ITC Limited Paperboards and Specialty Papers Division Supply 3.2.3 ANNEXURE 2 3.

.O TECHNICAL PARTICULARS : The technical particulars as given under shall be The live steam flows through the valve body of the followed : emergency stop valve, which is welded to the turbine casing, to the valve chest housing the control valves. These are actuated by a lift bar and are so designed that the lift 3.1 STEAM TURBINE GENERATOR bar, which is raised and lowered via a lever system by the relay cylinder, determines the lift and point of opening of the The design and manufacture of the turbo-generator and valves. The relay cylinder which is bracked mounted on the auxiliaries shall incorporate up-to-dated technology and valve chest, receives its control pulses from the hydraulic expertise for reliable and efficient performance. The TG speed governor. set shall be capable of operating, in parallel with existing 21MW capacity SUPPLIER turbo-generator set and APSEB grid and the design manufacture shall include the necessary features. The equipment shall also confirm to 3.2.4 CONTROL FITTINGS the latest applicable standards, safety codes, test codes, statutes and regulations. The figures indicated below may undergo slight changes during detailed engineering. However the performance guarantees stated under Annexure-4 shall remain unaltered. The final values shall be mutually agreed and all the systems and equipment shall be complete in all respects. 3.2 TURBINE: GENERAL 3.2.5 The turbine, Model EG 800 2, shall be supplied as complete unit with the control gear mounted on the casing and drains brought to convenient terminal points on the basement. Part of the steam is bled down from the turbine at the The parameters of the turbine and other particulars shall extraction branch behind the H.P. drum blading and fed to be according to annexure 4. The turbine shall be the extraction steam system. The control member here is designed in such a manner that it is suitable for operation an extraction stop valve which operates and is tripped out in from 450 Degree Centigrade temperature up to 480 the same manner as the H.P. emergency stop valve. The purpose of the extraction stop valve is to separate the Degree Centigrade temperature turbine from the extraction steam on tripout in order to prevent the turbine from over speeding due to reverse flow steam when the machine is shut down. The pressure at the 3.2.2 DESIGN extraction branch is controlled by the L.P.. control valve. The steam rate through the L.P. section is matched to the extraction rate in such a way that the pressure at the The single-cylinder extraction back-pressure turbine is ofextraction branch is kept constant within the design data. the axial flow type, i.e. the working steam flows in the axial Governing is by means of an extraction pressure controller. direction. Arranged before the turbine casing is the The L.P. section consists of a further length of drum blading. combined emergency stop valve whose function is to shut The H.P. drum blading is separated from the L.P. blading by off within the shortest possible time the total steam supply a diaphragm with labyrinth. from the boiler to the turbine in an emergency. The turbine casing is split axially. It is mounted on and aligned at the bearing blocks by means of the casing side brackets and centering guides. Particular importance has to be attached to the alignment because the turbine shaft and the outer shell are supported independently on the bearing STEAM EXTRACTION STEAM FLOW

The H.P. control valves admit the live steam via the nozzle groups to the single row regulating stage or, an opening of the automatic overload valves, directly to wheel chamber before the drum blading. After part of the energy of the live steam has been utilized in the regulating stage, the steam is passed to the drum blade rows for doing further work depending on the available heat drop.

3.2.1.

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ITC Limited Paperboards and Specialty Papers Division Supply blocks. Whilst the position of the shaft is fixed by the type. The governor impeller which produces the control bearings, the outer support of the casing must be so impulses is arranged in the casing of the main oil pump designed as to allow of thermal expansion. The correctwhich is flanged to the front-end bearing block the governor casing height is determined by the side bracket supportsimpeller and the main oil pump are driven from the turbine whilst the small clearance of the heads of the machine bolts shaft via gear trains. The function of the emergency used to bolt the cylinder side brackets to the bearing block governor is to interrupt the steam supply to the turbine as permits transverse thermal expansion of the casing relativesoon as speed rises to an inadmissible value in the event of to the two bearing blocks. The casing is centered in the a disturbance. horizontal plane through the turbine axis by the upper and lower casing centering guides which are designed to permit The reduction gear reduces the high speed of the turbine to the outer shell to expand freely in the vertical upward and the lower speed of the generator. downward direction.

3.2.6

For the supervision of the turbine a number of pressure measuring devices are connected in the different steam belts. Thermometers in the bearing oil drain lines enable periodic checks of the bearings to be made. Damage to or excessive wear of the thrust bearing would lead to a The rear end bearing block is fixed relative to the bedplate. reduction, below the safe limits, of the axial clearances of Since the lower casing centering guides do not allow of any the shaft and glands or of the blading. For this reason, the axial displacement of the casing blocks, the front-endposition of the shaft is measured at the front end by means bearing block is moved towards the front end on thermalof the measuring device arranged at the oil pump casing. expansion of the casing. The oil piping is therefore installed 3.2.6 BEARINGS with sufficient flexibility. Transverse displacement of the front-end bearing block is precluded by an axial feather key. Turbine rotor bearings shall be of white metal lined steel shell type the bearing surfaces being suitably designed The exhaust branch is cast integral with the turbine casing to ensure stable operation. Multi-lobe type journal and directed downwards. The turbine shaft is machined bearing shall be provided. The turbine thrust bearing from an alloy steel forging. The journal bearings supporting shall be of Michell tilting pad type capable of absorbing the turbine shaft are arranged in the two bearing blocks. both forward and reverse thrusts. The white metal faced The front-end bearing block also houses the thrust bearing titling pad shall be mounted in steel carrier rungs which which locates the turbine shaft axially and takes up the axial are fixed to the liner. The thrust bearing shall be provided with an "equalling ring" to ensure accurate load forces. sharing between pads. The thrust bearing shall be located in the steam end pedestal and shall maintain the The turbine shaft and reduction-gear pinion are connected correct axial clearance between the moving blades and by a tooth coupling to prevent the transmission of any axial the fixed blades. The bearing casings mounting bearings thrust or any bending moments to the reduction-gear pinion. shall be designed to take care of thermal expansions and movements as required. The blading consists of an impulse stage, which permits partial admission and consequent efficient governing and of number of reaction stages in the drum part. The radial and 3.2.7 STOP AND EMERGENCY VALVES axial clearances are liberally designed with a view to combining a high operational safety with an optimum Combined stop and emergency valves mounted on the utilization of the available heat drop. steam chest shall be provided to enable manual control of flow of steam to the turbine during starting sequence The function of the dummy piston is to compensate the axial and also to act as quick closing valves during thrust to the highest possible degree. Since the axial thrust emergency conditions. varies with the load, the residual thrust taken up by the thrust bearing mentioned above. At the same time, the The valve shall be of single seated design and shall be dummy piston seals off the high pressure in the wheel balanced to permit easy hand operation against full chamber against the pressure prevailing before the shaft steam pressure. The surfaces of both valve and seat shall be stellited/hardfaced to ensure maximum glands. operation life. A steam strainer shall be incorporated in the valve body to provide protection against the entry of The labyrinth glands seal off the casing at the points where foreign matter into the turbine. The valve shall be held in the shaft pass through it. open position under normal operating conditions by a trip ring which shall be connected by mechanical linkage The governing system of the turbine is of the oil hydraulic to a hydraulic trip cylinder. When the turbine tripping

CASING, SHAFT SUPPORT

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ITC Limited Paperboards and Specialty Papers Division Supply device is actuated, or on loss of oil pressure the valve shall close under the influence of the stop valve spring shutting off all steam to the turbine. Emergency trip solenoid operation shall be so arranged that the valve may be tripped from a push button station on the turbine front standard and from main control panel. The Desuperheating stations shall be provided at the extraction line after the turbine flange to reduce steam temperature from 274oC to 220oC as well as the exhaust steam line, after the turbine flange, to reduce steam temperature from 191-188oC to 165oC. The spray water for desuperheating shall be taken from single point tapping from the spray water pumps discharge at 30 KG/cm2 & 135C. The Purchaser shall arrange the tapping at the nearest point. The control valves shall be designed for long life. All control valves must be accompanied by manual isolation valves on both sides and a manual bypass valve. The necessary controls for PRDS shall be provided. The system shall be designed to meet IBR requirements.

3.2.8
3.2.8.1

STEAM PURITY Introduction

The build up of deposits in turbines due to impurities in the steam can cause both thermodynamic and Necessary flow measuring instruments and controls mechanical problems which can develop in to blade must be incorporated for measuring the extraction and failure if chlorides are present. This means that it is exhaust steam flow and spray-water flow. essential to eliminate chlorine and its compounds. E.g. MgCl2, NaCl, From the steam. It has been shown 3.1.10 LUBE OIL SYSTEM beyond doubt that even a quantity of 0. 0025% Cl is dangerous for all the high-temperature steels used in blade manufacture. The corrosion attack of the aggressive deposits affects primarily the alternating 3.1.10.1 GENERAL bending strength of the blade materials in the region of initial steam wetness. A satisfactory and continuous supply of oil is essential for the safe and reliable running of a turbine and its driven equipment. The oil supply system should ensure the 3.2.8.2 Guide values operational safety of bearings. The system is of the closed circuit type, i.e.; a definite amount of oil quantity, which is The VGB guidelines for feedwater and boiler water arepreviously determined, is continuously recirculated. recommended as the basis for the requirements concerning steam purity. Please refer tables 1-5. Apart from this, the oil supply system has to ensure the oil required for the governing system and the safety devices of Although it is basically high desirable for these guide the turbine at an increased pressure. For this, same oil is values to be attained, it is not always economically used whose pressure on leaving the pump equals first the feasible to do so. This is especially true when control oil pressure of governing system and then the lower commissioning new plant and also during all start- upsbearing oil pressure. and shut-downs. The oil supply system includes the following equipment: When assessing the cost of water treatment, however, the cost of possible turbine outages and repairs resulting from steam-impurity damage should always be offset against it. The oil tank from which the pumps draw in the oil and to which the oil is returned after passing through the governing system and the bearings. In order to avoid any misunderstandings we should emphasize that the guide value for steam purity given in the following tables are only a starting point they provide The main oil pump , driven by A.C. motor delivers the no guarantee of the complete elimination of turbine oil and raises its pressure to the necessary control oil deposits. pressure. If there is any possibility of improving the steam purity The A.C driven Auxiliary oil pumps has been designed above the given guide values it is strongly advised that it as full duty pump also so as to work as standby to main be taken. oil pump. 3.2.9 DESUPERHEATER STATIONS

The DC motor driven Emergency oil pump supplies oil to the turbine bearings during coasting down period of

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ITC Limited Paperboards and Specialty Papers Division Supply the turbine. The heat absorbed by the oil in the bearings and elsewhere in the oil system is dissipated in the oil cooler which is of shell and tube design.

The oil coolers in which the heat absorbed in turbine oil system is dissipated. The adjustable orifice in which the heat absorbed in turbine oil system is dissipated.

The system consists of two oil coolers each of 100% The adjustable oil throttle, provided between oil cooler capacity. A change over device (double 3 way transflow and duplex filter maintains the oil pressure in the lube valve arrangement) is provided for switching over to standby oil heater pressure to the required bearing oil pressure. oil cooler whenever it is necessary to take the main cooler for maintenance. . The change over device is so designed The adjustable bearing oil throttles, which permit tothat under any circumstances both the coolers are not adjust the oil quantity, required for the relevantallowed to be shutdown. Whenever feasible, the switching over to the standby oil cooler is to be carried out during the bearings. standstill condition of the turbine. If it proves unavoidable that the switching be made in the course of turbine Duplex type oil filters to clean the oil from possible operation, it should be done with utmost care before switching over to another oil cooler, this must be generously contamination. vented and the bearing oil pressure must be observed during a considerable period afterwards. The oil vapour extraction fan to remove oil vapours from oil tank.

3.1.10.2

OIL TANK 3.1.10.4 OIL FILTERS

The oil tank serves for storing the oil volume required for governing and lubricating systems. It allows oil to be filtered through strainers mounted in the oil tank and the impurities are deposited at the bottom of the tank along with the oil sludge. A gradient is provided at the bottom of the tank to The duplex type of oil filter having replaceable paper enable the impurities to be collected for easy drain off. cartridges with filtration of 10 microns are provided. This is Besides strainers, baffle plates are also provided to give ain addition to the oil strainer arrangement provided in the oil longer path for the returning oil by allowing it to remain tank. A changeover device is also fitted for switching over to longer time in the tank so that the entrapped air is effectively standby oil filter in case of choking of the working filter. The released. The oil level in the tank can be indicated by a floatchange over device is so designed that under any cylinder for direct indication on the operating floor. The oil circumstances both the filters are not allowed to be tank is further provided with necessary connections for oilshutdown. A differential pressure switch (DIPSH) set at 1.0Kg/cms is provided to annunciate high differential centrifuge. pressure.

3.1.10.3

OIL COOLER

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ITC Limited Paperboards and Specialty Papers Division Supply methods as permitted by design must be incorporated in the system such that the oil pressure is maintained in the system till such time the auxiliary oil pump develops sufficient pressure to bring the oil pressure to normal operating pressure. 3.1.10.5 OVERHEAD OIL TANK

c)

In addition an Overhead oil tank is provided for supplying oil to the turbine bearings when the other oil pumps are not in operation during turbine trip condition.

An oil pump A.C. motor driven for turning gear operating shall have sufficient capacity to lubricate all bearings of the unit and to supply oil to turning gear continuously. Starting control for the motor of each pump shall have independent bearing oil pressure switches/transmitters whereby the pump shall start from a drop of bearing oil pressure. The variation in Bearing oil pressure and pump condition shall be indicated in the DCS Separate pressure switch/transmitter shall be provided for inter-locking with turning-gear motor starter to prevent turning gear operation until oil pressure is established. Oil, vapour and other auxiliary piping systems shall be of welded construction to the maximum possible practical extent. Seamless stainless steel piping shall be used and shall be designed, constructed and installed so as to minimise oil fire hazards. The piping shall be adequately supported and braced so as to minimise vibration. Screwed or mechanical joints on these systems shall be minimised and used only where essential to the equipment. Friction type ferrule joints to be avoided. Wherever required couplings with integral ferrule ends only to be used. Oil lines in the vicinity of steam piping shall be shielded so that in the event of rupture, oil will be contained and returned to a reservoir. Pipe hangers as required by design shall be supplied by Supplier. All bearings shall have local thermometer for bearing temperature assessment. Each bearing shall be provided with R.T.D. assembly, its wires brought to the terminals for onward connection to instruments and DCS. GOVERNING SYSTEM

d)

3.1.10.6

INSTRUMENTATION

e)

Several local and remote panel mounted instruments are provided in the system to ensure monitoring of oil supply system. The instrumentation shall be as per lube oil scheme, and instrument data sheets.

f)
3.1.10.7 DESIGN CRITERIA The lube oil system shall be adequately designed, including the following features.

a)

Each oil cooler shall be designed for not less than 130 percent of actual heat duty at the nameplate rated capacity of the turbine - generator unit at the specified water rate and maximum water temperature. Main and auxiliary oil pumps shall each have sufficient capacity to lubricate all bearings at rated speed and to operate governor mechanism and trip valve. Auxiliary oil pump shall start automatically upon hydraulic oil pressure falling below normal operating pressure. Necessary NRVs or any other

3.1.11

b)

The speed of the unit shall be controlled to provide stable operation of the unit in parallel with existing 21MW SUPPLIER TG set and the APSEB Grid (as detailed in the next section), and the governing characteristics specified herein. All controls should be through MAX-DNA Distributed Control System. Performance of the governing mechanism shall be in accordance with AIEF recommended specification for speed governing steam turbine intended to drive Electric generators rated 500 KW and above or alternatively

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ITC Limited Paperboards and Specialty Papers Division Supply conforming to approved equivalent engineering standard of the country of origin of the equipment. All controls like load sharing between the turbines and grid must be conceived for both the turbines mentioned above. A) (redundant) for system cabinets. 2 Feeders of 5 Amps, 240 V AC, UPS Power (single) for maxSTATIONS. Steam Turbine Controls: Digital controller as per enclosed features and configuration drawing. Control hardware is proposed to be housed in 3 cabinets of dimension 750mm (W) x 750mm (D) x 2365mm (H). These panels above, shall include

3.2 3.2.1 1.

MAX-DNA DISTRIBUTED CONTROL SYSTEM GENERAL FEATURES

1)

1:1 Redundant Microprocessor based Automation units (32 bit DPU) for EHTC, Steam Turbine Bearing Metal Temperature Monitoring. EHTC functions are Speed Control, Load Control, Back pressure control and Extraction Pressure Control. 1:1 Redundant Microprocessor based Automation units (32 bit DPU) for Turbine Protection (TP) and Turbine I&P.

Distributed

Processing Units (DPU) with I/O modules, Power supply modules. 12 port Ethernet switches (one pair).

2.

Load transducer. 110V / 240V AC

converters.

to 24V DC power supply

2)

3.

Interfaces: maxLINKS to TSI and purchasers DCS and Link to DCS is envisaged primarily for DAS functions, Tthough two way communication is possible, all operations shall be carried out from maxSTATIONS 3) only. Pentium PC based MMI-DAS with maxSTATIONS, to be placed on table top. TWO

Two nos. maxSTATIONS (redundant OWS/EWS), two nos. printers (one Laser printer and one IJP) and one pair of 12 port Ethernet switches, in Control Room. maxNET cabling as indicated in sl no. 5 above. C&I cables:

4.

4)

a)

Field cables from sensors to JBs: 2P/4P, 0.5 sq mm, FEP/ PTFE, overall screened, un-armoured.

a)

The two stations provide for OWS and EWS functions and one station would be back up to the other.

b) Both stations are envisaged in control room at a

maximum distance of 50 metres from the STG system cabinets.

b)

Grouped cables

i)

Signal cables (analog): 4P/8P/12P, 0.5 sq mm, PVC FRLS, individual and overall screened, armoured.

5.

maxNET Components: 12 port Ethernet switches (one pair) and 10Mbps UTP cable connectivity from DPUs to switches and 10Mbps UTP cable connectivity from maxSTATIONS and printers to switches. Power supply shall be provided by the Purchaser (terminated in load transducer cabinet) for the above system is: 2 Feeders of 5 Amps, 240 V AC UPS Power

ii) iii) iv) v)

Binary signal cables: 4P/8P/12 P, 0,5 sq mm, PVC FRLS, overall screened, armoured. Solenoid cables: 1 2P, 1.5 sq mm, PVC FRLS, overall screened, armoured. Compensating cables: 2P/4P/, PVC FRLS, individual and overall screened, armoured. Cables between system cabinets and from system cabinets to MCC: 4P/6P, PVC FRLS, overall screened, un-armoured.

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ITC Limited Paperboards and Specialty Papers Division Supply

5)
Field Junction boxes for above cables. However, the Supplier shall upgrade the system and the specific inputs shall be incorporated as when required as per the detail engineering. 3.2.2 GOVERNING CONTROL

Operator interface consisting of max Stations, ASCII Keyboard and accessories performing MMI and DCS functions. Integral sequential event recording FUNCTIONAL DESCRIPTION

3.2.3

The MAX-DNA system provided shall be compact Digital control system for Steam turbines, which shall be built around a Microprocessor based process control system. The system shall be flexible, of modular structure and offer high reliability and availability. MAX-DNA shall feature the following :

MAX-DNA shall cater to the following functions :

Electronic Hydraulic Turbine Control, as detailed in section 3.2.1 above. Interlock and Protection for Turbine Auxiliaries Turbine Protection Generator protection MMI and DAS function ELECTRO GOVERNOR HYDRAULIC TURBINE

Electronic hardware and software to meet the requirements of main analog and digital control loops of electro-hydraulic turbine governing control. It should be suitable and capable of functioning in parallel with the existing 21MW SUPPLIER TG set and the APSEB Grid as detailed below

1.

Case 1 18.5MW Steam Turbine generator set (hereinafter called as TG4) running parallel with existing 21MW SUPPLIER TG set (hereinafter called as TG3) on load sharing and in solo mode, i.e. with APSEB grid isolated from system.

3.2.4

The Electro Hydraulic Turbine control positions the governing valves in the inlet steam line to the steam turbine. The control system drives a positioner which further drives the servomotor positioning the governing valves. This controller shall consist of the following :

2.

Case 2 TG4 running parallel with TG3 and APSEB grid on load sharing mode. -Speed Control -Load Control -Frequency Control -Extraction control -Back Pressure Control All the above controls must comply with the different operating conditions as mentioned in section 3.2.1 above.

3.

Case 3 TG4 running parallel with APSEB grid on load sharing mode and TG3 isolated from system, i.e. TG3 running in solo mode.

4.

Case 4 TG4 running in solo mode.

3.2.5

SPEED CONTROL

Electronic hardware and software to meet the requirements of interlock and Protection Drives for Turbine and turbine Auxiliaries.

This shall consist of speed reference, speed actual, speed controller and other associated logics. Speed reference is set from REMOTE. The rate at which Turbine accelerates/decelerates is determined by imposing time factor of startup curves in the time dependent speed reference block. Speed actual signal is measured in three channels. Signal measurement is possible even with only one

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ITC Limited Paperboards and Specialty Papers Division Supply channel being healthy, and other channels being under redundancy. A feature to detect and announce failure of 2 of the 3 channels shall be provided. Speed controller is realised as a PD function . REMOTE. It is set to the rated value of Controlled Extraction pressure . Extraction pressure is measured as a 4-20 mA signal from a Pressure Transmitter. Extraction controller is realised by a PD function . Extraction limiter provides limiting on the Extraction controller output. Extraction limiter shall be set to zero during startup and loading till such time conditions for taking extractions are fulfilled.

3.2.6

LOAD CONTROL

This shall consist of Load reference, Load actual and Load controller and other associated logic. Load reference is set from REMOTE. The rate at which the TG is loaded is determined by imposing time factor of Loading curves in the time dependent load reference block. Load actual signal is measured from 3 phase CTs and 3 phase PT ' s in a Load Transducer housed in the Cabinet. The Load Transducer offers a burden of 0.1VA for PT's and 0.5 VA for CTs. The CT's & PT's shall be of Instrument Class (0.5 class) as the signal is used for control purposes. Load control is realised as a PI Controller. The load controller maintains the generated load actual equal to set value irrespective of grid conditions. The load controls must be so designed such that it is capable of complying with all the different operating conditions as mentioned in section 3.2.1 above.

3.2.9

EXHAUST/BACK PRESSURE CONTROL

This shall consist of Back pressure reference, Back Pressure actual, Exhaust Controller and other associated logics. Exhaust/Backpressure reference is set from REMOTE. It is set to the rated value of Exhaust pressure . Exhaust pressure is measured as a 4-20 mA signal from a Pressure Transmitter. Exhaust controller is realised by a PD function .

3.2.10

RATIO SETTER

The power generated between HP and LP turbines for varied load and extraction requirements shall be met in this function block, which shall generate position setpoints for the different HP and LP positioners.

3.2.11 3.2.7
FREQUENCY CONTROL (Requiremnt to be decided during detailed engg)

POSITION REFERENCE

This shall consist of Frequency reference, frequency actual, Frequency controller and other associated logics. Frequency reference is from REMOTE during operation of TG4 not connected to TG3 or grid or both. When TG4 is running on TG3 and/or grid, frequency reference tracks the grid frequency and when TG4 is running in parallel with TG3. Frequency actual is measured using a frequency transducer in the range of 45 Hz to 55 Hz. Frequency controller is realised as PI function. Frequency control function shall be effective only when TG4 is not connected to TG3 or grid or both. This functlon is steplessly out in' and 'out out by frequency influence circuit.

Current signals of 4-20 mA corresponding to 0-100% valve lift drive, the forward acting current, to hydraulic pressure (I/H) converter which in turn shall supply a hydraulic fluid output pressure(directly proportional to input current signal) for positioning of the governing valves.

3.2.12

POSITION CONTROL

An analog position controller shall drive the Electrohydraulic Converter. The Electrohydraulic Converter shall generate required oil pressure to position the governing valves. The actual position of the Electrohydraulic Converter shall be measured by a LVDT mounted on the followup piston.

3.2.13

RUNUP LOGIC

3.2.8

CONTROLLED EXTRACTION PRESSURE CONTROL consist of Controlled Extraction Pressure Controlled Extraction Pressure actual, Limiter, Extraction Controller and other logics. Extraction reference is set from

This shall reference, Extraction associated

This logic feature shall do the task of checking the permissives for Start-up, releasing command for raising the speed of the turbine to soaking speed and after ensuring sufficient temperature margins, releasing commands to Electronic Governor for raising the speed to rated/synchronising speed. All critical parameters like shaft/casing/bearing vibrations, axial displacement and

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ITC Limited Paperboards and Specialty Papers Division Supply temperature margins shall be checked during the sequential operation.

3.2.14

INTERLOCK AND PROTECTION TURBINE AUXILLIARIES

FOR

For the easy identification of the turbine tripping, firstup alarm is envisaged through software SOE (60 points) with one millisecond time resolution. This integral to the turbine DCS and no hardware multiplication of the field signal is envisaged.

Turbine Auxiliaries like Main Oil Pump, Auxiliary oil pump, Jacking oil Pump, Emergency Oil Pump, Turning Gear Motor, Oil vapour Extraction fans, Gland steam exhaust, Extraction spray water control valve, Exhaust spray water control valve, Exhaust warm-up vent valve, backpressure control valve, Trip lever engagement (when envisaged) and Speeder Gear (when envisaged) shall be operated in either Auto/Manual mode as functionally envisaged for each drive/control. The logic for each drive takes into account the permissives for Start/stop and Actuator/MCC feedback, monitoring of status/check back discrepancy and MCC alarms. Protection signals over ride to switch the drive to the desired state. The control logics shall be realised using software function blocks. The logic outputs drive the coupling relays mounted in the system. The contacts from these coupling relays shall be interfaced to MCC.

3.2.17

PC BASED MMI AND DCS FUNCTION

The MMI and DCS software features shall be WINDOW based It shall be a menu driven, user-friendly package with following features. 3.2.17.01 GRAPHIC EDITOR maxDNA engineering station shall provide graphic editor and configuration editor facility. The graphic editor shall be used to create the various mimics needed for control system. The graphic editor shall support the drawing utilities such as line, rectangle, circle etc., with facility to fill colour and patterns. The editor also shall facilitate the loading and saving of different pictures that are created. It shall also provide the zooming facility for selected portion of the display on monitor. The configuration editor supports modification of control logic configuration.

3.2.15

TURBINE PROTECTION

3.2.17.2

MAN MACHINE INTERFACE

This function shall be realised in the same environment wherein I&P functions are implemented for Turbine Auxiliaries Protection system shall consist of acquisition and monitoring of the Trip Inputs, Trip logic processing (including 2 out of 3 evaluation wherever required) and outputting the resultant to drive the field trip solenoids. Protection scheme shall be generated as a single channel energised to trip. The following signals (not limited to) shall be used in Protection System.

The man machine interface shall provide process parameters information with the help of graph, trend display and MIMIC/plant schematic pictures.

3.2.17.3

GRAPHIC DISPLAYS

Any process parameter shall be able to configure for bar or real time line graph display. The graphic display shall be able to be made to change colour under alarm conditions. This utility shall also allow the user to configure and edit different frames . The features of the bar graph display shall be : -

Lube Oil Pressure Very Low Control oil Pressure very Low Vibrations very high Axial displacement very high Speed very high Extraction Pressure very high Extraction Pressure very low Backpressure very high Backpressure very low Turbine Trip -Manual Generator Trip ALARM ANNUNCIATION

Horizontal/Vertical bar graph display Real time line graph display Option to display the graph inside a window Display of stacked graphs for concurrent display of related parameters, as a group. MIMIC

3.2.17.4

3.2.16

Visual display of the plant shall be able to be created through the plant schematics using graphic editor to

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ITC Limited Paperboards and Specialty Papers Division Supply construct various plant schematics. Various references point can be marked which will dynamically display the plant values in Engineering units or bar or trend. The various mimics shall be arranged hierarchically. On start-up the over view mimic of the plant is displayed. The plant schematics shall exhibit 10 nos latest alarms. and current alarm shall be displayed on the last line of the screen. However, the printout shall give the entire alarm report showing all the alarms status. User shall be able to generate alarm history reports by entering date, starting time and ending time for which the alarm report is required to be generated .

3.2.17.5

TRENDING

3.2.17.7

HISTORY OF DATA

The current/historical trending shall provide an automatic and comprehensive means of sampling, storing and displaying process data over long period of time. Data collection shall run automatically on-line in the background. Trend assignment : With the menu driven trend assignment programs, one shall be able to specify the tan names of each process parameter. Trend Data Collection: The process parameter data assigned for trending shall be collected from process data base with time/date/value (with Engineering Units). Trend Display : The trend display program shall allow the user to view upto 6 trend so per Window with maximum of 8 windows per display frame. Each trend point shall be displayed with different colour inside the window.

The supplier shall ensure that the hardware and the software along with the required memory shall be provided for historisation of data. The details shall be furnished by the Supplier to the Purchaser/Project Consultant in due course during detail engineering.

3.2.18

DESIGN CONDITIONS

The MAX-DNA control and DCS system shall be suitable for the following ambient operating conditions : For modules in operation continuous permissible temp . Humidity condition : 0 to 60C

: Max. 90% RH Noncondensing

3.6.3

AUTOMATIC VOLTAGE REGULATOR

Direct connected, self-excited, differential compound wound, stabilised type, automatic fast acting Digital static voltage regulator shall be furnished with all features. The overall excitation system response ratio shall not be less than 1.3:1 The voltage level Betting device shall have a minimum range from +10 to -10 and shall be separately mounted.

3.2.17.6

REPORT GENERATION :

The report generation package shall provide comprehensive reporting capabilities which can be displayed on the screen or printed on the printer. The printer shall be of LASERJET type. The following reports shall be generated by the system : Hourly Report Shift Report Daily Report Weekly Report Any other specific time based report ALARM REPORTS

3.3

PIPING AND WELDING

3.2.17.6

All steam, water, air piping with necessary valves, control valves, flow elements along with necessary instrumentation within TG hall shall be supplied and shall be suitable for the duty intended, piping layout shall be done to meet functional requirement and aesthetics. The steam piping for extraction and exhaust/backpressure steam shall be of carbon steel seamless type and shall conform with the Indian Boiler Regulations, and with the American standard for pressure piping, ASA B 31.1 or its equivalent as determined by the Purchaser.

The alarm reports shall consist of tag name, tag description and alarm status with the time of occurrence. The screen shall contain the details of last ten alarms

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ITC Limited Paperboards and Specialty Papers Division Supply

A quick closing hydraulic non return valve shall be provided in the Controlled extraction steam line before the isolation valve. A suitably designed safety valve along with vent piping and silencer such that the sound level do exceed 85 Decibels, and necessary drain piping and valves shall be provided. Suitably designed vent piping along with necessary control and isolation valves shall be provided for warmup and backpressure control along with silencers such that the sound level do exceed 85 Decibels. All the main control and motorised valves should have a manual bypass valve. All oil piping shall be of seamless stainless steel material conforming to ASTM standards or its equivalent as determined by the Purchaser. However, the return oil pipelines and the oil tanks can be of carbon steel material. All joints must be of welded type to the maximum possible extent. Screwed or mechanical joints on these systems shall be minimised and used only where essential to the equipment. Friction type ferrule joints to be avoided. Wherever required couplings with integral ferrule ends only to be used. Oil lines in the vicinity of steam piping shall be shielded so that in the event of rupture, oil will be contained and returned to a reservoir. Pipe hangers as required by design shall be supplied by Supplier. All welding on piping shall be done, by qualified welders using methods approved by purchase, in accordance with The American Standard Code for pressure piping ASA B 31.1 or its equivalent as determined by the Purchaser. Piping within Boiler Code jurisdiction shall conform to Indian Boiler regulation Code requirements. Agency that performs inspection of welding shall, certify welders' qualification in accordance with requirements of applicable code. All the suitable supports for valves and piping shall be provided as per acceptable design parameters.

Mechanical equipment will have all machined and bright, surfaces coated with anti-corrosive solution and all external surfaces painted with zinc rich epoxy paint. Small assemblies such as valves, and similar equipment will be packed in wooden cases with suitable strapping; large assemblies shall be protected wherever necessary by mild steel plates or wooden slabs. Loose materials such as bolts, nuts etc., shall be packed in gunny bags after liberal application of rust preventive compound and sealed in polythene bags and then put in wooden boxes to avoid loss. Fragile material shall be amply fastened and packed to prevent shifting and rattling. The packing should be make in such a manner to absorb any shocks and impact.

3.5

THERMAL INSULATION

Heat retention insulating material, shall consist of the following : 1. Plastic insulating cement and/or block insulation for upper and lower turbine shells, steam valve bodies and exhaust casing, where required.

2. Preformed segmental pipe insulation (with canvas jacketing) for steam piping (between stop valve and turbine) steam-seal piping and all other steam piping furnished by Supplier.

3.

Removable, Aluminium Sheet of 0.71 mm (22 SWG) thick covers filled with block and/or plastic heat retention material for main stop valve, flanges, turbine shells and where required. Block and/or plastic in removable, reusable steel cages, for those horizontal and vertical joints that. must be parted for turbine maintenance. GENERATOR INTRODUCTION

3.4

PACKING OF MATERIALS

4.

For all equipment, the internal surfaces will be thoroughly cleaned and dried before preparing for shipment. All stubs shall be protected suitably with carJ9. All machined faces will be protected with Mild Steel plate. External surfaces of such equipment will be given liberal application of with zinc rich epoxy paint. Screwed ends will be protected by tightly wound tarred twine. Tubes would be strapped together in suitable bundles and protected properly for handling and transportation.

3.6
3.6.1

The synchronous generator Model TAII 1240-12P-15 is of 4pole, 3-phase air cooled type and is designed for continuous operation at its rated output. The constructional features ensure reliability, easy maintenance and economical operation. The generator is suitable for operation with any of All steel work, plate work, gallery flooring etc., will be the modern excitation systems. sand blasted and painted liberally with zinc rich epoxy paint.

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ITC Limited Paperboards and Specialty Papers Division Supply 3.6.1 GENERATOR ELECTRICAL CHARECTERISTICS The Generator, , shall have maximum continuous rating of 18.5 MW, 0. 8 Power Factor, 11.0 KV, 1500 RPM, 50 Hz. The generator shall be capable of supplying power to a 2 MW, 6 pulse rectifier load in isolated operation delivering 18.5MW. Generator shall be capable of delivering satisfactory continuous operation at rated KVA and power factor at any voltage not more than 5 percent above or below that rated voltage and within a frequency range of 47.5 to 51 Hz even if the voltage and frequency variations occur simultaneously without exceeding the safe temperature rises, but not necessarily in accordance with the performance standards established for operation at rated voltage and frequency. In order to withstand short circuit forces, the winding overhangs are stiffened by spacers between the coil ends and with bandage rings. The whole stator, including the winding will be kept in a tank and immersed in synthetic resin and impregnated under vacuum and pressure. After impregnation it will be cured at a specified temperature in an oven. This process results in extremely good mechanical and electrical strength. The insulation of the winding corresponds to Class 'F'. Three neutral terminals, three phase terminals are brought out on the non-drive end of generator. 3.6.3 3.6.3.1 ROTOR ROTOR SHAFT

The rotor shaft is forged out of chrome-nickel-molybdenum or equivalent material with the required mechanical and metallurgical properties. The shaft has axial ventilation Maximum phase current during phase to ground fault shall grooves milled on the barrel surface for supplying the be limited by means of a suitable resistance to a value cooling air to the rotor core. An axial bore is made in the which does not exceed 100 amps phase current obtained exciter side of the shaft for taking the input leads to the field winding through two inclined holes opening into the from the 3-phase fault. ventilation grooves at the rotor overhang portion Deviation of generator rated open circuit terminal voltage at rated speed from a pure since wave shall not exceed 3.6.3.2 ROTOR CORE 10%. The rotor core is made of low-loss silicon sheet steel 3.6.2 STATOR laminations of circular shape coated with synthetic varnish. Slots are punched in the stampings for accommodating the 3.6.2.1 STATOR FRAME windings and damper bars. The stator frame consists of two end clamping plates with The rotor core is divided into small packets by radial welded-on pressing fingers designed to hold the ventilation spacers for adequate cooling air passage. Steel laminations in position by means of axial ribs welded under clamping plates are used at both ends of the core and the pressure at the back of the core and to the clamping plates. fixing nuts of the tension bolts are welded to these plates after tightening. 3.6.2.2 STATOR CORE 3.6.3.3 ROTOR WINDINGS The stator core made of cold rolled non-grain oriented silicon steel steel punchings having low loss factor and high The rotor winding consists of single-layer former-wound permeability, is stacked between the two end clamping coils. The coils are of bare silver bearing copper and are plates. The laminations are slotted, deburred and varnished inserted into the slots and wedged with Class 'F' insulation. with high quality synthetic varnish. The core is divided into The rotor winding is impregnated with epoxy resin. The packets of required dimensions and these packets are damper bars are driven into the slots in the outer periphery separated by radial ducts to provide adequate passage for of the laminated core and welded to the clamping plate on the flow of cooling air. These ducts are formed by insulatedboth sides to form a damper cage. The overhang winding 1mm. thick stamping steel laminations on which ventilating will be protected against the centrifugal forces by glass-fibre spacers are spot welded. banding tapes and held in position by non-magnetic Austenitic steel retaining ring forgings. 3.6.2.3 STATOR WINDING 3.6.4 FANS Stator coils are of diamond pulled type with fine mica paper tape insulated copper strips and with ground insulation ofTwo radial-flow fans are mounted on both sides of the rotor resin poor mica paper tapes. This cured insulation hasto circulate the required cooling air into the machine. excellent electrical characteristics and provides highly reliable protection against mechanical and atmosphericFans shall have sufficient capacity under ordinary effects. These coils are inserted into the slots punched in conditions of installations and operations to supply the stator core and the individual coils are joined by brazing. generator with the air required in such a way that the

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ITC Limited Paperboards and Specialty Papers Division Supply maximum temperature rise of various component parts do 1. not exceed the permissible temperature rise. The fans shall create a positive pressure at the end seals of the generator or there shall be adequate sealing provided so that there is absolutely no change or oil vapours, etc. being taken into the air circuit. Facility shall be provided for running the machine on, open circuit ventilation by opening air-tight doors. 3.6.5 BEARINGS Resistance type temperature detectors calibrated at 53 ohms at 0oC shall be provided as follows : 12 (twelve) detectors, 4 (four) each located at 1/4, 1/2 and way in stator winding and 2 nos spare. These detectors shall be located between upper and lower armature coils in slots containing the different phase windings. 2 (two) detectors shall be located in the cooling system of the unit. 1 no at inlet and one at outlet. 3 (two) detectors shall be located in exciter air passage. All detectors shall be installed at locations where highest temperatures may be expected. Detectors are taken to an easily accessible terminal box so that it shall be possible to work on it with the unit in operation. The drawing indicating the location of detectors shall be furnished. Rack-mounted electronic Generator stator Temperature Scanner cum indicator with adequate number of channels having range of 0-150oC shall be provided.

Two radial sleeve bearings are provided to supprt the rotor. Each bearing essentially consists of the bearing pedestal, sealing rings,split bearing shell, a sight glass for checking the oil level and oil ring. The bearings are provided with ring lubrication in addition to the pressure lubrication. The 2. bearing pedestal is secured to the base frame by means of hexagonal bolts and is located in position after alignment by dowells. The bearing at the non-drive end is insulated from the machine baseframe to prevent the flow of shaft currents. 3. 3.7 BASE FRAME

The base frame is fabricated out of structural steel plates.4. This is designed to support the generator along with bearings and exciter (in case of brushless exciter) and to withstand short-circuit conditions. 3.8 ENCLOSURE

5.

The enclosure is fabricated out of structural steel material with adequate stiffening and is designed in two parts viz. top part of the enclosure and bottom part of the enclosure. The 6. As a protection to the operator all detector coils shall enclosure rests on the rubber beading on the base frame. be permanently grounded. The construction of the enclosure is such that it reduces the structure-borne noise to the minimum and provides the required protection to the machine. The design of the 3.11 GENERATOR COOLING enclosure shall suit the ventilation system required for the machine Generator cooling shall be by closed-air-circuit wherein air is drawn and circulated by fans mounted on both sides of 3.9 GENERATOR CONNECTIONS AND TERMINALS the generator rotor and the cooling air shall be recooled by means of water-cooled heat exchangers. Minimum of three main and three neutral terminals shall be brought out of the generator to an accessible position and Air filters shall be provided on the suction sides for either end of winding shall be suitable for use as line purifying the cooling air. terminals.

Air shall be cooled by water cooler sections, arranged Main terminals of armature windings shall be arranged for symmetrically with respect to generator .with their water adequate spacing between phases for attachment to connections under the operating floor. segregated bus duct enclosures. Adequate spacing between phase and neutral groups terminals shall be provided for attachment of neutral enclosure. The terminal Water cooler shall be of the extended surface finned tube board shall be sufficiently isolated from unit piping to permit type with the tubes made of Admiralty rnetal, the tube installation and service work of piping without disturbing sheets of steel and the water boxes of cast iron. Fabricated fame, bolts and nuts are made of steel treated main or neutral lead compartments. to resist corrosion.

3.10

GENERATOR TEMPERATURE DETECTORS

Water Cooler sections will be readily removable construction to enable inspection and maintenance.

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ITC Limited Paperboards and Specialty Papers Division Supply Complete generator cooling including filters, fans, flanges, duct work, insulation man-holes, supply and discharge loads to and fro from the cooler instruments and accessories shall be designed and supplied by the Supplier as an integral part of the main equipment. Similarly, for water system all accessories and instruments beyond the Purchasers water supply connections at the required pressure shall be designed and furnished by Supplier with the main equipment. rectifiers are used throughout. Since they rotate with the shaft, they are automatically provided with effective self ventilation. The air enters the machine at the drive end and leaves it at the nondrive end. The supporting disc of the rotor hub is provided with openings which permit the cooling air to flow over the heat sinks of the rectifier. Stubs incorporated in the end shields of the main exciter facilitate the connection of air ducts. If required, the cooling circuit can be connected to that of the main generator.

3.12

The stubs can also be designed so that they can be connected to the base frame of the main generator via The Excitation system shall be electronic brushless, seals. Through air paths in the base frame the cooling Permanent Magnet Generator type with all features, selfcircuit of the main exciter is then connected to the main regulating from no load to full load, generator terminal generator. voltage more or less close to rated 11.0 KV +/-5%. Main exciter rating shall be not less than 10% of the actual ampere excitation requirements of the generator when Since the main exciter has no bearings of its own, the cover operating at maximum MVA and at any voltage between at the nondrive end is designed to permit a shaft extension. This is used for accommodation of auxiliary sliprings for the 5% below and 5% above rated voltage. rotor earth leakage protection. 3.12.1 3.12.3 RECTIFIER PART : An excitation system with rotating rectifiers consists of an The diode modules consist of two stud type silicon diodes of auxiliary exciter with rotating permanent poles and a main opposite polarity and a light metal heat sink with cooling A.C.exciter with a stationary magnet system and a rotating 3 fins. Since the heat sinks are live, they are fitted to the rotor phase A.C. winding to which silicon rectifiers are connected. hub via insulation. Additional nonlinear resistors are provided to protect The rotors of these two machines are coupled direct to the the rectifiers against over voltages on the occurrence of shaft of the main generator. As in the case of direct coupled D.C.exciters, this makes the excitation circuit independent faults. These resistors consists of varistor discs. of any external auxiliary system. 3.13 CONTROL WIRING AND EARTHING The main advantages of this excitation arrangement are : No commutators No slip-rings No carbon brushes No pollution by carbon dust Minimum maintenance High reliability. All wiring for the generator and its earthing shall comply with the following : Control and instrument wiring shall be done with 2.5mm 2 standard copper wires having 650 volt polyvinyl chloride insulation with grey flameproof braid covering for current carrying conductors, 1.5mm2 for potential conductors. MAIN FEATURES :

EXCITATION SYSTEM

All wiring including that for spare contacts, relays, control ELECTRICAL switches, etc. for connection to the Purchasers cables shall DESIGN :be terminated at terminal blocks which shall be barrier type, The generator field winding is fed by the rectifier with direct made of moulded Bakelite or equal material and with current induced in the form of alternating current in the 3- washer screw contacts. phase rotor winding of the main exciter. The main exciter is of the rotating armature type in which the field winding is accommodated in the stator. The winding of the generatorBarriers shall be of sufficient height to prevent accidental rotor,the rectifiers, and the 3phase winding of the main shorting of adjacent contacts. A target strip shall be exciter are mounted on a throughgoing shaft assembly. The furnished on which each terminal can be identified. Terminal excitation power is fed from the exciter to the rotor of the blocks shall be located near the floor level at locations suitable for the Purchaser's external connection. A complete main generator through the shaft. set of wiring and raceways from the terminal blocks to the The 3phase alternating current produced in the armature of equipment shall be furnished.

3.12.2

MECHANICAL

AND

the main exciter is fed to the rotating rectifiers where it is rectified in a 3phase bridge connection. The direct current is Wiring shall be in exact accordance with approved then fed through the hollow machine shaft direct to the rotor drawings and diagrams. Sufficient tests shall be made by winding of the synchronous generator. Time proven silicon

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ITC Limited Paperboards and Specialty Papers Division Supply Supplier to ensure the correctness of the wiring and designed to protect 80% of the winding with a relay pickup proper functioning of all factory mounted equipment . valve of 10%-15% 3.14 ACCESSORIES

3.17

GENERATOR CONTROL METERING &

PROTECTIVE RELAYS/CONTROL SWITCHES, Space heaters for 240 V, 50 cycles, single-phase service METERS shall be provided with the main unit, to maintain inside temperature sufficiently above the outside ambient temperature to prevent condensation when the equipment Meters and control switches shall conform to high is not in service. standard of engineering. All indicating/integrating meters, shall have an accuracy of 1.5 indicating meters, shall be of 144 mm2 size and deflection 240o Wattmeter, Varmeter, 3.15 BUS DUCTS Watt hour meter. Phase Segregated bus ducts for line and neutral side of the generator, including current transformer and potential Varhour meter etc. shall be three phase, two element type suitable for measurement of unbalanced loads in three transformers. The details of the bus duct are phase, three wire circuits. The meters provided shall be as per the Main Single line diagram agreed between the 1 The Generator terminals on the line side shall be Purchaser/Project Consultant and the supplier. 1 no. connected to 11 KV Class, 1600A phase segregated Temperature scanner with selector switch, suitable for bus duct. This bus duct shall accommodate generator measurement of generator stator winding temperature CTs. Approximate length of the bus duct is mentioned in scope of supply. Connections to voltage transformers (and AVR power supply transformer, if Synchronising equipment with all hardware for required) shall be tapped off from the bus duct. These synchronising the Incoming TG3 supply or APSEB supply or both as bus coupler depending on requirement. equipment shall be located near to the generator.

One (1) set of shorting links rated 1600A for shorting all the three buses of the bus duct at the location of disconnecting links for testing shall be provided. At this location the bus duct enclosure shall be provided with readily removable, dust-tight, vermin and weatherproof covers to facilitate easy removal of links. CONSTRUCTION DUCTS FEATURES OF

1 no. MW transducer 1 no. current transducer 1 no. voltage transducer 1 no. Power Factor transducer 1 no. voltmeter of suitable range for measurement of generator field voltage . 2 nos. indicating lamps for generator circuit breaker OnOff position indication. CONTROL AND RELAY PANELS

3.15.1

BUS 3.17.1

The bus duct shall consist of three phases, aluminium bus-bars running in a common enclosure shall be effectively grounded by connecting to the earth bus provided along the duct. Insulating barriers shall be provided between phase conductors.

The generator protective relays shall be connected to trip Class-A and Class-B schemes.

The complete circuit arrangement including all hardware and wiring connections for Class-A and Class-B tripping schemes shall be included in the Suppliers scope of supply. Wherever any generator protective relays have to trip Class3.15.2 SUPPORTS B, the Supplier shall make provision on generator relay panel to bring out required tripping contacts for Bus ducts supporting structures of galvanised steel shall interconnection to panels supplied by Others. be included in scope of supply. Bus duct may be either ceiling supported or floor supported. The Supplier shall 3.17.1.1 CLASS-A TRIPPING SCHEME furnish to the Purchaser in advance the exact locations and details of the inserts to be embedded in floor/ceiling Class-A group shall operate on all electrical faults which for the bus duct supporting structures. need the complete shutdown of both the turbine and generator simultaneously and instantaneously. When 3.16 NEUTRAL GROUNDING RESISTOR Class-A is tripped, it initiates instantaneous tripping of Class-B also. In addition, it trips out the generator-circuit The generator Neutral Grounding resistance shall be of breaker, de-excites the unit. cast grid type with isolating single pole breaker and shall be suitable for 30 second duty. The NGR shall be

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ITC Limited Paperboards and Specialty Papers Division Supply The Supplier shall provide all hardware like hand-reset lockout relays, contact multiplying relays, tripping / control functions, contact multiplying relays, timers, logic circuits, auxiliary relays, for arrangement of Class-A tripping scheme. All necessary contacts as may be required by the Purchaser shall be brought out and terminated on external terminal blocks on generator relay panels. shall be supervised and unhealthy conditions shall be annunciated. Contacts shall also be provided for remote annunciation for supply failure. DC supply from 2 feeders shall be provided. Supplier shall provide manual changeover facility by way of using 3-position switch. The three positions being source-1, independent, source-2. Annunciation as well as contacts for remote annunciation of each DC supply failure shall be provided. Bright CLUSTER-LED type indicating lamps shall be provided for healthy indication of all supplies lock out relays etc. Filament type lamps for these purposes will not be accepted. All relays including numerical relays shall compulsorily be provided with test switch and plug / handle for on-line testing of relays. Contentions that numerical relays can be tested on-line by software blocking of output trip signals will not be accepted. The panel shall be fabricated from CRCA steel sheet of 2 mm thick for load bearing and 2 mm thick for others and the complete structure shall be free from twists and bends and shall be of self supporting type.

3.17.1.2 CLASS-B TRIPPING SCHEME Class-B group shall trip the turbine for (i) all mechanical faults of the turbine and generator and (ii) all electrical faults which are considered safe and for which it is safe to trip the turbine first. For all turbine trips, the generator shall be tripped subsequent to turbine-trip by set of reverse power relays. This is to ensure that the TG does not overspeed during shutdown due to trapped steam in the turbine. All mechanical trip conditions for Class-B trip shall be supplied by others. However, the Supplier shall supply necessary interface hardware and make arrangements to bring down sets of common tripping contacts from Class-B lockout relays located on generator relay panel to external terminal blocks. 3.17.2 CODES AND STANDARDS

The cubicle shall be suitable for floor mounting, shall be of dust-tight, vermin and weather proof construction. Hinged door with locking facility shall be provided at the The equipment covered under this specification shall rear. comply in all respects with the requirements and the latest codes and standards or to any other National/International Standards accepted by the Purchaser, having been Panels will be provided with 12mm thick anti-vibration established to be equal or superior to the listed standards. pads. The cubicle shall preferably be designed without However, the Supplier shall furnish the English version of all louvers. However, if a ventilated type of construction is the references standards to which the equipment conforms. essential, the louvers shall be covered by GI fine wire meshed screens to prevent ingress of insects and rodents. In the event of any conflict between the codes and standards, the specification requirements as mutually The inside and outside of the cubicle shall be painted with agreed in writing shall govern. zinc rich epoxy paint. 3.17.3 Each panel shall be provided with energy saving compact fluorescent lamps for panel illumination. Panels Trip circuit monitoring shall be provided to check healthiness shall be provided with space heater and a thermostat. of the trip circuit both during breaker close and open conditions. Unhealthy conditions shall be annunciated so All indicating meters shall be of size 144 x 144 mm. Full that the fault can be attended early and the system scale deflection of pointer shall be 240 deg. and availability is increased. Trip circuit supervising device shall accuracy be connected at the end of the tripping loop in order to include the whole tripping loop/circuit. All lockout relay coils 3.17.4 SPECIFIC REQUIREMENTS shall be supervised in a similar manner. 100% redundancy shall be provided for the power supply modules and distribution of auxiliary power supply to various relays and other equipment. All auxiliary supplies for the protective relaying schemes Equipment on Generator Relay Panel (GRP) Salient specification of various relays / relaying schemes are as follows :AVAILABILITY REQUIREMENTS

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ITC Limited Paperboards and Specialty Papers Division Supply Generator Differential Relay (87-G) High Impedance Relays Under Excitation Relay (40 G) Negative Phase Sequence Protection Relays (46 G) Generator Stator Over current Relay (50 G) Generator Pole Slipping Relay (78G) Distance Back up Protection (21 G) Generator Reverse Power Relay (32 G1) Generator Stator Main Earth Fault Protection (51 NG) Generator Backup Earth Fault Protection (64G) Under Frequency Relay (81 G) Over Voltage Relays (59 G) Rotor Earth Fault Relay (64 F) VT Fuse Fail Protection Tripping Relays for Excitation System Faults Dead Machine Protection (61B) Generator Circuit Breaker Failure Relaying (50 LBB) Lockout Relays (86) Wipe out Timers 3.17.5 GENERAL REQUIREMENTS FOR GRP: colour coding shall be used to distinguish Trip, AC & DC Supply Control Inter Locking and earthing wiring.

3.17.6

DC DISTRIBUTION PHILOSOPHY FOR CONTROLS, PROTECTION, INDICATION, ANNUNCIATION SYSTEMS

The DC distribution scheme in various panels shall be prepared based on following DC distribution philosophy for various functions.

3.17.6.1 PROTECTIVE FUNCTIONS In the event of shortage of contacts in main circuit breakers & isolators, contact multiplication shall be done using double coil, latching type relay. Latching type relay with one coil to Operate & second contact to Reset. Operate coil shall be wired to NO contact of CB or isolator and reset shall be wired to NC contacts of CB or Isolator. Each multiplier relay shall have 8 no. of contacts in a combination of NO & Each panel shall be provided with two(2) numbers of 220V NC contacts as required by the scheme. One NC contact of feeders in loopin / loopout fashion. Each of above feeder each coil shall be used to cut-off DC supply to its own coil. shall be fed from separate section of dc board or separate dc boards. Manually operated 8 pole, 3 position, selector switch; for positions called source-I, independent, source-II; shall be provided to select any one for protection supply for that panel and other as indication, alarm and DCS supplies. Each incoming supply before the selector switch and outgoing supply after the selector switch shall be separately A minimum of 2 NO contacts of Main protection Relay and 2fused and supervised by supply supervision relays having NO + 2 NC contacts of Trips lockout relays shall be wired totime delayed drop off type NC contact. Loss of supply shall the terminals exclusively for the Purchasers use. Thesebe wired for annunciation and event recorder. shall be in addition to the contacts provided for SER, SCADA, DCS, Interlocking and annunciation. Test terminaI blocks shall be provided for integrating meters. Facia type annunciation windows with translucent plastic window for each annunciation point shall be provided. Two lamps shall be provided for each annunciation window. Individual annunciation shall be able to reset independent of the condition of other annunciations. Name plates of all components shall be All CT & VT terminations in the control & relay panels shall PVC/Acrylic. be made on disconnective type, screw driver operable, stud type connectors with studs suitable for insertion of Banana 3.17.6.2 GENERATOR PROTECTION ( STATIC plugs for secondary injections. Terminal shall be suitable for RELAYS) 4 sq.mm. copper stranded, PVC cables minimum of 2 terminals per phase will have to be used. All control cables shall be of 2.5 sq.mm stranded copper, PVC cables distinct

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ITC Limited Paperboards and Specialty Papers Division Supply 1 (one) number integral static microprocessor based relay - Oil outlet from gearbox bearings for generator protection with 100% second redundancy - Oil outlet from generator F.J.B shall be available. - Oil outlet from generator R.J.B Apart from the above the protection relays mentioned above along with 100% second redundancy shall be available. All the necessary items as required for control panels like push buttons, indicating lamps, annunciators, Temperature scanners, Transducers, recorders, Control Switches, Indicating instruments and energy meters shall be provided. Synchronising Equipment with hard wiring to synchronize a) Incoming grid or TG3 or both supply with TG4 and b) Synchronise buscoupler with incoming and TG working.

Cooling water inlet & outlet to oil coolers Cooling water inlet & outlet to air coolers Spray water line for extraction & exhaust steam temperature control. Level gauges

3.18.1.3 Main oil tank Overhead oil tank

3.18.1.4 -

Instruments mounted on local gauge rack

Inlet steam pressure Wheel chamber pressure Inlet steam temp. Controlled extraction pressure Controlled extraction temp. Exhaust steam pressure Exhaust steam temp. Lube oil header pressure Control oil pressure Primary instruments required for alarms trips & interlocks (realised in DCS)

3.18

INSTRUMENTATION

Comprehensive instrumentation .should be provided including the followings for operation and control of the Turbo generator installation, The instruments shall be selected from a list of approved vendors by the Purchaser. 3.18.1 3.18.1.1 FIELD INSTRUMENTS (for STG integral portion) Local Pressure Gauges

3.18.2

- Lube oil header - Lube oil to individual turbine, gearbox and gen. Brgs - Jacking oil to individual turbine and generator brgs - Diff. pressure across lube oil filter - Main oil pump discharge - Auxiliary oil pump discharge - Emergency oil pump discharge - Jacking oil pump discharge - Oil above piston of stop valve

- MS inlet pressure- low , high - Exhaust steam pressure- low

Exhaust steam pressure - high

(realised from the corresponding pressure transmitters)

Oil below piston of stop valve - HP secondary oil - Trip oil to ESV pressure Stop valve testing device - Control oil pressure( in governing .console board) - Cooling water inlet & outlet from oil cooler - Cooling water inlet to & outlet air cooler

Exhaust steam pressure -very high (turbine trip-2/3 logic) Exhaust steam pressure -very low (turbine trip-2/3 logic)) Main steam temperature - low Controlled extraction steam pressure high Controlled extraction steam pressure - very high (turbine trip-2/3 logic) - Controlled extraction steam pressure - low - Controlled extraction steam pressure - very low (turbine trip-2/3 logic) - Lube oil header pressure - low

Spray water line for extraction & exhaust steam Local Temperature Gauges

3.18.1.2

Oil inlet to oil coolers Oil outlet from oil coolers Oil outlet from turbine thrust + F.J.B Oil outlet from turbine R.J.B

Lube oil header pressure -very low (turbine trip-2/3 logic) - Lube oil pump discharge header pressure- low (standby pump start) - Control oil header pressure -low - Control oil header pressure -very low - Lube oil header pressure -very low (emergency oil pump start) - Trip oil header pressure - low - Trip oil header pressure very low

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ITC Limited Paperboards and Specialty Papers Division Supply - Trip oil pressure- high (for remote engagement reset) - Starting oil pressure- high (for stop valve opening) - Oil pressure below stop valve piston- high(for stop valve opening) - lube oil tank level -low - Lube oil tank level high - Stop valve open (status indicator) - Stop valve close (status indicator) - Extraction-I QNRV- open (status indicator) - Extraction-I QNRV- close (status indicator) - Diff. Pressure across lube oil filter high - Relative shaft vibrations -high - Relative shaft vibrations -Very High (Turbine Trip) - Turbine Speed -High - Turbine Speed -Very High (Turbine Trip) - Turbine Axial Displacement -High Shaft Vibrations at Gearbox High speed Shaft Shaft Vibrations at Gearbox Low speed Shaft Turbine Axial displacement Key phasor Thermo elements for Bearing temp. monitoring (Monitoring in MMI of SUPPLIER EDN, Bangalores control system )

3.18.6

- Turbine Front Journal Bearing Temperatures - Turbine Rear Journal Bearing Temperatures - Turbine Thrust Bearing Temperatures (Active & Non active) - Gear Box Bearings Temperatures

Turbine Axial Displacement -Very High (Turbine Trip) Transmitters / Temperature remote Indication and Control Elements for

Generator Front Journal Bearing Temperatures Generator Rear Journal Bearing Temperatures

3.18.3

3.18.7

- Main Steam Pressure transmitter - Wheel chamber pressure transmitter - Main Steam Temperature element

Primary instruments to realize Turbine Auxiliaries interlock and protections for the following in EDN, Bangalore system

Controlled Extraction Steam Pressure transmitter Controlled Extraction Steam Temperature element Exhaust Steam Pressure transmitter Exhaust Steam Temperature element Lube Oil Header Pressure transmitter Control Oil Pressure transmitter Lube Oil Temperature elements after Coolers Trip oil pressure Transmitter JOP discharge pressure transmiter Level transmitter for lube oil tank Controlled extraction steam temperature after DS Exhaust steam temperature after DS CW inlet temp. of air cooler CW oulet temp.of air cooler

Main Oil Pump Auxiliary Oil Pump Emergency Lube Oil Pump Jacking oil pump Main& Stand By Oil Vapour Extraction Fan-Main & Stand By Turning Gear OTHER INSTRUMENTATION

3.18.8 -

Desuper heaters In Extraction line & exhaust line Flow nozzle in Extraction steam line after DS Flow orifice in spray water line to Exhaust DS. Impulse lines along with fittings within battery limits for instruments on pressure parts GEAR BOX AND COUPLINGS

3.19

3.18.4 -

Safety Relief valves

Controlled Extraction Steam Line Exhaust Steam Line Bently Nevada (3500 series)or make TSI monitoring system ( to be mounted in SUPPLIER EDN, Bangalores Control System cabinet)

3.18.5

Gear box shall be designed to the highest engineering standard and shall be of imported make as per the vendor list approved by the Purchaser. It shall be designed to suit every condition of operation. It shall be designed to withstand the condition of sudden tripping and/or overspeeding of the turbine of turbine. An electric turning gear along with manual barring device, in case of failure of the electrical turning device, shall be provided in the gearbox. A separate motor driven oilpump shall be provided to ensure lubrication of all bearings and moving parts of the gearbox.

Shaft Vibrations at Turbine Front bearing Shaft Vibrations at Turbine Rear bearing Shaft Vibrations at Generator Front bearing Shaft Vibrations at Generator Rear bearing

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ITC Limited Paperboards and Specialty Papers Division Supply Gear box shall be totally enclosed in a casing of suitable construction to assume positive alignment of all moving parts. Gear box casing shall be oil and dust tight. Suitable breathers shall be provided at openings in the casing meant for release of air/gases. The couplings shall be designed to the highest engineering standard and shall be of imported make as per the vendor list approved by the Purchaser. It shall be designed to suit every condition of operation. It shall be designed to withstand the condition of sudden tripping of turbine. The couplings shall be flexible type and shall be of suitable construction to assume positive alignment of all moving parts. A suitably designed coupling guard shall be provided for all couplings The coupling bolts must be of high tensile strength and fine finished with close tolerances.

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 3.21.2

Gland steam Piping Special Tools for Maintenance Prime Coat of Paint O & M Manuals 6 copies Turbine Insulation (Mineral Wool Mattresses) Turbine covers Insulation of Integral piping QCNRV in Controlled Extraction Line. Extraction & Exhaust Piping, insulation, supports & fittings up to Terminal point Auxiliary cooling water piping from terminal point. Warm up vent with silencer in exhaust steam line sized for no load steam quantity. Instrument air piping from terminal point to consumption points in STG hall Spray water piping from terminal point to all PRDS including spray water Pressure Reducing Stations , if required. Instrument air piping from terminal points to consumption point Oil Supply System Main Oil Tank (Carbon Steel Matl)Including - Drain & Maintenance Openings - Level Indicator - Level Signalisation High/Low - Connection for Purifier Main Oil Pump with AC motor Auxiliary Oil Pump with AC Motor Emergency Oil Pump with DC Motor Jacking oil pump with AC motor Jacking oil pump with DC motor Duplex Filter for Lube Oil Trans-flow Valves for Duplex Oil Filters & Oil coolers Oil Mist Fan with AC Motor (1 x 100%) Steel from Filter to Bearing) Complete Control Oil Piping ( Stainless Steel Material ) Overhead Lube oil tank with complete Piping ( Stainless Steel material) Oil Accumulators

3.20

SPARES

The spares and special tools to be supplied as per list in annexure 6.

1.

3.21
3.21.1 1.

SCOPE OF SUPPLY Steam Turbine Steam Turbine Emergency Trip Cum Stop Valve Blanket Plate for Steam Blowing Turbine Steam Governing Valves Steam Strainer Built into Stop Valve (Spare strainer also included) Reduction Gearbox between Turbine & Generator Coupling and Coupling Guard between Turbine & Gearbox Coupling and Coupling Guard between Gearbox & Generator Manual Barring Device Turning Device -Electric Solenoid Valve for Remote Tripping Turbine Sole Plates Foundation Bolts Shaft Grounding Device Mating Flanges for Turbine Inlet ,Extraction & Exhaust Flanges

2. 3. 4. 5. 6. 7. 8 9. 10. 11. 12. 13. 14. 15.

2. 3. 4. 5. 6. 7. 8.

9. 10. Pressure Throttles for Bearings 11. Complete Lube Oil Piping (Stainless 12. 13.

14. 15. Oil Purifier (2400 LPH) 16. Governing Console Consisting of
- Duplex Filter for Control Oil - Main Trip Solenoid Valve - Electric-Hydraulic Converters

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ITC Limited Paperboards and Specialty Papers Division Supply Local Gauge Board with Governing Oil system 1. Instruments Solenoid Valves for opening & closing 2. 3. Emergency Stop Valve - Solenoid Valves for remote engagement of4. 5. tripping device - Other hydraulic components 6. 220 V DC Lead acid battery 1 No. Battery charger 1 No. DCDB 1 No. DCSC for JOP motor UPSDB 1 No. AC distribution boards (if required for equipments in TG scope.) LT power & control cables along with cable trays from terminal point - LOT DC & UPS cables from terminal points Cable trays for cables in SUPPLIER scope of supply. Local control station Local Emergency Isolators for Drive Motors

7.
3.21.3 Lube Oil Coolers - 2x100%. Construction details

8. 9. 10. 11.

Vertical in orientation Admiralty brass Tubes Removable tube bundle

Carbon steel Shell, water box, tubesheets etc. 3.21.6 Carbon steel channel & channel cover Bolted end covers Sole plates & anchor bolts Primer coating on outer surface

GENERATOR AND AUXILIARIES. CLOSED circuit Air cooled Generator consisting of Stator with output leads taken out from the bottom of the machine. Rotor suitable for Overhang BLE Bearings, base frame, built in RTDs,space heaters with controls Bottom mounted Air to water coolers (CACW)

1.

Accessories

Change over valve device (1 set) Isolation valves on CW side Vent & drain valves Counter flanges on CW side with gaskets & fasteners 2.

Brush-less exciter with PMG.

3.21.4

Generator Air Coolers. Construction details Pit mounted Admiralty brass high fin tubes Tubesheet, frame, water box etc. Tube supports Sole plates & anchor bolts Primer coating Accessories CW inlet/ outlet headers Isolation valves on each header

3.21.5

3.

Segregated phase busduct with CTs, PTs, LA & SP equpment.

4.

Neutral Grounding with secondary loading resistor

Balance of Plant electrical

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5.

Generator control desk with generator protection3.22.1 Schedule of tests on BRUSHLESS EXCITER at works (1500 RPM Exciter) panels 1. Over-speed test on rotor before assembly at 120% of rated speed for 2 mts. 2. Mechanical run and measurement of vibrations at rated speed.

6.

CO2 fire extinguishing equipment for generator.

3. Open circuit characteristic. 4. Load magnetisation characteristics. 5. Measurement of D.C resistance of armature windings & Main pole winding.

7.

3.21.7

Interconnecting control cables for connection6. Measurement of IR value and High voltage test. between Generator and generator control and relay panels. (Length considered is 100m. Unit Note : rates applicable beyond this length.) The exciter will be assembled separately on a test foundation frame, driven by a D.C. drive motor. The exciter is excited from separate D.C. source and output will be taken through test pit sliprings to a water load Control, Protection and Supervisory System (resistance.).

Electro hydraulic turbine control, Turbine protection, Turbine3.22.2 Schedule of tests on GENERATOR at works auxiliaries interlocks & protections, Bearing temperature monitoring, load transducers, interposing relays are realized 1. Overspeed test of rotor before assembly at 120% rated in Suppliers EDN, Bangalore control system. speed for 2 mts. Max DNA control system includes the following : 2. Mechanical run and measurement of vibrations at rated speed. - Electronic governor for control of speed, Extraction Pressure, Load and back pressure Turbine Protection Interlock & Protection for turbine auxiliaries. SER for 64 points Bearing temperature monitoring Man machine interface for control equipment. Marshalling cabinets All junction boxes for steam turbine controls 5. Measurement of shaft voltage. 3. Measurement of mechanical losses, short circuit characteristic & losses Measurement of mechanical losses, open circuit characteristic & losses

4.

6. Checking of phase sequence. Control & signal cables, TSI cables from field instruments to junction boxes and from JBS to control 7. Measurement of rotor impedance (rotor inside stator). room. - All power supply distribution boards for EDN equipments 8 Measurement of insulation resistance of stator & rotor windings before and after High Voltage test (m/c at rest). All the primary field instruments and final control elements in STG integral portion are in Suppliers scope. 9. High voltage test of stator and rotor windings (m/c at rest). 10. Measurement of Polarisation Index of stator winding.

3.22

SCHEDULE OF TESTS

11. Measurement of d.c.resistances of Stator and Rotor Windings in cold condition.

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12.

Measurement of d.c. resistances and insulation resistance of RTDs.

4. 5. 3.24

AC power for battery charger : at the battery charger terminals 240V AC single phase power: at the incoming terminals of ac distribution board.

Note :

List of exclusions Mechanical

Generator will be assembled separately without coolers(if CACW cooled) / Filters if Open air cooled & enclosure (if any), on a test foundation frame driven by D.C drive motor & excited through slip rings from a separate test pit D.C. source.

1. 2.

3.23

List of terminal points Mechanical

1. 2. 3. 4. 5. 6. 7. 8.
9.

3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

Total main steam supply line up to inlet of turbine. Controlled extraction steam piping beyond terminal point Exhaust piping beyond terminal point ACW piping beyond terminal points All de-watering and de-aerating piping beyond terminal point. Instrument air piping beyond terminal point. Plant air, service water piping. Air conditioning and ventilation systems. Fire detection, alarm and protection systems. Service water, plant air and DM water systems. LP & HP dosing system Stairs and rails, access ladders, platforms Chequered plates and frames, embedments Engineering & construction of all civil,structural, carpenter and concrete works Laboratory & workshop equipments. EOT crane

Main steam : at inlet of ESV of turbine Controlled extraction : at out let of flow nozzle Turbine exhaust : at outlet of desuperheater Instrument air : at one point in the proposed tg hall extension Vents : at a safe elevation with silencer. Drains : at nearest drain point. Auxiliary cooling water : at one point in TG building. Spray water for extraction control station. : at the inlet of

Layout engineering except layout of Supplier supplied equipments in STG hall and piping in Supplier scope. Any other equipments not specifically mentioned in the scope.

Spray water for exhaust steam: at the inlet of orifice

Electrical

Electrical

1. 2. 3.

HT power: at outlet of 11KV switchgear( connection through bus duct) LT power : at the outcomer of STG MCC 230V ups power : at the incoming terminals of proposed UPS DB

1. 2. 3. 4. 5. 6. 7.

System studies Out door switchyard and associated cabling 415V PCC 415 V STG MCC HT switch gears HT cables Cable trays and accessories for cables not in Suppliers scope Underground earthing cables between Purchasers

8. 9. Clock system 10. Interconnecting

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ITC Limited Paperboards and Specialty Papers Division Supply

11.

12. 13. Termination

equipment and Suppliers equipment. All civil works including preparation for cable trenches/cable racks/cable trays/laying of cables beyond battery limits Checkered plates/RCC blocks above trenches. of cables including accessories at Purchasers equipment Fire proof sealing of cable opening terminating

14. 15. Generator transformers, aux. Transformers 16. Transformer rails 17. Laboratory equipment 18. Plant illumination 19. Telecommunications and public address system 20. Any other item specifically not shown as included in
the enclosed scope of supply.

Control & Instrumentation

1. 2. 3. 4. 5. 6. 7. 8. 9.

Feed control station. Furniture for monitoring operator/ programming station. Signal conditioning for das/dcs/plc Interconnecting cables between equipment. Termination of cables including accessories at purchasers equipment. Lab instruments. Analysers Any other equipment other than specifically included under scope of supply. SCADA system purchasers terminating

The details of scope and parameters are summarised in the data sheets enclosed.

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STEAM TURBINE

1.0

DESIGN AND PERFORMANCE DATA

1.1 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5

At TGMCR Condition Maximum continuous rating at generator terminals Throttle steam pressure at strainer inlet Throttle steam temperature at strainer inlet Throttle steam flow Extraction steam at turbine flange a) Presuure b) Temperature c) Flow Turbine exhaust at turbine outlet a) Pressure b) Temperature c) Flow Turbine rated speed Operating frequency range for turbine and auxiliaries Steam turbine swallowing capacity with turbine control valves in wide open (VWO) position No load steam flow through turbine Allowable throttle parameters a) Pressure b) Temperature Critical Speeds

MW Ata
0

18.5 60 450 157 12.5 220 (At outlet of Desuperheater) 52 (At outlet of Desuperheater) 5.8 165 (At outlet of Desuperheater) 109.3 (At outlet of Desuperheater) 5650 47.5 to 52.5

t/h Ata 0 C t/h Ata 0 C t/h rpm hertz t/h

1.1.6

1.2 1.3 1.4

1.5 1.6

t/h kg/cm2(a) 0 C

20 As per IEC-45 As per IEC-45

1.7

1.7.1

Critical speed for turbine rotor fully assembly

rpm

During detail engineering

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1.7.2 1.7.3 1.8 1.9 1.10 1.11

Critical speed for electrical generator rotor fully assembly Critical speeds of turbine and generator rotors together fully assembled Turning gear speed Is the turbine designed for full arc admission during start-up ? Coast-down time after turbine trip-out Governing System

rpm rpm rpm

During detail engineering During detail engineering 150 No, Sequential opening of valves

minutes

<10

1.11. 1 1.11. 2 1.11. 3 1.11. 4 1.11. 5

Mode of governing Type of governor Dead band of the governor Percentage regulation and its range of adjustability Emergency stop valve : (a) (b) Opening thorough full travel For closing through full travel sec. sec. % %

Through MAX-DNA DCS Electro - hydraulic 0.06 4-6

60-120 100 milli seconds

1.11. 6

On-load throw off : (a) (b) Temporary speed rise (TSR) Permanent speed rise % % % < 109 105 20- 110

1.11. 7 1.12

Range of adjustability of governor

Lubrication Oil System 1.12.1 1.12.2 1.12.3 Type of turbine lube oil Total lube oil system capacity Lube oil tank capacity m3 /hr m3 ISO VG 46 78 (Normal ) 10

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1.12.4 1.12.5 1.12.6

Normal lube oil pressure If turbine lube oil is used as the control oil, control oil pressure Degree of cleanliness to be maintained for the lube oil for satisfactory operation : (a) (b) Permissible suspended particle size Permissible water content in oil by volume

kg/cm2 (a) kg/cm2 (a)

During detail engineering 8.0

microns %

10 NIL

1.12.7

Main Oil Pump (a) (b) (c) (d) Type Capacity Discharge pressure m /h mlc
3

Centrifugal 150 80 Ground mounted oil tank A.C. motor driven Auxiliary oil pump D.C. motor driven emergency oil pump 1 -

1.12.8

Method of providing positive suction pressure to main oil pump Lube oil pumps :

(a) (b) (c)

Type Number of pumps in service Number of standby pumps No. No.

Centrifugal 1 1 (Motor driven main oil pump is a standby ) 150

2

(d) (e) (f) 1.12.9

Capacity of each pump Discharge pressure Motor rating

m3/h kg/cm (a) kW

60 3.0 15

8.0 75

Turning gear system (a) (b) (c) (d) (e) Type Speed of turbine during turning gear operation Capacity of pump (If applicable) Discharge pressure (If applicable) Motor rating rpm m3/hr kg/cm (a) kW
2

Electric Approx. 150 Not applicable Not applicable 15 AC motor driven Gear DC motor driven Gear

1.12.10

Jacking oil pumps (a) Type

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(b) (c) (d) (e) 1.12.11

Number of pumps Capacity of each pump Discharge pressure Motor rating

No. m /h kg/cm (a) kW

2 3

1 1.2 100 15

1 1.2 100 15

Vapour extractors (a) (b) (c) (d) Number in service Number in standby Capacity Motor rating No. No. m /hr kW
3

1 1 395 0.37

1.13

Lube oil conditioning equipment (a) (b) (c) (d) (e) outlet Type of conditioner Manufacturer Model Number Capacity of unit Suspended particle size at purifier m /sec micron %
3

Centrifuge During detail engineering During detail engineering During detail engineering <5 microns Less than 500 ppm

2.0 2.1 2.2

(f) Water content in oil by volume at purifier outlet CONSTRUCTION FEATURES AND OTHER DATA Number of cylinders Number of bearings including thrust bearing of turbine

No. No.

One 3

2.3 Number Of Stages (a) (b) 2.4 2.5 2.6 2.7 2.8 Number of impulse stages Number of reaction stages No. No. mm mm mm m/sec 206.2 Babbit 1 16 (Preliminary) 780 81.6 743.2

First stage diameter Length of last blades Tip diameter of last blades Maximum peripheral velocity of last blades Type of antifriction material used in bearings

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2.9 2.10

Type of thrust bearing Type of Turbine Shafts

Tilting pads Solid

2.11 Type of Shaft Couplings Between Turbine / Generator

Flexible: Turbine & Generator Rigid : Gear box & Generator

2.12 Number And Size Of External Connections 2.12.1 2.12.2 2.12.3 2.13 ESV Strainer Size 2.13.1 2.13.2 3.0 MATERIALS OF CONSTRUCTION 3.1 Turbine Casings 3.1.1 3.1.2 3.2 Turbine Shaft 3.3 3.4 Moving Blades 3.4.1 Turbine first stages _____ to ______ Turbine Disc (If shrunk on) Not Applicable Outer casing Blade carriers GS 22 Mo 4 GS 22 Mo 4 / GSC 25 28 Cr Mo Ni V 59 Temporary strainer Permanent strainer 1.5 mm particle size Turbine inlet Turbine exhaust MP extraction 1 , 250 1 , 800 1 , 500

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3.4.2

Turbine other stages

(i) _____ to _______ (ii) _____ to _______

X 20 Cr 13/ X 22 Cr Mo V 12

3.5 Fixed Blades 3.5.1 3.5.2 Turbine first stages Turbine other stages _____ to ______ (i) _____ to _______ (ii) _____ to _______ X 20 Cr Mo 13

3.6 3.7 3.8

Turbine Casing Joint Bolts Shaft Couplings Main Steam Chest

21 Cr Mo V 57/ 24 Cr Mo 5 -GS 22Mo 4

3.9 Main Steam Admission Valves 3.9.1 3.9.2 3.9.3 4.0 LOADING DATA 4.1 Attach Starting, Loading And Cooling Curves For Various Start-Up Regimes As Defined Below And List Curve Nos : For cold start conditions (greater than 36 hours shutdown) For warm start conditions (between 8 and 36 hours shutdown) For hot start conditions (less than 8 hours shutdown) THERMAL DATA Valve body Valve spindle Valve seat

Emergency Stop Valves

Governing Valves

--GS 22Mo 4 - -(Integral with outer casing) --X22 Cr Mo V 12.1- - -21 Cr Mo V 57- -

4.1.1 4.1.2 4.1.3 5.0

During detail engineering During detail engineering During detail engineering

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5.1

Complete heat balance diagrams in MKS units for all the conditions as called for

Guaranteed Perfornmance sheet TC-0212093-PF REV00 dtd 16/11/2002

5.2 5.3

Any other heat balances Molliers Chart marked to show turbine expansion lines corresponding to guarantee heat balances as asked for in items 2.21.2 above. Complete performance/Characteristic curves Any other correction curves

NIL During detail engineering

5.4 5.5 6.0

During detail engineering NIL

TESTS 6.1 Field And Performance Tests 6.1.1 6.1.2 6.1.3 6.1.4 6.1.5 Turning gear running tests Vibration checks Overspeed and tripping test Synchronising checks Demonstration of operation of governing system on load testing devices, load limiting device and other protective devices including ability to motor Full load rejection tests Tests for MW capability of turbine generator unit Guaranteed heat rate tests Quick start tests (as per curves for start-up) Startup spares as required 8.0 Essential spares as per specification Shall be supplied as required Shall be carried out Shall be carried out Shall be carried out Shall be carried out Shall be carried out

6.1.6 6.1.7 6.1.8 6.1.9 7.0

Shall be carried out Shall be carried out Not applicable Shall be carried out As per list enclosed

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9.0 10.0

Maintenance tools and tackles as required

As per list enclosed

CODES AND STANDARDS 10.1 10.2 10.3 10.4 10.5 10.6 Fluctuations / limitation or variations of pressure / temperature at turbine throttle Governor performance characteristics Design and construction code for turbine Specification for turbine lubrication oil Specification for turbine control fluid Performance testing of steam turbine IEC 45 NEMA SM23 IEC 45 ISO VG 46 ISO VG 46 PTC-6

OIL COOLER DATA SHEETS 1.0 GENERAL

1.1 Designation

Steam Turbine Oil Cooler

1.2 Heater manufacturer

BHEL

1.3 Tube supplier

During detailed Engineering

1.4 Type

Tube bundle removable

1.5 Orientation

Vertical

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1.6 Location

Indoor

1.7 No. of heat exchanger

2 X 100 %

2.0 DESIGN DATA

2.1 Shell side medium

Lube Oil

2.2 Shell side flow

m3/h

68.118

2.3 Shell side fluid inlet temperature

60.2

2.4 Shell side fluid outlet temperature

45

2.5 Shell side fouling resistance

h 0C m2/kcal

0.0001

2.6 Tube side medium

Water

2.7 Tube side flow

m3/h

120

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2.8 Tube side fluid inlet temperature

35

2.9 Tube side fluid outlet temperature

38.5

2.10 Tube side fouling resistance

h 0C m2/kcal

0.0002

2.11 LMTD

During detailed Engineering

2.12 Maximum heat load

Kcal/h

412800

2.13 Design heat duty

Kcal/h

412800

2.14 Shell side design pressure

Kg/cm2 (g)

2.15 Tube side design pressure

Kg/cm2 (g)

2.16 Shell side design temperature 2.17 Tube side design temperature

C C

80 80

2.18 Shell side test pressure

Kg/cm2 (g)

6.5

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2.19 Tube side test pressure

Kg/cm2 (g)

6.5

2.20 Tube side fluid velocity

m/s

1.95

2.21 Maximum shell side pressure drop

Kg/cm2

0.2

2.22 Maximum tube side pressure drop

Kg/cm2

0.8

3.0 CONSTRUCTIONAL FEATURES

3.1 Tube type

Straight fin

3.2 No. of tube passes

3.3 Tube OD x thick

mm x mm

OD 15.875 x 1.24 low fin

3.4 Shell OD x thick

mm x mm

774 x 12

3.5 No. of tubes

During detailed Engineering

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3.6 Effective surface area

m2

3.7 Type of joints between tube and tube sheet

Rolled

3.8 Shell side relief valve

Not required

3.9 Tube side relief valve

Not required

3.10 Corrosion allowance on shell side

mm

3.2

3.11 Corrosion allowance on tube side

mm

3.2

3.12 Type of baffles

Segmental

3.13 Tube pitch

mm

20.64

3.14 Type of pitch

Triangular

4.0 MATERIALS OF CONSTRUCTION

4.1 Shell

SA 516 Gr.70

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4.2 Shell cover

SA 516 Gr.70

4.3 Channel

SA 516 Gr.70

4.4 Channel Cover

SA 516 Gr.70

4.5 Tube

Admiralty Brass

4.6 Tube Sheet

SA 516 Gr.70

4.7 Flanges

SA 516 Gr.70

4.8 Gaskets

CAF

4.9 Studs, Bolts & Nuts

SA 193 B7

4.10 Nozzles

SA 106 Gr.B

4.11 Impingement plates

--

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4.12 Fin (If applicable)

SA 106 Gr.B

5.0 CODES AND STANDARDS

BHEL, ASME Sec VIII Div. I

GENERATOR

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0 13.0

Prime Mover for Generator Location : Indoor or Outdoor Make Type Quantity Rating Rated Lagging Power Factor Rated Frequency Rated Speed Rated Voltage Number of Phases Stator Winding Connection Type of cooling a) b) Stator Winding Rotor Winding and Stator Core

Nos. (MW/ MVA) (Hz) (RPM) (kV)

Steam Turbine Indoor BHEL - INDIA TAII 1240 12P - 15 ONE (1) 18.5 MW / 23.125 MVA 0.8 50 1500 11kV 3

Star

Closed air circuit cooling Closed air circuit cooling

14.0

Class of Insulation a) b) Stator Winding Rotor Winding (kVp) (Pu) (Pu) (Pu) 49 kV >0.5 0.1177 PU 0.1993 PU Class F with temperature rise limited to class B -- do --

15.0 16.0 17.0 18.0

Basic Impulse Level of Stator Winding Short Circuit Ratio Minimum Direct Axis Saturated Subtransient Reactance Maximum Direct Axis Unsaturated Transient Reactance

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19.0 20.0 21.0

Frequency Variation Expected in Operation as percentage of rated frequency Voltage Variation Expected in Operation as percentage of rated voltage Degree of Protection for the enclosure of : a) b) Turbo-Generator Main Exciter (if provided)

% %

5 5

IP 54 IP 44 3 BOTTOM 3 BOTTOM

22.0 23.0 24.0 25.0

Number of Line Terminals brought out Where brought out (Top / Bottom / Side) Number of Neutral Terminals brought out Where brought out (Top / Bottom / Side)

26.0

Number of current transformers provided on Line Side Busducts a) b) Protection Class per phase Metering Class per phase

3 nos. with two cores Core-1: for protection Core-2: for metering

27.0

Number of current transformers provided on Neutral Side a) b) Protection Class per phase Metering Class per phase 6 nos. nil Clock-wise (A) (V) (YES / NO) 510 139 YES

28.0 29.0 30.0 31.0 32.0

Direction of Rotation of Generator Rotor viewed from Turbine End Rated Field Current Rated Field Voltage If air-cooled Generator, is the fire protection system provided Regulation at a) b) c) Unity power factor 0.85 lag power factor Rated power factor % % % (MVAR) (Pu)

28.5 -33.8 10.8 2.12

33.0 34.0

Maximum permissible capacitive loading at rated voltage and zero power factor Synchronous reactance

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35.0 36.0

Negative phase sequence reactance Zero phase sequence reactance EXCITATION SYSTEM

(Pu) (Pu)

16.6 8.2

37.0 38.0 39.0

Type of Excitation system provided (Static / Brushless) Guaranteed Response Ratio of Excitation System Field Forcing capability : % of exciter voltage corresponding to generator MCR output at rated p.f and duration AUTOMATIC VOLTAGE REGULATOR

Brush less 2.0 214V for 10 sec.

40.0 41.0

Number of Auto Channels provided Manual channel & Auto follower provided

Nos. YES / NO

TWO YES

INSTRIMENTATION AND CONTROL : 1 Control System : TG#4 will operate with its own dedicated control system (Totally Integral system). Complete controls of TG & Auxiliaries including Governor control shall be realized on the same platform (maxDNA) This dedicated control system will be provided with two MMI stations with the following redundant levels : a. CPU, Power Supply and Communication (Module and media). There will be independent power supply with N+1 capability for system and field. b. All the TG auxiliaries ( Except Governor controls) logics/loops will be hooked up to a independent TG controller. Complete controls of TG & Auxiliaries Including Governor control shall be realized on the same max DNA platform c. Cabling upto to the control panels and total turbine control , monitoring and protection is in scope of TG supplier. d. TG shall be independently operable from the dedicated TG control system itself. The required data in boiler DCS system will be provided as a additional information only. Even in case of complete boiler system blackout, still turbine should be operational. e. Additional 16 nos. analog inputs, 8nos analog outputs, 8 nos. digital inputs and 8 nos. digital outputs shall be considered in the turbine control system for accepting the customer inputs. 2 3 4 Supplier shall call the Purchaser for FAT (Factory acceptance Test) at the suppliers works and all the drawings shall be approved by the Purchaser before manufacturing the panels.. All indications are CRT based. No backup digital indicators are being envisaged. However emergency PBs will be provided in the control room Turbine Governing System : A) Governor control system is an integral part of max DNA. B) No position feedback is envisaged for the HP and LP valves since position control is realized in I/H converter. C) From the Turbine control system, a MODBUS serial link will be provided for exchange of data to communicate with the Boiler DCS of the Purchaser. However, the communication cable for the above

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will be supplied and laid by the Purchaser. First up alarm: For the easy identification of the turbine tripping, first up alarm is envisaged through software SOE for minimum 64 points and with 1ms time resolution. This is integral to the turbine DCS system and no hardware multiplication of the field signals is envisaged. Out of the above, 20 digital inputs shall be from the generator panel for the firstup identification of the generator tripping. While selecting CPU/MMI, BHEL agreed to consider the following parameters as minimum : a) Alarm and Event Reports shall be generated with a resolution of 100 msec. However, the first-up alarm logic shall be built in the CPU program itself with minimum 1 sec program / I/O cyclicity. b) The MMI display update rate shall be one sec. c) The display page changeover shall be one sec. d) Trends shall be configured for all analog and important digital signals at a resolution of : 250 milli sec for one day, one sec for one week and 1 minute for one month. e) Trip log , indicating the parameter status before and after tripping shall be generated automatically upon any TG trip. The log sheet shall be prepared in such a way that it shall be possible to analyse the problem. Apart from the above, shift reports, daily reports, monthly reports shall be printed as per the description of operator. If any interposing relays are required between TG control system outputs and field, same shall be in the Suppliers scope only. The Supplier shall configure the formats for the plant operation & monitoring: shift report, daily reports, monthly reports etc.. For all pressure switches that trip the turbine, pressure transmitters also shall be provided with analog indication and trend logging to DCS. 3 PS shall be provided for trip logic (2/3) and a transmitter is provided for control/monitoring in extraction pressure, back pressure and lube oil pressure. Turbine vibration monitoring: Vibration/axial/speed(key phasor) monitoring electronics shall be mounted on the Turbine control cabinet. ITC asked for the hardwired 420ma signals for connecting to the turbine control system. Since quoted Bently Nevada 3500 system does not have the repeat 4-20mA output, hence the above function will be achieved through serial interface. Turbine Local console (Local gauge rack is provided in the field which includes all gauges & speed indicator ): a) Local Digital speed indicator shall be provided in the console. b) Pressure gauges/switches/ solenoids etc.. shall be clearly tagged. c) Sufficient space shall be made available inside the panel to facilitate easy removal of any components during maintenance. Control System panels : a) Panels shall be designed to have enough working space inside. Panels shall not be congested. b) Panel GA and internal wiring drawings shall be submitted for approval of Purchaser. c) Proper labelling shall be provided for all components inside the panel. d) Cross ferruling shall be followed for all wires. All cables from sensors to FJBs will be routed thru conduits with inspection junction boxes. Write-up/ process description/logic description shall be provided for all critical loops All detail engineering drawings such as wiring/inter- connection drawings, I/O list, Master Inst. list, cable tray layout, installation drawings etc. will be prepared by them and submitted to the Purchaser.

6.

7. 8. 9 10

11

12

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16 17 18 19 20 21 22 23 A

All the documentation shall be in English language only. Wetted parts material for all Instruments, in-line flow elements and Control/On-off Valves shall be suitable for the process medium. All the transmitters shall be SMART with HART protocol and accuracy of 0.075%. Output shall be isolated 4-20mA DC, with super imposed digital signal. Analog outputs other than 4-20mA are not acceptable. (Eg. 0-10V DC) All the field transmitters shall have integral field LCD indication. Limit switches (Micro Switches) shall not be used. Only proximity switches (2 wire, 24V DC) shall be used in place of limit switches. The proximity switches shall be of OMRON make. Diaphragm type Level transmitters, (for lube oil tank), shall be with 3 ANSI flange of suitable rating and shall be according to B 16.5 (Not DIN DN 80 flange) Use of field switches for Flow and Temperature shall be avoided. Instead, smart transmitters shall be provided and the necessary interlock logic / alarm can be configured in the control system. All the sensors will be directly connected to RTD/Thermocouple input cards in MaxDNA. Control Valves (for example, spray water control valves and exhaust dump/vent control valves and etc.) Positioner : - Electro- pneumatic positioner shall be supplied with 3 gauges ( supply, signal & output) - Separate I/P converter & Pneumatic positioner is not acceptable - Cable entry shall be NPTF Actuator: Actuator shall be designed for a supply of 4 kg/cm2 Delta P shut off considered for the actuator sizing shall be more than or equal to max. inlet pressure Manual wheel is required for all type of control valves.

Accessories : Position Transmitter: a) All HCVs shall be provided with position transmitter of reputed make. Position transmitters are not required for CCV, LCV, FCV & HVs. b) Position transmitter shall be 2-wire 24VDC. c) Cable entry shall be NPTF ( Applicable for all Control valves in Suppliers scope) Solenoid valve: a) All ON/OFF Valves shall be supplied with Solenoid valves of ASCO/Rotex/ IMI-Norgren make. b) Solenoid coil shall operate on 24VDC and shall be supplied with LED. c) Solenoid coil shall be rated for continuous operation and insulation shall be class F d) Flying leads are not acceptable. The leads shall be terminated into a IP65 junction box mounted on the valve body. e) Cable entry shall be NPTF Proximity Switches: f) All ON/OFF valve shall be supplied with 2 nos proximity switches (2 wire 24VDC) for open and close indication. g) Proximities shall be OMRON make model no : E2E2-X7D1-2M-M18-SN7-NO type with LED h) The leads shall be terminated into a IP65 junction box mounted on the valve body. i) Cable entry shall be 1 nos NPTF Air filter regulator : - One number Air Filter Regulator (AFR) of with gauge shall be supplied

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Mounting of accessories : - All accessories shall be completely mounted on the valve itself and shall be tubed before shipment. - Loose supply of accessories is not acceptable. - All tubing shall be A269TP316 , of sizes or 3/8 or as required. 6mm OD, 10mm OD or 12mm OD tubes/fittings shall not be used. - Tubing connections shall be or 3/8 or NPTF as required Tag plate: SS permanent tag shall be attached to the valve which shall contain following information as minimum . Tag No: Valve size Valve Cv Material Of construction SLNO Permanent flow direction shall be marked on each valve body. The supplier shall provide specifications for all instrument items, data-sheets will be provided for only critical items like control valves and safety valves for approval. BHEL to note that Indfoss make pressure switches are not acceptable. The order of preference for pressure switches shall be Varma Trafag / Switzer. MaxDNA control system shall have separate RTD and T/C cards to record all temperatures. In such case no separate transmitters for temperature may be required. Cables shall be considered as per the following : Signal a. 1Pair X 1.5 sqmm; Armoured and screened; Blue outer sheath, Core colours : White and Blue 6 Pair X 1.0 sqmm. and 16 Pair X 1.0 sqmm as required Armoured, individual pair and overall screened; Blue outer sheath, Core colours : White and Blue, Twisted pairs and pair numbers printed on all pairs at every 150mm. b. RTD: 1Triad X 1.5 sqmm ; Core colours as per standard; Blue Outer sheath c. T/C 1 Pair ; 16 or 18 AWG as per standard. Core colours and outer sheath colours as per standard,. d. Control : 1Pair X 1.5 sqmm; Armoured and screened; Black outer sheath, Core colours : Orange and Black 6 Pair X 1.5 sqmm and 16 Pair X 1.5 sqmm as required Armoured and overall screened; Black outer sheath, Core colours : Orange and Black, Twisted pairs and Pair numbers printed on all pairs at every 150mm. Power : 3 Core X 2.5 sqmm or higher as required. All cables from sensors to JB shall be 0.5 sq.mm FEP/PTFE. All grouped cables from JB to panel shall be 0.5 sq.mm PVC FRLS, armoured, overall screened (for all signal cables). However cables interconnecting panels shall be unarmoured.

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All signal/control cable shall have identified colour codes. Power cables to SV shall be 1.5 sq.mm. Instrument air header pressure 5.0 Kg/cm2 (g). All actuators shall be designed for a pressure of 4.0 Kg/cm2 Special cables if any, between sensors and transmitters shall be included in the scope of supply (Cable length shall be min. 15 metres). For vibration/axial integral cable 5m length shall be provided. Instrument air header shall be installed with the following specs : Header Pipe : 2" SS pipe with 6 Nos. and 10 Nos. tappings as required. Inlet from top and is of 1" sized with Union and Ball valves of !" All take off points thru' 1/4" SS Ball valves Drain at bottom with 1/4" SS Ball valve. 20% spare terminals shall be provided in each Junction Box and the multi core/pair cable shall have 20% spare cores/pairs as far as possible. 20% spare space shall be provided in all the main trays/branch trays for future use. Cable ferrules shall be of continuous printed type only. Individual circular ring type ferrules shall not be used. Cross ferruling shall be provided in panels / JBs and field side. A distance of minimum 250mm shall be maintained between control and instrumentation signal cable trays while erecting these at site. Separate trays shall be used for instrument signal , control & power supply cables. All Inst. Cable trays shall be perforated & galvanized. The scope includes supply of all Instruments and erection materials for installation at site and cabling upto junction boxes and from there, upto the TG control system cabinets. The supplier shall ensure to supply any Instruments, which have not been included in their scope of supply but are required for the safe and efficient operation of the plant without any time and cost implication to the Purchaser. The following are the minimum tests to be demonstrated by TG supplier at site during commissioning. 1. 18 MW Load throw off 2. oil pump auto changeover The two maxStations considered shall have facilities of OWS and EWS in both the machines. However EWS shall be utilized in one machine at a time. The following generator related are I/Os are to be monitored in maxDNA. DI 20 nos for SOE. AI- 15 nos. (4-20 mA) RTD-21 nos. JBs shall not be mounted on Turbine or Generator or Gear box. Bearing and winding temperatures to be monitored in maxDNA system. Speed Acquisition system (Qty.) : 3 speed sensors with speed acquisition modules are envisaged. These modules convert pulse signal to 4-20mA and will be monitored in maxDNA Turbine governing system consisting of Trip sovs / pressure switches / I to H converters as required. Indicative layout of panel and control desk arrangement : Two panels (typicals) with dimension of 750mm x 750 mm x 2395 mm. One wooden table top desk for mounting two CRTs. The final layout shall be as per OGA approved The supplier shall provide the following along with the other field 1. Diaphragm seal type level transmitter with isolation valve for lube oil tank. - 2. Trip oil pressure transmitter. - However, only one pressure switch for control oil and trip oil may be envisaged for trip. - 3. jacking oil pump discharge pressure transmitter to be provided. - One no. universal HART communicator.

37 38 39.

40. 41.

42. 43. 44. 45. 46. 53

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54

From each drive the following signals shall be considered from MCC to maxDNA. 4 DI 1 DO 1 AI

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With the maxDNA system being supplied, 1 milli sec SOE time resolution is possible for identification of the turbine / generator trip cause Max DNA system along with associated hardware will be the latest, that is available at the time of delivery Switches being supplied shall be of D-link / Cisco / 3 com make. Operator station hardware shall be the latest that is available at the time of delivery. Make shall be HP / IBM / Compaq Additional max station for max links with customer DCS and TSI is included in the scope of supply. DI / DO cards must have status LEDs for monitoring the individual channel status. The system shall be supplied with separate field power supply and system power supply. Importing the data from the history to windows applications like excel etc. shall be possible. Totalizers can be configured for the flow inputs. Alarm list is stored in Historian along with the trends and adequate for the process requirements. DPUs being supplied shall not be loaded for more than the 60% of CPU and memory capacity. The required tuning/programming for the smooth parallel of operation of TG3 and TG4 shall be taken care in all respects. OPC connectivity with ITC MIS is possible from MaxDNA system. The required S/w and hardware in MAxDNA system shall be part of the supply. The number of SOE points will be 60. The Purchaser insisted the Supplier to make a separate offer for complete maxDNA system as a retrofit for the existing TG3. The four number of turbine control panels shall be with dimensions 800mmX800mmX2235mm The purchaser shall provide the supplier with four feeders of 230VAC UPS is required for power supply. The colour shall be RAL 7032. The configuration software with interfacing and serial cable for Bently Nevada 3500 TSI is included in the Suppliers scope and the Supplier shall ensure that this software is loaded in maxLink station supplied by the Supplier. The Supplier shall ensure redundant power supplies for speed acquisition modules. The following additional I/Os shall be considered for realizing CW and spray water pump logics. Digital Inputs : 16 nos Digital Outputs : 4 nos Analog Input : 5 nos ( 4- 20ma) AI ( RTD) : one no. The cabling upto DCS cabinets is included in the Purchasers scope. Remote start / stop shall be envisaged from DCS for these pumps. For CW pumps auto/manual selection shall be envisaged in DCS with auto starting of standby pump ON from the MCC stop feedback of main pump. The Supplier shall ensure that the I/H converter being supplied for TG4 shall be interchangeable with I/H converter supplied for TG#3. The supplier shall ensure that the required tuning/programming for the smooth parallel operation of TG3 and TG4 will be taken care in all respects. FAT procedure for max DNA will be submitted by the Supplier for the Purchaser/Project Consultants review/approval. The Supplier shall impart training to ITC personnel at BHEL(Hyd) and EDN ,Bangalore for a minimum of 10 persons and 6 persons respectively in two to three batches. The supplier shall provide temp elements are required in CW inlet & outlet (in common lines) of Steam turbine oil coolers. Synchronisation:

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Since synchronisation function cannot be implemented as a part of DCS and a separate auto synchronizer must be supplied as a part of generator relay and control panel. The auto synchronizer can be initiated with Auto synchronizer start PB available in the generator control and relay panel. Also this command can be given through a CRT command from DCS. 82 Generator Protection circuits: The supplier shall ensure that trip impulse from generator protection circuits shall go to generator circuit breaker directly for tripping. Load shedding: The Purchaser/Project Consultant shall develop the electrical trip logics related to load shedding and will be furnished to the Supplier for incorporating required logics in DCS. Also The Purchaser/Project Consultant shall indicate the contact rating of the output signals from DCS.

83

1 All motors shall be provide with local emergency isolators(associated with each motor). 2 2nos. of 100% float cum boost chargers included in Suppliers scope. 3 All oil pumps and vapour extraction fans motors including the associated local isolators and PB stations shall be flame proof. 4 All local emergency isolators shall be provided with pad locking facility as specified and shall also have phase barriers and shrouded terminals. Battery and chargers shall be adequately sized to cater for the DC oil pumps for the required time. The battery banks shall be of lead acid type and must be supplied from the Purchasers approved vendor. The battery backup shall be of minimum 30 minutes duration. The generated power shall be brought up to the 11kV switchgear by phase segregated bus-duct as specified (50M on phase side+6M on neutral side) with aluminium conductor & aluminium enclosure with CTs, PTs, LA & SP equipt.

7 8 9 10 11

The creepage distance of the insulators and seal off bushing shall be 250mm. Phase segregation material in SPBD shall be fibre glass. The PTs provided in PTSP cubicle shall be draw out type. The PTSP and NGR cubicles shall be suitable for busduct entry from TOP. The motorized isolator shall be provided in the NGR cubicle which shall be suitable for remote control ( from GCP ) and a semaphore indicator shall be provided on GCP mimic.

12 13 14 15 16

The TG is required to operate in parallel with the existing co-generators. Hence the TG offered shall have the sophisticated load sharing feature in addition to load-frequency controls. TG offered shall also be equipped with Auto power factor control in AVR. BHEL to offer.AVR with twin channel two Auto channel(main & standby ) 6nos. spare diodes shall be offered as spare. Two stage Rotor E/F relay shall be provided.It does not have provision for monitoring the brushes

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17 19

The diodes shall be of 150% higher rating than the field current requirement such that the failure of diode does not causes unit shutdown.Thus Diodes together have a rating of 900A where as field current requirement to deliver the full load is 540 A Varisters shall be provided as protection against overvoltage.

20 Minimum excitation limiter shall be provided. 21

22 23

Meters for indicating excitor field current and voltage shall be provided. The mimic on GCP shall cover 6.6kV and 415V systems also. For that BHEL will include extra panel for CI

One number multifunctional relay with 100% redundancy shall be provided for generator protection apart from the regular protection relays. 24 Under frequency relay offered shall have minimum two stages of df/dt and each stage shall be associated with an auxiliary relay having four NO contacts adequately rated to trip various loads. The contacts of the auxiliary relay shall be suitable to use in 220V DC circuit. 25

The CO2 fire extinguishing system offered for alternator shall have a standby bank of cylinders. 26 27 In addition to the analogue energy meter asked for on GCP one digital type energy meter shall also be provided. Please confirm inclusion of following RTDs in your scope: For Generator(6+1 spare )x 2 Nos Simplex RTDs for stator winding .No RTDs in Stator core For Cooler circuit3 RTDs .(One No duplex RTD in each bearing.Two nos duplex RTDs in the cold air and one no duplex RTD in hot air region) And 2 duplex RTDs for air cooler water inlet and outlet. 28 Water leakage detector for generator cooler arrangement shall be provided. 30 XPLE insulated FRLS armoured cables as mentioned in Scope of supply are in BHEL scope 31 All cable terminations shall be of heat shrinkable type and double compression type cable glands shall be used with proper gland earthing. The cables and accessories shall be as per BHEL vendor list with Purchasers approved

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Makes of all equipment shall be as specified in BHEL vendor list Wherever makes are not specified, the makes shall be subject to mutual agreement Three No Dual core CTS are to be provided on line side-core 1 for differential protection and core 2 for metering. Similarly 6CTS are considered on neutral side 3 Nos for differential protection & 3 Nos for other protection NGR is offered

33

34

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Check synchronising relay and guard relay is in the scope of supply for use in manual synchronisation of generators/supplies. TGMCC is excluded from scope of supply.

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