Performance Guarantee Test Procedure For Tg Cycle & Auxiliary Power Consumption

BHEL/ POWER SECTOR-EASTERN REGION(HQ)/TECHNICAL SERVICES

ट�जी और सहायक पॉवर उपभोग हे तु �नष्पाद गारं ट� पर��ण प्र�क (संशोधन-00)

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV-00)

प�रयोजना नाम: �संगरे नी को�लयर�ज ट� पी एस।

भारत हे वी इलेिक्ट्र �ल�मटे ड

प�रयोजना स्था: बी एच ई एल साइट कायार्ल

पावर सेक्ट:पूव� �ेत:: कोलकाता

जयपुर (मंडल) िजला: अ�दलाबाद, आंध प्रद-504216.

(भारत सरकार का उपक्)

Bharat Heavy Electricals Limited (A GOVERNMENT OF INDIA UNDERTAKING)

Power Sector: Eastern Region: Kolkata

(2X600 मेगावाट), �संगरे नी ट�पीपी, पगडपललट (गांव),

Project name: SINGARENI COLLIERIES TPS Project location:

BHEL SITE OFFICE (2X600 MW),

SINGARENI TPP, PEGADAPALLI (VILLAGE), JAIPUR (MONDAL) DIST. ADILABAD, ANDHRA PRADESH504216.

भारत हे वीइलेिक्ट्रकल्स�ल� Digitally signed Signature Not पावर सेक्ट:पूव� �ेत, कोलकाता,प्लॉटसंड़ी ज- 9/1, सेक्ट-II, by PVerified Rकरुणामय, SEN

सॉल्टलेकसीट,कोलकाता-700 091.रिजकायार ्लयःबीएचईए, �सर�फोटर13:45:26 , नयी�दल्ल़ IST -110 049 Date: 2016.08.10

Reason: CAT II Location: LimitedNTPCEOC

Bharat Heavy Electricals POWER SECTOR-EASTERN REGION (HQ), DJ-9/1, SECTOR-II KARUNAMAYEE SALT LAKE CITY, KOLKATA-700091,PHONE: 033 2321 1958.Registered Office: BHEL House, Siri Fort, New Delhi - 110 049.

STG PG TEST PROCEDURE FOR MAITHON POWER LIMITED 2X525MW MAITHON RIGHT BANK TPP

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Comments on the document is attached please.

 

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

  INDEX    TITLE  NO.   

TITLE 

PAGE NO 

1.0 

OBJECTIVE  

4 

2.0 

TEST CODE  

6 

TEST SCHEMATIC 

6 

SELECTION OF MEASURING INSTRUMENTS  

6 

ADVANCE PLANNING FOR THE TEST  

7 

      3.0  4.0       5.0  6.0 

PREPARING THE TG CYCLE FOR THE TEST 

7‐8 

7.0 

PRETEST SHUT DOWN ACTIVITIES BY BHEL 

8.0. 

INSTALLATION OF TEST INSTRUMENTS 

8‐9 

9.0 

GENERAL GUIDELINES 

9‐10 

8 

10.0 

INSTRUMENTS CALIBRATION AND CORRECTION 

10 

11.0 

ITEMS ESSENTIAL FOR AGREEMENT 

10 

12.0 

NUMBER OF TEST RUNS 

10 

13.0 

FREQUENCY OF OBSERVATION 

10 

14.0 

RECORDING OF READINGS 

11 

15.0 

DURATION OF TESTS 

11 

16.0 

ACTIVITIES BEFORE OFFICIAL TEST 

11 

17.0 

POST TEST ACTIVITIES 

12 

18.0 

AGEING 

12 

19.0 

ANNEXURE  ( 1 TO 25 ) 

13‐129 

   

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

  1.0 OBJECTIVE      To carry out the performance guarantee tests in line with the contract document   To prove “HEAT RATE” and output of the turbine cycle   To prove guaranteed Auxiliary power consumption and other contractual guarantees related to Turbine and  its auxiliaries.  2.0 GUARANTEED PARAMETERS UNDER LIQUIDATED DAMAGES (Category‐I)    Sr. no. 

Guaranteed Parameters 

Guaranteed figures 

(i) 

Turbine cycle Heat Rate in Kcal/Kwhr under rated steam conditions at  design condenser pressure with zero make up at 600 MW unit load.  (HBD. NO. PE‐DC‐381‐100‐N151)  Turbine cycle Heat Rate in Kcal/Kwhr under rated steam conditions at   design condenser pressure with zero make up at 480 MW unit load.  (HBD. NO. PE‐DC‐381‐100‐N152)  Continuous TG output of 600 MW under rated steam conditions at  worst condenser pressure with 3% make up.  (HBD. NO. PE‐DC‐381‐100‐N161)  Condenser pressure in mm Hg(abs) measured at300mm above the top  row of condenser tubes under VWO condition, 3% make up, design CW  temperature and CW flow.  CW pumping power in KW for design CW flow and the pressure drop in CW side by measure bunker for terminal points. (Power consumption  shall be computed based on overall efficiency of 83.1 of CW pump and  drive set.  The  total  unit  auxiliary  power  consumption  for  all  the  Turbine  Generator  Auxiliaries,  steam  generator  auxiliaries,  ESP  and  turbine  cycle  and  other  common  auxiliaries  required  for  continuous  unit  operation  at  100%  TMCR  (600MW  unit  load)  under  rated  steam  conditions  at  worst  condenser  pressure  with  3%  make‐up  and  with  ambient air temperature of  270C and RH of 60% shall be guaranteed.  The  total  unit  auxiliary  power  consumption  for  all  the  Turbine  Generator  Auxiliaries,  steam  generator  auxiliaries,  ESP  and  turbine  cycle equipment and other common auxiliaries required for continuous  unit  operation  at  80  %  TMCR(480MW  unit  load)  under  rated  steam  conditions  at  worst  condenser  pressure  with  3%  make‐up  and  with  ambient air temperature of 270C and RH of 60% shall be guaranteed. 

1927.1 Kcal/Kwhr 

(ii) 

(iii) 

(iv) 

(v) 

(vi) 

(vii) 

1975.7 Kcal/Kwhr 

600MW 

77mmHg(abs)  Refer to annexure‐21  1037 KW (per unit  basis)  Refer to annexure‐22  19,659 (Per unit) KW   Refer to annexure‐18  

15,301 (Per Unit) KW   Refer to annexure‐18 

  2.1 Demonstration parameters / capabilities for Turbine Generator  Sr. no. 

TURBINE GENERATOR SET CAPABILITY

Value/Remarks 

(i) 

The  steam  turbine  generator  unit  shall  be  capable  of  delivering  the  output at generator terminals corresponding to VWO condition under  rated conditions at design condenser pressure 0% make‐up.  The  steam  turbine  generator  unit  shall  be  capable  of  maximum  continuous  output  at  generator  terminals  corresponding  to  all  HP  heaters  out  of  operation,  under  rated  steam  conditions  at  a  design  condenser pressure and 3% make up. 

As per HBD No. PE‐DC‐ 381‐100‐N167 

(ii) 

         

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600 MW  HBD no. PE‐DC‐381‐100‐ N170  Refer to annexure‐16 

 

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

      2.2 Demonstration parameters / Turbine Auxiliaries –  Sr.  no.  1.

Sr.  no.  1. 2. Sr.  no.  1. 

2.  Sr.  no.  1.  2.  3.  Sr.  no.  1. 

STEAM CONDENSING PLANT 

Remarks

Life  of  sponge  rubber  balls  and  number  of  balls  lost  during  1000hrs of  plant  Refer to annexure‐23 operation  shall  be  as  indicated:  Life  of  sponge  ball  =  3  Weeks.  Balls  lost  during  1000 Hrs of plant operation less than or equal to 10%  FEED WATER HEATERS & DEAERATORS Remarks   The Dissolved Oxygen content in feed water at De‐aerator effluent at De‐aerator   Refer to annexure‐19 outlet without chemical dosing at all loads shall not exceed 0.005cc/litre.  Difference  between  the  saturation  temperature  of  the  steam  entering  the  De‐ aerator and temperature of the feed water leaving De‐aerator.  Condensate extraction pumps 

Refer to annexure‐20 Remarks

Each  CEP  set  shall  be  capable  of  delivering  flow  &  total  dynamic  head  Refer to annexure‐24 corresponding to run out point as specified.  The vibration, noise level and parallel operation of any two of three pumps shall  be demonstrated.  Boiler feed pumps  Remarks   Each  BFP  set  shall  be  capable  of  delivery  flow  and  total  dynamic  head  Refer to annexure‐25 corresponding to run out point.  The vibration level and parallel operation of any two of the three pumps shall be  demonstrated‐ Noise level‐85 db (With acoustic enclosure)  Cold/Hot start ups of the unit using TDBFP with motive steam from auxiliary steam  header.  Noise  Noise level measurement shall be carried out using applicable and internationally  acceptable  standards.  The  measurement  shall  be  carried  out  with  a  calibrated  integrating Sound level meter meeting the requirement of IEC 651 or BS:5969 or  IS:9779.  The  steam  turbine  generator  unit  shall  perform  continuously  without  exceeding the level of noise 90 db (A) for TG set and 85 db (A) for auxiliaries over  the  entire  range  of  output  and  operating  frequency.  During  HPLP  bypass  operation, sound level may go to 110 db (A)for short duration.  Sound pressure shall be measured all around the equipment at a distance of 1.0m  horizontally from the nearest Surface of the machine and at a height of 1.5m from  the floor level in elevation.  A  minimum  of  6  points  around  each  equipment  shall  be  covered  for  Measurement.  Additional  measurement  Points  shall  be  considered  based  on  the  Applicable  standards  and  the  size  of  the  equipment.  The  measurement  shall  be  done  with  slow  response  on  the  A‐weighting  scale.  The  average  of  A‐weighted  sound  pressure  level  measurements  expressed  in  decibels  to  a  Reference  of  0.0002  microbars  shall  not  exceed  the  guaranteed  value.  Corrections  for  background noise shall be considered in line with the Applicable standards. All the  necessary  Data  for  determining  these  corrections,  In  line  with  the  applicable  standards, shall be collected during the tests. 

     

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Remarks             ‐‐ 

 

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

  2.0   TEST CODE   Performance guarantee Test for heat rate & output will be carried out in line with contract test code ASME‐PTC‐6.  3.0 TEST SCHEMATIC  The approved test scheme titled “PERFORMANCE GUARANTEE TEST INSTRUMENTATAION SCHEME” of Drawing no.  PG‐DG‐381‐100‐N121 shall be used. Refer Annexure‐11    4.0 SELECTION OF MEASURING INSTRUMENTS   The instruments meeting accuracy/uncertainty requirements, as specified in ASME‐PTC‐6shall be selected and shall  be as per the TG PG test instrumentation schematic drawing no PE‐DG‐381‐100‐N121 Rev04.The brief detail of  instruments to be used during the PG test is provided in the following table. Refer Annexure‐11 for TG‐PG test  instrumentation list. 

Sl  No 

Parameter 

Range

Instruments

Accuracy/Uncertain ty 

1 

Mass flow 

‐‐

Nozzle/orifice  supplied byBHEL 

As per Performance  test code 

2 

Differential pressure across the  flow orifice/ nozzle. 

Various ranges upto  0‐2.5 Kg/cm2 

DP Transmitter

Accuracy +/‐ 0.05 %  or better. 

3 

Pressure 

various  ranges  up  to  Pressure  0‐250 kg/cm2    transmitters 

Accuracy  +/‐ 0.1 %

4 

Temperature  

0‐350 0 C 

Platinum resistance  thermometer  

Uncertainty ±0.55 0C

5 

Temperature 

0‐650 0 C

Uncertainty ±0.55 0C

6 

Generator power 

‐‐

K type  thermocouple   Digital power  Analyser 

7 

Auxiliary power measurement 

8 

0‐1A 0‐125V  0‐190.5W  LT  drives  power  consumption  0‐440 Volt measurement  0‐400 A 

Uncertainty +/‐ 0.1 %

Power transducer

Uncertainty +/‐ 0.1 %

Digital‐Multimeter (voltage), Clamp‐on  meter(Amp) & Power  factor meter (pf)/three  phase power tong  tester.

Accuracy 1% 

8 

Secondary measurement for  Voltage (PT, DPT, TC & Power  Transducer), Resistance (RTD). 

‐‐

Data logger

Accuracy +/‐ 0.03 %

9 

Atmospheric pressure 

0‐780mmHG

Barometer or abs  pressure  transmitter  

 Accuracy +/‐ 0.1 % or  better 

10 

Ambient temp. 

0‐350degC

RTD connected to  data‐logger 

Uncertainty ±0.55 0C

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

5.0   ADVANCE PLANNING FOR THE TEST             During  the  commissioning/erection  period  of  the  unit  every  effort  shall  be  made  to  ensure  the  provision  of  all  test‐tapping points as per test scheme.           Any missing tapping points or practical difficulty to make availability of tapping points and point of measurement   due to unavoidable reasons will be mutually discussed between BHEL and Customer at site and agreed upon  prior   to start of final test . Effort had been made to keep PG test tapings points separate from the normal operational  measurement  points,  however  in  case  of  practical  difficulties  and  extreme  emergency,  things  will  be  discussed  with customer and agreed upon for taking measurement through existing operational points at the time of test.   5.1  All  tapping  points  will  be  checked  by  BHEL  during  commissioning  stage  that  no  pipeline  or  installation  etc.  interferes with approach to the tapping points as far as possible. The temperature elements are of 300‐400 mm  length  and  enough  space  should  be  made  available,  so  that  the  test  temperature  elements  can  be  inserted  without any difficulty. In case of any obstruction, an alternate/operational test stub is to be used as far as possible.   5.2  Welded type thermo‐wells shall be used by BHEL for all critical lines (High temperature / pressure). These thermo‐ wells will remain permanently installed on the pipelines. Screwed type thermo‐wells (Low pressure / temperature)  shall  be  used  for  temperature  measurement  and  may  be  installed  in  the  unit  just  prior  to  the  test.  For  these  thermo‐wells, matching stub with suitable plug will be provided in the erection stage itself.   5.3  All  pressure  tapping  are  supplied  with  single  or  double  root  valves  depending  upon  the  pressure  rating  of  the  pipelines. In case some of the pressure tapings are found not available, the same will be provided or alternatively.  Either  a  'T‐off  shall  be  taken  from  the  process  tapping  point  or  process  point  itself  shall  be  used  after  mutual  agreement. Impulse pipe of suitable size and strength shall be laid during pre‐test preparation stage. The pressure  lines will be rigid enough to withstand any type of vibrations.  5.4   Test CTs and PTs of 0.2 accuracy class are to be provided by the BUS duct supplier. The installation and/or test  data for ratio and phase angle errors at different VA burdens and power factors shall be provided by the Customer  for  accurate  power  calculations.  Additionally,  test certificates giving  the  above  information  as  submitted  by  the  Generator bus duct supplier shall also be arranged for BHEL use.  5.5  CT terminals should be provided with termination arrangement for shorting/opening links. Effects of connecting  leads  shall  be  neutralised  in  power  calculations  by  measuring  voltage  drop  across  Pt  terminals  in  bus  duct  and  measuring point.  6.0      PREPARING THE TG CYCLE FOR THE TEST     Efforts are to be made by BHEL to ensure that all the TG systems /equipment are brought into service at the time  of trial operation. The unit readiness for conducting the PG test is to be ensured as per the checklist given below.  6.1  Ensure that all the heaters are in normal operation and drips of these heaters are cascading properly as per the    cycle. It is to be checked that there is no bypassing of the drips either to condenser or to de‐aerator and this is to  be ensured for sufficient time before actual commencement of the test.   6.3 Check that there should not be any tube leakage in the heaters.  6.3  If required, ensure the cleanliness of condenser tubes and get the same cleaned, if called for, during the shutdown  prior to the test.  6.4 Ensure that pressures of main steam, CRH, HRH and extractions to various heaters and condenser back pressure for  full  load  are  near  to  their  expected  values.  Ensure  that  all  test  flow  elements  are  available  at  site  with  all  their  matching flanges and fasteners.    6.5 Ensure that the pressure drop of cooling water across the inlet and outlet of the condenser is within design figure  and there is no tube leakage in condenser. Conductivity and oxygen content at condenser hot‐well should also be  within the prescribed limit.   

6.6 Ensure that requisite tapings are available in flow element to be used for condensate flow measurement.   

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

  6.7  Ensure  the  cleanliness  of  the  E.S.V  strainers.  In  case  of  the  excessive  pressure  drop  across  it,  the  same  shall  be  cleaned.    6.8 System tightness check to be carried out during commissioning of the machine i.e. de‐aerator level drop 

test  may  be  done  for  around    two  hours  by  keeping  the  interconnection  with  other  units  (if  any)  on  steam and feed side  isolated and also by closing the make‐up inlet and by keeping the CBD, EBD isolated.  The de‐aerator level is to be raised to the maximum permissible before this exercise. Fall in de‐aerator  level i.e. system losses are then to be observed. The problem, if any, is to be identified and rectified and  the  efforts  shall  be  made  to  bring  down  the  system  leakages  to  minimum.  (Ref  drawing/  calculation  procedure for de‐aerator level drop, which is enclosed). When the system is properly isolated for a performance test, the unaccounted leakage shall not exceed  0.1% of design throttle flow at full load. To achieve the above value of unaccounted leakages, BHEL shall  prepare  the  unit  during  pre‐test  available  shutdown.  However,  during  the  test,  if  it  is  found  that  the  unaccounted  leakage  is  more  than  0.1%  of  design  throttle  flow  at  that  load,  the  heat  rate  will  be  increased by an amount equal to half the difference between actual unaccounted for leakage expressed  as  percentage    of  design  throttle  flow  at  that  load  and  0.1%  (allowed  by  the  code).  However,  if  the  unaccounted  leakage  during  the  test  shall  be  more  than  0.5%  of  design  throttle  flow  at  that  load  and  appreciable leakage is visible in boiler area, mutual agreement shall be made regarding consideration of  excess leakage in the calculation of test result.    6.9 Ensure the proper tightness of the valves for passing etc.    6.10 Ensure the best availability of all test tapings points as per test scheme.   

7.0      PRE‐TEST SHUTDOWN ACTIVITIES BY BHEL               After  the  unit  is  ensured  ready  for  the  test,  a  suitable  shutdown  shall  have  to  be  agreed  between  BHEL  and    Customer. BHEL shall supply the calibrated test instruments prior to the start of the shutdown. Major activities to  be carried out during this shut down shall be as follows.  7.1 

Mounting/Installing screwed type thermo‐wells, provision for 'T'‐offs, laying‐out of impulse pipelines etc. 

7.2 

Providing any additional test tapping points if found necessary/applicable. 

7.3 

Necessary  arrangement/rectifications  for  meeting  the  system  isolation  i.e  required  defective/passing  valves  identified during the joint inspection to be attended.  

7.4 

 Mounting of temperature elements in identified hot areas and laying‐out their cables. 

7.5 

Laying‐out impulse pipeline (if not already laid) from the root valves in hot zones and terminating with pressure  transmitter isolating valves. Their root valves to be kept open. 

7.6 

 If required, Condenser tube cleaning and condenser air tightness checks to be carried out   and any leakages to be  got attended. 

8.0      INSTALLATION OF TEST INSTRUMENTS   8.1      Flow measuring devices               The flow assembly with matching flanges is supplied during commissioning stage. Flow measuring devices is to be  mounted by replacing the spool piece provided in condensate line preferably during the planned shutdown for PG  test so that these are used for minimum duration prior to the test. However the actual mounting may vary from  site to site as per availability of material. The actual drawing with calibration certificate will be furnished before  PG test. A typical installation sketch for DP transmitters for measuring assemblies is enclosed. Installation sketch  of  flow  assembly  as  per  requirement  shall  be  arranged  by  BHEL  prior  to  pre‐test  shutdown.  It  is  preferable  to  check the impulse pipeline connections after installation for  any leakage/chocking etc. by pressurizing the system 

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by running condensate pump to the extent possible during the unit shutdown itself. Problem noticed if any has to  be attended during the shutdown itself.  8.2      Temperature measuring instruments                K‐Type  Thermocouple  and  platinum  resistance  thermometer  elements  will  be  used  for  temperature  measurements. After connecting extension leads (Chromel‐Alumal compensating cable for TCs and copper cable  for  PRTs),  these  elements  shall  be  mounted  into  thermo‐wells  as  per  instrument  allocation  list  and  PG  test  scheme. The connection to measuring instruments to be made as per the sketch enclosed. Thermocouple wire is  to  be  connected  such  that  Chromel  portion  of  the  extension  lead  is  connected  to  Chromel  part  and  Alumel  portion to Alumel part of the sensor. To identify this, a positive sign has been marked on each Chromel terminal.  The  reference  junction  temperature  for  thermocouples  will  be  maintained  at  zero  degree  by  using  ice  box  or  through  electronic  zero  degree  reference  junction  compensator.  The  mV  output  from  the  thermocouples  and  Ohms output from PRTs shall be measured with precision data logger.  8.3 

Pressure measuring instruments  

             Impulse  pipelines  (of  appropriate  length)  with  isolation  valves  are  to  be  laid  for  mounting  the  pressure  transmitters. Impulse pipeline for the vacuum (negative pressure) measurement points should be laid such that  transmitter  is  mounted  above  the  tapping  point.  Thus  these  lines  should  be  laid  with  upward  slope.  All  the  impulse lines should be rigid enough to avoid any vibration in the instrument. For water height correction, the  vertical distance from the centre of the transmitter to the tapping points is to be measured for each tag number  and joint protocol by BHEL and Customer to be signed prior to test. The vertical distance above the tapping point  is to be taken as positive whereas same below the tapping is to be taken as negative for pressure correction. The  impulse pipelines are to be purged/ flushed sufficiently and steam to be allowed to condense before mounting  the  transmitters.  A  transmitter  will  be  charged  only  before  use  otherwise  it  should  be  kept  isolated  to  avoid  exposure to vacuum in case the unit trips.  

8.4 

Power measuring Instruments  

           CTs and PTs for PG test use should be identified well in advance and locations of their terminals in panels checked  for the connection of the power meters referring the generator schematic drawings. The lead resistance voltage  drop  in  the  circuit  of  PTs  shall  be  measured  if  required  along  with  customer  and  protocol  for  the  same  to  be  made  during  the  PG  test.  The  digital  power  meter  will  be  connected  to  the  identified  CTs  and  PTs  terminals  preferably in three‐phase four‐wire mode.  

 8.5      Level measurement               Level  measurement  in  5  minutes  of  interval  are  to  be  recorded  for    all  the  storage  tanks    by  means  of  digital  recording system (MAX /DAS panel) available at site with metric scales.  A sample data sheet for readings to be  recorded is enclosed herewith.   8.6     Secondary measurement by data acquisition system              Data  acquisition  system  is  based  on  a  digital  processor.  It  is  interfaced  with  computer  that  utilizes  software  to  activate the logger to view and analyse the collected data. Data acquisition system consists of many components  that are integrated to sense electrical parameter sent by the transducers (RTD, TC, Pressure transmitter & Power  transducer) mounted in the field.     9.0       GENERAL GUIDELINES  9.1 

All  electrical  instruments  should  be  placed  away  from  any  magnetic  field.  Their  proper  levelling  should  also  be  ensured.  

9.2         The  tips  of  thermocouples  and  PRTs should  always touch  the bottom  of  the  thermo  wells.  If  felt  necessary, the  adjustable mounting coupling can be removed and in that case the element should be properly pressed downward  and tied with a piece of wire. Stub projections and sensor stems, which are protruding out of thermo‐well, should  be covered with asbestos rope providing thermal insulation.  9.3     All the instruments should be stored in clean dry place nearer to unit under test preferably at turbine floor level. 

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9.4     At least two tags (including Tag No./service etc.) should be provided each at the instrument end near tapping points  and Data‐logger end.           9.5   All the pressure transmitters should be mounted in vertical position.  9.6   Depending  upon  the  likelihood  of  completion  of  the  above  activities,  date  of  conductance  of  final  test  will  be  jointly agreed with the customer under mutually agreed deviations, if any.   

10.0     INSTRUMENTS CALIBRATION AND CORRECTION   10.1   All the test instruments and other applicable instruments shall be duly calibrated at NABL accredited BICC (BHEL  Instruments Calibration  Centre)  at Noida  or  any  other  NABL  accredited  lab. Calibration  of  Pressure  transmitters,  RTD, TC sensors may also be carried out at site/HQ by BHEL engineer/NABL agency before conductance of the test  in  presence  of  customer  representative  (if  felt  necessary).  In  general  the  validity  of  calibration  for  all  PG  Test  sensors (RTD, TC, PT, Transducer & Power meter) will be of two years from the date of calibration.   10.2    All Copy of valid calibration certificate (on the day of installation) will be handed over to customer suitably before  the start of test.  10.3   Pressure transmitters' readings shall be additionally corrected for water column height corrections by measuring  the difference in levels between centre of the transmitter and the corresponding tapping point‐(Height correction).   Note: Calibration validity for all the PG test instruments will be ensured on the day of installation for conductance of TG  cycle PG test.  11.0    ITEMS ESSENTIAL FOR AGREEMENT   11.1   Nomination of test coordinating Engineer from customer side.  11.2   All the test instruments shall be transported to site as per the proposed date.   11.3   Means for obtaining steady operating parameters at their specified values.  11.4   Provision of a separate room of adequate size on the turbine floor for storing the test instruments and materials  for use during the test under lock and key shall be in the scope of the customer.  11.5    Deployment of round the clock proper security personnel from the time of installation of sensors till removal of all  equipment/sensors, if not in the scope of BHEL.  11.6   Provision of illumination by Customer at all measuring junctions and working places.  11.7    Provision of T&P by Customer like UPS power supply of 15 Ampere to at‐least five locations under TG area for Data‐ loggers station, Compressed air etc. 

12.0    NUMBER OF TEST RUNS     In addition to trial run and Preliminary test, Duplicate heat rate tests will be performed at 600MW and 480 MW unit  loads to prove the heat rate. The test result of the duplicate test runs shall agree within +/‐ 0.25%. If they differ more  than 0.25%, a third test shall be run at the same test points. Corrected results of any one of the three tests runs, which  deviate from the corrected average heat rate of all the three by more than 0.25%, shall be eliminated. Otherwise, the  results of all the three test runs shall be acceptable.    Further one test shall be carried out to prove unit output and condenser back pressure/CW pumping power at VWO  condition as stipulated under category‐1 and demonstration tests category.    13.0   FREQUENCY OF OBSERVATION    It will be carried out meeting the requirements of clause no. 3.9.1, ASME PTC‐6 which is as follows:  For  Heat  rate  tests  and  Output  Tests,  the  readings  for  pressures,  flows,  temperatures  and  Generator  Power  shall  be  recorded  in  the  data‐logger  at  an  interval  of  minimum  30  seconds.  In  case,  Digital  power  meter  for  measurement  of  Generator Power not hooked up with Data‐logger, measurement shall be recorded with the help of manual reading of the  Digital Power meter at an interval of one minute. Other parameters at the interval of 5 minutes shall be taken either from  DCS or by manual recording.   

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              14.0   RECORDING OF READINGS    14.1    Data  logger  will  be used  to  record  the  test  readings  at  an  interval  of  minimum 30  seconds  in raw  values  for  the             following:        Sl.  Parameter Unit No.  1  Pressure /DP transmitter output Volt    2  PRT output   Ohms 3  TC output  mV   4  Power transducer output  Volt    5  Power meter output  Watt   14.2   Recording will be done for every 5 Minute during the test through MAX/DAS system or manually for the following  data     A   De‐aerator level                                       mm  B   Hot‐well level                                            mm    C   CST Level                                                    mm  D   Boiler drum level                                      mm  E   Generator Hydrogen Pressure          ata  F   Frequency                            Hz    15.0   DURATION OF TESTS    As  per  ASME  PTC‐6,  Tests  shall  be  normally  carried  out  at  a  steady  state  run  of  two  our  duration.  However,  duration will be mutually decided depending upon the conditions prevailing during conductance of PG tests.Any  deviations  of  parameters  from  the  rated  conditions  shall  be  corrected  with  the  help  of  correction  curves.  The  applicable correction curves as per the “Method of Computation of Heat Rate” for heat rate correction & Output  correction are enclosed as per annexure‐14.    16.0 ACTIVITIES BEFORE OFFICIAL TEST   16.1  The  completion  of  test  preparation,  mounting  of  instruments,  isolation  of  thermal  cycle  and  briefing  of  the  local  observers.    16.2   The load is brought to rated capacity with rated parameters for taking a set of trial readings of all instruments.  16.3   The readings of the mock test to be analysed for their correctness, if they are correct, final test can be started.  16.4   The following operations shall not take place during the test, for which the isolation is carried out.           

 

       

Continuous Blow Down   Dusting of the Associated Boiler Unit   Steam Supply to Fuel atomisation, if any  Fuel Heating and SCAPH, if any  Soot blowing  Water and steam sampling  Any other flow from the system which affects the Heat Rate 

  16.5  The system is isolated so that no unaccounted steam goes out or comes into cycle. The makeup quantity shall be  measured / estimated by noting down the level drop in de‐aerator/hot‐well and also taking into consideration the  various storage tanks' levels at periodic intervals of the test.  16.6   Any  other  unaccounted  losses  like  high  gland  leakage  from  CEP,  if  exists,  shall  be  measured/estimated  for  their  quantity.  16.7 Sensitivity of the condenser hot well level control shall be reduced or preferably the level controlled be on manual  mode to avoid excessive fluctuation in the condensate flow to de‐aerator.   

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16.8   PRDS  control  valve  spindle  cooling  water,  atmospheric  valve  gland  sealing  water  flow  shall  be  adjusted  for  minimum flow.   16.9    Proper sealing water supply to vacuum system especially to atmospheric valve seals shall be ensured.  16.10   All means shall be put to maintain the parameters constant through out the test.   17.0    POST TEST ACTIVITIES     17.1  All  the  test  readings  of  average  value  shall  be  jointly  signed  &  one  copy  will  be  handed  over  to  site/customer/consultant  after  completion  of  all  tests.  One  set  of  average  readings  signed  by  customer  shall  be  retained by BHEL for calculation of test results and submission of test reports.    17.2    A shut down of the unit is to be arranged for a minimum period of 5 days for dismantling of all the test instruments  and flow measuring assemblies, if called for.     18.0    AGEING    Ageing  allowance  will  be  given  during  evaluation  of  PG  test  results  and  hence  guaranteed  heat  rates  shall  be  increased by the amount calculated as per the formula given in cl. No. 3.07, sub‐sesction‐3 of ASME‐PTC‐6 report  1985  (Reaffirmed  1991).  Period  of  ageing  shall  be  considered  from  the  date  of  successful  completion  of  initial  operation to the date of conductance of PG test, irrespective of the reasons for delay in conducting the PG test  attributable to employer or contractor.  In calculating the above factor any period(s) during which the turbine has not been in operation at a stretch for  more than a week shall not be considered. 

  **********************************************             

                   

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19.0  Annexure:      List of Annexure  ANNEX.  NO 

TITLE 

Page no 

1 

Details of welded type test thermo‐well pocket (with plug) 

14 

2 

Details of screwed type test thermo‐well 

15 

3 

Details of pressure stub 

16 

4 

Diagram for connection between pressure source and transmitter 

17 

5 

Diagram for connection between vacuum source and transmitter 

18 

6 

Diagram for connection between flow orifice to differential  pressure transmitter 

19 

7 

Temperature measurement lay out scheme for RTD 

20 

8 

Temperature measurement lay out scheme for T/C 

21 

9 

Pressure measurement lay out scheme for PT  

22 

10 

Typical connections for measuring Electrical power output by the  three wattmeter method 

23 

11 

PG test instrumentation scheme & list 

12 

Computation procedure for De‐aerator level drop 

34 

13 

Computation procedure for hot well level drop 

35 

14 

Method for computation of heat rate 

36‐47 

15 

Correction curves  

48‐70 

16 

Heat balance diagram 

71‐76 

17 

System check list 

24‐33 

77 

18 

Auxiliary power consumption test procedure 

19 

DISSOLVED OXYGEN CONTENT AT DEAERATOR OUTLE 

78‐80  81 

21 

DIFFERENCE BETWEEN THE SATURATION TEMPERATURE OF THE  STEAM ENTERING THE DE‐AERATOR AND  THE TEMPERARTURE OF THE FEED WATER LEAVING DE AERATO Condenser Back Pressure test procedure 

22 

TEST PROCEDURE FOR CW PUMPING POWER 

100‐105 

23 

TEST PROCEDURE FOR CONDENSER ON LOAD TUBE CLEANING  SYSTEM 

106‐110 

24 

PG TEST PROCEDURE FOR CONDENSATE EXTRACTION PUMP 

111‐118 

25 

PG TEST PROCEDURE FOR BOILER  FEED  PUMP 

119‐129 

20 

       

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ANNEXURE –1 

  

Details of welded type test thermo‐well pocket (with plug):   

  1. M‐type of stub and thermowell to be used for main steam, CRH,HRH, bled steam (To HPH‐5 & DEA)  feed water lines, HPH drains, HPT rear (1st leak  off) HPT front (2nd leak off), IPT front (1st leak off).  2. N‐type of stub to be used on condensate, cooling water and law pressure/temp steam pipe lines  (Bled steam to LPHs, Ejectors, GSC, LPH drain lines, IP rear leak off, mixture of leak offs to EXT‐4,  cross over pipe lines, exhaust hood, BFP suction line, sealing steam to glands. )  3. M‐type of stub to be provided with welded thermowell .  4. ‘X’ to be fixed based on pipe wall thickness.  14 of 129

 

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ANNEXURE – 2       

 Details of screwed type test thermo‐well:   

PIPE DIA

‘U’

100‐180 180‐260 260‐360 360‐500 Above 500

120 160 200 250 320

Working Pressure Working  Temperature  Test Pressure

 

 

Note:  1. 2. 3. 4. 5.

All dimensions are in MM.  Material AISI 316 SS.  ‘U’ to be decided based on Pipe Diameter.  To be I.B.R. Approved.  Each thermowell to be provided with 2MM TH. Annealed copper washer &  M20X1.5 Carbon steel Bolt. 

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180 Kg/cm2  550 Deg C  360 Kg/cm2 

                                                                                                                                                            

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ANNEX XURE – 3 3       

 Deetails of prressure stub:  

 

  Note:    1. 2. 3. 4.

This stub is to o be used for a all the pressu re test tappin ng coming und der performannce test schem me.  For pressure above 40ata, two root valvve to be used. For pressure below 40ata, one root valvve to be used. Impulse pipe material same or equivalenntas the stub material. 

           

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ANNEXURE – 4 

     Diagram for connection between pressure source and transmitter:   

    Note: 

 

I. II. III. IV. V. VI.

Gauge may be above, below or level with pressure tap.  Gauge must not be subjected to vacuum.  Shut valve immediately if turbine is tripped out or before shut down.  Impulse/Connecting pipe shall not be less than 3/8 inch (10mm) inside diameter and ½ inch  (13mm) nominal outside diameter or equivalent tubing.  For pressure greater than 40kg/cm2 use 3mm wall thick impulse pipe.  For pressure less than 40kg/cm2 use 2.5mm wall thick impulse pipe.  

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ANNEX XURE – 5 5     

 Diagrram for co onnection n between n vacuum source an nd transm mitter:     

               

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  ANNE EXURE–6 6     

 Diaagram  fo or  connecction  bettween  flo ow  orificce  to  diffferential  pressure e  traansmitter      ASME P PTC 6      

 

                       

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  ANNE EXURE–7 7 

       Temperaturre measurrement layy out sche eme for RT TD     

               

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ANNEXURE –8 8                                                                                                                                             

 Tem mperature e measure ement lay  out schem me for T/C C 

   

       

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ANNEXURE –9 9           Presssure meassurement lay out sccheme forr PT 

 

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

ANNEXURE 10 0       Typiccal connecctions for measurin ng Electriccal power output byy the thre ee  wattm meter me ethod 

 

   

   

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

                           

ANN NEXURE – 11

 

PG test instru umenta ation sch heme 

 

& 

     

Instrum mentatiion list ffor 2X60 00MW Singareeni TPS 

 

         

       

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

25 of 129

 

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

TG PG test instrumentation list for 2x600MW Singareni TPS  TEMPERATURE MEASUREMENT   *APPROXIMATE  VALUES AT 100%  LOAD (In deg c) 

Tag No  Service 

  Inst. 

1  2 

TW01  TW02  

SH Spray Comm. Header   SH Spray Comm. Header  

T/C   T/C 

‐  

3 

TW03  

HPT inlet bef. Strainer (L) 

T/C  

537 

4 

TW04  

HPT inlet bef. Strainer (L) 

T/C 

5 

TW05  

HPT inlet bef. Strainer (R)  

T/C  

537  537 

6 

TW06  

HPT inlet bef. Strainer (R)  

T/C 

537 

7  8 

TW07   TW08  

Extraction 7 to HPH 7 (TE)  Extraction 7 to HPH 7 (TE) 

T/C  T/C 

391.3 

9 

TW09  

Extraction 7 to HPH 7A (HE) 

T/C 

389.1 

10 

TW10  

Extraction 7 to HPH 7A (HE) 

T/C 

11 

TW11  

Extraction 7 to HPH 7B (HE) 

T/C 

389.1  389.1 

12 

TW12  

Extraction 7 to HPH 7B (HE) 

T/C 

389.1 

13  14 

TW13   TW14  

HPT Exhaust steam   HPT Exhaust steam  

PRT  PRT 

332.7 

15 

TW15  

CRH steam after HPBP 

PRT 

332.7 

16 

TW16  

CRH steam after HPBP 

PRT 

17 

TW17  

CRH Before spray (L) 

PRT 

332.7  332.7 

18 

TW18  

CRH Before spray (R) 

PRT 

332.7 

19  20 

TW19   TW20  

Downstream of HPBP  Downstream of HPBP 

T/C   T/C 

‐  

21 

TW21  

Extraction 6 to HPH 6A (HE) 

PRT 

330.6 

22 

TW22  

Extraction 6 to HPH 6A (HE) 

PRT 

23 

TW23  

Extraction 6 to HPH 6B (HE) 

PRT 

330.6  330.6 

24 

TW24  

Extraction 6 to HPH 6B (HE) 

PRT 

330.6 

25  26 

TW25   TW26  

Steam to PRDS hdr.  Steam to PRDS hdr. 

T/C  T/C 

‐ 

27 

TW27  

HRH bef. Strainer (L) 

T/C  

565.0 

28 

TW28  

HRH bef. Strainer (L) 

T/C 

29 

TW29  

HRH bef. Strainer (R) 

T/C  

565.0  565.0 

30 

TW30  

HRH bef. Strainer (R) 

T/C 

565.0 

31  32 

TW31   TW32  

Extraction 5 to HPH 5 (TE)  Extraction 5 to HPH 5(TE) 

T/C   T/C 

463.4 

33 

TW33  

Extraction 5 to HPH 5A (HE) 

T/C  

462.9 

34 

TW34  

Extraction 5 to HPH 5A (HE) 

T/C 

35 

TW35  

Extraction 5 to HPH 5B (HE) 

T/C 

462.9  462.9 

36 

TW36  

Extraction 5 to HPH 5B (HE) 

T/C 

462.9 

37  38 

TW37   TW38  

IPT Exhaust steam (L)  IPT Exhaust steam (L) 

PRT   PRT 

328.2 

39 

TW39  

IPT Exhaust steam (R) 

PRT 

328.2 

40 

TW40  

IPT Exhaust steam (R) 

PRT 

41 

TW41  

LPT I/L steam common header (R) 

PRT 

328.2  328.2 

42 

TW42  

LPT I/L steam common header (R) 

PRT 

328.2 

S. No 

43  TW43  LPT I/L steam common header (L)  PRT  0 * APPROXIMATE VALUES AT 100% LOAD (In  C) ARE GIVEN FOR REFERENCE ONLY. 

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‐  

391.3 

332.7 

‐  

‐ 

463.4 

328.2 

328.2 

 

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

TG PG test instrumentation list for 2x600MW Singareni TPS  TEMPERATURE MEASUREMENT   Sl.  No 

Tag No 

Service 

Inst. 

LPT I/L steam common header (L)  44  TW44  PRT  45  TW45   PRT  Extrn.4 to Deaerator (TE) 46  TW46   PRT  Extrn.4 to Deaerator (DE) 47  TW47   PRT  Extrn.4 to Deaerator (DE) 48  TW48   PRT  TDBFP‐A steam inlet 49  TW49   PRT  TDBFP‐B steam inlet 50  TW50   PRT  FW BFP A discharge 51  TW51  PRT  FW BFP B discharge 52  TW52   PRT  RH spray comm. Header 53  TW53   PRT RH spray comm. Header 54  TW54   FW inlet to HPH 5A PRT 55  TW55   FW inlet to HPH 5A PRT 56  TW56   FW inlet to HPH 5B PRT 57  TW57   FW inlet to HPH 5B PRT 58  TW58   FW HPH 5A outlet  PRT 59  TW59   FW HPH 5A outlet  PRT 60  TW60   FW HPH 5B outlet  PRT 61  TW61   FW HPH 5B outlet  PRT 62  TW62   FW HPH 6A inlet  PRT  63  TW63   FW HPH 6A inlet  PRT  64  TW64   FW HPH 6B inlet  PRT  65  TW65   FW HPH 6B inlet  PRT  66  TW66   FW HPH 6A outlet  PRT  67  TW67   FW HPH 6A outlet  PRT  68  TW68   FW HPH 6B outlet  PRT  69  TW69   FW HPH 6B outlet  PRT  70  TW70   FW HPH 7A inlet  PRT  71    TW71 '   FW HPH 7A inlet  PRT  72  TW72   FW HPH 7B inlet  PRT  73  TW73   FW HPH 7B inlet  PRT  74  TW74   FW HPH 7A outlet  PRT  75  TW75  FW HPH 7A outlet  PRT  76  TW76  FW HPH 7B outlet  PRT  77  TW77  FW HPH 7B outlet  PRT  78  TW78  FW before economiser PRT  79  TW79  FW before economiser PRT  80  TW80  HPH 7A Drain to HPH 6A PRT  81  TW81  HPH 7A Drain to HPH 6A PRT  82  TW82  HPH 7B Drain to HPH 6B PRT  83  TW83  HPH 7B Drain to HPH 6B PRT  84  TW84  HPH 6A Drain to HPH 5A PRT  85  TW85  HPH 6A Drain to HPH 5A PRT  86  TW86  HPH 6B Drain to HPH 5B  PRT  87  TW87  HPH 6B Drain to HPH 5B PRT  88  TW88  HPH 5A drain to DEA (HE)  PRT  89  TW89  HPH 5A drain to DEA (HE)  PRT  90  TW90  HPH 5B drain to DEA (HE)  PRT  91  TW91  HPH 5B drain to DEA (HE)  PRT  92  TW92  CRH bef. Mixing to Extraction 4 PRT 93  TW93  CRH after spray (R) PRT  94  TW94  CRH after spray (R) PRT  95  TW95  CRH after spray (L) PRT  * APPROXIMATE VALUES AT 100% LOAD (In 0C) ARE GIVEN FOR REFERENCE ONLY. 

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*APPROXIMATE  VALUES AT 100%  LOAD (In deg c)  328.2  328.2 327.5 327.5 327.2 327.2 167.3 167.3 ‐  ‐  167.3 167.3 167.3 167.3 207.5 207.5 207.5 207.5 207.5 207.5 207.5 207.5 250.8 250.8 250.8 250.8 250.8 250.8 250.8 250.8 278.0 278.0 278.0 278.0 278.0 278.0 255.6 255.6 255.6 255.6 212.3 212.3 212.3 212.3 172.2 172.2 172.2 172.2 332.7 ‐  ‐  ‐ 

 

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

TG PG test instrumentation list for 2x600MW Singareni TPS  TEMPERATURE MEASUREMENT   Sl.  No 

Tag No 

Service 

Inst. 

96  TW96  CRH after spray (L) PRT  97  TW97  TDBFP A exhaust steam to condenser‐A PRT  98  TW98  TDBFP B exhaust steam to condenser‐B PRT  99  TW99  PRT  TDBFP‐B steam inlet 100  TW100  PRT  TDBFP‐B steam inlet 101  TW101  PRT  TDBFP‐A steam inlet 102  TW102  PRT  TDBFP‐A steam inlet 103  TP01   CEP inlet from condenser‐A hot‐well PRT  104  TP02   CEP inlet from condenser‐A hot‐well PRT  105  TP03   CEP inlet from condenser‐B hot‐well PRT  106  TP04   CEP inlet from condenser‐B hot‐well PRT  107  TP05   GSC drain to Flash Tank PRT  108  TP06   Main condensate inlet GSC  PRT  109  TP07   Main condensate outlet. GSC  PRT  110  TP08   Gland steam to GSC  PRT  111  TP09   Main condensate inlet DC  PRT  112  TP10   Main condensate inlet DC  PRT  113  TP11  Main condensate inlet LPH 1A PRT 114  TP12  Main condensate outlet LPH 1A PRT  115  TP13  Main condensate outlet LPH 1B PRT  116  TP14  Main cond. O/L LPH1A&B common header PRT  117  TP15  Main condensate inlet LPH 2 PRT 118  TP16  Main condensate outlet LPH 2  PRT  119  TP17  Main condensate inlet LPH 3  PRT  120  TP18  Main condensate outlet LPH 3  PRT   121  TP19  Main condensate outlet LPH 3  PRT   122  TP20  Main cond. aft LPH3 aft mixing   PRT   Main cond. to Dea. after flow element  123  TP21  PRT  124  TP22  Main condensate to Dea. After  NRV  PRT  125  TP23  Main condensate to Dea. After  NRV  PRT  126  TP24  Extraction 3 to LPH 3 (TE) from LPT‐A  PRT  127  TP25  Extraction 3 to LPH 3  (HE)  PRT  128  TP26  Extraction 3 to LPH 3  (HE)  PRT  Extraction 2 to LPH 2 (TE) 129  TP27  PRT  Extraction 2 to LPH 2  (HE) 130  TP28  PRT  Extraction 2 to LPH 2  (HE) 131  TP29  PRT  132  TP30  LPH 3 drain to LPH 2 near LPH3   PRT  133  TP31  LPH 2 drain to LPH 1A&B near LPH2   PRT  134  TP32  LPH 1A drain to DC   PRT  135  TP33  LPH 1B drain to DC   PRT  136  TP34  DC drain to CFT   PRT  137  TP35  CW inlet to COND‐A  (L)  PRT  138  TP36  CW inlet to COND‐A  (L)  PRT  139  TP37  CW inlet to COND‐A  (R)  PRT  140  TP38  CW inlet to COND‐A  (R)  PRT  141  TP39  CW inlet to COND‐B  (L)  PRT  142  TP40  CW inlet to COND‐B  (L)  PRT  143  TP41  CW inlet to COND‐B  (R)  PRT  144  TP42  CW inlet to COND‐B  (R)  PRT  * APPROXIMATE VALUES AT 100% LOAD (In 0C) ARE GIVEN FOR REFERENCE ONLY. 

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*APPROXIMATE  VALUES AT 100%  LOAD (In deg c)  ‐  0.9635 0.9635 327.2 327.2 327.2 327.2 46.4 46.4 46.4 46.4 ‐  46.6 47  ‐  47  47  49.9 71.6 71.6 71.6 71.6 94.7  94.7  123.6  123.6  123.6  123.6  123.6  123.6  209.2  208.9  208.9  118.6  118.3  118.3  99.5  76.4  74.4  74.4  51.8  ‐  ‐  ‐  ‐  ‐  ‐  ‐  ‐ 

 

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

TG PG test instrumentation list for 2x600MW Singareni TPS  TEMPERATURE MEASUREMENT   Sl.  No 

Tag No 

Service 

Inst. 

145  TP43  CW outletto COND‐A (L)  PRT  146  TP44  CW outlet to COND‐A  (L)  PRT  147  TP45  CW outlet to COND‐A  (L)  PRT  148  TP46  CW outletto COND‐A  (L)  PRT  149  TP47  CW outlet to COND‐A  (L)  PRT  150  TP48  CW outlet to COND‐A  (L)  PRT  151  TP49  CW outlet to COND‐A  (R)  PRT  152  TP50  CW outlet to COND‐A  (R)  PRT  153  TP51  CW outlet to COND‐A  (R)  PRT  154  TP52  CW outlet to COND‐A  (R)  PRT  155  TP53  CW outlet to COND‐A  (R)  PRT  156  TP54  CW outlet to COND‐A  (R)  PRT  157  TP55  CW outletto COND‐B (L)  PRT  158  TP56  CW outlet to COND‐B  (L)  PRT  159  TP57  CW outlet to COND‐B  (L)  PRT  160  TP58  CW outletto COND‐B  (L)  PRT  161  TP59  CW outlet to COND‐B  (L)  PRT  162  TP60  CW outlet to COND‐B  (L)  PRT  163  TP61  CW outlet to COND‐B  (R)  PRT  164  TP62  CW outlet to COND‐B  (R)  PRT  165  TP63  CW outlet to COND‐B  (R)  PRT  166  TP64  CW outlet to COND‐B  (R)  PRT  167  TP65  CW outlet to COND‐B  (R)  PRT  168  TP66  CW outlet to COND‐B  (R)  PRT  169  TP67  Vacuum pump  Suction L of COND‐A    PRT  170  TP68  Vacuum pump  Suction R of COND‐A    PRT  171  TP69  Vacuum pump  Suction L of COND‐B    PRT  172  TP70  Vacuum pump  Suction R of COND‐B    PRT  173  TP71  Vacuum Pump  SucCommhdr of COND‐A    PRT  174  TP72  Vacuum Pump  SucCommhdr of COND‐B    PRT  175  TP73  LPBP to COND‐A    PRT  176  TP74  LPBP to COND‐B  PRT  177  TP75  TDBFP B booster pump suction  PRT  178  TP76  TDBFP B booster pump suction  PRT  179  TP77  TDBFP A booster pump suction  PRT  180  TP78  TDBFP A booster pump suction  PRT  181  TP79  Extraction 3 to LPH 3 (TE) from LPT‐B  PRT  182  TP80  Extraction 2 to LPH 2 (TE) from LPT‐B  PRT  183  TP81  LPH 2 drain to LPH 1A near LPH 1A  PRT  184  TP82  LPH 2 drain to LPH 1B near LPH 1B  PRT  185  TP83  Main condensate inlet LPH 1B  PRT  186  TP84  DC drain to CFT   PRT  187  TP85  Main condensate outlet LPH 2  PRT  188  TP86  Main condensate inlet LPH 3  PRT  189  TP87  LPH 3 drain to LPH 2 near LPH2  PRT  190  TP88  Main condensate inlet LPH 2  PRT  Main cond. to Dea. after flow element  191  TP89  PRT  * APPROXIMATE VALUES AT 100% LOAD (In deg c) ARE GIVEN FOR REFERENCE ONLY. 

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*APPROXIMATE  VALUES AT 100%  LOAD (In deg c)  ‐  ‐  ‐  ‐  ‐  ‐  ‐  ‐  ‐  ‐  ‐  ‐  ‐  ‐  ‐  ‐  ‐  ‐  ‐  ‐  ‐  ‐  ‐  ‐  ‐  ‐  ‐  ‐  ‐  ‐  ‐  ‐  163.8  163.8  163.8  163.8  209.2  118.6  76.4  76.4  49.9  51.8  94.7  94.7  99.5  71.6  123.6 

 

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

  TG PG test instrumentation list for 2x600MW Singareni 1X600 MW TPS  PRESSURE MEASUREMENT   S. No  

Tag No  

1  2  3  4  5  6  7  8  9  10  11  12  13  14  15  16  17  18  19  20  21  22  23  24  25  26  27  28  29  30  29  30  31  32  33  34  35  36  37 

PD01   PD02   PD03   PD04   PD05   PD06  PD07  PD08   PD09   PD10   PD11   PD12   PD13   PD14   PD15   PD16   PD17   PD18   PD19   PD20   PD21   PD22   PD23   PD24   PD25   PD26   PD27   PD28   PD29   PD30   PD31   PD32   PD33  PD34  PD35  PD36  PD37  PD38  PD39 

Service  

 Range (in kg/cm2)  

MS to HPT bef. Strainer R   MS to HPT bef. Strainer L   HPT 1 st stage   Extraction 7 to HPH 7 (TE)  Extraction 7 to HPH 7A (HE)  Extraction 7 to HPH 7B (HE)  HPT Exhaust  (TE)  CRH steam   CRH before spray L   CRH before spray R  PRDS steam   Extraction 6 to HPH 6A (HE)  Extraction 6 to HPH 6B (HE)  HRH to IPT L before strainer  HRH to IPT R before strainer  IPT Inlet L   IPT Inlet R   Extraction 5 to HPH 5 (TE)  Extraction 5 to HPH 5 (TE)  Extraction 5 to HPH 5A  (HE)  Extraction 5 to HPH 5B  (HE)  FW BFP A discharge   FW BFP B discharge   RH Spray common header   SH Spray common  header   FW HPH 5A inlet   FW HPH 5B inlet   FW HPH 5A outlet   FW HPH 5B outlet   FW HPH 6A outlet   FW HPH 6B outlet   FW HPH 7A outlet   FW HPH 7B outlet   HPH‐7A drain to HPH‐6A   HPH‐7B drain to HPH‐6B  HPH‐6A drain to HPH‐5A   HPH‐6B drain to HPH‐5B   HPH‐5A drain to Deaerator  HPH‐5B drain to Deaerator 

0‐250   0‐250   0‐250   0‐100  0‐100  0‐100  0‐60   0‐60   0‐60   0‐60   0‐60   0‐60   0‐60   0‐40  0‐40  0‐40  0‐40  0‐25   0‐25   0‐25   0‐25   0‐250   0‐250   0‐250   0‐250   0‐250   0‐250   0‐250   0‐250   0‐250   0‐250   0‐250   0‐250   0‐100  0‐100  0‐60  0‐60  0‐25  0‐25 

  * APPROXIMATE VALUES AT 100% LOAD (In Kg/cm2) ARE GIVEN FOR REFERENCE ONLY. 

    30 of 129

* APPROXIMATE  VALUES AT 100%  LOAD (in kg/cm2)  170  170  ‐  65.54  62.59  62.59  43.03  43.03  43.03  43.03  ‐  40.88 40.88 38.72 38.72 38.72 38.72 19.36  19.36  18.39  18.39  205.02  205.02  ‐  ‐  205.02  205.02  ‐  ‐  ‐  ‐  202.02  202.02  ‐  ‐  ‐  ‐  ‐  ‐ 

 

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

TG PG test instrumentation list for 2x600MW Singareni 1X600 MW TPS  PRESSURE MEASUREMENT  * APPROXIMATE  VALUES AT 100%  LOAD (in kg/cm2) 

S. No 

Tag No 

38 

PA01 

CW DP L ‐ COND‐A   

0‐1 

‐ 

39 

PA02 

CW DP R ‐ COND‐A   

0‐1 

‐ 

40 

PA03  

CW DP L ‐ COND‐B 

0‐1 

‐ 

41 

PA04  

CW DP R ‐ COND‐B 

0‐1 

‐ 

42 

PA05  

IPT exhaust L 

0‐10 

7.7 

43 

PA06  

IPT exhaust R 

0‐10 

7.7 

44 

PA07  

0‐10 

7.7 

45 

PA08  

0‐10 

7.7 

46 

PA09  

LPT inlet steam to common header(L)  LPT inlet steam to common header(R)  d (R) Extraction 3 to LPH 3 (TE) from LPT‐A 

0‐4 

2.597 

47 

PA10  

Extraction 3 to LPH 3 (HE)  

0‐4 

2.468 

48 

PA11  

Extrn.4 to deaerator (TE)

0‐10 

7.7 

49 

PA12 

Extrn.4 to deaerator (DE) 

0‐10 

7.08 

50 

PA13  

Extraction 2 to LPH 2 (HE)  

0‐780 mmHg 

0.944 

51 

PA14  

TDBFP‐A steam inlet 

0‐10 

6.78 

52 

PA15  

TDBFP‐B steam I/L 

0‐10 

6.78 

53 

PA16  

Extraction 2 to LPH 2 (TE)  from LPT‐A 

0‐780 mmHg 

0.944 

54 

PA17  

Gland steam to GSC  

0‐780 mmHg 

‐ 

55 

PA18  

Main condensate inlet GSC  

0‐25 

21.99 

56 

PA19  

Main condensate inlet DC  

0‐25 

‐ 

57 

PA20  

MC to Deaerator after Flow Element  

0‐10 

‐ 

58 

PA21  

Deaerator shell pressure  

0‐10 

‐ 

59 

PA22  

TDBFP B booster pump suction 

0‐10 

6.93 

60 

PA23  

TDBFP A booster pump suction 

0‐10 

6.93 

61 

PA24 

TDBFP A exhaust steam to Cond. A 

0‐780 mmHg 

0.106 

62 

PA25 

TDBFP B exhaust steam to Cond. B 

0‐780 mmHg 

0.106 

63 

PA 26 

CW I/L  pressure (L) Condenser‐A 

‐ 

64 

PA27 

CW O/L pressure (L) Condenser‐A 

0‐10  0‐10

‐ 

CW I/L  pressure (R) Condenser‐A 

0‐10

‐ 

CW O/L pressure (R) Condenser‐A 

0‐10

‐ 

CW I/L  pressure (L) Condenser‐B 

0‐10

‐  ‐ 

65  66  67 

PA 28  PA29  PA30 

Service 

Range(in  kg/cm2) 

68 

PA31 

CW O/L pressure (L) Condenser‐B 

0‐10

69 

PA32 

CW I/L  pressure (R) Condenser‐B 

0‐10

‐ 

70 

PA33 

CW O/L pressure (R) Condenser‐B 

0‐10

‐ 

71 

PA34 

Condenser vacuum  L COND‐A 

0‐780 mm Hg 

0.1047 

72 

PA35 

Condenser vacuum  L COND‐A 

0‐780 mmHg 

0.1047 

73 

PA36 

Condenser vacuum  L COND‐A 

0‐780 mmHg 

0.1047 

74 

PA37 

Condenser vacuum  L COND‐A 

0‐780 mmHg 

0.1047 

75  PA38  Condenser vacuum  R COND‐A  0‐780 mmHg  0.1047  * APPROXIMATE VALUES AT 100% LOAD (In Kg/cm2) ARE GIVEN FOR REFERENCE ONLY      31 of 129

 

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

   

TG PG test instrumentation list for 2x600MW Singareni 1X600 MW TPS  PRESSURE MEASUREMENT 

Service 

Range(in  kg/cm2) 

* APPROXIMATE  VALUES AT 100%  LOAD (in kg/cm2) 

S. No 

Tag No 

76 

PA39 

Condenser vacuum  R COND‐A 

0‐780 mmHg 

0.1047 

77 

PA40 

Condenser vacuum  R COND‐A 

0‐780 mmHg 

0.1047 

78 

PA41 

Condenser vacuum  R COND‐A 

0‐780 mmHg 

0.1047 

79 

PA42 

Condenser vacuum  L COND‐B 

0‐780 mmHg 

0.1047 

80 

PA43 

Condenser vacuum  L COND‐B 

0‐780 mmHg 

0.1047 

81 

PA44 

Condenser vacuum  L COND‐B 

0‐780 mmHg 

0.1047 

82 

PA45 

Condenser vacuum  L COND‐B 

0‐780 mmHg 

0.1047 

83 

PA46 

Condenser vacuum  R COND‐B 

0‐780 mmHg 

0.1047 

84 

PA47 

Condenser vacuum  R COND‐B 

0‐780 mmHg 

0.1047 

85 

PA48 

Condenser vacuum  R COND‐B 

0‐780 mmHg 

0.1047 

86 

PA49 

Condenser vacuum  R COND‐B 

0‐780 mmHg 

0.1047 

87 

PA50 

CEP I/L from Condenser‐A Hot‐well 

0‐780 mmHg 

‐ 

88 

PA51 

CEP I/L from Condenser‐A Hot‐well 

0‐780 mmHg 

‐ 

89 

PA52 

CEP I/L from Condenser‐B Hot‐well 

0‐780 mmHg 

‐ 

90 

PA53 

CEP I/L from Condenser‐B Hot‐well 

0‐780 mmHg 

‐ 

91 

PA54 

LPBP to COND‐A   

0‐60 

92 

PA55 

0‐60 

93 

PA56 

LPBP to COND‐B  Extraction 3 to LPH 3 (TE) from LPT‐B

‐  ‐ 

0‐4 

2.597 

94 

PA57 

Extraction 2 to LPH 2 (TE) from LPT‐B

0‐780 mmHg 

0.994 

95 

PA58 

Extraction 1 to LPH 1B 

0‐780 mmHg 

0.402 

96 

PA59 

Extraction 1 to LPH 1A 

0‐780 mmHg 

0.402 

97 

PA60 

TDBFP‐A steam inlet 

0‐10 

6.78 

98 

PA61 

TDBFP‐B steam inlet 

0‐10 

6.78 

  * APPROXIMATE VALUES AT 100% LOAD (In Kg/cm2) ARE GIVEN FOR REFERENCE ONLY 

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

  TG PG test instrumentation list for 2x600MW Singareni TPS  FLOW MEASUREMENT  S.No 

Tag No 

Service 

Range(in kg/cm2) 

1 

FP01A  

Condensate flow to deaerator 

0‐2.5  

    2 

FP01B  

Condensate flow to deaerator 

0‐2.5  

3 

FP02  

Steam flow to TDBFP A  

0‐0.5  

4  5  6 

FP03   FP04   FP05  

Steam flow to TDBFP B  SH Spray  L  SH Spray  R 

0‐0.5   0‐0.5   0‐0.5  

7  8 

FP06   FP07  

RH Spray  L  RH Spray  R 

0‐0.5   0‐0.5  

9 

FP08 

Auxiliary steam  

0‐0.5  

10 

FP09  

Makeup from DM System to COND‐A 

0‐0.5  

11 

FP10 

Makeup from DM System to COND‐B 

0‐0.5  

Note ‐ FP02 TO FP09: PROCESS NOZZLE WITH PGT INSTRUMENTS. 

S.No  1  2  3 

Tag No  Lvl1   Lvl 2   Lvl 2  

S.No 

Tag No 

1 

PWM 

LEVEL MEASUREMENT  Service  Deaerator  Hot well COND‐A  Hot well COND‐B  POWER MEASUREMENT  Service  POWER MEASUREMENT  

Remarks   Readings will be taken from DCS Readings will be taken from DCS  Readings will be taken from DCS  100% Value in MW   600 

 

                   

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

 

ANNE EXURE – 12  CA ALCULATIION PROCCEDURE FO OR DEAER RATOR LEV VEL DROP P   

L’ = L + 2(2/3) H    H mean = ((h1+h2)/2   ‐ D//2                        Slant Heiight(S) = 2 ( D D/2) 2 – (h meann) 2                  L’ x S x h x  x 60    Qm = ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐                   t x 1000  Where:  h = h1 –– h2  h1 = Startt reading of le evel from botttom of tank in n m = H1 + D/2 + y  h2 = End reading of levvel from bottoom of tank in m m = H2 + D/2 + y  + H1 = Start Gauge level reading from m NWL in m  H2 = End Gauge level rreading from N NWL  H = Lengtth of Dished e end of Tank inn m     = Density of fluid in n Kg/m3  t    = Time of measurem ment in min y   =   Heiight of NWL frrom Tank cen tre line in m. Qm = Rate of Level dro op/ rise in T/H r.   

For 2x6000MW Singaareni TPS  60 mm L= 4566 F= 4761 10 mm H= 975 mm

D= 3600 mm m y= 457 mm

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

ANNEXURE – 13 CALCULATION PROCEDURE FOR HOTWELL LEVEL DROP    

 

For levels in straight portion of tank  Qm = (W1 – W2) x 60   in T/Hr   

1000x  t 

Where:  W1  =  Start Weight of condensate corresponding to H1 in T                                                                                                     =  W x L x H1 x d  W2  =  End Weight of condensate corresponding to H2 in T         =   W x L x H2 x d    d   =   Density of condensate in  Hotwell in Kg/m3   H1   =  Start Gauge level reading from NWL in m  H2   =  End Gauge level reading from NWL in m  t      =  Time of measurement in min  Qm = Rate of Level drop/ rise in T/Hr  For 2x600MW Singareni TPS 

  L            =    12700 mm    W          =    6968 mm 

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

  

   

 

 

  ANN NEXUR RE – 1 14 

 

METH HOD FO OR COM MPUTAT TION O OF   H HEAT RA ATE   

 

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

DOCUMENT TITLE: METHOD FOR COMPUTATION OF HEAT RATE PROJECT TITLE: 2X600 MW SINGERENI TPP AT ADILABAD

1.0

DOCUMENT NUMBER: PE-DC-381-100-N122 REV 04 PAGE 2 OF 10

HEAT AND MASS BALANCE ACROSS HP HEATERS:

Steam extractions to HP heaters is to be evaluated from thermal balance of the heaters. Feed water Mffw going to the economizer comprises of the feed water quantities Ma and Mb coming from HP heater trains A and B respectively. The heat and mass balance equations at this point are: Ma+Mb = Mffw

(A)

Ma.H6a + Mb.H6b = Mffw.H14

(B)

From these two equations, the value of Ma and Mb can be evaluated in terms of Mffw. 1.1

HEAT BALANCE ACROSS HPH-7A:

Ma.(H6a-H5a) = Za.(H12a-H7a) 1.2

(C)

HEAT BALANCE ACROSS HPH-7B:

Mb.(H6b-H5b) = Zb.(H12b-H7b) 1.3

(D)

HEAT BALANCE ACROSS HPH-6A:

Ma.(H5a-H4a) = Za.(H7a-H8a)+Ya.(H11a-H8a) 1.4

(E)

HEAT BALANCE ACROSS HPH-6B:

Mb.(H5b-H4b) = Zb.(H7b-H8b)+Yb.(H11b-H8b) 1.5

(F)

HEAT BALANCE ACROSS HPH-5A:

Ma.(H4a-H3a) = (Ya+Za).(H8a-H9a)+Xa.(H10a-H9a)

(G)

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

DOCUMENT TITLE: METHOD FOR COMPUTATION OF HEAT RATE PROJECT TITLE: 2X600 MW SINGERENI TPP AT ADILABAD

1.6

DOCUMENT NUMBER: PE-DC-381-100-N122 REV 04 PAGE 3 OF 10

HEAT BALANCE ACROSS HPH-5B:

Mb.(H4b-H3b) = (Yb+Zb).(H8b-H9b)+Xb.(H10b-H9b)

(H)

Putting the values of Ma and Mb in terms of Mffw, we can calculate the values of Za, Zb, Ya, Yb, Xa & Xb in terms of Mffw.

2.0

HEAT AND MASS BALANCE ACROSS THE DEAERATOR:

M2.H2 = (Xa+Ya+Za).H9a+(Xb+Yb+Zb).H9b+W.H1+M1.H13

(I)

M2 = M1+W+Xa+Xb+Ya+Yb+Za+Zb± Mdea

(J)

From the equations (I) and (J), the value of M2 can be calculated in terms of Mffw.

3.0

FINAL FEED WATER FLOW:

Mffw = M2 –Mshs-Mrhs

(K)

Mshs = 0, when spray is taken from HPH outlet.

In the above equation,Mshs and Mrhs is measured and M2 is calculated in terms of Mffw. Hence, the value of Mffw can be calculated. NOTE: 1. 2. 3. 4.

4.0

When there is an increase in the level of Deaerator, -ve sign shall be used for Mdea. When there is a decrease in the level of Deaerator, +ve sign shall be used for Mdea. When there is an increase in the level of Boiler Drum, -ve sign shall be used for Mdrum. When there is a decrease in the level of Boiler Drum, +ve sign shall be used for Mdrum.

SUM OF STORAGES [Msto] INCREASES OR DECREASES FOR THE FOLLOWING TANKS: a) Hotwell Storage b) Drum Storage

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

DOCUMENT TITLE: METHOD FOR COMPUTATION OF HEAT RATE PROJECT TITLE: 2X600 MW SINGERENI TPP AT ADILABAD

NOTE:

DOCUMENT NUMBER: PE-DC-381-100-N122 REV 04 PAGE 4 OF 10

c) Condensate Make up storage d) Deaerator Storage

For the above storages if there is a net increase in the level, +ve sign is to be taken for Msto and if there is a net decrease in level, -ve sign is to be used for Msto to arrive at the Total Cycle Losses to be reflected in the main steam flow [Mms]. Mms = Mffw ± Msto ± mdrum + Mshs

(L)

Mshs = 0, when spray is taken from HPH outlet. Reheat Steam Flow, Mrh = Mms-Za-Zb-Ya-Yb-Md+Mrhs

5.0

(M)

SYMBOLS:

M1 = Mass flow measured from flow measuring device FP01 [Condensate flow to deaerator]  (Kg/hr) Md = Gland leakages A, B and C from HP turbine to be computed  (Kg/hr) Msto = Total increase/decrease of storage in system [from level gauges] during test  (Kg/hr) Mdea = Change in deaerator storage during the test  (Kg/hr) Mdrum = Change in drum level during test  (Kg/hr) W = Extraction steam flow to deaerator [Calculated from thermal balance]  (Kg/hr) Xa = Extraction flow to HPH-5A [Calculated from thermal balance]  (Kg/hr) Xb = Extraction flow to HPH-5B [Calculated from thermal balance]  (Kg/hr) Ya = Extraction flow to HPH-6A [Calculated from thermal balance]  (Kg/hr)

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

DOCUMENT TITLE: METHOD FOR COMPUTATION OF HEAT RATE PROJECT TITLE: 2X600 MW SINGERENI TPP AT ADILABAD

DOCUMENT NUMBER: PE-DC-381-100-N122 REV 04 PAGE 5 OF 10

Yb = Extraction flow to HPH-6B [Calculated from thermal balance]  (Kg/hr) Za = Extraction flow to HPH-7A [Calculated from thermal balance]  (Kg/hr) Zb = Extraction flow to HPH-7B [Calculated from thermal balance]  (Kg/hr) H1 = Enthalpy of steam entering deaerator based on measurements PA12 & TW46, TW47  (Kcal/kg) H2 = Enthalpy of feed water at deaerator outlet based on measurements (PA22, TP75 & TP76) and (PA23, TP77 & TP78)  (Kcal/kg) H3a = Enthalpy of feed water at HPH-5A inlet based on measurements PD26, TW54 & TW55  (Kcal/kg) H3b = Enthalpy of feed water at HPH-5B inlet based on measurements PD27, TW56 & TW57  (Kcal/kg) H4a = Enthalpy of feed water at HPH-5A outlet based on measurements PD28, TW58, TW59, TW62 & TW63  (Kcal/kg) H4b = Enthalpy of feed water at HPH-5B outlet based on measurements PD29, TW60, TW61, TW64 & TW65  (Kcal/kg) H5a = Enthalpy of feed water at HPH-6A outlet based on measurements PD30, TW66, TW67, TW70 & TW71  (Kcal/kg) H5b = Enthalpy of feed water at HPH-6B outlet based on measurements PD31, TW68, TW69, TW72 & TW73 (Kcal/kg) H6a = Enthalpy of feed water at HPH-7A outlet based on measurements PD32, TW74 & TW75  (Kcal/kg) H6b = Enthalpy of feed water at HPH-7B outlet based on measurements PD33, TW76 & TW77  (Kcal/kg) H7a = Enthalpy of HPH-7A drain based on measurements PD34, TW80 & TW81  (Kcal/kg) H7b = Enthalpy of HPH-7B drain based on measurements PD35, TW82 & TW83  (Kcal/kg) H8a = Enthalpy of HPH-6A drain based on measurements PD36, TW84 & TW85  (Kcal/kg) H8b = Enthalpy of HPH-6B drain based on measurements PD37, TW86 & TW87  (Kcal/kg)

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

DOCUMENT TITLE: METHOD FOR COMPUTATION OF HEAT RATE PROJECT TITLE: 2X600 MW SINGERENI TPP AT ADILABAD

DOCUMENT NUMBER: PE-DC-381-100-N122 REV 04 PAGE 6 OF 10

H9a = Enthalpy of HPH-5A drain based on measurements PD38, TW88 & TW89  (Kcal/kg) H9b = Enthalpy of HPH-5B drain based on measurements PD39, TW90 & TW91  (Kcal/kg) H10a = Enthalpy of extraction steam entering HPH-5A based on measurements PD20, TW33 & TW34  (Kcal/kg) H10b = Enthalpy of extraction steam entering HPH-5B based on measurements PD21, TW35 & TW36 (Kcal/kg) H11a = Enthalpy of extraction steam entering HPH-6A based on measurements PD12, TW21 & TW22  (Kcal/kg) H11b = Enthalpy of extraction steam entering HPH-6B based on measurements PD13, TW23 & TW24  (Kcal/kg) H12a = Enthalpy of extraction steam entering HPH-7A based on measurements PD05, TW09 & TW10  (Kcal/kg) H12b = Enthalpy of extraction steam entering HPH-7B based on measurements PD06, TW11 & TW12  (Kcal/kg) H13 = Enthalpy of condensate entering deaerator based on measurements PA20, TP22 & TP23  (Kcal/kg) Ta = calculated on the basis of PD07 and Enthalpy correspondinmg to PD01, PD02 and TW03 to TW06…………..………….(Deg C)

6.0

HR =

HEAT RATE: Mms[Hms-Hffw] + Mrh[Hrho-Hrhi] + Mshs[Hffw-Hshs]+ Mrhs[Hrhi-Hrhs] Pnet

(N)

HR = Heat Rate (Kcal/KW.Hr) Mms = Main steam flow at HPT inlet [As calculated]  (Kg/Hr) Mrh = Reheat steam flow at IPT inlet [As calculated]  (Kg/Hr) Mshs = Superheater attemperation flow measured from plant flow measuring device FP04 & FP05  (Kg/Hr)

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

DOCUMENT TITLE: METHOD FOR COMPUTATION OF HEAT RATE PROJECT TITLE: 2X600 MW SINGERENI TPP AT ADILABAD

DOCUMENT NUMBER: PE-DC-381-100-N122 REV 04 PAGE 7 OF 10

Mrhs = Reheater attemperation flow measured from Plant Flow measuring device FP06 & FP07 (Kg/Hr) Hms = Enthalpy of steam before ESV based on measurements PD01 to PD02 & TW03 to TW06 (Kcal/Kg) Hffw = Enthalpy of final feed water after HP heaters based on measurements PD32, PD33 & TW78, TW79 (Kcal/Kg) Hrho = Enthalpy of Hot Reheat steam before IV based on measurements PD14 to PD15 & TW27 to TW30  (Kcal/Kg) Hrhi = Enthalpy of Cold Reheat steam based on measurements PD07 & TW13 to TW14  (Kcal/Kg) Hshs = Enthalpy of superheater attemperation based on measurements PD25 & TW01, TW02  (Kcal/Kg) Hrhs = Enthalpy of Reheater attemperation based on measurements PD24, TW52 & TW53  (Kcal/Kg) Pnet = Pgen-Paux (kW) Pgen = Power measured at Generator Terminals (kW) Paux = Power required for Turbine Integral Auxiliaries (150KW) (kW) NOTE: When SH spray is tapped from downstream of HP heaters then Hshs = Hffw and accordingly SH term becomes redundant in the HR (Eq. N) calculation.

7.0

COMPUTATION OF TOTAL GLAND LEAKAGES:

Steam leakage through the glands A, B and C is calculated using the formula given below: 2

G=KX

2

[P1 – P2 ]  [P1.V1]

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

DOCUMENT TITLE: METHOD FOR COMPUTATION OF HEAT RATE PROJECT TITLE: 2X600 MW SINGERENI TPP AT ADILABAD

DOCUMENT NUMBER: PE-DC-381-100-N122 REV 04 PAGE 8 OF 10

G = Steam Leakage through the Glands (T/Hr) P1 = Pressure before the Glands (Ata) P2 = Pressure after the Glands (Ata) 3

V1 = Specific volume at inlet conditions to the Glands (m /kg) Data for guarantee case is given below [Refer HBD No. PE-DC-381-100-N151, REV 00] PARAMETER

HPT INLET END

HPT OUTLET END

G P1 P2 V1

2.522 43.03 7.71 *0.0791496

3.33 43.03 7.71 **0.0602803

* Based on 43.03 Ata and 810.7 Kcal/kg. ** Based on 43.03 Ata and 333.0°C. For design case P1, P2 and V1 and G are known and hence K can be evaluated. K values calculated for the design case are as given below: A) B)

For Gland Leakage from HPT inlet end K = 0.1099435 For Gland Leakage from HPT outlet end K = 0.126687

For test case, by putting this value of K and the test values of P1, P2 and V1 the computation of G can be done. For the test case, the values of P1, P2 and V1 are determined as given below: FOR HPT INLET END: P1 is based on measurements PD07

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

DOCUMENT TITLE: METHOD FOR COMPUTATION OF HEAT RATE PROJECT TITLE: 2X600 MW SINGERENI TPP AT ADILABAD

DOCUMENT NUMBER: PE-DC-381-100-N122 REV 04 PAGE 9 OF 10

P2 is based on measurements PA05 to PA06 V1 is based on measurements PD07 and Ta Ta is calculated on the basis of PD07 and Enthalpy correspondinmg to PD01, PD02 and TW03 to TW06.

FOR HPT OUTLET END: P1 is based on measurements PD07 P2 is based on measurements PA05 and PA06 V1 is based on measurements PD07 and TW13, TW14

8.0

NOTE:

1.0

The Heat Rate is guaranteed with 0% makeup and hence no makeup will be supplied to the condenser during the PG test. Under these conditions the storage in the deaerator feed storage tank and Hotwell are utilized towards the leakages losses and the measured Heat Rate shall be corrected using the correction curves viz. change in Heat Rate vs. change in storage of feed water storage tank and change in Heat Rate vs change in Hotwell Level.

9.0 GUARANTEE CONDITION: 1. Turbine Cycle Heat Rate at 100% LOAD = 1927.1 Kcal/KWHr (Refer HBD Nos. PE-DC-381-100-N151 REV00 Titled “600MW, 0%MU, 77mm Hg a Back Pr.” ) Turbine Cycle Heat Rate at 80% LOAD = 1975.7 Kcal/KWHr (Refer HBD Nos. PE-DC-381-100-N152 REV00 Titled “480MW, 0%MU, 77mm Hg a Back Pr.” ) 2. If the test is carried out later than three (3) months, after the date of commissioning, due to any reason whatsoever, Aeging shall be applicable inline with the clause 2.05.04 (i) sub section-V, Part-A page 44 of 48 of the tender specification and S.No 11 of Amendment-1 to technical specification.

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

DOCUMENT TITLE: METHOD FOR COMPUTATION OF HEAT RATE PROJECT TITLE: 2X600 MW SINGERENI TPP AT ADILABAD

10.0

DOCUMENT NUMBER: PE-DC-381-100-N122 REV 04 PAGE 10 OF 10

LIST OF CORRECTION CURVES:

HEAT RATE CORRECTION CURVES: 1. Throttle Steam Pressure 2. Main Steam Temperature 3. Reheat Steam Temperature 4. Condenser Back Pressure 5. Change in Deaerator Level 6. Change in Hot Well Level 7. Power Factor 8. Frequency 9. Generator Hydrogen Pressure 10. Generator Voltage 11. SuperHeater Spray (Applicable only when SH spray is taken after BFP discharge) OUTPUT CORRECTION CURVES: 1. Throttle Steam Pressure 2. Main Steam Temperature 3. Reheat Steam Temperature 4. Condenser Back Pressure 5. Change in Deaerator Level 6. Power Factor 7. Frequency 8. Generator Hydrogen Pressure 9. Generator Voltage 10. Change in Hot Well Level 11. SuperHeater Spray (Applicable only when SH spray is taken after BFP discharge)

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

 

                 

  ANNE A EXUREE – 15 CORREC C CTION C CURVES  

                    48 of 129

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

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2X600 MW SINGERENI TPP AT ADILABAD LIST OF CORRECTION CURVES Slon. DOCUMENT TITLE 

DRAWING No.

REV. NO.

1

HEAT RATE CORRECTION CURVE FOR THROTTLE STEAM PRESSURE

PE‐DC‐324‐100‐N221

00

2

HEAT CORRECTION CURVE FOR MAIN STEAM TEMP

PE‐DC‐324‐100‐N222

00

3

HEAT RATE CORRECTION CURVE FOR REHEAT STEAM TEMP. 

PE‐DC‐324‐100‐N223

00

4

HEAT RATE CORRECTION CURVE FOR CONDENSER PRESSURE.

PE‐DC‐324‐100‐N224

01

5

HEAT RATE CORRECTION CURVE FOR CHANGE IN DEA. LEVEL 

PE‐DC‐324‐100‐N225

00

6

HEAT RATE CORRECTION CURVE FOR GENERATOR VOLTAGE. 

PE‐DC‐324‐100‐N226

01

7

HEAT RATE CORRECTION CURVE FOR FREQUENCY. 

PE‐DC‐324‐100‐N227

01

8

HEAT RATE CORRECTION CURVE FOR POWER FACTOR 

PE‐DC‐324‐100‐N228

01

9

HEAT RATE CORRECTION CURVE FOR GEN. HYDROGEN PRESSURE

PE‐DC‐324‐100‐N229

01

10

OUTPUT CORRECTION CURVE FOR MAIN STEAM PRESSURE 

PE‐DC‐324‐100‐N230

00

11

OUTPUT CORRECTION CURVE FOR MAIN STEAM TEMP. 

PE‐DC‐324‐100‐N231

00

12

OUTPUT CORRECTION CURVE FOR REHEAT STEAM TEMP. 

PE‐DC‐324‐100‐N232

00

13

OUTPUT CORRECTION CURVE FOR CONDENSER PRESSURE 

PE‐DC‐324‐100‐N233

01

14

OUTPUT CORRECTION CURVE FOR GENERATOR VOLTAGE 

PE‐DC‐324‐100‐N234

00

15

OUTPUT CORRECTION CURVE FOR FREQUENCY 

PE‐DC‐324‐100‐N235

00

16

OUTPUT CORRECTION CURVE FOR POWER FACTOR 

PE‐DC‐324‐100‐N236

00

17

OUTPUT CORRECTION CURVE FOR GENERATOR HYDROGEN PRESSURE

PE‐DC‐324‐100‐N237

01

18

OUTPUT CORRECTION CURVE FOR CHANGE IN DEA. LEVEL 

PE‐DC‐324‐100‐N239

00

19

OUTPUT CORRECTION CURVE FOR CHANGE IN HOT‐WELL LEVEL

PE‐DC‐324‐100‐N241

01

20

HEAT RATE CORRECTION CURVE FOR CHANGE IN HOTWELL LEVEL

PE‐DC‐324‐100‐N245

00

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

0.1047 ATA

01

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

2X600MW SINGERENI TPP AT ADILABAD GUARANTEED VOLTAGE : 21.0 KV

HEAT RATE CORRECTION FACTOR Vs. GENERATOR VOLTAGE

1.001

HEAT RATECORRECTION FACTOR

100% 80%

1

0.999 19.500

20.000

20.500

21.000

21.500

22.000

22.500

GENERATOR VOLTAGE < kV>

1. Correction curves for operating conditions deviating from guarantee conditions. 2. To obtain the corrected value multiply the measured value by the correction factor.

Doc. No.: PE-DC-381-100-N226

PREP: AKS

DEPARTMENT: MSE

CHECKED: AKS

NOIDA

APPD. : AK

REV-01

BHEL PEM

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

2X600MW SINGERENI TPP AT ADILABAD

HEAT RATE CORRECTION CURVE FOR FREQUENCY GUARANTEED FREQUENCY = 50 Hz

1.00025 1.00020 1.00015 1.00010 1.00005

HEAT RATE CORRECTION FACTOR

1.00000 0.99995 0.99990 0.99985 0.99980 100%MCR

0.99975 0.99970

80%MCR

0.99965 0.99960 0.99955 0.99950 0.99945 0.99940 0.99935 0.99930 0.99925 47

47.5

48

48.5

49

49.5

50

50.5

51

51.5

52

FREQUENCY (Hz)

REV-01 1. Correction curves for operating conditions deviating from guarantee conditions. 2. To obtain the corrected value multiply the measured value by the correction factor.

Doc. No.: PE-DC-381-100-N227

PREP: AKS

DEPARTMENT: MSE

CHECKED:AKS

NOIDA

APPD. : AK

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

2X600MW SINGERENI TPP AT ADILABAD GUARANTEED POWER FACTOR : 0.85

HEAT RATE CORRECTION FACTOR Vs. POWER FACTOR

1.0036

1.0031

1.0026

HEAT RATE CORRECTION FACTOR

1.0021

1.0016 100%

1.0011 80%

1.0006

1.0001

0.9996

0.9991

0.9986 0.80

0.85

0.90

0.95

1.00

POWER FACTOR

REV-01 1. Correction curves for operating conditions deviating from guarantee conditions. 2. To obtain the corrected value multiply the measured value by the correction factor. Doc. No.: PE-DC-381-100-N228

PREP: AKS

DEPARTMENT: MSE

CHECKED: AKS

NOIDA

APPD. : AK

BHEL PEM

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

2X600MW SINGERENI TPP AT ADILABAD GUARANTEED GEN HYDROGEN PR = 5.0 BAR(g)

HEAT RATE CORRECTION FACTOR Vs. GEN. HYDROGEN PR.

1.00016

1.00012

HEAT RATE CORRECTION FACTOR

100%

80%

1.00008

1.00004

1

0.99996 4.250

4.450

4.650

4.850

5.050

5.250

GEN. HYDROGEN PR.

1. Correction curves for operating conditions deviating from guarantee conditions. 2. To obtain the corrected value multiply the measured value by the correction factor.

Doc. No.: PE-DC-381-100-N229

PREP: AKS

DEPARTMENT: MSE

CHECKED: AKS

NOIDA

APPD. : AK

REV-01

BHEL PEM

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

0.1047 ATA

REV-01

63 of 129

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

VOLTAGE CORRECTION CURVES FOR 600 MW GENERATOR (THDF 115/67 + BRUSHLESS EXCITATION) (RATED VALUES : 600 MW / 21.0 KV / 0.85 PF / 5.0 BAR(g) H2 PR. / 50 HZ) 250 200 150

CORRECTION (KW)

100 21.000 KV 21.525 KV 22.050 KV 20.475 KV 19.950 KV

50 0 -50 -100 -150 -200 0

0.25

0.5

0.75

1

MW LOAD (P.U.)

REV. NO. 00 DATE: 17.11.2009 PE-DC-381-100-N234

PREPARED BY: A.K. GOYAL 64 of 129

CURVE NO.: TG:THDF 115/67:026

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

FREQUENCY CORRECTION CURVES FOR 600 MW GENERATOR (THDF 115/67 + BRUSHLESS EXCITATION) (RATED VALUES : 600 MW / 21.0 KV / 0.85 PF / 5.0 BAR(g) H2 PR. / 50 HZ) 400 350 300

CORRECTION (KW)

250 200

50.0 HZ 50.5 HZ 51.0 HZ 51.5 HZ 49.5 HZ 48.0 HZ 47.5 HZ

150 100 50 0 -50 -100 -150 0

0.25

0.5

0.75

1

MW LOAD (P.U.)

REV. NO. 00 DATE: 17.11.2009 PE-DC-381-100-N235

PREPARED BY: A.K. GOYAL 65 of 129

CURVE NO.: TG:THDF 115/67:027

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

P.F. CORRECTION CURVES FOR 600 MW GENERATOR (THDF 115/67 + BRUSHLESS EXCITATION) (RATED VALUES : 600 MW / 21.0 KV / 0.85 PF / 5.0 BAR(g) H2 PR. / 50 HZ) 1000

500

CORRECTION (KW)

0

0.85 P.F. 0.90 P.F. 0.95 P.F. 1.00 P.F. 0.80 P.F.

-500

-1000

-1500

-2000

-2500 0

0.25

0.5

0.75

1

MW LOAD (P.U.)

REV. NO. 00 DATE: 17.11.2009 PE-DC-381-100-N236

PREPARED BY: A.K. GOYAL 66 of 129

CURVE NO.: TG:THDF 115/67:028

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

HYDROGEN PRESSURE CORRECTION CURVES FOR 600 MW GENERATOR (THDF 115/67 + BRUSHLESS EXCITATION) (RATED VALUES : 600 MW / 21.0 KV / 0.85 PF / 5.0 BAR(g) H2 PR. / 50 HZ) 50

30

CORRECTION (KW)

10

5.00 bar(g) 4.75 bar(g) 4.50 bar(g)

-10

-30

-50

-70 0

0.25

0.5

0.75

1

MW LOAD (P.U.)

REV. NO.:00 DATE: 17.11.2009 PE-DC-381-100-N237

PREPARED BY: A.K. GOYAL 67 of 129

CURVE NO.: TG:THDF 115/67:029

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

2X600 MW SINGARENI TPP AT ADILABAD

RATED VALUE OF DEA. LEVEL DROP = 0%

CHANGE IN DEA. LEVEL VS OUTPUT CORRECTION CURVE. 1.00700

1.00600

OUTPUT CORRECTION FACTOR.

1.00500

1.00400

1.00300

1.00200

1.00100

1.00000

0.99900 0.00

1.00

2.00

3.00

4.00

5.00

DROP IN DEA. LEVEL (% OF MS FLOW)

1. Correction curves for operating conditions deviating from guarantee conditions. 2. To obtain the corrected value multiply the measured value by the correction factor. 3. This curve is applicable for load conditon of 600MW & 480MW. Doc. No.: PE-DC-381-100-N239

PREP: VJ

DEPARTMENT: MSE

CHECKED: AKS

NOIDA

APPD. : AK

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

2X600MW SINGERENI TPP AT ADILABAD REV-01 RATED VALUE OF BLOW DOWN = 3% RATED VALUE OF BACK PR. = 0.1047 ATA

OUTPUT CORRECTION CURVE Vs CHANGE IN HOTWELL LEVEL 1.004

OUTPUT CORRECTION FACTOR.

1.002

1.000

0.998

0.996

0.994

0.992

0.990 -3

-2

-1

0

1

2

3

4

5

CHANGE IN HOTWELL LEVEL<%OF MS FLOW>

1. Correction curves for operating conditions deviating from guarantee conditions. 2. To obtain the corrected value multiply the measured value by the correction factor. 3. This curve is applicable for load conditon of 600MW & 480MW. Doc. No.: PE-DC-381-100-N241

PREP: AKS

DEPARTMENT: MSE

CHECKED: AKS

NOIDA

APPD. : AK

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

2X600 MW SINGARENI TPP AT ADILABAD

HEAT RATE CORRECTION CURVE FOR CHANGE IN HOTWELL LEVEL

HEAT RATE vs CHANGE IN HOTWELL LEVEL

HEAT RATE CORRECTION FACTOR

1.013

1.008

1.003

0.998

0.993

0.988 -3

-2

-1

0

1

2

3

CHANGE IN HOTWELL LEVEL (% OF MS FLOW)

1. Correction curves for operating conditions deviating from guarantee conditions. 2. To obtain the corrected value multiply the measured value by the correction factor. 3. This curve is applicable for load conditons of 600MW, 480MW and 360MW.

DR.No:PE-DC-381-100-N245

PREP: VJ

DEPARTMENT: MSE

CHECKED: AKS

NOIDA

APPD. : AK

70 of 129

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

  ANNEXURE – 16    HEAT BALANCE DIAGRAM      Sr. no. 

Document title 

Drawing No. 

Page No. 

   

1 

600MW, 0 % MU, 77 mmHg (A) BACK PR. 

PE-DC-381-100-N151  

72 

   

2

480MW, 0 % MU, 77 mmHg (A) BACK PR.

PE-DC-381-100-N152

73 

   

3

600MW, 3 % MU, 89 mmHg (A) BACK PR.

PE-DC-381-100-N161

74 

   

4

VWO, 0% MU, 77 mmHg(A) BACK PR.

5

600MW, 3 % MU, 77 mmHg (A) BACK PR (All HP Heaters out of service)

PE-DC-381-100-N167

75 

   

PE-DC-381-100-N170

76 

   

                    71 of 129

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

   

             ANNEXURE – 17  System check list‐      Ensure  the  plant  is  able  to  operate  without  any  constraints  at  full  load  for  a  minimum  of  4  hrs  with  following  conditions. 

1.

Plant to run at rated steam parameters.  

2.

All equipment which are needed for proper functioning of TG to be in service.  

3.

De‐aerator level drop test to be carried out & effort to be made to keep leakage level at lowest.  

4.

All HP & LP Heaters to be in normal operation and drips of these heaters to be cascaded properly without any  bypassing to HP/LP flash tank of condenser. 

5.

All connections to and from external sources like plant PRDS header, make up, dozing, steam for external use,  boiler drains and blow‐down , external spray to flash tanks ,valves etc. to be cut off/minimised.  

6.

Alternate lines which are not designed for normal use like CRH pegging to De‐ aerator/BFPT, auxiliary pegging  to de‐aerator/BFPT, De‐aerator initial heating system & fill lines, HPH6 drain to de‐aerator, etc should not be  charged.  

7.

System would be tight as per Design Heat Balance Diagram.  

8.

Any equipment required from boiler side should be available so to get the steady required steam parameter.  

9.

Sealing line for CEP & Vacuum Pumps to be connected from CEP discharge and supply from DM MU to this line  to be closed.  

10. Turbine/ Boiler controls should be fine tuned, so that tests can be done at stable conditions.    

             

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

 

ANNEXURE – 18   

Auxiliary Power Consumption Test Procedure   

OBJECTIVE:  To prove total auxiliary power consumption of the applicable HT and LT drives as per contract guarantee schedule at  following TMCR conditions.    Sr. no. 

Parameter 

Guarantee Value 

I) 

The  total  auxiliary  power  consumption  for  all  the  Turbine  Generator  Auxiliaries, steam generator auxiliaries, ESP and turbine cycle and other  common  auxiliaries  required  for  continuous  unit  operation  at  100%  TMCR  (600MW  unit  load)  under  rated  steam  conditions  at  worst  condenser  pressure  with  3%  make‐up  and  with  ambient  air  temperature of  27deg c and RH of 60% shall be guaranteed.  The  total  auxiliary  power  consumption  for  all  the  Turbine  Generator  Auxiliaries,  steam  generator  auxiliaries,  ESP  and  turbine  cycle  equipment and other common auxiliaries required for continuous unit  operation  at  80  %(480MW  unit  load)  TMCR  under  rated  steam  conditions,  and  at  worst  condenser  pressure  of  with  3%  make‐up  and  with  ambient  air  temperature  of  27deg  c  and  RH  of  60%  shall  be  guaranteed.   

At 100% TMCR    19,659 (Per unit) KW     

II) 

At 80% TMCR    15,301 (Per Unit) KW     

 

a.

The power consumption (HT/LT) of SG & ESP auxiliaires will be measured separately during Boiler PG & ESP PG  test. 

b.

The power consumption of TG auxiliaries and other continuously operating equipment will be measured during  TG PG test.  

c.

Total auxiliary power consumption will be calculated after completion of Boiler, ESP and TG PG tests.  

 

PREPARING THE MACHINE FOR 600MW FOR CONDUCTANCE OF PG TEST 

Turbine–Generator and associated equipment will be raised to the rated load of 600 MW. The auxiliary power  consumption test is to be conducted during main PG test at 600 MW as per the guarantee clause mentioned   above.    

GENERAL GUIDE LINES  a.

All HT power will be measured through power transducers/ power meter. Output of the power transducers (if  used) will be connected to data logger. 

b.

It will be ensured that the power transducers are connected in the correct phase sequence.  

c.

All  LT  power  will  be  measured  through  use  of  digital  multi‐meter  (voltage),  Clamp‐on  meter  (Amp.)  &  Power  factor meter (pf) / three phase power tong tester.   

d.

For measurement of Transformer losses, shop test results shall be used. 

e.

Shop test results /type test/rated power/ data sheet, if required  for computation of Aux. Power consumption  due to non availability of specific drive,  shall be made available during PG test and will be used for calculation of  total power, if called for. 

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

    LIST OF INSTRUMENTS AND ITS ACCURACY  a.

All the identified CTs and PTs used in the existing panel of each HT drives will be connected to power transducers  and hooked on to the main data logger for recording.  

b.

Power  transducers  using input : 110V, (0‐1A)for an  output  of (4‐20)mA,  with  an  uncertainty  equal  to or  better  than+/‐0.1%. 

c.

3.5  digit  Digital  multi‐meter  (voltage),  Clamp‐on  meter  (Amp)  &  Power  factor  meter  (pf)  /  Three  phase  power  tong tester will be usedfor measurement of power for LT drives and data will be recordedmanually. 

d.

All valid calibration certificatesshall be furnished at the time of the test.   

LIST OF AUXILIARIES CONSIDERED FOR AUXILIARY POWER CONSUMPTION   2X600MWSingareniTPP(Rev02)  (I) 

UNIT AUXILIARIES   

  a)  b)  c)  d) 

  Unit oil purifier  Unit control oil purifier.  Electric oil heater for lube oil.  Feed and discharge pumps of oil purification system. 

e)  f)  g)  h)  i)  j)  k)  l)  m)  n) 

Condenser air evacuation pumps.  Condenser tube cleaning systems pumps.  Condensate extraction pumps.  Drip Pumps (Not envisaged)  Hydrazine dosing pumps.  Ammonia dosing pumps.  Oil purifiers of 2x 50% TDBFPs, and their feed and discharge pumps. Lube oil pumps of 2x 50% TDBFPs, and their electrical oil heater for lube oil.  Auxiliary oil pumps for MDBFP.  Oil pumps for HP‐LP bypass system. 

o) 

Motor driven boiler feed pump  (for this purpose only 15% of the deemed power consumed by the MDBFP  is considered at 100% TMCR only)  Mills/PA Fans/FD Fans/ID Fans/Air heaters/Coal Feeders/Seal Air Fans/Lube  oil pumps for Fans/Fuel oil pressurizing pump/Boiler water circulation  pump/Scanner air fans/Air heater and mill system/Electrostatic  Precipitators(corona only)   

P   to  aa)   

AA 

Total for (I)

     

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POWER  CONSUMPTION  (KW)  (INDICATIVE  BREAKUP) 600MW load 

POWER  CONSUMPTION  (KW)  (INDICATIVE  BREAKUP) 480MW load

85 

85 

1700 

1648 

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

(II)     

Common auxiliaries (Power consumption indicated is per unit basis)

ab)        ac)        ad)     

DM  Cooling  (Normally  working)  water  pumps to  supply  cooling  water  on  the  primary  (DM)  side  of  the  plate  type  heat  exchangers  in  the  closed loop Equipment cooling (Unit auxiliaries) water system.    Auxiliary  Cooling  (normally  working)  water  pumps  to  supply  cooling  water  on  the  secondary  side  of  the  plate  type  heat  exchangers  in  the  closed loop Equipment cooling (unit auxiliary) water system.    Power consumption of any other continuously operating auxiliary for  unit operation at different guarantee point loads (Condensate transfer  pump) 

  ae)   

Air Conditioning (Main control room ESP control room) & Ventilation  System. 

af) 

POWER  POWER  CONSUMPTION  CONSUMPTION  (KW)  (KW)  (INDICATIVE  (INDICATIVE  BREAKUP) BREAKUP) 600MW load  480MW load

850 

850 

773 

773 

1623 

1623 

17049 

13036 

Mill Reject System    Total for (II) 

TOTAL GUARANTEED AUXILIARY POWER CONSUMPTION PER UNIT (Pu)                    (Total for (I)+ Total for (II)) 

  (III)     

Transformers (Power consumption indicated is per unit basis)

 

Transformer losses (GT/ST/UT/UAT/MSST/LT)

BB

TOTAL GUARANTEED LOSSES PER UNIT TRANSFORMER (TL)

POWER  POWER  CONSUMPTION  CONSUMPTION  (KW)  (KW)  (INDICATIVE  (INDICATIVE  BREAKUP) BREAKUP) 2610  2265 2610 

2265

  Notes:  1. The auxiliary power consumption break‐up given above is for indicative purpose & total value as indicated in  guarantee schedule is guaranteed.   2. Auxiliary power consumption for common steam generator and auxiliaries corresponds to design coal & 27 0C  ambient, 60%c RH design coal with moisture.  3. Auxiliary power consumption for common station auxiliaries has been proportionately considered for single  unit.  4. ‘TL’ losses of transformers under bidder’s scope. Total power ‘Pa’ as arrived is as follows    Pa (KW) = PU + TL = 17049 + 2610 = 19659 KW (for 100% Load)  Pa (KW) = PU + TL = 13036 + 2265 = 15301 KW (for 800% Load)  Pa (KW) = Guaranteed Auxiliary Power Consumption  PU (KW) = Power consumed by auxiliaries of unit under test  TL   (KW) = Losses of the transformer supplied by the bidder.   

 

 

5.

Transformer losses are at actual loading of transformer at TMCR load.    Normal operation of transformers without outage is considered.     

6.

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

  Annexure‐19      DISSOLVED OXYGEN CONTENT AT DEAERATOR OUTLET      The dissolved oxgen content in feed water at Deaerator outlet shall be measure in the power plant laboratory  by the Indigo‐Carmine method or ASTM D‐888 reference method‐A.  Deaerator  is considered to be performing satisfactorily if the measured value is less than 0.005 cc/litre at al  loads and without chemical dosing.  This test shall be carried out before PG test or along with PG test.  BHEL shall ensure protocol with Customer at site.              BHEL                                                                                                                                                       CUSTOMER                     

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

   

Annexure‐20      DIFFERENCE BETWEEN THE SATURATION TEMPERATURE OF THE STEAM ENTERING THE DE‐AERATOR AND  THE TEMPERARTURE OF THE FEED WATER LEAVING DE‐AERATOR      Difference between the saturation temperature of the steam entering the De‐aerator and temperature of the  feed water leaving De‐aerator shall be evaluated /measured and it shall be 1.11 deg.C.  This test shall be done along with PG test.  BHEL shall ensure protocol with Customer at site.            BHEL                                                                                                                                                       CUSTOMER                       

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

                     

ANNEXURE – 21 

 

 

Condenser Back Pressure test  procedure 

 

 

 

                             

83 of 129

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

2X600 MW SCCL STPP THE SINGARENI COLLIERIES COMPANY LTD. POWER PROJECT DIVISION

CONDENSER BACK PRESSURE TEST PROCEDURE (PROCEDURE NO: HXE - PT - CONDR - 073- 00)

HEAT EXCHANGER ENGINEERING HARDWAR

84 of 129

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

HXE-PT-CONDR-073-00 Rev. No. : 00 Dated : 11/06/2016 Page 1 of 15 HEAT EXCHANGER ENGG BHEL, HARDWAR

PROCEDURE FOR BACK PRESSURE DEMONSTRATION TEST ON STEAM SURFACE CONDENSER

(PROCEDURE NO: HXE-PT-CONDR-073-00)

1.0: SCOPE:

The purpose of this write-up is to provide detailed procedure for demonstrating the performance of steam surface condenser with regard to the following:

1.1 : The absolute back pressure of 77 mmHg(a) achieved by the equipment 300 mm above the top rows of condenser

tubes

when turbine operation

corresponds to VWO conditions, at 3% make-up, at design inlet cooling water temperature of 33oC, at design circulating water flow rate and tube cleanliness factor of 0.9.

2.0: COMPARISON: The condenser is said to have fulfilled its design requirement when the measured back pressure when corrected for differences in measured and designed values of C.W. quantity, heat rejected in condenser, C.W. inlet temperature and cooling surface area is found to be equal or less than the designed back pressure of 77 mmHg(a).

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HXE-PT-CONDR-073-00 Rev. No. : 00 Dated : 11/06/2016 Page 2 of 15 3.0: DESCRIPTION AND DEFINITION OF BASIC TERMS

Term

Symbol

Description

Condenser Load

H

Rate at which heat is rejected to Kcal / hr circulating water in condenser

ts

Saturation temperature of steam corresponding to back pressure Ps (measured in mm HgC)

Inlet Temperature

tw1

Temperature of cooling measured at condenser inlet

Outlet Temperature

tw2

Temperature of cooling measured at condenser outlet

Temperature rise

tw

Increase of cooling water temperature from inlet to outlet.

Inlet Steam Temperature

Unit

o

C

water

o

C

water

o

C

o

C

Cooling water Qw flow

Quantity of cooling water circulating m3/hr through condenser per unit time

Specific heat

Specific heat of cooling water

Cp

kcal/kg-oC

4.0: COMPLIANCE TO STANDARD: The procedure is guided by recommendations of ASME-PTC 12.2 for steam surface condenser.

5.0: MEASUREMENT:

The test scheme and mounting of instruments is as per approved PG Test instrumentation scheme and approved write-up on Performance Guarantee test for TG Package. Worked By : Deepak Kr. Yadav

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HXE-PT-CONDR-073-00 Rev. No. : 00 Dated : 11/06/2016 Page 3 of 15 5.1

: Condenser Back Pressure:

12 Nos. (6 nos on each condenser) measurement points will be located 300 mm above top row of tubes. These are fitted with ASME basket to ensure static pressure measurement. These shall be uniformly located so as to cover total area above tubes.

5.2

: Circulating Water Temperature:

5.2.1 : Inlet Temperature: For PG Test measurement purpose of inlet temperature eight nos. (Four nos for each condenser) test points, two nos. on each condenser inlet nozzle will be provided.

5.2.2 :

Outlet Temperature:

For PG Test purpose outlet temperature will be measured by providing six nos. symmetrically spaced measurement points on each outlet pipe at least five meters away from condenser nozzle. The points may be provided after bends and the length of insertion of each point will be different to obtain bulk mean temperatures.

5.2.3 : Correction: All temperatures will be measured with the help of RTDs in conjunction with digital multimeters. Test data-logger can also be used with prior agreement. The following corrections shall be applied to the measured values for arriving at the test values: - PRT/ RTD, Instrument calibrations. - Lead wire resistance, if applicable.

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HXE-PT-CONDR-073-00 Rev. No. : 00 Dated : 11/06/2016 Page 4 of 15 5.3

: Circulating Water Flow:

No direct method shall be employed for measurement of C.W. quantity flowing through condenser. The same shall be computed from heat rejected to condenser obtained from test heat rate calculations. Hence condenser test shall be conducted in conjunction with turbine test. Details are as per Annexure-3.

5.4

: Cleanliness Factor:

Prior to test, physical/chemical cleaning of the tubes and water boxes shall be done to obtain the desired tube cleanliness. After cleaning, the following cleanliness factor will be considered for computation of results: Titanium Tubes: 0.9

5.5

: Specific Heat:

Specific heat of water which is used in condensers at Singreni will be taken as 1.0 Kcal/Kg C.

6.0

: CONDITIONS FOR TEST:

6.1

: General Condition:

During condenser demonstration test, the air leakage into the vacuum systems should not exceed 16 kg/hr. Air shall be measured by the flow device provided on the air evacuating device.

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HXE-PT-CONDR-073-00 Rev. No. : 00 Dated : 11/06/2016 Page 5 of 15 6.2

: Machine Load:

Demonstration of Condenser Back Pressure will be carried out in conjunction with turbine test. The machine load shall be kept corresponding to VWO condition of Turbine with 3% make-up.

6.3

: Make-Up:

Condensate make-up of approx. 3% will be added to condenser during the test. This shall be accounted for by opening the CBD during the test with quantity of blow down set at 3% of condensate flow. Level of hot well and De-aerator shall be maintained by adding make-up. Any other method can also be decided during test.

6.4

: Leakage/By-pass of Drains/Steams:

Prior to test, it will be ensured that drain flow to condenser (direct or through flash boxes) will be strictly as per the design load regimes. Any bypass of drains /steam to condenser must be identified and isolated.

6.5

: Allowable Deviations:

Testing shall be performed under conditions of inlet-water temperature, heat load, and cooling-water flow within the limits as specified in Table 3.1 of ASME PTC 12.2.

Testing Parameters

Deviations from specified conditions

Inlet Water Temperature

+/- 10 oF

Heat Load

+/- 5%

Cooling Water Flow

+/- 5%

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HXE-PT-CONDR-073-00 Rev. No. : 00 Dated : 11/06/2016 Page 6 of 15 7.0 : INSTRUMENTS AND THEIR ACCURACIES (PRESSURE / TEMPERATURE GAUGE): The accuracy of various gauges shall generally conform to the recommendations of ASME PTC 12.2 for steam surface condensers (refer enclosed Annexure - 1) or as agreed between SCCLPPD and BHEL.

8.0

: FREQUENCY AND DURATION OF MEASUREMENT:

In case the readings are recorded through PG. Test data-logger, the frequency of recording shall be governed by the data-logger characteristics. However for manual recordings, the frequency of readings shall be 5 min. both for back pressure readings and C W inlet/outlet readings. For condenser calculations, one hour data will be considered from minimum test duration of two hour period during steady state condition.

9.0

: COMPUTATION OF RESULTS:

9.1 : Heat rejected to condenser will be calculated based on the uncorrected and actual heat rate of the Turbine Generator package at the time of test. Heat rejected to condenser will be the difference of Heat supplied to the Turbine less the Turbine output (Generator output corrected for mechanical / electrical losses and turbine losses). Enclosed Annexure - 3 gives detailed relationship for computation of condenser heat load.

9.2 : Computation of circulating water quantity / velocity will be done based on circulating water temperature measurements, heat load on condenser as per item 9.1 above and actual total tube sectional area per pass. Details of calculations will also be as per Annexure - 3. Worked By : Deepak Kr. Yadav

Checked By : Deepak Kr. Yadav

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HXE-PT-CONDR-073-00 Rev. No. : 00 Dated : 11/06/2016 Page 7 of 15 9.3 : The next step determines the actual (test) log mean temperature difference. Annexure - 4 gives the procedure for calculation of the same. The test LMTD corresponds to measured back pressure, C.W. velocity, actual surface area and C.W. inlet temperature. Hence, it shall be corrected for designed C.W. inlet temperature, velocity, surface area and heat rejected as identified in Annexure2. The corrected condenser back pressure will be computed from corrected test LMTD as per Annexure-5. Correction curves for the above varying parameters are enclosed as Annexure-6, 7 & 8.

9.4 : The corrected back pressure will be compared with the design back pressure for the purpose of final evaluation.



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HXE-PT-CONDR-073-00 Rev. No. : 00 Dated : 11/06/2016 Page 8 of 15 ANNEXURE – 1

INSTRUMENT LIST FOR SURFACE CONDENSER TEST

SL NO

MEASUREMENT PARAMETERS

NOMINAL VALUE

TYPE OF INSTRUMENT

RANGE OF INSTRUMENT

ACCURACY OF INSTRUMENT

01

Back Pressure

60-89 mmHgC

Absolute Manometer/ U-tube Manometer/ Pressure Transmitter

02

C.W. inlet temperature

15 -40oC

RTD / Glass thermometers

0 -50 oC

+/-0.1 oC

03

C.W. outlet temperature

25 -46oC

RTD / Glass thermometers

0 -50 oC

+/-0.1 oC

04

Atmospheric Pressure

700 –760 mmHgC

Fortins Barometer (Site Lab.)

0-760 mmHgC

+0.25 mmHgC

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0-780 mmHgC

+0.10 mmHgC

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REMARKS

With vernier attachment

With vernier attachment and scale

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HXE-PT-CONDR-073-00 Rev. No. : 00 Dated : 11/06/2016 Page 9 of 15

ANNEXURE-2

GUARANTEE DATA

Sl No. 01

Symbol

Description

Unit

-

Design, Mfg and Testing Code

-

02

Hlg

Heat Load

kcal/hr

03

Qg

Cooling Water Flow per condenser 31650

04

tw1d

Cooling Water Inlet Temperature

05

Psg

06

o

Guarantee Data HEI 325.93 x 10 31650

6

33.0

Back Pressure

C mmHgC

77.0

L

Effective Tube Length

mm

13000

07

N

Number of Tubes

no.

17266

08

do x t

mm x mm 28.575X0.7112

09

-

Tube outside dia. x thickness Dissolved Oxygen in hotwell condensate

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cc/l

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0.015

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HXE-PT-CONDR-073-00 Rev. No. : 00 Dated : 11/06/2016 Page 10 of 15 ANNEXURE – 3 MAIN CALCULATION Station: 2X 600 MW SCCL STPP

Date:

Unit:

Duration :

Symbol

Description

Derivation

Units

tw1m

Mean C W in temp

(tw11 + tw12) / 2

o

C

tw2m

Mean C W out temp

(tw21 + tw22) / 2

o

C

tw

Mean C W temp rise

(tw2m – tw1m)

o

C



Density of water

-

kg/m3

1000

Cp

Specific Heat of water

-

kcal/kg

1

Ha

Heat added in the cycle

HR x Pg

kcal/hr

To

Output of Turbine

(Pg / g + 1500) x 859.846

kcal/hr

Hr

Heat rejected to condenser* (Ha – To)/2

Qw

C W flow rate

Hr / (tw x  x Cp)

m3/hr

Aw

C W flow area

0.785 x di2 x N / p

m2

V

C W velocity

Qw / Aw x 3600

m/sec.

A

Condensing surface area

 x do x L x N

m2

Value

kcal/hr

LEGEND : : C W Inlet temp – 1st half Pg : Generator output, KW nd : C W Inlet temp – 2 half g : Generator efficiency : C W Outlet temp – 1st half di : tube inside dia., mm nd : C W Outlet temp – 2 half p : number of C W passes : Cycle Heat Rate ‘*” : Heat rejection to condenser is for one condenser. tw11 tw12 tw21 tw22 HR

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HXE-PT-CONDR-073-00 Rev. No. : 00 Dated : 11/06/2016 Page 11 of 15 ANNEXURE – 4

TEST LMTD COMPUTATION Symbol

Description

Derivation

Units

Pa

Measured condenser Pressure

-

ata

ts

Saturation temperature

Corres to Ps

o



LMTD

tw/ln[(ts–tw1m)/ts–tw2m)] oC

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Value

C

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HXE-PT-CONDR-073-00 Rev. No. : 00 Dated : 11/06/2016 Page 12 of 15

ANNEXURE – 5

CORRECTION OF LMTD AND BACK PRESSURE

Symbol

Description

Derivation

Units

ft

C W inlet temp correction factor

Annexure – 6

-

fv

C W Velocity correction factor

Annexure – 7

-

fh

Heat load correction factor

Annexure – 8

-

c

Corrected LMTD

 x ft x fv x fh

o

X

Exponential

exp (twd / c )

-

twd

Design C W Temp. rise

hlg/ (Qg x  x Cp)

o

C

tsc

Corrected steam temp.

tw1d + X x twd /(X – 1)

o

C

Psc

Test condenser pressure corrected to design point

Saturation pressure corresponding to tsc

mmHgC

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Value

C

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HXE-PT-CONDR-073-00 Rev. No. : 00 Dated : 11/06/2016 Page 13 of 15

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HXE-PT-CONDR-073-00 Rev. No. : 00 Dated : 11/06/2016 Page 14 of 15

Worked By : Deepak Kr. Yadav

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HXE-PT-CONDR-073-00 Rev. No. : 00 Dated : 11/06/2016 Page 15 of 15

Worked By : Deepak Kr. Yadav

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

   

  ANNEXURE – 22  PROJECT: 2X600 MW SCCL ADILABAD TPP TEST PROCEDURE FOR CW PUMPING POWER 

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PROJECT: 2X600 MW SCCL ADILABAD TPP TEST PROCEDURE FOR CW PUMPING POWER

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2 X 600 MW SCCL ADIALABD TPP Procedure For Measurement Of Equivalent CW Pumping Power: for Pressure Drop In CW system Between BHEL Terminal Points. 1.0 This procedure covers the calculation of equivalent CW pumping power for Design flow through condenser corresponding to pressure drop in CW system within BHEL Terminal points (Refer Section VI, Part A, Functional Guarantees & Liquidated Damages, Cl.1.01.01 (iv) of technical specification). The total pressure drop within BHEL Terminal points constitutes of pressure drop through following:  Condenser  Balls collecting strainer of Condenser on Load Tube cleaning System  Piping and fittings 2.0 The equivalent pumping power thus can be obtained from the pressure drops measured in these components for the CW flow through them, using following calculations. The formula used for calculating the Test CW pumping power (Ptest) with reference to design conditions, within BHEL terminal points is as follows: Ptest Where: Qdesign

=

Qdesign * DPcorrected ----------------------367.2 * o

= Design Condenser CW flow = 28000 m3/hr

o

= Overall efficiency of CW pump & Drive Set = 0.83 (as per Section VI, Part A, Functional Guarantees & Liquidated Damages, Cl.1.01.01 (iv), of technical specification)

DPcorrected

= Test pressure drop corrected for design conditions = ( Qdesign / Qtest )1.75 * DPtest * ( Ctd / Ctt )

Here; Qtest

= Test flow through condenser as computed. (VWO, 3% Make-Up condition)

DPtest

= Test CW side pressure drop within BHEL terminal points measured across Pressure Test points.

Ctd

= Design temperature correction factor for friction loss as per HEI (Ref Annexure-I)

Ctt

= Test temperature correction factor for friction loss as per HEI (Ref Annexure-I)

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3.0 The pressure drop for Condenser, Balls Collecting Strainer, piping and fittings within BHEL terminal points can be measured directly at site across the Pressure Test Points (PTP’s) (viz. the pressure drop measured across pressure test points shall include the pressure drop of condenser, COLTCS, piping and fittings within BHEL terminal points) and tabulated in the log sheet attached as Annexure II. The PTP’s shall be calibrated before the test in an approved reputed test lab. The calibration certificate in original shall be submitted to customer before start of the PG Test for their acceptance. 4.0 The design CW pressure drop within BHEL terminal points is 6 MWC at design CW flow (viz. condenser – 4.10, Ball strainer – 0.15 MWC and Piping and fittings – 1.75 MWC) The Condenser On Load Tube Cleaning System should be in clean condition for the purpose of test and this is to be ensured after backwashing the strainer.

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HXE-PT-CONDR-074-00 Rev. No. : 00 Dated : 11/06/2016 Page 3 of 3 ANNEXURE-1

Worked By : DK Yadav

Checked By : DK Yadav

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PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

Annexure II Log sheet for CW Pumping Power Test Project: 2X600 MW SCCL ADILABAD TPP

S.No. (1)

Pressure at PTP provided at BHEL’s supply Terminal Point (2)

Pressure at PTP provided at BHEL’s return Terminal Point (3)

Flow as calculated Qtest

Differential pressure between BHEL terminal points, DPtest

(4)

(5) = (3) - (2)

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DPcorrected

 

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  ANNEXURE – 23  PROJECT: 2X600 MW SCCL ADILABAD TPP TEST PROCEDURE FOR CONDENSER ON LOAD TUBE CLEANING SYSTEM 

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9661-110-27PE-PVM-W-004, Rev-00

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ANNEXURE – 24  PROJECT: 2X600 MW SCCL ADILABAD TPP PG TEST PROCEDURE FOR CONDENSATE EXTRACTION PUMP 

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112 of 129

PRODUCT STANDARD Form No.

TD-106-1 Rev No. 05

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

HYDERABAD

FP 12947

PUMPS

Rev No. 00

HYDERABAD

Page 2 of 6

SINGARENI THERMAL POWER PROJECT (2X600MW)

FP10495

The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED, It must not be used directly or indirectly in any way detrimental to the interest of the company.

Ref. Doc

COPYRIGHT AND CONFIDENTIAL

PROCEDURE FOR PERFORMANCE GUARANTEE TEST OF CEPs AT SITE

1.0.0

OBJECT OF TEST : The site performance guarantee tests shall cover the following tests on CEPs against “Guarantees under category-III”.

1.1.0

Each CEP shall be capable of delivery flow and total dynamic head corresponding to to Run out point.

1.2.0

The vibration, Noise level and parallel operation of any two of the three pumps shall be demonstrated ,

2.0.0

GUARANTEE PARAMETERS:

SI.NO

CONDITION

01

3.0.0

FLOW

DYNAMIC

TEMP

SPEED

cubic

HEAD

°C

RPM

M/hr

MLC 46.4

1485

RUN OUT CONDITION 975

190

TEST SCHEME : The Schematic arrangement for conducting the test is indicated in sheet-6.

4.0.0

TEST MEASUREMENT:

4.1.0

FLOW: Suction flow shall be measured using the plant flow orifice. Differential pressure across flow nozzle shall be measured using differential pressure transmitter of accuracy 0.25% and flow shall be calculated based on the calibration data of flow orifice.

4.2.0

HEAD : Head shall be measured by pressure transmitters having an accuracy of ±0.10%.

Revisions :

Prepared :

Approved :

Refer to record of revisions :

(ROHIT P)

(SRINIVAS P)

113 of 129

Date : 07.06.16

PRODUCT STANDARD Form No.

TD-106-2 Rev No. 5

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

PUMPS

Rev No.00

HYDERABAD

Page 3 of 6

HYDERABAD

4.4.0

FP 12947

Temperature:

The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED . It must not be used directly or indirectly in any way detrimental to the interest of the company.

COPYRIGHT AND CONFIDENTIAL

Temperature shall be measured using platinum RTDs.

4.5.0 Speed: Speed shall be measured using digital, Non-contact type optical speed indictor having an accuracy of 1 RPM/STROBOSCOPE. 4.5.0 Vibration: Vibration of CEP shall be measured at BEP condition using portable vibration meter. 4.6.0 Noise level: Noise level shall be measured at BEP condition at a distance of 1.0m from the outer most surface of CEP and 1.5m above floor level, using portable noise level meter. Correction for back ground noise shall be applied in line with HIS. 4.7.0 List of instruments:

The list of instruments required for the PG tests are indicated in sheet-6. 4.8.0 Calibration of instruments: All Instruments used for Pumps PG test will be calibrated at BHEL(R & D) prior to the PG test, and calibration certificates shall be furnished to NTPC. 4.9.0 Data logging: Primary sensors of flow, pressure and temperature will be connected to a data logger And recorded for evaluation. 5.0.0 PERFORMANCE AT RUN OUT CONDITION: The pump flow will be adjusted to the Run out condition, and measurements will be made for all parameters. Various parameters will be logged at interval of 1 minute. 15 sets of reading will be recorded continuously. Average of at least 10 sets of consistent data shall be considered for evaluating the performance guarantee data. Run out condition: - Test will be conducted at 3 flow point. i.e Run out point, +5% and -10% of Run out condition flow. Curve for flow vs head will be plotted after applying speed and temperature correction. Guarantee parameters will be read from this curve.

114 of 129

The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED . It must not be used directly or indirectly in any way detrimental to the interest of the company.

6.0.0

COPYRIGHT AND CONFIDENTIAL

FP 12947

PRODUCT STANDARD Form No.

TD-106-2 Rev No. 5

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

PUMPS

Rev No.00

HYDERABAD

Page 4 of 6

PARALLEL OPERATION : Parallel operation of any two CEPs will be demonstrated at best efficiency point. 15 sets of flow reading will be recorded continuously at 1 minute intervals. Average of at least 10 consistent readings will be considered for evaluating the performance guarantee data. Test will be conducted at 1 flow point i.e at BFP point (615 Cu.m/hr).

7.0.0

ACCEPTANCE CRITERIA FOR TESTS :

7.1.0

Capability at Run out condition : Total dynamic head of CEP at Run out condition shall not be less than the guaranteed dynamic head of CEP at relevant operating condition flow.

7.2.0

Parallel operation: variation in flow between the pumps shall not exceed 5%.

7.3.0

Vibrations: Vibration shall not exceed 7.0 mm/sec (rms.)

7.4.0

Noise Level: Noise level shall not exceed 85 dBA.

7.5.0

Sample calculations :

7.5.1

Flow calculations : (a)

Correction for temperature : Q1 = Q/WT

Where ,Q = WT = (b)

Measured flow in T / Hr, Q1 = Sp.Weight at test temperature

corrected flow in Cu.M/Hr

Correction for speed : QS = Q1 (NS /NT)

Where ,QS NS NT

= Flow in Cu.M/Hr at specified speed = Specified speed = Test speed

115 of 129

PRODUCT STANDARD Form No.

TD-106-2 Rev No. 5

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

7.5.2

The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED . It must not be used directly or indirectly in any way detrimental to the interest of the company.

PUMPS

Rev No.00

HYDERABAD

Page 5 of 6

Head calculations : (a)

COPYRIGHT AND CONFIDENTIAL

FP 12947

Correction for temperature : H = ( P2- P1) X10/WT

Where, P2 = P1 = H = (b)

CEP disch. Pr.in kg/sq.cm CEP suct. Pr. in kg/sq.cm Dynamic head of CEP in MLC at test speed

Correction for speed : HS = H X SQUARE (NS /NT)

Where ,HS

=

Dynamic head of CEP in MLC at specified speed

116 of 129

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

117 of 129

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

450

400

REV

DATE

01

27-07-2012

ALTERED:

AS KALYAN

APPROVED:

M M RAO

M IN. RE CIRC FLOW

THE NPSHR VALUE IS UPDATED TO SECOND DECIMAL PLACE

Head (m)

350

A

300

D

REF

250

E

C

B

200

150

100

FLOW HEAD ACT. TEMP (deg. HEAD (mlc) C) (cu.m/hr) (mlc)

SP. WT (kg/m3)

EFFIC (%) POWER (KW)

SPEED (RPM)

NPSHR (mlc)

A

900

290

290

49.2

988.4

80.5

873

1485

3.35

B

975

190

267

46.4

989.6

79.2

885

1485

3.54

C

715

240

329

46.4

989.6

80.5

787

1485

2.89

D

825

290

309

49.2

988.3

81.1

845

1485

3.16

E

1015

215

252

59.7

983.3

78.2

877

1485

3.65

1200

POWER (KW)

A - Design condition

51.5 HZ

1000

A

D

B - Runout Condition

B

800

C

E

50 HZ

C - Best Efficiency Point D - HPH out Condition

47.5 HZ

600

E - Maximum Capability condition

400

200 5.5

A

80.0 80

16

70.0 70

14

60.0 60

12

A

50.0 50

40.0 40

C C

30.0 30

E

D

400 200

600 300

10

8

A

6

400800

5001000

600 1200

367 mlc.

2. INPUT POWERS AT B , C , D & E ARE CALCULATED

4.5

BASED ON ACTUAL HEADS GENERATED AT 50 Hz. 4

3.5

3

2.5

Digitally signed Signature Not Verified by Sign Sunil

JOB NO. :

381

STATUS: CONTRACT DRG./REF.NO. (INTERNAL)

50 HZ

200 100

1. SHUT OFF HEAD AT 50Hz =

B

10 10.0

0 0.0 00

5

B

51.5 HZ 20 20.0

NOTE :

NPSH (R) m

A

18

NPSH (R) m

Efficiency (%)

Efficiency (%)

90.0 90

700 1400 800

1600 900

1800 1000

4

2

2

1.5

0 2000 1100

1 1200

Flow (m3/ h)

Flow (m3/ h)

FP12910

Jumde NTPC DRAWING NO: 9661-110-02HY-PVM-N-002, REV-01 Date: 2012.08.03 14:41:13 IST M/s The Singareni Colliries Company CUSTOMER: Reason: CAT IV Limited (SCCL) Location: NTPCEOC CONSULTANT: M/s NTPC Ltd.

PUMPS ENGINEERING BHARAT HEAVY ELECTRICALS LTD. HYDERABAD TITLE: ESTIMATED PERFORMANCE CURVES OF CEP

118 of 129

SCCL COAL BASED THERMAL POWER PLANT (2X600MW)

PROJECT:

PRPD. CHKD. APPD.

NAME

SIGN

DATE

AS Kalyan M M RAO B RAJKUMAR

----

05-05-2012 05-05-2012 05-05-2012

DRG. NO.

HY-DG-4-FP12910 REV 01

SHEET NO: 1

NO. OF SHEETS: 1

 

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

                   

ANNEXURE – 25  PROJECT: 2X600 MW SCCL ADILABAD TPP PG TEST PROCEDURE FOR BOILER FEED PUMP 

119 of 129

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

120 of 129

PRODUCT STANDARD Form No.

TD-106-1 Rev No. 05

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

HYDERABAD

FP 12948

PUMPS

Rev No.00

HYDERABAD

Page 2 of 6

SINGARENI THERMAL POWER PROJECT (2X600MW)

The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED, It must not be used directly or indirectly in any way detrimental to the interest of the company.

COPYRIGHT AND CONFIDENTIAL

PROCEDURE FOR PERFORMANCE GUARANTEE TEST OF BFP SETS AT SITE 1.0.0

OBJECT OF TEST : The site performance guarantee tests shall cover the following tests on BFP sets against “Guarantees under category –III”.

1.1.0

Each BFP set shall be capable of delivery flow and total dynamic head corresponding to Run out point.

1.2.0

The vibration, Noise level and parallel operation of any two of the three pumps shall be demonstrated

2.0.0

GUARANTEE PARAMETERS:

2.1.0

Run-out condition:

SI.NO

EQUIPMENT

FLOW

TOTAL DYNAMIC

Cubic m/hr

HEAD (BP+BFP)

TEMP °C

BP/ BFP SPEED rpm

m/c 01

MD BFP SET

1350

2025

148.7

1495 / 5630

02

TD BFP SET

1350

2025

148.7

1475 / 5635

3.0.0

TEST SCHEME: The Schematic arrangement for conducting the test is indicated in sheet-6.

4.0.0

TEST MEASUREMENTS:

4.1.0

FLOW: Suction flow shall be measured using the plant flow nozzle. Differential pressure across flow nozzle shall be measured using differential pressure transmitter of accuracy 0.25% and flow shall be calculated based on the calibration data of flow nozzle.

4.2.0

HEAD : Head shall be measured by pressure transmitters having an accuracy of ±0.10%.

4.3.0

Temperature:

Ref. Doc FP10 495

Temperature shall be measured using platinum RTDs.

Revisions :

Prepared :

Approved :

Date :

Refer to record of revisions :

(ROHIT.P)

(P.SRINIVAS)

07.06.16

121 of 129

PRODUCT STANDARD Form No.

TD-106-2 Rev No. 5

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

HYDERABAD

The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED . It must not be used directly or indirectly in any way detrimental to the interest of the company.

COPYRIGHT AND CONFIDENTIAL

4.4.0

FP 12948

PUMPS

Rev No.00

HYDERABAD

Page 3 of 6

Speed TD Booster pump speed,MD Booster pump speed and MD BFP Speed shall be measured using digital,non-contact type optical speed indicator having an accuracy of 1 RPM/STROBOSCOPE. TD BFP Speed will be derived from measured TD BP Speed, using gear box gear ratio.

4.5.0

Vibration: Vibration of BFP at BEP point shall be measured using portable vibration meter.

4.6.0

Noise level: Noise level shall be measured at a distance of 1.0m from the outer most surface of BFP and 1.5m above floor level, using portable noise level meter. Correction for back ground noise shall be applied in line with HIS.

4.7.0

List of instruments: The list of instruments required for the PG tests are indicated in sheet-6.

4.8.0

Calibration of instruments: All Instruments used for Pumps PG test will be calibrated at BHEL(R & D) prior to the PG test, & calibration certificates shall be furnished to NTPC.

4.9.0

Data logging: Primary sensors of flow, pressure and temperature will be connected to data logger And recorded for evalution.

5.0.0

PERFORMANCE AT RUN OUT CONDITION: The pumps flow and pressure will be adjusted to the RUN out condition, and measurement will be made for all parameters. The inter stage and kicker-stage lines will be closed during the test .Various parameters of Booster pump & BFP will be logged at interval of 1minute. 15 sets of reading will be recorded continuously. Average of at least 10 sets of consistent data shall be considers for evaluating the performance guarantee data. Run out condition :- Test will be conducted at 3 flow points.i.e Run out point,+5% and (-)10% of Run out condition flow. Curve for flow vs. head will be plotted after applying speed and temperature Correction, Guarantee parameters will be read from this curve. Total dynamic head of BFP set is the sum of Booster pump head and BFP head at guaranteed flow.

122 of 129

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

Form No.

TD-106-2 Rev No. 5

FP 12948 PRODUCT STANDARD PUMPS HYDERABAD

6.0.0

Rev No.00 Page 4 of 6

PARALLEL OPERATION: Parallel operation of two TD BFP sets will be demonstrated at Best efficiency point. The inter-stage and kicker-stage lines shall be closed during the test. 15 sets of reading will be recorded continuously at 1 minute intervals. Average of at least 10 consistent reading will be considered for evaluating the performance guarantee data.

COPYRIGHT AND CONFIDENTIAL The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED . It must not be used directly or indirectly in any way detrimental to the interest of the company.

Test will be conducted at 1 flow point i.e at BEP point (855 Cu. m/hr). 7.0.0

ACCEPTANCE CRITERIA FOR TESTS:

7.1.0

Capability at Run out Condition: Total dynamic head of BFP set at Run out condition read from the site tested curve shall not be less than the guarantee dynamic head of BFP set at relevant operating condition flow.

7.2.0

Parallel operation of BFP sets: The variation in flow between the pumps shall not exceed 5%.

7.2.0

Vibrations: Vibration will be measured and the same shall not exceed 7.0 mm/sec (rms.)

7.3.0

Noise Level: Noise level shall not exceed 85 dBA.

7.4.0

Sample calculations:

7.4.1

Flow calculations: (a)

Correction for temperature: Q1 = Q/WT1

Where, Q = Q1 = WT1 = (b)

Measured flow in T/Hr Corrected flow in Cu.M/Hr sp. Weight at BFP suction temperature

correction for speed : QS = Q1 (NS / NT)

Where, QS NS NT

= = =

flow in Cu.M/Hr at specified speed specified speed Test speed

123 of 129

PRODUCT STANDARD Form No.

TD-106-2 Rev No. 5

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

7.4.2

The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED . It must not be used directly or indirectly in any way detrimental to the interest of the company.

COPYRIGHT AND CONFIDENTIAL

PUMPS

Rev No.00

HYDERABAD

Page 5 of 6

Head calculations for BP (a)

correction for temperature HBP = (P2- P1) X 10/ WT1

Where, P2 = P1 = HBP = (b)

BP Disch./BFP Suction Pr.in kg/Sq.cm Booster pump suction Pr.in kg/Sq.cm Dynamic head of BP in MLC at test speed

correction for speed HBPs = HBP X SQUARE (NS /NT)

Where, HBPs = 7.4.3

FP 12948

Dynamic head of BP in MLC at specified speed

Head calculations for BFP (a) correction for temperature HBFP = (P3 –P2) X 10/WT2 P3 = P2 = WT2 = HBFP = (b)

BFP discharge pressure in kg/sq.cm BFP Suction / BP Disch . Pr.in kg/sq.cm SP.Weight at BFP Disch.Temperature. Dynamic head of BFP in MLC at test speed

correction for speed

HBFPs = Where ,HBFPs =

HBFP X SQUARE(NS / NT) Dynamic head of BFP in MLC at specified speed

124 of 129

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

125 of 129

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

Rev-01

Rev-02

3100

Test code updated.

MIN RC FLOW

NPSHR values revised as per 9661-110-03HY-PVM-N-008, pump frame and test code indicated.

2800

D

Head ead (m)

2500

F

2200

E

A B C D E F

A

C

1900

FLOW (m3/hr) 1220 1350 1055 1165 1195 1165

REF

B

HEAD (mlc) 2127 1840 2048 2409 2365 2339

SP. GR. 0.903 0.918 0.904 0.904 0.904 0.903

EFFICIENCY (%) 80.2 77.9 81.2 80.7 80.5 80.7

POWER (KW) 7957 7972 6551 8562 8643 8304

SPEED (RPM) 5710 5630 5430 5910 5905 5845

NPSHR (mlc) 68.5 87.8 54.9 62.9 65.8 62.9

1600

1300

ABCDEF-

1000 0

100

200

300

400

500

600

700

800

900

1000

1100

1200

1300

1400

1500

Flow (m3/h) 10000

D E F A

POWER ER (KW)

8000

DESIGN POINT RUNOUT POINT BEST EFFICIENCY POINT EMERGENCY POINT U/F CASE 1 U/F CASE 2

B

C

6000

NOTE : 1. DISCHARGE FLOW AT THE DESIGN CONDITION IS WITH INTER STAGE CLOSED. 2. MIN. RC FLOW INDICATED IS FOR BFP OPERATION. THIS IS INDICATED ONLY FOR THE PURPOSE OF CALCULATING BFP SET SHUT OFF PRESSURES AT RC FLOW. 6010 RPM 3. HYDRAULIC COUPLING MAXIMUM OUTPUT SPEED =

4000 2000 0 0

100

200

300

400

500

600

700

800

900

1000

1100

1200

1300

1400

1500

Flow (m3/h) 90

A

80

B

70 60

PUMP FRAME MODEL: FK4E36

75

F E A D

50

TEST CODE: ANSI/ HI 14.6-2011

C

40

Digitally signed Signature Not by PVerified R SEN

NPSH (R) m

Efficienc iency (%)

100

50

JOB NO. : 381 STATUS: CONTRACT

30

DRG./REF.NO. (INTERNAL) 20

25

FP12880

NTPC DRAWING NO: 9661-110-03HY-PVM-N-001 Date: 2013.04.17 14:04:55 IST M/s The Singareni Colliries Company Limited CUSTOMER: Reason: CAT IV (SCCL) Location: NTPCEOC CONSULTANT:

PUMPS ENGINEERING

0

BHARAT HEAVY ELECTRICALS LTD. HYDERABAD

100

200

300

400

500

600

700

800

900

1000

1100

1200

1300

1400

0 1500

TITLE: ESTIMATED PERFORMANCE CURVES OF MD BOILER FEED PUMP

Flow (m3/h)

126 of 129

SCCL COAL BASED THERMAL POWER PLANT (2X600MW)

PROJECT:

10

0

M/s NTPC

NAME PRPD. CHKD. APPD.

AS Kalyan M M RAO B RAJKUMAR

DRG. NO.

SIGN

DATE

----

13-08-2012 13-08-2012 13-08-2012

HY-DG-4-FP12880 REV 02

SHEET NO: 1

NO. OF SHEETS: 1

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

Rev-03

260

Rev-02

Test code updated.

Rev-01

Test code updated.

Pump frame and test code are

MIN. RE CIRC. FLOW

240

220

C

Head (m)

200

180

D E F A

51.5 HZ

B 50 HZ

160

47.5 HZ REF

FLOW (m3/hr)

HEAD (mlc)

SP. GR.

EFFICIENC Y (%)

POWER (KW)

SPEED (RPM)

NPSHR (mlc)

A

1220

193

0.9030

82.3

704

1495

5.75

B

1350

185

0.9180

81.5

766

1495

6.64

C

1055

202

0.9040

81.8

641

1495

4.79

D

1165

196

0.9040

82.3

683

1495

5.41

E F

1195 1165

195 196

0.9040 0.9030

82.3 82.2

697 683

1495 1495

5.60 5.41

140

120

100 0

100

200

300

400

500

600

700

800

900

1000

1100

1200

1300

1400

1500

Flow (m3/h) 900

POWER (KW) POW

800

D

700 600

F

C

500

51.5 HZ

E

ABCDEF-

B 50 HZ

A

47.5 HZ

400 300 200 0

100

200

300

400

500

600

700

800

900

Flow (m3/h)

1000

1100

1200

90

1300

1400

NOTE : 1. DISCHARGE FLOW AT THE DESIGN CONDITION IS WITH INTER STAGE CLOSED. 2. MIN. RC FLOW INDICATED IS FOR BFP OPERATION. THIS IS INDICATED ONLY FOR THE PURPOSE OF CALCULATING BFP SET SHUT OFF PRESSURES AT RC FLOW.

1500 9

A

80

8

B

60

C

50 40

F

E

7

A

TEST CODE: ANSI/ HI 14.6-2011

D

5 4

51.5 HZ 50 HZ 47.5 HZ

30

3 2

10

1

0 100

200

300

400

NTPCDigitally DRAWING NO: 9661-110-03HY-PVM-N-002 signed Signature Not by PVerified R SEN

JOB NO. : 381

Date: 2013.04.25 CUSTOMER:

STATUS: CONTRACT DRG./REF.NO. (INTERNAL)

20

0

PUMP FRAME MODEL: FA1B75

6

N NPSH (R) m

70

Efficiency (%)

DESIGN POINT RUNOUT POINT BEST EFFICIENCY POINT EMERGENCY POINT U/F CASE 1 U/F CASE 2

500

600

700

800

900

1000

1100

1200

1300

1400

FP12881

19:25:04 IST Reason: CAT IV Location: CONSULTANT: NTPCEOC

BHARAT HEAVY ELECTRICALS LTD. HYDERABAD TITLE: ESTIMATED PERFORMANCE CURVES OF MD BOOSTER PUMP

Flow (m3/h)

127 of 129

M/s NTPC SCCL COAL BASED THERMAL POWER PLANT (2X600MW)

PROJECT:

PUMPS ENGINEERING

0 1500

M/s The Singareni Colliries Company Limited (SCCL)

NAME PRPD. CHKD. APPD.

AS Kalyan M M RAO B RAJKUMAR

DRG. NO.

SIGN

DATE

----

13-08-2012 13-08-2012 13-08-2012

HY-DG-4-FP12881 REV 03

SHEET NO: 1

NO. OF SHEETS: 1

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

3400

Rev-02

Rev-01

Test code updated.

NPSHR values revised as per 9661-110-03HY-PVM-N-008, pump frame

3100

and test code indicated

MIN RC FLOW 2800

Head (m) H

2500

D 2200

A

C

1900

B

1600

REF

1300

A B C D

1000 0

100

200

300

400

500

600

700

800

900

1000

1100

1200

1300

1400

FLOW (m3/hr) 1220 1350 1055 1165

HEAD (mlc)

SP. GR.

2127 1846 2068 2394

0.903 0.918 0.904 0.904

EFFICIENCY (%) 80.2 77.9 81.2 80.7

POWER (KW) 7956 7999 6615 8507

SPEED (RPM) 5710 5635 5450 5895

NPSHR (mlc) 68.5 87.8 54.9 62.9

1500

Flow (m3/h) ABCD-

10000

D

POWER (KW (KW)

8000

B A

6000

DESIGN POINT RUNOUT POINT BEST EFFICIENCY POINT EMERGENCY POINT

C NOTE : 1. DISCHARGE FLOW AT THE DESIGN CONDITION IS WITH INTER STAGE CLOSED. 2. MIN. RC FLOW INDICATED IS FOR BFP OPERATION. THIS IS INDICATED ONLY FOR THE PURPOSE OF CALCULATING BFP SET SHUT OFF PRESSURES AT RC FLOW. 3. DRIVE TURBINE TRIP SPEED= 6281 RPM

4000 2000 0 0

100

200

300

400

500

600

700

800

900

1000

1100

1200

1300

1400

1500

Flow (m3/h) 90

A

80

100

B 60

PUMP FRAME MODEL: FK4E36

75

A

50

D

C

40

TEST CODE: ANSI/ HI 14.6-2011

NPSH (R) m

Efficiency (%)

70

Digitally signed Signature Not JOB NO. : 381 by PVerified R SEN

50

25

10

PUMPS ENGINEERING

0

BHARAT HEAVY ELECTRICALS LTD. HYDERABAD

0

100

200

300

400

500

600

700

800

900

1000

1100

1200

1300

1400

M/s The Singareni Colliries Company Limited (SCCL)

CUSTOMER:

Date: 2013.04.17 STATUS: CONTRACT 17:18:25 IST CONSULTANT: DRG./REF.NO. (INTERNAL)Reason: CAT IV Location: FP12882 PROJECT: NTPCEOC

30 20

NTPC DRAWING NO: 9661-110-03HY-PVM-N-003

0 1500

TITLE: ESTIMATED PERFORMANCE CURVES OF TD BOILER FEED PUMP

Flow (m3/h)

128 of 129

M/s NTPC SCCL COAL BASED THERMAL POWER PLANT (2X600MW) NAME PRPD. CHKD. APPD.

AS Kalyan M M RAO B RAJKUMAR

DRG. NO.

SIGN

DATE

----

13-08-2012 13-08-2012 13-08-2012

HY-DG-4-FP12882 REV 02

SHEET NO: 1

NO. OF SHEETS: 1

PERFORMANCE GUARANTEE TEST PROCEDURE FOR TG CYCLE & AUXILIARY POWER CONSUMPTION (REV‐00) FOR 2x600MW SINGARENI TPS

Rev-03

300 280 260

MIN. RE CIRC. FLOW

250 240

Head(m) (m) Head

Test code updated.

Rev-01 Pump frame and test code are indicated

T-TRIP(BP) 1645RPM

480 m3/hr for Condition - A

220 200

Rev-02

Test code updated

C

A

200 150

B

180

C

D

167.8889645 A B

160 100

REF

FLOW (m3/hr)

HEAD (mlc)

SP. GR.

EFFICIEN CY (%)

POWER (KW)

SPEED (RPM)

NPSHR (mlc)

140

A

1220

193

0.9030

82.3

704

1495

5.75

50

B

1350

179

0.9180

81.5

741

1475

6.59

C

1055

182

0.9040

81.8

578

1427

4.61

D

1165

211

0.9040

82.3

735

1543

5.54

120 100 0 00

100 200200

300 400

400 600500

600 800

7001000800

1200 900

10001400 1100

1200 1600

13001800 1400

1500 2000

Flow Flow(m3/h) (m3/h)

ABCD-

800 900

POWER (KW) POWER (KW)

800 700

A D

C

700 600 600 500 500 400 400

B

B A

NOTE : 1. DISCHARGE FLOW AT THE DESIGN CONDITION IS WITH INTER STAGE CLOSED. 2. MIN. RC FLOW INDICATED IS FOR BFP OPERATION. THIS IS INDICATED ONLY FOR THE PURPOSE OF CALCULATING BFP SET SHUT OFF PRESSURES AT RC FLOW.

C

300 300 200 00

100 200200

300 400

400 600500

600 800

7001000800

1200 900

Flow (m3/h) Flow (m3/h)

10001400 1100

90 90

1200 1600

13001800 1400

8 16

70 70

B

60 60

D

A

40 40

5 10 84

C A

30 30

63

B

20 20

PUMP FRAME MODEL: FA1B75

6 12

TEST CODE: ANSI/ HI 14.6-2011

C

50 50

7 14

Digitally signed DRAWING NO: 9661-110-03HY-PVM-N-004 SignatureNTPC Not by PVerified R SEN

NPSH NPSH(R) (R) m m

Efficiency (%) (%

Efficiency (%)

1500 2000 9 18

A

A

80 80

100 200200

300 400

400600500

600 800

7001000800

900 1200

1000 14001100

1200 1600

CUSTOMER: 19:23:06 IST

STATUS: CONTRACT DRG./REF.NO. (INTERNAL) FP12883

Reason: CAT IV Location: CONSULTANT:

M/s NTPC

NTPCEOC

SCCL COAL BASED THERMAL POWER PLANT (2X600MW)

PROJECT:

PUMPS ENGINEERING

21

00

M/s The Singareni Colliries Company Limited (SCCL)

Date: 2013.04.25

JOB NO. : 381

42

10 10 00

DESIGN POINT RUNOUT POINT BEST EFFICIENCY POINT EMERGENCY POINT

BHARAT HEAVY ELECTRICALS LTD. HYDERABAD

00 1300 1500 18001400 2000

TITLE: ESTIMATED PERFORMANCE CURVES OF TD BOOSTER PUMP

Flow (m3/h)

Flow (m3/h)

129 of 129

NAME PRPD. CHKD. APPD.

AS Kalyan M M RAO B RAJKUMAR

DRG. NO.

SIGN

DATE

----

13-08-2012 13-08-2012 13-08-2012

HY-DG-4-FP12883 REV 03

SHEET NO: 1

NO. OF SHEETS: 1