3

Free Bearing 6314
2.3 COAL PIPING & BURNERS
2.3.1 COAL PIPING

Material of straight pipe Carbon steel
Fuel pipe diameter 660.4 mm
Fuel pipe thickness 14.2 mm
2.3.2 COAL BURNERS

Type Tilting Tangential
Make BHEL
No. of coal burners feed by each mill 4 (Total No. of coal burners 36)
No. of burners elevation 9
Temp of coal air mixture in PF Pipes 75 ° c
2.4 OIL FIRING SYSTEM
2.4.1 HEAVY FURNACE OIL BURNERS

Burner Tilting Tangential; Corner fired
Oil gun Parallel piping design, Steam atomized
External mixed; Constant pressure atomizer
Air nozzle Rectangular
Diffuser 190 mm; 10 off 45 ° c vanes with leading
edge with scanner & ignitor cuttings
Oil gun assembly dimension KF=2689+/-3 mm
Atomizer Designation Spray plate 90 J24
18
Atomizer Spray Angle 90° c

Fuel Fuel oil to IS1593; 1971 LSHS, HPS oil
Capacity Maximum 7.5 % MCR heat input per elevation.
30 % MCR total in 4 elevations
One elevation stand by
No. of oil guns 20 (4 per elevation )
Location of oil guns Auxiliary air nozzles, AB, CD, EF, FG & HJ
OIL GUN PERFORMANCE DATA CHART
MAXIMUM MINIMUM SCAVENGING

HFO Flow per gun 2220 Kg/hr 820 Kg/hr -
HFO Pressure 9.3 Kg/cm2 (g) 3.5 Kg/cm2 (g) -
Atomising steam flow/gun 205/210/200 260/260/260 325 Kg/hr
Kg/hr Kg/hr
Atomising steam pressure 5.25 Kg/cm2 (g) 5.25 Kg/cm2 (g) 5.25 Kg/cm2 (g)
Minimum allowable HFO Pressure 4.0 Kg/cm2 (g)
Minimum allowable steam 3.5 Kg/cm2 (g)
Pressure
Oil viscosity at the gun 15 to 30 CST
Steam quality 10 to 15 ° C Superheat
NOTE: Pressure are measured at the oil gun connection .Minimum firing rate is the minimum
energy required for coal fuel ignition and stabilization. At no time the oil burners shall be
operated below this rating.
2.4.2 LIGHT DIESEL OIL BURNERS

Service Initial startup & warm up
Atomiser External Mixed, Constant Pressure,
Compressed Air Atomised
Fuel LDO to IS 1460/1974
Capacity (Max.) 7.5 % MCR heat input & total 7.5 % MCR
No. of oil guns 4 guns in one elevation
Location of oil guns In Auxiliary air nozzle AB.
OIL GUN PERFORMANCE DATA CHART

MAXIMUM MINIMUM SCAVENGING
LDO Flow/gun 2325 Kg/hr 850 Kg/hr
LDO Pressure 9.50 Kg/cm2 (g) 3.0 Kg/cm2 (g)
Atm. Air flow/gun 190 NM3/Hr 210 NM3/Hr 245 NM3/Hr
Atm. air Pressure 5.25 Kg/cm2 (g) 5.25 Kg/cm2 (g) 5.25 Kg/cm2 (g)
The same HFO gun is used for LFO firing also without changing the atomizer .Data other than
the ones indicated above are same as Heavy Fuel Oil burners.
19
2.4.3 IGNITERS
Make Unison Industries /USA

Service Oil burner light off
Type High energy arc Igniter
Location Burner Mounting Panel
Input 240 VAC ,50 Hz
Output Min.4 sparks/second, 12 joules/spark
Retractor Stroke 8”
Flexible Spark Rod B=115 inches
Flexible Guide Pipe L=2095mm
2.4.4 HEAVY FUEL OIL SPECIFICATION

Standard IS-1593/1971 Gr HV/OIL
Pumping Temp 57 ° c
Flash point min 66 ° c
Firing temp 120 ° c
Kinematic Viscosity 370 CST at 50 ° c
Total Sulpher CONTENT 4.5 % by weight
Specific Gravity 0.925 @ 50 ° c
Gross heating value 10270 Kcal/kg
2.4.5 LDO SPECIFICATIONS

Standard IS-1460-1974
Pumping temp 40 ° c
Firing temp 40 ° c
Viscosity 2 TO 20 @ Firing temp
Total Sulpher 1.8 % by weight
Density @ 15 ° c 0.83 Kg/Liter
High heating value 10000 Kcal/Kg approx.
2.5 INDUCED DRAFT FAN (ID FAN)
2.5.1 FAN
Type NDZV 47 SIDOR
Make BHEL
Suction / Delivery Orientation 60deg top left/Horizontal right centre
Medium handled Flue gas
No. per boiler 2
Location Outdoor
2.5.2 FAN DESIGN RATING

Capacity 626 m3/Sec
Temp of medium 150 ° c
Specific Wt. of medium 0.752 kg/m3
Speed 580 RPM
Cooling water flow for the fan Brgs 8 TPH
20
2.5.3 FAN RESERVE

Flow 50.95 %
Pressure 88.17 %
2.5.4 FAN DRIVE COUPLING
TYPE HOLSET PM 400 Flexible
2.5.5 LUBRICATION EQUIPMENT
Fan 80 LPM FLOS. (OIL ISO VG 68)
2.5.6 TYPE OF FAN REGULATION Speed by VFD & Inlet damper
2.5.7 BEARINGS
Fixed bearing 10” RLT (Water cooled)
Free bearing 10” RLT (Water cooled
2.5.7.1 VARIABLE FREQUENCY DRIVE (VFD)
Motor Rating Data

Single channel (6 Pulse) Dual channel (12 Pulse)
Speed (RPM) 398 579
Current (Amp)
Motor Voltage(v ) 1650 2300
Power (KW) 1580 4500
Power Factor (LEADING) .95 .95
Exciter voltage (RMS) (Stator 3 238 299
Ph. L-L) Volts
Exciter Stator line current RMS 39 56
VFD TRANAFORMERS
Manufacturer Voltamp Transformers Limited Vadodara
Service class /KVA Rating 3250 KVA/Rectifiers Duty, Mineral of filled,
Outdoor type
Applicable standard IS 2026
Rated Voltage
HV winding KV 11 KV+/- 6%
LV winding KV 2.3 KV
Rated frequency 50 Hz with variation of +3% to -5%
Number of phases 3 Phase
Type of cooling ONAN(Oil Natural & Air Natural )
Tap Changing Equipment
Manufacturer Voltamp/Paragon
Type Off circuit tap changer
No of steps 4 steps/ 5 position
Tap range % to % +5% to -5% @2.5%
Connections Channel #1 Channel #2
HV winding Delta Delta
LV winding KV Delta Star
Connection symbol Ddo Dyn 1
21
VFD Reactors (Both Channel#1 & Channel#2)

Manufacturer Sudhir Intra Vidyut Ltd.
Quantity 8
Type Air Core DC Reactor, Dry type, Self cooled,
Smoothing type
Type of application Indoor
Rated current 1000 Amp DC
Value of inductance 10 mili Henry +10%-0%
System voltage 3600 V DC
Cooling AN
Temp rise Ambient/Winding 50 ° c/ 70 ° c
DC Resistance at 70 ° c 20 milli ohms +/- 10%-
Class of insulation F
Dimension in (mtrs) 2.35X2.25X1.975(LXBXH)
VFD Motor Exciter

Make BHEL
Type Brushless
Number of poles 8
Stator/Rotor turns ratio 6.01
Exciter stator supply (Rated values )
PHASES 3
FREQUENCY 50 Hz
VOLTS (Max) 415 V (L-L RMS)
AMPS 80 A (MAX)(LINE)
Exciter Rotor (Rated values)
Poles 8
RPM 579
KW 26.1KW
Volts 87.4 V DC
AMPS 299 A DC
2.5.8 MOTOR
Frame size 1 DQ 4344,
Type Max Synchronous Motor 2X2300 V
Rating 4500 kW (Both channels together)
Speed 100 to 530 RPM
PF 0.95 Lead
Insulation F
Connection Double Star
Max Stator Voltage 2 X 2300 V
Max Stator Current 2 X 615 A
22
2.5.9 LUBE OIL SYSTEM
2.5.9.1 PUMP
Oil Tank Capacity 600 litre
Pump Type & Make Screw Pump/ Alekton
Pump Model HF210-560-3S, 1.825 KW
Speed 2880 RPM

Normal design Pressure 6.0 BAR
Motor Rating 3.7 KW, 6.7 A, 2855 rpm
Motor details ABB make, bearings-6206-2Z/C3, 6205-2Z/C3
Quantity of cooling water/Boiler 80 LPM
Lube Oil Quantity ISO-VG-68
2.5.9.2 OIL FILTERS

Type Basket Type
Mesh material SS Rating 60 microns
Working Pressure 5 Ksc
Capacity 150 LPM
Suction strainer 149 micron SS mesh
2.5.9.3 HEAT EXCHANGER

Design Pressure Shell side 14 Ksc, Tube side 8 Ksc
Capacity 80 LPM, Temp- 64 to 54 0C
Heat Exchanger Capacity 21600 Kca/Hr
2.6 FORCED DRAFT FAN (FD)
2.6.1 FAN
Type FAF 24.5/11.8-1

No. Per Boiler Two

Capacity 275 m3/Sec.
Total head developed 410 mmWC
Medium handled Atmospheric Air
Location Out door
Orientation Vertical Suction Horizontal Delivery
Temp. of medium 50 ° c
Density of medium 1.027 Kg/m3
Fan Speed 990 RPM
Fan regulation Blade Pitch Control
Fan Weight without motor and coupling 17700kg
2.6.3 FAN BEARINGS

Fixed Bearing 7248
Free Bearing NU 248C3
23
2.6.4 MOTOR
Manufacturer M/S BHEL BHOPAL
Motor type SQ.IND.MOTOR
Direction of rotation as viewed from driving end Clockwise
Standard continuous rating at 40 ° c Ambient temp. 1710 KW
as per Indian Standard
Derated rated for specified normal condition i.e. 1600 KW
Ambient temp.
Rated Votlage (Volts) 11000
Permissible Variations of
(a) Voltage (Volts) +/- 6%
(b) Frequency (Hz) +3 % , -5%
(c) Combined Voltage & Frequency +/- 10 % (Abs)
minimum permissible starting voltage 80 % RV
Rated speed at rated voltage and frequency 996 RPM
At rated voltage and frequency
Full load current 104 Amps.
No load current 40 Amps.
Starting time with minimum permissible voltage
of 80 % of rated value
Without driven equipment coupled 5.8 Sec
With driven equipment coupled 8.4 Sec
MOTOR BEARING
Type Antifriction (Ball & Roller)
Recommended Lubrications IOC Servogem-3 or equ. Grease
Lubrication Self
Guaranteed life in Hrs. 40000 Hrs
2.6.5 LUBE OIL SYSTEM
25 LPM at 35 Bar high pressure system supplied by Cenlub oil systems.

• Control oil pressure- Min. 8 Ksc (permissive), 6 ksc alarm and standby pump on
• Lub oil- Pressure 4 ksc for standby pump ON, Flow- < 4 lpm alarm
2.6.5.1 FOLS (Forced Oil Lubrication System) for FD & PA fans
Pump Make Alekton

Motor Make ABB
Pump type Screw pumps (Triple Screw)
Motor Rating 3 phase, 415 v, 7.5 HP ,11.1 A, 0.78 pf
Speed 1455 RPM
Design Pressure Different settings for PA and FD fans
Relief v/v Range 35 Bar
System discharge capacity 35LPM
Oil tank capacity 300 Ltrs.
Fluid ISO-VG-68
24
2.6.5.2 LUBE OIL FILTER

Type Double reversing type
Mesh Material SS 304 Rating 25 microns
Working Pressure 35 Bar
Capacity 40 LPM
Suction Strainer Filtration size-125 micron
2.6.5.3 LUBE OIL COOLERS

Shell Side Tube Side
Flow 10 LPM 80 LPM
Design Pressure 8 Ksc 8 Ksc
Test Pressure 10 Ksc 10 Ksc
DesignTemp 100 ° c 100 ° c
2.7 PRIMARY AIR FAN (PA FAN)
2.7.1 FAN
Type PAF19/10.6-2
No. per boiler 2
Orientation Vertical Suction Horizontal Delivery
Medium Handled Atmospheric Air
Location Out door
Type of regulation Blade pitch control

Capacity 183 m3/Sec.
Temp. of medium 50 ° c
Specific Wt. of Medium 1.027 kg/m3
Speed 1490 RPM
2.7.3 FAN BERAING

Fixed Bearing 7234 & NU 330
Free Bearing 7234 & NU 330
2.7.4 MOTOR
Type SQ.IND.MOTOR
Type of duty Continuous
Direction of rotation as viewed from driving end Clockwise
Rated Voltage 11000 Volts
Standard continuous rating at 40 ° c Ambient temp. 3207 KW
as per Indian Standard
Derated rated for specified normal condition 3000 KW
Permissible Variations of
(a) Voltage (Volts) +/- 6%
(b) Frequency (Hz) + 3/-5 %
25
(c) Combined Voltage & Frequency 10% Abs

minimum permissible starting voltage 80%
No load current 46 Amps.
of 80 % of rated value
Without Fan 2.0 Sec.
With Fan 10.5 Sec
Rated speed at rated voltage & frequency 1494 RPM
Motor Bearing
Type Antifriction
Recommended lubrication Grease IOC Servogem-3 or equi.
Guaranteed life in Hrs. 40000 Hrs.
Lubrication type Self
2.7.5 PA FAN LUBE OIL SYSTEM
Same as FD fans except the pressure settings as below:

• Control oil pressure- Min. 25 Ksc (permissive), 17 ksc alarm and standby pump on
• Lub oil- Pressure 4 ksc for standby pump ON, Flow- < 6 lpm alarm
2.8 SCANNER AIR FAN
2.8.1 FAN
No. 2( One is AC Driven + One is DC Driven ,
100% Standby )
Type of fan Radial/ Backward curved Blade, single
suction
Make CB DOCTOR MAKE, SB 80 II M3
Pressure developed 200 mmwc
Medium Handled Dust laden air
Efficiency of the fan 71 % (Static)/79.5 % (Total)
Power Consumption 6.13 BKW at operating
Fan Speed 1440 RPM
Capacity 8000 Cum/hr
Direction of rotation CW (Seen from DE Side)
2.8.2 A.C. MOTOR

Make Kirlosakar Electirc Company Ltd.
Type & frame size Squirrel cage induction motor, P132M, IP55
Rated Output 7.5 KW
Rated Voltage, Frequency & Phase 415 V , 50Hz,3 Phase
Efficiency 86 %
Duty Cycle S1
26
2.8.3 D.C. MOTOR

Make Crompton Greaves Ltd,
Applicable standard IS 4722, BS 5000
Type TEFC, SOLID YOKE, Shunt
Frame size AFS 225 M
Duty S1(continuous)
Rated Output 7.5 KW
Armature rated voltage 220 VOL DC
Type of excitation Shunt , Self excited
Full load armature current 40.0 A DC
Full load shunt field current 0.55 A DC
Full load efficiency 84.0 %
Type of duty S1, Continuous
Method of starting Reduced Voltage Starting
2.9 PRIMARY AIR REHEATER (PAPH)

Make BHEL
Type Lungstram Bisector (Regenerative)
Air heater Size 27.5 VIM 2150
No. of air pre heater 2 per boiler
ELEMENTS
END NUMBER HEIGHT OF DESCRIPTION THICKNESS

OF ELEMENT
BASKETS
HOT 240 925 mm DU .8mm
INTER 240 925 mm DU .8mm
COLD 288 300 mm NF 1.2mm
CASING MATERIAL: IS 2062

CASING THICKNESS: 6&10 mm
2.9.0 TYPE OF RADIAL SEALS

HOT END Leaf type bend seals
Cold End Leaf type bend seals
Type of circumferential seals : Staggered leaf type

Type of axial seals: Leaf type bend seals
2.9.1 ROTOR SEALS

Radial Seals-Hot End 2.5 mm Corten-A
Radial Seals-Cold End 2.5 mm Corten-A
Axial Seals 2.5 mm Corten-A
By pass Seals 1.6 mm Corten-A
Rotor post Seals HE & CE 6.0 mm IS-2062
27
2.9.2 ROTOR DRIVE ASSEMBLY

Electric Motor Squirrel cage, Induction motor (415 V,3, 50Hz )
Motor Rating 11 KW
Motor speed 1460 RPM
Frame & class 160L& F
Speed reducer Type- ID. 3 Input, up shaft, M/s Shanthi Gears
Limited
Speed ratio
Fluid coupling 11.5 FCU- M/S Pembril/T12/04- M/s Fluidomat
Final speed
2.9.3 AUXILIARY DRIVE

Air M/s IngersolRand,IR92RA014,5.51:1
Motor Coupling M/S Bibbly coupling type 124 A
Solenoid valve 230 V,1 PH,AC, 50 Hz,-1 “BSP
Pressure Switch 1/4" NPT (F), 0-10 Kg/cm2
Filter & Lubricator 1 “BSP
2.9.4 Rotor stoppage Alarm
Go switch M/s Smart Technologies/New Delhi
2.9.5 BEARINGS
Support Bearing Sph. Roller thrust bearing SKF 294/500 E

Guide Bering Sph. Roller bearing (23060/CCK/C3/W33)
RTD 1 “BSP (M) Duplex -thermo well
2.9.6 OIL CIRCULATION SYSTEM

Motor guide & support bearing 0.75 KW, 415 V, 3,50 Hz,1500 RPM
Type Screw Pump
Pump Tushaco Delta,model:T3S-25/46 John
Type of lubrication Sump oil
Filter Fowler/hp values-15 LPM
Cooler M/s Patel Air Temp Ltd.
Coupling Love Joy-L-095
Pr. Gauge with needle valve M20 X1.5; 0-10 Kg/cm2
Flow switch Universal flow monitors
Dial thermometer with well 3/4" BSP 0-100 ° c
2.9.7 DELUGE AND WATER WASHING
Pressure Gauge M20 X1.5; 0-10 KG/CM2
28
2.9.8 CLEANING DEVICE ASSEMBLY

2.9.8.1 SOOT BLOWERS
Type of nozzle Twin

Type of drive Sweep
Location Gas inlet & outlet
Quantity 2/APH
Motor 0.18 KW, 3, 50 Hz, 415 v, 750 RPM,
Reducer M/s Shanthi-Radicon-AOD/237/2RL ,4900:1
Coupling M/s Love Joy Coupling L-095 & L-110
Limit switch 240 V Cuttler Hammer
Steam consumption 2100kg/hr/device
2.9.9 FIRE SENSING THERMOCOUPLE
Location Gas Outlet and air outlet

Make M/S Pyrotech Electronic/Udaipur
Quantity Thermocouple 10 Point T/C
2.9.10 SERVICE WATER CONSUPTION
HOT END COLD END

Water washing 114 Cum/hr/pipe 114 Cum/hr/pipe
Deluge Assembly 114 Cum/hr/pipe 114 Cum/hr/pipe
2.9.11 BEARING HOUSING OIL CAPACITY
Guide Brg. Housing 50 liters

Support Brg. Housing 150 liters
2.10 SECONDARY AIR PRE HEATER (SAPH)
Make BHEL
Type Ljungstorm Bisector (Regenerative)
Size 30.5 VIM 2150
SAPH ELEMENTS
END NUMBER OF HEIGHT OF MATERIAL DESCRIPTION OF

BASKETS ELEMENT ELEMENTS
HOT 336 925 mm Carbon steel 0.8mm-Du profile

INTER 336 925 mm Carbon steel 0.8mm -Du profile
COLD 384 300 mm Carten -A 1.2mm-NF6 profile
29
2.10.1 ROTOR SEALS
Radial Seals-Hot End 2.5 mm Corten-A

Radial Seals-Cold End 2.5 mm Corten-A
Axial Seals 2.5 mm Corten-A
By pass Seals 1.6 mm Corten-A
Rotor post Seals HE & CE 6.0 mm IS-2062
2.10.2 ROTOR DRIVE ASSEMBLY
Electric Motor Squirrel cage, Induction motor (415 V, 50Hz )

Motor Rating 18.5 KW
Motor speed 1460 RPM
Frame & class 180 L& F
Speed reducer Type- II D. 3 Input, Down shaft, M/s Shanthi Gears Limited
Speed ratio
Fluid coupling 12.75 FCU- M/S Pembril/T12/04 M/S Fluidomat
2.10.3 AUXILIARY DRIVE
Air Motor M/s IEC Dusterloh/Pune.8:1

Coupling M/s Bibbly coupling type 124 A
Solenoid valve 230 V,1 PH,AC, 50 Hz,-1 “BSP
Pressure Switch 1/4" NPT (F), 0-10 Kg/cm2
Filter & Lubricator 1 “BSP
2.10.4 Rotor stoppage Alarm

Go switch M/S Smart Technologies/New Delhi
2.10.5 BEARINGS
Support Bearing Sph. Roller thrust bearing SKF 294/500 E
Guide Bering Sph. Roller bearing (23072/CCK/C3/W33)
RTD 1“ BSP (M) Duplex.- thermo well
2.10.6 OIL CIRCULATIO N SYSTEM
Motor guide & support bearing 0.75 KW, 415 V, 3,50 Hz,1500 RPM,fr.90S
Type Screw Pump
Pump Tushaco Delta,model:T3S-25/46 John
Type of lubrication Sump oil
Filter Fowler/hp values-15 LPM
Cooler M/s United transfer (P)Ltd.
Coupling Love Joy-L-095
Pr. Gauge with needle valve M20 X1.5; 0-10 KG/CM2
Flow switch Universal flow monitors
Dial thermometer with well 3/4" BSP 0-100 ° c
30
2.10.7 DELUGE AND WATER WASHING

Pressure Gauge M20 X1.5; 0-10 KG/CM2
2.10.8 CLEANING DEVICE ASSEMBLY

2.10.8.1 SOOT BLOWERS
Type of nozzle Twin

Type of drive Sweep
Location Gas inlet & outlet
Quantity 2/APH
Medium Steam at 340 ° c & 14 kg/cm2
Motor 0.18 KW, 3, 50 Hz, 415 v, 750 RPM, Insulation Class-F
Reducer M/s Shanthi- Radicon-AOD/237/2RL
Coupling Love Joy Coupling L-095 & L-110
Limit switch 240 V Cuttler Hammer
Steem consumption 2100kg/hr/device
2.10.9.2 FIRE SENSING THERMOCOUPLE
Location Gas Outlet and air outlet

Make M/S Pyrotech Electronic/Udaipur
Quantity Thermocouple 10 Point T/C
2.10.10 SERVICE WATER CONSUPTION
HOT END COLD END

Water washing 182 Cum/hr/pipe 182 Cum/hr/pipe
Deluge Assembly 182 Cum/hr/pipe 182 Cum/hr/pipe
2.10.11 BEARING HOUSING OIL CAPACITY
Guide Brg. Housing 75 liters

Support Brg. Housing 225 liters
2.11 STEAM COILED AIR PREHEATER (SCAPH)
2.11.1 PRIMARY SCAPH
No. of steam coil APH 2 No. per boiler

Supplier M/S C Doctor & Co. Pvt. Ltd.
Size of steam coil APH 3150X4700X350 mm
Installed position Vertical
Design pressure 20 kg/cm2(ata)
Design temperature 240 ° c
Hydraulic Test pressure 30 kg/cm2
Weight of one steam coil APH 4650 kg.
31
2.11.2 SECONDRAY STEAM COIL APH
No. of steam coil APH 2 No. per boiler

Supplier M/S Patel’s Air Tem. Pvt. Ltd.
Size of steam coil APH 6000X3700X350 mm
Installed position Vertical
Design pressure 20 kg/cm2(ata)
Design temperature 240 ° c
Hydraulic Test pressure 30 kg/cm2
Weight of one steam coil APH 5550 kg.
3.0 ELECTROSTATIC PRECIPATOR (ESP)
3.1 DESIGN CONDITION

Gas flow rate 855.1 m3/sec
Gas temperature 125 ° c
Inlet dust concentration 46.08 gm/Nm3
Outlet dust concentration 18 mg/Nm3
Type 4xFAA-9x45M-2x92150-2
ESP Efficiency 99.961 %
No. of precipitator Four
No. of gas path per ESP One
No. of fields in series in each gas path nine
No. of bus sections Two
Velocity of gas inside ESP 0.77m/sec
Treatment Time 52.6 sec.
3.2 COLLECTING ELECTRODES
No. of rows of collecting electrodes per fields 47

No. of collecting electrodes per fields 282
No. of collecting electrodes arranged in each 6
row
Total no. of collecting plates per boiler 10152
Nominal height of collecting plate 15 M
Nominal length of collecting plate 750 mm
Specific collecting Area 261.44 m2/m3/sec.
3.3 EMITTING ELECTRODES
Type Spiral with hooks

Size 2.7 mm dia
No. of electrodes in the frame forming one row 54
No. of electrodes in each field 2484
Total No. of electrodes per boiler 89424
Total length of electrodes per fields 15500 M
Plate/Wire spacing 200 mm (across ESP )
32
3.4 GAS DISTRIBUTION SYSTEM
INLET
Type & quantity Perforated-(3 screen arrangement) with GD
rapping system 1 set..
Location Inlet of Precipitator
OUTLET
Type & quantity Thin sheets formed to a shape of ”U” located
with 600 mm pitch-one no.
Location Outlet of Precipitator
3.5 ELECTRICAL ITEMS
HV RECTIFIER ( BY BHEL BHOPAL/JHANSI)

Rating 95 KV DC (Peak) 1000 mA DC (mean)
Quantity/ESP 18
Type Silicon oil, Silicon diode, Full wave bridge connection
Location Mounted on the roof of ESP
ELECTRONIC CONTROLLER
Type of controller Thyristor
Quantity/ESP 18
Location In the control room at ground level
BAPCON
Microprocessor based TR Controller 18
BAPCON PLUS Quantity/ESP
RAPCON
Microprocessor based rapper Controller 04
RAPCON 24 /ESP
RAPPER CONTROL PANEL

Quantity per boiler 8
Equipment controlled Housing RAPCONs along with relay card, data communication
card &buffer cards of all rapping motors
STATCON E
Microprocessor based status controller qty 04
per boiler
STATCON PANEL
Quantity per Boiler 4
Equipment controlled Housing STATCONs along with data Communication card and
buffer cards.Details of Heaters on/off and Ali status are connected
to the controller.
33
NT-IOS
Quantity per Boiler 01 set
Equipment controlled Communicates & control all BAPCONs, RAPCONs, &
STATCONs. All data on fields, rapping motor running , opacity
readings as well as logging of data
AUXILIARY CONTROLL PANEL

Quantity per Boiler 04
Equipment controlled Geared motor rapping mechanisms of collecting & emitting
electrodes, heating elements on hoppers, Insulator housing &
shaft insulators.
Location In the ESP Controlled room
3.6.1 RAPPING OF EMITTING ELECTRODES

Quantity per ESP 18
Rating Geared motor, 0.50 Hp, 2.5 RPM, 3 phase, 415 V, 50Hz,AC.
Location On middle frame of emitting system frame work
3.6.2 RAPPING OF COLLECTING ELECTRODES & GAS DISTRUBUTION SCREENS

Quantity per ESP 18/02
Rating Geared motor, 0.50 Hp, 1.1 RPM, 3phase, 415 V, 50Hz,AC.
Location On the ESP side panel./GD Housing
3.6.3 RAPPERS FOR COLLECTING ELECTRODE

No. & Type of Rappers One drop hammer per row of collecting electrodes having a
collecting surface of 135 m2
Rapper size 4.9 kgs
Frequency OF Rap Varying from 12 raps. per hour at the inlet field to 0.10
rap/hour at the exit field. The frequency of rapping at
intermediate fields can be adjusted between 15 & 0.10 rap
per hour according to the requirement
Drive Geared Electric Motor
Location At the bottom of collecting electrodes
3.6.4 RAPPERS FOR EMITTING ELECTRODES

No. & Type of Rappers Approximately One drop hammer for two rows of Electrodes
Rapper size 3.0 kgs
Frequency OF Rapping 10 Raps per hour
Drive Geared Electric Motor
Location On middle frame of emitting system frame work
34
3.7 HOPPERS
3.7.1 HOPPERS SPECIFICATIONS

Type Pyramidal
No. of hopper/ESP 36 per pass
Heating Panel type heating elements provided at the bottom of hoppers
Baffling Arrangement 2 sets of deflector plates for each hopper across the gas flow
direction underneath the collecting plates to prevent the gas
sneakage.
3.8 HEATING ELEMEMTS
For Hopper
Quantity per ESP 36 Set
Type Panel Type
Rating 10 Kw, 1 phase ,415 volt,50 hz
Location At the bottom of the hopper
Recommended Thermostat setting for 120 ° c
heater trip.
For shaft Insulators

Quantity per ESP 18
Type Tubular heaters of breathing type
Rating 0.1 kw, 1 Phase, 415 AC, 50 Hz
Location In the shaft Insulator housing
For Support Insulator

Quantity per ESP 72
Type Tubular heaters breathing type
Rating 0.1 kw 1 Phase, 415 AC, 50 Hz
Location In the support Insulator housing
Recommended Thermostat setting for the 120 to140 ° c
heater tripping
4.0 SOOT BLOWER
Source of steam for soot blowing Tap off from SH Division Outlet Header
Set pressure on pr. Reducing valve 30 kg/cm2
Set pr. On safety valve 40 kg/cm2 (38.4 KSC reset)
Maximum flow rate 20 T/Hr
Temp after pressure reducing 368 ° c
* 105 R, 106 L, 109 R, 110 L, 115 R, 116L
** 107 R, 108L, 111 R-114L, 117R-124L, 133R-144L
*** 125R-132L
35
S. DESCRIPTION TYPE OF SOOT BLOWERS

No. WB IE LRD IIE
1 Blower Numbers 1 to 88 * ** ***
(6) (26) (8)
2 Travel in MM 305 9700 9700 9700
3 Dead Travel in MM - 370 370 370
4 Nozzle size in mm/No. off nozzle ɸ 26/1 ɸ 32/2 ɸ 25/2 ɸ 25/2
5 Blowing pre. In kg/cm2 (G) 11 12.5 12.5 10.5
6 Speed of travel in MPM/ Rotary in RPM 6.1/.7 1.55/5.87 1.55/5.87 1.55/5.87
7 Blowing rate per group in kg/min 89 152 93 79
8 Blowing time per group in MIN 1.4 12.04 12.04 12.04
9 Operating time per group in MIN 1.5 12.52 12.52 12.52
10 Operating time per cycle in MIN 66 75.12 325.52 100.16
11 Steam consumption per group in Kg 125 1830 1120 951
12 Steam consumption per cycle in Kg 5500 10980 29120 7608
13 Cycles per day (Assumed) 3 3 3 3
14 Steam consumption per day in Kg 16500 32940 87360 22824
15 Blowing Angle 360 ° c 360 ° c 360 ° c 360 ° c
(PER DAY ) TOTAL STEAM CONSUPTION IN Kgs =159624
NOTE: BLOWING RATE IS GIVEN FOR BLOWERS OPERATED IN A GROUP OF TWO.
LRD IIE LONG RETRACTABLE SOOT BLOER ELECTRICITY OPERATED .

WB IE WALL BLOWER ELECTRICITY OPERATED .
5.0 HP DOSING SYSTEM
5.1 MIXING TANK

Capacity 1700 Liters
Design temp 60 ° c
Design pre 1.5 kg/cm2
Mixing motor 1.5 hp
Speed 925 RPM
Manufacturer Power Piping Company Mandaiyur
5.2 METERING TANK

Tank Capacity 1700 Liters
Temp 60 ° c
Motor Capacity 1.5 hp
Speed 925 RPM
Manufacturer Power Piping Company Madras
5.3 DOSING PUMP

Make M/S V. K. Pump Industries. Pvt. Ltd.
Type Reciprocating Plunger type
Capacity 100 Liter/Hr.
Pressure 225 kg/cm2
No. of pumps boiler 2
Fluid handled Trisodium Phosphate
36
MOTOR DETAILS
Make CGL/KEC/BBL
Applicable Standard IS 325
Type SCIM
Frame ND 100L
Duty S1
Type of Enclosure IP 155
Method of cooling TEFC (IC 141)
Motor Rating 2.2 KW
Motor Speed 1500 RPM
Power Factor 0.82
Volt 415 V, 50 Hz, 3 PHASE
Starting Current 24 Amps
Class of Insulation CLASS “F”WITH TEMPERATURE RISE
LIMITED TO CLASS “B”
AGITATOR MOTOR DETAIL

Make CGL/KEC/BBL
Applicable Standard IS 325
Type SCIM
Frame 90L
Duty
Type of Enclosure IP 55
Method of cooling (TEFC)IC 411
Motor Rating 1.1 KW
Motor Speed 935 RPM
Power Factor 0.7
Volt 415 V, 50 Hz, 3 PHASE
DOR Bi-directional
Starting Current 13.5 Amps
Class of Insulation CLASS”F’” WITH TEMPERATURE RISE
LIMITED TO CLASS “B”
AGITATOR DETAIL
Make V.K.Pumps INDUSTRIES PVT. LTD
VOLUME TO be Mixed 1.7 m3
Component to be Mixed Water/Tri sodium phosphate
Impeller SS316 MOC
Speed 140 rpm
6.0 BLOW DOWN VESSELS
IBD TANK CBD TANK

No. 1 1
Type IBD TANK 25000X16 CBD TANK 20000X16
Design Pressure 7.0 Kg/cm2 (g) 10 Kg/cm2 (g)
Design Temp 169 ° c 183 ° c
37
Hydraulic test press 10.5 Kg/cm2 (g) 15 Kg/cm2 (g)

Shell Thickness 16 mm 16 mm
Shell dia 2500 mm 2000 mm
Wt. when empty 6900 Kg 4100 Kg
Medium Steam & Water Steam & Water
Material Specification SA 515 Gr. 170 SA 515 Gr. 170
7.0 PRESSURE REDUCING & DESUPERHEATING STATION (PRDS)
HT PRDS LT PRDS
Pressure 16 ata 16 ata
Temperature 310 ° c 210 ° c
Volume of steam 114.74 T/Hr 80.70 T/Hr
Application TG Gland Sealing/ TDBFP Gland Deareator Pegging/ HFO
sealing/ AH Soot blowing/ Mill Automisation/ SCAPH/ Turbine
Inerting/ AC Plant wet steam washing
7.1 SPECIFICATIONS
MS & CRH PRDS
MS CRH
Pressure 186.6 to 20.0 ata 52.4 to 20.0 ata
Temperature 540 to 350 ° c 360 to 350 ° c
Volume of steam 92.5 T/Hr 10 T/Hr
Spray Required 10.6 T/Hr (200 bar & 185 ° c) 8 T/Hr (200 bar & 185 ° c)
7.1.2 PRDS STATION SAFETY VALVES
No. of Safety Valves
Number Set Pressure (Kg/cm2) Blown Down (%)

AS 32 18.0 3 to 5
AS 33 18.5 3 to 5
AS 34 19.0 3 to 5
8.0 SG EQUIPMENT COOLING WATER SYSTEM
8.1 DMCW PUMPS
Make WPIL Ltd.

Model No. 8 LN 18C
No. of pumps 2
Shut off head 74.8 mwc
Rated Capacity 575 m3/hr
38
Pump Rated Speed 1485 RPM

NPSH required at Rated capacity 4.5 MWC
Total dynamic head at rated capacity 65 MWC
Number if stages One
Coupling type Flexible
Type of sealing Mechanical Seal
Bearing DE/NDE
Type & Make Ball/SKF/FAG or Equivalent
Bearing No. Inboard/Outboard 6212/6212
Type of Lubrication Grease
Design Life More than 40000 Hrs.
8.2 DMCW PUMPS MOTOR
Make MARATHON ELECTRIC MOTORS LTD.

Motor type Sq. cage Induction Motor
Frame 315
Type of duty S1 Continuous
DOR CW Pump from DE Side
Standard continuous rating at 40 °c 180 KW
Rated voltage/Frequency 415 Volts/50 Hz
Full load current 310Amps
No load current 125 Amps
Power factor at Full load 0.85
Efficiency at Full load 95 %
Make IDMC Ltd, V.U Nagar, Anand

Model No./type S188
No. of PHE 2
No. of Pass Single
Maximum Temperature 60 ° c
Design Pressure 12 bar
LMTD 2.827 ° c
Total eff Heat transfer area per HE (M2) 455.648
Area of each plate (M2) 1.964
Thickness (mm) 0.6
Material AISI 316
No of plate per HE 234
39
9.0 CHEMISTRY PARAMETERS & EXPRESS LAB (SWAS)
9.1 Recommended Chemical Parameters
BOILER WATER PARAMETERS

Parameters Limit Values
Boiler water Regime AVT
Boiler water conductivity(µS/cm) 7.0 to 15
Boiler water pH 9.0 to 9.5
Boiler water After Cation conductivity (µS/cm) Less than 2.0
Boiler water Chloride, (ppb) Less than 120
Boiler water Silica, (ppb) Less than 200
SYSTEM WATER PARAMETER

Parameters Limit-Values
Feed water Regime AVT-O
pH at Eco inlet 9.0-9.6
Conductivity (us/cm) 5.0 to 10.0
Ammonia (ppb) 800 to 1250
After Cation conductivity (uS/cm) for All Less than 0.2
Dissolve-O2 (ppb) at Eco inlet Less than 5.0
Dissolve-O2 (ppb) at CEP Discharge Less than 10
Oxidation reduction potential- Eco inlet, mV Oxidizing
Main Steam & condensate Sodium (ppb) Less than 2.0
Main Steam & condensate Chloride (ppb) Less than 2.0
9.2 Instrument Schedule (ABB Make)
Parameters Model Range Samples analyzed

Specific AX41050001 0-100 µs/cm DM makeup water, Cond discharge
Conductivity + AC221/231201 after CPU, Feed water at Eco Inlet,
Drum Water, Sat Steam and Main
Steam
CATION AX41050001 0-1 µs/cm Same As above
CONDUCTIVITY +AC221/231201
pH AX460/50001+ 0-14 Feed Water at ECO inletl, CEP
AP302/11001001 discharge, CPU outlet, Boiler drum
Water, Main Steam, Condenser Cooling
Water, ECW-SG & ECW-TG
DISSOLVED 9437/0021230 0-20 ppb CEP discharge, Deaerator Outlet, Feed
OXYGEN Water at ECO Inlet
Phosphate Navigator 600 0-15 ppm Drum Water
(AW642/54000010)
Hydrazine 7835-00000500 0-999 ppb Feed Water at ECO Inlet
Sodium 8037/000121200 .01µg/kg to CEP discharge, CPU outlet, Main
10 mg/kg Steam, Saturate Steam
Chloride 8234/0020 0-1000 ppb Drum Water
40
10.0 FUEL OIL PUMP HOUSE
10.1 HFO PUMPS
Particulars 3 X 50% triple screw pumps

Make & Model Alekton Model: DH 600-1600-2-SJ
Suction/discharge Pressure -0.5 / 30 kg/cm2
Speed & DOR 1450 RPM, CLOCKWISE FROM MOTOR END
Pumping Temperature 57 to 90 0C
Viscosity 180 cst (min.)/500 cst max
NPSH required 4.58 m
Capacity at min/max CST 989 / 1010 lpm
BHP at min/max cst 58.6 kW/ 63 kW
Efficiency at min/max cst 95.3% & 84.2%
Mechanical Seal Single Action John Crane make, Model: 2100 size 65 mm
Safety relief valve Integral type, Spring range-15 to 45 ksc, set @ 35 ksc
Coupling 3-piece PIN-PUSH type, Love joy make
10.1.1 HFO PUMP MOTOR
Make Bharat Bijlee Ltd

Type & Frame Size MD28M453 / 280M /IP 55 PROTECTION
Application Standard IS 325; IS 2148 (Flame Proof)
Rating 90 kW at 1480 RPM
Rated current 147 A ; 42 A approx. at no load
Bearings SKF/FAG Ball/Ball, 6317 C3/ 6316 C3
10.2 LDO PUMPS
Particulars 2 X 100% triple screw pumps

Make & Model Alekton Model: DH 375-1000-3
Suction/discharge Pressure -0.5 / 25 kg/cm2
Speed & DOR 2920 RPM, CLOCKWISE FROM MOTOR END
Pumping Temperature 40 0C
Viscosity 2.5 cst (min.)/ 15.7 cst max
Capacity at min/max CST 451 / 476 lpm
BHP at min/max cst 22.9 kW/ 23.9 kW
Efficiency at min/max cst 88.3% & 82%
Mechanical Seal Single Action John Crane make, Model: 2100 size 45 mm
Safety relief valve Integral type, Spring range-12.5 to 37.5 ksc, set @ 30 ksc
Coupling 3-piece PIN-PUSH type, Love joy make
41
10.2.1 LDO PUMP MOTOR
Make Bharat Bijlee Ltd

Type & Frame Size MD20L253 / 200L /IP 55 PROTECTION
Application Standard IS 325; IS 2148 (Flame Proof)
Rating 37 kW at 2955 RPM
Rated current 62.9 A ; 20 A approx. at no load
Bearings SKF/FAG Ball/Ball, 6212 C3/ 6212 C3
HEATER COOLER
Nos 03 02
Surface Area 50 sq M
Type Oil in shell, Water in U-tube Oil in shell, Water in U-tube
Design Press (HFO side) 32 ksc
Design Press (Steam side) 24 ksc
LOCATION: One in Pump House, one each at boiler zero meter-both units.
Nos. 3
Pump Type Internal Gear Pump to handle LDO/HFO/LSHS at temp range-57 to
1200C
Make & Model Tushaco Pumps- R20-DG
Rating 67 to 71 LPM at 10 ksc, Suction pr.-(-)0.5 ksc
Rotation 1445 RPM, clockwise as seen from motor end.
Pump Motor CGL make 5.5 kW SCIM
Coupling Love Joy- RC 042
10.5 HFO SUMP PUMP (PUMP HOUSE)
Nos. 2 (1 working)
Pump type Vertical submerged to handle HFO/sludge
Make & Model Sam Turbo, VO 32/200+ CPC
Size & Rating 50x32 (SuctionX discharge), 10 m3/hr at 53 m total head
Pump Motor Marathon make 5.5 Kw @2900 RPM SCIM
Coupling SAM make Pin & Bush
Bushes Total-03 nos, CFT (Carbon filled Teflon) bearings
Lubrication External with Clear water
42
10.6 LDO UNLOADING PUMPS
Nos 2 (1 Working +1 Standby)

Pump Type Twin Screw External Bearing Pump with Mech Seal & Timing Gear
Make & Model Tushaco Pumps: TDSH 105/058
Pump Speed 1460 RPM rated (500 RPM min.- 1533 rpm max)
Rating Flow:50 m3/hr at 20 mlc head (1.6 ksc)
Motor 11 KW rated (160L frame size)
Coupling Spacer coupling
Relief Valve Built on relief valve set @2.6 ksc
10.7 DIRTY(DRAIN) OIL PUMPS (LDO UNLOADING SYSTEM)
Location OWS Pit (Oil Side) Drain Oil Tank (LDO Unloading pit)
Nos 2 2
Pump Type Single screw vertical pump to handle dirty fuel oil(LDO/HFO)
Model/Make TISK 100.1 VT / Tushaco Pumps TIS 200.1 EWVT
Pump speed 434/150/480 RPM (Rated/Minimum/ 446/150/480 RPM
Maximum) (Rated/Minimum/ Maximum)
Rating Flow- 6 m3/hr @ 1.8 ksc Flow- 10.8 m3/hr @ 5.76 ksc
Motor 2.2 kW, 1450 rpm CGL make 5.5 kW, 1450 rpm CGL make
DOR Clockwise from Drive End Clockwise from Drive End
Speed Helical Gear reducer/ PBL make/ Helical Gear reducer/ PBL make/
Reducer Model-M0620 Model-M0620
Gear Ratio 3.25 : 1 (Input speed-1450 3.25 : 1 (Input speed-1450
rpm/Output speed-434 rpm) rpm/Output speed-446 rpm)
Gear ISO VG 68 ISO VG 68
lubrication
10.8 SUMP PUMP (FOHS)
Location LDO unloading Pit sump Oil Water Separator Pit

Type/Make Vertical Submerged / Kishore Pumps Ltd
Model NVE 65-315 VERSA EG 50-200
Capacity 30 m3/hr @ 10 mlc (1ksc) 30 m3/hr @ 10 mlc (1ksc)
Speed 960 rpm 1450 RPM
Motor CGL make, 3.7 kW CGL make, 2.2 kW
Coupling Flexible(Steel & Rubber) Flexible(Steel & Rubber)
Min Submergence 400 mm 360 mm
43
11.0 MILL REJECT HANDLING SYSTEM
11.1 GENERAL SPECIFICATIONS
Supplier: M/s Macawber Beekay Pvt Ltd in collaboration with CLYDE BERGMANN
MATERIALS HANDLING LTD., U.K.
Material Handled:
Mill rejects with assumed bulk density of 1.6 T/m3. Size of particles - below 25 mm (95% of
reject). Oversize particles to be removed from the grid in pyrite hopper through plate valve.
Air receivers: 02 nos of 20 m3 capacity in each unit. One no at compressor house common for
both units.
Storage bunker: Capacity- 101 Tons with bag filter. One no with bag filter for each unit.
Service Water: Sourced from plant service water system. Needed for quenching spray in pyrite
hopper and for dome valve top plate cooling.
Instrument Air: Sourced from plant instrument air system.
11.2 SYSTEM DESIGN (Denseveyor/ Convey Pipe/ Pyrite Hopper)
Guaranteed Conveying Rate : 0.8 TPH/Mill

Bulk Density of Mill Rejects (volumetric flow and Bunker volume) :1.6 T/CuM
Bulk Density of Mill Rejects considered for Load Design of Bunker : 2.4 T/CuM
(Note: For PG test, actual BD would be checked but a minimum value
of 1.6 has to be considered)
Approximate effective length of convey pipe : 58 to 151 m
Average convey Velocity : 3.5 to 5.7 m/s
Dome Valve open time (material fill time) : 5-10 Sec
Dome valve closing/seal inflation : 03 sec
Convey Time : 13 to 34 Secs.
Reset time : 05 sec
Total cycle time : 33 to 52 Secs.
Max particle size of mill rejects : 50 mm
For lumpy material as above, pipe size provided is generally minimum of twice the lump size.
Required pipe size : 80 mm
Pipe size provided :125 NB
(OD:139.7,ID:128.9 mm
Vessel capacity (6 cft) : 0.17 cum
Material volume/batch : 0.17 cum
Batch weight per cycle : 0.17*1600 kg
=272 KG
Hence, for 800 kg/hr capacity, cycles required : 800/272 2.94 say
3 cycles / hr.
44
11.3 DENSEVEYOR DATA
Model 6/8/5
Nos. 01 per mill
Total cycle capacity 6 cft (0.17 m3) effective, 7 cft gross
Pressure rating 5.0 ksc
Design Temperature 200 0C (Quenching spray opens at 90 degree)
Material Inlet size 200 NB
Air inlet size 50 NB
Material of Denseveyor body-MS- IS 2062 Gr. E250A
construction Outlet bend - Alloy Cast Iron
11.4 COMPRESSORS
Nos. 02 (1 working + 1 Standby)

Make Ingersoll Rand (India) Ltd
Model 16 & 10 X 7 PHE7 PKG
Type Reciprocating ,Horizontal, Two Stage, Double
Acting, Water Cooled & Non Lubricating
Rated Capacity 27 m3/min at 4.5 kg/cm2
Unload pressure 4.5 kg/cm2
Load Pressure 4.05 kg/cm2
Volumetric efficiency 83.3 %
Mechanical Efficiency 91.73%
Motor Rating 160 KW
Shaft Power 125.35 KW @ 4.5 kg/cm2 compressor flange
Compressor Speed 725 RPM
Motor Make ABB Ltd.
Motor Rating 160 KW, 415 V, 1485 RPM
Starting time 1.1 sec with compressor coupled.
Type of Coupling V-Belt
Cylinder Stroke & Bore Stroke-7 Inches, Bore: Ist stage-16 inch, 2nd stage-10 Inch
Cylinder water flow 75 lpm at 5.5 ksc
Air Temperature First stage discharge- 135 degrees, 2nd stage- 129 deg
Air discharge temperature 46.33 degree C
at aftercooler
Intercooler water flow 185 LPM (Water in shell, Air in tubes)
Aftercooler water flow 250 LPM
MOC of coolers Shell- SA 106 Gr. B, Tubes- Copper
Lubrication CRANKPIN, PISTON PIN, CROSS HEAD SHOES
lubricated with Force feed
Lubricating Pump 01 no mounted on compressor shaft
Oil Pump pressure 2.0 kg/cm2
Lubricant type INGERSOLL RAND RECIP PRIME
Sump capacity 26 litres
45
NTPC DRG. No.: 1240-101-02-TR-PVM-N-001
JOB NO : NTPC LIMITED
STATUS: CONTRACT
RIHAND STPP, STAGE-III (2 x 500 MW)
DISTRIBUTION
STEAM GENERATOR WITH
ELECTROSTATIC PRECIPITATOR PACKAGE
TO Dept Name Sign Date
Code
No. of BHARAT HEAVY ELECTRICALS LTD. DRN SR -Sd- 16.02.10
REV. Date ALTD CHD APPD UNIT : HIGH PRESSURE BOILER PLANT DESN JLJ/AVR -Sd- 16.02.10
TIRUCHIRAPPALLI – 620 014 CHD MA -Sd- 16.02.10
APPD MA/SCS -Sd- 16.02.10
TITLE:
COMBINED BOILER TURBINE START UP CURVES
DEPT. SCALE DRAWING NO.
SIGN.
DATE. SHEET 1 OF 4 REV 00
CAUTION: THIS DRAWING IS THE PROPERTY OF BHARAT HEAVY ELECTRICALS LTD., AND IS NOT TO BE REPRODUCED OR USED TO FURNISH ANY INFORMATION FOR
MAKING OF DRAWINGS OR APPARATUS EXCEPT WHERE PROVIDE FOR AGREEMENT WITH SAID COMPANY.
START-UP TIME (MINUTES)
CAT-IV
HP ROTOR TEMP. : 50 0C
HP CASING TEMP. : 50 0C
NTPC, IP ROTOR TEMP. : 50 0C
2 X 500 MW RIHAND STAGE-III
START-UP CURVES / COLD START NAME SIGN. DATE
CONSTANT PRESSURE OPERATION DRN. NEERAJ 30.09.2009
1240-110-03-HW-PVM-N-206 CHD. NEERAJ 30.09.2009
TURBINE MODULES H30-100-2, M30-63 APD. A.SHAH 30.09.2009
BHEL, RANIPUR, HARDWAR STE-TD-260-MS REV. 02 SH.1 OF 3
Based on these curves, combined start up curves will be generated during contract stage in conjunction with boiler &
system engineering for demonstration.

START-UP CURVES / 36 HRS SHUT DOWN NAME SIGN. DATE
CAT-IV START-UP TIME (MINUTES)
START-UP CURVES / COLD START NAME SIGN. DATE
SLIDING PRESSURE OPERATION DRN. NEERAJ 30.09.2009

NTPC, HP CASING TEMP. : 410 0C
IP ROTOR TEMP. : 275 0C

TECHNICAL DIARY
TURBINE & AUXILIARIES

RAHUL YADAV SUSHIL KUMAR M K SINGH
STAGE-3 TECHNICAL DIARY (TG)
CONTENTS
1. MAIN TURBINE
1.1 SPECIFICATIONS 49
1.2 TURBINE LUBE OIL SYTEM 53
1.3 GENERATOR 56
1.4 TURBINE CONTROL FLUID SYSTEM 58
1.5 CONDENSER 60
1.6 LP HEATERS 61
1.7 DEAERATOR & FST 62
1.8 HP HEATERS 63
1.9 LP DOSING SYSTEM 64
1.10 CENTRAL LUBE OIL STORAGE & PURIFICATION UNIT 64
1.11 HP BYPASS SYSTEM 65
1.12 LP BYPASS SYSTEM 66
2.1 CONDENSATE EXTRACTION PUMP 67

2.2 BOILER FEED PUMP & AUXILIARIES
2.2.1 BOILER FEED PUMP (MAIN) 68
2.2.2 BOOSTER PUMP 69
2.2.3 HYDRAULIC COUPLING OF MDBFP 70
2.2.4 LUBE OIL SYSYTEM FOR MDBFP 70
2.2.5 BFP DRIVE –MOTOR 71
2.2.6 TDBFP LUB OIL SYSTEM 71
2.2.7 OIL PURIFIER (CENTRIFUGE) 72
2.3 VACCUM PUMP 73
2.4 TG EQUIPMENT COOLING WATER SYSTEM 74
2.6 AUXILIARIES COOLING WATER SYSTEM (ACW) 75
2.7 CONDENSER ON LOAD TUBE CLEANING SYSTEM (COLTCS) 76
3.0 DM MAKEUP & CPU REGENERATION SYSTEM 77
4.0 COMPRESSED AIR SYSTEM 79
48
1.0 MAIN TURBINE
1.1 SPECIFICATIONS
Make BHEL
Design KWU, West Germany
Type Three cylinder reheat condensing turbine
Stages HPT 17 Reaction stages.
IPT 12X2 Reaction stages.
LPT 6X2 Reaction stages.
Valves HPT- 2 main stop & control valve.
IPT- 2 Reheat main stop & control valve.
CRH Line-1 swing check valve
2 Bypass Stop and Control Valves with actuators & HPSU.
Direction of rotation Anti-clockwise (Viewed from front pedestal towards Generator)
Load
Rated load 500 MW
Max Load 524.2 MW (VWO-Valve Wide Open Condition)
Speed
Rated speed 50 C/Sec
Max speed 51.5 C/Sec (No time limitation)
Min speed 47.5 C/Sec (No time limitation)
*Speed Exclusion Range (Without Load) 7 to 47.5 C/Sec
Standard Over Speed trip setting 55.5 C/Sec
*This speed range should be passed through in one smooth operation to avoid endangering
the blades due to resonance.
1.1.1 EXTRACTION VALVES
Extraction 1 No valve
Extraction 2 1 Swing check valve with actuator and 1 swing check valve without actuator
Extraction 4.1 2 Swing check valves with actuator
Extraction 4.2 2 Swing check valves with actuator
Extraction 6 No valve
1.1.2 STEAM PRESSURE AND TEMPERATURE (RATED)
Pressure (Bar) Temperature (ºC)

Initial Steam/MS at HPSV Inlet 166.7 537
Before 1ST Stage of HPT 154.2 537
HP Cylinder exhaust 44.0 336.1
IP Cylinder stop valve Inlet 39.6 565
Extraction 6 44.0 336.1
49

LP Cylinder exhaust 0.1027 46.4
1.1.3 TURBINE EXTRACTIONS
Extractions Source Going to

1 LPT 5 th Stage LPH-1
2 LPT 3rd Stage LPH-2
3 LPT 2 nd Stage LPH-3
4 IPT Exhaust Deaerator (4.1) & TDBFP-A/B (4.2)
5 IPT-7th Stage HPH-5A/5B
6 CRH HPH-6A/6B , TDBFP-A/B
1.1.4 CASING TEMPERATURE LIMITING VALUES
Wall Temperatures Alarm at Machine must be shut

down at
HP Turbine casing exhaust 485 ºC 500 ºC
Outer casing of LP cylinder 90 ºC 110 ºC
Spray water L.P. Turbine must be switched on at 90 ºC
Temperature Difference Alarm at Machine must be
tripped
Between upper & lower casing halves of HP +/- 90 ºC +/- 100 ºC
turbine (Middle)
Between upper & lower casing halves of IP +/- 30 ºC +/- 45 ºC
turbine,front and rear
Permissible temperature difference between parallel steam supply lines
No time limitation 17 ºC
Short term period (15 Min) 28 ºC
1.1.5 FEED WATER HEATER OUT OF SERVICE
Operation with feed water heater out Main Steam flow kg/s Load MW
of Service
Extraction A6,A5(Both streams out) 369 500
1.1.6 OUTPUT LIMIT WITH ATT
Output limit during the testing with Automatic Turbine Tester

Testing of the main steam Stop & Control Valves <300 MW
Testing of the HRH steam Stop & Control Valves 200 to 500 MW
50
1.1.7 MOTORING
Motoring is the condition in which the turbine is driven by the generator at the rated
speed with the stop valve & control valves closed. Motoring must not be allowed to continue
beyond one minute. If the condenser low vacuum limit of 0.3 bar is exceeded, motoring
must not be allowed to continue beyond 4 sec.
1.1.8 LOW VACUUM TRIP STANDARD SETTING
Hydraulic low vacuum trip 0.3 bar

Electrical low vacuum trip 0.3 bar
Electrical low vacuum trip Bypass operation 0.6 bar
1.1.9 TURBINE SEAL STEAM SYSTEM
Seal steam supply header pressure (Above 35 mbar

atmospheric)
Condenser vacuum 0.1027 bar
1.1.10 BARRING GEAR
Speed 80 to 120 RPM

Drive Turbine lube oil (Hydraulic Turbine)
Cut in /Cut out Speed 210/240 RPM
Location Front bearing pedestal
1.1.11 TURBOVISORY
Axil Shaft ALARM TRIP

+/-0.5 mm +/- 1 mm
Differential Expansions
(i) HPT -0.5 to +3.5 mm
(ii) IPT -1.0 to +3.5 mm
Over all Expansion of IP+LP Rotor -3 to 30 mm
1.1.11.1 VIBRATION
Absolute Bearing Housing Absolute Shaft Vibration

Vibration
Standard Alarm Setting 50 µm above normal level
Maximum Alarm Setting 84 µm 200 µm
Limit value of tripping 106 µm 300 µm
Fixed Points
For HP Casing Turbine bearing pedestal-2
For IP Casing Turbine bearing pedestal-2
For LP Casing Turbine bearing pedestal-3
For Turbine rotor Thrust Bearing
All HP, IP & LP Turbine Bearing Pedestal are fixed.
51
1.1.11.2 BEARING TEMPERATURES
Alarm Machine must be shut down at

Operating temperature below 75 ºc 90 ºc 130 ºc
Operating temperature 75 ºc to 85 ºc 100 ºc 130 ºc
Operating temperature 85 ºc to 90 ºc 110 ºc 130 ºc
Operating temperature above 90 º C 115 ºc 130 ºc
1.1.13 WEIGHTS (TONS)
HP turbine complete assembly 95 T

IP turbine, top half outer casing 26 T
IP turbine, top half inner casing, complete with blading 16 T
LP turbine, top half outer casing complete 43 T
LP turbine, top half inner outer casing, complete with blading, guide 37 T
blade carriers & diffusers
HP turbine rotor, complete with blading 16 T
IP turbine rotor, complete with blading 23 T
LP turbine rotor, complete with blading 100 T
Main stop and control valve, complete with servo motors, without bend 22 T
and pipe section
Reheat stop and control valve, complete with servo motors, without 32 T
bend & pipe section
1.1.14 TURBINE LOAD SHARING CAPACITY
HP Turbine 26 %
LP Turbine 34 %
IP Turbine 40 %
1.1.15 HEAT BALANCE DATA
Rating 500 MW 400 MW 300 MW 250 MW

Vacuum(mmHg) 77 (0.927 ksc) 77 77 77
DM Make-up (%) 0 0 0 0
Turbine Gross Output 508.489 407.608 306.076 255.734
Turbine Net Output(MW) 500 400 300 200
Heat Rate(Kcal/KW-Hr) 1932.5 1975.5 2059.5 2129.3
Losses (in MW)
Mechanical 1.44 1.44 1.44 1.44
Gen 6.895 5.474 4.482 4.410
TG Auxiliary 0.15 0.15 0.15 0.15
Efficiency (%) 98.33 98.26 98.01 97.757
52
1.2 TURBINE LUBE OIL SYSTEM
1.2.1 MAIN OIL TANK
MOT Capacity 25/40 m3

1st oil filling 53 m3
Flushing oil quantity 32 m3
Filtration particle size of tank filter element 250 µm
1.2.2 OIL REQUIREMENT OF BEARING (dm3/S)
Bearing 1 0.8
Bearing 2 15.4
Bearing 3 4.55
Bearing 4 9.29
Generator front bearing 7.92
Generator rear bearing 7.92
Exciter Bearing 0.70
Estimated oil requirement for the hydraulic bearing gear at 4.5-5.0 bar 57.4
Min. 38 0C
Oil temperature at cooler outlet, unit in operation Normal 45 0C
Max. 47 0C
Oil temperature at cooler outlet, unit shut down Max. 75 0C
Temperature rise of oil in bearings Normal 20 0C

Maximum 25 0C
1.2.3 DUPLEX OIL FILTER (FOR BRG. OIL SUPPLY HEADER )
Number 1
Type RFLD 4020
Make M/S HYDAC FILTER TECHNIK
GMBH
Filtration particle size of duplex filter 25 µm
Filtration particle size of main oil tank filter element 250 mm
1.2.4 JACKING OIL SYSYTEM
safety valve setting 200 Bar

Pressure Regulating valve setting 178 Bar
1.2.5 DUPLEX OIL FILTER FOR JACKING OIL
Number 1
Type DFDK 330 D40 W/Hc/-V-So212
Make M/s: HYDAC FILTER TECHNIK GMBH
Filtration particle size of filter element 37 µm
53
JACKING OIL PUMPS CUT IN / CUT OUT SPEEDS
Jacking oil pump must be in operation at turbine speed bellows 510 RPM.
Jacking oil pump should be cut out at speeds above 540 RPM.
1.2.6 OIL PUMPS SPECIFICATIONS
MOP AOP DC EOP JACKING OIL PUMP

Number 1 2 1 AC:1 DC:1
M&P
Make BHEL M&P Tushaco Tushaco
VERTICAL
VERTICAL
EXECUTION
EXECUTION
Type Centrifugal 4’’/5’’
5/6 EHLG T 38/46
Type12 KL
Model 70
Capacity(m3/HR) 87.48 360.96 108 1.85 LPS
Dish. Pressure (bar) 8.4 6.3 2.3 178
Speed (RPM) 3000 3000 1425 2900
Drive Turbine AC Motor DC Motor AC Motor DC Motor
Voltage (V) - 415 V 220 V 415 V 220 V
Motor Power(KW) - 110 13 60 60
Rated Current
- 173 97 95 310
(Amp)
DOR From top - Clockwise Clockwise Clockwise Clockwise
Make (motor) - CGL CGL CGL CGL
1.2.7 LUB OIL COOLERS
Number 2X100 %
Type of Cooler Shell & tube type (Straight tube)
Heat transfer area provided/ cooler 640 m2
Oil flow 190.8 m3/Hr
Heat load on cooler 100% 1900 kw
Temp. of oil at inlet of cooler 65 ºc
Temp. of oil at outlet of cooler 45 ºc
Tube (water ) side design pressure 10 Ksc
Cooling water flow/ cooler 500 m3/hr
Temp of cooling water at Inlet of cooler 38 ºc
(Design )
Max allowable Temp of cooling water at Inlet 38 ºc
of cooler
Temp. of cooling water at outlet of cooler 41.3 ºc
Pressure drop across the cooler on tube side 3.5 m.w.c.
Shell (oil) side design pressure 9.4 kg/cm2
Oil side pressure drop 4 m.w.c.
Tube Material Admiralty Brass
Tube Plate Material Carbon Steel IS:2062
54
Cooler shell & water Boxes material Carbon Steel IS:2062

Velocity of water through cooler tube 1.54 m/sec
Number of tubes 956 (Low fin tubes)
Length of tubes 3750 mm
Tube OD X Thk. X L (Effective) 22X2.1X3597 mmX mmX mm
Design code TEMA
Heat transfer coefficient 260 K Cal/hr-m2- ºc
Oil pressure at cooler Inltet 9.4 kg/cm2 g
No. of tubes side passes 2
1.2.8 TURBINE OIL CENTRIFUGE SYSYTEM
No. of units One

Make Alfa Laval
Type MAB 206 S-24
Speed of Bowl (Max) 8423 RPM
Max. hydraulic capacity 10,600 lit/hr
Recommended oil flow (for best performance) 7500 lit/hr at 65 °C
Centrifuge drive Motor rating 11kW (AC)
CENTRIFUGE FEED PUMP
Type Positive displacement
Capacity 8250 LPH
Speed 1450 rpm
Discharge pressure 1.5 kg/cm2
Max allowable pump pressure 4.0 kg/cm2
CENTRIFUGE MATERIALS
Bowl body SS Alloy AL 111 2377
Bowl head SS Alloy AL 111 2377
Separating discs AISI 316
Drive shaft EN 8
Gear / Worm Tin bronze /EN 8
Oil injection nozzle AISI 316
1.2.9 MOT OIL VAPOUR EXHAUSTER FAN
Make S. K. System Pvt. LTD.

Type SHSH-10-X
Capacity 396 M3/hr
Pressure Developed 220 mmwc
No. of fans 2X100 %
Motor Make Bharat Bijlee
Contd. From prev. page
Power rating 0.75 kW (415 V)
Current rating 1.650 Amps
Speed 2830 RPM
1.2.10 LEKEAGE OIL PUMP
Make / Model No. Tushaco Pumps pvt Ltd.

Discharge Pr. 2.0 kg/cm2
55
Capacity 40 lpm
Motor Make CGL India
Rating .75 kw (415 V)
Current 1.60 Amps
RPM 1410 RPM
1.3 GENERATOR
1.3.1 TECHNICAL DATA
Generator type THDF 115/59

Main exciter type ELR 70/90-30/6-20
Pilot exciter type ELP 50/42-30/16
Rated data and output Turbogenerator Main Exciter Pilot Exciter
Apparent power 588 MVA - 65 kVA
Active power 500MW - -
Current 16.166 kA 4040 A 195 A
Voltage 21 kV ±1.05 kV 343 V 220 V±22 V
Speed (rpm) 3000 3000 3000
Frequency 50Hz - 400Hz
Power factor 0.85 (lag) - -
Stator winding conn. YY - -
H2 pressure 3.5 bar(g) - -
Cont. perm. Unbalanced load 8% - -
Rated field current and rated output 4040 A - -
Rated field voltage 340 V - -
Critical speed (calculated) ή1 864 rpm
(Generator + Exciter coupled) ή2 2388 rpm
ή3 4680 rpm
Generator volume and filling quantities Volumes Units
Generator volume (gas volume) 80 M3
CO2 filling quantity 160 M3 (s.t.p.)
H2 filling quantity (to 3.5 bar) 480 M3 (s.t.p.)
Main Weights (in Tonnes)
a) Heaviest lift of generator stator with 260
trunnions etc. 360
b) Weight of complete Generator stator 68
c) Weight of complete rotor 428
d) Weight of complete generator
1.3.2 GENERATOR SEAL OIL SYSTEM
1.3.2.1 SEAL OIL PUMPS
Pumps/specification Air side seal oil Air side seal oil H2 side seal oil
pump (AC) pump (DC) pump (AC)
Make TUSHACO TUSHACO TUSHACO
Type Three Screw pump Three Screw pump Three Screw pump
Model T3S-52/54 T3S-52/54 T3S-52/46
Nos. 2×100 % 1×100 % 1×100 %
Capacity (lpm) 258 258 130
56
Discharge pressure 12 kg/cm2 12 kg/cm2 12 kg/cm2

Pump motor CGL, ND132M CGL,AFS225L CGL,ND132M
Power rating 7.5 kw/415 V 8.5 kW/ 220V 4 kW
Current 14.5 A 67 A 9.3 A
Speed 1500rpm 1450 rpm 940 rpm
1.3.2.2 SEAL OIL FILTER
Kind of filter Strainer-type filter

Type BFD (M/s Boll & Kirch)
Volumetric flow rate 12 m3/hr
Degree of filteration 100 microns
Pressure drop across filters 0.3 bar with clean filter /1.2 bar with 100 % blockage
Nos. of air side 2×100 % Capacity
Nos. of H2 side 2×100 % Capacity
1.3.3 PRIMARY WATER SYSTEM
Primary Water Pumps
Kind of pump Centrifugal pump

Make / Model M/s KSB /CPK-CM65-250 (S)
Capacity 70m3/hr
Discharge head 80 m
Motor make /Model Crompton greaves Ltd./ ND225 M
Power rating 37 kW /415 V
Speed 2950 rpm
MAIN FILTERS
Type of filters Strainer-type filters with magnet bars
Make M/s Boll & Kirch
Degree of filteration 150 mm
Nos. 2 ×100% capacity
Pressure drop across filters 0.1 bar with clean filter and 1.2 bar with 100% fouling
FINE FILTER
Type of filter 1 plug , 1 cartridge
Make M/s Boll & Kirch
Pressure drop across filter 0.15 bar with clean filter, 1.2 bar with 100 % fouling
Nos. 1×100% capacity
Ion Exchanger
Volume 83 litres
Resin Lewatit
Resin volume 56 litres (45 kg)
Nos. 1×100% capacity
57
1.4 TURBINE CONTROL FLUID SYSTEM
1.4.1 FIRE RESISTANT FLUID (FRF) SPECIFICATION
Flash point >235 ºC

Pour point ≤ 18 ºC
Neutralization Number ≤ 0.1 mg KOH/g
Ignition temp >550 ºC
Air release at 50 ºC ≤ 3 Minutes
Water content(By Weight ) ≤ 1000 mg/kg
Particle distribution 15/12 mini code
Foaming tendency at 25 ºc ≤100 ml
Foaming Stability ≤ 450 sec.
Kinematic viscosity at (40 ºc) 41.4 to 50.6 mm2/s
Solid particle content 0.05% (BY WEIGHT)
Density at (15 ºc) 1250 Kg/m3 max.
Oxidation Stability ≤2.0 mg KOH/g
Electrical Resistivity >50 MΩm
1.4.2 CONTROL FLUID TANK
Tank capacity 10/16 m3

1st fluid filling 15 m3
Flushing fluid capacity 12 m3
Highest fluid level from top of tank 650 mm
Lowest fluid level from top of tank 750 mm
1.4.3 REGENTRATIVE SYSTEM (C.F. PURIFICATION)
FILTERS (Make: HISCHE AG GERMANY)

Type of filter Purpose Number Design pr./ temp.
Drying To take off water 1 3 bar/ 80 ºC
Fuller Earth Neutralization of acidity 1 3 bar/ 80 ºC
Fine filter Fine filtration & security 1 3 bar/ 80 ºC
REGENTRATIVE SYSTEM (C.F. PURIFICATION PUMPS)
Number of Pumps 2x100 %
Type Gear Pump
Make & Model Tushaco RT 15 HBC 13 L
Fluid flow 15 lpm
Discharge pressure 3 bar
Speed 1410 RPM
MOTOR
Make CGL
Motor Power 0.55 kW
Current 1.44 Amps
Speed 1410 RPM
58
1.4.4 CONTROL FLUID PUMPS
Number of Pumps 2
Make KSB
Type WKV M80/1+3
Discharge pressure 11.5 bar/38.5 bar
Fluid flow 27.36/22.18 m3/hr
Motor
Make Siemens AG
Type ILG 4313-2AB94-Z
Rated current 224 Amps
Motor rating (at 50 ºC/40 ºC) 121/132 kW /415 V
1.4.5 C.F. VAPOUR EXTRACTION FANS
Make Air Link Pvt. Ltd.

Number of fan 2x100 %
Type / Size AHSH L1 /10
Capacity 60 CMH
Pressure Developed 60 mmwc
Motor Make Crompton Greaves
Power rating 0.55 KW
Current rating 1.29 Amps
Speed 2820 rpm
1.4.6 CONTROL FLUID COOLER
Number of cooler 2
Heat transfer area provided/cooler 31.4 m2
Fluid Flow /cooler 30.09 m3/Hr
Heat load on cooler 100% 90 KW
Temp. of fluid at inlet of cooler 60 ºc
Temp. of fluid at outlet of cooler 54 ºc
Fluid side pr. Drop 2.5 MWC
Temp. of cooling water at inlet of cooler (design) 38 ºc
Temp. of cooling water at outlet of cooler 39.29 ºc
Cooling water flow/cooler 60 M3/Hr
Pressure drop across the cooler on tube side 2.4 MWC
Tube (water) side design pressure 10 Kg/cm2
Shell (CF) side design pressure 13 Kg/cm2
Number of tubes 276
Length of tubes 2340 mm
Tubes material Stainless steel
Casing(shell) Stainless steel
Water box Carbon steel IS:2062
59
1.5 CONDENSER
1.5.1 CONDENSER SPECIFICATION
Make & testing agency BHEL

Type Double pass ,Single Shell
Total heat transfer surface area required/provided 30059/32367 m2
Total number of tubes 24398
Numbers of tubes which can be plugged without affecting 5%
condenser performance
Tube length between tube plates 13300 mm
Size of tubes (OD X Th.) 31.75X0.7112 mm x mm
Tube material SS 304 Welded
Design CW temp 33 ºc
Temp. rise of cooling water 10.05 ºc
Design CW quantity 54300 m3/Hr
CW side pressure drop 4.05 MWC
Designed heat load 546.16×10^6 K Cal/hr
Vacuum in the condenser with inlet water temp. of 33 deg. 77 & 89 mm Hg (abs)
And 36 deg.
Water box design/test pressure 5.0/7.5 kg/cm2
Water box material thickness 40 mm
No of tubes support plates 32
Total empty wt of condenser (Without LPH-1) 685 tonnes
Operating Wt. of condenser 1930 tonnes
Tube density (No of tubes per m2 of tubes sheet surface 460
area)
1.5.2 GLAND STEAM CONDENSER (GSC)
Manufacturer BHEL
Number off 1x100 %
Type & Arrangement Shell & tube type
Tubes material Welded SS, SA 249 TP 304
Shell, tube plates, water box material BQ Steel, IS:2002
Pipes, Partition Carbon Steel,IS:2062
Min /Max Condensate flow 220000/1324225 kg/hr
Pressure drop through water tubes 0.1/3.0 mwc
corresponding to above flows
Number of tubes 799
Tube outside dia. X thickness 16.0x0.889 mm x mm
Overall length of shell 1.44 m
Shell outer diameter 760 mm
Shell thickness 25.0 mm
Number of vent fans 2x100 %
Type of vent fan Centrifugal
Power absorbed by vent fan 3.0 kw (approx.)
Rated power vent fan motor 3.7 kw (approx.)
Rated capacity of vent fan 0.4 m3/sec
60
1.5.3 SEAL STEAM EXHAUSTER FANS
Make Air Link Engineers pvt. Ltd.

No. of fans 2X100%
Type AHSH
Head developed 310 mmwc
Capacity 1080 CMH
Speed 2880 rpm
Power rating 3.7 kW
Rated Currennt 7.25 Amps
1.5.4 DRAIN COOLER
Type Shell & Tube type (Straight tube)

Surface area (m2) 154.56
Size of tubes OD X Thk 19.05 mmx0.899mm
Number of tubes 675
Velocity of condensate (M/Sec.) 2.18
Number of tube side passes 1
Number of shell side zones 1
Design pressure on shell side (kg/cm2)(g) 3 & full vacuum
Design temp on shell side (ºc) 120
Design pressure on tube side(kg/cm2)(g) 40 &full vacuum
Design temp on tube side (ºc) 144
Test pressure on shell side (kg/cm2)(g) 4.5
Test pressure on tube side(kg/cm2)(g) 52
Materials
Shell SA516 Gr.70
Flanges SA 105
Support plates IS 2026
Tubes SA 249 TP 304
Weights
Dry Kg. 4800
Operational Kg. 7200
Flooded Kg. 7200
1.6 LP HEATERS
1.6.1 LP HEATERS SPECIFICATION
HEATER-1 HEATER-2 HEATER-3

Type U-Tubes/ U-Tubes/ U-Tubes/ horizontal
horizontal horizontal
Surface (m2) 984 1337 847
Size of tubes ODX Thk 19.05 mm X 20 19.05 X1 mm 19.05 X1 mm
BWG
Number of tubes 717 “U” 917 “U” 725 “U”
Velocity of condensate 1.98 1.57 2.00
(M/Sec.)
61
Number of tube side passes 2 2 2

Number shell side zones 1 2 2
Design pressure on shell side 3 & FULL 3 & FULL 4 & FULL VACUUM
Kgf/cm2 (g) VACUUM VACUUM
Design temp on shell side (ºc) 120 155 216
Design pressure on tube 39 & FULL 40 & FULL 40 & FULL
side(kgf/cm2)(g) VACUUM VACUUM VACUUM
Design temp on tube side 150 152 152
(ºc)
Materials
Shell channels SA 516 GR 70 SA 516 GR 70 SA 516 GR 70
Tube plats & covers SA 516 GR 70 SA 516 GR 70 SA 516 GR 70
Flanges IS:2002 GR2 SA 105 SA 105
Support plates IS 2062 IS 2062 IS 2062
Tubes SA 688 TP 304 SA249TP304 SA688TP304 0.05%
Carbon (max)
Impingement plates SS 304 or EQ SA240 Gr.304 SA240 Gr.304
Weights
LP Heater empty Kg. 23000 Kg. 26000 Kg. 18000
LP Heater in Operation Kg. 26800 Kg. 33000 Kg. 24000
LP Heater Flooded Kg. 39500 Kg. 43000 Kg. 31500
1.7 DEAERATOR & FST
1.7.1 DEAERATOR SPECIFICATION
Make BHEL Hyderabad

Type Spray cum Tray
Design & construction standard ASME Sec VIII Div. I 2004,add.2006 & HEI 98
Design pressure kgf/cm2(g) 9.0 & Full Vacuum
Design temperature (ºc) & 360 (max)/0(min)
Design vacuum (mm of Hg ) & 760 mm of Hg
Hydrostatic test pressure (kg/cm2) 11.7
Number of trays 576
Number of spray valves 108
Shell diameter & thickness (mm) 3000 ID & 16
Straight length & overall length of 8450 & 10614
shell(mm)
Type of dished end & thickness 2:1 ellipsoidal 16 (min)
Material of construction
Header & dished end SA 516 GR 70
Trays SS 304
Packing CAF
Nozzles SA106 Gr B
Restricting orifices SS 304
Vent pipes SA 312 TP 321
62
1.7.2 FEED WATER STORAGE TANK
Capacity 170 M3
Shell diameter & thickness (mm) 3600 ID & 18
Straight length and overall length of shell (mm) 35970 & 38795
Type of dished end & thickness(mm) 2:1 ellipsoidal 18.0 (min)
Storage tank shell & dished end SA 516 GR 70
Type of storage tank support to mount to the Saddle support (sliding & fixed)
Deaerator on floor
Number of supports on the storage tank 2 sliding &1 fixed
WEIGhTS
Storage tank & Header dry 115.4 Tonnes
Storage tank & Header in operation 367.6 Tonnes
Storage tank & Header flooded 558.7 Tonnes
Water level from center line of horizontal vessels (mm)
Normal 457 Above
Low 20 Above
Low- Low 990 Above
High 1000 Above
High- High 1200 Above
1.7.3 DEAREATOR SAFETY VALVE
Manufacture BHEL Trichy

Type Spring loaded
Nos. provided 6 nos.
Size 8”/10”
Capacity of each at 10% accumulation 60000 kg/hr
Set pressure (kg/cm2) (g) 8(for 2 nos.),8.5 for 2 nos. ),9.0 (for 2 nos.),
Blow down pressure (kg/cm2(g)) 7.2 7.6 8.1
1.8 HP HEATERS
1.8.1 HP HEATERS SPECIFICATIONS
5A/5B 6A/6B
Manufacturer BHEL, Hyderabad
Type and arrangement U-Tube/Horizontal U-Tube/ Horizontal
Number of U-tubes 1181 1181
Velocity of feed water (M/Sec.) 2.15 2.17
Number of tube passes 2 2
Number of shell side zones 3 3
Design pressure on shell side (Kg/cm2) 24 & Full vacuum 57 & Full vacuum
Design temp on shell side(ºc) 224 273
Design pressure on tube side (Kg/cm2) 330 & Full vacuum 330 & Full vacuum
Design temp on tube side (ºc) 330 330
Skirt design temp(ºc) 224 273
Materials
Shell channels SA 516 GR70 SA 516 GR70
Tube plats & covers SA350LF2 with SS SA350LF2 with SS
OVERLAY OVERLAY
63
Flanges SA 105 SA 105

Support plates SA516 Gr.70 & IS 2026 SA516 Gr.70 & IS 2026
Tubes SA 688 TP 304 SA 688 TP 304
Condensate Inlet/Outlet nozzles SA 106 Gr B C.S SA 350 LF 2
Steam Inlet nozzles SA350LF2&SA106Gr.B SA350LF2&SA106Gr.B
Impingement plate SA 240 TP 304 SA 240 TP 304
Weights
HP Heater dry Kg. 44500 Kg. 54000
HP Heater in Operation Kg. 49000 Kg. 59300
HP Heater Flooded Kg. 59080 Kg. 70700
1.9 LP DOZING SYSYTEM
1.9.1 LP DOZING PUMPS
No. of Pumps 2 Nos. Ammonia dozing & 2 Nos. Hydrazine dozing Pumps
Make METACHEM Dosing pumps
Model MC-2RL
Capacity 53 lit/hr
Disch. pressure 45 Kg/cm2
Power rating 0.75 kW (415 V)
Rated current 1.81 amp.
RPM 1410
1.9.2 TANK DETAILS
Measuring Tank Mixing cum Storage Tank

Quantity 1 1
Capacity 30Liters (Hydrazine) 2300 Liters Both
125Liters (Ammonia)
Material of construction SS-304 SS-304
Type of tank Vertical Cylindrical Conical Vertical Cylindrical Conical
bottom tank bottom tank
1.10 CENTRAL LUB OIL STORAGE & PURIFICATION UNIT
1.10.1 OIL TANKS
Clean oil tank Dirty oil tank Unloading tank

No. of tanks 1 1 1
Capacity 60m3 60 m3 1 m3
1.10.2 Oil Transfer Pumps
Clean oil transfer Pump 1 no. for transferring oil from clean oil tank to
Any of unit oil tank.
Dirty oil transfer Pump 1 no. for transferring oil from Dirty oil tank to
Central oil purifier.
64
Pump
Pump Make Tushaco Pumps Pvt. Ltd.
Model No. R-50-EG
Speed 1430 RPM
Flow 137.5 LPM
Disc. Pressure 2 Kg/cm2
Motor
Motor Make Crompton Greaves Pvt. Ltd.
Speed 1430 RPM
Motor Rating 3.7 kW /415 V
Rated Current 7.39 Amps
1.10.3 Central Oil Purifier
No. of units One

Make Alfa Laval
Type MAB 206 S-24
Speed of Bowl (Max) 8423 RPM
Max. hydraulic capacity 10,600 lit/hr
Recommended oil flow (for best performance) 7500 lit/hr at 65 °C
Centrifuge drive Motor rating 11kW (AC)
CENTRIFUGE FEED PUMP
Type Positive displacement
Capacity 8250 LPH
Speed 1450 rpm
Discharge pressure 1.5 kg/cm2
Max allowable pump pressure 4.0 kg/cm2
CENTRIFUGE MATERIALS
Bowl body SS Alloy AL 111 2377
Bowl head SS Alloy AL 111 2377
Separating discs AISI 316
Drive shaft EN 8
Gear / Worm Tin bronze /EN 8
Oil injection nozzle AISI 316
1.11 HP BYPASS SYSTEM
10.11.1 OIL SUPPLY UNIT
Oil tank Capacity 70 ltr.

Pump Manufacturer DENISON HYDRAAULIC
Model T-7B-B05-2R00 AIMO
Supply Capacity 24 Ltr./min
System operating pressure 110 bar
Speed 1440 RPM
Maximum oil pressure 170 Bar
Motor Make Kirloskar
Normal Power 7.5 kw / (415 V)
Hydraulic Accumulator
Manufacturer BOSCH.
Volume 31 Ltr.
65
Pressure 210 bar (max)

Operating gas Nitrogen only
Bladder material Nitrile (Synthetic rubber )
1.11.2 VALVE DATA FOR HP BYPAS SYSTEM
BD BPE1, BPE2 BP-1, BP-2

No. of valves 1 2 2
Valve type E45S E45S ARS 140 A
Design pressure kg/cm2 321 321 189.5/55
Design temp ºc 185 185 545/500
1.12 LP BYPASS SYSTEM
1.12.1 OIL SUPPY UNIT
Oil tank capacity 630 litrs

Manufacturer Welland and Tuxhorn AG
No. of OSU pump 2×100 %
Pump type Radial piston pump
Purpose Supplies the necessary pressure and massflow of control
fluid to actuate @ combined LP bypass stop and control
valves and corresponding cooling water control valves
Operating pressure 160 bars
Motor make AC-Motorn GmbH
Motor power 11 kW
Speed 1460 rpm
Current 216/125 A
Regeneration pump 1×100 %
Purpose To reduce acid and remove water and mechanical
impurities
Recirculation pump 2×100 %
Purpose Installed on top of HPSU frame two filtration-cum-cooling
units in order to keep CF at optimal operating temp.
Accumulator 6 Nos.
Purpose Works as buffer for any pressure peaks that’s occurs &
ensures at least two complete opening and closing can be
performed with them
1.12.2VALVE DATA FOR LPBP VALVES
NO. OF VALVES 2 LPBP stop and control valves and two corresponding
water injection valve.
Body material SA217C12A
Type of construction Angle type
Design pressure 50.40 bar
Design temp. 568 ºC
66
2.1 CONDENSATE EXTRACTION PUMP

Make BHEL-HYDRABAD
No. of pumps/Model No. 3 (50% duty )/ EN6J40/500
Type of first Impeller Double suction Radial
Number of stages 6
Design flow rate 785 m3/hr (775894 kg/hr)
Inlet temperature 49.2 ºc
Inlet Specific gravity 0.98884
NPSH required (3% head break down) 3.05 Meters
Discharge pressure 28 ata
Total dynamic head 270 Meters
Shut off head 353 Meters
Pump speed 1486 RPM
Minimum condensate flow for continuous stable 300 m3/hr
operation
Suction strainer size 400 µ
Peripheral speed at the eye of first stage 19.21 m/s
impeller
Critical speeds(RPM) 3380, 5798
Bearing
Radial bearings Type & no. Cutless rubber , 8 no.
Size 100 mm
Lubrication
Condensate
Thrust bearing Location In pump
Type and no. Tilting pad,1 no.
Design load
2732 kg
Maximum load
6038 kg
Motor
Make BHEL , BHOPAL
Motor type SCIM
Type of duty Continuous
Standard continuous rating at 40/50 ċ ambient 962 kW/900 kW
temp.
Rated voltage 11 kV
Rated speed 1492 rpm
Full load / No load current 58 amps / 18 amps
67
2.2 BOILER FEED PUMP AND AUXILIARIES
2.2.1 BOILER FEED PUMP
MDBFP
Manufacturer BHEL/HYDRABAD
Model No. FK 4E36
No. of pumps 1X50%
No. of stages 4+1 Kicker stage
Casing type Outer-Barrel, Inner-Radially spilt
Casing design pressure and minimum wall thickness 356 kg/cm2 ,126mm
Suction temp. ºc 163
Discharge temp. for main pump ºc 163
Suction pressure (booster) kg/cm2 9.292
Discharge pressure for booster pump kg/cm2 27.8
Discharge pressure for main pump kg/cm2 213.2
NPSH at 3% head break down (m) 50
Sp. Gravity of feed water at inlet 0.9043
Booster/main pump suction flow (kg/hr) 895257
Normal recirculation flow m3/hr 400
Shut off head (BFP+BP) at RC flow (m) 2864
Efficiency of main pump (MD & TD) 81%
Efficiency of drive motorat 100% load 97.4%
Overall efficiency of pump set(MD&TD) 67.5 %
Pump speeds (Design condition)
Main pump (MD & TD) 5465 rpm
Booster pump (MD & TD) 1495 rpm
Power consumption at design condition:
Main pump input (MD&TD) 6171 kw
Booster pump input (MD&TD) 613 kw
Losses in hydraulic coupling (MDBFP) 624 kW
Losses in step up gear box (MDBFP) 451 kW
Total input required at motor shaft (MDBFP) 7859 kW
2.2.1.1 JOURNAL BEARINGS
Type Thick wall Babbitt lined

Journal bearing –size (dia) 130-DE, 110-NDE
Journal bearing –length 100-DE, 80-NDE
Journal bearing clearance 150 Microns
Bearing lubrication type Pressurized oil
Required flow per journal bearing 0.42 m3/hr
Bearing temp.(max) 80°C
68
2.2.1.2 THRUST BEARINGS
Type Tilting pad

Thrust bearing design capacity 14.45 tonnes
% of axial thrust carried by the thrust bearing 5%
Bearing lubrication type Pressurized oil
Required flow per journal bearing 13.44 m3/hr
Bearing temp. (max) 100°C
2.2.1.3 MECHANICAL SEAL

Make / Type Burgmann / Cartridge type Mechanical
Material of rotating /stationary faces SILCAR-1/N17 carbon
Medium to be sealed Boiler feed water
Pressure to be sealed 25 bar
Stuffing box cooling By pump jacket cooling
Axial movability of M.S. ± 2 mm
Safe operating temp. <55 °C at seal outlet
2.2.1.4 SEAL COOLER

Type WED3110/A100
Design Temperature Shell-150 ºc Tube-150 ºc
Cooling water flow rate 6 m3/hr
Seal water flow rate 3 m3/hr
2.2.1.5 MAGNETIC FILTER

Type MAF2000/NPT ½-00
Maximum operating pressure bar 63 63 BAR
Test pressure 82 BAR
Maximum operating temperature 150 ºc
Volume 0.3 LTRS
2.2.2 BOOSTER PUMP
SPECIFICATIONS MDBFP TDBFP

Manufacturer BHEL-HYDRABAD BHEL-HYDRABAD
Model No. FA1B75 FA1B75
No. of pumps 1X50% 1X50%
Casing type Horizontal spilt, Volute Horizontal spilt, Volute
Direction of rotation (from drive end) CW CCW
Suction temp (ºc) 161.7 161.7
Suction pressure(bar) 9.08 9.08
NPSH required (3% head break down) 4.5 4.5
Discharge pressure (BAR) 27.8 27.8
Pump speed RPM 1495 1495
POWER consumption KW 614.14 614.14
Efficiency (%) 81.5 81.5
69
2.2.3 HYDRAULIC COUPLING OF MDBFP
Manufacturer M/S VOITH, Germany

Type Hydrodynamic (Geared variable speed)
R18 KGS-14 API
Rotation seen in direction of power flow Input shaft Hydr. shaft Output shaft
CCW CW CCW
Gear ratio U1 109/32
U2 62/53
Primary speed 5092 RPM
Secondary speed 4975 RPM
Full load slip 2.30%
Max output speed 5820 RPM
Regulation range 4:1 downwards
Bearing temp <90ºc
2.2.4 LUB OIL SYSTEM FOR MDBFP
2.2.4.1 LUBRICATING SPECIFIACTION
Oil reservoir filling capacity 2500 L

Brand name ISO VG 32
Capacity of lube oil tank 2.5 M3
Working oil flow rate 1300 L/min (max.)
Lube oil flow rate to hyd. coupling 550 L/Min
Total Lube oil flow rate 300 L/Min
(for pps, coupling & motor)
Lube oil pressure 1.5 to 3.0 bar
Control oil pressure 3 to 4 bar
Working oil pressure 1.6 to 2.1 bar(max)
Working oil flow rate 1300 L/Min
2.2.4.2 OIL COOLERS
Working oil Lube oil

Type Voith , Germany Voith , Germany
Type of cooler (Duplex) L1 N1 13 17 13-D L1 N1 09 19 13-D
Fluid medium Oil-shell side, Oil-shell side, water
water – tube side – tube side
Oil flow rate 78 m3/hr 51 m3/hr
Cooling water flow 120 m3/hr 75 m3/hr
2.2.4.3 LUBE OIL PUMPS
Auxiliary oil pumps Main oil pumps

Manufacturer VOITH/Germany VOITH/Germany
Type Gear Centrifugal
Pump drive AC motor Shaft driven
Rated head bar 4.0 4.0
Motor make ASEG -
Motor type DE 200 LA2 -
Power rating 30 Kw -
Rated capacity 820 LPM 820 LPM
70
2.2.4.4 LUBE OIL REQUIREMENT IN BEARINGS
BFP Booster pump

Journal Thrust Journal Thrust
Oil flow (LPM) 18 (total) 224 10 (total) 12
Oil pressure (bar) 2.5 2.5 2.5 2.5
Drive motor(LPM) 17.8 (total)
2.2.5 BFP DRIVE MOTOR
Type SCIM
Manufacturer BHEL BHOPAL
DOR from DE Side CW
Rated voltage /Frequency 11KV/50Hz
Power rating 10 MW
A rated voltage & frequency
(a) Full load current 605 AMPS
(b) No load current 135 AMPS
2.2.6 TDBFP LUBE OIL SYSTEM
2.2.6.1 GENERAL
Oil brand name Servo prime 46

Oil supplier IOC
Main oil tank Capacity 10 M3
Lube oil pressure to brg 0.9 to 1.3 bar for journal brg
0.3 to 1.3 bar for thrust brg
Lube oil header pressure at (17m) 2 to 2.5 bar
2.2.6.2 LUBE OIL COOLERS
Manufacturer BHEL
No of coolers 2X100 %
Type Shell & Tube
Oil flow rate 46.53 m3/hr
Water flow rate 100 m3/hr
No. of tubes per cooler 436
Design pressure shell side /tube side 13.5 Kg/cm2 / 10 ksc
Tube length 4000 mm
Inlet/Outlet oil temp 60 ºc / 45 ºc
Inlet/Outlet water temp 38 ºc /41 ºc
Empty weight 5700 kg
Working weight 6800 kg
Flooded weight 7200 kg
71
2.2.6.3 OIL PUMPS SPECIFICATIONS
Aux. oil p/p DC oil p/p (EOP) Jacking oil pump

Numbers 2 1 1
Make Tushaco pumps Kirloskar Ebara Tushaco pumps
pumps Ltd.
Type Screw Centrifugal External gear (HPG2A)
RPKEM 50-200
Capacity (LPM) 2500 415 9
Rated head(kg/cm2) 11.6 4.5 100.0
Speed (RPM) 1480 2900 1450
Drive A.C. Motor D.C. Motor A.C. Motor
Motor make Crompton Greaves Kirloskar Crompton Greaves
Voltage (v) 415 220 415
Power (kw) 90 11 3.7
Rated current 147 A 59 A 7.389 A
DOR CW From DE CW from DE CW from NDE
2.2.6.4 OIL VAPOUR EXTRACTOR FAN

Make Patel airflow ltd.
Model LP. 10.25
Capacity 0.11 M3/S
Head 100 mmwc
Speed 2880 RPM
Motor Details
Make Bharat Bijali
Rating 0.37 kw
Voltage 415 v
Current 0.810 A
Speed 2880 RPM
2.2.7 OIL PURIFIER (CENTRIFUGE)

Make GEA Westfalia Separator Group
Solid holding space (total) 1.6dM3
Speed 12000 RPM
Rated output 3000 Litrs./hr
Pressure head 1-2 bar
Motor
Power rating 4kW
Voltage 415 v
Speed 3000 rpm
Seal water requirement 0.5 l
2.3 VACCUM PUMP
2.3.1 GENERAL
Make Edwards Ltd UK
Duty Condenser air evacuation
Type Liquid ring pump
Model SHR 22500
72
2.3.2 DESIGEN AND PERFORMANCE
Codes & Slanderers HEI

Capacity in free dry air at slandered 30 SCFM (Standard cubic feet per minute)
condition with condenser operating at design
pressure of 1” (25.4 mm) of Hg-abs & sub
cooled to 4.17 ºc with inlet CW temp of 12.8 ºc
Hogging capacity at 10 Hg-abs at condenser 80 SCFM@ 15 ºc
CW temp of 15 ºc & 33 ºc 80 SCFM@ 33 ºc
Discharge pressure Above atmospheric
Operating liquid Water at 15 ºc temp
DOR (For NDE) Clockwise
Cooling water required 50.3 m3/hr.
Cooling water pressure drop(across heat 2.70 MCW
exchanger)
Sealing water flow 71 m3/hr.
Sealing water pressure drop(across 3.83 MCW
heat exchanger)
2.3.3 VACCUM PUMP DETAILS
No. of PPs 2
No. of Stages 2
Pump rated speed 585 RPM
Rotor vane tip speed 19.4 M/Sec
Seal water heat exchanger Shell and tube type
Range of CW inlet temp 12-37 ºc
Heat transfer area 22 m2
2.3.4 SEAL WATER RECURCULATING PUMP
Make Lowara
Type Centrifugal
Model 40-125/15 SP
Design capacity 21 m3/hr.
Total developed head at design capacity 10 MWC
Shut off head 14 MWC
Power absorbed 1.3 kw
Motor rating 1.5 kw
2.3.5 HEAT EXCHANGER
Make Funke
Type of tubes straight
No. of passes 2
Tube size (O/D×thickness×length) 16 mm×1 mm×4000mm
Tube material ASTM A249 TP316L
Shell material ASTM A106 B
73
2.4 TG EQUIPMENT COOLING WATER SYSTEM
2.4.1 DMCW PUMPS
Make WPIL Ltd

Type 12 LN 14 A
No of pumps 3
Total head 38 MWC
Shut of head 53 MWC
Rated capacity 1250 m3/hr.
Range of operation of pump Min-375 m3/hr : max - 1625 m3/ hr
Speed 1485 RPM
Coupling type between pump motor Flexible
Motor
Make BHEL BHOPAL
Power rating 180kW/3.3 kV
Rated full current 40 amp
2.4.2 PLATE HEAT EXCHANGER (PHEs)
Manufacturer IDMC LIMITED

Model no./Type S-188 IS
Flow pattern Counter current
Design pressure 10 bar
Design temperature 60 ºC
Heat load 5940000 KcL/hr.
LMTD 2.0 ºC
Packed length 1490 mm
Total eff. heat transfer area per HE(M2) 651.3
Area of each plate (M2) 1.964
Plate dimension (mmXmm) 868×2508
Thickness (mm) 0.6
Material SS 316
No of plates per heat exchanger 468
Primary (DM) side Secondary (ACW) side
Flow rate (m3/hr.) 1100 1100
Inlet temp (ºc) 43.4 36
Outlet temp (ºc) Cleaned 37.8 41.60
Fouled 38.0 41.4
Pressure drops across heat exchanger from inlet to outlet (MWC)
For designed flow 7.0 7.0
For 110 % design flow rate 7.95 7.95
Film heat transfer co-efficient(Kcal/hrm2ºc) 11336 1336
Flouncing factor (m2hr ºc/Kcal)) 0.00008 0.00008
Over all heat transfer co-efficient (Kcal/hrm2ºc)
In Cleaned condition 4383
In Fouled condition 3245.128
Average velocity (m/sec) through-ports 4.18 4.18
Plate channels 0.5 0.5
74
2.4.3 TG ECW -OVER HEAD TANK

Supplier BHEL
Capacity 10 m3
Empty weight 6 tones
Flooded weight 26.85 tones
Design temp. 70 ºc
2.5 SG EQUIPMENT COOLING WATER (SGECW)

Manufacturer WPIL Ltd
Model no. 8 LN 18 C
No. of pumps 2 (1 W + 1 S) per unit
Rated capacity 575 m3/hr
Total dynamic head at rated capacity 65 MWC
Shut off head 74.8 MWC
Range of operation of pump Min-172.5 m3/hr ; Max- 747.5 m3/hr
Pump rated speed 1485 rpm
Type of pump casing Horizontally axial Split casing
Type of coupling between pump and motor Flexible coupling
Motor
Make ABB
Power rating 132 kw/415 V
Rated full load current 267 amp
2.6 AUXILIARY COOLING WATERE SYSTEM (ACW)
2.6.1 ACW PUMPS & MOTOR
No of pumps 3 (2 W +1 S)
Make WPIL L TD.
Model No 14 LN 19 A
Total head 17 MWC
Rated capacity 1700 M3/hr.
Speed 987 rpm
Motor
Make Marathon Electric Motors (India) Ltd.
Power rating 125 kW/415 V
Rated current 215.6 amp
2.6.2 SELF CLEANING FILTER
2.6.2.1 STRAINER
Number 2(1w+1s)
Fluid handled Clarified water
Make Gea bgr energy system India ltd.
Filter type/Duty type Online/continuous
Location ACW pump discharge
Normal /Max flow rate 3400/4080 m3/hr.
Operating pressure 3 to 3.5 bar(g)
Design pressure 7 kg/cm2(g)
Design temperature 60 ºc
Design differential pressure for filter 1.5 bar( minimum)
section/screen
75
2.6.2.2 WORM PALENTARY GEAR
Make Bonfigilo
Model 3/VF 01 L3 127 HC HS AF
Design temperature 60 °C
Input speed 196 rpm
Output speed 1.54 rpm
2.7 CONDENSER ON LOAD TUBE CLEANING SYSTEM (COLTCS)
2.7.1 GENERAL INFORMATION & DESIGN DATA
Make Multitex Filteration Engineering Ltd.

No. of condenser on load tube cleaning system Two (02) nos. viz. one independent set for
sets required for unit each half of Condenser
Liquid handled Clearified water
Operating pressure at Condenser Inlet flange 1.5 to2.0 (approx..) Kg/cm2(g)
Design pressure for ball separator 5.0 kg/cm2 (g) & vacuum 0.1 kg/cm2
Test pressure 7.50 Kg/cm2(g)
Maximum pressure drop across ball separator 0.15/0.30 MWC
in clean /choked condition
No. of balls required per COLTCS for 610
recirculation
No. of balls losses in 1000 hrs of normal It will be within 10% of no. of balls charged
operation
2.7.2 CLEANING BALL DETAILS
Make Klump & Koller , Germany

Normal ball 32- SL-1 (dia 32 mm)
Abrasive ball 31-RL-1 (dia 31mm)
Material Natural rubber
Required no. of balls per charge 10% of no. of tubes per pass (610)
Combination of no. of balls per charge Normal balls-458 : abrasive balls-152
2.7.3 BALL RECIRCULATING PUMP
Make Multitex Filteration Engineering Ltd.

Type Non clogging solid handling centrifugal pump
Quantity 1 per COLTCS
Rated flow 60 m3/hr
Differential head 16 MWC
Efficiency 68 %
Type of sealing Gland packing( Teflon impregnated)
Motor rating 5.5 KW
76
3.0 DM WATER AND CPU REGENERATION SYSTEM
3.1 NORMAL MAKEUP SYSTEM
No. of Pumps 3
Make SAM Turbo Industries Pvt. Ltd.
Pump type 4 TU 14
Capacity 85 m3/hr
Designed Head 60 m
Motor
Make M/s Crompton Greaves ltd.
Rated power 22 kW (415 V)
Speed 1450 rpm
Full load current 40 amp.
3.2 EMERGENCY MAKEUP SYSTEM
No. of Pumps 2
Make Mather and Platts Pumps Ltd.
Designed Head 70 mtrs
Rated flow 300 m3/hr
Motor
Rated power 90 kW (415 V)
Rated current 146 amps
Speed 1475 rpm
3.3 BOILER FILL PUMPS
No. of pumps 2
Make/Type Sam Turbo / 6 MD 125/305
Capacity 175 m3/hr
Head 150 mtrs
Motor
Rated power 110 kW
Rated current 175 amps
Speed 1450
3.4 DM TRANSFER PUMPS
Purpose: For filling of DM and Condensate storage tanks from Stage-II DM plant
No. of Pumps 2
Make/ Model Kirloskar Brothers Ltd / KPD 100/40
Design Head 50m
Rated flow 150 m3/hr
Motor
Make ABB
Rated power 37 KW
Rated current 67 A
Speed 1470 rpm
77
3.5 DM WATER STORAGE TANK
Capacity 1800 m3
ID 14000 mm
OD 14120 mm
Working height 10.5 m
3.6 DM WATER PUMP FOR REGENERATION
No. 2
Make Mather & Platts
Capacity 45 m3/hr
Discharge head 25 mtrs
MOTOR
Make Crompton Greaves Ltd.
Power rating 7.5 kW
Rated current 15.4 amps.
Speed 1455 rpm
3.7 RESIN TRANSFER PUMP
NOS. 2
MAKE Mather & Platts
Capacity 45 m3/hr
Discharge head 75 mtrs.
MOTOR
Make Crompton Greaves Ltd.
Power rating 22 kW
Rated current 39 amps.
Speed 1475 rpm
3.8 EFFLUENT NEUTRALISATION AND WASTE DISPOSAL SYSTEM
Neutralization Pit
Nos. 2
Size 10m X 5m X 4.5m
Pumps
Details Waste recirculation cum Recirculation cum disposal
disposal pumps pump for resin transfer waste
water
Nos. 3 2
Make SU Chemical pumps Mather & Platts
Capacity 80 m3/hr 15 m3/hr
Discharge head 40 mwc 10 mwc
MOTOR
Make Crompton Greaves Ltd. ABB
Power rating 37 kW (415 V) 3.7 kW (415V)
Rated current 68 Amps. 7.3 Amps.
Speed 1475 rpm 1450 rpm
78
4.0 COMPRESSORS
Make Atlas Copco (India) Ltd

Model & Type ZR 275 / Oil Free Water Cooled
Quantity Instrument Air Service Air
03 (2 Working + 1 Standby) 02 (Both working)
Capacity as per design criteria 36 NM3/MIN.
Disch Pr at After Cooler Outlet 8.0 kg/cm2(g)
Disch Pr at Drier Outlet 7.5 kg/cm2(g)
Capacity considering design ambient 46.7 m3/min FAD (free air discharge)
condition
Outlet air temperature after high 160 to 180 0C
pressure stage
Outlet Air Temperature 45 0C
KW input required at rated condition 290 KW
KW input required at unload condition 59 KW
Total Cooling water requirement 7.75 litre/second
considering delta T of 10 degrees
Type of Drive Gear
Bearing Type / lubrication Antfriction /Force Feed
Air Intake filter Dry type Paer (99.99% with particle size 3 micron)
Motor
Rated power and voltage 320 KW & 3.3 KV
Full load/ No load current 66 A /19 Amps
Power factor at duty point 0.89
Starting time - compressor coupled 1.8 secs
Bearings DE- 6220 C3; NDE- 6220-C3
Lubrication Grease (Life- 50000 hrs)
Compressed Air Drier
Make Atlas Copco Airpower, Belgium
Model MD 600 W
Type of Operation Continuous
Rated Flow 36 NM3/MIN.
Dew point at Drier Outlet -40 degree C
Maximum Electric power input 120 W
Cooling Water Consumption wrt 5 2.5 litre/second
degree water temp rise
Air Pressure Drop 0.3 bar
79
TECHNICAL DIARY
Electrical systems

HARENDRA SINGH GURJAR SUSHIL KUMAR M K SINGH
STAGE-3 TECHNICAL DIARY (ELECTRICAL)
CONTENTS
1.0 Transformers 80
1.7 Coal Handling Transformer (CHPT)
1.9 Unit Service Transformer (UST)
1.12 Fire water Transformer
1.13 Raw water Transformer
1.15 PT Service Transformer
2.0 Breaker 84
2.1 400 KV Switchyard breaker
2.2 11KV and 3.3KV MV Switchgear breaker
2.3 415V LT switchgear Breaker
79
1.0 Transformers

Manufacturer M/S CGL
MVA 200
KV (no load ) HV 420
KV (no load) LV 21
Amperes HV 824.8
Amperes LV 9523.8
Type of Cooling ODAF
Vector Group YNd11

MVA 80
KV (no load ) HV 400
KV (no load) LV1 11.5
KV (no load) LV2 11.5
Amperes HV 115.5
Amperes LV1 2008.2
Amperes LV2 2008.2
Type of Cooling ONAF
Vector Group YNyn0yn0

MVA 45
KV (no load ) HV 21
KV (no load) LV 11.5
Amperes HV 1237.2
Amperes LV 2259.2
Type of Cooling ONAF
Vector Group Dyn1

Manufacturer M/S Areva
MVA 16
KV (no load ) HV 11
Amperes HV 839.8
Amperes LV 2677.6
Type of Cooling ONAN
Vector Group Dyn1
80

MVA 16
KV (no load ) HV 11
Amperes HV 839.8
Amperes LV 2677.6
Vector Group Dyn1

MVA 7.5
KV (no load ) HV 11
Amperes HV 393.6
Amperes LV 1255.1
Vector Group Dyn1
1.7 Coal Handling Plant Transformer (CHPT)

MVA 7.5
KV (no load ) HV 11
Amperes HV 393.6
Amperes LV 1255.1
Vector Group Dyn1
Manufacturer M/S Vijay

MVA 2
KV (no load ) HV 3.3
Amperes HV 349
Amperes LV 2666
Vector Group Dyn11
1.9 Unit Service Transformer (SST)
Manufacturer M/S Vijay

MVA 2
Amperes HV 349
Amperes LV 2666
81

Vector Group Dyn11

MVA 1.6
Amperes HV 279.9
Amperes LV 2133.4
Vector Group Dyn11

MVA 1
Amperes HV 174.9
Amperes LV 1333.4
Vector Group Dyn11
1.12 Fire Water Transformer

MVA 2
Amperes HV 349.9
Amperes LV 2666.7
Vector Group Dyn11
1.13 Raw Water Transformer

MVA 1
Amperes HV 174.9
Amperes LV 1333.4
Vector Group Dyn11
82

MVA 1.6
Amperes HV 279.9
Amperes LV 2133.4
Vector Group Dyn11
1.15 PT Service Transformers

MVA 1
Amperes HV 174.9
Amperes LV 1333.4
Vector Group Dyn11

MVA 1
Amperes HV 174.9
Amperes LV 1333.4
Vector Group Dyn11

MVA 1
Amperes HV 174.9
Amperes LV 1333.4
Vector Group Dyn11

MVA 1
83

Amperes HV 174.9
Amperes LV 1333.4
Vector Group Dyn11
2.0 Breaker
2.1 400KV Switchyard breaker
Manufacturer M/S Areva T&D India LTD

Type of Circuit Breaker SF6
Rated Voltage 420 KV
Rated Current 3150A/2000A
Closing time 110 ms (max)
Maximum opening time 20 ms
Short time current rating (1 sec) 50 KA
Rated operating duty O-0.3S-CO-3min-CO
Rated pressure of SF6 in operating 0.75MPa(abs) at 20C
chamber
2.2 11KV and 3.3KV MV switchgear breaker
Manufacturer M/S ABB

Type of Circuit Breaker SF6
Rated Voltage 12 KV
Rated Current 3150A/1250A
Maximum closing time 75 ms (max)
Maximum opening time 50-60 ms
Rated operating duty O-3min-CO-3min-CO
Rated pressure of SF6 in operating 3-3.5 bar (Abs.)
chamber
2.4 415V LT switchgear breaker
Manufacturer M/S GE India

Type of Circuit Breaker AIR Circuit Breaker
Rated Voltage 415 V
Rated Current 3200A/2500A/1600A
Maximum closing time 70 ms (max)
Maximum opening time 60 ms
Rated operating duty O-3min-CO-3min-CO
84
STAGE-3 TECHNICAL DIARY (OFFSITE)
TECHNICAL DIARY
OFFSITE & COMMON SYSTEMS
ABHISNEH KUMAR SUSHIL KUMAR M K SINGH

85
CONTENTS
1. CW system Page No.
1.1 CW pump 88
1.2 CW motor 89
1.3 Electro hydraulic actuator 91
1.4 EOT crane 92
2. SACW system
2.1 SACW pump 93
2.2 SACW motor 94
2.3 EOT crane 95
3. Cooling tower
3.1 Thermal design calculation 95
3.2 Blades 96
3.3 Gearbox 96
3.4 Motor 97
3.5 Sludge pump 98
4. Raw water system
4.1 Pump 98
4.2 Motor 100
4.3 Lube water system 101
5. Fire water system
5.1 General 102
5.2 Diesel engine 102
5.3 Pump 104
5.4 Motor 105
5.5 Foam system 106
5.6 Sprinkler system 108
6. PTCW
6.1 PT Clarifier 108
6.2 Clarifier water system
6.2.1 Clarified water makeup system 109
6.2.2 HVAC makeup system 110
6.2.3 Potable water system 111
6.3 Pressure filter 111
6.4 Sludge disposal system 111
6.5 ETP(Effluent Treatment Plant) system
6.5.1 Waste water pump 112
6.5.2 Treated Effluent Disposable pump 113
6.5.3 ETP clarifier 113
6.6.1 Service water pump 114
6.6.2 APH wash water pump 114
86
6.7 Chemical dosing system

6.7.1 Alums dosing pump for PT-clarifier 115
6.7.2 Alum dosing pump for LET-clarifier 115
6.7.3 Lime dosing pump 115
6.7.4 Lime slurry transfer pump 116
6.7.5 Agitator 116
6.8 Chlorination system 116
6.9 Coal settling system(CHP area) 118
7. ADPH
7.1 Ash slurry pumps 119
7.2 BAHP 120
7.3 BALP 121
7.4 FAHP 122
7.5 Flushing water pump 122
7.6 HP seal water pump 123
7.7 LP seal water pump 124
7.8 Drain pump in ASPH 124
7.9 BA seal water pump 125
7.10 Vacuum pump in ESP 125
7.11 Bottom ash overflow pump 126
7.12 Sludge pump for settling tank 127
7.13 Eco booster pump 128
7.14 Clinker grinder 128
7.15 Instrument Air Compressor(IAC) 129
7.16 Instrument Air Drier 130
7.17 Transport Air Compressor(TAC) 130
7.18 Transport Air Drier 131
7.19 Fly Ash Conditioner water pump 131
7.20 Drain pump( Silo area) 132
7.21 Wash Water pump (Silo area) 132
7.22 Silo fluidizing blower 132
7.23 Buffer Hopper Aeration blower 132
7.24 Heaters of silo & buffer hopper 133
87
1.0 CW System
1.1 CW PUMP
General
Make Kirloskar Brothers Limited (KBL)
Model Number BHM125
Type Vertical / Mixed flow
Number 05 Nos.
Type of Discharge Above Floor discharge
Discharge Butterfly valve size 2200 NB
Type of Lubrication Self-water lubricated
PUMP PERFORMANCE
Guaranteed design capacity 30,000 cu.m/hr
Guaranteed Total Head at pump discharge flange 23.5 MWC
Bowl head at guaranteed design capacity 23.98 MWC
Total head loss from suction bell inlet to pump discharge flange 0.48 MWC
Rated Speed 371 rpm
Direction of rotation (viewed from top) Clockwise
Shut Off head of pump 42 MWC
Pump Efficiency at design capacity 88%
Pump input at design capacity 2181.74 KW
Power consumption at duty point, at motor terminals 2272.64 KW (Guaranteed)
Maximum & Minimum power consumption at motor terminals in 2291.67 kW
the pump operating range 2172.09 kW
Run-away speed (reverse) 525 rpm(approx.)
Are pumps and motors capable of withstanding the reverse run- Yes (approx. 5 mins.)
away speed
Maximum & minimum capacities upto which pump can be Max / Min
operated satisfactorily, cu.m./hr.
i)at maximum water level 37500 / 18000
ii)at minimum water level 36500 / 18000
Guaranteed noise level 85 dBA at 1.0 m
Guaranteed vibration level 100 Microns
Bowl efficiency at design capacity 90.01%
Minimum Submergence required 4643 mm
Type of coupling Flexible Pin-Bush type coupling
TECHNICAL PARTICULARS
Impeller type and design Mixed flow, semi open type
Pull out/non pull out Non pull out type
Number of stages Single stage (one)
NPSH available at
i) Design condition 14.02
ii) Run out condition 14.02
Pumps & motor combined critical speed, (rpm)
a) 1st 2168.00
b) 2nd 8546.48
Rotor over speed tested for 525 RPM
Type of Pump Bearings (Thrust & Radial) Tilting pad type thrust brg
Minimum submergence required above suction bell inlet, Max. 4550
mm, (at maximum flow & guaranteed flow) Guaranteed 4000
Minimum hoisting clearance of crane 13000 mm.
hook above the operating floor
88
Heaviest weight to be handled by the crane during

a) Erection Pump 32500 Kgs.
b) Maintenance Pump 32500 Kgs
Total empty weight of the pump assembly Approx. 32500 Kgs.
Recommended capacity of the overhead crane for 45 Tonnes
erection/ maintenance of the pump & motor
Normal axial hydraulic thrust 28186.9 Kg
Maximum axial hydraulic thrust 49797.2 Kg
PUMP DIMENSIONS
Impeller shaft diameter 160 mm Nominal
Size of pump suction bell mouth 2300 mm
Size of pump discharge flange 1650 NB
Pump setting length upto suction bell below operating floor level 8000 mm
Impeller diameter at inlet 1220 mm
Max Impeller diameter at outlet 1562 mm
THRUST BEARING
Make KBL make
Location & number In Pump, 1 No.
Type of thrust bearing Tilting pad type
Capacity More than 52000 Kg.
Number of shoes Eight
Method of lubrication and cooling. Oil bath lubricated, water cooled
Power loss in thrust bearing at duty point 4.5 KW
1.2. CW MOTOR
GENERAL
Make HYOSUNG corporaion,South Korea
Motor type Squirrel cage
Quantity 5
DESIGN AND PERFORMANCE DATA
Frame size 900D
Type of duty Continuous (S1)
Type of enclosure and method of cooling Weather Protected(WPI)
Degree of protection IP23 / Self Cooled
Applicable standard to which motor generally confirms IEC, IS
Type of mounting Vertical(V1)
Direction of rotation as viewed from driving end CCW looking from DE
Standard continuous rating at 40 deg.C. ambient temp. 2683kW
Derated rating for specified normal condition 2510kW
i.e. ambient temperature 50 deg. C
Rated Voltage / Rated Frequency 11000V / 50Hz
a) Voltage +/-6%
b) Frequency +3%/-5 %
c) Combined voltage and frequency +/-10%
Minimum permissible starting Voltage (Volts) 80%
Rated speed at rated voltage and frequency 371 rpm
At rated Voltage and frequency
a)Full load current (Amps) 171.5
b)No load current (Amps) 75.6
89
Power Factor at
a)100% load 0.81
b)75% load 0.77
c)50% load 0.66
d)Starting 0.12
e)At duty point 0.80
Efficiency (%) at rated voltage and frequency at
a)100% load 96.1%
b) 75% load 95.8%
c) 50% load 95.3%
d) At design duty point 96.0%
Starting current (amps) at
a) 100 % voltage 892A
b) Minimum starting voltage (80%) 758A
a) With driven equipment coupled 13 sec
b) Without driven equipment coupled 6 sec
Torque (in %/ N-m)
a) Starting (at min. permissible voltage.) 60% / 38747 Nm
b) Pull up at 100% voltage. 60% / 38747 Nm
c) Pull out at 100% voltage. 205% / 142385 Nm
d) Rated load (N-m) at 100% voltage 64578 Nm
e) Min accelerating torque (kg.m) available 6458 Nm at 80% voltage
Stator winding resistance per phase 0.6223(ohms) at 25 deg.C
Moment of motors (GD²) 6482 kgf-m²
No. of permissible Starts from Hot condition 2
Locked rotor KVA / Rated KW 6.77
Vibration at No Load (Bearing housing) 2.8 mm/s
Noise level 85dB(A) at one meter at no load
CONSTRUCTIONAL FEATURES
Stator winding insulation F/VPI (resin poor) with MICA Non
a) Class & Type hygroscopic, oil resistant, flame resistant
b) Tropicalized (Yes/No) Yes
c) Temperature rise over specified ambient of 50℃ 70℃
d) Method of temperature measurement Winding resistance
e) Stator winding connection Y
f) No of terminals brought out 6
Type of terminal box for
a) Stator leads Elastimold
b) Space heater Fabricated steel
c) Temperature detectors Fabricated steel
d) Instrument switch etc. N/A
For main terminal box
a) Location (from DE) Vertical(As per GA drawing)
b) Entry of cables Bottom
c) Fault level (kA) / Duration (sec) 44 / 0.25
For bearing
a) Type Anti-friction ball bearings
b) Make SKF or NSK or FAG
c) Recommended lubricant Alvania RL3 or Equivalent
d) Guaranteed life in hours 200,000 (L10)
e) Lubricant type Grease
f) Bearing cooling Self-Cooling
g) Location of thrust bearing Top
Weight of
a) Motor stator(including frame and terminal box) (kg) : 15500
b) Motor Rotor (kg) 8850
90
c) Cooler (kg) 650

d) Total weight (kg) 25000
Maximum permissible temperature of Rotor 400 deg C
ACCESSORIES
RTDs for winding : (Type/ Nos./ Leads/ location/ make/ Pt100 Duplex / 6 / 6 / Between coils
Resistance at 0℃) sides in slots /Sung-sil / 100 ohm at 0℃
RTDs for bearing (Type/ Nos./ Leads/ location/ make/ Pt100 Duplex / 2 / 6 / Between in Brg.
Resistance at 0℃) housing /WISE / 100 ohm at 0℃
Space Heaters : Yes
a) Numbers 10 (paralleled)
b) Power (Watts) 1000W
c) Supply voltage (VOLTS) 220V
d) Location Winding
Stator terminal box : Yes
a) Type Fabricated T/Box
b) Fault level (kA) 44
c) Fault level duration (sec.) 0.25
Neutral TB : Yes
Current transformers : Yes
a) Numbers 3
b) Ratio 200 / 1A
c) Kpv / Rct ≥ 150V / ≤ 1ohms
d) Exciting current ≤ 30mA at Vk/2
e) Fault level 40kA / 1sec
Dial type thermometer(Type/ make/ accuracy/ Temp. Indicator/ WISE / 1 / each bearing
connection type & size) & Air
a) For Bearings (Nos.) 1
b) For Air Inlet (Nos.) 2
c) For Air Outlet (Nos.) 2
1.3 ELECTRO HYDRAULIC ACTUATOR
General
Make Bosch Rexroth (India) Ltd.
No. of power packs provided One per valve
HYDRAULIC ACTUATOR (CYLINDER)
Type Double acting
Cylinder pressure rating 250 Bar
Bore of cylinder 160mm
Stroke of cylinder 900mm
Piston rod diameter 110mm
End cushioning (both ends) Cap end cushioned (Adjustable)
Port connection 1 1/2” BSP
Cylinder construction Screwed and bolted construction on both ends
Mounting Method Body trunnion mounting
PUMPING unit
Type of Pumps Provided Gear
No. of pumps provided / working One per power pack
Rated capacity & head of each pump 42 lpm, 125 Bar
Non Return valve provided at the discharge of each pump Yes
Motor details (KW, speed, Enclosure insulation class) 15KW, 1450 rpm, IP55, 415V±10%,
50HZ, 3PH, Class-F Insulation
Stand by Hand Pump provided Yes
91
OIL TANK
Capacity of the Oil tank, Cu.m 250 Liters
Type & material of construction CS (IS: 2062 Fabricated) of the tank
Oil Grade ISO VG-46
ACCUMULATOR
Nominal Capacity 50 Liter
Type of construction Bladder Type
With Backup Nitrogen Bottle Yes
Bottle Capacity 50 Liter
No. of Backup bottles 01 Nos.
Bladder Material NBR
Operating Pressure / Design pressure 125 Kg/cm2
SOLENOID VALVE
Type Poppet Type
Type of Operation Solenoid Operated spring return
Actuator Type Air gap solenoid- 24V DC
Voltage 24 V DC
Power requirement 35 W
Qty. 1 / 3 / 1 per power pack
1.4 EOT CRANE OF CW PH
Make Unique Industrial Handlers Pvt.Ltd.Nasik

Type of Crane EOT
Number of cranes 1 No.
Design Standard of EOT Crane Class - M5 of IS:3177-1999
Span (center to center of rails) 14000mm
Guaranteed Lifting Capacity of the main hook 45 Tonnes
Nature of load Intermittent
Guaranteed maximum lift of the main hook 13.0 mtrs.
Maximum speed at full load(meters/min.)
a) Main hoist 1.6
b) Trolley cross travel 4.0
c) Bridge travel 8.0
d) Creep speed of main hoist 0.16
e) Creep speed of Trolley cross travel 0.4
f) Creep speed of Bridge travel 0.8
Crane Bridge
a) Type Box type
b) Material E250 IS: 2062
c) Method of fabrication Fusion welded
d) Size 1300 x 500 mm OVERALL
e) Vertical Deflection. Span / 800 as per specification
f) Type of connection to the end carriage Bolted
g) Width 500
h) Length 14600
Cabin No cabin provided
Motor particulars M.H. C.T. L.T.
a) Size(KW) 17.5 0.9 1.7
b) Speed (RPM) 975 918 930
Hoisting
a) Construction 6 x 36 construction
b) Steel quality Best plough Steel
c) Tensile strength 200 kg / mm2
d) Diameter (mm) 24mm
e) Length of the rope ~ 120 mtrs.
f) No. of falls 8
92
g) Minimum breaking load (kg) 386.00

h) Factor of safety 6.000
Crane hooks
a) Type Ramshorn type
b)Size IS 5749
c) Material Forged steel
d) Safety latch Provided
e) Locking device on swiveling Provided
Controller for motors Control from floor through RRC&
pendent
Limit Switches Rotary + Gravity operated type for hoist
a) Type and lever type for CT & LT(make /break
contacts in control circuit only)
b) Current rating 10 Amp
c) Control voltage 110V, AC
d) Control voltage for pendent 24V AC
2.0 SACW(Station Auxiliary Cooling Water) system
2.1 SACW PUMP
GENERAL
Name of Make Kirloskar Brothers Limited(KBL)
Model Number BHR 50, Single Stage
Type Vertical Turbine Pump
Number 03 Nos.
Type of Discharge Above Floor discharge
Type of Lubrication Self water lubricated
PUMP PERFORMANCE
Guaranteed design capacity 1000 cu.m/hr
Guaranteed Total Head at pump discharge flange 50 MWC
Bowl head at guaranteed design capacity 50.26 MWC
Total head loss from suction bell inlet to p/p disch. flange 0.26 MWC
Rated Speed 1488 rpm
Direction of rotation Clockwise(viewed from top)
Shut Off head of pump 76 MWC (Approx)
Pump Efficiency at design capacity 89 %
Pump input at design capacity 153 KW
Thrust bearing loss 0.65 KW
Transmission bearings loss, 0.24 KW
Power consumption at duty point,at motor terminals 161.05 KW (Guaranteed)
Maximum & Minimum power consumption at motor terminals in the 162.43 KW/149.46 KW.
pump operating range
Pump shaft power required at rated speed& closed disch. 135 KW (Approx.)
Maximum shaft power required at any p/p charactristic point 153 KW(KW)
Shaft Power required at runout-flow (i.e. at maximum disch.) 149.51 KW
Run-away speed (reverse) 1895 rpm. (approx.)
Are pumps and motors capable of withstanding the reverse run- Yes
away speed
Maximum & minimum capacities upto which pump can be operated
satisfactorily, cu.m. /hr. Max / Min
a) at maximum water level 1200 / 400
b) at minimum water level 1200 / 400
93
Guaranteed noise level 85 dBA at 1.0 m

Guaranteed vibration level 100 Microns
Bowl efficiency at design capacity 90 %
2.2 Motor
GENERAL
Make Crompton greaves ltd
Motor type 3phase, ac squirrel cage induction motor
DESIGN & PERFORMANCE DATA

Frame size , Type of duty ND315L, S1
Type of enclosure & method of cooling TEFC Safe Area IC 411
Type of mounting V1
Direction of rotation viewed from DE Bidirectional
Standard continuous rating at 40 deg.C 195.65 Kw
ambient temp. as per Indian Std.
Derated rating for specified normal 180.00 Kw
condition i.e. 50 deg. C ambient
Rated voltage 415 V
a) voltage (volts) +-10%
b) Frequency (Hz) 50 +3% -5%
c)Combined voltage & frequency 10% ( Absolute)
Minimum permissible starting voltage(v) 80%
Rated speed at rated voltage & frequency 1488
a) Full load current ( A ) 290.00
b) No load current ( approx) ( A ) 87
Power factor at
a) 100% load 0.9
b) 75% load 0.82
c) 50% load 0.74
d) Design duty point 0.86
e) No load 0.1 to 0.2
f) Starting 0.4 to 0.5
Efficiency at rated voltage & frequency
a) 100% load 95.8%
b) 75% load 95.5%
c) 50% load 94%
Starting current % FLC at
a) 100% voltage 700
b) 85% voltage 595
c) 80% voltage 560
a) without driven equipment coupled < 2.0 sec
b)with driven equipment coupled < 4.0 sec
Safe stall time with 110% of rated voltage
a) From hot condition in sec. 12.39669421
b) From cold condition in sec. 24.79338843
Rated torque kg-m 117.82
Stator winding resistance per phase 24.15 ohm
(ohm/milli ohm at 20 ° C.)
GD square value of motor kg-m sq. 21.10
No. of permissible successive starts when 2
motor is in hot condition
94
Bearings
a) Type Antifriction deep groove ball/ roller,Self
Lubricated
b) Guaranteed life > 40,000 hours
Noise level db(A) at 1 m at no load 85 db at 1m
CONSTRUCTIONAL FEATURES
Stator winding connection Delta
Number of terminals brought out 6
For main terminal box-Recommended cable size 3R x 1C x 300 sq. mm
Fault level (MVA) 25
Space power/number 60WX2
Weight of
a) Motor stator 696
b) Motor rotor 464
2.3 EOT crane
Make Unique Industrial Handlers Pvt.Ltd.Nasik

Type of Crane EOT
Number of cranes 1 No.
Span (center to center of rails) 5300mm
Guaranteed Lifting Capacity of the main hook (m) 10 Tonnes
Nature of load Intermittent
Guaranteed maximum lift of the main hook 8.0 mtrs.
Maximum speed at full load
a) Main hoist (meters/min.) 1.6
b) Trolley cross travel (meters/min) 4.0
c) Bridge travel (meters/min) 8.0
d) Creep speed of main hoist (meters/min) 0.16
e) Creep speed of Trolley cross travel(m/min) 0.4
f) Creep speed of Bridge travel (meters/min) 0.8
Controls RRC+ Pendant
Cabin No
Power supply at the crane Long Travel Collectors
a) AC Voltage 415V AC± 10 percent
b) No of phases 3PH
c) Frequency 50Hz + 3 percent
Motor particulars M.H. C.T. L.T.
a) Size (KW) 5.2 0.9 0.9
b) Speed (RPM) 955 918 918
3.0 Cooling tower
3.1 Thermal design calculation
Design data
3
Circulating water flow rate for a tower 30000 m /hr
Hot water (inlet) temp. 42.5 degree
Cold water (outlet) temp. 32.5 degree
Ambient WBT 27.4 degree
Range 10.0 degree
Barometric pressure 943 m bar
Pumping head above FGL 13 mjwc
Basin top above FGL 0.3 m
95
Selected data
Design wet bulb temp. 28 degree
No. of working cells 8
No. of standby cell 1
Cell length (effective) 14.25 m
Cell width (effective ) 21.0 m
Pumping head above basin level 13-0.3 = 12.7 m
Frictional losses 1.2 mwc
Air inlet area / cell 175.275 sq.m
3
Water flow rate/ cell ( 8 cells) 3750 m /hr
Fill area / cell 277.875 sq.m
Liquid gas ratio 1.833
Air flow through typical cell 568.29 kg/s
3.2. Blades
Make Aerotech Parag

No. of Blade/ cell 8 6
Blade Type AEROM13/10FB8 Axial flow, Fibre Glass Reinforced
polyester(Hollow cast)
Air density 1.019 kg-m3 1.019 kg-m3
R.P.M 95.8 rpm 98 rpm
Fan Diameter 10000 mm 10000 mm
Blade length - 4564 mm
Volume Air Flow 586.83 m3/s 586.83 m3/s
Static Pressure 67.326 Pa 6.863 mmWC
Static Pressure (Including Stack 60.393 Pa 5.974 mmWC
Recovery)
Pitch Angle(Tip) 12.2 Degree 12.5 +/- 5 deg.
Fan Shaft power 64.91 kW 62.4 KW
Tip speed 50.17 m/s -
Tip Clearance 50 mm Max. 0.5% of fan dia
Axial Thrust Load 18441.47 N -
Natural Frequency of Blade 9.31 Hz -
Radial Load Per Blade 9060.32 N -
Total efficiency 81.5 % 82.1 %
Static Efficiency 54.59 % 55.1 %
Torque 6470.19 N.m -
Fan Blade Power 8.11 kW -
Maximum Force Per Blade 1304.5 N -
Hub Diameter 1.5 M 1.2 M
Air Velocity Across the Fan 7.64 M/s
Stack Exit Dia 10.85 M 10.85 M
Stack Exit Velocity 6.34 M/s 6.34 M/s
Stack Recovery Efficiency 75 % 75 %
3.3 Gear Box (main CT)
Mechanical rating 270 KW / 1500 RPM

Ratio 15.480/1
Lubrication Splash
Oil Type Servomesh SP 460
Oil quantity 72 litres
Net weight 1280 Kgs
Case material CI
Type of gear Stage I : Spiral Bevel type, Stage II : Helical type
Max. temp G/Box can withstand 110 deg
96
3.4 CT motor
Main CT Aux CT
Make KIRLOSKAR ELECTRIC CO. KIRLOSKAR ELECTRIC CO.
LTD. LTD.
Motor type TEFC SQUIRREL CAGE TEFC SQUIRREL CAGE
Technical Main CT Aux CT
Frame size SC 280M SC 180M
Rating 90 kW 18.5 kW
Type of duty: S1 (CONTINUOUS DUTY) S1 (CONTINUOUS )
Type of enclosure and method of cooling TEFC & IC 411, IP 55 TEFC & IC 411, IP 55
Degreeof protection
Direction of rotation as viewed from DE END BI ‐ DIRECTIONAL BI ‐ DIRECTIONAL
(clockwise with fan) (clockwise with fan)
Rated Voltage (volts): 415 V 415 V
Rated Frequency (Hz): 50 Hz 50 Hz
a) Voltage (%): +10%/‐10% +10%/‐10%
b) Frequency (%): +3%/‐5%\ +3%/‐5%\
c) Combined voltage and frequency: 10% 10%
Rated speed at rated Volt & frequency 1483 rpm 1475 rpm
a) Full load current (Amps): 146 Amps 32 Amps
b) No load current (Amps): 43 Amps 13 Amps
Power Factor at
a) 100% load: 0.90 0.87
b) At duty point: 0.90 0.87
c) 75% load: 0.86 0.83
d) 50% load: 0.80 0.75
e) NO load: 0.1 0.08
f) Starting: 0.27 0.35
Efficiency at rated voltage and frequency,
a) 100% load: 95.0% 92.2
b) At duty point: 95.0% 92.2
c) 75% load: 95.0% 92.2
d) 50% load: 93.0% 90.0
Starting current (amps) at 100 % voltage: 700% OF FLC 700% OF FLC
Starting time at minimum permissible V
a. Without driven equipment coupled: 2.0 SEC 1.5 SEC
b. With driven equipment coupled: 4.0 SEC 3 SEC
Torques :
a) Starting torque at min. permissible V 75.66 kg.m 15.64 kg.m
b) Pull up torque at rated voltage.: 150% 150%
c) Pull out torque: 240% OF FLT 230% OF FLT
d) Min accelerating torque: 88.66 kg.m 18.33 kg.m
e) Rated torque : 59.11 kg.m 12.22 kg.m
Stator winding resistance per phase (ohms 0.054 ohms 0.43 ohms
at 20 Deg. C.):
GD2 value of motors: 9.5 kg.m² 0.62 kg.m²
No of permissible successive starts when 2 Starts / Hour 2 Starts / Hour
motor is in hot condition:
Bearings
a) Type: Open type Open type
b) Make: SKF SKF
c) Self-Lubricated or forced Lubricated: Forced Forced
d) Recommended Lubricants: Grease Grease
e) Guaranteed Life in Hours: 40000 hrs direct drive 40000 hrs
Noise level (DB): 85 db @ 1 metre 85 db @ 1 metre
97
3.5 Sludge Pump
Make AQUA
Type of Pump Submersible Pump
Rated capacity of Pump 150 m3/hr @ 10 mtr head
Head / Stage 10 mtr. / Single
Max. Shut off Pressure 18.5 mtr.
Efficiency of Pump 71 % at duty point
Speed of Pump Motor set 1440 rpm
Type of Impeller Non Clog Type
Max. BHP required by the pump 6 kW
Make & Type of Motor AQUA / Full Submersible, Air Filled, Class F
Insulated, Squirrel Cage Induction Motor
HP of Motor 10 HP
Rotor construction Squirrel Cage Type
Max. staring current 250%
Rating 7.5 kW
(i) Full load Speed (RPM) 1440 rpm
(ii) Full load Current (amp) 15 A
(iii) No load current (amp) in free condition 6A
Direction of rotation Clockwise from non-drive end
4.0 Raw water system
4.1 Pump
General RAW WATER- PT RAW WATER- ASH
Name of Make Kirloskar Brothers Limited Kirloskar Brothers Limited
Model Number BHR 60 BHQ 37
Type Vertical Turbine Pump Vertical Turbine Pump
Number 03 Nos 02 Nos.
Type of Discharge Above Floor discharge Above Floor discharge
Type of Lubrication External Forced water External Forced water
lubricated lubricated
PUMP PERFORMANCE
Guaranteed design capacity 1800 cu.m/hr 2000
Guaranteed Total Head at pump 25 MWC 20.0
discharge flange
Bowl head at guaranteed design 25.27 MWC 20.29
capacity
Total head loss from suction bell inlet to 0.27 MWC 0.29
pump discharge flange
Rated Speed 990 rpm 980
Direction of rotation Clockwise (viewed from Clockwise
top)
Shut Off head of pump 35 MWC 32
Pump Efficiency at design capacity 87.5 % 87.5
Pump input at design capacity 140.06 KW 124.49
Thrust bearing loss 0.37 0.36
Transmission bearings loss 0.35 0.24
Maximum power consumption 149.00 KW 132.44
at motor terminals in the operating
range
Run-away speed (reverse) rpm. 1287 (approx.) 1274 (approx.)
98
Are pumps and motors capable of Yes Yes

withstanding the reverse run-away
speed
Maximum & minimum capacities
upto which pump can be operated
satisfactorily, cu.m. /hr. Max / Min Max / Min
a) at maximum water level 2200 / 720 2400 / 800
b) at minimum water level 2160 / 720 2460 / 800
Guaranteed noise level 85 dBA at 1.0 m 85 dBA at 1.0 m
Guaranteed vibration level 100 Microns 100 Microns
Bowl efficiency at design capacity 88.9% 89.20%
Submergence required 1400 mm 1200 mm
TECHNICAL PARTICULARS RAW WATER-PT RAW WATER-ASH

Impeller type and design Modified Radial-enclosed Modified Radial flow, Semi
type open type
Pull out/non pull out Non pull out type Non pull out type
Number of stages Single stage Single stage
NPSH required by pump at run out cond. 6.9 M 7.1 M
NPSH required by pump at Duty Point 6.4 M 6.6 M
NPSH required by pump at Minimum flow 5.9 M 6.1 M
NPSH available at Design condition 11.51 M 11.891 M
Minimum submergence required above Max. 1600 Max. 1400
suction bell inlet, mm, (at maximum flow & Guaranteed 1400 Guaranteed 1200
guaranteed flow)
Pump specific speed 3234.71 US units 3990.13 US units
Pumps & motor combined critical speed,
a) 1st 1560 3363
b) b) 2nd 6060 12638
Minimum hoisting clearance of crane 8000 8000
hook above the operating floor, (mm.)
Heaviest weight to be handled by the 4700 Kgs. 3500 Kgs.
crane
Total empty weight of the pump assembly Approx. 4700 Kgs. Approx. 3500 Kgs.
PUMP DIMENSIONS PT ASH
Spacing between shaft bearing, 1.5 m (Max) 1.5 m (Max)
Impeller shaft diameter, 60 mm Nominal 60 mm Nominal
Line Shaft diameter 60 mm Nominal 60 mm Nominal
Size of pump suction bell mouth 825 (mm) 800
Size of pump discharge flange, 450 NB(mm.) 450NB
Pump setting length upto suction bell 8900 mm 8900 mm
below operating floor level
THRUST BEARING PT ASH

Name of Make SKF make SKF make
Location & number In Pump 1 No & in Motor 1 No In Pump, 1 No.
Type of thrust bearing Spherical taper roller type Antifriction (Type-Spherical
roller)
Bearing life. More than 40000 hours More than 40000 hours.
Lubrication & cooling. Oil bath lubricated, water cooled Oil bath lubricated, water cooled
Thrust bearing capacity 204 KN 62202 kg (Dynamic)
176410 kg (Static)
Power Loss in Thrust bearing 0.37 kW 0.36
99
MATERIAL OF PT ASH
CONSTRUCTION
Suction bell CI IS210 FG260 Ni 2% (MIN) CI IS210 FG260 Ni 2
(MIN)
Casing /Bowl CI IS210 FG260 Ni 2% (MIN) CI IS210 FG260 Ni 2
(MIN)
Impeller ST ST ASTMA351/351M-CF8M SS ASTMA 351 CF8M.
Pump shaft ST ST ASTMA276-410 ANLD ST ST ASTMA-276-410
PUMP-MOTOR RAW WATER-PT RAW WATER- ASH
COUPLING
Type of coupling Flexible Pin-Bush type coupling Flexible Pin-Bush type coupling
Name of Make KBL make KBL make
Material of construction CI IS 210 FG260 CI IS210 FG260
4.2 Motor
General RAW WATER-PT RAW WATER- ASH

Make CROMPTON GREAVES LTD. CROMPTON GREAVES
LTD.
Motor type 3 PHASE, AC SQUIRREL 3 PHASE, AC SQUIRREL
CAGE INDUCTION MOTOR CAGE INDUCTION MOTOR
DESIGN & PERFORMANCE DATA PT ASH

Frame size ND315L ND315L
Type of duty S1 S1
Degree of protection IP55 IP55
Type of mounting V1 V1
Direction of rotation viewed from DE BIDIRECTIONAL BIDIRECTIONAL
Standard continuous rating at 40 deg.C 163.04 Kw 163.04 Kw
ambient temp. as per Indian Std.
Derated rating for specified normal 150.00 150.00
condition i.e. 50 deg. C ambient ( Kw)
Rated voltage (volts) 415 415
a) voltage (volts) +/-10% +/-10%
b) Frequency (Hz) 50 +3% / -5% 50 +3% / -5%
c) Combined voltage & frequency 10% ( Absolute) 10% ( Absolute)
Minimum permissible starting voltage(v) 80% 80%
Rated speed at rated voltage & frequency 990 990
a) Full load current ( A ) 255.00 255.00
b) No load current ( approx) ( A ) 76.5 76.5
Power factor at
a) 100% load 0.86 0.86
b) 75% load 0.82 0.82
c) 50% load 0.74 0.74
d) Design duty point 0.86 0.86
e) No load 0.1 to 0.2 0.1 to 0.2
f) Starting 0.4 to 0.5 0.4 to 0.5
Efficiency (%)at rated voltage & frequency
a) 100% load 95.1 95.1
b) 75% load 95.1 95.1
c) 50% load 93 93
Starting current % FLC at
100
a) 100% voltage 700 700

b) 85% voltage 595 595
c) 80% voltage 560 560
Starting time with minimum permissible
a) without driven equipment coupled < 2.0 sec < 2.0 sec
b) with driven equipment coupled < 4.0 sec < 4.0 sec
Rated torque - kg-m 147.58 147.58
Stator winding resistance per phase 24.15 24.15
(ohm/milli ohm at 20 ° C.)
GD square value of motor - kg-m sq. 29.90 29.90
No. of permissible successive starts 2 2
when motor is in hot condition
Bearings PT ASH
Type Antifriction deep groove ball/ Antifriction deep groove ball/
roller roller
Make SKF/FAG/NTN/EQUIVALENT SKF/FAG/NTN/EQUIVALENT
Self-lubricated or forced lubricated Self-lubricated Self-lubricated
Recommended lubricants Lithium base grease grade II Lithium base grease grade II
Guaranteed life in hours > 40,000 hours > 40,000 hours
Noise level db(A) at 1 m at no load 85 db at 1m 85 db at 1m
CONSTRUCTIONAL FEATURES PT ASH
Stator winding connection Delta Delta
Number of terminals brought out 6 6
space heater cast iron on top of main t.b. cast iron on top of main t.b.
weight 1160 kg 1160 kg
4.3 Lube Water system
Pump
Make KBL
Quantity 2
Pump Type/model CPHM 32/20
Bearing lubrication Standard grease/optional oil
3
Capacity 12 m /hr
Total head 45 m
Shut-off head 51.75 m
Efficiency 48 %
Overhead tank capacity 2000 ltr.
Motor
Make Crompton greaves ltd.
Motor type 3phase, ac squirrel cage induction motor
Frame size ND100L
Type of duty , protection IP55
Standard continuous rating at 40 deg.C 4.02 KW
Rated voltage & frequency 50 Hz
a) voltage (volts) +-10%
b) Frequency (Hz) +-5%
c) Combined voltage & frequency 10% ( Absolute)
Minimum permissible starting voltage(v) 80%
Rated speed at rated voltage & frequency 2850 RPM
a) Full load current 7 Amp
101
b) No load current ( approx) 3.5 Amp

Power factor at
a) 100% load 0.83
b) No load 0.1
c) Starting 0.3
Efficiency (%)at rated voltage & frequency
a) 100% load 87.5
b) 75% load 86
c) 50% load 83
Rated torque 1.26 kg-m
No. of permissible successive starts 2/3
when motor is in hot / cold condition
Bearings Type Antifriction deep groove ball
Self-lubricated or forced lubricated Self-Lubricated, Greased for life
Guaranteed life in hours > 40,000 hours
5.0 Fire fighting system
5.1. General
Fire Water Storage Tank 2 nos

Capacity 2130 m3
5.2 Diesel Engine
DESCRIPTION HYDRANT PUMP SPRAY PUMP BOOSTER PUMP

Make Greaves Cotton Ltd. Greaves Cotton Ltd. Greaves Cotton Ltd.
Quantity 1 1 1
Type HE cooled HE cooled HE cooled
Model No. TBD3V6MKI TBD3V6MKI 4G11NA
No. of cylinders,bore & 6, 128x130 mm 6, 128x130 mm 4, 105x130 mm
stroke
Rated RPM 1500 1500 1500
Brake Horse Power of 253 HP 253 HP 52 HP
Engine at rated RPM
Net power available 251HP 251HP 50 HP
Exhaust System Silencer Silencer Silencer
Type (Muffler / Silencer)
Exhaust back pressure 50 mm in 50 mm 50 mm
Exhaust after turbocharger 550 deg C(Average) 550 deg C (Average) 550 deg C (Average)
temp.
Oil Lubrication System In built with Engine In built with Engine In built with Engine
Material & wire mesh size of Spin on type combo Spin on type combo Spin on lub oil filter 30
filters filter having 30 filter having 30 micron raying
micron for full type micron for full type
If pumps are crank driven Yes Yes Yes
Capacity and location of 22 Ltr. Max in the oil 22 Ltr. Max in the oil 10.5 Ltr.
reservoirs pan of engine pan of engine
Lube Oil Cooler Yes Yes Yes
Lube Oil Flow 150 LPM 150 LPM 36 LPM
Lube Oil Inlet Temp 80-850 C 80-850 C 80-850 C
Lube Oil Outlet Temp. 1500C (Max) 1500C (Max) 1500C (Max)
102
Cooling Efficiency 65 to 70 % 65 to 70 % 65 to 70 %
Cooling Water Flow 400LPM 400LPM 90 LPM
Speed Governing 5% Max./ MICO / 5% Max./ MICO / 5% Max./ MICO /
System/make BOSCH BOSCH BOSCH
Prescribed Speed Bar(rpm) 1450-1550 1450-1550 1450-1550
Self-starting system Through Battery Through Battery Through Battery
Voltage 24 V 24 V 12 V
Starting motor make & type Lucas / Equivalent Lucas / Equivalent Lucas / Equivalent
Alternative manual starting No No No
arrangement provided
Lubricating oil pressure Yes/one/ On Engine Yes/one/ On Engine Yes/one/ On Engine
gauge/no./location/range control panel/0-10 control panel/0-10 control panel/0-10 bar
bar bar
Thermometer for coolant Yes/one/ On Engine Yes/one/ On Engine Yes/one/ On Engine
temp./no./location/range control panel /400C - control panel /400C - control panel /400C -
1100C 1100C 1100C
Tachometer for Engine Yes/one/ On Engine Yes/one/ On Engine Yes/one/ On Engine
RPM/no./location/range control panel /0 - control panel /0 - control panel /0 -
9999 RPM 9999 RPM 9999 RPM
Turbocharger yes yes Not Applicable
Charged air pressure at 1.72 bar 1.72 bar Not Applicable
rated load
Turbine blade High Nickel Alloy High Nickel Alloy Not Applicable
steel steel
Blower blade Aluminium Alloy Aluminium Alloy Not Applicable
Throttle Mechanism Provided Provided Not Applicable
Flywheel with guard (i.e. Yes Yes Yes
flywheel housing) provided
Whether engine is capable of Yes Yes Yes
starting at an engine room
temp of say 7° C
Whether Amp hr capacity of Yes, 24 V, 180AH Yes, 24 V, 180AH Yes, 12 V, 88AH
the battery matches with the
starting requirement of the
engine
Weight of the engine 1150 Kg 1150 Kg 450 Kg
Diesel Storage tank capacity 500 ltrs 500 ltrs 300 ltrs
Diesel Storage tank capacity 6 6 6
(in hrs.) at full load condition
Fuel Level Indicator Yes, Part of Tank Yes, Part of Tank Yes, Part of Tank
Fuel High Speed Diesel High Speed Diesel High Speed Diesel
(IS:1460) (IS:1460) (IS:1460)
Specific fuel consumption 154 Gram / 154 Gram/ BHP/Hr.+ 172 Gram / BHP/Hr.+
(rated load) BHP/Hr.+ 5% 5% prodution tol 5% prodution tol
prodution tol
Water outlet temperature 96± 20C (max) 96± 20C (max) 96± 20C (max)
Lube Oil Pressure (1500rpm) 2.5 bar (Min) 2.5 bar (Min) 2.5 bar (Min)
Vibration (mm/sec.) 15 mm/sec 15 mm/sec 12 mm/sec
Noise Level at 1.5 Metres 85 db with Acoustic 85 db with Acoustic 85 db with Acoustic
above floor and 1.0 m from Enclosure Enclosure Enclosure
the equipment shall be less
than 105 db.
103
5.3 Pump
DESCRIPTION Electric Diesel Electric Diesel Electric Diesel Electric

Hydrant Hydrant Spray Spray Booster Booster Jockey
Pump Pump Pump Pump Pump Pump Pump
Make Flowmore Flowmore Flowmore Flowmore Flowmore Flowmore Flowmore
Limited Limited Limited Limited Limited Limited Limited
Model No. F5826- F5826- P5932- P5932- 5823- 5823- 5625-
200x150 200x150 200x150 200x150 150x125 150x125 80x50
Type of Pump Horizontal Horizontal Horizontal Horizontal Horizontal Horizontal Horizontal
Split Split Split Split Split Split End
Casing Casing Casing Casing Casing Casing suction
Number of One One Two Two One One One
Stages
Suction Pr 0.0 0.0 0.0 0.0 10.50 10.50 0
(ksc)
Capacity(m³/hr) 410 410 410 410 171 171 75
Min./Max. 125 / 615 125 / 615 125 / 615 125 / 615 55 / 256.5 55 / 256.5 25 / 100
capacity at
which the
pump may run
continuously
Total dynamic
head in MWC
a) At rated 105 105 120 120 45 45 105
capacity
b) At max. 76 76 85 85 35 35 90
capacity
c) At 150% of 76 76 85 85 35 35 Not
rated capacity Required
Efficiency at 78% 78% 89% 89% 81% 81% 60%
rated duty point
NPSH
Required
(Mtrs.)
a) At rated 5.5 5.5 5.5 5.5 3 3 3
capacity
b) At max. 7.0 7.0 6.6 6.6 4 4 4.7
capacity
(Approx.)
Shut off head 124.0 124.0 144.0 144.0 49 49 115
Power in KW
a) At rated duty 150.31 150.31 150.55 150.55 25.87 25.87 35.74
point
b) At shut-off 85 85 110 110 20 20 20
condition
c) At run out 174.37 174.37 176.85 176.85 30.94 30.94 43.76
Speed (RPM) 1485 1500 1485 1500 1470 1500 2960
Size of pump - 200 X 150 200 X 150 200 X 150 200 X 150 150x125 150x125 80x50
suction x
delivery (mm.)
MOC
a) Impeller SS CA 15 SS CA 15 Bronze Bronze Bronze Bronze Bronze
b) shaft Stainless Stainless Stainless Stainless Stainless Stainless Stainless
Steel Steel Steel Steel Steel Steel Steel
c) Casing 2.5% NICI 2.5% NICI 2.5% NICI 2.5% NICI Cast Steel Cast Steel 2.5%
Nickel CI
104
Pump Bearing
a) Type Antifriction Antifriction Antifriction Antifriction Antifriction Antifriction Antifriction
al al al al al al al
b) Location DE / NDE DE / NDE DE / NDE DE / NDE DE / NDE DE / NDE DE / NDE
c) Shaft Sealing Gland Gland Gland Gland Gland Gland Gland
Arrangement Packing Packing Packing Packing Packing Packing Packing
Pump Grease Grease Grease Grease Grease Grease oil
Lubrication
Coupling type Pin-Bush Flexible Pin-Bush Flexible Pin-Bush Spider Flexible -
Type Spider Type Spider Type spacer
DOR (viewed CW CW CW CW CW CW CW
from prime
mover's pos.)
Casing Test Pr 21 21 24 24 30 30 21
(kg/cm²)
Noise Level ( at 85 db (A) 85 db (A) 85 db (A) 85 db (A) 85 db (A) 85 db (A) 85 db (A)
1M from pump)
Vibration 75 75 75 75 75 microns 75 75
guaranteed microns microns microns microns microns microns
Motor Input at 156.57 156.57 156.82 156.82 27.64 27.64 37.98
duty Point (KW)
5.4 Motor
Description Hydrant Pump Spray Pump Jockey Pump Booster pump

Make ABB Ltd. ABB Ltd. ABB Ltd. ABB Ltd.
Quantity 3 1 2 1
Motor type 3 phase Squirrel 3 phase Squirrel 3 phase Squirrel 3 phase Squirrel
cage motor cage motor cage motor cage motor
Rated output at 50 200 kW 200 kW 55 KW 37 KW
Deg .C air Ambient
Class & type of F F F F
insulation
Temperature rise at 70 70 70 70
rated output at 50 C
Type of enclosure & TEFC/IC411 TEFC/IC411 TEFC/IC411 TEFC/IC411
method of cooling
Degree of protection IP55 IP55 IP55 IP55
Rated voltage & 415 V ±10% 50 Hz 415 V ±10% 50 415 V ±10% 50 415 V ±10% 50
frequency with +/-5%, Combined Hz +/- Hz +/-5%, Hz +/-
variation Variation :+/- 10 5%,Combined Combined 5%,Combined
%(absolute) Variation :+/- 10 Variation :+/- 10 Variation :+/- 10
%(absolute) %(absolute) %(absolute)
Min. permissible 85% of rated volt 85% of rated volt 85% of rated volt 85% of rated volt
starting voltage
No load current 100 A 100 A 26A 26A
Rated current (Amp) 329 329 91.4 A 65.5
Starting current (A) 1974.0 1974.0 639.8 393.0
Rated speed(rpm) 1485 1485 2960 1470
Efficiency at rated
output 96% 96% 94.1% 93.6%
a) at 75% 96% 96% 94.1% 93.6%
b) at 50% 95.00% 95.00% 93.1% 92.8%
Power factor
a) at rated output 0.88 0.88 0.89 0.84
b) at starting 0.32 0.32 0.36 0.40
c) at no load 0.05 0.05 0.10 0.06
105
Rated torque(kgm) 131.0 131.0 18.1 24.5

Ratio of locked rotor 7.1 7.1 8.4 7.6
kVA and rated kW
Direction of rotation BI-Directional BI-Directional BI-Directional BI-Directional
from drive end
Weight of the motor 1260 kg 1260 kg 420 KG 310 Kg
Recommended Lithium complex Lithium complex Lithium complex Lithium complex
lubricant grease grease grease grease
Guaranteed running 40000 hrs 40000 hrs 40000 hrs 40000 hrs
life
2
GD value of motor 17 kgm2 17 kgm2 1.88 kgm2 1.4 kgm2
2
GD value of load 6.2 6.2 1.10 1.000
(kgm2)
Fault level withstand 45 kA for 1 sec 45 kA for 1 sec 45 kA for 1 sec 45 kA for 1 sec
cap
Type of coupling direct direct direct direct
between motor and
driven equipment
No load starting
time (sec) 0.292 0.292 0.338 0.102
a) at rated voltage 0.549 0.549 0.548 0.057
b) at minimum
starting voltage (at
80%)
Starting time with
drive coupled, sec.
a) at rated voltage 0.42 0.42 0.680 0.220
b) at minimum 0.74 0.74 1.3 0.440
starting voltage (at
80%)
No of permissible 3/2 3/2 3/2 3/2
starts when motor is
in cold/hot condition
Noise Level 85 db at 1 m 85 db at 1 m 85 db at 1 m 85 db at 1 m
5.5 Foam Pump
Pump
Item / equipment Motor driven
Make Del pd pumps & gears
Model No. / Quantity RDMS 200 M/1 Set
Liquid to be handled Foam
Type of pump Gear pump
Rated Capacity ( flow rate ) 5 m3/hr + 10%
Rated discharge pressure 10 Kg/cm2 g
Efficiency at rated capacity and discharge pressure 40% -5%
NPSH required 5.0 m
Power consumed by pump in KW at
a) At rated capacity and discharge pressure (duty point) 6 Bhp +10%
b) At 12 bar discharge pressure 8.0 +10% Bhp
Prime mover rating 10 Hp
Speed ( RPM ) 1440/1500(diesel pump)
Material : casing/rotor/end cover/wearing plates CF8M/ SS/ SS/ Ph Bronze
Stuffing box packing Mechanical seal
Gland /Coupling guard/ Integral Relief valve SS/ALUMINIUM/SS
Pump bearing Make/Type/ Quantity/ Lubrication NTN-Nachi/ Ball Bearing ZZ Ty/8/ Self
106
Shaft sealing arrangement Mechanical seal

Coupling Type/Make FLEXIBLE/ LOVEJOY
Weight of pump ( approx.) 22 Kg
Direction of rotation viewed from prime mover's pos. CW
Static Load with Prime mover 124 Kg/309Kg(diesel pump)
Dynamic Load with Prime mover 186 Kg/463KG(diesel pump)
Vibration 70 Micron/200 Micron (diesel pump)
Noise 85 db/105db(diesel pump)
Motor
Make & Country of origin Crompton Greaves Limited
Motor type Squirrel cage induction motor
Type of duty S1
Frame size & type designation ND 132 M
Standard continuous rating at 50 deg.C ambient temp. 7.5 Kw (10 hp)
Direction of rotation as viewed from non-driving end CW
Full load current 14.85
No load current 6
Power factor at rated load 0.78
Degree of protection IP -55
Rated voltage and frequency 415 + - 10 % 50 Hz +- 5% & 10%
Rated speed 1445
Efficiency at design duty point at 100% full load 90.1% (EFF 1)
Power factor at design duty point 0.78
Bearing type Ball bearing SKF Or Equivalent
Rated torque (kg-mtr) 5.06
GD2 value of motors 0.12kgm2
No. of permissible successive starts when motor is in hot 2 Starts
condition
Noise level (dB) 85dba from 1 Mtrs
Diesel engine
Quantity 1
Type Vertical Air Cooled Total Enclosed
Compression Ignition Four Stroke Cycle
Make KOEL
Number of cylinder, bore and stroke (in mm) 2, 87.5, 110
Rated RPM 1500
Brake horse power rating of engine at rated of engine 12 BHP AT 1500 RPM
RPM (HP)
Exhaust system (general information)
a) Type Dry Manifold type
b) manifold back pressure 6.66 kPa
c) manifold temperature 2250C
d) Max. allowable temp. difference from the cylinders 150C
e) Silencer type / make Pepper pot type
f) Max.noise alternation at distance of 1m 95 db
g) Material of construction M.S.
h) Wheather spark arrestor provided NO
Whether pumps are crank driven? YES
Capacity and location of reservoirs 7.2 LIT., inbuilt in cr. Case
Cooling arrangement for oil lubrication system provided NO
Speed governing system type Mechanical /centrifugal type
Cooling System Air cooled
107
Self Starting System Yes

Voltage & Capacity 12 VOLT, 35 A
Starting motor make & type Autolek/Lukas
Battery numbers per engine 2 Nos
Type of engine protection provided Overload stopper
Emergency stop push button at the engine provided Yes Lever Type
Flywheel with guard (I.e. flywheel housing ) provided no
Engine shall be capable of starting temp. of 7 Deg.C YES
Fuel Supply System Gravity Tank,Intergral with Engine,11.5 L
Specific Fuel Oil Consumption 251 g/Kwh
FOAM MAKER WITH VAPOUR SEAL CHAMBER

Make HD Fire Protect Pvt. Limited
Size INLET 80 NB & OUTLET 150 NB
Foam Expansion Ratio 1:6 (-1, +2 Unit, as per UL-162 CL.8 /1/ 1b)
Vapor Seal glass Burst Pressure 0.7 Kg / SQ. CM to 1.7 Kg/Sq. CM as per UL 162 CL 7.2.2
5.6 Sprinkler system
Bulb
Make HD Fire Protect Pvt. Limited
Item QB Detector/Sprinkler (Standard Response)
Color of Bulb Liquid Yellow
Bulb Operating Temperature 79 deg C
Bulb Glass
Deluge valve
Make HD Fire Protect Pvt. Ltd.
Mounting 900 Pattern Inlet to Outlet, Vertical Mounting.
Size 150NB 100NB 80NB 50NB
Maximum Rated Pressure 12.3 KG/SQ.CM.
Seat Test Pressure 18 KG/SQ.CM.
6.0 PTCW
6.1 PT Clarifier
General
Description Central driven full bridge type, bottom central feed
reactor clarifier
Design flow 2600 m³/hr
Design flow (@ 3% sludge) 2678 m³/hr
Size (Inside/Dimension) D X H + FB 38 m dia. X 4.5m SWD + 0.5m FB ,
SWD : side water depth, FB: free board
Quantity 2 Nos.
Bottom Slope 1 : 12
Surface overflow rate, (OR) 2.6 m3/m2/hr
Dia of Draft tube (ID) 1900 mm
Net retention time in clarification zone 92.98 min
Rake arm details
Type Centrally rotating
Rake speed (approx.) 0.03 RPM
108
Motor for Rake drive 1 HP, TEFC, SQ. Cage, 415 V, 3 ph, 50 Hz., class -
F, IP - 55, Ambient temp. 50°C.
Impeller Details
No.of blades 6
Propeller Dia (D) 1524 mm
Speed Max , min 63, 21 rpm
Speed variation Through VFD
Motor for Impeller drive 10 HP, 6 Pole, TEFC, SQ. Cage, 415 V, 3 ph, 50 Hz.,
class -F, IP - 55, Ambient temp. 50°C.
Radial Launder Details

No. of radial launder 16 Nos.
Width of launder 0.250 m
No. of 90° V-notches @ 120 c/c for radial 219 Nos.
launder
Head over V-notch 26 mm
Peripheral launder
Size of peripheral launder 900 mm wide x 700 mm LD
No. of V-notch @ 100 c/c for peripheral 1087 Nos.
launder = peripheral length / 0.1
Angle of V-notch 90 deg
Materials
Tank RCC
MOC of Draft tube RCC
Reaction Cone MS
Bridge assembly MS
Rake Arm assembly MS
V-notch weir plate MS
Squeegees Neoprene Rubber
Propeller assembly MS
Radial launder MS
Paint
All the metallic parts of equipment, which are Three coats of bitumastic heavy duty paint over a
embedded in concrete or in contact with water coat of primer & total thickness shall be 400 microns.
All other parts of equipment One coat of primer & three coats of chlorinated
rubber paint & total thickness shall be 200 microns.
6.2 Clarified water system
6.2.1 Clarified water makeup pump

Make SAM TURBO INDUTRY LIMITED
Type of pump Horizontal centrifugal , single stage
Total no of pumps 3 , [ 2W + 1 Std by]
Guaranteed flow of each pump 1500 cum/hr
Total head ( Guaranteed ) 25 MWC
Shut off Head 35 MWC
Range of Operation 40%-120% of rated flow.
Type of lubrication Grease
Type of coupling (Motor & Pump) Flexible
109
Pump efficiency at rated duty 85%

Pump BKW at rated duty point. 120.21 KW
Noise Level 85 dBA from 1M Distance
Motor
Make Marathon Electric Motors (India) Limited
Motor type Sq.Cage
Rating 160 KW , 415 V , 1485 rpm
No load current ( Approx.) 105 Amps
Power Factor at 100% load 0.88
Efficiency at 100% load 95.8 %
Rated torque 104.84 kg.m
No. of permissible successive starts when & 2
motor is in hot condition.
Bearing Lubricants, life Lithium based grease, 40,000 hrs
6.2.2 HVAC Makeup Pump

Type of Pump Single stage
Total no of pumps 2 [ 1W + 1 Std by ]
Total head ( Guaranted ) 80 MWC
Range of operation 40%-120% of rated flow.
Type of pump casing Axially Split type
Type of coupling ( motor & pump ) Flexible
Pump efficiency at rated duty 75 %
Motor
Motor type Sq.Cage , 415 volts , 1475 rpm
Rating 45 KW
No load current (Approx.) 29 Amps
Efficiency at 100% load 94 %
No. of permissible successive starts 2
6.2.3 Potable water pump

Type of pump Horizontal centrifugal multistage pump , 8 stages
Total no of pumps 2 [ 1W + 1std by ]
Total head ( guaranteed ) 80 MWC
Type of pump casing Barrel type-Ring Section
Type of coupling (Motor & Pump) Flexible-Pin and Bush Type
Pump efficiency at rated duty 72
110
Potable water pump Motor

Motor type Sq.Cage , 415 volts , 1475 rpm
Rating 22 KW
Efficiency at rated voltage and frequency 93 %
6.3 Pressure filter system
Pressure filter
Design flow per filter 50 cum/hr
Maximum flow per filter 51 cum/hr
Quantity 2 nos
Size of each filter 2600 mm Dia x 1800 mm Hos
Filter vessel design standard IS 2825-1969 ; class 2
Design pressure 14 KSC
Pressure drop across filter 0.5 Ksc ( max. )
Blower
Make KAY International Ltd.
Type of blower Positive displacement twin lobe blower
Quantity 02 nos.
Inlet pressure Atmospheric
Discharge pressure 0.35 kg/cm2 + atmospheric
Capacity (flow rate) 270 m3/hr.
Blower rpm 1263
Blower bhp 5.03
MOTOR type Foot mounted 3 phase induction motor
Motor rating 5.5 KW , 1440 rpm ,10 A FLC, 5.2 A no load current
Blower efficiency
Volumetric 74.1 %
Mechanical 68.5 %
Drive arrangement Pulley and v-belt drive
6.4 Sludge Disposal System
Sludge disposal pump

Make Sam turbo industry ltd
Type of pump Vertical , non-clog sump pump
Total no of pumps 3 [ 2 W + 1 Stdby ]
Total head ( guaranteed ) 30 MWC
Shut Off Head 33 MWC
Type of working fluid Sludge water with particle size upto 10 mm
Type of Impeller Open
Type of lubrication Grease, forced
Suction condition Submerged
Type of shaft coupling Flexible
Pump efficiency at rated duty 69%
111
Type of Thrust Bearings 7311 X 2 (double row angular contact ball bearing)
Motor
Motor type Sq. cage, 415 V , 1460 rpm
Rating 15 KW ,
No load current (Approx.) 11.5 Amps
Rated torque 10 kg.m
Air blower
Make KAY International Ltd.
Quantity 02 nos.
Discharge pressure 0.35 kg/cm2 + atmospheric
Blower rpm 1010
Blower bhp 7.38
Motor type Foot mounted 3 phase induction motor
Motor rating 7.5 KW ,1440 rpm ,13.4 A FLC, 5.5 A no load current
Blower efficiency
Volumetric 72.2 %
Mechanical 69.2 %
Drive arrangement Pulley and v-belt drive
6.5 ETP(Effluent Treatment Plant) System
6.5.1 Waste water pump

Make WPIL LTD
Type Vertical wet pit and non-pull out type
Type of working fluid Untreated drain water
Total no of pumps 3 nos. [2W + 1stdby ]
Guaranteed flow of each pump 100 m3/hr.
Total head (Guaranteed ) 50 MWC
Pump Shut of Head(mwc) max - 70 , rated- 63.75 ,min- 58
Type of Impeller Closed
Type of lubrication Force water lubrication
Suction condition Submerged, mm minimum submergence required
from bottom of Suction Bell = 5.45 mtr.
Sump invert level (+) 270.05 RL
Operating floor level (+) 275.50 RL
Type of shaft coupling Pin bush type flexible coupling bet. pump& motor
Pump efficiency at rated duty 82.00%
Guaranteed power at motor terminals at 16.62 KW (Pump input power); 17.87 KW(Power at
rated duty (KW) motor terminals)
Type of Thrust Bearings Anti-Friction Type(Angular contact ball Bearing)
Type of Pump Bearings Cutless bubber in Bronze Shell in pump Bowl assy.
Motor
Motor type Sq.Cage , 415 V , 1468 rpm
Rating 22 KW
112

Rated torque () 14.58 kg.m
6.5.2 Treated Effluent Disposal Pump
Make SAM TURBO INDUsTRY LIMITED

Type of Pump Horizontal centrifugal, single stage
Total no of pumps 3 [2W+ 1stdby]
Shut-off head 57 MWC
Type of pump casing Radially Split Type
Type of lubrication Oil
Suction condition Flooded Suction
Motor
Make Marathon Electric Motors
Motor type Sq.Cage , 415 V, 1468 rpm
Rating 22 KW
6.5.3 ETP clarifier
Description Central driven Full bridge type, Central feed Reactor

clarifier
Design flow 200 m³/hr
Design flow (@ 3% sludge) 206 m³/hr
Size (Inside/Dimension) D X H + FB 11.0 m dia. X 4.5m SWD + 0.5m FB
Quantity 1 No.
Bottom Slope 1 : 12
Surface overflow rate, (OR) 2.5 m3/m2/hr
Dia of Draft tube (ID) 1016 mm
Size of peripheral launder 350 mm wide x 135 mm LD
No.of V-notch@80c/c for peripheral launder 382
Angle of V-notch 90 deg
Impeller blades, propeller dia 8, 1820 mm
Impeller speed Max:15rpm ,min:5rpm,speed variation through VFD
No. of radial launder 04 Nos. , .20m width
No.of 90° V-notches 80c/c for radial launder 85 Nos.
Rake arm Centrally rotating, 0.09 RPM
Geared motor for Rake drive 0.75 HP, TEFC, SQ. Cage, 415 V, 3 ph, 50 Hz., class -
F, IP -55, Ambient temp. 50°C
Motor for Impeller drive 3 HP, 8 Pole, TEFC, SQ. Cage, 415 V, 3 ph, 50 Hz.,
class -F, IP - 55, Ambient temp. 50°C
113
6.6.1 Service water pump
Make Sam Turbo Industry Limited

Type of Pump Horizontal centrifugal, Two Stage
Total no of pumps 3 [2W+ 1stdby]
Type of coupling (motor & pump ) Flexible
Pump BKW at rated duty point 51.9
Motor
Motor type Sq.Cage , 415 V , 1485 rpm
Rating 75 KW
Rated torque (kg.m ) 49.14
6.6.2 APH Wash Water Pump
Make SAM TURBO INDUSTRY LIMITED

Type of Pump Horizontal centrifugal , single stage
Total no of pumps 2 [ 1W+ 1stdby]
Pump efficiency at rated duty 72.5 %
Pump BKW at rated duty point. 165.37
Motor
Motor type Sq.Cage , 415 V, 1487 rpm
Rating 200 KW
6.7 Chemical House

Overhead tank capacity 300 m3
Alum dosing tank 3 nos , 4.1mx4.1mx2.5m dimension
Lime dosing tank 2 nos, 4.5mx4.5mx2.5m dimension
Lime slacking tank 2 nos, 3.5mx3.5mx2.5m dimension
114
6.7.1 Alum Dosing Pump PT-Clarifier
Make MILTON ROY INDIA LTD

Quantity 3 Nos
Type Hydraulically actuated diaphragm type metering pp
Duty Continuous
Stroke adjustment Manual
Volumetric Efficiency >85%
Stroke Length 50mm
Liquid to be handled Alum Solution 10% W/V
Maximum Capacity 1800 LPH
Max.pr: 7 Kg/sq.cm
Required capacity-LPH 1200 Lit/hr
Suction pressure / Req. discharge pressure Flooded / 2 Kg/Sq.cm
Motor make CROMPTON GREAVES LTD.
TYPE 3phase, ac squirrel cage induction
Volts/frequency/phase 415/50/3
Motor rating 2HP(1.5KW)
Full load current 4.13 AMP
Full load torque 1.57 KGM
Rotation viewed from de Clockwise from DE
Type of lubrication Greased for life
Type of coupling Direct/flexible –coupling cable size
6.7.2 Alum Dosing Pump LETS-clarifier
Make MILTON ROY INDIA LTD

Quantity 2 Nos
Type Hydraulically actuated diaphragm type metering pp
Duty Continuous
Stroke adjustment Manual
Stroke Length 34 mm
Liquid to be handled Alum Solution 10% W/V
Maximum Capacity 600 LPH
MAX.PR: 10 Kg/sq.cm
Required capacity-LPH 300 LPH
Suction pressure / Req. discharge pressure Flooded / 2 Kg/Sq.cm
Motor make Crompton greaves ltd.
TYPE 3phase, ac squirrel cage induction
Volts/frequency/phase 415/50/3
Motor rating 0.75 KW
Full load torque 0.51 KGM
Rotation viewed from de Clockwise from DE
Type of lubrication Greased for life
Type of coupling Direct/flexible –coupling Cable size
6.7.3 Lime Dosing Pumps

Total no of pumps 2
115

Type of working fluid Lime Solution ( 6 % w/v)
Motor Make Marathon Electric Motors (India) Limited
Motor type Sq.Cage , 415 V
Rating 5.5 KW
6.7.4 Lime Slurry Transfer Pump

Total no of pumps 2
Type of working fluid Lime Solution (10 % w/v)
Type of coupling (motor & pump ) Flexible
Motor Make Marathon Electric Motors (India) Limited
Motor type Sq.Cage
Rating 0.75 KW
6.7.5 Agitator in Alum/Lime dosing tank
Make Ceecons India

Type 3 bladed impeller, 60 rpm
Impeller material SS
Gear box Helical : ratio 23.8:1 , Premium make
Motor 1.5 KW, 1420 rpm, 415 v, 3 phase SCIM , CGL make
Rotation viewed Clockwise from DE side
6.8 Chlorination system
6.8.1 CW Chlorinator
Make Capital Controls India Pvt. Ltd.
Maximum Rated Capacity 120 kg/hr
Operating Capacity 100 kg/hr
Qty 3 Nos. ( Two working + One standby)
Type Vacuum Operated Solution Feed Type
Design Pressure for Pressure Relief Valve 25” Hg Vacuum
Set Pressure for Pressure Relief Valve 3.5” to 4” Water Column
116
Water flow through ejector 49.2 m3 / hr

Water Pressure at ejector inlet required 3.0 kg/cm
Maximum Allowable Back Pressure 1.0 kg/cm²
6.8.2 Chlorine Water Booster Pump for CW

Make M/s. SAM TURBO INDUSTRY LIMITED
Quantity in NOS 03 (Three)
Type Radial Split
Capacity 60 m3 / hr
Differential Head 50 m
Shut off head 55 m
Power at duty point 14.34 KW
Duty point efficiency 57%
Recommended Motor Rating 18.5 KW
Speed in RPM - Pump 1463
Brg Lubrication Grease Lubrication
6.8.3 Chlorine Water Booster Pump for PT

Make M/s. SAM TURBO INDUSTRY LIMITED
Quantity in NOS 02
Type Radial Split
Capacity 16 m3 / hr
Shut off head 57.5 m
Recommended Motor Rating 5.5 KW
Speed in RPM - Pump 1455
Brg Lubrication Grease Lubrication
6.8.4 Absorbant circulation pump -CW chlorination

Make M/s. CAPITAL CONTROLS INDIA
Quantity 2
Pump Description Horizontal centrifugal pump
Liquid Handled 20% NaOH
Suction Conditon Flooded
Capacity 20 m3 / hr
Shut off Head 16.5 m
Speed 1435 rpm
Power at motor input terminal at rated duty point 1.93 KW
Recommended motor rating 2.2 KW
Lubrication Grease
6.8.5 Blower for CW chlorination
Make Fibre Plast
Number Two(1w+1stdby]
3
Capacity 3750 m /hr at 225 mm WG
Type Centrifugal, “V” belt drive
Speed 1500 rpm
Blower power 6 BHP
Bearing 2 nos/ Double row self aligned ball type
Efficiency at rated condition 50% aprrox.
117
Suction nozzle 300mm ID

Motor rating 7.5 HP, 5.5 KW/1440 rpm
6.9 Coal settling Pond (CHP area)
Coal decant pump

Make WPIL LTD
Total no of pumps 2 nos.[1W+1stdby]
Type of Pump Vertical wet pit and non-pull out type, 3 stages
Guaranteed flow of each pump 150 m3/hr.
Total head (Guaranteed ) 30 MWC
Pump Shut of Head(MWC) max- 49 , rated - 44.4 , min- 40
Operating speed (maximum ) 1500 RPM
Type of working fluid Treated Effluent from coal slurry settling ponds
Water temperature Max & min. 36 & 25 deg C
Type of discharge Above Floor Discharge
Type of Impeller Closed
Type of lubrication Force water lubrication
Suction condition submerged
water level 310 mm minimum submergence required from bottom
of Suction Bell. Sump Depth =7.2 mtr.
Type of shaft coupling Pin bush type flexible coupling between pump &motor
Pump efficiency at rated duty 82.00%
Maximum power input to the pump at rated 17.46 kw
speed over the entire range of operation.
Type of Thrust Bearings Anti-Friction Type(Angular contact ball Bearing)
Type of Pump Bearings Cutless bubber in Bronze Shell in pump Bowl assy.
Motor
Motor type Sq.Cage
Type of enclosure and method of cooling, TEFC/IC411 / IP55
Degree of protection.
Type of mounting IMV1
Rating KW
Rated Voltage ( volts ) 415
Rated speed at rated voltage and frequency 1468
Full load current - Amps 37.4
No load current ( Approx.) - Amps 15
Power factor at 100% load 0.88
Efficiency at 100% load 93%
Rated torque 14.58 Kg-m
GD² value of motors 0.575 Kgm²
No. of permissible successive starts when 2
Self-Lubricated or forced Lubricated Self, Lithium based grease
118
7.0 ADPH
3
Ash slurry sump capacity 2X170 m
3
Ash water sump capacity 1456 m
7.1 Ash slurry Pump
Make SAM TURBO INDUSTRY PVT LTD

Type Horizontal Centrifugal Twin Casing Ash slurry p/p
Numbers furnished 16 NOS. [4 nos. fluid coupling and gear
box driven and 12 nos. belt driven]
Numbers operating 4 SERIES [ 2W + 2S] [each series consists of 1 no. fluid
coupling and gear box driven + 3 nos. of belt driven]
3
Rated capacity 1040 m /hr
Type of Suction FLOODED [capable of 2m suction lift]
Total dynamic head at rated capacity 46 mwc
Shut off head 51 mwc
Rated speed (RPM), max , min 790,869,435
Pump efficiency at rated capacity & head 86%
(with liquid of sp.Gr.1.0 or with slurry of
specific gravity as being handled 1.154)
Pump input power at rated capacity When 151.57 KW
handling clear water/Liq with Sp Gr 1
Pump input power at rated capacity When 174.92 KW
handling Liq with Sp Gr 1.154
Maximum transmission losses in the drive
system corresponding to pump operation
a) Variable speed hydraulic coupling(for first KW 31.34
stage slurry pump
b) Gear Box KW 2.66
Impeller size and type Ø660 / CLOSED
Number of vanes 3
Impeller tip speed, m/min 1637
Material of constructions
Casing outer ASTM A 216 Gr WCB
Casing inner, impeller, wear plate CHROME NICKEL CAST IRON
Arrangement of cooling External
Pump thrust bearing [NDE] SPHERICAL ROLLER THRUST BEARING X 1 No
Gland sealing arrangement External, 5 cum/hr/ pump@ 1 Kg/cm2 above disc. Pr.
Coupling Pin and bush type coupling for fluid
Coupling and gear box driven pumps
Fluid coupling
Make Premium transmission ltd.
Type of fluid coupling Variable speed fluid coupling
Max. Power transmission capacity 352 kw/1500rpm
Speed regulating range 5:1
Coupling speed Rated 1311,max.1443,min.721
Max.slip 3%
Oil cooler
Oil flow 125 lpm
I/l & o/l oil temp 75 deg.c & 54.5 deg.c.
3
Water flow 12.1 m /hr
119
I/l & o/l water temp 36deg.c. & 41degc.

Oil capacity of fluid coupling 270 LITRE
Oil type SERVO SYSTEM-46
Fluid coupling efficiency Rated speed (790 rpm) 85%
Max. speed (869 rpm) 94%
Min. speed (434.5 rpm) 44%
Ash Slurry Pump Motor

Make Marathon Electric Motors (I) Ltd. Kolkata
Motor type Sq. Cage Ind. Motor
Type of duty S1(CMR)
Type of enclosure and method of cooling, TEFC / IC411 / IP55
Degree of protection
Type of mounting Horizontal Foot (B3)
Rating 325 KW
Rated Voltage 3300 volts
a) Voltage (Volts) +/-10%
b) Frequency (Hz) +/-5%
c) Combined voltage and frequency 10%
a) Full load current 67.5 Amps
b) No load current 24 Amps. (Max.)
Power Factor at
a) 100% / 75% / 50% load 0.85 / 0.83 / 0.75
b) No load 0.087
c) Starting. 0.21
Efficiency at rated voltage and frequency,
a) 100% load 94.5 %
b) 75% load 93.8%
c) 50% load 92.5 %
Starting time with minimum permissible volt
a) Without driven equipment coupled 0.6 Secs.
b) With driven equipment coupled 1.4 Secs.
2 2
GD value of motors 26 Kg.m
No of permissible successive starts when 2
motor is in hot condition
Bearing Self-Lubricated , grease
7.2 BAHP(Bottom Ash High Pressure) PUMPS

Type Horizontal Split-casing Pump
Numbers furnished 2 nos
3
Total dynamic head at specified rated capacity 81 mwc
Pump efficiency at rated capacity & head 82%
Pump input power at specified rated capacity 121.12 KW
Critical Speed 30% ABOVE RATED SPEED
Number of stages Single
Impeller size and type, no. of vanes Ø 485 / CLOSED,6
120
Bearing lubrication Oil

Arrangement of cooling Self
Coupling type Pin & bush
Motor
Motor Type Sq. cage
Type of Duty S1
Rating 180 KW
Rated voltage (Volts) & Frequency (Hz) 415 Volt & 50 Hz
Rated current 310 Amp
No load current 125 A
Efficiency at full load 95.5 %
Power factor at full load 0.85
Rated torque 117.9 Kg-m
2 2
GD motor 11.2 Kg-m
Bearing lubrication, life Lithium based grease 40,000 hrs
No. of permissible start in hot condition 2
7.3 BALP(Bottom Ash Low Pressure) PUMPS

Numbers furnished 3 nos [2W +1S]
Pump efficiency at rated capacity & head 82 %
Critical Speed 30% above rated speed
Impeller size and type , no. of vanes Ø 345 / CLOSED, 7
Bearing lubrication Grease
Bearing Type Double row angular contact ball bearing,
Single row deep groove ball bearing
Coupling between motor shaft and pump shaft Pin & bush
Motor
Motor Type Sq. cage
Type of Duty S1
Rating 90 KW
Rated current 151.5 Amp
Efficiency at full load 95 %
Rated torque 59 Kg-m
GD2 motor 7.385 Kg-m2
121
7.4 FAHP(Fly Ash High Pressure) PUMPS

Numbers furnished 3 NOS (2W+ 1S)
3
Number of stages SINGLE
Impeller size and type, no. of vanes Ø 484 / CLOSED, 8
Bearing lubrication Grease
Type Single row deep groove ball bearing, single
Row angular contact ball bearing
Coupling Pin & bush
Motor
Motor Type Sq. cage
Type of Duty S1
Rating 160 KW
GD2 motor 10.434 kg-m2
7.5 Flushing Water Pump

Type Horizontal Centrifugal Pump
Numbers furnished 1 NO
3
Pump efficiency at rated capacity & head % 87
Impeller size and type, No of Vanes Ø 435 / open , 5
Bearing lubrication, type Oil, taper roller bearing
Arrangement of cooling Self
Coupling between motor shaft and pump shaft Ph spacer
Motor
Motor Type Sq. cage
Type of Duty S1
Rating 75 KW
122

Rated speed 990 rpm
2 2
GD motor 11.93 kg-m
7.6 HP Seal Water Pump

Type Horizontal Multistage Pump
Numbers furnished 2 NOS (1 W +1S)
3
Number of stages Nine
Impeller size and type, No of Vanes Ø 251 / closed, 7
Bearing lubrication, Type Grease, cylindrical roller bearing
Motor
Type Sq. Cage
Type of duty S1
Rating 37 KW
GD² value of motors 1.141 Kg-m²
7.7 LP Seal Water Pump

Numbers furnished 2 NOS (1W + 1S)
123

Impeller size and type, No of Vanes Ø 200 / closed, 7
Motor
Type Sq. Cage
Type of duty S1
Rating 22 KW
GD² value of motors 0.575 Kgm²
7.8 DRAIN PUMP IN ASPH

Type Vertical Centrifugal Pump
Numbers furnished 2 NOS
Shuf off head 18 mwc
(considering Sp Gr 1.17)
when handling water
Coupling type Pin & bush
Motor
Make & Country of origin Marathon Electric Motors (India) Limited
Type Sq. Cage
Type of duty S1
Type of mounting V1 (vertical)
Type of enclosure and method of cooling, TEFC/IC411 /IP55
Rating 7.5 KW
Speed 965 rpm
124
7.9 BA Seal Water Pump

Numbers furnished 2 NOS
3
Motor
Type Sq.Cage
Type of duty S1
Type of mounting V1
Type of enclosure and method of cooling, TEFC/IC411 /IPW55
Rating 7.5 KW
7.10 Vacuum pump (in ESP deashing system)
Make Kakati Karshak Industries Private Limited

Type & Model Liquid Ring & KVL-750
3
Guaranteed Vacuum pump capacity at pump inlet 3319.681 m /hr
conditions of 60 Deg F Gas Temp ( 50% RH) and 60 Deg
F seal water temp. at 14”Vacuum & 275.5 M above MSL
3
Vacuum pump capacity at pump inlet conditions of 50 3400 m /hr
Deg C Gas Tem ( 50% RH) and 36 Deg C seal water
temp. at 14”Vacuum & 275.5 M above MSL
Rated Vacuum at atm pressure 28.99 " Hg. (736 mm Hg) 14" Hg.
Shut off Vacuum at barometric pressure 28.99 " Hg 22" Hg.
Guaranteed Power consumption at shaft 54 KW
Rated speed 450 rpm
Total Vacuum Pumps Quantity per unit 8 NOS. ( 2 per pass )
No. of Vacuum Pumps working & standby 8 (4 W + 4 S)
Type of transmission between pump & motor and V-Belt, transmission efficiency 97%
transmission efficiency
Maximum pump input power (shut off vacuum) 66 BkW
Bearing Spherical roller & Radial.
Material :
Body (Casing) C.I. Gr FG 260 IS 210
Rotor SS 410 ( ASTM A -217 Gr CA 15)
Shaft EN-8 (C-40)
Seal Water requirement 120 lpm at 1 Kg/cm2 (g) pressure at 36 deg
Volumetric Efficiency : 84.86%
125
Isothermal efficiency : 58.58%

Mechanical efficiency : 64.47%
Max. Permissible inlet gas temp. at suction of vacum p/p 150 Deg C
Noise level at 1m distance from equipment 85 dBa
Motor
Type Sq.Cage, S1, IMB3
Type of enclosure &method of cooling,Degree of protection TEFC/IC411 /IP55
Rating 90 KW
Full load current / No load current (Approx.) 151.5 Amps /62 Amps
Power Factor & Efficiency at 100% load 0.87 & 95%
7.11 Bottom Ash Overflow Pump

Type Horizontal centrifugal Twin casing
Numbers furnished 2 per unit
3
Storage capacity of bottom ash overflow sump 75 m
Arrangement Motor – Fluid coupling –gearbox-pump
Type of Suction Flooded
Shut off head 33
Rated speed 890 rpm
Pump efficiency at rated capacity & head (with 68 %
ash slurry of specific gravity 1.07 as being handled)
Pump input power at specified rated capacity When 50.70 KW
handling Liq with Sp Gr 1.1
Impeller size and type, Number of vanes Ø495 / CLOSED,5
Bearing lubrication oil
3
Gland sealing arrangement By External supply of clear water, 3m /hr @ 1
Kg/cm2 above delivery pressure
Coupling Pin and bush type coupling for fluid
Coupling and gear box driven pumps
Maximum proportion of weight of ash in slurry 30%
that pump can handle at rated capacity,%
Min Guaranteed life of wear parts 8000 Hrs
Fluid coupling
Make PREMIUM TRANSMISSIONLTD.
Type of fluid coupling Variable speed fluid coupling
Max. Power transmission capacity 136kW/1500RPM
Speed regulating range 5:1
Coupling speed RATED 1185 , MAX. 1422, MIN. 948
Max.slip 3%
Oil cooler
Oil flow 83 lpm
I/l & o/l oil temp 75 deg.c & 66 deg.c.
Water flow 3.5 m3/hr
i/l & o/l water temp 36 deg.c. & 41 degc.
126
Oil capacity of fluid cplg 140 LITRE

Oil type SERVO SYSTEM-46
Fluid coupling efficiency RATEDSPEED(785RPM)77%
MAX.SPEED(942RPM)94%
MIN.SPEED(628RPM)60%
Motor
Type Sq.Cage
Type of duty S1
Type of mounting IMB3
Type of enclosure and method of cooling, TEFC/IC411 /IP55
Rating 90 KW
Rated speed 1485
2
GD² value of motors 7.385 kg-m
No. of permissible start when in hot condition 2
7.12 SLUDGE PUMP for settling tank

Type Horizontal centrifugal Twin casing
Numbers furnished 2
Numbers operating 1W + 1S
Capacity of settling tank, both upper and lower 600 m3
3
Type of Suction Flooded
Pump efficiency at rated capacity & head 30
(with ash slurry of specific gravity as handled 1.16)
Pump input power at rated capacity KW
When handling clear water 8.45
When handling Liq with Sp Gr 1.1 9.80
Gland sealing arrangement External supply of clear water , 1.5 m3/hr
@ 1 Kg/cm2 above delivery pressure
Maximum proportion of weight of ash in slurry 30%
that pump can handle at rated capacity
Motor
Rating 15 KW
Rated voltage and frequency 415 Volts & 50 Hz
Efficiency at rated Volt and freq. at 100% load 91.8 %
127
Rated torque 10 kg-m

No. of permissible successive starts when & motor is in 2
hot condition.
7.13 Eco Booster Pump ( for providing water to eco hopper, eco bypass hopper )
Quantity in nos 2 per unit

Liquid Handled Water
Capacity in 37 m3/hr
Head 34 mwc
Efficiency 71 %
Motor KW / Speed in RPM 7.5 / 1450
Coupling Type Pin & Bush Type
No. of Stages 3
7.14 Clinker Grinder
Motor
Motor type Sq. Cage
Rating 11 KW
Efficiency at rated voltage and frequency,(%) 89.7
2
GD² value of motors 0.378 kg-m
Gear box
Type Inline Double Reduction Helical Gear Box
Make Premium Energy Transmission ltd.
Mounting Foot Mounting
Output ratio Nom. 13.8/1
Gear box input/output speed at rated cond. 965/69.92 RPM
Efficiency of gear box 96 % approx.
Mechanical rating at 980rpm 26.54KW
Type of lubrication Oil Splash Lubrication, 14 ltrs
Type of cooling Air cooled by natural convection through
exposed surfaces of main case
Fluid coupling
Make PREMIUM ENERGY TRANSMISSION LTD.
Type of fluid coupling Fcu traction type fluid coupling
Thermal rating[heat dissipation capacity] 2.38 KW[MAX]
Fusible plug blow off temp 145 ±5 DEG C
Max. Power transmission capacity 24.76 kw /1000 NOM.RPM
Oil quantity 13.6 LITRE
128
7.15 Instrument Air Compressor (IAC)
Make KIRLOSKAR PNEUMATIC CO. LTD., PUNE.

Type of Compressor Horizontal, balanced opposed, reciprocating,
non-lubricated
Number offered Total Four ( 4 ) Numbers [For each Unit ( 1
Working & 1 Standby ) ]
3
FAD of each compressor at design ambient 600 m /hr
Discharge pressure after cooler 8.0 ksc
Discharge capacity 454.3 Nm3/Min
Air temperature after first/last stage 146/160 deg C
Outlet air temperature (after cooler) 45 deg C above
Maximum Shaft input power required 57.43 KW
in the entire operating range
Type of transmission between motor & compressor Belt Drive
Motor rating at 50 deg C Ambient 75 KW
Crank shaft speed 515 rpm
Number of stages Two
Single acting or double acting Double acting
Cooling by air or water , pressure in Water
Kg / cm2(g) / LPM 2.5 / 175 (for cyl. Jacket)
2.5 / 175 (for intercoller)
2.5 / 125 (for aftercooler)
Intake Air Filter area (m2), Filter efficiency (% 0.0065, 99.5%,synthetic foam with
microns), Filtering media Galvanised wire mesh
Belt loss in % 3%
Outlet temperature of cooling water 5 deg c more than inlet tap
Maximum allowable pressure drop at stated 0.013 kg/cm2
air flow in new condition of filter
Volumetric efficiency 76.9(Min.), 83.311(Max.)
Mechanical efficiency at design condition 81.36
Total cooling water requirement within battery limit, 9 m3/hr
pressure drop and temperature rise
Lubrication Crank pin, piston pin, cross head shoes
lubricated by force feed lubrication
Oil pump discharge pressure, 2 to 3 kg/cm2
Motor
Make Marathon Electric Motors
Motor type Sq. Cage
Rating 75 KW
Efficiency at rated voltage and frequency 94.7 %
GD² value of motors 5.846 kg-m2
No. of permissible successive starts when the 2
motor is in hot condition.
129
7.16 Instrument Air Drier
Quantity 04 (01 set per IAC)

Make Mellcon Engineers Pvt Ltd
Capacity 600 m3/hr FAD
Cycle Time (A) Adsorption 8 hrs
(B) Regeneration 8 hrs ( 4 hrs heating, 3 hrs cooling, 1 hr idling)
Rgeneration temperature 180 oC
Heater Capacity 24 KW (2 KW x 12 elements)
Blower Capacity & Nos. 2.2 KW (02 per drier-1 working)
Dessicant Silica Gel (6-10 mm size, 460 kgs/bed)
Guaranteed Total power consumption / day 299.37 KWH
Pre/After Filters 02 nos each (Vertical with ceramic candle
cartridge; filtration size- 5 micron)
7.17 Transport Air Compressor (TAC)
Quantity 6 (4 Working + 2 standby)

Make Atlas Copco India Ltd
Type/ Model No. Oil Injected Screw / GA 400W
3 2
Capacity 3996 m /hr @ 4.5 kg/cm
Guaranteed Power consumption (rated) 323 KW
Compressor rotor speed 1542 RPM
No of screws 02 (1 male+ 1 female)
Transmission Gear Drive
Coupling Renold Flexible Coupling
Main Bearings Anti Friction (SKF make)
Lubrication Forced feed through pressurized oil tank
Cooling Water requirement 10 LPS (10 degree delta T)
Air intake filter Dry type paper filter (Clean DP-50 mbar)
TAC Motor
Make & Country of origin Marathon Electric Motors (I) Ltd. Kolkata
Motor type Sq. Cage Ind. Motor
Type of enclosure and method of cooling, TEFC / IC411 / IP55
Degree of protection
Type of mounting Horizontal Foot cum Flange
Direction of rotation as viewed from DE END Uni-directional. (CCW from DE side)
Standard continuous rating at 40 deg.C. 365 KW
Derated rating for specified normal condition 50 355 KW
deg.C.
Rated Voltage 3300 volts
Current 77 Amps FLC, 25 Amps no load current
Starting current (amps) at 100 % voltage 600% FLC
Pull up torque at rated voltage. 100 % FLT
GD2 value of motors 28 KgM2
No of permissible successive starts when 2
& motor is in hot condition.
Bearing Type Anti-Friction, Self Lubricated
130
7.18 Transport Air Drier
Quantity 06 (1 per compressor)

Drier
Product Refrigerated type compressed Air dryer
Inlet flow Capacity 3996 m3/hr
Inlet pressure 4.5 kgf/cm2 g
Maximum working pressure 6.5 kgf/cm2 g
Outlet Pressure 4.3 kgf/cm2 g (max. pr. Dr. across dryer= 0.2 kgf/cm2)
Relative humidity 100% / Outlet 9.1%
Inlet temperature 45 deg.C
Outlet temperature 41 deg.C
Dew point pressure +2 deg.C at 4.5 kgf/cm2 g
Ton of refrigeration required 9.45651TR
Power Input 14.25 kW at 45 deg.C inlet air temperature
Compressor for Drier
Make Copland – USA
Quantity 1 per dryer
Compressor type Hermetically sealed, Scroll technology
Refrigerant gas R407C
Cooling capacity 49300 watt (14.0182 TR) at 0 deg. C Evaporation and
43 deg. C Condensing.
Rating of crankcase heater 120 watt
Motor Speed 2900 rpm
Power Input(kW) Rated 14.25 kW at 45 deg.C Inlet temperature
Mass flow rate of refrigerant 300 g/sec
Air to Air Heat exchanger Plate type, cross flow Al. alloy heat exchanger, To
handle 3996 m3/hr @ 4.5 kg/sq.cm g
Evaporator with Moisture separator Plate type, cross flow Al. alloy heat exchanger, To
handle 3996 m3/hr @ 4.5 kg/sq.cm g
Condenser type Stainless steel brazed plate heat exchanger
Water consumption 175 Lpm
Water temperature In /Out 36 deg. C/ 41 deg.C
Water pressure 2.5 To 6 kg/cm2 g
7.19 Fly Ash Conditioner Water Pump
Make SAM TURBO INDUSTRY PVT LTD,

Numbers furnished 5 NOS (4 W + 1S)
Type Horizontal Multistage Pump, 4 stages
Total dynamic head at specified rated capacity 45 MWC
Shuf off head 52 MWC
Rated output of the drive motor 7.5 KW
Motor current 13.4 FLC, 5.5 no load current
131
7.20 Drain Pump( Silo area)

Type Vertical Centrifugal Pump, Single stage
Numbers furnished 2 NOS(1W+1S)
Shuf off head 44 MWC
Pump input power at specified rated 16.72 KW
capacity,considering sp gr as 1.17
Rated output of the drive motor 22 KW
Motor current 37.4 A FLC , 15 A no load current
Lubrication GREASE
Coupling between motor shaft and pump shaft PIN & BUSH
7.21 Wash Water pump (Silo area)

Type Horizontal Multistage Pump, 5 stages
Numbers furnished 2 NOS (1W + 1S)
Shuf off head 70 mwc
Rated output of the drive motor KW 11
Motor current 19.6 A FLC, 7A no load current
7.22 Silo Fluidizing Blower

Make KAY INTERNATIONAL LIMITED
Type Positive displacement twin lobe blower
Numbers furnished 5 NOS (4 W + 1S)
Discharge pressure 7 mwc + atmospheric
Blower speed 877rpm
Blower power 11.85 KW
Motor power, rpm 15KW, 1460 rpm
Motor current 27.3 FLC, 11.5 no load current
Discharge temperature Atmospheric + 710 c
Volumetric efficiency 66.29%
Mechanical efficiency 64.4%
Safety valve (relief valve) Spring loaded type
7.23 Buffer Hopper Aeration blower
Make KAY INTERNATIONAL LIMITED

Quantity 04 nos.
Discharge pressure 4 mwc + atmospheric
132
Blower rpm 958

Blower bkw 7.5 kw
Motor power, rpm 7.5KW, 1450 rpm
Discharge temperature Atmospheric + 410 c
7.24 Heaters of Silo & Buffer Hopper
Make M/s. Escorts limited

Type Cylindrical with u shaped heating element
Quantity Buffer hopper 04 nos, silo 05 nos
Rate of air flow per heater Buffer hopper 360 m3/hr & silo fluidising 400 m3/hr
Air pressure 0.9878 kg/cm2
Temperature rise across heater 50 degc
Number of heating element 9 nos
Rating of each heating element 1222w
No. of banks 02 bank, each of 7.33kw & 3.67kw
Type of insulation between heating element Magnesium oxide powder
Wire and sheathing tube
Density of insulation material 2.4gram / cm3
Fusion point 2800 deg. C
Shell insulation Glass wool
Material of heater wire Nichrome
Sheath temperature when heater is on and no 400 deg. C
Air flow
Time required to attain the specific 10-15 min.
Temperature [stabilized]
Wire temperature when heater is on and no air 800 deg.c
flow
133

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TECHNICAL DIARY

COMPILED BY: O&M COMMISSIONING

(Shivendra Kumar Sinha)

TAB 1 : BOILER & AUXILIARIES

TAB 2 : TG & AUXILIARIES

TAB 3 : ELECTRICAL SYSTEMS

TAB 4 : OFFSITE & COMMON SYSTEMS

N.B.- The schematics are available as PDF documents on

1.0 BOILER Page No.

2.0 BOILER AUXILIARIES

2.1 BOILER WATER CIRCULATING PUMP 13

3.0 ELECTOSTATIC PRECIPITATOR (ESP)

3.1 DESIGN CONDITION 32

4.0 SOOT BLOWER 35

6.0 BLOW DOWN VESSELS 37

8.0 SG EQUIPMENT COOLING WATER SYSTEM 38

9.0 SWAS PARAMETERS 40

9.1 CHEMICAL PARAMETERS LIMIT

10.0 FUEL OIL PUMP HOUSE 41

10.1 HFO PUMPS

11.0 MILL REJECT SYSTEM 44

12.0 STARTUP CURVES As Annexure

12.1 COMBINED BOILER TURBINE STARTUP CURVES

12.2 TURBINE STARTUP CURVES- CONSTANT PRESSURE

2.0 TURBINE AUXILIARIES

2.1 CONDENSATE EXTRACTION PUMP 67

2.3 VACCUM PUMP 73

2.4 TG EQUIPMENT COOLING WATER SYSTEM 74

2.5 SG EQUIPMENT COOLING WATER SYSTEM 75

2.6 AUXILIARIES COOLING WATER SYSTEM (ACW) 75

2.7 CONDENSER ON LOAD TUBE CLEANING SYSTEM (COLTCS) 76

3.0 DM MAKEUP & CPU REGENERATION SYSTEM 77

4.0 COMPRESSED AIR SYSTEM 79

BOILER AND AUXILIARIES

Prepared By Reviewed By Approved By

1.0 BOILER Page No.

2.0 BOILER AUXILIARIES

2.1 BOILER WATER CIRCULATING PUMP 13

3.0 ELECTOSTATIC PRECIPITATOR (ESP)

3.1 DESIGN CONDITION 32

4.0 SOOT BLOWER 35

6.0 BLOW DOWN VESSELS 37

7.0 PRESSURE REDUCING & DESUPERHEATING STATION (PRDS) 38

8.0 SG EQUIPMENT COOLING WATER SYSTEM 38

9.0 SWAS PARAMETERS 40

9.1 CHEMICAL PARAMETERS LIMIT

10.0 FUEL OIL PUMP HOUSE 41

10.1 HFO PUMPS

11.0 MILL REJECT SYSTEM 44

12.0 STARTUP CURVES As Annexure

12.1 COMBINED BOILER TURBINE STARTUP CURVES

12.2 TURBINE STARTUP CURVES- CONSTANT PRESSURE

BOILER & ITS AUXILLIARIES

1.1 GENERAL SPECIFICATION

19177 301-51 CC+

1.3 FURNANCE SPECIFICATION

Type Balance Draft Furnace With Fusion Welded Water

1.4 WATER WALLS

Total water wall tubes 1072 Nos.

1.4.1 WATER WALL RIFLE TUBES

OD 51.0 & 63.5 mm

1.4.2 WATER WALL SMOOTH TUBES

OD 51.0 & 63.5 mm