Energy Audit Report by CPRI

No.
: CPRI/ECDD/ EA/76/10
Report
Submitted to
JOJOBERA TPS, TATA POWER

JAMSHEDPUR
on
ENERGY AUDIT AT JOJOBERA TPS UNIT 3, 120 MW
(Po No 5300076114 )
Submitted by
DECEMBER 2010
Volume 1 (Boiler, Turbine & Overall Unit)

ENERGY CONSERVATION & DEVELOPMENT DIVISION
Central Power Research Institute,
Prof. Sir C.V. Raman Road, P.B. No 8066,
Sadashivanagar, Bangalore 560 080
E-mail: ecdd@cpri.in
Web-site: http://www.cpri.in
Vol. 1 Jojobera Unit No 3 CPRI Report TPC-G
Project Summary
01 Title: Energy Audit & Performance Test of 1 x 120 MW Unit at

Jojobera Power Plant, Jamshedpur- Unit No. 3
02 Work Order No. PO No. 5300076114 dt. 16.04.2010
03 Sponsoring agency: TATA POWER, The Tata Power Company Ltd
Jamshedpur 831 016 India
Tel 91 657 2276875, 6511543
Fax 91 657 2276875, 2278352.
Registered Office Bombay House 24 Homi Mody Street
Mumbai 400 001
04 Contact Person (sponsorer): Mr. U. S. Bapat, Vice President Operation (ER)
The Tata Power Company Ltd,
Jamshedpur 831 016 India
Tel 91 657 2276875, 6511543
Fax 91 657 2276875, 2278352.
Registered Office Bombay House, 24 Homi Mody Street
Mumbai 400 001
05 Contact Person (TPC-G): Mr. P.K. Bandhu,
Manager Operations,
The Tata Power Company Limited
Jojobera Power Plant, Jamshedpur 831 016
Mob. 09204858087
06 Project implementing agency: Central Power Research Institute,
P.B. No. 8066, Sir C.V.Raman Road,
Sadashivanagar Sub-P.O.,
Bangalore-560080
Tel:080-23604682, 23604736
FAX: 080-23604682, 23601213
07 Contact Person (project M. Siddhartha Bhatt, Additional Director (EC & DD)
implementing agency): Central Power Research Institute,
P.B. No. 8066, Sir C.V.Raman Road,
Sadashivanagar Sub-P.O.,
Bangalore-560080
Tel: 080-23604682, 23604736
FAX: 080-23604682/23601213
E-mail:msb@cpri.in; msbhatt1@yahoo.co. in
08 Energy audit team : M. Siddhartha Bhatt, Additional Director

(At site) Rajashekar P. Mandi, Engineering Officer
N. Rajkumar, Engineering Officer
09 Objectives: Energy Audit and performance test for TPC-Gs thermal

power stations and suggestions for their improvements
10 Scope of work: 1: To assess the achievable station heat rate and improvements
1
in auxiliary consumption and specific oil consumption.
2: Suggest measures to improve performance parameters (SHR,

auxiliary consumption and specific oil consumption) over a
period of time.
3: Preparation and submission of report.
11 Report No.: EC&DD/EA/76/2010
12 Power station:
Jojobera TPS, Tata Power Jamshedpur
13 Date of issue of report: October 25th 2010/ December 21 2010
14 Signature of Energy Audit

Team Leader:
15 Signature of the Division
Head:
2
EXECUTIVE SUMMARY
This study presents the results of the tests on major equipment (boiler, turbine,
generator, heat exchangers, condenser, auxiliaries, etc.) of Unit No. 3 at TPC-G,
Jojobera.
The gross overall efficiency of the Unit 3 TG set is 33.4 % against the design
efficiency of 38.2 %. The gross overall TG heat rate (TG HR) is 2577.1 kcal/kWh
at the test load of 100 % and representative GCV as compared to the design heat
rate of 2253.7 kcal/kWh. The TG heat rate considers the boiler, turbine and
generator efficiencies. The deviation in the test TG heat rate from the design value is
as follows:
Unit 3
Test UHR 2577.07 kcal/kWh
DHR 2253.7 kcal/kWh
Dev due to Boiler 48.1 kcal/kWh
Dev due to Turbine 274.8 kcal/kWh
Dev due to Generator 0.5 kcal/kWh
Test efficiency 33.4 %
Design efficiency 38.2 %
Overall difference 4.8 %
Overall difference 323.4 kcal/kWh
The deviation in the test TG heat rate is 323.4 kcal/kWh which can be attributed to
48.1 kcal/kWh due to the boiler, 274.8 due to the turbine and 0.5 kcal/kWh due to
the generator. Hence the turbine is the component leading to maximum losses.
Unit 3
Test Efficiency 33.4 %
HR-Seasonal dev 0 kcal/kWh
HR-Cycling dev 26.00 kcal/kWh
HR-Dev DM 29.49 kcal/kWh
HR-Dev-rejects 8.04 kcal/kWh
HR-Dev-MS& RH pipe 2.7 kcal/kWh
Annual unit HR 2643.3 kcal/kWh
Annual Efficiency 32.5 %
3
The annual unit heat rate (UHR) of the unit considering all factors such as load
factor, DM water make up to account for steam for non-motive applications, rejects,
energy consumption in hot, warm and cold starts; seasonal variations is 2643.3
kcal/kWh for Unit 3. Since during the test coal of representative GCV is fired, the
heat rate also accounts for quality of coal fired. Hence the UHR adequately
represents the annual heat consumption in the unit.
Immediate measures include operational optimization of parameters such as

combustion optimization, mill fineness optimization, coal flow equalization, etc. Fine
tuning of parameters, parameter setting and parameter trending, reduction of steam
and air leaks, etc., would help in operational optimization. Procurement of
combustion optimizer, field instruments for performance monitoring and condition
monitoring is required. Cleaning of internals of pressure parts, condenser, feed
heaters and coolers is also envisaged as an immediate measure. The steam path
audits of turbines are required in view of the turbine internal losses.
Medium term measures include smart soot blowing system, VFDs for pumps and
fans, heat recovery devices and heaters; energy efficient BFPs, CEPs and CWPs, etc..
Long term measures include IP & LP turbine retrofits & up gradation of DCS.
The suggested measures for energy efficiency are given under the summary of
recommendations. The recommendations have been classified under immediate,
medium and long term measures based on their investment criteria and time period
required for implementation.
The savings are as follows:

Sl. Type of measure Investment Reduction in Pay back
No. (Rs. in lakhs) test period
heat rate (months)+
(kcal/kWh)*
01 Immediate measures 562 10 48
02 Medium term measures 440 10 52
03 Long term measures 3600 25 58
* As compared to present test annual UHR + Benefits include life extension
The total investment is Rs. 0.38 Crores/MW for all the measures.
4
SUMMARY OF RECOMMENDATIONS
Immediate term measures
Sl. Anticipated Anticipated Time Pay

No. Recommendations reduction in investment, frame for back
heat rate, Rs. implement period,
kcal/kWh* (lakhs)# ation, months
months +
01 Retrofitting of VFDs for Process 30.0 6
emergency lift pumps, seal improvement
air fans, fire fighting pump.
02 TGA analysis of coals fired Process 30.0 6
into the boiler can help to improvement
optimize combustion
controls.
03 Continuous monitoring Process 22.0 4
system for CO in the furnace improvement
and flue gas ducting
04 Boiler performance Process 50.0 5
optimization using improvement
Air/combustion/mill/exit
gas/ash optimizer from
STORM TECH/ Bacharach/
KENT/ABB/Pegasus/GE
05 Gas proportioning dampers, Process - 4
flue gas, primary and improvement
secondary air dampers
should be retrofitted with
cold hardened material
(medium alloy steel or high
carbon steel) with in built
hard overlay of tungsten
carbide.
06 During overhaul all the gas Process 5.0 4
flow guide vanes, direction improvement
vanes, diversion baffles are
to be inspected. Materials of
diversion baffles must use
alloy steel with overlay of
hard materials like silicon
carbide or tungsten carbide.
07 Drain, drip valves and Process 30.0 6
extraction NRVs: replace improvement
damaged valve stem by
stellited seats, valve plug
5
with Inconel 750, plug by

Nitronic 60.
08 Temperature sensors with Process - 2
indicators may be installed improvement
for energy monitoring of
passing of high energy
drains.
09 Chemical cleaning of boiler Process 20.0 2
improvement
10 Retrofitting of coal feeder Process 10.0 6
drive motor with VFD for improvement
smooth control and
invocation of oil guns.
11 Installation of D-Scall meter Process 30.0 6
(scale control device) at the improvement
inlet of coolers with severe
scaling intensity
12 Additional 6 nos wall soot Process 36.0 4
blowers for the Divisional improvement
panel/sonic soot blowers
13 Energy efficiency parameters Process - -
of the boiler, turbine and improvement
generator side like
condenser vacuum, MS &
RH temperatures and
pressures, mill fineness,
furnace exit gas temperature
(FEGT), O2 in flue gas before
and after APH, etc., may be
specially recorded in EXCEL
sheets for analysis, trending
study and sharing with O &
M and management for
energy control
14 The daily, weekly, monthly Process - -
and annual averaging of KPI improvement
( UR, SOC, SFC, AP, etc.) as
well as machine related
parameters must be made
on EXCEL available for
sharing with the O & M and
management.
15 Monthly efficiency tests on Process 50.0 -
boiler, turbine, feed water improvement
heater, condensers, may be
conducted by procurement
of instruments for field tests
6
16 Online performance analysis 10 30.0 36

software
17 Energy management system Process 30.0 -
for online performance index improvement
generation
18 Ultimate analysis mapping Process 20.0 -
of coal from different mines improvement
and sources at least once a
month
19 Replacement of conventional Process 30.0
auxiliary motor relays with improvement
numerical relays
20 Modification of ID fan Process 50.0 4
blading with aerodynamic improvement
profile with hard weld
overlay
21 Replacement of selected old Process 50.0 4
brass impellers of pumps improvement
with SS 304 impellers.
22 CCTVs for monitoring of Process 15.0 4
leaks & video cameras or improvement
capture of maintenance and
operations knowledge
23 Repair of boiler lifts Process 20.0 4
improvement
24 Passively turbo
powered Process 4.0 4
vaned flywheeling eco improvement
ventilators
25 Review of present overhaul Process - -
pattern of one COH in 2 improvement
years
26 Kaizen for maintenance Process - -
improvement
27 While procuring replacement Process - -
spares, material up improvement
gradation and new
technology options must be
kept in mind instead of old
time tested spares.
28 Vendor development in Process - -
critical areas: HVOF coating, improvement
Martensitic steel materials,
Reverse engineering,
Computational fluid
dynamics (CFD) solutions,
Computational
electromagnetics (E-MAG)
7
solutions, Erosion and

corrosion resistant materials,
software resources, etc.
29 Conduct of steam path Process - -
audits before and after a improvement
COH
30 Ready rekoner books on O & Process - -
M improvement
31 Development of Process - -
maintenance standards improvement
10 562 - 48
*As compared to present test annual UHR
+ Benefits of life extension also.
# Routine maintenance related costs are not indicated as they are a part of
maintenance.
$ Cost proportioned to unit
8
Medium term measures
No Recommendations reduction in investment, frame for back
. heat rate, Rs. (lakhs) implement period,
kcal/kWh* ation, months
months +
01 Energy efficient BFP Process 100 12
cartridges improvement
02 Energy efficient CEPs and Process 200 8
CWPs improvement
03 Improvements in the mills: Process 40 6
Strain gauge under the improvement
bearing supports for on-line
weight of the mill; dynamic
classifier; noise level
monitoring; steam supply
system for quenching; coal
mill performance evaluation
one in a month using
isokinetic sampler.
04 Smart soot blower Process 100 12
system. improvement
Total 10 440 - 52
9
Long term measures

No. Recommendations reduction in investment, frame for back
heat rate, Rs. (lakhs) implement period,
kcal/kWh* ation, months
months +
01 IPT retrofit excluding 10 1500 12
casing- 3 d blading
02 LPT retrofit- 3 d blading 10 1500 12
03 Upgrading of DCS, data Process 600 12
storage and data improvement
highway including FSSS,
field instruments, alarms
and MIS
Total 25 3600 - 58
10
CONTENT (Volume 1)
Page
Nos.
1.0 INTRODUCTION 1
1.1 Energy audit
1.2 Scope of the energy audit
1.3 Period of the experimental work
1.4 Design rating of major equipment
1.5 Age and service period
1.6 Current level of performance measured
2.0 BOILERS AND ASSOCIATED EQUIPMENT 4
2.1 Coal analysis and boiler efficiency tests
2.2 Boiler Temperature & pressure survey
2.3 Boiler and Associated Systems-Component wise analysis
of Performance; equipment assessment for damage,
restriction, de-rating and loss
3.0 TURBINE GENERATOR 13
3.1 Turbine Efficiency Tests
3.2 Turbine Temperature and pressure survey
3.3 Turbine & associated systemsComponent wise analysis
of performance; equipment assessment for damage,
restriction, de-rating and loss
4.0 CONDENSER & COOLING TOWER-ANALYSIS OF PERFORMANCE 17
5.0 STEAM AUDIT AND STEAM UTILIZATION SYSTEM- ANALYSIS OF 18
PERFORMANCE; EQUIPMENT ASSESSMENT FOR DAMAGE,
RESTRICTION, DE-RATING AND LOSS
6.0 CAPACITY ADEQUACY ANALYSIS OF AUXILIARY EQUIPMENTS 19
7.0 FORCED OUTAGE & START UP ANALYSIS 19
8.0 OPERATION & MAINTENANCE PRACTICES 20
8.1 Operational practices
8.2 Maintenance practices
8.2.1 Day to day maintenance
8.2.2 Annual and capital overhauls
9.0 OVERALL SYSTEM 28
9.1 Test heat rate at 100 % load
9.2 Heat consumption due to steam lost to non-motive
applications represented by DM make up
9.3 Heat consumption due to cycling/abnormal operation-
start up and shut down
11
9.4 Additional heat consumption due to year round variations

in environmental and fuel parameters from test values
9.5 Accounting of mill rejects
9.6 Accounting of heat loss in piping in-between boiler and
turbine
9.7 Overall annual unit heat rate assessment
9.8 Categorization of remedies for improvement of the
parameters
9.8.1 Immediate heat rate improvement (over a 12
month period)
9.8.2 Medium term heat rate improvement (over
2-3 year period)
9.8.3 Long term heat rate improvement (over 5
year period and further)
9.9 Degradation of unit heat rates
9.9.1 Degradation of the commercial unit heat rate
(UHR) as computed by the station
9.10 Trajectories and projections
10.0 CONCLUSIONS 37
Annexure 1: Figures
Annexure 2: Tables
Annexure 3: Procedures
Annexure 4: Documents
12
13
Abbreviations/Nomenclature
ABT Availability based tariff

AC Alternating current
AFB As fired basis
AHP Ash handling plant
AOH Annual overhaul
AP Auxiliary power ( MW or MWh for a time period)
APH Air pre-heater
ARW Aerial ropeway
AVF Availability factor (%)
BDV Breakdown voltage
BFP Boiler feed pump
BTL Boiler tube leakage
C Capacity of the unit or station (design or operating, MW)
C&I Control and instrumentation
CA Chemical Analysis
CC Carrying capacity
CEP Condensate extraction pump
CHP Coal handling plant
COH Capital overhaul
CT Current transformers
CW Cooling water
DA Deposit analysis
DC Direct current
DCS Distributed control system
DIM Dimensional measurement
DM De-mineralized
DT Destructive test
ECO Economizer
ERP Enterprise resource package
ESP Electrostatic precipitator
ESV Emergency stop valve
FDF Forced draft fan
FO Furnace oil
F/O Forced outage
GCR Generation control room
GCV Gross calorific value (kcal/kg or MJ/kg)
H Time period block (hours)
HCV Higher calorific or heating value (kcal/kg or MJ/kg)=GCV
HGI Hardgrove Index of coal
HP High pressure
HPT High pressure turbine
HT High tension ( 6.6 kV and above)
HV High voltage
HVOF High velocity oxyfuel flame
IBR Indian Boiler Regulation
14
ID Inside diameter
IDF Induced draft fan
IED Intelligent electronic device
IP Intermediate pressure
IPT Intermediate pressure turbine
KPI Key performance indicators
LDO Light diesel oil
LE Life extension
LP Low pressure
LPT Low pressure turbine
LT Low tension (415 V)
Max. Maximum
MCCB Moulded case circuit breaker
MCR Maximum continuous rating of the unit
Min. Minimum
MIS Management information system
MOD Merit order dispatch
MS Main steam
NDT Non-destructive test
NF Natural frequency
NRV Non return valve
O&M Operation and maintenance
OD Outer diameter
OEM Original equipment manufacturer
p Pressure (kPa or MPa)
P Power output (MW)
PADO Performance analysis, diagnostics and optimization
PAF Primary air fan
PC Personal computer
PLF Plant load factor (%)
PT Potential transformers
R&M Renovation and modernization
RH Reheat
RLA Remaining life assessment
RR Railway receipt
SAIDI System average interruption duration index
SAIFI System average interruption frequency index
SEC Specific energy consumption (kWh/t)
SFC Specific coal consumption (kg/kWh = t/MWh)
SH Superheater
SHR Station heat rate ((kcal/kWh)
SOC Secondary specific fuel oil consumption (ml/kWh)
SPM Suspended particulate matter
SR Steaming rate (t of steam /t of coal)
SSC Specific steam consumption (kcal/kWh=t/MWh)
ST Station transformer
T Temperature (0C)
TDBFP Turbine driven boiler feed pump
15
UAT Unit auxiliary transformer

UHR Unit heat rate (kcal/kWh)
v Velocity (m/s)
VI Visual inspection
WTP Water treatment plant
Greek letters
Excess air factor (dimensionless: 1.0-3.0)
Leakage rate (dimensionless: 0 to 1.0), deviation in heat rate
Difference
Efficiency (dimensionless or %)
Subscripts
a Ambient
av Average
A Auxiliary
B Boiler
BA Bottom ash
e Electric
f Flame
G Generator
in Input
m Mechanical
max Maximum
min Minimum
O Gross overall
ref Reference
S Steam
T Turbine
Units of power
inputs/outputs
MW Electrical power
MWm Mechanical shaft power output rate
MWt Rate of energy change in water or steam (heat input/output
rate)
16
1.0 INTRODUCTION
The objective of the study is the independent assessment of achievable
performance parameters for Tata Powers thermal power station (Unit No. 3) and
suggestions for its improvements. The overall study report is in two volumes:
Volume 1 covers Boilers, turbines, heat exchangers, etc., and overall systems
Volume 2 covers Unit & station auxiliaries and generator.
In this Volume the fuel systems and overall systems are discussed.
This section introduces the power plant and defines the scope of work.
The Tata Power Jojobera had established coal fired thermal power station of 67.5
MW (Unit 1) and 4 units of 120 MW. The present station capacity is 547.5 MW. Unit
3 is presently under study.
Unit 3 of 120 MW has multi-fuel firing capability and consists of BHEL corner fired
boilers with BHEL turbines supplied by BHEL.
The energy audit study is carried out for the Unit 3.
1.1 Energy audit

An energy audit is basically a technique used to establish the patterns of energy use,
identifying how and where losses are occurring and suggest measures for enhancing
energy efficiency with the economic implications.
1.2 Scope of the energy audit

An energy audit is carried out at TPC-G TPS, for energy accounting of coal, fuel oil,
power and auxiliary power leading to suggestions on measures for energy efficiency
improvement.
The scope of the Energy Audit presented is as follows:
1: To assess through tests of individual equipment, the achievable unit heat rate,
loadability, capacity adequacy and improvements in auxiliary consumption and
specific oil consumption
2: To quantify the performance of various sub-systems through an energy balance

and energy efficiency of boiler, turbine, major auxiliaries, heat exchangers, etc.
3: Suggest measures to improve performance parameters (UHR, auxiliary

consumption and specific oil consumption) over a period of time
4: Preparation and submission of report
1
The energy audit covers the major equipment, auxiliaries and includes fact finding,
assessment of equipment and loss levels, performance measurement, analysis,
suggestions for improvement of performance parameters over a period of time,
maintenance improvements, operational improvements & strategic planning. The
detailed scope of work is as per the PO No. 5300076114 dt 16.04.2010.
1.3 Period of the experimental work

The energy audit field work was carried out as per scope during August 2010.
1.4 Design rating of major equipment

The details of the boiler & its auxiliaries and turbine & its auxiliaries are given in
Table 1 to 6 (see Annex 2).
Sl. Unit
No. Particulars No. 3
01 Fuel type Coal
02 Unit capacity MW 120
03 Steam to fuel ratio t/t 4.31
04 SSC t/MWh 2.960
05 DHR Kcal/kWh 2253.47
1.5 Age and service period

The capacity and age of the Unit is given in Table 7 (Annex 2).
1.6 Current level of performance measured by TPC-G

The unit performance indices are as follows:
Plant load factor
Plant availability factor
Gross overall efficiency
Unit heat rate
Specific fuel consumption
Specific fuel oil consumption
Auxiliary energy consumption
Figures 1-6 (see Annex 1) give the monthly variation of the KPI for Unit 3 for the
past 3 years.
2
Figures 7-11 (Annex 1) give the sensitivity of the KPI to PLF. It can be seen that
there is reasonable correlation with the data (R2=around 0.6). However, there is
opportunity to improve the quality of the data acquisition and measurement.
1.6.1 Routine measurements of critical parameters and its

documentation
Routine measurement of critical parameters is being done at present through the

DCS. The majority of the parameters except those which require manual
measurements like mill fineness, unburnts in ash, etc., are available on the DCS but
special recording of the critical parameters on daily average, weekly average,
monthly average , yearly average or trends of these is not available for sharing with
the O & M and management of the TPS for energy control.
Recommendation: Parameters which have a bearing on energy efficiency of the

boiler, turbine and generator side like condenser vacuum, MS & RH temperatures
and pressures, mill fineness, furnace exit gas temperature (FEGT), O2 in flue gas
before and after APH, etc., may be specially recorded in EXCEL sheets for analysis,
trending study and sharing with O & M and management for energy control.
Recommendation: A water monitoring software package is to be in place.

The package must have capability to draw inputs from the various field instruments
(which will act like IEDs) and make an on-line continuous data base grid of the
information for generation various types of information such as consumption per
unit per shift, consumption during cycling operations, operator wise consumption,
etc., to enable the performance optimization group to take control action on the
areas of wastage and excessive consumption. Consumption and production should
be separately monitored. At present only gross data is being recorded and is not
useful for energy control.
1.6.2 Trends and comparisons
At preset, the bare machine variables and KPI data are available but the majority of
data is not available for energy control. The important KPI are presently being
analyzed on a daily, weekly and monthly basis.
Recommendation: The daily, weekly, monthly and annual averaging of KPI (UHR,
SOC, SFC, AP,etc.) as well as machine related parameters must be made on EXCEL
available for sharing with the O & M and management. The same must be made
available on EXCEL sheet for analysis and in graphical form for trend analysis.
1.6.3 Efficiency & performance test results
At present efficiency and performance tests are not being done in the units as a part
of the in-house energy efficiency program. This would give valuable data such as
3
effects of moisture and coal quality on the boiler efficiency, etc. Also efficiency tests
on boilers for different sources of coals are not presently available. Also efficiency
tests on boilers for different sources of coals are not available. Performance tests on
turbines, condenses, feed water heaters, generator, etc., and evaluation of AP are
not being practiced. Valuable information can be generated from these.
Recommendation: Monthly efficiency tests on boiler, turbine, feed water heater,

condensers, may be conducted for 2 hours duration at the maximum load and the
data may be archived for further analysis and future archiving. This will be useful
for observing the seasonal trends as well as sensitivity to GCV and moisture content.
1.6.4 Detailed analysis
Detailed analysis of root causes for failures is being done to the extent required or
replacement and further operation. Detailed analysis of performance is done at a
macro level covering the KPI. At a micro level or parameter level, detailed root cause
analysis is not being done at present.
Detailed analysis is being done for the following:

Events
Failures
Performance parameter variations
2. BOILERS AND ASSOCIATED EQUIPMENT

The boiler (BHEL) is of the sub-critical cycle, type, two pass, tangentially fired,
tilting injection, balanced draught, natural circulation, radiant, reheat, wet bottom
with direct fired pulverized coal with XRP 783 Raymond bowl mills. The furnace is of
the membrane type wall construction. The outer side of the combustion chamber,
pent house and all the equipment are insulated with lightly bonded wool mattresses.
In the top deck, deck below drum, rear arch deck and at buck stay portions pour
able insulation is applied.
2.1 Coal analysis and boiler efficiency tests

Coal and ash samples were collected during the tests. The results of the coal
analysis from CPRI laboratories are given in Table 8 (see Annex 2). The results of
the unburnts analysis of bottom ash and fly are given in Table 9 (see Annex 2). The
results of the flue gas analysis are given in Table 10 (see Annex 2).
CPRI observations: The GCV of coal during the test is the representative coal
used by the TPS. The boiler has been tested in this coal condition.
Boiler efficiency test results
4
The results of the boiler efficiency are given in Table 11 (see Annex 2). The
measured boiler skin temperature is given in Table 12 (see Annex 2). The
performance of the tubular air pre-heaters are given in Table 13 (see Annex 2).
The observations and recommendations regarding the boiler performance are as
follows:
i. Boiler efficiency of the unit at a GCV of 4623 kcal/kg is 85.31 % .
ii. O2 in flue gas is in the range of 3.72-4.96 % before APH and 5.15-8.98 %
after APH.
iii. The CO content measured in flue gas was 274-442 ppm. The measured CO is
on the higher side indicating incomplete combustion.
iv. Unburnt losses in bottom ash and fly ash are high. Unburnts in bottom ash is
5.6 % and 1.9 % in fly ash.
v. The wet flue gas loss is 4.81 % against the design value of 6.14 %.
vi. The maximum skin temperature is as high as 185 C which is high at certain
zones. Loss due to convection and radiation loss is 1.56 % compared to
design value of 1.21 %. The average overall surface temperature measured
is 72.7 C. The surface temperature should be 10 C above the ambient
temperature. Recommendation: The flexible insulation of the boiler needs
to be replaced at hot spots. Partial need based insulation replacement is
recommended.
The site observations along with recommendations are as follows:
Recommendation: Some measures for the boiler involving operational optimization

through balanced flows are as follows:
Sl. No. Parameter Optimal values

01 Coal flowTo within 10 % of the mean value. Earlier
balance practice was use of static devices such as
between pipes Ni-hard flow equalization nozzles. Present
in an elevation
practice is to use a variable air jet at a
pressure of 110-120 kPa and at an angle of
45 across the pulverized coal flow pipe
passage to introduce dynamic flow
resistance which can be controlled for flow
equalization.
02 primary air Primary air to different mills within 5% of
the mean.
03 Coal Fineness 70 % of the mass passing 75 m size with a
deviation of 5% of the mean fineness.
04 Minimum coal 0.8-1 m/s
line velocity
5
05 Mill outlet
> 85 C while the operating values are in
temperature the range 88-96 C.
06 Secondary AirTo within 5 % of the mean value. SADC
balanced at
(secondary air damper control) must be on
wind boxes auto for the unit.
07 Furnace 2.5 % to 3.0 % and with less than 5 %
Oxygen leakage between Furnace Exit and
Economizer and less than 10 % leakage at
APH. O2 control in the furnace is in place.
The operating furnace O2 is 3.7-4.9 %.
08 Oxygen after < 4.2 % as per design and the operating
APH O2 is 5.6 %
09 Bottom ash < 4 % as per design and the operating
value is 0.1 to 0.2 %.
10 Fly ash < 1 % as per design and the operating
value is 1.9 %
11 Carbon < 100 ppm as per design and the operating
monoxide value is 272 ppm to 442 ppm.
2.2 Boiler Temperature & pressure survey

Table 14 gives the flue gas temperature survey and Table 15 gives the flue gas
pressure survey. From the above named Table 14 (see Annex 2), it is seen that the
operating temperature profile is deviating from the design value. The operating flue
gas temperature before APH is 384 C against the design value of 298 C and after
the APH it is 154 C against the design value of 139.0 C .
2.3 Boiler and associated systems -component wise

analysis of performance; equipment assessment for
damage, restriction, de-rating and loss
Heating surfaces: Water wall, economizer, super heaters, reheater, air
pre-heaters, etc.
Table 16 (Annex 2) gives the specific heating surfaces. The furnace volume is
undersized by 16 % for the present coal while the EPRS is OK. The SH is OK and
the RH is also OK. The ECO and APH are is also OK.
The performance of the economizer is given in Table 17 and the performance of the
water walls is given in Table 18.
The observations regarding the heating surfaces are as follows:
i. It is seen that the furnace gas tightness is OK.
6
ii. The performance of ECO is OK. The design flue gas velocity at ECO is
expected to be in the range of 8.5 to 9.5 m/s. Due to ash
accumulation and fouling, the velocities increase to nearly 12 m/s or
more resulting in enhanced erosion rates. To reduce erosion, close
monitoring of flue gas velocity is needed. Also suitably designed
cassette baffles of ceramic/steel with hard overlay may be introduced
for reduction of erosion. Recommendation: During a shut down,
before cleaning and clearing of the debris a clean air velocity test may
be conducted to confirm the velocity profile in the ECO in the running
condition. After clearing of all debris and fouling, the same may be
repeated and it may be ensured that the velocities are within 8.5 to 9.5
m/s. Gas velocity at the gap between the ECO coil bundle and the
boiler furnace wall must be minimized by frequent cleaning of debris.
Ceramic/hard coated steel cassette baffles may be introduced for
reduction of erosion. Material up gradation must also be considered.
Partial replacement of ECO coils is recommended.
iii. The APHs are tubular shell and tube type with two secondary APH and
one primary APH.
iv. Air leakage occurs in the APH because of the pressure difference
between the high pressure air and the low pressure exiting flue gases.
The air leaks into the flue gas stream and exits to the stack resulting in
energy loss of hot air, pressure loss of hot air and additional load on
the ID fan. The flue gas temperature at the APH outlet increases on
account of this besides resulting in reduced boiler efficiency and
increased auxiliary power to the fans. The LHS side leakage of
Secondary APH is 9.3 % and for RHS it is 21.3 % which is on the high
side, against the design value of 7.7 %. The leakage of primary APH is
19.8 % compared to the design value of 16.3 %. Air leakage in APH is
from two sources:
Punctured tubes at the centre of the nest
Punctured tubes at the sides (edge of the APH) and the boiler.
v. The erosive nature of Indian coals giving rise to wear and erosion of
high severity is also a cause for the tube punctures. Besides, the cold
end corrosion of heat exchanger materials leads to tubes being eaten
away due to the combined effects of wear and corrosion. APH leaks
reduce boiler efficiency by as much as 1 %. Recommendation: The
measures for the APH are as follows:
Clean air velocity tests to understand the air velocities in the
gap between the APH and boiler water wall surfaces.
Installation of ceramic cassette baffles for alteration of the flue
gas flow to avoid direct impingement on the tubes and
reduction of the flow velocities.
7
Application of sacrificial weld overlays of hard materials like

tungsten carbide over tube surfaces prone to high velocity flue
gas flow.
Furnace combustion, thermal sealing and control: combustion equipment,

Ducts, heat leakage, insulation, refractory, pent house sealing & Furnace
bottom sealing, etc.
The observations regarding the furnace are as follows:
i. One of the objectives of achieving good combustion and efficiency is

making heat flux distribution even with symmetric fireball. It must be
noted that uneven heat flux distribution gives rise to reduced heat
transfer and tube failures.
ii. Particle size distribution and percentage of volatiles in coal affects

combustion efficiency and combustion characteristics. Combustion
reactivity of coal determined by percentage volatiles. De-volatilization
of coal 60-100 ms while char combustion 1-2 s. Recommendation:
TGA analysis of coals fired into the boiler can help to optimize
combustion controls.
iii. Long term erosion is an effect for consideration in this boiler. The
main factors affecting erosion in the boiler are:
Flue gas velocity
Composition and percentage of mineral content
Changes in the flue gas direction
Arrangement of pressure parts
Flue gas temperatures
iv. The boiler efficiency is affected by some of the design parameters like:
Boiler volume
Gas temperature entering the first pendent at the goose neck
level.
Furnace exit gas temperature
Location and number of soot blowers
Burner input, clearance, mouth design and tilting mechanism
Heat input available at the primary combustion zone (burner
elevations).
In all the above design parameters, the boiler is satisfactory and
appropriate except for water wall under sizing for high ash coals.
v. Erosion could be combated by measures such as:

Reduction of gas velocity in second pass
In-line arrangement for all 2nd pass heat transfer surfaces
8
Refractory/steel with hard facing liner shielding of faces

prone to erosion
Cassette baffles of 2nd pass heat exchangers
vi. Flue gas temperature at boiler outlet (APH outlet) is dependent on:
Furnace heat absorption rate and slagging cum fouling
behavior
APH leakage (from air side to the flue gas side)
Excess air factor of the flue gas which is dependent on
gas tightness and air tightness in the boiler
APH effectiveness
Burner tilting mechanism and their response
Ambient air conditions
Fuel quality
vii. The high flue gas temperature at the boiler out can be controlled by:
Furnace cleaning through smart soot blower system
Water washing of APH during an outage
Optimizing of primary and secondary A/F ratios
viii. FEGT (furnace exit gas temperature) measurement and High quality
visible flame safe scanner system are already available and the
performance is good.
ix. The present soot blowing system is time based and open looped. This
can be converted into a closed loop system by installation of smart soot
blowing system or intelligent soot blowing system the heart of which is
the furnace cleanliness probe. This is nothing but a heat flux sensor
which gives a measure of the fouling through a deposition probe which
gives the degree of fouling or slagging and heat flux through a chordal
thermocouple which measures the furnace inner skin temperature.
Such heat flux sensors are incorporated in boiler water wall sections.
Based on the output of the sensors the soot blowing interval is decided
automatically through a logic based system incorporated into the plant
DCS. If the cleanliness value falls below a certain value it signals for a
soot blowing cycle. The benefits of the smart soot blowing system are
an increased level of furnace heat absorption (by around 10 %), a
lower exit flue gas temperature (around 10 C) and reduction in soot
blowing frequency and auxiliary steam (around 5 %) in the long term.
Recommendation: To maintain a high level of cleanliness in the
furnace, the present soot blower system needs to be converted into
smart soot blower system.
x. Oxygen measurement: The measurement process needs to be

strengthened by more probes forming a grid. The O2 measurement
may also be introduced after the APH.
9
xi. Recommendation: On-line CO measurement is presently not in

service. Continuous monitoring of CO before APH may be introduced
for combustion optimization using multi-grid measurement with 4
sensors.
Furnace and piping: Flow control and sealing: Ducts, dampers, valves,
wind box, etc.; supports and fixtures
The observations regarding the furnace flow systems are as follows:
i. Recommendation: Periodic cleaning of ash and debris collection in

fan duct during any available outage.
ii. Recommendation: During overhaul all the gas flow guide vanes,
direction vanes, diversion baffles for flow diversions are to be inspected
and need to be replaced. Materials of diversion baffles must be alloy
steel with overlay of hard materials like silicon carbide or tungsten
carbide.
iii. Valves: Recommendation: In the case of badly damaged internals,

it is recommended to replace valves by new valves with stem by
stellited seats, valve plug with Inconel 750 (ASTM A45; Rockwell
hardness 35), plug by Nitronic 60 (ASTM A479 with hard facing).
iv. Downstream side of high energy drains: Recommendation:

Temperature sensors with indicators may be installed for energy
monitoring of passing.
Coal/oil circuit: pipes, feeders, burners etc.
The observations regarding the coal and oil circuits are as follows:
i. Recommendation: Replacement of drives of coal feeders with

VFDs.
ii. Recommendation: Retrofitting of fuel oil pump motor with VFD for
smooth control and invocation of oil guns.
Boiler auxiliaries: ID Fan, FD fans, PA fans, mills, etc.
The observations regarding the boiler auxiliaries are as follows:
The performance of the ID fan is affected by:

Increased clearance between fan impeller blades & casing
Deterioration in blade profile, surface finish of blades
Increased air heater pressure drop and choking
10
Excess air flow through the system

Leakage seal passing
Flue gas duct choking causing reduced cross section area
ID fan capacity drop occurs due to wear and erosion of internals and results in
reduced efficiency as well. The damaged components are impeller, casing, scroll and
inlet damper. The options for improved performance are:
a. Brazed Tungsten Carbide cladding
b. Chrome Carbide weld overlay
c. Hard alloy steel
i. The ID fans generally have high erosive deterioration tendencies.

Recommendation: Modification of ID fan impeller blades & casing through
material upgradation such as either upgraded material or conventional
material with chrome carbide weld overlay to fill the damaged portions, so
that its performance will not deteriorate over a period 5 to 6 years.
ii. The velocities of coal and flue gas also get altered due to high flow rates
which results in increased wear and erosion by 3 to 4 time (as erosion rate is
directly proportional to ~ v3). Change over to superior grade wear resistant
materials (medium alloy steels with hard weld overlays) is imminent. Control
of heat and air leaks is also equally important in system performance
restoration.
iii. Energy efficient variable frequency drives: The traditional speed

changing devices like gear boxes, belt drives, chain drives have low
efficiencies of the order of 85-92 % whereas the present voltage sensing
technology gives efficiencies as high as 94-96 % Recommendation:
Replacement of the following drives with VFDs: Emergency lift pumps,
oil handling pumps, seal air fans, hydrogen cooler booster pump, fire fighting
pump & compressed air system.
iv. Energy Efficiency pumps: Replacement of pumps of brass impellers with

SS impellers can give an improvement in 8-10 % points improvement in the
composite pump-motor efficiency. Recommendation: Replacement of
selected old brass impellers of pumps with SS 304 impellers.
v. Mill controls: Recommendation: Replacement of analog controls of mills

by digital controls.
vi. Mill safety: Recommendation: Replacement of present mill vents with

expansion vents to handle explosions due to combustion of volatiles in the
system.
vii. The recommended measures for the mills are as follows:
Sl. No. System/parameter Optimization
11
01 Classifier setting Frequent classifier settings and cleaning to

ensure the fineness and ensuring that the
coal air mixture temperature and velocity
are as per design. Alternatively, backward
curved exhausters with wear resistant, dust
deflectors at the mill outlet can improve the
mill performance as well as increase its
wear resistance.
02 Spring load and roll Constant adjustment of spring load setting
clearance and roll clearance setting
03 Classifiers Simple classifiers result in collar formation
in rolls which acts as a funnel in passing
heavier particles back to the mill. Extension
of centre feed pipe can avoid this problem.
Dynamic classifier where the segregation of
coal particles is done with the help of active
powered fan.
04 Mill internal Maintain mill internals. Replacement of mill
clearances internals on performance basis rather than
on hours basis is already in place. Condition
based maintenance for the mills in practice
at the TPS.
05 Rotating vane Rotating vane assembly in place of
assembly stationary vane assembly.
Recommendations: For improving the mills, in the medium term, some additional
measures are:
Strain gauge under the bearing supports of the mill for on-line
weight of the mill to indicate the status of the loading of the mill. This
practice is used in International practices to know the level of loading rather
than other indirect parameters such as mill current and mill differential
pressure.
Retrofitting of mill with dynamic classifier
Monitoring of noise level inside the mill to assess the loading level
especially when the service air lines are choked. Sonic sound detection may
also be used for mills for mill condition monitoring.
Modification of explosion vents to handle mill related explosions.
Steam supply system for quenching of mill fires.
Coal mill performance evaluation one in a month using isokinetic

sampler.
12
The condition assessment of steam generator components is given in Table 19. The
leakages in boilers are given in Table 20.
3.TURBINE- GENERATOR
The steam turbine is of the KWU (Siemens) design, three cylinder, throttle
governing, multi stage, reaction, tandem compound, single flow HP, double flow IP
and double flow LP with six uncontrolled extractions.
3.1 Turbine efficiency tests

Turbine efficiency test results
The results of the efficiency tests and heat rate of the turbines are presented in
Table 21. The loss of work in the turbines is given in Table 22.
The observations regarding the turbine performance are as follows:
i. The turbine efficiency is 39.67 % and specific steam consumption is 3.25

t/MWh against the design value of 44.46 % and 2.96 t/MWh.
ii. The turbine internal losses as indicated in Table 22 above are around 6.76
MWm. The total loss of work in the turbine is 7.12 MWm. These losses are
due to the turbine internals not converting the thermal energy in the
steam to mechanical work (turbine irreversibility) as per the design.
iii. Internal leaks in the turbine circuit result in loss of auxiliary power and
loss of work in steam. BFP recirculation valve passing of 10 t/h could lead
to loss of 75 kW. Similarly, SH, RH spray valves, HP vent valves passing
lead to losses.
iv. Sliding pressure operation: The provision is presently in use and may
be continued.
v. ATRS: Recommendation: Provision for rolling of the turbine through

ATRS may be implemented. Turbine rolling must only be through ATRS.
3.2. Turbine Temperature and pressure survey

The steam temperature survey is given in Table 23. The steam pressure survey is
given in Table 24. The MS entrance pressure is lower by 0.8 MPa against the design
of 12.70 MPa. The MS temperature is 4 C less than design. The CRH temperature is
higher by 10 C. The HRH is on par with the design.
13
3.3 Turbine & associated systemsComponent wise

analysis of performance; equipment assessment for
damage, restriction, de-rating and loss
Steam flow path system
The observations regarding the steam flow path are as follows:
i. The rated MS and RH temperatures are normal.
ii. The HRH temperatures are almost on par with the design. The HRH and
CRH pressures are lower the design by 0.8 MPa. The CRH temperature is
higher by 10 C.
iii. The LPT exit temperature is 55.7 C as compared to the design value of
46.4 C. The condenser vacuum is 12.0 kPa against the design value of 10.6
kPa. The cold end is optimized. However, the TTD across the condenser is
2.4 C against the design value of 3.4 C.
iv. Steam path audit: The deterioration in the operating heat rate is mainly
because of the steam turbine internal losses. The energy losses are in the
blading and steam paths of the turbine. Recommendation: During the
next capital overhaul steam path audit may be conducted to quantify
deterioration in heat rate at every stage of the turbine and for initiating
corrective action.
LPT and IPT retrofits: The earlier concept of R & M was generally thought of as
replacing highly stressed components and deformed members to increase the plant
availability and continue plant operation beyond the service life. In the light of the
above analysis, recommendations are given which are of replace philosophy. The
investment for this activity has its own justification that investment is relatively low
and keeps the system running in the present healthy and safe condition till a new
technology is infused enhancing the efficiency as well as health and life.
The present day concept of R & M is to make full use of state-of-the-art

technology available to meet the long term objectives set for the exercise, viz.,
improvement in availability, continuous operation and efficiency of the plant and to
extend the life of the plant by 20 years. To meet these objectives of the R & M it is
necessary to harness the up-to-date technology of the turbines rather than to stop
at simple replacement of damaged components or conventional re-blading.
Considering the large improvement potential to the gross overall efficiency it is

economically beneficial to go in for the new design high efficiency turbines rather
than simple re-blading or replacement of stressed/damaged components of the old
turbine. In this light the recommendation for R & M and life extension of the
turbine is as given below.
14
Recommendation for turbines: Considering the above facts the present steam
turbine IP & LP cylinders may be replaced with standard 3-d stage specific bladed
turbines with 3-d modeled exhaust diffuser, improved tip to tip sealing, modified
exhaust hood spray and a turbine supervisory system. The standard added features
of the retrofitted turbines are as follows:
Modification in location of exhaust hood spray such that the excessive

ventilation heating (during low load operation and load rejection) is not
experienced in the LPT on the generator side.
Endoscopes for examination of blading without opening of the casing.
The expected life of the turbine is 15 years or 100,000 hours. The time for
replacement of the turbine is around 3 months. The efficiency is expected to
result in reduction in heat rate by around 10 kcal/kWh for IPT and 10 kcal/kWh
for the LPT for identical inlet conditions and exhaust condition.
Feed Heaters, turbine side lines, valves, pumps and heat exchangers
The performance of the feed water is indicated in Table 25 (see Annex 2).
The observations regarding the feed water heaters are as follows:
i. The TTD of HPH-6 is 13.6 C against the design value of 0.9 C.

Recommendation: Cleaning of tube nest of HPH 6 to improve the
performance.
ii. The TTD of HPH-5 is 11.7 C against the design value of 1.4 C. Higher TTD
indicates poor heat transfer. Recommendation: Cleaning of tube nest of HPH 6
to improve the performance.
iii. The TTD across LP heater 3 is -3.0 C against design value of 3.7 C. This gives
good performance of the heater but indicates that the energy conversion in the
steam turbine LP module is not as per the design.
iv. The TTD across LP heater 2 is -6.8 C against the design value of 12.2 C. This
indicates that the extraction steam is entering at a higher degree of superheat
than the design value. This again points out the poor performance of the turbine.
The reasons for the sub-optimal performance of HP feed water heaters are:
Air blanketing and improper venting in HP heaters due to isolation of vent air
line
Air blanketing and improper venting in LP heaters at sub-atmospheric
pressure
15
Steam side contamination due to presence of oxygen above 100 ppb resulting
in exfoliation of tube material in the formation of scale layer.
The recommendations for the feed water heaters are:
Regular venting of air lines in HPH.

HPH & LPH feed water outlet temperatures to be maintained.
Reduction in permissible oxygen in steam to below 100 ppb.
i. Valves: Valves bodies and seat damage may be ascertained during an

internal inspection for suspected of passing. Normally, the seats/discs of
new valves are hard faced with Cobalt Carbide or Nickel Molly alloy. The
stems are of 18/10 Class 300 - SS or ASTM A 453 GR 660.
Recommendation: In the case of badly damaged internals, it is
recommended to replace valve stem by stellited seats, valve plug with
Inconel 750 (ASTM A45; Rockwell hardness 35), plug by Nitronic 60 (ASTM
A479 with hard facing). The following valves are recommended for
inspection: PRDS pressure control valves, HPT control valves, BFP
recirculation valves, drain valves & auxiliary steam valves.
ii. Extraction & NRVs: Recommendation: Need based Replacement of

major extraction & NRVs with valves of better materials such as valve stem
by stellited seats, valve plug with Inconel 750 (ASTM A45; Rockwell
hardness 35), plug by Nitronic 60 (ASTM A479 with hard facing). Valves for
HPH drip to deaerator, drain of HP, Auxiliary steam, drain valve, etc. , may
be considered for improvement.
iii. Deaerator: The deaerator temperature and pressure are below their design
values and boiling is affected because of feed being sub-cooled.
Recommendation: Oxygen measurement must be introduced in the
deaerator.
iv. Heat recovery devices: Gland steam condenser, stack steam

condenser and vent steam condensers: The performance of these is
normal.
v. Coolers and secondary heat exchangers: Recommendation:

Installation of D-Scall meter (scale control device) at the inlet of coolers
with severe scaling intensity.
vi. BFP Lube oil cooler & BFP scoop oil cooler: These are shell and type
heat exchangers and operation is normal.
vii. Feed water pumps: Recommendation: Replacement of cartridges of

feed pumps with energy efficient cartridges with efficiencies (pump+ motor)
of around 70-80 %.
16
viii. CW and condensate extraction pumps: Recommendation:

Replacement of CW pumps and CEPs with energy efficient pumps of
composite efficiency (pump+ motor) of at least 60 %. The pumps may be
modified to antifriction bearings.
ix. Other turbine side pumps: Recommendation: Replacement of turbine

side pumps like sump pump, drip pump, etc. of bronze, brass impellers with
pumps of SS impellers which have 8-10 % points higher composite pump-
motor efficiency. SS impeller pumps are inherently higher in efficiency than
bronze, brass or non-ferrous impeller pumps.
The condition assessment of steam cycle components is given in Table 26.
4. CONDENSER, COOLING TOWER- ANALYSIS OF

PERFORMANCE; EQUIPMENT ASSESSMENT FOR
DAMAGE, RESTRICTION, DE-RATING AND LOSS
The surface condensers are able to meet the unit requirements. Table 27 gives the
performance of the condenser. The performance of the condenser is almost on par
with the design. The TTD of the condenser is on par with the design 3.4 0C. The
condenser vacuum is 12.0 kPa against the design of 10.6 kPa
Cooling tower - 3
Cooling tower is of counter flow with 4 cells. During study period all the 4 fans
were in service. Table 28 gives the performance of cooling towers.
The observations are

i. LHS side heavy bush growth obstruction the air flow to cells 3A, 3B
and 3C.
ii. Water spillage from raiser duct was observed.
iii. Drift eliminators are blocked with heavy algae.
iv. In few locations fill material is damaged and water is flowing through
this damaged area without splashing.
v. Inspection door topside and movable door gap leads to fresh air entry
into fan suction.
vi. The operating range varies from 6.9 to 7.0 C against design value of
10.0 C.
vii. The operating approach varies from 9.0 to 9.3 C against design value
of 4.2 C.
viii. The operating effectiveness varies from 42.4 to 43.8 % against design
value of 70.4 %.
Recommendation:
17
i. The cooling water quality to be monitored and controlled to avoid algae

growth.
ii. The damaged fills need to be replaced.
iii. The cooling water to each cell need to be equalized to improve the
performance.
iv. The bushes near the cooling tower need to be cleared off to have
resistance free air entry to CT.
5. STEAM AUDIT AND STEAM UTILIZATION SYSTEM-

ANALYSIS OF PERFORMANCE; EQUIPMENT
ASSESSMENT FOR DAMAGE, RESTRICTION, DE-RATING
AND LOSS
In this unit, steam related losses are quite low (1 % of the main steam flow). The
unit has steam vacuum pumps and oil heating /tracing by steam. It is assumed that
all the steam out of the boiler goes to the turbine. But in practice a certain
percentage of steam is lost from the boiler side as auxiliary steam. The auxiliary
steam consumption is around 3-8 t/h.
The auxiliary steam is taken from the CRH line through auxiliary steam station after
pressure reduction and de-superheating.
The DM water consumption is normally designed at 1-3 % of the main steam flow
and the operating values are normally supposed to be in the range of 1-3 %. In this
unit the DM make up is well within limits.
The recommendations for auxiliary steam are as follows:
Sl. System/parameter Particulars

No.
01 Blow down Optimization of blow down (CBD+IBD)
based on judicious setting of purity.
02 Valves Check for passing of CBD and IBD valves
and high energy drains on the turbine side is
in place and can be further strengthen by
use of local temperature sensor to check for
passing.
03 Steam leaks Arresting of steam leaks from soot blower
and auxiliary steam lines typically at flanges,
valve stems, etc. must be done proactively.
04 Make up Monitoring of make-up water to control
excessive steam consumption through actual
flow measurement of make up.
18
05 Steam loss Steam loss in areas outside the unit area

such as oil tank heating, oil line tracing, may
be curtailed by plugging uncontrolled losses.
Steam losses are seen at a number of
locations in the oil plant.
06 Insulation Insulation of steam lines by 50 mm
unbonded, felted, inorganic based
mineral/rock/slag wool of thermal
conductivity followed by MS pipe skin
cladding. The insulation is damaged at many
locations in the boiler gallery and at the oil
plant.
07 Cycling operations Steam loss during cycling and abnormal
operation must be regulated.
6. CAPACITY ADEQUACY ANALYSIS OF AUXILIARY

EQUIPMENTS
Capacity limitation is characterized by the load factor of the auxiliary at the operating
unit load. When the actual load factor of the auxiliary is higher than the expected
load factor (at that plant load) it leads to capacity limitations at higher loads. When
designing the auxiliary motors, they are provided with 20 % margin (10 % in
pressure and 10 % in flow). The design load factor of auxiliary motors is 100 % at
100 % MCR rating of the unit, except in the case of FD fans which is set at 30 %.
The present limiting unit capacity is arrived at without considering the margins.
The capacity adequacy analysis was carried out for each of the major HT auxiliary
equipments. The Load factor of the auxiliary motor at 99.28 % MCR (test load) are
worked out and given in Table 29 (see Annex 2).
It can be seen from the Table that at the operating unit load of 100 % PL of the
unit, the auxiliaries CEPs pose capacity limitation as these are getting loaded to
almost 95 % of their power rating. At 100 % MCR , i.e., 120 MW, in the case of CE
pumps there is capacity limitation of 10 % and there are no margins. There is no
capacity limitation on any other auxiliaries.
7. FORCED OUTAGE & START UP ANALYSIS
The tripping reports for the Unit for the past 2 years is given in Annex 4:A4-1.
The average rates are as follows:
BTL: 0-1/year
19
No of trippings/year: 6/year
Mean time between failure (days): 61 days
Average time per outage: 3.5 hours/outage
The number of forced outages are showing a decreasing trend from over 8
outages/year to 5/year over the years.
It is seen that the average time taken for hot warm and cold starts is as follows:
Average time from Boiler light up to 100 % Load (h)
Unit no. Hot start Warm start Cold start

Unit 3 2.0 36.0 72.0
8. OPERATION & MAINTENANCE PRACTICES

8.1 Operational practices
The review of the operating procedures is given in Table 30.
The recommendations regarding operation practices are as follows:
i. Run the unit as close to the design parameters as possible. The heat
rate will be minimum when the unit parameter deviation is minimum.
For every deviation of operating parameter there will be increase in
heat rate. Focus areas are O2 in flue gas and mill fineness.
ii. The operation criterion is based on running of the unit. The unit is
automated to a good extent to enable efficient operation. With the aid
of a few operator aids for start up and optimal operation the unit can
perform efficiently.
iii. The operation must consider the various inputs from Performance
optimization group and Chemists for process optimization.
iv. The operation practices must be aligned to operation of the units

steadily without tripping with the maximum availability and minimum
no of outages.
v. The ISO objectives and engineering declarations must be focused on

operation considerations such as minimizing the number of trippings,
minimizing resource consumption for restarts.
20
vi. Maintaining 100 % availability of all feed water heaters and heat
recovery condensers.
vii. All OEM manuals must be thoroughly studied and donts must be
carefully understood and observed. This will avoid long term damage to
asset equipment and irreversible degradation of heat rate which will be
costly to reverse.
viii. Keep target parameters and maintain un-burnts in bottom ash and un-
burnts in fly ash, make up water %, etc., within limits. The combustion
limits are as follows:
o Bottom ash limits 4 %,
o Fly ash < 1 %.
o Optimal CO: 100 ppm
In addition to the above, installation of software packages for unit management

such as the following will aid in the operations:
o On line maintenance schedule package
o Enterprise resource planning
o Spares inventory management
o Condition monitoring through vibration analysis
o Asset management package
The TPC-G has installed SAP ERP package for their material management, preventive
maintenance, finance and HR activities.
Above objectives may be achieved by developing following system:
A close monitoring and reporting system.

An efficient system of review which ensures timely attention to the
maintenance requirement.
Training and capacity building for improved knowledge of
operational practices to operation staff.
Efficiency up keep of instruments, auto control loops, annunciation
system, protections & interlocks.
Good house keeping and working environment.
Training for O & M staff.
Operational aids:
Sl. System Particulars

No.
01 Multi media To aid in quick decision making of deviated
annunciation parameters
02 On-line Parameter trending on-line and indication of
software deviations from the design.
21
03 ATRS Turbine rolling must be only through ATRS
04 Expert systems For decision support during abnormal operations

and emergencies
05 Simulator To simulate new and unusual situations
Measurement of losses through Chemist: Periodic (daily) measurement once in

a shift are being taken for unburnts in bottom ash, unburnts in fly ash, CO in flue
gas, mill fineness, mill rejects, etc. These are useful aids for operational
optimization. This input is presently available but not being used for process
optimization. Recommendation: The data recorded in each shift by the Chemists
may be integrated by Performance Optimization Group into online optimization of
the boiler and turbine, mill operating parameters to improve the unit performance
through minimization of losses on account of these. Presently unburnts report on
daily basis, coal mill fineness weekly, and CO measurement is on need basis. When
the parameters are out of good range these must be addressed through parameter
defect card system.
Closed circuit TVs: Recommendation: CCTVs may be installed in boiler

elevations AB, CD, EF, etc., on all corners. The viewing must be in control room and
in Station Heads office. In all around 8-10 CCTVs/unit may be installed for
monitoring the boilers for coal leaks, steam leaks, oil leaks etc. Also CCTVs may be
used for conveyor monitoring.
Performance trending as an operational guideline: Recommendation: The

process of performance trending presently using off line data and gradually using on
line data, can be taken up for operational optimization, the aid of TGA of fired coal,
stress evaluation, etc., can also be used as guidelines. The performance trending
software capability can be strengthened by procurement of standard software
(typically PADO, Ebsilon, Pro-engineer, Steam Master, IPSEPro, etc.,) having
flexibility of downloading into a standard data base such as EXCEL.
Ready rekoner books for data: Recommendation: Ready rekoner books of

100-150 pages need to be brought out by the TPS for each unit for all major
operating parameters in sufficient copies and distributed to operation and
maintenance staff.
Capture and dissemination of operational knowledge: Knowledge capture,

recording, transferring are the most important aspects for operational processes.
Multimedia based knowledge management system is of great help in this
context. The system requires a well documentation, recording & multimedia support
which can yield most cost effective training results for the operations sections.
Development of a knowledge centre will be a good move for long term benefits of
the TPS. Recommendation: Setting up of infrastructure for capture of operational
knowledge including simulating faults through video recording and replay on LCD
screen. Video and LCD projectors may be procured for specific purpose of
22
operational capture, documentation and transfer among the operators. The areas of
knowledge capture in operations are as follows:
Cold start boiler side activities venting / draining and

other activities)
Cold start turbine side activities
Auxiliary preparation an manual operation
Oil gun preparation
Auxiliary changeover (with dos & donts)
TGA analysis of the coal as an operational aid: (Thermo gravimetric analysis)

TGA analysis of coal is a good operational aid. The combustion characteristics are
not dependent on the GCV alone but on the percentage of volatiles. If the volatiles
are too low in the coal then even though GCV is high its combustion characteristics
are retarded and maintaining the fireball is problematic. On the other hand, if the
volatile content is too high then pre-combustion occurs before entering the furnace
in the coal pipe itself if the coal air mixture temperature is around 90 C. This
information can also be used to ascertain that the flame temperature is appropriate
for a given coal. This analysis must be done before the coal goes to the bunker so
that the operator is well aware of the combustion characteristic during the shift. It is
clarified here that obtaining a TGA after the combustion is over is only of academic
interest and does not provide the operator with any inputs for operational
optimization. This will be useful when there is over 3 days coal stocks if coal yard
coal is taken. If bunker coal is used then it needs to be around 6 hours in advance.
Energy management systems: On line energy monitoring systems which includes

software and sensors can be useful for measurement of electrical energy,
measurement and monitoring of performance of auxiliaries in terms of efficiency as
well as specific energy consumption. Other benefits include energy balancing, data
trending and online feedback on performance deterioration of major and selected
minor auxiliaries. Quantification of losses and establishment of baselines are
possible. Recommendation: Energy management system is a useful tool for
monitoring and control of auxiliary power of in-plant and outlying major auxiliaries.
8.2 Maintenance practices
Some of the best practices followed are as follows:
i. Valve Wide Open Operation of Turbine to eliminate throttling noises.

ii. Energy conservation measures.
iii. Cross Functional Teams for improvement of plant performance viz., Heat rate,
auxiliary consumption, occurrence analysis, resource conservation (water,
steam etc).
iv. Bench mark outage time.
23
v. Corporate Social Responsibility

vi. Institutionalization of Business Excellence Model.
8.2.1 Day to day maintenance
i. Water/steam leaks: Drain water leakages are seen at few places.

These must be minimized.
ii. Valves: In-between two overhauls, boiler and turbine side valves some
times develop gland leaks or stem leaks.
8.2.2 Annual and capital overhauls
Unit Age Expected Actual Expected Actual

No. No. of No. of No. of No. of
AOH AOH COH COH
3 9 7 7 2 2
The Unit which has undergone 9 years of service has undergone 7 annual overhaul
(AOH) and 2 capital overhauls (COH) against their designated 7 AOH and 2 COH.
Overhauls are a part of the asset management process and their optimization is
required. The general practice is to go in for AOH every year for a period of 24-26
days and COH once in four years. Other patterns of overhauls are also being
followed such as a long AOH once bi-annually, or short AOH once every 8 moths,
etc. Normally, overhauls must be scheduled and done as per schedules and must
not be delayed by over 2 months. The maintenance planning must be oriented to
achieve the COH & AOH as per schedule. Recommendation: The overhaul pattern
may be reviewed and the optimal pattern may be established as there is scope for
further optimization. The overhauls must be so organized that the asset
management is optimized (asset value is preserved) and the TPS gets maximum
benefit in terms of restoration of UHR from the overhaul and also prevention of
leaks and damage in-between overhauls.
The major works undertaken during the COH are the overhauling of the turbine
modules and partial replacement of pressure parts like ECO, LTSH, water wall tubes,
etc.
8.2.4 Recommended maintenance practices

KAIZEN for maintenance: KAIZEN is a Japanese word which means gradual,
orderly and continuous improvement with minimal investment. Kaizen is
ongoing process focusing on elimination of waste in all systems of an organization.
Kaizen has two elements viz., improvement\change for betterment and continuity.
The three functions -Maintenance, Innovation and KAIZEN should occur in an
organization simultaneously as follows:
24
i. Maintenance refers to smooth functioning of current status, setting up

of procedures and implementation of standards. Usually Artisans and
technicians of the organization are responsible for maintenance.
ii. Innovation are a break through routine and run of the mill activities
such as buying new machines, major renovation of machines, etc
iii. Kaizen is an intermittent function involving small steps but with
continuous betterment. The actual working is expected from workers
(technicians and Artisans) and lower management (Supervisors) but
mandate and encouragement of upper management (Station head and
General Managers) with facilitation from middle management
(Executives and Superintendents) is essential.
iv. It is believed in Japanese management that managers should spend
50 % of their time in making improvements.
Recommendation: KAIZEN is recommended for identifying wastes and long

term sustainability of the organization.
Maintenance procedure documentation: Work instructions for maintenance are

well documented. The maintenance procedures and data recording on routine
maintenance, AOH and COH along with breakdown maintenance procedures are in
order and well maintained. The quality of the documents is good but can be
improved and made more systematic over the next two years with very little effort.
Also the formats can be standardized for all plant equipment or class of equipment.
Capture and dissemination of tacit maintenance knowledge: Knowledge

capture, recording, transferring are also important for maintenance processes.
Recommendation: Setting up of Multimedia based knowledge management
infrastructure for capture of maintenance knowledge through video recording and
replay on LCD screen. Video and LCD projectors may be procured for specific
purpose of operational capture, documentation and transfer among the operators.
The areas for knowledge capture are:
Maintenance side (Mechanical)
Valve maintenance (Gland replacement, overhaul, quality checks)
Coal mill maintenance
Coal mill lube oil system maintenance
Pump maintenance
Boiler tube leakages ( Reason-wise programs)
Lubricant replacement
Maintenance side (Electrical)
Motor testing & Quality checks
Zirconia O2 sensor calibration
Meter replacement
Relay testing
Charging procedure of Transformer
Maintenance side (control & instrumentation)
25
Valve, Damper, IGV : Actuators maintenance (I/P convertor, positioner

feedback transmitter checks)
Primary Sensor Checks (Temp. RTD,T/C, Level etc.), site Instruments
checks (Press. gauges, Temp. gauges, switches, etc.)
Analyzers Operation checks (O2,CO, Opacity,etc. )
Transmitters, Converters operation checks (pressure, temp., flow, level,
etc)
Control circuit & electronic cards checks. Indicators, Recorders, meters
operation checks.
Standardization of routine maintenance processes: Maintenance work should

governed by maintenance standards and these are to be developed by the
managers with involvement of workers and (a) include industry and operating
experience with reference to national and international standards (b) provide
guidance for more definitive documents which govern maintenance activities. At
present only work plans are documented through Enterprise Process manual (SAP)
but not standardized. Recommendation: The development and implementation of
the standards must be made mandatory for all major maintenance works.
Measurement of maintenance performance: Maintenance data is presently

being measured through SAP ERP.
Material up gradation considerations during procurement of spares:

Recommendation: While procuring replacement spares, material up gradation and
new technology options such as bimetal extrusions, coated tubes, internally ribbed
tubes, etc., must be kept in mind instead of old time tested spares.
Vendor development in critical areas: Recommendation: The boiler and

turbine maintenance must initiate vendor development either through Vendor-TPS
meet or other mechanisms for identification of competent vendors in the areas of:
HVOF coating
Martensitic steel materials
Reverse engineering for problematic or obsolete components with difficult to
get or spares
Computational fluid dynamics (CFD) solutions to hydrodynamic and heat
transfer related re-engineering problems.
Computational electromagnetics (E-MAG) solutions to electrical machine
design and re-engineering problems.
Erosion and corrosion resistant materials
Software resources
Innovative maintenance practices: The innovative maintenance practices must

be documented and shared to all concerned.
Maintenance budgeting: The budgeting process is based on historical trends of

previous budget along with a cost index for price rise.
26
Long term rate contracts for better inventory management:

Recommendation: For many items long term rate contract (3-5 years) with price
escalation formulae can be entered into by one TPS to minimize inventory levels.
These contracts may also be made applicable to other TATA stations (as per terms
of contract with the vendor) so that the duplication or efforts of processing can be
eliminated at other stations. Long term contracting having the following features
shall strengthen the inventory management system leading to a win-win situation:
Assured business-committed yearly quantities
Minimum inflation risks: Price variation (on both sides) with clauses linked to
basic raw material /key ingredient cost based on national /market
/international /exchange prices can be fixed.
Penalty for delay and incentive for early supply against pre-defined delivery
periods.
Timely payment with cash discount for early payment and interest for delay
payment.
Well defined contract termination applicable to both parties clarifying notice
period and amount.
In case contract is with authorized dealer/stockist, backing of OEM/OES for
quality and quantity assurance.
Exclusively defined taxes and levies, so as to get free float.
Role of cleanliness as a maintenance procedure: It is now recognized that

cleanliness of each and every equipment plays a far more serious role than envisage
earlier. Though thorough cleaning of equipment either with water or air may
temporarily hamper other maintenance jobs, it is now recognized that cleanliness
plays a vital role in the long run in the form of secondary damage control. Pipe
conveyors are being used to prevent fall out of coal from conveyors.
Recommendation: Air washer units (5 nos/unit) are installed for improvement in

dust cleanliness. Passively powered turbo vaned flywheeling eco ventilators
with no electrical consumption may be used for expelling the air from the turbine
halls.
Condition monitoring group: Successful condition monitoring can bring down

maintenance costs by making a distinction between defective equipment and
excluding good equipment for maintenance. It also helps in identifying equipment
when they enter the danger zone well before they reach damage zone.
Recommendation: For realization of benefits of condition monitoring in terms of

quick identification of abnormal operation and danger zone well before it reaches the
damage zone or catastrophic zone, the following measures are required:
Step 1: A policy for organized online condition monitoring may be evolved. A

condition monitoring group which is a nuclear group for monitoring HT auxiliaries
once monthly and other auxiliaries as and when required, must be in place.
27
Step 2: Cost economical condition monitoring of the station hardware/ equipment

may be divided into four categories:
On-line monitoring and tripping on parameters outside safe range.
On-line monitoring with annunciation on parameters outside safe range.
Off-line daily monitoring.
Off-line weekly/monthly monitoring.
Recommendation: For on-line and continuous monitoring equipment SMS alert

systems may be installed to be activated only if the parameter goes out of range.
Step 3: Presently the condition monitoring group is entering the scene only when
high level of vibrations are sensed in any auxiliary such as ID fan, cooling water
pump, PA fan, etc. Recommendation: It is recommended to have a round the
clock condition monitoring group with the job responsibility of monitoring the
condition of equipment like vibrations, temperature rise, leakage levels, oil depletion,
loss of lubricant, leakage, etc., and recommend to the Maintenance Sections which
equipment needs to be attended to and give advance warning of the path to failure
well before it happens.
Step 4: Recommendation: The group must be treated as an operations group

and must not be burdened with responsibilities that will not give them time for real
full time field monitoring. The complete condition assessment responsibility must be
theirs.
Operational optimization and performance monitoring through

performance monitoring group: Operational optimization means operating the
unit at the optimal parameters. While the parameters directly affect the efficiency,
the sensitivity of other parameters is indirect and low. The operating philosophy is to
maintaining the parameters to as near the design set point parameter as possible.
Parameters such as burner tilts, minimization of RH spray, coal air mixture
temperature, oxygen in flue gas, etc., need to be brought as near the design as
practically possible.
Recommendation: Monthly performance tests are to be conducted on the

boiler and turbine, Tri-monthly mill performance tests. Also performance tests are to
be conducted on heaters, condensers, cooling towers, etc., Field instruments are
also to be available with POG for conduct of tests.
Boiler performance optimization: Since boiler is the weakest in terms of energy
efficiency boiler performance optimization is required. Recommendation: Boiler
performance optimization using Air/combustion/mill/exit gas/ash optimizer from
STORT TECH/Bacharach/KENT/ABB/Pegasus/GE, etc.
9. OVERALL SYSTEM
9.1 Test heat rate at 100 % load
The gross and net overall parameters are given in Tables 31 (Annex 2). The
deviation in efficiency and heat rate from design is given in Table 32 & 33.
28
The basis for computing the difference in heat rate is by keeping all variables at their
design value and varying only the variable accounting for the increase in heat rate.
By this process simulation the difference in heat rate is arrived at.
Unit 3
DHR 2253.7 kcal/kWh
Dev due to Boiler 48.1 kcal/kWh
Dev due to Turbine 274.8 kcal/kWh
Dev due to Generator 0.5 kcal/kWh
Test efficiency 33.4 %
Design efficiency 38.2 %
Overall difference 4.8 %
Overall difference 323.4 kcal/kWh
The observations regarding the overall system are as follows:
i. The overall design gross efficiency is 38.2 % and the overall operating
gross efficiency is 33.4 % at 100 % MCR.
ii. The design TG heat rate is 2253.71 kcal/kWh. The operating TG heat
rate (test) is 2577.10 kcal/kWh at the tested load of 100 % MCR.
iii. The deviation of the design TG heat rate from the operating Test TG heat
rate is 323.4 kcal/kWh which is attributed to 48.1 kcal/kWh due to boiler,
274.8 kcal/kWh due to turbine and 0.5 kcal/kWh due to the generator.
Thus, boiler is the equipment with maximum deviations.
9.2 Heat consumption due to steam lost to non-motive

applications represented by DM make up
This heat loss is represented by the DM water make up which represents the steam
lost from the process. Normal DM water make up is around 3 % of the main steam
flow.
The annual heat consumption for DM water make up (Q) in Mcal/h, is given by,
Q (Mcal/h) = {10-3[DM water make up (%) * Main steam flow at 100 % load
(kg/h)*(hsteam-hwater) (kcal/kg)/(boiler efficiency=0.86)] }
The power generated (considering 100 % PLF) (E) in MW is given by,
P (MW)= Unit capacity x 1.0
29
The heat rate component due to cycling and abnormal operations is given by,
Annual heat rate component due to DM water make up = HRsteam = [Q/P]
9.3 Heat consumption due to cycling/abnormal operation- start

up and shut down
This heat consumption can be computed based on the number of hot, warm and
cold starts.
The heat consumption (Mcal) for any type of start as a function of the average
resource (coal, fuel oil and DM water) consumption (averaged over an year) for that
start is given by:
Heat Consumption/start (Mcal)= 10-3{[Raw coal consumption (kg) * weighted

average GCV of raw coal (kcal/kg)] + [FO Consumption (m3) * density (kg/m3) *
GCV of FO (kcal/kg)]+ [LDO Consumption (m3) * density (kg/m3) * GCV of LDO
(kcal/kg)] + [DM water consumption (m3) * density (kg/m3) *(hsteam-hwater)
(kcal/kg)/(boiler efficiency=0.86)] }
The annual heat consumption for cycling operations (Qc) in Mcal/year, is given by,
Q (Mcal/year) = {[Qhot start (Mcal) x number of hot starts/year]+ [Qwarm start (Mcal) x
number of warm starts/year]+ [Qcold start (Mcal) x number of cold starts/year]}
The annual energy generated (considering 100 % PLF) (E) in MWh is given by,
E (MWh/year)= Energy generated = Unit capacity x 8760 x 0.8
The heat rate component due to cycling and abnormal operations is given by,
Annual heat rate component due to cycling and abnormal operations =

HRcycling = [Qc/E]
9.4 Additional heat consumption due to year round variations in

environmental and fuel parameters from test values
This is the algebraic sum of the difference between the test heat rate of the station
in the month of CPRI test and the individual test heat rates or every month over the
year. In case, in the month of test, the heat rate is the highest or higher than the
standard deviation, seasonal variation is taken as zero.
HR seasonal variation = UHR test month and other months
9.5 Accounting of mill rejects

This is taken as,
30
HR reject= {(Reject production (% of coal through mill)) * weighted average GCV of

Raw coal (kcal/kg)* SFC (kg/kWh))}
9.6 Accounting of heat loss in piping in-between boiler and

turbine
This is taken as,
HR MS, RH piping = {* (Running length of piping (m)) * (diameter of piping coal

(m))* (convective and radiative heat transfer rate (natural convection)
(kcal/hm2C))* (Tpipe ( C )}/E
The actual formulae are worked out in EXCEL sheets.
9.7 Overall annual unit heat rate assessment
9.7.1 Computation of annual unit heat rate
In the present study the annual heat rate is computed as follows:
Test heat rate based on actual performance test under conditions of zero
make up and zero auxiliary steam consumption.
Heat consumption translated into a heat rate component due to steam

consumption for non-motive applications which is reflected in terms of DM
water make up.
Heat consumption translated into a heat rate component due to cycling or

abnormal operations like hot, warm and cold starts.
Heat consumption translated into heat rate components due to deviation in

test parameters all though the year (positive and negative deviations).
Energy components to account for reject coal at the mill. This is because the
coal entering the bunker is considered as entering coal and GCV of the
bunkered coal is taken. The component due to mill ejects is to be subtracted.
The unit heat consumption is computed considering all the above which portrays
the realistic heat consumption vis--vis the energy generated.
The heat rate credit is added algebraically to the unit heat rate in computing the
annual unit rate assessment.
31
The annual heat rate therefore considers the seasonal variations, the cycling heat
requirements (due to hot/warm/cold starts), the energy components in rejects and
the heat lost in MS & RH piping. The basic data on DM water, rejects, resource
consumption in various types of starts, heat losses in piping between boiler and
turbine and calculations of the heat rate component based on these are given in
Annex 3 in the form or reproduction of the original EXCEL sheets.
Unit 3
Test Efficiency 33.4 %
HR-Seasonal dev 0 kcal/kWh
HR-Cycling dev 26.00 kcal/kWh
HR-Dev DM 29.49 kcal/kWh
HR-Dev-rejects 8.04 kcal/kWh
HR-Dev-MS& RH pipe 2.7 kcal/kWh
Annual unit HR 2643.3 kcal/kWh
Annual Efficiency 32.5 %
The following is to be noted from the above annual UHR components:
i. In the cyclic deviations the hot/warm/cold starts is taken as 5/3/2 and

the energy components are taken as 1/2/3 kcal/kWh for each type of
start. The total deviation due to starts is quite low and well within
limits and there is no possibility for reducing this further.
ii. The loss due to rejects is also within limits as rejects are only 0.2 % of
the total coal and well within the 1 % limit. Hence no further
optimization is possible on this count.
iii. The loss due to DM make up is also well within limits. The DM make up
is 1.0 % of the MS flow and much lower than the limit of 3 % and
hence no further optimization is possible.
9.8 Categorization of remedies for improvement of the

parameters
9.8.1 Immediate heat rate improvement (over a 12 month period)

The immediate objective of the heat rate improvement program of the Station is to
contain the degradation trend and keep the performance parameters steady over the
whole year.
Some of the measures to be achieved are as following:
i. Operational optimization of parameters. Presently there is no online

performance software for tracking and optimization of operational
parameters. The same may be installed and used.
32
ii. Proactive round the clock involvement of Performance Optimization Group

and Condition Monitoring Group in control of plant parameters. Field
instruments for performance monitoring may be procured and tests may be
conducted on the unit. Monthly performance tests are recommended to
reconcile the values of heat rates to be declared.
iii. Replacement of selected old brass impeller pumps with SS impellers.
iv. Maintaining 100 % availability of all feed water heaters and heat recovery
condensers.
v. Cleaning of feed water heat tube nests and heat exchangers; and
replacement of self cleaning strainers.
vi. Modification of ID fan blading with aerodynamic profile and with hard weld
overlays.
vii. Passively powered eco ventilators.
viii. Retrofitting of VFDs for selected pumps.
The immediately achievable TG heat rate reduction for this unit is 10 kcal/kWh.
9.8.2 Medium term heat rate improvement (over 2-3 year period)
The medium term measures are as the following:
i. Furnace exit gas temperature and CCTVs for boiler firing elevation
viewing from the control room.
ii. Smart soot blower system for steam economy.
iii. Furnace skin insulation replacement.
iv. Energy efficient pumps especially BFPs, CWPs and CEPs.
v. Improvements in milling systems
The TG heat rate reduction achievable under medium term scenario for this unit is
10 kcal/kWh.
9.8.3 Long term heat rate improvement (over 5 year period and further)
In the long term scenario of 5 years and over future the heat rate can be brought
down through extensive R & M of the units. The major replacements already done
and proposed are given above under the section on major replacements done and
proposed.
33
The major R & M works envisaged for long term improvement are as follows:
i. IP and LP turbine retrofits with 3-d blading.
ii. Partial replacement of superheater coils.
iii. Up gradation of the existing DCS with additional capacity of data storage,
engineering station, work station and data highway including FSSS, alarms
and MIS.
It is mentioned here that since long term measures are cost intensive, all easier
avenues of operational optimization, good housekeeping and wastage reduction
must be used to the optimal extent.
The TG heat rate reduction achievable under long term scenario for this unit is 25
kcal/kWh.
9.9 Degradation of unit heat rates
9.9.1 Degradation of the commercial unit heat rate (UHR) as computed by

the station
The comparative chart of the degradation of the UHR with the commercial heat rate
as declared by the TPS is as follows:
Comparison of TG HR as per std degradation rates and actual values reported by

TPS
Year FY Design Years % Degraded % %

Heat Rate Heat Rate at 0.4 Degraded degradation
(DHR) % Heat of actual
(kcal/kWh) Rate at heat rate
0.7 %
2009-10 2253.7 10.0 4.0 7.0 17.50
2008-09 2253.7 9 3.6 6.3 15.01
2007-08 2253.7 8 3.2 5.6 18.74
2006-07 2253.7 7 2.8 4.9 10.97
Degradation rate at 2009-10 kcal/kWh/year 39.43
%
Degradation rate at 2009-10 degradation/year 1.75
34
Comparison of CPRI TG test HR as per std degradation rates and actual values
Year Design Years % Degraded HR % %

FY Heat Rate at 0.4% Degraded degradation
(DHR) HR at of actual
(kcal/kWh) 0.7% TG HR
2009- 2253.7
10 10 4.0 7.0 14.35
Degradation rate at 2009-10 kcal/kWh 32.34
%
Comparison of CPRI test annual UHR with std degradation rates
Year Design Years % Degraded HR % %

FY Heat Rate at 0.4% Degraded degradation
(DHR) HR at of actual U
(kcal/kWh) 0.7% HR
2009- 2253.7
10 10 4.0 7.0 17.29
Degradation rate at 2009-10 kcal/kWh 38.96
%
The degradation of the station commercially declared UHR is 17.50 % over design
UHR. The degradation rate is 1.75 %/year which works out to 39.43 kcal/kWh per
year.
9.10 Trajectories and projections
The trajectories are given on the following basis:
35
Experimental test annual UHR (snap shot test UHR + factors to account for annual
effects) + [degradation rate based on 0.4 %/year of DHR] + [improvements due to
short term, medium term and long term measures]
FY UHR achieved Test UHR with Test UHR with degradation

by TPC-G degradation + improvements
kcal/kWh kcal/kWh kcal/kWh
2006 2539
2007 2501
2008 2676
2009 2592
2010 2648
2011 2643 2633
2012 2652 2642
2013 2661 2651
2014 2670 2645
2015 2679 2654
2016 2688 2663
Figure: Trajectories based on test annual UHR-coal firing

for Unit 3 of TPC-G
2680
2650
Annual UHR
(kcal/kWh)
2620
-coal
2590
2560
TPC-G achieved
2530 Test UHR + degradation
Test UHR+ degradation+improvements
2500
2006 2008 2010 2012 2014 2016 2018
FY
36
10.CONCLUSIONS
The main conclusions of the study are as follows:
i. The gross overall efficiency of the Unit 3 TG set is 33.4 % against the
design efficiency of 38.2 %. The gross overall TG heat rate (TG HR) is
2577.1 kcal/kWh at the test load of 100 % as compared to the design
heat rate of 2253.7 kcal/kWh.
ii. The deviation in the test TG heat rate is 323.4 kcal/kWh which can be
attributed to 48.1 kcal/kWh due to the boiler, 274.8 due to the turbine and
0.5 kcal/kWh due to the generator. Hence the turbine is the component
leading to maximum losses.
iii. The annual unit heat rate (UHR) considering all factors such as PLF, DM
make up, rejects, energy consumption in starts, etc. is 2643.3 kcal/kWh for
Unit 3. This annual UHR represents the annual heat consumption of the unit
considering all annual realistic factors.
iv. Immediate measures include operational optimization of parameters such as

mill fineness optimization, coal flow equalization, etc. Fine tuning of
parameters, parameter setting and parameter trending, reduction of steam
and air leaks, etc., would help in operational optimization. Procurement of
field instruments for performance monitoring and condition monitoring is
required. Cleaning of internals of pressure parts, condenser, feed heaters
and coolers is also envisaged as an immediate measure.
v. Medium term measures include smart soot blowing system, insulation,

VFDs for pumps and fans, heat recovery devices and heaters; energy
efficient BFPs, CEPs and CWPs, furnace exit gas temperature measurement,
etc..
vi. Long term measures include waste heat recovery boiler, IP & LP turbine
retrofits with 3-d blading & up gradation of DCS.
vii. The investment in immediate, medium term and long term measures works
out to Rs. 562, 440 & 3600 lakhs respectively. The total cost is Rs. 0.38
crores/MW.
viii. The degradation of the station commercially declared UHR is 17.50 % over
design UHR. The degradation rate is 1.75 %/year which works out to 39.43
kcal/kWh per year.
ix. Trajectories of unit heat rate is provided on the basis of test snapshot heat
rate with factors for annual effects and annual degradation rate of 0.4% of
DHR. About 9 kcal/kWh/year degradation in UHR is predicted based on the
37
test snap shot and improvements due to short, medium and long term
measures.
****************
38
Vol. 1 Jojobera Unit No 3 Annex 1 CPRI Report TPC-G
Annex 1
(Figures, Graphs & Photographs)
1
A 1-1: UNIT PERFORMANCE
Plant load factor v/s years
100
90
80
70
60 2008
PLF (%)
50 2009
40 2010
30
20
10
0
APR MAY JUN JUL AUG SEP OCT NOV DEC JAN FEB MAR
Months
Availabilty factor v/s Years
120
100
Availabilty factor
80
2008
60 2009
2010
40
20
0
Months
2
Auxiliary consumption (%) v/s Years
14
12
Auxiliary consumption (%)
10
8 2008
2009
6 2010
0
Months
Specific coal consumption (kg/kWh) v/s Years
0.88
Specific coal consumption (kg/kWh)
0.86
0.84
0.82
0.8 2008
0.78 2009
0.76 2010
0.74
0.72
0.7
0.68
APR JUN AUG OCT DEC FEB
Months
3
Specific fuel oil consumption (ml/kWh) v/s Years
Specific fuel oil consumpton (ml/kWh) 14.0
12.0
10.0
8.0 2008
2009
6.0 2010
4.0
2.0
0.0
Months
UHR (kcal/kWh) v/s Years
3100
3000
2900
UHR (kcal/kWh)
2800
2008
2700
2009
2600
2010
2500
2400
2300
2200
Months
4
2
y = -0.0155x + 2.782x - 24.199
2
R = 0.9471
Availiablity factor v/s PLF
120.00
100.00
Avaliablity factor
80.00
60.00
40.00
20.00
0.00
0 10 20 30 40 50 60 70 80 90 100
PLF (% )
y = -0.004x + 10.674
2
Auxiliary consumption v/s PLF R = 0.0191
14
12
10
PLF(%)
0
0 10 20 30 40 50 60 70 80 90 100
Auxiliary consumption (% )
5
2
y = 3E-06x - 0.0011x + 0.8549
2
R = 0.2252
Specific coal consumption v/s PLF
0.88
Sp. coal consumoption (kg/kWh)
0.86
0.84
0.82
0.80
0.78
0.76
0.74
0 10 20 30 40 50 60 70 80 90 100
PLF (% )
2
y = 0.0029x - 0.4844x + 20.926
2
R = 0.9307
Specific fuel oil consumption v/s PLF
14
Sp. fuel oil consumption (ml/kWh)
12
10
0
0 10 20 30 40 50 60 70 80 90 100
PLF (% )
6
2
y = 0.0368x - 8.1995x + 3054.1
2
UHR v/s PLF R = 0.3977
3000
2950
2900
2850
2800
PLF (%)
2750
2700
2650
2600
2550
2500
0 10 20 30 40 50 60 70 80 90 100
UHR (kcal/kWh)
7
Annex 2
(Tables and Charts)
1
Table 1: Design rating of major equipment (100 % MCR)
Sl. No. Particular of equipments Units Unit 3
01 Boiler
Steaming rate t/h 352.2
Boiler efficiency % 87.03
02 Turbine
Electrical output rate MW 120
Specific steam consumption t/MWh 2.935
Turbine efficiency % 44.46
Turbine heat rate kcal/kWh 1934.53
03 Turbo Generator
Turbo generator efficiency % 43.85
Turbo generator heat rate kcal/kWh 1961.4
04 Generator
Electrical output rate MW 120
Generator efficiency at unity power factor % 98.63
Table 2: Design rating of the TPC-G Unit No. 3 (100 % MCR)
Sl. Particular Units Unit

No. 3
01 Unit installed capacity MW 120
02 Unit de-rated Capacity (present) MW 120
03 Gross over unit efficiency % 38.16
04 Unit design heat rate kcal/kWh 2253.47
05 Station capacity (present) MW 547.5

06 Station heat rate kcal/kWh NA
2
Table 3: Details of the boiler and its auxiliaries-1.
Sl.
Particulars Details
No.
01 Type Outdoor, two pass, pie type, radiant, Natural
circulation, balanced draft, dry bottom ash,
single drum, corner fired fusion welded water
walls.
02 No. of boilers per 1
turbine
03 Fuel used
Primary Coal / Oil
Secondary HFO
04 Fuel firing equipment
Type of fuel firing Direct corner firing
Type of coal mills XRP 783 Raymond Bowl mill, 36.5 t/h per mill,
442 kW motor
No. of coal mills 5/3 (total/ service)
Type of coal burners Coal Tilting Tangential Burners
Load per coal burner 8.33 % MCR per burner, 9.125 t/h
No. of coal burners 20/12 (total/service)
No. of coal elevations 5
Type of oil burners HFO, BHEL make
No. of oil elevations 3
No. of oil burners 12
05 Soot blowers Wall Blowers, Long Retractable Soot Blowers
Furnace zone 40 Nos., Wall blower, Medium used -
Steam
Platen, Convection and 20, Long retract, Medium used Steam
Reheater and ECO zone
06 Steaming capacity 352.2 t/h
07 Steam pressure
SH outlet 130.7
Drum pressure 140.8 kgf/cm2
Reheater outlet 28.78 kgf/cm2
08 Steam temperature
SH outlet 540 C
Reheater outlet 540 C
09 Heater types
3
Economiser Plain tube

Superheaters Low temp super heater, Platen super heater,
Spaced Final super heater
Air heater type Tubular Pri- 3 blocks, Sec- 6 blocks
Desuperheating Spray
10 Boiler efficiency 87.03% (design)
11 Boiler aux. (Fans)
ID fans NDZV 26 SIDOR BHEL
FD fans AP1 17/11, BHEL
PA fans AP2 17/12, BHEL
12 Auxiliary steam Gland steam, oil heating, fuel oil atomization
at burners, soot blowers, steam tracing lines of
fuel oil lines
4
Table 4: Details of the boiler and its auxiliaries-2.
SL. Description Units Unit-3

1.0 Steam Generator
Nos 1
Make BHEL
Type Pulverized fuel fired,
Corner fired, single
drum
Circulation Natural
Draft Balanced
Furnace bottom Wet
Max. continuous rating: 100% BMCR t/h 390.0
100 % TMCR t/h 352.2
Pressure at Super heater outlet kg/cm2 130.7
Temperature at SH outlet C 540
at RH outlet C 540
Flue gas temp at Air-heater outlet C 139
Guaranteed Boiler efficiency at
GCV % 87.03
1.1 Air Pre-heaters
Type Tubular
Nos PAPH 1 No.
SAPH 2 Nos.
1.2 Milling Plant
Mills
Type Raymound bowl mill
XRP 783
Nos. Working / Standby 3/2
Capacity per mill t/h 36.5
PA fans
Nos 2
Type AP 2 17/12
Capacity m3/s 44.26
Pressure mmWC 1179
Motor rating kW 675
Speed rpm 1480
1.3 Draft Plant
ID fans
Type NDZV 26 Sidor
Nos: Working/Standby 2 / Nil
Capacity m3/s 127.6
Pressure mmWC 360
Drive : Fixed / Variable speed Fixed
5
Electric capacity kW 680

Speed rpm 740
FD fans
Type API-17/11
Nos. 2
Capacity m3/s 75.83
Pressure mmWC 487
Electric rating kW 480
Speed rpm 1480
Heat Balance
100 % 100 % 60% 100 % TMCR
Losses unit BMCR TMCR TMCR with HPH out
Dry Gas % 4.23 4.19 3.49 3.53
H2O & H2 in Fuel % 6.15 6.14 6.06 6.07
H2O in Air % 0.13 0.13 0.10 0.10
Unburnt Carbon % 1.10 1.10 1.10 1.10
Radiation & Unaccounted % 1.18 1.21 1.36 1.12
Manufacturers Margin % 0.20 0.2 0.20 0.20
Total Losses % 12.99 12.97 12.31 12.12
EFFICIENCY % 87.01 87.03 87.69 87.88
6
Design Fuel Composition

Description Unit Value
Proximate Analysis
Fixed Carbon % 21.2
Volatile Matter % 21.8
Moisture % 12
Ash % 45
Grindability Index HGI 55
Higher Heating Value kcal/kg 3350
Size Of Coal to Mill mm 25
Ultimate Analysis
Carbon % 35.11
Hydrogen % 2.36
Sulphur % 0.6
Nitrogen % 0.64
Oxygen % 4.29
Moisture % 12
Ash % 45
Fuel Burning
Equipment
Type Oil Burner
Make & Nos BHEL:12
Capacity 22.5 % SGMCR
Disposition Corner
Furnace Volume 2663 m

Heating Surface
Area
Water Walls 1871m
Low Temp Super
Heater 3046 m
Platen Super Heater 513 m
Final Super Heater 352 m
Reheater 1470 m
Economiser 4607 m
Secondary Air Heater 21370 m
Primary Air Heater 11575 m
7
Predicted Performance
Description Unit 100% 100% 60% 100% TMCR
Flow BMCR TMCR TMCR with HPH out
Steam
Superheater Outlet t/h 390 352.2 212.6 333.7
Reheater Outlet t/h 320 301.8 185.1 316.7
Water
Feed Water t/h 401.7 352.2 212.6 343.7
SH Spray Stage-1 t/h 0 0 3.9 6.8
Stage-2 t/h 0 2.3 2.2 3.3
Air
Air Heater Outlet- Primary t/h 135 125.6 90.9 144.6
Air Heater Outlet- Secondary t/h 299.1 257.6 141.2 273
Tempering Air t/h 17 21.3 4.9 4.2
Total Combustion Air(including
Leak) t/h 491.4 448.4 277.3 462.1
Fuel
Coal(HHV-3350 kcal/kg) t/h 90.4 81.8 51.1 83.6
Gas
PAH Outlet t/h 167.2 158.9 117.1 173.3
SAH Inlet t/h 373.8 330.6 188.1 335.2
PAH Outlet t/h 167.2 158.9 117.1 173.3
SAH Outlet t/h 373.8 330.7 188.1 335.2
Temperature
Steam
Saturation Temp in Drum C 337 336 331 336
LTSH outlet C 424 426 419 438
Platen SH inlet C 424 426 407 423
Platen SH outlet C 522 528 535 530
Final SH inlet C 522 521 525 520
Final SH outlet C 540 540 540 540
RH inlet C 334 333 322 344
RH outlet C 540 540 540 540
Water
Economiser inlet C 235 234 212 188
Economiser outlet C 287 286 268 260
Air
Ambient C 33 33 33 33
AH outlet(Primary) C 277 274 244 250
AH outlet(Secondary) C 274 273 246 250
Gas
Leaving Furnace C 981 973 891 969
Entering Platen SH C 1082 1070 1012 1070
Leaving Platen SH C 981 973 891 969
Entering Reheater C 981 973 891 969
Leaving Reheater C 765 754 671 755
8
Entering LTSH C 664 642 566 644

Leaving LTSH C 464 456 412 460
Entering Economiser C 464 456 412 460
Entering Airheater C 305 298 262 285
Leaving Air Heater C 140 139 122 121
At Stack Entrance C 136 136 122 121
Pressure (Steam & Water)
Superheater MSSV outlet kgf/cm 131 130.7 128 131
LTSH outlet kgf/cm 140 138.3 131 138
Drum kgf/cm 143 140.8 132 140
Economiser Valve Inlet kgf/cm 146 143.5 134 143
Reheater Outlet kgf/cm 30.2 28.78 17.4 30.1
Reheater inlet kgf/cm 31.7 30.15 18.2 31.5
Pressure Drop
Superheater System kgf/cm 12.2 10.1 3.99 9.14
Reheater System kgf/cm 1.5 1.37 0.82 1.37
Economiser System kgf/cm 2.84 2.64 2.23 2.6
Pressure & Drafts (Air & Gas)
Primary Air
PA Fan Inlet mmWC 285 244 149 256
PA Fan outlet mmWC 882 834 757 870
Airheater Inlet mmWC 862 815 749 851
Airheater Outlet mmWC 750 716 693 728
Mill Inlet mmWC 639 606 587 618
Mill Outlet mmWC 260 239 227 247
Secondary Air
FD Fan Inlet mmWC -17 -14 -5 -15
FD Fan Outlet mmWC 300 259 156 271
Airheater Inlet mmWC 274 238 148 248
Airheater Outlet mmWC 141 134 112 136
Windbox Pressure(at inlet) mmWC 100 100 100 100
Gas
Furnace mmWC -4 -4 -4 -4
SH Platen inlet mmWC -4 -4 -4 -4
Reheater Inlet mmWC -5 -5 -5 -5
LTSH inlet mmWC -11 -10 -6 -10
Economiser Inlet mmWC -23 -20 -10 -21
Airheater Inlet mmWC -47 -40 -18 -43
ESP Inlet mmWC -127 -109 -60 -112
ID Fan Inlet mmWC -178 -154 -88 -159
ID Fan Outlet mmWC 20 16 6 18
9
O2, CO2 (Dry Volume), Excess Air

O2 in Gas at Economiser outlet % 3.56 3.56 3.56 3.56
CO2 in Gas at Eco outlet % 15.5 15.5 15.5 15.5
Excess Air in Gas at Eco outlet % 20 20 20 20
Heat Balance
Losses (As per ASME PTC 4.1)
Dry Gas % 4.23 4.19 3.49 3.53
H2O and H2 in Fuel % 6.15 6.14 6.06 6.07
H2O in Air % 0.13 0.13 0.1 0.1
Unburnt Carbon % 1.10 1.1 1.1 1.1
Radiation and unaccounted % 1.18 1.21 1.36 1.12
Manufacture's Margin % 0.20 0.2 0.2 0.2
Total Loss % 12.99 12.97 12.31 12.12
Efficiency (Bases on HHV) % 87.01 87.03 87.69 87.88
Material
Boiler Drum SA270 GR70
Water Wall Tubes SA210 Gr.C
Inlet of All Super Heaters P11,T11 1.25 Cr,1Mo (Medium Alloys)
and Reheaters
Just Before the outlet of P22,T22 2.25 Cr,1 Mo (High Alloys)
Super Heaters & Reheater
Outlet of Super heaters P91, T91 12% Cr
and Reheaters
Soot Blowers
Wall Blowers 40 Nos
LRSB(For SHs, RH And
Eco) 20 Nos
MILL AND BURNER PERFORMANCE

100% 100% 60% 100% TMCR
BMCR TMCR TMCR (HPH Out)
Mill Type XRP-783
No. of Mill in operation Nos. 3 3 2 3
Mill Loading % 83 74.8 70 78
Air Flow per Mill t/h 51 48.95 48 50
Air Temperature at Mill Inlet C 251 242 234 244
Mil Outlet Temperature C 66-90
Fineness % (thro' 200 mesh) % 70 70 70 70
Burner Tilt Degree -19 0 17 -5
Burner Elevation in operation C, D, E C, D, E C&D C, D, E
10
MILLS
Type Bowl Mill - XRP 783
Make & Nos BHEL: 3
Capacity 36.5 t/h
Motor kW 300
System Pressurized Booster Cold PA
FD Fan 2 Nos
Make BHEL
Type AP1 17/11 - Axial Flow
Capacity 75.83 m/s
Specific Weight 1.04 kg/m
Total Head 487 mmWC
Speed 1480 rpm
Design Air Temp 50 C
Control Blade Pitch
Fan Reserve
Flow 34.90%
Pressure 64.88%
FDF MOTOR
Make BHEL
Rating 480 kW
Current 52 A
Insulation Class F
PA Fan 2 Nos
Make BHEL
Type AP2 17/12 Axial Flow
Capacity 44.26 m/s
Total Head 1179 mmWC
Speed 1480 rpm
Control Blade Pitch
Fan Reserve
Flow 47.60%
Pressure 97.40%
PAF MOTOR
Make BHEL
Rating 675 kW
Current 71 Amps
Insulation Class F
11
ID Fan 2 Nos
Make BHEL
Type NDZV 26 SIDOR
Orientation 45C Inclined Suction
Capacity 127.6 m/ s
Total Head 360 mmWC
Speed Variable
Control IGV and Scoop
Fan Reserve
Flow 42.30%
Pressure 81.80%
IDF MOTOR
Make BHEL
Rating 680 kW
Current 79 A
Speed 740 rpm
Insulation Class F
ID FAN HYDRAULIC COUPLING
Make Voith
Rotation CCW viewed in the direction of the power flow.
Scoop Tube Stoke 242 mm
Motor Speed 740 rpm
Sleep 3.10%
Turbo Coupling Speed 717 rpm
Regulating Range 05:01
Oil Tank Capacity 650 litre
12
Table 5: Details of the turbine and its auxiliaries-1.
Sl. Particulars Details- Unit 3
No.
01 Type BHEL design, Three cylinder, throttle
governing, multi stage, reaction,
tandem compound, single flow with
six uncontrolled extractions
02 Electrical capacity 120 MW
03 Steam flow
Turbine inlet 355.6 t/h
04 Steam paths in the turbine
HP turbine Single flow, 25 reaction stages
IP turbine Single flow, 19 reaction stages/flow
LP turbine Double flow, 2x9 reaction
stages/flow
05 Steam temperature
HP turbine inlet 540 C
IP turbine inlet 540 C
LP turbine outlet 46.4 C
06 Steam pressure
HP turbine inlet 127.0 Kg/cm2
IP turbine inlet 28.80 Kg/cm2
IP turbine outlet 4.16 Kg/cm2
Turbine outlet 0.1060 Kg/cm2
07 Feed water heaters
HP 2
LP 3
Deaerator (open feed heater) 1
Heat recovery devices Yes
Gland steam condenser Yes
Stack steam condenser Yes
(condenser flash tank)
Vent steam condenser Yes
08 Turbine-generator Efficiency 44.46 %
09 Turbine-generator heat rate 1934.53 kcal/kWh
10 Turbine efficiency 43.85%
11 Turbine heat rate 1961.40 kcal/kWh
13
12 Condenser type Shell and tube surface type

Condenser vacuum 10.60 kPa
13 Turbine auxiliary pumps
Boiler feed pump Scoop coupling,
MDBFP 3 Nos., 1515 kW
(installed/operating) 3/2
Condensate ext. pump Direct coupling, 250 kW, 2/1
(installed/operating)
Manufacturers Name Bharat Heavy Electricals Limited

Type 2 Casing , Reheat, Condensing, Tandem
Model No K-30-16 + N-30- 2*3.2
No of Steam Turbine Two(HP+IP) + Two (LP)
Efficiency Design
HP Cylinder 88%
IP Cylinder 95%
LP Cylinder 72%
DESIGN AND PERFORMANCE DATA

Max. Continuous Rating at Generator terminal at 3 %
make-up and design condenser cooling water inlet
temperature 120 MW
Turbine Rated speed 3000 rpm
Throttle Steam at HP strainer Inlet
Pressure 126kgf/ cm
Temperature 535 C
Flow 352.251 t/h
CRH Steam
Pressure 32.070 kgf/cm
Temperature 335.2 C
Flow 301.775 t/h
HRH Steam
Temperature 535 C
Flow 301.775 t/h
LP Turbine Inlet
Temperature 285.3 C
14
Flow 285.05 t/h

LP Turbine Outlet/ Condenser Inlet
Temperature 46.6 C at 0.9324
dryness factor
Flow 249.33 t/h
Max. Make-Up to Turbine Cycle (at condenser hotwell) 0.03
Steam pressure drop in the reheat circuit (HP outlet to IP
inlet) 3.27 kgf/cm
Feed water Temperature 233.6 C
Operating Frequency Range for Turbine 7 Auxiliaries 47.5-51.5
Steam Turbine Swallowing Capacity with turbine control
valve in wide open (VWO) condition 370.329 t/h
Max. allowable turbine exhaust pressure at MCR 0.3 kgf/cm
Min. allowable turbine exhaust pressure at MCR 0.05 kgf/cm
No Load Steam flow through
HP Turbine 40 t/h
IP/ LP Turbine 5 t/h
Shaft Vibration at each bearing house (peak to peak) 100 microns
Critical speed
HP/ IP Turbine 2400 rpm
LP Turbine 1900 rpm
Critical Speed of turbine and generator rotor together 1140, 1440, 1900, 2160
assembled rpm
Turning Gear Speed 50 rpm
Is turbine is designed for full arc admission during start-
up Yes
Max. allowable temperature at LP turbine exhaust hood 90 C
Is exhaust hood spray system included Yes
Coasting Down time (min) after turbine trip To turning gear speed/
To stand still
With Vacuum 28/ 33
Without Vacuum 18 / 23
GOVERNING SYSTEM
Mode of Governing Throttle Governing
Type of Governing Electro Hydraulic
Dead Bank of the Governor 0.0006
Percentage regulation and its range of adjustability 3.5-6 ; 2-10
Emergency Stop Valve
Opening through full travel 5-15 sec.
For closing through full travel 0.1 +/ - 0.01 sec.
On load throw off Full Load 50 % Load
Temporary speed rise (TSR) 8% 7%
Permanent Speed rise 5 % 2.5 %
Range of adjustability of speeder reference 0- 110 %
15
MATERIAL OF CONSTRUCTION
Turbine casing
HP outer casing/ barrel casing Cast Steel GS22 MO4
HP inner casing GS 17 CrMo V 511
IP casing Not Applicable
LP outer casing IS-2062 & IS 960
LP inner casing & LP blade carriers 4L, 4R GS 22 Mo4
LP blade carriers(1L, 1L, 3L, 1R, 2R, 3R) between blade IS 2062 & DIN 17155
carriers & diffusers HII
Turbine Shaft
HP/ IP rotor shaft 30 Cr MoNi V 511
LP rotor shaft 26 Ni Cr Mo V 115
Turbine disc (if shrunk on) Not applicable
Moving Blades
HP Turbine 1st stage X 22 Cr Mo V 121
HP Turbine other stages X 22 Cr Mo V 121
IP Turbine stages X 22 Cr Mo V 121
LP Turbine stages X 20 Cr 13
LP Turbine last stage X 5 Cr Ni 134/ X 7 Cr
Al 13
Fixed Blades
HP Turbine 1st stage X 22 Cr Mo V 121
HP Turbine other stages X 22 Cr Mo V 121
IP Turbine stages X 22 Cr Mo V 121
LP Turbine stages X 20 Cr 13
LP Turbine last stage X 20 Cr 13
Casing Joints Bolts
HP/ IP Turbine casing 21 Cr Mo V 57
LP Turbine casing Carbon steel (P8.8)
Shaft Coupling Rigid (integral), same
as rotor material
IP-LP cross around piping ASTM 533 GR 70
CONSTRUCTION FEATURE & OTHER DATA

Number of Cylinder 2
No. of bearings including thrust bearing of turbine 3
No. of Stages
HP- No. of Impulse stages Nil
HP- No. of Reaction stages 25
IP- No. of Impulse stages Nil
IP- No. of Reaction stages 19
LP- No. of Impulse stages Nil
16
LP- No. of Reaction stages 2x9

First stage diameter 625 mm
Length of last LP blades 560 mm
Tip diameter of last LP blade 2270 mm
Max. Peripheral velocity of last LP blade 356.6 m/ sec.
Annulus area of last stage 2 x 3.2 m
Method of moisture removal at last stage None
Type of blade protection against moisture erosion Based on erosion index
or coating not required
No. of low pressure stages protection against moisture None
erosion
Type of joint to the condenser Welded
Type of anti friction material used in bearings ORGOV- 738
Type of thrust bearing Tilting pad
Type of turbine shaft
HP/ IP Turbine shaft No Bore type
LP turbine shaft No Bore type
Method of turbine shaft quenching
HP/ IP rotor Oil/ Mist
LP rotor Not applicable
Type of shaft coupling between
HP/ IP Not applicable
IP/ LP Rigid
LP/ Generator Rigid
Manufacturer BHEL,Hydrabad
Type Bottom Mounted
Orientation To Condenser Perpendicular to Turbine
Tube Axis Rotor Axis
Number 1
No of Pass 2
Hot well Divided
Water Box Divided
SHELL SIDE DESIGN CONDITION

Steam From Turbine(3% make-up & 34 C CWDT)
Quantity 257.953 t / h
Pressure .106 kgf/cm
Temperature 46.6 C
Enthalpy 578.4 kcal/kg
Steam from HP & LP Bypass (during bypass operation)
Quantity 329.89 t/h
Pressure .12 kgf/cm
Temperature 49 C
17
Drain from Feed Cycle at Turbine VWO Condition

Quantity 37.847 t / h
Pressure .3393 kgf/cm
Temperature 53.5 C
Condensate Make-up at turbine VWO condition
Quantity 11.11
Temperature Ambient
Other Steam/Drains through flash box or directly to condenser at turbine

VWO
Source DC/GSC/ GS Excess
Quantity in t/h 37.847/0.154/1.239
Pressure in kgf// cm 0.3393/0.98/-
Temperature in C 53.5/99.9/-
Enthalpy in Kcal/Kg 53.5/100/730.8
Design heat load corresponding to turbine 145.23 Gcal/h
VWO condition with 5% margin
Design Back Pressure 0.106 kgf/cm
Condensate Temp at Hotwell outlet 46.6 C
Temp of air vapour mixture at air cooler
section 42.43 C
Volume of condensate stored at normal
level to low level 15.76 m(3 min.capacity)
Cooling Water Design Parameter

Flow Quantity 16000 m/h
Inlet/Outlet Temperature 34/43.077 C
Cleanliness Factor 85%
Velocity of water in tubes 1.96 m/s
Cooling surface 7774 m
Condenser Tube
In Condenser Section
Outer diameter 22 mm
Inner diameter 18 BWG
Number 14000
In Air Cooler Section
Outer diameter 22 mm
Inner diameter 22 BWG
Number 1200
Effective Condenser tube length 7400 mm
Method for securing tube to tube Roller Expansion
sheet
Exit end of tube protrude beyond 3 mm each side
face
18
Material of Construction
Shell SA516 Gr70
Condenser Neck SA516 Gr70
Water Box SA516 Gr70
Tube Sheet SA516 Gr70
Tube in Condensing Zone SB111UNS70600 (C-Ni 90/10)
Tube in Air Cooling Zone SA249TP304
Tube Support Plate SA516 Gr70
Vacuum Pump
GENERAL
Manufacturer Nash Korea Ltd.
Model no. AT 2006 E
Number 1+1
Stage of Pump 2
Standard condition for Air Suction HEI
Ejector Not provided
Coupling Flexible
DESIGN DATA
Guaranteed capacity of pump 15 scfm
Speed of Pump 490 rpm
Volume of Surface condenser, 450 m
turbine steam space and piping
Motor Rating 93 kW
Motor Current 191.6 A
Guaranteed Vibration Level 7 mm/sec
Guaranteed noise level at 1.0 m 85 dBA
COOLING WATER
Quality Passivated DM water
Design temperature 39 C
Design pressure 10 kgf/cm
Casing Cast Iron
Shaft JIS G4051 S45C (CS)
Impeller Nodular Iron
VACUUM PUMP RECIRCULATION PUMP
Quantity 13 m/h
Head 22 m
Motor Rating/ current 3.5 kW/ 7.5 Amps
19
Cooling Tower
Supplier BDWT, Chennai
Induced Draft, Counter
Type Flow
No. of Cell 6
DESIGN DATA
Water Flow 18000 m/h/ tower
Hot water temperature 43C
Cold water temperature 33 C
Wet bulb temperature 28.8 C

Range 10 C
Approach 4.2 c
Evaporation Loss 289.8 t/h
Drift Loss 1.8 t/h
REDUCTION GEAR BOX

Manufacture Flender (Kharagpur)
Model no. Kens 200
Type Bevel-helical
Quantity 6
Reduction Ratio 12.5:1
Type of Gears Bevel- Helical and Spur
No. of Stages 2
Nominal KW Rating 45
Transmission Efficiency 97.50%
FAN
Manufacture Parag Fans, Indore
No. of Fans per Cell 1
No of Fans per Tower 6
No of Blades per Fan 4
Max. Discharge through Fan 1789369.2 m/h
Static Head at Max. Discharge 6.8 mWC
Speed 116 rpm
Motor Make ABB
Capacity/ Current/ Speed 45 kW/ 1500 rpm
BUTTERFLY VALVE
Purpose Hot water line isolation/ cell
Manufacturer Durga Engineering Co.
20
Size 700 mm
No. of Valves per Tower 6
Method of operation Manual
Max. Flow m/h
Normal flow m/h
CONSTRUCTION FEATURE
Fills PVC Fills
Fills Height 1.5 m
Surface area per fills 412771.52 m2
Basin Size 16.8 x 16.8
Volume of water per basin 4572.3 m3
No of Heaters 6
HP Heaters 2
Deaerator 1
LP Heaters 3
HP Heater-6 Extraction Pressure 29.5
Ex. Temp 340
Drip Temp 192
FW inlet temp 185
FW outlet temp 233.6
FW Flow 355.6
FW pressure 156
Steam flow 33.32
HP Heater-5 Extraction Pressure 10.6
Ex. Temp 398
Drip Temp 158
FW inlet temp 152
FW outlet temp 185
FW Flow 355.6
FW pressure 156
Steam flow 17.873
Deaerator Extraction Pressure 3.8
Ex. Temp 281
FW inlet temp 119.5
FW outlet temp 149.6
FW Flow 355.6
FW pressure 3.8
Steam flow 14.687
LP Heater-3 Extraction Pressure 1.187
Ex. Temp 195
Drip Temp 98
Cond inlet temp 92
Cond outlet temp 119.5
Cond Flow 289.3
21
Cond pressure 20
Steam flow 13.68
LP Heater-2 Extraction Pressure 0.17
Ex. Temp 105
Drip Temp 74
Cond inlet temp 68
Cond outlet temp 92
Cond Flow 289.3
Cond pressure 20
Steam flow 11.68
LP Heater-1
Ex Enthalpy kcal/kg 609.9
Drip Temp 71
Cond inlet temp 50
Cond outlet temp 68
Cond Flow 289.3
Cond pressure 20
Steam flow 9.5
H. P. HEATERS
H.P.- 5 H. P.- 6
GENERAL
Manufacturer BHEL BHEL
Tube Supplier Vallinox, France Vallinox, France
Type Shell/ removable Shell/removable
Number of closed feed water heater 1 1
per STG unit
Orientation Vertical Vertical
Tube Type U- Tube U-Tube
No. of Tube Passes 2 2
DESIGN DATA
Shell side data
Unit
Extraction Steam:
Flow t/h 19.201 36.633
Inlet temperature C 400.1 334.4
Shell inlet pressure kgf/cm 12.098 31.702
Drain Entering:
Source H.P.H.- 6
Flow t/h 36.633
Temperature C 193.5
Other drain entering NA NA
Drain Leaving:
Flow t/h 55.834 36.633
22
Temperature C 159.9 193.5

Design Pressure kgf/cm 16 38
Design Vacuum 0/ Full Vacuum
Test Pressure kgf/cm 24/ 410 57/ 360
/Temperature
Fouling Resistance As per HEI

Tube Data Sheet
Feed Water Flow t/h 381.439
Inlet Temperature C 153.5 187
Outlet Temperature C 187 235.3
Inlet pressure kgf/ cm ~ 166 ~ 165
Design/ Test Pressure kgf/ cm 264/ 396
Design temperature C 210/ 230 250/ 270
Fouling Resistance h.m.C/ kcal As per HEI
Feed water velocity through tubes
at average operating temp. m/ s 2.1313 2.2413
De superheating Section:
LMTD C 95.1 51.5
Transfer Rate kcal/h.m.C 483.1 722.4
Pressure drop kgf/ cm 0.27 0.35
Heat transfer surface m 40.7 50.65
Condensing Section:
LMTD C 13.23 17.49
Transfer Rate kcal/h.m.C 2693 2796
Heat transfer surface m 275.1 333
Drain Cooling Section:
LMTD C 15.01 19.65
Transfer Rate kcal/h.m.C 1865 1761.8
Heat transfer surface m 56.2 48
Whether heater is design for

additional load during Yes
abnormal condition
CONSTRUCTIONAL FEATURE
1032/ 16/ 1050/ 25/
Shell OD/ Thick/ L mm 10280 11250
Tube
Number 490
OD/ Length mm 15.875/ 9600
Gauge BWG 14/ 15
Shell SA 516 Gr 70
23
Shell cover SA 516 Gr 70

Tube SA 213 T304
Deaerater
Type of Deaerating Feed water Heater Spray Tray type
Manufacturer BHEL,Hyderabad
DESIGN DATA
Feed water flow 381.439 t/h
Temperature of Deaerated Water 150.7 C
Condensate Inflow 309.673 t/h
Temperature of Condensate Inflow 120.1 C
Heating Steam Quantity 15.931 t/h
Heating Steam Pressure 4.94 kgf/ cm
Heating Steam Temperature 284.1 C
Steam/ Flashed drains into Deaerator: Flow/ Temperature
From HP Heater 55.834 t/h / 159.9 C
From CBD 12.24 t/h / 170 C
Steam/ Flashed drains into Feed Water Storage Nil
Tank
Deaerating Heater Operating Pressure 4.94 kgf/ cm
Pegging Steam pressure at low load/ part load 3.0 kgf/ cm
Pegging Steam Temperature at low load/ part 200 to 330 C
load
Load Range as percent of TG MCR for pegging
steam < 60 %
Whether heating steam rakes are provided in Yes
deaerating feed water storage tank
Is a separate, initial heating steam rake provided Yes
6 kgf/ cm & FV/ 350
Deaerator Design Pressure/ Temperature C
Deaerator Feed water storage tank design 6 kgf/ cm & FV/ 230
Pressure/ Temperature C
Water storage capacity provided in feed water 60 m
storage tank upto normal water level
Sprayer Assembly Detail
Number of sprayer assembly 22
Spray assembly type Spring Loaded
Manufacturer of Sprayer assembly BHEL , Hyderabad
Condensate flow through each sprayer assembly 14.076 t/h
Pressure drop under design condensate flow 0.32 kgf/ cm
Tray Detail
Thickness 1.6 mm
No. of horizontal Trays in one Stack and no. of
Stacks 20 and 8
Total No. Trays 160
24
Deaerator shell Carbon Steel
Feed water storage tank shell & dished end SA 516 Gr 70
Sprayer SS TP 304
Tray SS 304
L.P. HEATERS Units LPH-1 LPH-2 LPH-3

1 GENERAL
1.1 Manufacturer BHEL
1.2 Tube Supplier Vallinox, France
1.3 Type Bundle, Shell
Numberof
closedfeed water
heater per STG
1.4 unit 1 1 1
1.5 Orientation Horizontal Vertical Vertical
1.6 Tube Type U- Tube
No. of Tube
1.7 Passes 2 2 2
2 DESIGN DATA
2.1 Shell side data
Extraction Steam:
Flow t/h 10.583 12.523 14.74
Inlet temperature C 71.5 110.6 199.4

Shell inlet
2.1.1 pressure kgf/ cm 0.3393 0.8853 2.2526
Drain Entering:
Source L.P.H.- 2 L.P.H.-3 --
Flow t/h 27.264 14.74 --
2.1.2 Temperature C 74.6 98.8 --
Other drain
2.1.3 entering NA NA NA
Drain Leaving:
Flow t/h 37.847 27.264 14.74
2.1.4 Temperature C 71.5 74.6 98.8
2.1.5 Design Pressure kgf/ cm 4 4 4
2.1.6 Design Vacuum 0/ Full Vacuum
2.1.7 Test Pressure/ kgf/ cm 6.0/ 150
25
Temperature C
2.1.8 Fouling Resistance h.m.C/ kcal As per HEI

2.2 Tube Data Sheet
2.2.1 Feed Water Flow t/h 309.673
2.2.2 Inlet Temperature C 49.5 68.3 92.4

Outlet
2.2.3 Temperature C 68.3 92.4 120.1
2.2.4 Inlet pressure kgf/ cm ~ 9.0 ~ 8.2 ~ 7.6
Design/ Test
2.2.5 Pressure kgf/ cm 24/ 36
Design
2.2.6 temperature C 15
2.2.7 Fouling Resistance h.m.C/ kcal As per HEI

Feed water
velocity through
tubes at average
2.2.8 operating temp. m/ s 1.6 1.63 1.65
De
superheating
Section
LMTD C
Transfer Rate kcal/h.m.C NA NA NA
Pressure drop kgf/ cm
Heat transfer
2.3 surface m
Condensing
Section
LMTD C 9.78 10.9 11.97
Transfer Rate kcal/h.m.C 2419 2751 3073
Heat transfer
2.4 surface m 245 230 224.7
Drain Cooling
Section
LMTD C -- 13.78 15.2
2.5 Transfer Rate kcal/h.m.C -- 1634 1439
26
Heat transfer
surface m -- 25.5 16.7
Whether heater is
design for Yes
additional load
during abnormal
2.6 condition
3 CONSTRUCTIONAL FEATURE
Shell OD/ Thick/ 878/ 14/ 878/ 14/ 878/ 14/
3.1 L mm 8860 9700 9000
3.2 Tube
3.2.1 Number 350 350 350
15.875/ 15.875/ 15.875/
3.2.2 OD/ Length mm 7500 8600 7900
3.2.3 Gauge BWG 20
4 MATERIAL OF CONSTRUCTION
4.1 Shell SA 516 Gr 70
4.2 Shell cover SA 516 Gr 70
4.3 Tube SA 213 TP 304
Condensate Extraction Pump

GENERAL
Manufacturer BHEL, Hyderabad
Model No. EN7H32
No. of Pump 1+1
Type of Pump Vertical, BowlType, MultiStage,
Canister
Stages 7
Type of suction Double suction at 1st stage
Type of Coupling Flexible, Spacer type
Type of seal Mechanical
Michell ( Tilting pad type)
Type of thrust bearing between Pump & Motor)
Type of shaft Flexible
DESIGN DATA
Design Capacity per Pump 360 m3/h
Run-out Flow per Pump 396 m3/h
27
Minimum Flow per Pump 100 m3 h

5.401 mlc
st
Suction pressure at design capacity at 1 stage
Design pressure at Design Capacity 180.401 mlc

Total Head at design capacity 175 mlc
Shut off Head 218 mlc
NPSH available (minimum) 4.233 mlc
Rated Speed 1478 rpm
Pump Efficiency at design point 81%
Pump Power required at design point 210 kW
Drive Motor Rating/ Current 250 kW/ 27.5 A
Critical speed 3714 rpm
Max. Vibration level 10 mm/ sec
LIQUID DATA
Liquid Handled Condensate
Temperature range 25- 85 C
Specific Gravity at design temp. of 46.6 C 0.999

PH 8.8 to 9.2
COOLINGWATER REQUIREMENT
Flow per Pump 0.60 m3/h
Inlet temperature 39 C
Quality D. M. Water
Temperature rise across H.E 10 C
Supply Pressure 4.8- 5.0 kgf/cm2
Design Pressure 10 kgf/cm2
MATERIALOF CONSTRUCTION
Bowl or Casing BS 1452 GR 260 (IS:210, Gr: FG 260)
Diffuser & Guide vane Part of Bowl
-
Impeller All Stage BS 1504 425 C11
Shaft Sleeves BS 970 431 S29 (T)
Lower Pump Shaft & Upper Pump shaft BS 970 420 S29R (Forging)
28
BOILER FEED PUMP

UNIT BOOSTER PUMP MAIN
PUMP
1 DESCRIPTION
1.1 Make KSB, Pune

1.2 Number of Set 3 3
1.3 Pump Model WK 150/ 2 CHTC 4/ 12
Multistage, Multistage
1.4 Type of Pump RingSection BarrelCasing
1.5 Type of Drive Common Elec. Motor
directly driving Booster
pump & Main Pump
through variable speed
hydraulic gear coupling
2 DESIGN & PERFORMANCE DATA
t/h / 215.2/ 215.2/
2.1 Inlet Flow m3/ h 235 235
215.2/ 215.2/
t/h/
2.2 Outlet Flow m3/ h 235 235
2.3 Minimum Recirculation Flow at
design speed (Main Pump-
3950rpm 59.53/ 91.6/
t/h/
Booster pump-1487 rpm) m3/ h 65 100
Total Dynamic Head at rated
2.4 Speed & capacity mlc 1990
2.5 Max. Shut off Head mlc 83 2442

NPSH required at Booster
2.6 Pump mlc 3.85
Efficiency at rated point Hot n
2.7 as per HIS % 69 75.1
2.8 Power Input to Pump kW 51 1515

2.9 Max. Vibration Level <2.8 for <2.8 for 192
192 to 235 to 235 m3/
mm/ s m3/ h. h.
29
< 4.5 for

65 to 192
m3/ h. & < 4.5 for 65
235 to to 192 m3/
258.5 m3/ hr. & 235 to
h. 270 m3/ h.
<6.5 for
258.5 to
270 m3/ h.
89 + 3 dBA
2.1 Max. Noise Level & with Noise
Hood < 85
dBA 77 + 3 dBA dBA
3 CONSTRUCTION FEATURE OF B.F.P.

3.1 Casing Type Ring Section Outer : Barrel
Inner : Ring
3.2 Impeller Arrangement Tandem Tandem
3.3 Number of Stage 2 12
3.4 Journal bearing, Type ANTIFRICTION Plain Bearing
NDE : Deep grove ball C. Steel +
Brg.6410C3 White
DE : Cylindrical Roller Brg.
NU410C3 Metal LGSn 80
3.5 Thrust Bearing -- Segmental
Tilting Pad
Type Double
Acting
3.6 Coupling Type Flexible Membrane, TSKS- Flexible
0075-0178-1450, Triveni Membrane,
Flexibox TSKS-0930-
0177-2100,
Triveni
Flexibox
3.7 Type of Axial Balancing Through Balancing Holes in the
Device impeller & wearing ring on both Double Piston
side of impeller + Thrust
Bearing
3.8 Pump designed with Diffuser Diffuser
diffuser or volute
3.9 BFP Suction Strainer:
Type Simplex
Back washing facility No
Filtration Ring 150 micron
30
Min. running clearance

0.175
( Radial) 0.15
4 MATERIAL OF CONSTRUCTION
4.1 Inner Casing CA6NM CA6NM
ASTM A105/ SS
4.2 Outer Casing NA Cladding
4.3 Impeller CA6NM CA6NM
4.4 Diffuser CA6NM CA6NM
4.5 Casing Wearing Ring:
Chrome Chrome Hard
Material Hard 400 400
Hardness BHN Min. 350 Min. 350
Impeller Wearing Ring:
4.6 Material 1.4024.19 1.4024.19
Hardness BHN Man. 250 Man. 250
4.7 Shaft ASTM A276 ASTM A182
Type 410 Gr.F6NM
(Forged) (Forged)
CHR.PLATED CHR.PLATED
4.8 Shaft Sleeves AISI 316 AISI 316
4.9 Stuffing Box CA6NM CA6NM
ASTM A182
4.1 Balancing Device Gr.F6A
4.1 Pressure bolting studs EN24 V/ T EN24 V/ T
4.1 Nuts EN24 V/ T EN24 V/ T
5 LUBE OIL SYSTEM FOR BFP
Oil from lube oil system of
Hydraulic Coupling will be
5.1 Type of Pump supplied to Main Pump Bearing
5.2 Number of Pump 1 MOP + 1 AOP
MOP- 3847
5.3 Pump Speed rpm AOP- 1485
5.4 Motor Rating of Pumps kW AOP- 5.5 KW/ 11 A
5.5 Lube Oil Cooler type Shell & Tube type
6 TYPE OF COUPLING
6.1 Between Motor & Hydraulic Type : Flexible Membrane
Coupling Make : Triveni
Flexibox
Model : TLPW-1850- 0133-
x001
6.2 Between Hydraulic Coupling & Type : Flexible Membrane
BFP Make : Triveni
31
Flexibox
Model : TSKS-0930- 0177-2100

6.3 Type : Flexible Membrane
Between Motor & Booster Pump Make : Triveni
Flexibox
Model : TSKS-0075- 0178-1450
7 RECIRCULATION VALVE
7.1 Manufacturer MIL Controls Ltd.
7.2 Capacity t/h/ 91.6/ 100
m3 /h
Table 6: Design parameters at various load conditions for the Unit
Sl. Temperature, Pressure, Flow at various

No. points
Descriptions 100 % 100 % 60 % 100 %
BMCR TMCR TMCR TMCR with
HPH out
01 Steaming rate of the boiler, t/h 390.0 352.2 212.6 333.7
2
02 Pressure at SH. Outlet , kgf/cm 131.0 130.7 127.6 131.0
03 Temp. at SH. Outlet , C 540.0 540.0 540.0 540.0
2
04 Pressure at RH. Inlet , kgf/cm 31.65 30.15 18.20 31.47
05 Temp. at RH. Inlet , C 334.0 333.0 322.0 344.0
2
06 Pressure at RH. Outlet , kgf/cm 30.15 28.78 17.38 30.10
07 Temp. at RH. Outlet , C 540.0 540.0 540.0 540.0
08 Feed water temp. , C 235.0 234.0 212.0 188.0
09 Ambient air temp. , C 33.0 33.0 33.0 33.0
10 Combustion air temp. secondary, C 274.0 273.0 246.0 250.0
11 Fuel quantity, t/h 90.4 81.8 51.1 83.6
12 Air quantity, t/h 491.4 444.8 277.3 462.1
32
Table 7: Capacity and age of units
De- Age
Unit Make
No of rated Date of (years)
Capacity
Units Capacity commissioning
(MW) Boiler Turbine
(MW)
1 2 3 4 5 6 7
Unit-3 120 120 27 Aug 2001 BHEL BHEL 9
Table 8: Results of proximate & ultimate analysis of raw coal samples collected
during Unit heat rate test
SL. Particulars Unit Design Analyzed

No. value
01 Gross calorific value kcal/kg 3350.0 4623
02 Carbon in fuel % 35.11 47.22
03 Hydrogen in fuel % 2.36 3.20
04 Sulphur in fuel % 0.60 0.60
05 Oxygen in fuel % 4.29 6.55
06 Ash in fuel % 45.00 38.93
07 Moisture in fuel % 12.00 6.60
Table 9: Results of unburnts analysis of bottom ash and fly ash samples collected
during Unit heat rate test
SL. Particulars Unit Analyzed Value

No.
01 Bottom ash % 5.60
02 Fly ash % 1.90
Table 10: Flue gas analysis
Sl. No. Particular O2, %

1 Before SAPH-LHS 3.97, 4.06
2 After SAPH-LHS 5.15
3 Before SAPH-RHS 3.80, 3.72
4 After SAPH-RHS 6.16
5 Before PAPH 4.96
6 After PAPH 8.98
33
Table 11: Boiler thermal performance by losses method
Sl. Design, Operating,

No. Particulars % %
1.1 Loss due to sens. Heat in dry FG 5.77
1.2 Loss due to unburnt CO in flue gas 0.17
1 Dry flue gas loss 4.19 5.94
2.1 Loss due to moisture in fuel 0.90
2.2 Loss due to hydrogen in fuel 3.91
2 Wet flue gas loss 6.14 4.81
3 Loss due to moisture in comb. Air 0.13 0.16
4.1 Loss due to bottom ash 0.76
4.2 Loss due to fly ash 1.03
4.3 Loss due to sens. Heat of bottom ash 0.37
4.4 Loss due to sens. Heat of fly ash 0.16
4 Losses due to ash 1.10 2.32
5 Loss due to radiation 0.50
6 Loss due to convection 1.06
7 Un-accounted losses 1.21
Manufacturing margin 0.20
8 Heat equivalent of auxiliary power -- -0.11
Heat loss due to puffing in furnace first
9 pass -- 0.00
10 Total losses 12.97 14.69
11 Thermal efficiency 87.03 85.31
Correction factor to account for annual
-- --
12 average station GCV
13 Corrected test boiler efficiency 87.03 85.31
34
Table 12: Boiler skin temperature measurement
Drum level
104.5 63.1 77 324.4 197 50.1 67.6 43.1 50.7 45.1
59.9 60.4 330 195.1 120.7 127 235 329.8 331.1 97.3
73.1 65 64.3 64.9 70.3 305 329.4 280.6 138.5 139
Front
40.4 42.1 40.9 40.2 39.2 86.3 65.7 80.8 77.4 93.9 48.6
42.8 40.8 38.6 38.6 38.5 40.7 37.7 38.1 41
Rear
36.7 36.4 33.5 38 36 62.2 74.9 74.2 78.9 61.1 62.2
34.6 43 41.3 40.3 35.1 40.5 38.2 40.2 35.9 38.9 39.6
1 Level down
64.2 59.1 96 74.8 60.2 69.5 90 53.1 70.7 50.7
113.4 80 138 80.7 69.8 74.5 78.2 75.6 68.7 60.7
99.2 87.2 56.5 113.7 98.2 49.3 51.2 51.6 58.3 120.5
67 65.4 63.4 50.8 54.5 58.3 51.6 51.2 49.3 51.4
58.2 54.5 55.8 56.2 52.1 41.4 44.6 47.8 46.30 48.5
Rear
57.1 58.1 66 60.3 62.2 52.4 71.1 59.4 72.7 55.1 64.8
67.8 63.7 64.1 66.1 70.2 67 66.8 60.3 73.8 71.7 62.3
64.7 67.8
1 Level down
59.9 62.1 56.4 81.2 66.2 59.8 62.4 56.4 76 64.2
158.9 81 193 57.8 77.2 49.8 56.1 120 78.2 70.1
118.6 179 96.4 55.6 59.9 58.1 60.2 56.8 71.8 68.4
120.7 71.8 59.1 92 83.5 59.8 65.4 64.6 60.2 59.6
59.8 59.4 56.4 52.8 55 50.8 54.2 60.8 64.4
54.2
Rear
52 52.2 58.6 57.5 57.3 59.6 52.8 54.56 55.4 60.8 69
59 58.1 69.8 64.80 66.8 66.1 64.7 65 68.1 62.6 76.1
60.1
1 Level Down
60.8 61.5 58.1 53.9 59.6 57.1 57.9 57.4 56.4 52.5
66 68.4 62.8 77.9 73.6 60.7 44 62.8 61.1 53.4
96.8 73.8 90.7 70.4 119.2 60.5 61.2 185 197.2 122.1
72.8 68.7 77.8 68.3 106.3 111 99.6 66.1 107.1 48.5
68.5 83 70.4 84.2 54.5 54.2 70 70.5 68.5
62.5 61.9 67.1 62.8 62.3
Rear side
54.9 52.5 72.4 63.7 66 65.4 68.4 66.8 74.9 75.6 73.4
66.8 75 146 86.40 91.2 106 71.1 50.6 64.8 54.1 77
72.1 69.1 75.9 97.80
1 Level Down
35
60.4 66.4 61.2 69.3 60.5 67.8 67.4 57.9 60.5 61.2
68.4 67.5 63.4 62.4 65.7 113 75.1 66.9 70.4 64
69 87.8 72.7 141.9 131.00 178 110 107.6 87.3 53.3
53.7 54.4 55.6 57.3 101.4 55.9 49.5 48.3 48.6 49.7
57.3 55.6 54.4 53.7 62.6 58 59.4 56.6 49.3 67.3
60 61.2 61.9 58.4 57.3 47.5 58.9 62.1 61.1 58.1
76.6 75.1 60.1 60.5
Rear side
58.6 59.1 58.5 64.6 69.1 63.3 62.6 59.1 68.8 64.2 63.5
63.2 53.4 73.3 69.8 68.4 70.4 62.3 62.5
1 Level Down
(1st left 1st Right)
60.6 63.2 65.1 75 67.8 56.3 55.1 67.6 62.9 77.2
61.8 170 127 115.8 116.8 61.2 69.4 107.9 125.9 123.5
186.8 106 70.4 61.4 57.3 90.2 75.8 56.4 57.4 61.9
160.9 58.4 59.1 56.1 54.3 62 54.6 59.5 57.9 54.3
56.8 59 64.2
front side
64.7 73.7 62.9 70.7 77.3 64.8 65.9 114.1 113.6 94.2 110.2
67 63.8 64.3 65.2 70.9 73.2 63 72.5 73.6 85 95
Rear side
86.6 78.8 76.5 70.3 63.7 63.5 113 140.4 122.3 178.3 105.2
81.5 68.3 71.6 66.1 71 69.2 67.6 66.9 75.5 115.3 77.7
(2nd left 2nd Right)
74.8 67.5 58.7 55.5 56.7 65.3 68.1 57.8 87.8 65.6
193.6 191 193 100.8 58.2 65.2 55.25 127.1 123.4 143
170.6 108 165 94.4 71.2 58.6 146.3 168.8.2 85 98.5
65.8 61.3 61.8 64.1 69.4 56.1 54.2 62 49.5 68.5
68.5 71.1 64.2 60.7
Rear side
63.1 64.1 63.6 65.9 65.7 71.7 61.6 65.4 59.3 57.3 56.7
61.4 59.3 58.4 65.9 64.6 70.1 72.1 69.2
1 Level down
64 57.3 71 73.8 61.4 55.3 57.3 76.3 68.5 54.3
122.6 77 75.6 74.5 64.7 136 140.5 90.2 57.8 56.1
106.8 101 125 162.3 132.2 120 98.5 155 152.7 146.8
82.7 67.5 64.8 67 70.3 52.1 55.6 70.5 52.4 160.8
60.7 73.2 62.9 64.2 86.8 58.6 70.6 75.9 68.9
front side
67.3 61.4 55.8 63.5 58.9 72.9 67.8 56.5 65.6 109.4 107.7
66.8 59.8 62.5 61.5 60.5 58.6 52.5 69.6 82.5 101.8 107.8
Rear side
56.1 56.1 67.8 61.3 56.9 67.3 53.2 117.2 104.1 96.9 98.8
85.4 57.2 61.9 61.4 67.5 64.5 56.2 62.3 61.6 64.2 68.5
36
64 60.9 61.3 62.3 54.8 56 67.2 67.8 67.5 67.3

57.9 56.4 53.4 48.9 60.7 83 59.3 137.7 181.20 100
153.5 161 114 128.3 177.6 94.2 101.5 178.1 157.2 140.4
70.1 72.1 65.9 198.1 190.2 58.9 60.4 56.4 70.1 60.3
78.8 72.9 74.4 75.2 64.3 70.6 64.4 70.4 58.9 67.6
Rear side
75.6 65.6 66.6 68.4 60.2 68.7 63.3 68.1 74 66.4 76.6
74.2 68.3 63.3 64.6 59.8 55.8 59.3 58.3 56.3 60.6
1 Level Down
69.4 76.3 93.1 83.1 75.6 56.7 59.4 63.8 56.9 57.8
84.5 61.5 67.3 54.8 73.5 60.8 61.6 72 74.5 90.2
99.7 99.7 98.5 129.3 130.5 91.4 105.9 111.5 150.2 174.9
64.7 61.6 76.5 63.9 54.6 65.1 66.2 68.7 71.3 68.9
58.4 56.4 60.6 76.8 69.7 70.2
1st Front side
62.9 63.1 66.6 59.3 62.3 69.2 121 116.5 107 105.5 78
171.1 185 63.9 69.3 66.1 94.9 56.2 71.9 61.2 66.4 65.6
63 67.4 62.3 64.4 60.6 65.5
1st Rear side
86.5 61.3 66 64.2 82.6 71.6 63.7 110.3 115.2 94.9 107.2
175.4 112 121 71.1 72.8 62.1 66.2 68.5 70.5 65.8 65.8
61.4 62.4
64.1 74.5 56.9 59 53.8 55.8 60.3 58.5 58.8 62.9
57.2 56.8 55 56.8 54.7 53 55 84.7 55.2 56.3
58.9 60.1 65.2 44.8 79.7 61.1 56.5 61.2 60 54.2
58.2 64.1 80.1 71.9 49.2 61.4 64.2 66.9 54.3 58.9
49.7 69 50.2 51.2
2nd Front side
57.7 60.4 57.3 60.1 59.7 57.3 56.4 53.8 65.9 66.8 64.2
63.9 59.2 55.8 65.7 69.7 64.3 65.8 54.9 69.5 66.3 65.6
2nd Rear side
66.3 63.6 63.4 66.1 63.5 70.2 75.3 69 64.5 64.4 64.4
67.5 60.4 64.3 65.8 66.9 68.4 70.2 64.6
1 Level Down
74.4 50.7 60.8 57.7 56.9 51.1 49.2 114.5 72.5 72
62.5 70.2 64.2 66 48.3 55.9 48.1 53.8 57.4 76.9
63.8 59.5 80.3 64.1 60.1 66.6 45 44 64 63.8
52.1 50.6 54.7 80.1 58.1 75.5 54.3 58.6 59 60.2
44 50.1 62.4 64 41.7 45 49.2
Front side
98.8 75.4 62.5 57.9 58.5 56.2 52.8 53.8 42.5 99.8 75.4
88.4 99.2 71.4 70.6 61.5 58.2 99.2 55.6 56.4 58.1 78.1
82.5
Rear side
37
72.9 68.5 59.7 62.6 59.1 53.4 69.3 62.3 99.2 103.2 95.6
105.5 72.8 96.2 61.1 69.2 64.2 74.9 73.2 64.3 59.8 56.4
61.8 77.6 69.4 75.5 76.1 80.1 131 72.7
1 Level Down
51.5 55.5 50.9 54.3 49.7 51.7 62.9 111.9 64.1 46.4
55.1 53.5 53 46.3 71.8 59.4 48.3 47.5 41.9 43.7
67.9 44.7 73.8 44.6 75.6 44.3 50.9 51.2 48.4 60.5
68.9 72.3 66.2 68.9 54.3 52.2 55.4 56
Front side
122.4 41.6 84 92.60 79.3 113 85 62 51.3 58.4 61
61.4 45.1 46.6 48.6 42.8 53.8 42.5
Rear side
53.5 58.2 53.6 45.1 56 54.7 54.8 54.5 52.7 52.8 66.1
65.8 42.4 40.3 60.4 79.6 49.9 40.3 39.9
1 Level Down
70.3 62 58.7 56.3 61.3 61.7 70.4 60.1 77.6 59.9
55 54.2 77.3 83.6 118.1 60.6 62.9 46.7 53 58.3
57.8 115 124 96.2 108 109 110.6 105.9 86 120
100 112 63.2 60.8 64.5 46 61 102.7 100.8 92.8
46.4 45 75.6 56.4 86.4 55.6 69.1 70.7 67.3 72.3
44.3 81.3 49.4 54.2 54.2 56 57.1 64
Front side
62.4 56.8 55.8 78.1 66.1 66.7 67.5 74.8 87.1 90.3 90.6
101.9 88.8 72.5 153.6 129.7 117 128 72.8 55.3 47.4 46.3
62.5 55.3 57 60.9 55.8 64.5 56.8 60.6
Rear side
61.4 61.2 57.5 69.4 60.1 64.7 59.1 58.7 121.4 75.4 85.4
103.2 120 80.5 101.7 121.4 61.2 57.1 63 57.8 74.2 61.5
62.2 65.1 60.1 64 64.1 62.6 72.3 60.2
1 Level Down
51 46 40.5 40.7 38.9 48.8 46.1 42.1 47.3 40
53 49.2 45.6 54.5 43.4 38.9 41.3 48.1 45.6 46.4
109.4 112 93 147.6 43 42.4 40.8 48.2 128.3 130.3
47.3 48.2 59.4 96 85 105 103.8 108.9 105.4 92
43.1 50.1 41.8 46 47.2 55.4 44.6 55.8 44.3 46.1
41.5 50.1 52.2 46.4 44.5 48.3 38.9 40.4
Front side
47.5 46 43.8 47.3 53.4 42.5 52 47.7 48.9 43.9 50.2
50.1 41.5 46.1 44.3 55.8 44.6 48.2 56.1 84.1 49.9
Rear side
45.2 38.7 40.4 39.2 47.4 54.8 42.5 50.8 37.8 46.3 42.8
35.4 59.1 54.2 45.3 38.9 36.6 41.2 42.8 36.2 38.4 37.5
Average 72.7
38
Table 13: Thermal Performance of air pre-heaters
Sl. Operating (SAPH)

Particular Unit Design
No. LHS RHS
Oxygen in flue gas
1 Before APH % 3.6 4.0 3.9
2 After APH % 4.56 5.2 6.2
Flue gas temp
3 Before APH C 298.0 379.4 399.9
4 After APH C 139.0 153.2 155.0
5 T C 159.0 226.2 244.9
Air temperature
6 After APH C 273.0 285.9 286.0
7 Before APH C 33.0 35.6 35.6
8 T C 240.0 250.3 250.4
Air flow
9 Total [a] t/h 257.6 134.6 126.5
Leakage
10 APH in-leakage [a] t/h 19.7 12.5 26.9
11 APH in-leakage % 7.65 9.32 21.26
Thermal load
12 Thermal load MWt 17.8 9.7 9.1
[a] Total air flow and APH in-leakage in design column indicates for both the APH
T - Differential temperature
39
Sl. Operating
Particular Unit Design
No. PAPH
Oxygen in flue gas
1 Before APH % 3.6 4.0
2 After APH % 5.56 9.0
Flue gas temp
3 Before APH C 298.0 373.5
4 After APH C 139.0 152.8
5 T C 159.0 220.7
Air temperature
6 After APH C 274.0 308.4
7 Before APH C 33.0 35.6
8 T C 241.0 272.8
Air flow
9 Total t/h 125.6 179.2
Leakage
10 APH in-leakage t/h 20.5 35.5
11 APH in-leakage % 16.29 19.79
Thermal load
12 Thermal load MWt 8.7 14.2
T - Differential temperature
40
Table 14: Flue gas temperature survey in boiler
Sl. Particular Unit Design Operating

No.
0
01 Furnace outlet C 973.0 --
0
02 SH Platen outlet C 973.0 --
0
03 Reheater outlet C 754.0 --
0
04 LTSH inlet C 642.0 670.3
0
05 LTSH outlet C 456.0 496.7
0
06 Economiser inlet C 456.0 496.7
0
07 Airheater inlet C 298.0 384.2
0
08 Airheater outlet C 139.0 153.7
Table 15: Flue gas pressure survey in boiler

No.
01 Furnace mmWc -4.0 -7.6
02 SH Platen inlet mmWc -4.0 -7.6
03 Reheater inlet mmWc -5.0 -5.6
04 LTSH inlet mmWc -10.0 -10.5
05 Economizer inlet mmWc -20.0 -14.7
06 Air pre heater inlet mmWc -40.0 --
07 ESP inlet mmWc -109.0 -104.8
08 ID fan inlet mmWc -154.0 -176.9
09 ID fan outlet mmWc +16.0 -1.2
Table 16: Specific heating surfaces (Calculated)
Sl.No. Particulars Unit 3

3
1 Specific furnace volume m /MW 22.19
Specific Effective Projected Radiant Surface
2 area m2/MW 15.59
2
3 Specific super heater area m /MW 32.59
2
4 Specific reheater area m /MW 12.25
2
5 Specific economizer area m /MW 38.39
2
6 Specific air preheater area m /MW 274.54
2
7 Specific condenser area m /MW 64.78
41
Table 17: Performance of economizer
SL. Particulars Unit Design Operating

No.
01 Feed water temp. before economizer C 234.0 224.2
02 Feed water temp. after economizer C 286.0 291.6
03 Feed water flow through economizer t/h 352.2 387.6
04 Thermal Load (Water side) MWt 41.0 58.2
Table 18: Performance of water walls

No.
01 Boiler drum pressure kgf/cm2 140.8 135.9
02 Saturation temp. at drum pressure C 337.2 334.4
03 Water temp. at outlet of economizer C 286.0 291.6
04 Degree of sub-cooling of water
C 51.2 42.8
entering water walls
05 Evaporative water wall load MWt 103.2 115.8
06 Sub-cooled water wall load MWt 29.4 26.9
07 Total thermal load MWt 132.6 142.7
42
Table 19: Condition assessment of steam generator components

Sl. No. Particular Observation
01 Boiler
1.1 Furnace and water walls
Tubes panel flatness OK
Tube swelling OK
Damage from falling slag No
Condition of ash hopper OK
refractories
Furnace fire ball symmetry Coal flow equalization to be done
Condition of fire ball Not uniform
Water wall deposit Internal deposits suspected
Gas side corrosion Not observed
Erosion from soot blowers Not Observed
Furnace gas tightness OK
1.2 Ring header
Presence of debris & corrosion Minor debris; corrosion absent
1.3 Economizer
Alignment of assemblies Distorted/deteriorated tubes to be
replaced
Condition of welds, attachments, OK
supports, spacers, shields baffles
Ash erosion No
Condition of anti erosion devices OK
1.4 Super heaters
Alignment of assemblies OK
Condition of welds, attachments, OK
supports, spacers, shields baffles
Ash erosion No
Condition of anti erosion devices OK
Steam erosion Not observed
LTSH OK
Rear RH tubes OK
1.5 Soot blowers
Condition of wall soot blowers OK & in service
Condition of long retractory soot OK & in service
blowers
Manual/automation of soot Remote
blowers
1.6 Coal burners
Condition of coal burners OK
Burner tilting mechanism Operative in gang operation
1.7 Insulation, lagging and cladding

Condition of insulation and OK
cladding
43
1.8 Valves and dampers

Boilers stop valves OK
Safety valves (drum S/H, R/H) OK
Attemperator/spray valves OK
Isolation valves Not passing
Drain valves
All dampers OK
1.9 Pent house
General cleanliness (ash Clean
accumulation)
Integrity of header/drum OK
supporting arrangement/
attachment welds
Gas tightness OK
Corrosion of pent house casing No
02 Piping
2.1 Steam generator integral piping
Condition of fixed & variable OK
supports
Deformation of pipes Not observed
Saddle weld for cracking Not observed
2.2 Steam generator hanging system and structure
Condition of beams, supports, Not observed
washer springs fittings etc.
Deformation, cracks and loss of Not observed
strength due to corrosion of
various structural members
Corrosion of hanger tie rods Not observed
03 Ducts
3.1 Air/gas ducts
Air/gas tightness Leakage observed
Expansion joints OK No leakage seen
Dampers Ok
Duct supports and hangers OK
Corrosion of dampers/stiffness/ Not observed
baffle plates etc.
Corrosion of ducts work Not observed
downstream of air heaters
General condition of wind box OK
04 Air Pre-heater
4.1 Basket including any low Cold end elements eroded. Corrosion
temperature corrosion not observed.
Axial and Radial seals Deteriorated
Sector plates Deteriorated
Expansion joints OK
05 PF piping
5.1 Pulverized fuel piping for erosion OK
44
Table 20: Leakages in the boiler and associated equipment
SL. Particulars Gradating

No. A E
01 Coal leaks from adjoining bunker conveyors B
02 Coal leaks from coal pipes B
03 Coal leaks from mill area including reject gates B
04 Steam leaks from main piping (valve passing, drain leaks,
safety valve opening) A
05 Steam leaks from auxiliary steam lines (soot blowing
lines, oil heating/atomizing lines, sampling lines, spray
lines, etc.) B
06 Hot air leaks (wind box area, air ducts, APH, etc.) B
07 Flue gas leaks (boiler puffing, flue duct leaks, etc.) A
08 Heat leaks (boiler skin insulation, duct insulation, main
pipe insulation, auxiliary piping insulation, insulation of
valve bodies, etc.) B
09 DM water leaks A
10 Soft water leaks A
11 Overall cleanliness gradation B
Scale of cleanliness:
A: no B: insignificant C: significant D: major E: excessive
leaks leaks leaks leaks leaks
45
Table 21: Performance of steam turbine

No. (MCR)
01 Plant load MW 120.00 119.14
02 Main steam flow t/h 355.6 387.4
03 Specific Steam consumption (SSC) t/MWh 2.96 3.25
04 Turbine efficiency % 44.46 39.67
05 Turbine heat rate kcal/kWh 1934.53 2167.97
06 Turbine heat rate kJ/kWh 8098.04 9075.22
Table 22: Losses in the turbine-condenser system
Sl.No. Particular Unit Operating
01 Poor main steam temperature and pressure than

design MWm 0.05
02 Poor re-heat steam temperature and pressure
than design MWm 0.14
03 Loss due to re-heat spray MWm 0.04
04 Higher than design absolute pressure at the
condenser MWm 0.13
5.1 Loss in turbine internals HPT MWm 0.0
5.2 Loss in turbine internals IPT MWm 1.65
5.3 Loss in turbine internals LPT MWm 5.11
5.0 Deterioration in turbine performance due to
irreversibility MWm 6.76
06 Loss of thermal energy in condensate sub cooling MWm 0.00
07 Total loss of work in the turbine-condenser MWm 7.12
46
Table 23: Steam temperature survey in turbine

No. (MCR)
0
01 MS temperature at HPT inlet C 535.0 531.2
0
02 CRH temperature C 342.0 352.0
0
03 HRH temperature C 535.0 534.0
0
04 HPH-6 Extraction C 340.0 336.5
0
05 HPH-5 Extraction C 398.0 411.9
0
06 Deaerator Extraction C 281.0 299.1
0
07 LPH-3 Extraction C 195.0 238.3
0
08 LPH-2 Extraction C 105.0 196.7
0
09 LPH-1 Extraction C NA NA
0
10 Exhaust hood temp C 46.4 55.7
Table 24: Steam pressure survey in turbine

No. (MCR)
01 MS pressure at HPT inlet kgf/cm2 127.0 119.2
02 CRH pressure kgf/cm2 32.0 32.9
2
03 HRH pressure kgf/cm 28.8 30.3
2
04 HPH-6 Extraction kgf/cm 29.5 32.3
05 HPH-5 Extraction kgf/cm2 10.6 12.6
2
06 Deaerator Extraction kgf/cm 3.8 6.0
2
07 LPH-3 Extraction kgf/cm 1.19 2.1
2
08 LPH-2 Extraction kgf/cm 0.17 0.7
2
09 LPH-1 Extraction kgf/cm NA NA
10 Condenser vaccum kPa 10.6 12.0
47
Table 25: Feed heater data for UNIT 3
Sl. HPH 6 HPH 5

Particular Unit
No. Design Operating Design Operating
o
1 FW inlet temperature C 185.00 178.40 152.00 158.80
o
2 FW outlet temperature C 233.60 224.10 185.00 178.40
3 Specific heat capacity of FW kJ/kgo K 4.58 4.54 4.39 4.39
4 FW flow kg/s 98.78 109.35 98.78 109.35
5 Ext. steam pressure kgf/cm2 29.50 32.30 10.60 12.60
o
6 Ext. steam temperature C 340.00 336.50 398.00 411.90
o
7 Ext. steam sat. temperature C 234.50 237.73 186.40 190.11
8 Ext. steam enthalpy kJ/kg 3111.25 3101.09 3259.89 3287.87
o
9 Drain temperature C 192.00 190.10 158.00 164.80
10 Enthalpy of sub cooled liquid kJ/kg 816.72 808.32 666.57 696.19
11 Heat gained by Feed water kWthermal 22010.5 22684.4 14303.8 9400.7
12 Heat released by Ext. Steam kj/kg 2294.5 2292.8 2593.3 2591.7
13 Steam flow through the heater kg/s 9.6 9.9 5.5 3.6
o
14 TTD C 0.9 13.6 1.4 11.7
o
15 DCA C 7.0 11.7 6.0 6.0
o
16 Degree of subcooling of drain C 42.5 47.6 28.4 25.3
17 Steam flow through the heater t/h 34.53 35.62 19.86 13.06
Sl. LPH 3 LPH 2 LPH 1
Particular Unit
No. Design Operating Design Operating Design Operating
o
1 FW inlet temperature C 92.00 96.80 68.00 70.20 50.00 55.20
o
2 FW outlet temperature C 119.50 124.90 92.00 96.80 68.00 70.20
3 Specific heat capacity of FW kJ/kgo K 4.21 4.22 4.20 4.20 4.21 4.21
4 FW flow kg/s 80.36 89.14 80.36 89.14 80.36 89.14
5 Ext. steam pressure kgf/cm2 1.19 2.10 0.17 0.70 -0.10
o
6 Ext. steam temperature C 195.00 238.30 105.00 196.70
o
7 Ext. steam sat. temperature C 123.24 121.90 104.20 90.03
8 Ext. steam enthalpy kJ/kg 2865.02 2949.73 2694.88 2871.21 2553.04
o
9 Drain temperature C 98.00 102.00 74.00 79.40 71.00 79.40
10 Enthalpy of sub cooled liquid kJ/kg 411.22 428.03 310.54 333.21 246.00
11 Heat gained by Feed water kWthermal 9305.6 10566.3 8095.9 9953.6 6089.9 5626.1
12 Heat released by Ext. Steam kj/kg 2453.8 2521.7 2384.3 2538.0 2307.0
13 Steam flow through the heater kg/s 3.8 4.2 3.4 3.9 2.6
o
14 TTD C 3.7 -3.0 12.2 -6.8
o
15 DCA C 6.0 5.2 6.0 9.2 21.0 24.2
o
16 Degree of subcooling of drain C 25.2 19.9 30.2 10.6
17 Steam flow through the heater t/h 13.65 15.08 12.22 14.12 9.50
Table 26: Condition assessment of steam cycle components
Sl. No. Particular Remark/observations

01 Turbine
1.1 Piping
MS & RH steam piping OK
Cross over piping OK
HP/LP turbine bypass OK
Exhaust hood OK
Cladding of piping OK
1.2 Valves
Emergency stop valves OK
Control valves OK
Extraction valves OK
NR valves OK
1.3 Main steam flow paths & sealing passages
Inlet nozzle chambers OK
Diaphragms OK
Stationary and moving blades OK
Inter blade clearances OK
HP, IP & LP sealing at inlet and exit side OK
1.4 Governing system
Speed governor OK
02 Condenser
Shell OK
Tubes OK
Water box Minor leakage observed
Expansion joint with LPT casing OK
03 Feed water heaters
HP regenerative feed water heaters Cleaning of tube nest required
LP regenerative feed water heaters OK
Deaerator OK
04 Heat recovery devices
Gland steam condenser OK
Vent steam condenser OK
Stack steam condenser OK
48
Table 27: Thermal performance of Condenser
Sl. Particulars Unit Design Operating

No.
0
01 Temperature at LPT exhaust C 46.4 55.7
02 Condenser absolute pressure kPa 10.6 12.0
03 Saturation temperature in
0
condenser C 46.4 49.4
0
04 Condensate depression C 0.0 -6.3
0
05 TTD across condenser C 3.4 2.4
0
06 CW inlet temperature C 34.0 37.3
0
07 CW outlet temperature C 43.0 47.0
08 Rise in circulating water
0
temperature C 9.0 9.7
09 Vacuum loss due to the higher
cooling water inlet temperature kPa -- --
10 Vacuum loss due to lower cooling
water flow kPa -- --
11 Vacuum loss due to dirty tubes,
lowered area of condenser, in-
leakage of cooling water, air
ingress in condenser and
inadequate capacity of air kPa -- 1.4
removing vacuum pump.
Table 28: Performance of cooling tower 3
Particular Unit Design Trial-1 Trial-2 Trial-3

o
Cooling water inlet temperature C 43.0 42.5 42.6 42.7
o
Cooling water outlet temperature C 33.0 35.7 35.7 35.7
o
Inlet dry bulb temperature C NA 31.8 31.4 31.1
o
Inlet wet bulb temperature C 28.8 26.3 26.6 26.7
o
Range C 10.0 6.9 6.9 7.0
o
Approach C 4.2 9.3 9.1 9.0
Effectiveness % 70.4 42.4 43.0 43.8
49
Table 29: Capacity adequacy of auxiliaries of Unit 3 at test load of 119.14 MW

(99.28 % of MCR)
Unit 3 : Load: 119.14 MW

Rating, Operating Load factor Load factor at
Equipment kW power, kW at test load 100 % MCR
BFP 3A 2000 1450.48 0.73 0.74
BFP 3B 2000 1449.27 0.72 0.74
BFP 3C 2000 1072.87 0.54 0.55
CEP 3A 250 233.31 0.93 0.95
CEP 3B 250 224.93 0.90 0.92
ID fan 3A 680 493.92 0.73 0.74
ID fan 3B 680 418.83 0.62 0.63
FD fan 3A 480 284.09 0.59 0.60
FD fan 3B 480 289.22 0.60 0.61
PA fan 3A 675 306.33 0.45 0.46
PA fan 3B 675 295.48 0.44 0.45
Mill 3A 300 225.28 0.75 0.76
Mill 3B 300 171.63 0.57 0.58
Mill 3D 300 274.99 0.92 0.93
Mill 3E 300 254.62 0.85 0.86
CWP 3A 765 575.60 0.75 0.77
CWP 3B 765 525.26 0.69 0.70
Air Compressor 3C 754 598.93 0.79 0.81
50
Table 30: Review of operation procedures of Unit 3
Sl. Procedure CPRI remarks

No.
01 Pre-operation procedures OK
Clean up OK
Chemical cleaning OK
Blowing steam lines OK
Setting safety valves OK
02 Cold start up OK
Pre-light up OK
Initial firing OK
Light off OK
03 Hot start up OK
04 Warm start up OK
Normal operation OK
05
Increasing load OK
Decreasing load OK
06 Normal shut down OK
07 Emergency procedures OK
Procedures adopted for operational
08 OK
optimization
51
Table 31: Gross efficiency, heat rate and specific fuel consumption
Sl. No. Particular Unit Gross

Efficiency
01 Design overall
efficiency % 38.16
02 Operating overall
efficiency % 33.37
Heat rate
03 Design unit heat rate kcal/kWh 2253.47
kJ/kWh 9433.11
04 Operating unit heat kcal/kWh 2577.07
rate kJ/kWh 10787.72
Specific Fuel Consumption (SFC) at test coal
05 Design SFC kg/kWh 0.48
06 Operating SFC kg/kWh 0.55
Table 32: The deviations in gross overall efficiency from design
Sl. Particular Operating

No.
Difference in components efficiency from design (% points)
01 Boiler 1.72
02 Turbine 4.79
03 Generator 0.02
04 Auxiliary steam Considered separately
05 Auxiliary power Considered separately
Deviation in gross overall efficiency (% points)
06 Boiler related losses 0.71
07 Turbine related losses 4.07
08 Auxiliary steam related losses Considered separately
09 Generator related losses 0.01
10 Total deviation from design efficiency 4.79
52
Table 33: Causes for deviation of gross heat rate from design
Sl. Particular Value

No. (kcal/kWh)
01 Difference in the boiler efficiency from the design efficiency

given by the manufacturer 48.10
02 Difference in the turbine efficiency from the design efficiency
03 Difference in generator efficiency from the design efficiency
04 Due to steam consumption in the boiler, turbine and auxiliary
steam requirements such as blow down, gland steam, vent Considered
steam, stack steam, loss through steam traps, steam tracing separately
and fuel oil tank heating, giving rise to proportional make up
Total difference in gross heat rate 323.6
53
Annex 3
(Procedures, Calculations &
Spread sheets)
1
A 3-1: Efficiency, specific fuel consumption

and heat rate
Q
Steam from boiler
=
Boiler Q
Fuel in to boiler
PMechanical from turbine

Turbine =
Q steam to turbine
QSteam to turbine
Auxiliary steam =
QSteam from boiler
PElectrical from generater

Generater =
PMechanical to generator
PElectrical sent out to generator

PAuxiliary power =
PElectrical generated
Net overall = BoilerTurbine Auxiliary steamGenerator Auxiliary power
2
Gross overall = BoilerTurbine Auxiliary steamGenerator
The detailed formulae are given as follows:
The overall performance of the composite unit can be estimated by using

the individual component performance as inputs. Efficiency is the ratio of
the rate of energy output to the rate of energy input to the system under
consideration. The performance indices are defined as:
i. Gross overall efficiency (o,g)
= P =
O (1)
o, g
Q I
B S T G
ii. Net overall efficiency (o,n)

( )
= P P =
o ,n
O A
O,g
(2)
Q I
A
Where PA is the auxiliary electrical power.
The component efficiencies are defined as follows:
iii. Boiler (B)
Boiler efficiency (
B) is the ratio of the rate of energy output of steam produced
at the boiler outlet to the rate of the energy input in raw coal at the mill inlet.
Q B,s
= (3)
B
Q I
Where QB,s is the rate of energy flow in steam produced by the boiler (in case of
steam generation) .
iv. Turbine efficiency (T)
T) is the ratio of the rate of energy output at the shaft to the

Turbine efficiency (
net rate of energy in steam supplied from the boiler to the turbine.
3
= P T
(4)
T
Q T ,s
Where QT,s is the rate of energy flow in steam drawn by the turbine (in case of
steam turbine). PT is the rate of mechanical energy output of the turbine.
v. Generator efficiency (G)

Generator efficiency (G) is the ratio of the rate of electrical energy output at the
generator terminal to the rate of energy output at the turbo-generator shaft.
= P O
(5)
G
P M
Where PM is the mechanical shaft output of the turbine (gas turbine or steam
turbine).
vi. Auxiliary power efficiency (A)

Auxiliary power efficiency ( A) is the ratio of the rate of energy output exported
from the station to the corresponding rate of energy output at the generator
terminal.
= P P
O A
(6)
A
P O
vii. Auxiliary steam efficiency (S)
Auxiliary steam efficiency (

S) is the ratio of the rate of energy output in steam
supplied to the turbine to the rate of energy output produced at the boiler outlet.
This efficiency is included to take into account any auxiliary steam consumption and
differences between the steam output of the boiler and that of the turbine.
Q T ,s
= (7)
S
Q B ,s
This refers to the usage of auxiliary steam in between the boiler outlet and the
turbine inlet.
4
viii. Specific fuel consumption (SFC)
SFC =
3.6 m f
(8)
P O
Where mf is the rate of primary fuel consumption
ix. Unit heat rate (UHR)

3600
HR = (9)
o, g
The HR is with reference to gross overall efficiency (gross heat rate).

x. Turbine heat rate (THR)
3600
HR = (10)
T
The THR is the turbine efficiency (turbine heat rate).

xi. Turbine isentropic efficiency (is,T)
=
m h s u (11)
is
m h s is
where his is the isentropic enthalpy change (flow weighted) across the turbine and
hu is the net useful enthalpy change (flow weighted) across the turbine (the
enthalpy change which has been converted into work plus the enthalpy change
which has led to heat transfer from the turbine skin). Isentropic efficiency refers to
the fraction of enthalpy difference that is convertible into work.
5
Procedure for efficiency testing of boilers

Efficiency tests were performed on the unit as per BIS 8753:1977.
Conditions maintained for boiler efficiency tests

The following conditions are maintained:
i. Unit must run on3/4th of the test load (TMCR) or more for the last 12 hours
ii. Unit must run at near test load(rated load) (TMCR) for the last 2 hours
iii. Setting period before the test: 60 minutes
iv. Test period: 120 minutes (load to be held constant)
v. Further run on period after test: 15 minutes
vi. Coal from the same source must be used for the past 24 hours
vii. Bunker level at the time of start of test: Full or near to full
viii. Steam output variation during the test: less than 3% of the value test value
ix. Steam pressure variation during the test: less than 6% of the test value
x. Intermittent blow down must be reduced to nil
xi. CBD & MS attemperation flow must be kept constant.
xii. Drum, de-aerator and hot well levels must be maintained steady
xiii. All HP and LP heaters must be in service
xiv. Wherever possible all re-circulation flows HP/LP heater bypass, HP/LP turbine
bypass and valve passing must be reduced to nil
xv. Steam/water lines to service/station requirements, drains on valves and
heaters, auxiliary requirement
xvi. Fuel oil must not be used during the test
xvii. A fuel soot blowing cycle must be carried out before the test
xviii. Wherever possible all maintenance, mill rejection, etc. must be stopped during
the test
xix. All unit auxiliaries must be measured before and after the test.
xx. Operators both at the local site and at the control room must be informed in
advice.
6
Duration of the test:

Two hours excluding one hour stabilization period prior to the test.
Data collection during the test:

Readings were taken from the control room instruments at regular interval of fifteen
minutes. The readings were taken half an hour before the start of the test followed
by every fifteen minutes till the completion of the test.
Samples collected during the tests

1. Raw coal to be collected about 500 gm of 2 samples of which one sample to
be analyzed for proximate and CV analysis. Another sample to be handed
over to CPRI.
Period of collection: to be collected after one hour from the start of the test.
2. Pulverized coal for sieve analysis- from each mill in service from all 4 corners
to constituting a total weight of about 200 gm sieve analysis of these samples
to be carried out.
Period of collection: to be collected after one hour from the start of the test.
3. Fly ash and bottom ash to be collected during the cycle followed by the test
and unburnt test to be carried out.
Period of collection: to be collected during the cycle immediately followed by the

test.
4. Orsat analysis of flue gas at before and after the APH in both LHS and RHS.
Percentage of CO2, O2 and CO to be analyzed.
Period of collection: to be collected half an hour after the start of the test and the
7
second sample to be collected after one and half an hour from the start of the test.
Procedure for efficiency testing of turbines

Conditions maintained for turbine efficiency test
The following conditions are maintained:
(1) Unit must run on 3/4th of the test load or more for the last 12 hour
(2) Unit must run at near test load (rated load) for the last 2 hours
(3) Settling period before the test: 60 Minutes
(4) Test period : 120 Minutes (load to be held constant)
(5) Further run on period after test : 15 Minutes
(6) Coal from the same source must be used for the past 24 hours
(7) Bunker level at the time of start of test;
(8) Steam output variations during the test: less than 3% of the test value
(9) Steam pressure variations during the test: less than 6% of the test value
(10) Intermittent blow down must be reduced to nil
(11) CBD & MS attemperation flow must be kept constant
(12) Drum, de-aerator and hot well levels must be maintained steady
(13) All HP and LP heaters must be in service
(14) Wherever possible all re-circulation flows. HP/LP heater bypass. HP/LP
turbine bypass and valve passing must be reduced to nil
(15) Isolation of the following is required: large volume storage tanks, by pass
systems, auxiliary steam lines, drain lines on stop, interceptor and control
valves; interconnecting lines to other units, steam coil APH,DM water
equipment, soot blowers, heater shell drains, heater drain bypass,
steam/water lines and turbine washing lines
(16) All Unit auxiliaries must be kept in constant condition during the test
(17) Bunker level must be measured before and after the test
(18) Operators both at the control room must be informed in advance
8
Duration of the test:

Two hours excluding one hour stabilization period prior to the test
Data requirement:
Readings were taken from the control room instruments at regular interval of fifteen
minutes. The readings were taken half an hour before the start of the test followed
by every fifteen minutes till the completion of the test.
9
Boiler efficiency calculation
Sl.
Particular Unit Unit # 3
No.
1 Gross calorific value of fuel (HCV) kcal/kg 4623
2 % of Carbon in fuel % 47.22
3 % of Sulphur in fuel % 0.60
4 % of moisture in fuel % 6.60
5 % of ash in fuel % 38.93
6 % of Hydrogen in fuel % 3.20
7 % of Oxygen in fuel % 6.55
8 % of UB in bottom ash % 5.60
9 % of UB in fly ash % 1.90
o
10 Bottom ash temp. C 900.00
o
11 Fly ash temp. C 153.67
12 Sp. Heat of bottom ash kJ/kgK 1.05
13 Sp. Heat of fly ash kJ/kgK 0.84
14 CO in flue gas ppm 350.00
15 % O2 in flue gas after APH % 6.76
o
16 FG temp. at APH outlet C 153.67
o
17 Ambient air temperature C 35.61
18 Humidity fraction of ambient air kg/kg 0.0206
19 Mill input shaft power kW 926.51
20 PA Fan input shaft power kW 601.82
21 FD Fan input shaft power kW 573.32
o
22 Avg. furnace skin temperature C 72.70
23 Furnace outer surface area m2 1629.50
24 Calorific value of CO kJ/kg 10092.40
25 % O2 in flue gas before APH % 4.14
26 % O2 in furnace % 4.14
o
27 Leaking FG temp. at first pass C 0.00
--
28 FG puffing factor in first pass 0.00
10
Boiler efficiency calculation (Contd)
Sl.
No.
29 Gross calorific value of fuel (HCV) kJ/kg 19351.88
30 Net calorific value of fuel (LCV) kJ/kg 18648.63
CO2 in flue gas (Computed from
31 O2) % 12.58
32 Mass of air required for combustion kg/kg 6.84
33 Heat loss due to unburnt CO kJ/kg 33.62
34 Excess air factor at furnace -- 1.25
35 Excess air factor at APH inlet -- 1.25
Heat loss due to puffing in furnace
36 first pass kJ/kg 0.00
37 Loss due to bottom ash % 0.76
38 Loss due to fly ash % 1.03
Loss due to sens. Heat of bottom
39 ash % 0.37
40 Loss due to sens. Heat of fly ash % 0.16
41 Loss due to unburnt CO in flue gas % 0.17
42 Loss due to sens. Heat in dry FG % 5.77
43 Loss due to moisture in fuel % 0.90
44 Loss due to hydrogen in fuel % 3.91
45 Loss due to moisture in comb. Air % 0.16
46 Loss due to convection % 1.06
47 Loss due to radiation % 0.50
48 Heat equivalent of auxiliary power % -0.11
Heat loss due to puffing in furnace
49 first pass % 0.00
50 Total losses % 14.69
51 Thermal efficiency % 85.31
Correction factor to account for
52 annual average station GCV 0.00
53 Corrected test boiler efficiency % 85.31
11
Turbine efficiency calculation
Sl.
No.
1 MS flow into turbine t/h 387.35
2 HRH flow t/h 355.34
3 RH spray t/h 1.10
4 Plant load MW 119.14
5 Enthalpy of MS kJ/kg 3437.63
6 Enthalpy of HRH kJ/kg 3533.54
7 Enthalpy of CRH kJ/kg 3133.24
8 Enthalpy of RH spray kJ/kg 710.10
9 Enthalpy of FW at oulet of final feed heater kJ/kg 981.28
10 Generator efficiency % 98.61
11 Generator efficiency fraction 0.99
12 THR __ 2.52
13 Turbine heat rate kJ/kWh 9075.22
14 Turbine heat rate kcal/kWh 2167.97
15 Turbine efficiency % 39.67
16 Specific steam consumption t/MWh 3.25
12
Overall efficiency calculation
Sl. No. Particular Unit Unit # 3

1 Boiler efficiency (Operating) % 85.31
2 Turbine efficiency (Operating) % 39.67
3 Generator efficiency (Operating) % 98.61
4 Auxiliary power (Operating) MW 0.0
5 HCV of fuel kcal/kg 4723
6 MS flow to turbine (Operating) t/h 387.35
7 Auxiliary steam flow (Operating) t/h 0
8 RH spray (Operating) t/h 1.10
9 Cont. blow down (Operating) t/h 0.0
10 Intermittent blow down (Operating) t/h 0.0
11 MS enthalpy (operating) kJ/kg 3437.63
12 RH spray enthalpy (operating) kJ/kg 710.10
13 Aux. Stm. Enthalpy (Operating) kJ/kg 3076.4
14 Blowdwon enthalpy (Operating) kJ/kg 0.0
15 Gross overall efficiency (Operating) % 33.37
16 Plant load (Operating) MW 119.14
17 Net overall efficiency (Operating) % 33.37
18 Gross heat rate (Operating) kcal/kWh 2577.07
kJ/kWh 10787.72
19 Net heat rate (Operating) kcal/kWh 2577.07
kJ/kWh 10787.72
20 Operating gross SFC kg/kWh 0.55
21 Operating net SFC kg/kWh 0.55
22 Plant load (Design) MW 120
23 Boiler efficiency (Design) % 87.03
24 Turbine efficiency (Design) % 44.46
25 Generator efficiency (Design) % 98.63
26 Auxiliary power (Design) MW 0.00
27 Aux. Power efficiency (Design) % 1
28 MS flow to turbine (Design) t/h 355.6
29 Aux. Steam flow (Design) t/h 0
30 Aux. Steam efficiency (Design) % 1.00
13
Overall efficiency calculation (Contd)
31 Aux. power efficiency (Operating) % 1.00

32 Aux. Steam efficiency (Operating) % 1.00
33 Gross overall efficiency (Design) % 38.16
34 Net overall efficiency (Design) % 38.16
35 Gross heat rate (Design) kcal/kWh 2253.47
kJ/kWh 9433.11
36 Net heat rate (Design) kcal/kWh 2253.47
kJ/kWh 9433.11
37 Design gross SFC kg/kWh 0.48
38 Design net SFC kg/kWh 0.48
Difference in efficiencies
39 Boiler % pts 1.72
40 Turbine % pts 4.79
41 Generator % pts 0.02
42 Aux. Power % pts 0.00
43 Aux. Steam % pts 0.00
Deviation in net overall efficiencies (%pts)
44 Boiler related loss % pts 0.71
45 Turbine related loss % pts 4.07
46 Generator related loss % pts 0.01
47 Aux. Power related loss % pts 0.00
48 Aux. Steam related loss % pts 0.00
49 Total dev. From design efficiency % pts 4.79
SFC at various points in the circuit
50 SFC to produce unit electrical t/MWh(net
energy exported elec.) 0.55
51 SFC to produce unit electrical t/MWh(gross
energy at the generator terminal elec.) 0.55
52 SFC to produce unit mechanical t/MWh
energy at turbine shaft (mech.) 0.54
53 SFC to produce unit energy in flue t/MWh
gas in furnace (thermal) 0.21
14
Overall efficiency calculation (Contd)
Saving in fuel
54 Saving in fuel t/h 8.16
55 Saving in fuel % 12.56
Deviation in gross overall efficiencies (%pts)
56 Boiler related loss % pts 0.71
57 Turbine related loss % pts 4.07
58 Generator related loss % pts 0.01
59 Aux. Power related loss % pts 0.00
60 Aux. Steam related loss % pts 0.00
61 Total dev. From design efficiency % pts 4.79
15
Annex 4
(Documents Copied)
1
A 4-1: TRIPPING DATA.
Reason for Energy

Sl Date of Date of Duration Fault-
Time Time shut down / lost
No. outage syn (Hrs) Int/ext
Tripping (MWH)
Boiler
tripped on
1 23.05.08 10:01 23.05.08 11:41 1.67 Tripped 200.4
RH
protection
Boiler
tripped on
2 27.05.08 07:38 27.05.08 10:16 2.63 Tripped 315.6
RH
protection
Generator
tripped on
3 03.06.08 16:46 03.06.08 19:03 2.25 Tripped 270
reverse
power
Turbine
tripped on
4 15.06.08 10:57 15.06.08 13:26 1.5 Tripped condenser 180
vacuum very
low
Condenser
5 03.08.08 23:34 04.08.08 18:17 18.75 Planned water box 2250
cleaning
Generator
tripped on
6 22.08.08 09:50 22.08.08 13:02 3.2 Tripped 384
Class-A
protection
Flame
7 17.09.08 22:18 18.09.08 01:16 3 Tripped 360
Failure
Flame
8 28.09.08 16:35 28.09.08 18:12 1.63 Tripped 195.6
Failure
Condenser
9 30.09.08 13:31 30.09.08 15:04 1.55 Tripped Pressure 186
very high
2
Human
error, during
change over
10 25.11.08 14:16 25.11.08 14:38 0.37 Tripped 44.4
of Bus
configuration
for export.
Boiler
tripped on
11 17.02.09 16:32 17.02.09 18:08 1.6 Tripped 192
Flame
failure
Total Time 38.15 4578
Reason for Energy

Sl Date of Date of Duration Fault-
Time Time shut down / lost
No. outage syn (Hrs) Int/ext
Tripping (MWH)
1 09.06.09 13:15 09.06.09 14:50 1.42 Tripped Over speed 170.4
Boiler tripped
2 01.08.09 04:05 01.08.09 07:06 3 Tripped on Flame 360
Failure
Boiler tripped
3 11.08.09 07:51 11.08.09 10:24 2.55 Tripped on Flame 306
Failure
Turbine
Tripped on
4 09.09.09 03:03 09.09.09 07:05 4 Tripped Lub oil 480
Pressure Very
Low
Boiler tripped
5 03.12.09 05:22 03.12.09 07:50 2.5 Tripped on RH 300
Protection
6 23.12.09 18:09 Planned Desynchronised
Total Time 13.47 1616.4
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66
TATA POWER COMPANY LIMITED
JOJOBERA THERMAL POWER STATION
JOJOBERA, JHARKHAND
Proposal for PC-Based Progress 3 Engineering cum Diagnostic Station

and 800xA Human Machine Interface for 2 x 120 MW Units
ABB OFFER NO: E.UAPS.RE.8.0052. R1 DATED 04. 05.2009
ENQUIRY REF : Site Visit of our Representative
TECHNO -COMMERCIAL PROPOSAL
ABB LIMITED
PS POWER GENERATION
PLOT NO. 5 & 6, PHASE II,
PEENYA INDUSTRIAL AREA
BANGALORE 560 058
ABB
Customer TPC Ltd, Jojobera Thermal Power Station
Project
Offer No
Enquiry ref
Proposal for Progress3, and 800xA HMI
E.UAPS.RE.8.0052. R1 dated 04.5.200 9
Site Visit of our Representative ABB
1.0 Preface
2 x 120 MW TPC, Jojobera Thermal Power Station has Procontrol P13 make control system of ABB
design with WSPose in units 2,3 as HMI. This system is utilized for realizing various functions
required for control; monitoring and operation of the FSSS and ATRS of 120 MW power generating
Unit # 2,3. The existing Procontrol system is provided with One Diagnostic station and Logic
development station for each unit. The existing system in each unit is using 2 IPBs.
Due to the age of the installed system and difficulty in maintenance and operation of the old
hardware, there is a requirement to upgrade the control system HMI. The requirement is for HMI
system that is Windows 2003/XP based compatible with the existing ABB make Procontrol System
with no loss/degradation in functionality/performance. ABB offers tailor made solutions for
upgrading/refurbishing the existing systems at minimum costs and without compromising on the
system performance. The interface for P13 is an original ABB design hardware developed for
Procontrol P13. This hardware is utilized as the interface for the HMI developed by ABB for its
Procontrol P13/42 and Advant series of DCS. The 800xA is a truly open HMI system based on
standard PC hardware, based on industry standard software like Windows 200X/XP and MS
Excel/ODBC/DDE/OPC etc.
The diagnostic station present at the plant is PRAUT microcomputer based SK06, which is used for
the logic development and monitoring of the system.
Due to shortcomings of SK06, the plant can face problem whenever there arises a need in
modification of the program or forcing of signals is to be done under the certain conditions, when
SK06 is connected to a particular 70PR03/70PR05. Also it is not possible with SK06 to do subsequent
operation w ith different participants.
This offer gives a detailed description of the upgrade for the existing Diagnostic Station to
Progress 3 and HMI to ABB latest state of the art solution -800xA. The offer is divided into two
phases, in the first phase we propose to upgrade the Engineering Station and in the second Phase, the
existing HMI to 800xA. Both the activities will be carried out in parallel.
2.0 Procontrol P13 Upgradation of Engineering cum Diagnostic Station:
2.1Technical Proposal:
Progress 3, is based on Windows XP Operating station platform and compatible with the existing
Procontrol P13 system with no loss/degradation in functionality/performance.
Techno-Commercial Proposal
Techno-Commercial Proposal Page 2 of 36
Preliminary Draft- For Discussion Only-Confidential
We reserve all rights in this document and in the information contained therein. Reproduction, use or disclosure to third parties without express
authority is strictly forbidden. Copyright 2008 ABB. All rights reserved.
Project
Offer No
Enquiry ref
E.UAPS.RE.8.0052. R1 dated 04.5.200 9
Based on the initial discussions at ABB Bangalore, ABB had proposed to introduce 6 number of
70BK03 modules to access data from the TMR local panels into Progress3. However, based on site
visit and discussions at site, it is proposed to extend the existing IPB (One Number) to all the TMR
panels. This will have the following advantages.
Access of Trend Data from the signals.
Separate FKB signals will not be required.
Trip Conditions (22 signals) from each of the TMR channels shall be connected to the new HMI
System to help trip analysis. This will help in root cause analysis for the trip conditions.
Internal Signals of BK and PR modules will also be available for analysis into Progress3.
However, the existing TMR Configuration, its functionality and the communication from TMR panels
to common panel will be retained as existing.
The existing TMR panels communicate with the IPB by means of communication through 70BK03
modules. The schematic below shows the existing configuration.
Fig-01: Existing Configuration
Project
Offer No
Enquiry ref
E.UAPS.RE.8.0052. R1 dated 04.5.200 9
For the TMR configuration of EHTC and Turbine Protection, it is proposed to extend the IPB to the
se local Buses for better data aquisison.
In order to extend the IPB, ABB will introduce 2 BK02 (One for Turbine Protection and One for
EHTC) and One 70FA01 box with FK coupler cards for each TMR panel. Please refer below schematic.
Progress 3 Computer will placed near the diagnostic panels within a distance of 2mtrs.
Connection to the control system
The Procontrol P13 Progress 3 is connected to the platform via one or more 70BK03 modules.
The process of up gradation will include the replacement of existing PC for diagnostic Station. The
connection to IPB will be through 70BK03C module installed in the existing diagnostic panel. The
Progress 3 computer will be connected to the 70BK03C module over serial (RS232) communication.
The Progress 3 computer will be communicating through 70BK03C in the diagnostic panel to the IPBs
and hence to the different stations on the IPBs.
Project
Offer No
Enquiry ref
E.UAPS.RE.8.0052. R1 dated 04.5.200 9
The Proposed configuration is shown in the above drawing.
In the present case in a 70BK03 will be placed in the existing diagnostic station where the progress 3
computer will be connected to the 70BK03. The system will be communicating through the 70 BK02
modules in the diagnostic station to the IPBs and to the local stations.
2.2 Attractive Features:
Procontrol Progress 3 is a Programming documentation and service tool. It has been specifically
designed to enable upgrade or replacement of older generation of Procontrol Engineering. The
system runs on Microsoft Windows 2000/XP Professional Personal Computers or Notebooks. It is
controlled interactively on monitor with aid of state of the art user-friendly graphical interface
windows techniques.
1) Single Point Uploading: The instruction codes can be read and loaded to the EEPROMs of the
70PR05 processors of all the P13 stations from single point i.e Progress 3 engineering station. This
eases the conventional process of program loading by connecting to the processors individually.
2) Easy Code Transfer: The ease of code transfer from existing EPROMs and graphical
documentation of the codes makes it an ideal choice for Procontrol Processor Upgrades. Additional
import functions allow the as built documentation of existing application programs generated by
older Procontrol P13 tool generations.
3) Over all Administration and Addressing: Progress 3 provides all the facilities the user needs to
Engineer, Commission and service the Procontrol P13 Platform. This includes the administration of:
Project
Offer No
Enquiry ref
E.UAPS.RE.8.0052. R1 dated 04.5.200 9
Projects
Intra Plant busses
Local busses
Bus Couplers
Stations, racks, devices
Signals
Documentation Structure
Load Modules
Parameters
Test sets
Also the addressing includes of:
Devices
Signals
Parameters
Service RAM
4) Online Functions: These mainly include:

Debugging with Function Block diagram.
Recording of Signals
Forcing of Signals
Loading of Parameters
Loading of Programs
Reading of EPROM data
Disturbance bit display
Project
Offer No
Enquiry ref
E.UAPS.RE.8.0052. R1 dated 04.5.200 9
5) Print Functions: This includes printing of:

Functional block diagram
Signals
Hex-code
Intra Plant Bus Listing
Local Bus Listing
Parameter Listing
Racks with module occupation.
6) Spare Inventory Minimization
With the implementation of PC based Progress 3, Procontrol modules like 70SK30, 70SK31, 70SK32,
70SK33, 70SK34, 70SK35, 70SK36, 70SK37 modules are not required and hence bringing down the
inventory and spare requirement for these modules.
Note: The above features are the software features of Progress 3 software. The complete use of the
functionality and the features will depend on the existing Procontrol P13 system, its interface to the
existing P13 and available engineering backups.
Project
Offer No
Enquiry ref
E.UAPS.RE.8.0052. R1 dated 04.5.200 9
2.3 Development of Functional Block Diagram
As the logic back-up available with M/s Tata Power is in the form of hex -code, the logic for each
controller will be developed in the form of functional block diagram from the existing hardcopy
documentation available at Plant.
From the available document we find that there is 28 redundant pair of controllers and 18 non
redundant Controllers. There is approximately 85 drive control modules (AS04 modules) installed in
the Plant.
The Process of development of a Function Block diagram will involve the following steps.
Development of signal list from the existing documents.
Creation of Function Block diagram from the existing documents in the Function Block editor of
Progress 3.
Comparison of the target code generated with the one existing in the Controller in the form of
Hex Code. Correction if any.
Commissioning the Function Block diagram.
3.0 Upgradation of the WS Pose HMI System to ABB 800xA HMI
As per ABBs standard policy and in order to bring your plant to the current technology level from time
to time and market trends, ABB is committed towards providing you with the best solutions based on
the technological upgrades and continuous enhancements, globally over the years.
It is our endeavor to inform and provide you the opportunities for implementing state of the art
technology as a step towards protection of your investment and prolonging plant & system life.
Upgrades of the Procontrol P13/42 system with the latest HMI Operator system have been carried out
at a number of other installations by ABB.
ABBs latest generation of Human System Interface, the 800xA (Process Portal A), combines the
comprehensive process know-how and installation experience with advanced software functionality.
Project
Offer No
Enquiry ref
E.UAPS.RE.8.0052. R1 dated 04.5.200 9
Based on Windows 2003/XP platform, the 800xA unified user interface provides a consistent method
for accessing enterprise wide data in real-time for managerial decisions as well as for launching multiple
applications from any connected workstation in your plant or office. The software, 800xA is a truly
open HMI system based on standard PC hardware and works on industry standard software like
Windows 200X/XP and MS Excel/ODBC/DDE/OPC etc.
The seamless integration of ABBs Procontrol P13 Platform in to the world of Industrial IT allows you
to increase your overall efficiency and to achieve greater asset optimization by making real-time data
available across the entire enterprise. 800xA Process Portal provides flexible opera tion with a high
level of scalability in order to respond to changing operation and production needs.
3.1 Proposal
It is proposed an two 800xA servers with 100% data handling capacity will be installed to achieve data
concentration from the local P13/42 IPB for the HMI system.
With our 800xA and P13 Connect solution, we provide the possibility for step wise, continuous
migration solutions to the latest automation technology. This unique ABB approach ensures investment
protection by preventing equipment obsolescence through out the plants life.
The modifications in the 800xA application program are limited to the interconnection functionality
to the new 800xA.
A modification of the Procontrol P13 application programming to change the functionality of the plant
control is neither envisaged nor required.
A sample overview of the new operator station system is shown below.
Project
Offer No
Enquiry ref
E.UAPS.RE.8.0052. R1 dated 04.5.200 9
Fig 01: Procontrol P13/42 configuration with 800xA

3.2 Details of the Installation process:
The installation process is a detailed operation involving a high level of design, engineering and
planning in order to achieve the required level of reliability and functionality. In order to achieve this,
the following procedure is followed as a standard:
1. Data collection of existing HMI : This step involves the process of collecting data and details of
the existing configuration and various other aspects like the Mimics, trends, logs, reports etc. This
step also involves the handover of critical data like the VPC command structures; partitioning
diagrams and the engineering database dump from the EDS/ OWS, Performance calculation details
etc by the customer to ABB.
2. Design and Engineering of the New HMI package: In this step, the New HMI package
configuration and functionalities are built in line with the existing plant operation philosophy and
system configuration. Many improvements in the mimic layout and look and feel can be integrated
during this procedure with the involvement of the plant engineers with ABB engineers during this
stage. The new Mimic layouts, trend configurations, log and report configurations are carried out in
this step. Configuration and migration of the existing engineering and configuration data is also
carried out.
Project
Offer No
Enquiry ref
E.UAPS.RE.8.0052. R1 dated 04.5.200 9
Fig:02
3. Installation of New HMI software server: As the first step, the data acquisition server is loaded and
initialized with the new HMI software. The newly installed server is then connected to the P13/42 IPB
using the spare set of tapping from the FA coupler box. This server is assigned the last available address
on the IPB. Please refer figure below for details of the retrofit. This step is carried out online during
plant operation with out any hindrance to normal control and operations of the plant.
Once the parallel data acquisition server is put online, the acquisition of data on this server and its
associated client is monitored. Commands are given from this operator station and checked on the
Diagnostic station by calling the telegram address for that command. These commands will not have any
effect on the normal plant operation or DCS functioning as the addresses used will be un-used in the P13
logics. Hence these commands can only be read by the Diagnostic station and will not be read by the P13
controllers. This monitoring process is carried on till each of the tags configured have been physically
verified for correctness of configurations. Refer fig:03
Project
Offer No
Enquiry ref
E.UAPS.RE.8.0052. R1 dated 04.5.200 9
4. Hot commissioning of the installed server: This step is carried out during any available plant
shutdown, which could be of a very small duration to enable on-line HOT testing of the commands from the
new HMI stations. In this step, one of the existing servers is shutdown and brought offline. Now, the new
HMI server is assigned the address of this existing server, which has been brought offline, and normal
operation is resorted to from this new Server client setup. As all the data acquisition tags and command
tags including feedbacks have already been tested using parallel server and the Diagnostic station, in step
# 3, this step will involve actual operation of only the required drives and valves etc in order to HOT
commission the new HMI system.
Project
Offer No
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E.UAPS.RE.8.0052. R1 dated 04.5.200 9
3.3 Highlights of 800xA HMI System
IMPORTANT TECHNICAL ASPECTS:
1) P13 interface with OperateIT:
The P13 interface represents the linking element between the process visualization software and the
P13 bus through PIF Board. The PIF board serves to connect to the P13 bus directly. In turn, the P13
interface accesses the PIF board, which is mounted directly in the PCI slots instead of the conventional
ISA slots that are obsolete. Interfacing of Operate IT with ABB make Procontrol P13 system is done
by the PIF card, which communicates directly with the P13 without any third party communication
device in between. Hence the hardware reliability is maintained. Following are some of the advantages
of the PIF card:
Project
Offer No
Enquiry ref
E.UAPS.RE.8.0052. R1 dated 04.5.200 9
Advantages:
Interface 800xA directly with P13 without any third party interface between P13 & 800xA.
Interface mounts directly in PCI slots, which eliminates the hardware obsolesce problem as in
traditional ISA slots.
Control program to watch several Statistical values concerning P13 Interface
Interface device driver diagnosis tool in Windows NT to check the status, interrupt used and I/O
port address area reserved by the device driver.
Typical layout of the interface card:
2) Drive Control with 800xA:
The control functions can be easily and efficiently designed using the Functional Unit libraries included
in 800xA, which reflect power plant standards and practice. These libraries include standard basic
function blocks for analog and binary functions. Furthermore, proven solutions for handling drives,
pumps, controllers etc. have also been programmed into function blocks and are offered with the
800xA shown in table 1. Furthermore, to increase engineering efficiency and quality on a functional
level, a library of Functional Units is offered with the 800xA. A Functional Unit serves as an entity,
keeping all the components for a specific solution such as a drive, across the control system.
Accordingly, and as shown in figure 1, each Functional Unit consists of: 1) process I/O functions 2)
application macro communication over the Control Bus, HMI presentation data (faceplate and object
display attributes)
Project
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E.UAPS.RE.8.0052. R1 dated 04.5.200 9
ProcontrolP13
Examples of Functional Units
1. Two-state drive control

2. Servo drive control
3. Solenoid valve control
4. Analog drive control
5. Incremental drive control
6. Binary control logic
7. Group logic control
8. Group control
9. Selector (2, 3, 4)
10. Manual station
11. Set point integrator
12. Analog input
13. Digital input
Note: The above features are the software features of P13 connect software. The complete use of
the functionality and the features will depend on the existing Procontrol P13 system, its limitations
and available engineering backups.
Attractive features and Benefits:

Existing PRAUT ,PMS, POSE, WS -Pose operator stations are based on general purpose computing
platforms, which became obsolete much faster than the basic control system. Replacing these operator
stations provides attractive features and benefits:
Data Integration:
Using the 800xA Servers and through Fiber Optic Communication all real time data including process
graphic, trends, logs, alarms etc for individual, multiple units can be made available at a single place.
PC based operator stations

Open the Procontrol P13 system to the new industrial standards and improve its connectivity as a result
of the OPC technology used in the P13 Connect design.
Ease of use
800xA and P13 Connect, is a dedicated power plant operator station solution designed to increase power
plant operation efficiency and reduce engineering effort.
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E.UAPS.RE.8.0052. R1 dated 04.5.200 9
Information transmission security
Redundant Interface design and high coupler performance allow safe bi-directional transmission of any
signal without loss of information.
Full compatibility
As the original Procontrol P13 equipment supplier, and based on our large experience and reference in
hundreds of power plants world wide, we guarantee the full compatibility of the new 800xA with the
Procontrol P13 automation solution.
On-line retrofit
As the original Procontrol P13 equipment designers, and based on our large experience a high degree of
Design and Engineering reliability has been built into the retrofit solution for P13/42 systems. Due to
this, it is possible to perform a really On-line retrofit solution even in a critical application such as a
power plant control system. This provides an opportunity to upgrade/retrofit the P13 systems without
the requirement of an actual plant shutdown. A plant shutdown would be required only for a few days
for the purpose of HOT testing of the critical drives etc.
Investment protection
With our OperateIT and P13 Connect solution, we provide the possibility for stepwise, continuous
migration solutions to the latest automation technology. This unique ABB approach ensures investment
protection by preventing equipment obsolescence through out the plant life.
Real time information

OperateIT and P13 Connect ensure real time access to all information available within the control
system wherever the information is needed. ABBs Aspect Object Technology ensures easy
configuration and access to the required information.
ASPECT OBJECT: Special tool with 800xA

Def: An aspect is a description of some properties of a real world entity. The properties described
could be mechanical layout, how the object is controlled, a live video image, name of the object etc.
Using Aspect Object property in 800xA one can access various real world entities with a single click of
the mouse.
With the click of a mouse we can access all relevant information concerned to an object as shown in the
fig below .
Project
Offer No
Enquiry ref
E.UAPS.RE.8.0052. R1 dated 04.5.200 9
Aspect Object
...one integrated thing that Aspects
hides all the differences"
Process
IFS Graphics
Real ABB Operator Interaction
Object Object
Maintenance record
Operator interaction
Control
Control
MS Word
Builder
Control
Data sheet
Simulation
iGES
ElMaster Model
Simulation
Electrical Model
diagram
AutoCad
MS
P&IExcel
Diagram
P&ILoop
Diagram
spec
Aspect
Systems
ABB Automation
OIT Overview 000907
Page 10
The enabling technology for this data access, storage, and management is ABBs patented Aspect
Object framework. Aspect Objects relate all of your plant data, the Aspects, to specific plant assets,
the Objects. The headache of locating information spread between different people, locations,
computers, and applications is over. Aspect Object navigation presents the entire production facility in
a consistent, easy to view fashion. This allows a single window environment to include smart field
devices, asset optimization functions, information management, batch management, safety systems, and
MES (Manufacturing Execution Systems) applications.
Figure 1 More examples of Aspects of an Object
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Offer No
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E.UAPS.RE.8.0052. R1 dated 04.5.200 9
800xA OPC Client Connection
The 800xA OPC Client Connection is intended for use with third party clients. In an ABB Industrial
IT installation, the connectivity packages are used to integrate the operator workplaces, etc. with
the Industrial IT controllers.
All run-time data, and some configuration data in the system is available for other clients via OPC.
The 800xA System acts as an OPC-Server for OPC-DA and OPCHDA. The 800xA System acts as an
OPC-Server for OPC-DA (1.0, 2.0), OPC-HDA (1.20), and OPC -AE (1.1). Several OPC-Clients can be
connected simultaneously to the system to exchange data.
Operations
The Operator Workplace is built on Operate IT process portal technology and it is the 800xA
System Operator Interface.
The key functions provided are: presentation of process graphics, execution of process faceplates,
presentation of trends, and presentation of alarms.
Two types of Operator Workplace clients exist:
Operator Workplace - Client.
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Offer No
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E.UAPS.RE.8.0052. R1 dated 04.5.200 9
Operator Workplace - Remote Client.
Features:
Personalized workplaces for focused information access
Intuitive and flexible navigation for fast information access

Integrated data for informed decision-making
Comprehensive operator functionality for reliable control
Operator Workplace Client
The Operator Workplace provides efficient control and supervision of different kinds of processes in
integrated systems.
The Operator Workplace uses client/server capabilities allowing both client and server applications to
run in one PC for a small configuration, or to run in a configuration with one server and up to thirty
client workplaces.
Functional overview:
Graphics displays, with support for ActiveX components to include any third
party graphical component.
Faceplates for process objects.

Alarm and Event management and presentation.
Operator History, including trend presentation and Alarm and Event history.
Excel based reporting (scheduled and on demand).
System Status Viewer.
Topology Status Viewer.

The Operator Workplace provides a number of configurable options that allow a user to tailor the
workplace to suit their needs, be they a senior or junior operator, an engineer, a maintenance
technician, a manager supervisor or a system administrator.
Faceplates
Faceplates are designed mainly for operator use, to monitor and effect control of a process. Each
object can have up to three different sized faceplates, depending on the needs of the object and the
user (see Figure 2 Faceplates.)
The Operator Workplace provides a flexible faceplate framework, making the creation and the
customization of the product-supplied faceplates straightforward and intuitive. The faceplate
framework is composed of five main areas.
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E.UAPS.RE.8.0052. R1 dated 04.5.200 9
1. At the top of the faceplate is the header area. This includes the object name and description,
as well as alarm state indication, acknowledgement button, and object in-use (or locked)
indication.
2. Below the header area is the status area. This includes object state indication (e.g., manual
mode) and link buttons to other aspects (e.g., operator note).
3. At the bottom of the faceplate are the faceplate size selection buttons (for reduced, normal,
and expanded size faceplates).
4. Above the faceplate size selection buttons is the control button area. The configuration of the
status and button areas is done through simple fill-in-the blanks configuration and provides the
ability to link in button and status indicators.
5. Between the status and button area is a faceplate element area. This is a free-form graphic
that is configured in the same way as any process graphic.
Figure 2 Faceplates
Quad Display
It is possible to divide the display area in four smaller areas where each area can hold an individual
display to get a better overview of a process. The content of each mall area can be maximized to
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E.UAPS.RE.8.0052. R1 dated 04.5.200 9
cover the whole display area and will return to the original quarter area again when minimized. See
Figure 7A.
Figure 7A Operator Workplace Quad Display layout
Navigation
The Operator Workplace supports the ability to right click on any object to view and select available
actions or display call-ups from a context menu. For a given user, the context menu is the same, no
matter where the object is displayed. The configuration of an object in and of itself automatically
defines the possible selections available within the context menu. The context menu is filterable
based upon the user log-in, such that an engineer might have access to certain actions that are
configuration-related, while an operator would not have access to them. The context menu also
contains a reference list of other graphics or displays in which the same object is used, allowing the
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E.UAPS.RE.8.0052. R1 dated 04.5.200 9
user to quickly navigate to them. This reference list is provided automatically without requiring the
user to do any manual mapping.
Within the tool collection of the application bar, a number of navigational buttons and pull down menus
are available to provide quick access to displays and information. Object and aspect history lists as
well as back and forward buttons allow an operator to view and recall past selections quickly.
Associated displays of a selected object or aspect can be quickly called up using short cut buttons
that are automatically enabled when the object or aspect is selected.
Alarm List
The Alarm List displays all events matching the configured alarm filter. All, or a subset of an events
attributes, along with the current value for that objects can be displayed. Viewing the alarms is very
flexible. Use the default sort order or adjust the sorting by double clicking on the headers. Adjust
the layout by drag & drop columns to suit your needs. Return to the default layout by just clicking on
the reset button.
Figure 3 Alarm list

Acknowledge of individual alarms, selected multiple alarms, or an entire page of alarms can be
performed from the Alarm List.
The colors and blinking of alarms are configurable. It is also possible to define what columns to
present, the time format, and the sorting order of the list.
Event List
The Event List displays all events matching the configured event filter. The event list functionality is
the same as for alarm list, except acknowledge.
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E.UAPS.RE.8.0052. R1 dated 04.5.200 9
Trend Display
Trend displays are some of the most important tools associated with operating and analyzing
industrial process. The Operator Workplace addresses this need by presenting the operator wing an
extensive set of trending features and functions.
Figure 4 Trend Display
Operator Workplace - Remote Client (Optional package, not quoted)

The Terminal Service concept enables remote access to an 800xA system from a standard PC without
ABB-specific software installed. The remote client provides operation capabilities and access to
historical information. Configuration capabilities are limited on the remote client. The same security
concept utilized for a rich client will be used for the remote client, making it possible to define those
actions that are permitted from a remote client.
The Remote Clients adhere to the access control concept generally supported by Operator Workplace
Clients.
The following functions are remote client enabled:

Plant Explorer navigation
Operation graphics, alarm&event, trend, history logging, system status, and faceplates
Information Manager
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Offer No
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E.UAPS.RE.8.0052. R1 dated 04.5.200 9
Batch client
A third party solution from Citrix is used to implement remote clients. Ci trix Metaframe Presentation
Server software must be installed on an Application Server running an Operator Workplace rich
client to enable access from remote clients.
Audit Trail
The Security and Access Control System allows audit of operator actions and security. The system
supports logging of security violations, configuration changes, and operator actions to the process.
The audit logs can be viewed in the alarm and event list. This makes it possible to see the effect of
an operation. The audit log contains the following information:
Date and time for the operation
Node from which the operation was performed

User name of the individual performing the operation
Type of operation
Object, property or aspect affected by the operation
Additional information from the involved aspect system
Figure 5A An Example of an Audit List
Some more features and benefits are:
PC system based on Windows /200x/XP
Power plant specific look and feel
Platform for process and information management software with easy access to process data.
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E.UAPS.RE.8.0052. R1 dated 04.5.200 9
Replacement /Up gradation needs minimal Engineering.
Easy maintenance and availability of spare parts
Use of latest computing and information technology
Mouse only operation and multi screening
Full graphics 1280 x 1024 pixels process presentation
Process operation from any of the operator stations using face plates for interaction
Display of sequence and interlocking control conditions
Advanced alarm and event handling, using priorities and configurable filters
Trend recording and real-time monitoring
Excel based reports (standard and user definable).
Configurable history for events, analog values and reports
Open for user applications due to international standards
Comprehensive set of application packages
Engineering support for Procontrol P13/42
Project
Offer No
Enquiry ref
E.UAPS.RE.8.0052. R1 dated 04.5.200 9
5.0 Replacement of Critical Modules.
Based on the site visit and discussion, it is proposed that the following critical modules whose
malfunctioning may cause Unit Tripping will be replaced with imported modules of ABB. This
replacement is to be done in each of the TMR Channels
It is also proposed to replace some of the existing modules of the Turbine Protection Panel (CJJ32)
and EHTC Common (CJJ31) with ABB manufactured modules. The list of these modules is enclosed
below.
Sl No Modules CJJ31 CJJ32 CJJ21 CJJ22 CJJ23
1 70EB01 10 8 8 8
2 70EB02 5
3 70AB01 30
4 70AB02 4 4 4
5 70BK03 3 3 3
In TMR panels EB01 will be replaced at locations, EA10, EA11, FA01, FA02, FA10, FA11, GA10 and GA11.
Similarly, AB02 will be replaced at locations FA34, FA35, GA34 and GA35.
The Quantity mentioned above is for One Unit only.

As discussed, the Unit rate of the above modules are given in the Commercial Section of this offer, so
that the modules can be procured and replaced by M/s TPC as per their requirement and suitability.
6.0 Major Considerations and Assumptions of the Offer
1. The offer covers only signals available in the present system and available in the IPB.
2. Availability of existing documentation with logics for P13 system with M/s Tata Power
3. The specification of the server will be strictly in accordance with the ABBs recommended
hardware for 800xA systems.
4. The modifications in the 800xA application program are limited to the interconnection functionality
to the new 800xA.
5. There is space in the TMR Panels to keep BK03 modules.
6. A modification of the Procontrol P13 application programming to change the functionality of the
plant control is not included and not required .
Project
Offer No
Enquiry ref
E.UAPS.RE.8.0052. R1 dated 04.5.200 9
7.0 Duration of the Project
Commissioning of Engineering Station will require at most 15 days for commissioning at site. The system
can be commissioned online, however for downloading to the controller, it is recommended to have
shutdown. That limits the actual Plant outage required to be maximum 4 days. A detailed Activity
schedule will be submitted after the award of Offer.
The 800xA HMI system will need a max. Of 15 days for installation, testing and commissioning at site,
after the material has reached the site and design and engineering has been done in our office. Please
also refer to the upgradation procedure mentioned in the beginning of the proposal. This limits the
Commissioning time by checking the input signals in the IPB during online running of the Plant.
Commissioning is only limited to the outputs from the system.
8.0 Scope of the offer:
The scope of this offer for one unit is as detailed in sections below.
8.1 Scope of supply:
Progress 3 and Extension of IPB

Sl. No. Item description Qty/Unit Total Qty UOM
1 Workstation for Progress 3 EWS
1.6 GHz or better , 512 MB RAM,
1 2 No
80 GB HDD , CD R/W/DVD
Combo drive.
2 Interface of Progress 3 with Procontrol Station
1 2 No
-Latest 70BK03C-E/R1/R3 communication
3 EPROM Programmer 1 2 No
4 Progress 3 Tool (Engineering / Maintenance)
SW - Package including license: Hex-editor,
1 2 No
monitoring function including CD ROM 1No with
Manual and Hard Lock Dongle-1No
5 70BK02 Modules 6 12 Nos.
6 70FA01 with 2 Numbers 70FK01 3 6 Nos.
7 IPB Cable 1 1 Lot
Project
Offer No
Enquiry ref
E.UAPS.RE.8.0052. R1 dated 04.5.200 9
HMI Upgrade
Qty/ Total
Item description UOM
No. Unit Qty
A Procontrol P13/42 Upgradation
Server Workstation for 800xA :
Xeon Dual/Quad core 1.6GHz, 1x 73GB SAS /80GB SATA HDD,
2 4 Nos.
2 GB RAM,20" TFT Monitor, Std Keyboard, Mouse,
Win 2003 Server. (Make: DELL/HP/IBM/Equiv)
2. Operator Workstation for 800xA
P4 Dual/Quad core 1.6GHz, 1x 73GB SAS /80GB SATA HDD,
4 8 Nos.
1GB RAM,20" TFT Monitor, Std Keyboard, Mouse, Win XP.
(Make: DELL/HP/ IBM/Equiv)
4 P13 interface cards (PIF03) for HMI server
4 8 Nos.
(PCI slot compatible) with connecting cable
7 800xA software for Server Workstation with license for
1 2 Lot
2000 tags and 300 history points, license dongle and media box
6 Communication Setup
Switch, LAN cable, redundant Networking within the distance of 1 2 Lot
100 mtrs.
7 A4 Color Laser printer for Reports 1 2 No
8 Dot matrix printer for Alarms 1 2 No
9 Rev Drive for external data storage. 1 2 No
Note:
This offer quantity is for two units only
8.2 Exclusions: Scope of Supply:
1) Power Cables.
2) UPS and associated Power supply equipment
3) Furniture
Project
Offer No
Enquiry ref
E.UAPS.RE.8.0052. R1 dated 04.5.200 9
8.3 Scope of Work:
Our process of up gradation will include:
Progress 3:
Installation of software in the Progress 3 PC.
Establishment of communication with 70BK03.
Uploading the 70PR02, 70PR03 data through EPROM Programmer and uploading the BK02
and FV01 data in the Progress 3. Modification in Hex Editor and downloading.
Uploading the 70PR05b data in the Progress 3. Modification in Hex Editor and downloading
and any simulation in the controller.
Taking back up, Design, Engineering and Up gradation of the existing database to ABBs
make Progress 3.
Preparation of Function Block Diagram based on the latest Hardcopy available in the Plant
and Signal List available in the Plant.
800xA HMI Upgradation:
ABBs scope is limited to the data and tags available in the present system. Any modification
for any new tag in the control system is not considered.
Supply, Design, Engineering, Supervision of installation, commissioning & Testing of the
system Engineering, Software Development, Assembling, Testing of the System.
Supervision on Pre-Commissioning activities and commissioning of the supplied system.
8.4 Exclusions: Scope of Work

All Products and services are excluded which are not specifically mentioned.
Power cable lying.
Any civil or erection work.
Changes and Modification in Cabinets, dismantling and mounting of racks, IO cards etc.
Providing any features which are not available in offered package.
Project
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E.UAPS.RE.8.0052. R1 dated 04.5.200 9
Any logics or schemes that is non existent and not operational in the present system as on
date.
Any interface with the SOE(70EB10) system
Notes:
1. One 230VAC/110VAC UPS Power Supply is to be provided by M/s Tata Power for the 800xA
server and operator work stations and Progress 3 PC.
2. Furniture for the computers to be provided by M/s Tata Power .
3. FBD Hard Copy and updated documentation must be provided by M/s Tata Power
Project
Offer No
Enquiry ref
E.UAPS.RE.8.0052. R1 dated 04.5.200 9
9.0 COMMERCIAL PROPOSAL
Price Schedule:
800xA HMI Upgradation
Sl. No. Description Qty Total Basic Price(Ex-works) in

Indian rupees
Rs. 21,600,000/-
Price for Design, Engineering, Supply of 800xA HMI (Rupees Twenty One Million
1 1 Unit
System as per above mentioned scope of Supply. and Six Hundred Thousand
Only)
Rs. 40,500,000/-
Price for Design, Engineering, Supply of 800xA HMI 2
2 (Rupees Forty Million and Five
System as per above mentioned scope of Supply. Units
Hundred Thousand Only)
Progress 3
Price for Design, Engineering, Supervision of Rs. 7,470,000/-

Installation, implementation, testing, Commissioning, (Rupees Seven Million Four
1 1 Unit
and Supply of Progress 3 System as per above Hundred and Seventy
mentioned scope of supply. Thousand Only)
Price for Design, Engineering, Supervision of Rs. 14,670,000/-
Installation, implementation, te sting, Commissioning, 2 (Rupees Fourteen Million Six
2
and Supply of Progress 3 System as per above Units Hundred and Seventy
mentioned scope of supply. Thousand Only)
Engineering Services on Procontrol P13( To be ordered with Progress 3)
Rs 150,000/-
1 Development of Function Block Diagram per Controller 1 Num (Rupees One Hundred and
Fifty Thousand Only)
Development of Function Block Diagram per Drive Rs. 50,000/-
2 1 Num
Control Module (Rupees Fifty Thousand Only)
Note: for number of Controllers, see their relevant technical section. The Quantity is based on site feedback.
For Critical Modules , please check the relevant portion.
Project
Offer No
Enquiry ref
E.UAPS.RE.8.0052. R1 dated 04.5.200 9
9.3 Unit price for Critical Modules
Sl No Modules Unit Rate of Modules

(INR)
1 70EB01 B-E 58,000/-
2 70EB02C -ES 65,000/-
3 70AB01C-ES 87,000/-
4 70AB02B-E 110,000/-
5 70BK03C -E/R3 450,000/-
10.0 GENERAL TERMS AND CONDITIONS
Your Acceptance of our offer should be communicated through a written purchase order
specifying the following terms and conditions as an explicit acceptance of it.
IMPORTANT NOTICE
This Budgetary offer No E.UAPS.RE.8.00 52.R1 dated 04.05.200 9 is preliminary and not final and
as such non binding. It is tendered for discussion only, does not constitute a term to contract and
ABB can, without notice, mak e any changes in ABBs own discussion.
Prices The quoted prices are net & firm and on DELIVERY, EX WORKS PEENYA
BANGALORE. Our scope is based on the above mentioned items in scope of
supply and services only.
Excise Duty The offered prices are exclusive of all taxes and excise duties,
Sales Tax levies, cess & octroi, Service Tax etc. which have to be borne by you
And Other at actual as per the prevailing rates at the time of delivery and
Levies service. Present prevailing rate, ED on hardware (including CESS) is
8.24%, ED on Software in CD-ROM (including CESS) is 8.24%, Sale
Tax is 2% and Service Tax (Including CESS) 10.3%. You shall furnish
necessary declaration forms wherever applicable.
In case of any statutory variations in terms of variations of rates /

tariff / classification of Excise Duty, Sales Tax or any other tax /
duty / levy for both self - manufactured and bought-out items if
become livable by Central / State / Local authorities shall be paid /
Project
Offer No
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E.UAPS.RE.8.0052. R1 dated 04.5.200 9
reimbursed at actual on demand by concerned authorities at
applicable rates at the time of dispatch / levy within the contractual
delivery period.
If the cost of the bidder / contractor for the performance of the

contract are increased or decreased by levy of a new tax on the
final equipment, by a new act of Central / State / Local authorities
and which are not in force as on date of offer, such liability /
benefit shall be to Owners account.
Terms of FOR SUPPLY:

Payment
30% payment as interest free advance along with Purchase Order
Balance 70% payment through bank against dispatch documents.
The bank Charges will be at individuals account.
FOR E &C: 50 % against site mobilization.

Balance 50 % against job completion.
LD Clause Not Applicable.
Delivery All items as per the B.O.M shall be supplied within 20 weeks on receipt
of technically and commercially clear order. The above delivery reckons
the availability of frozen engineering information within 30 days of
receipt of technically / commercially clears order.
Packaging and Extra at 1%

Handling
Freight and The prices quoted do not include cost towards freight and transit insurance.
Insurance Freight charges and insurance will be in your scope.
Note We shall intimate you the dispatch details to enable you to arrange
insurance. If you do not arrange the insurance, goods will be dispatched to
you at your risk.
Warranty The warranty of the supplied system is limited against manufacturing

defects for the hardware items supplied as per the bill of material for a
period of 18 months from date of dispatch Or 12 months from the date of
Project
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E.UAPS.RE.8.0052. R1 dated 04.5.200 9
commissioning, whichever is earlier.
The warranty period shall expire prematurely if the customer or a third

party undertakes inappropriate modifications or repairs to the Supply or if
the customer, in the event of a defect, does not immediately take all
appropriate steps to mitigate the damage and give ABB the opportunity to
remedy such defect.
Validity of offer Unless otherwise specified in writing, this quotation will expire thirty (30)
days from the date of offer.
Change in Scope This quotation is based on our understanding of the enquiry. If subsequent to
of Supply. the tender evaluation and placement of order, changes in the specification
alter the quoted scope of supply and services, we reserve the right to re-
negotiate the contract price. In case the quantities would increase or
decrease during the execution of the Works, the Contract price will be
adjusted on the basis of the prices valid at that time.
Routine Progress, Visits for the above by customer's engineers will not be subject to an
Witness Testing additional charge provided such visits do not affect the agreed production
& Inspection. program. Also the charges for travel, lodging, boarding of customers /
Purchasers persons shall not be in ABB scope.
Test Certificates Internal Testing Certificates will be provided.
Exclusion of Exclusion of Consequential Losses and Limitation of Liability:
Consequential Notwithstanding anything contained in the conditions to the contrary, the
damages & Supplier shall not be liable for any special, indirect or consequential damages
Limitation of or losses, such as, but not limited to, loss of revenue, loss of use, loss of
liability production, loss of data, loss of con tracts, costs of capital or costs
connected with interruption of opera tion.
The total liability of the supplier, irrespective of whatever legal reason,
shall be limited to the 1% value of the contract price.
Erection and Our scope of job will be completed in all respects within 15 days from
Commissioning: the clearance and availability of the control room and Shutdown.
In case of extended stay of our commissioning engineers at site for

reasons not attributed to ABB, Per Day charges will be applicable extra.
Service Charge Extra Man day @ Rs. 25,000/- for Commissioning and Service, in case the
reason of delay of commissioning is not attributed to ABB.
Project
Offer No
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E.UAPS.RE.8.0052. R1 dated 04.5.200 9
Force Majeure Force Majeure is herein defines as any cause which is beyond the
control of the contractor or owner as the case may be, which they could
not foresee, or with a reasonable amount of diligence could not be
foreseen, and which substantially affects the performance of the
contract such as:
a) Natural phenomena including but not limited to floods, droughts,

earthquakes and epidemics.
b) Act of Government, domestic or foreign including but not limited to war,
declared or undeclared priorities, quarantines, embargoes.
c) Riots and Civil commotion.
d) Transportation delay due to above force Majeure clause (a), (b) and (c)
of above.
Scope of Supply & The scope of our supply shall be limited to the items mentioned in the
Works Bill of Material. The scope of our works shall be limited to the
Supervision of installation and commissioning of the items mentioned in
the Bill of Material.
End User ABB Will provide an end user statement once the order is finalized.
Statement The same needs to be signed and attached along with the Purchase
Order.
ARBITRATION & All disputes and differences arising out of or connected with the
JURISDICTION execution of the contract/ order, failing amicable settlement on mutual
terms shall be referred to arbitration in line with the provision of the
Indian arbitration act in force. In the event of dispute the jurisdiction
for settlement of the same.
Project
Offer No
Enquiry ref
E.UAPS.RE.8.0052. R1 dated 04.5.200 9
Procontrol P13 HMI/EWS
Power
Year End User Plant Country Retrofit Existing Technology
MW
Ref.
1 IPGCL IPGCL INDIA R Pose90 AS160 OS
2 2006 REL Dahanu INDIA 250 R PMS 800xA
3 2006 REL Dahanu INDIA 250 R PMS 800xA
4 2007 TNEB TTPS INDIA 210 R Pose90/SK06 800xA/Progress3
5 2007 NTPC TSTPS INDIA 500 R Sk06 Progress 3
6 2007 TVNL TVNL INDIA 210 R Sk06 Progress 3
Desk
7 2008 APGENCO Pochampadu INDIA 3x9 R Operation 800xA/Progress 3
2008/
8 UE AGBP NEEPCO INDIA R Pose90 800xA
9 2008 GSECL WTPS INDIA 210 R WS Pose 800xA/Progress 3
2008/
10 UE RRVUNL KTPS INDIA 210 R Pose90 800xA/Progress 3
11 2008 REL DTPS INDIA 250 R SK06 Progress 3

2008/
12 UE MSPGCL KTPS INDIA 210 R SK06 Progress 3
2008/
13 UE MSPGCL CSTPS INDIA 210 R SK06 Progress 3
14 2009 PSEB Ropar INDIA 210 R 70PR03 70PR05

15 2009 APGENCO Rayelseema INDIA 210 R 70PR03 70PR05
UC: Under Execution
JOJOBERA, JHARKHAND
QUOTATION FOR PROCONTROL P13 SPARES
ABB OFFER NO:E.UAPS.RE.10.024.R0 DATED 8.2.2010
COMMERCIAL PROPOSAL
ABB LIMITED
PS POWER GENERATION
BANGALORE 560 058
ABB
Customer Tata Power Jojobera
Project
Offer No
Enquiry ref
Quotation for Procontrol P13 Spare
E.UAPS.RE.10.024.R0 Dated 8.2.2010
Your Discussion with our Representative
ABB
Commercial Offer
Price Offer:
Sl. Unit Price Total Price

Item Description Qty.
No. (INR) (INR)
1. 800xA HMI Cold Standby Server consisting of:
a) PC for HMI Server with Quad-Core Intel(R)

Xeon processor, 2x6MB Cache, Integrated
Dual Broadcom Gigabit Network Card,
3X146GB 3.5-inch 15K RPM SAS Hard Drive,
1.44MB 3.5" Floppy Drive, USB Keyboard, 2 2,250,000* /- 4,500,000 /-
USB Mouse, 16x SATA DVD + / - RW Drive,
UltraSharp(TM) 20" Flat Panel LCD Monitor
1 no
b) PIF cards installed in the server 2 nos
c) Dongle 1 no
PC for HMI Client with:
Intel(R) Core(TM)2 Duo processor, 2.83GHz,

1066MHz FSB, 3MB cache, Broadcom 5754 Gigabit
2. 2 165,000 /- 330,000/-
NIC, 1GB (2x512MB) 667MHz NECC Dual Channel
DDR2 SDRAM Memory, 1.44MB 3.5 " Floppy Drive,
USB Keyboard, USB Mouse, UltraSharp(TM) 20 " Flat
Panel LCD monitor, 146GB SAS HDD (15k RPM)
3. 70BK03C-E - Interface to local bus module 1 535,000 /- 535,000 /-
Total in INR: Rupees Five Million Three Hundred and Sixty Five Thousand Only 5,365,000 /-
* The price quoted includes the services required for installation of cold standby server. No software or
licenses have been considered.
Commercial Proposal
Page 2 of 4
Commercial Proposal
Project
Offer No
Enquiry ref
E.UAPS.RE.10.024.R0 Dated 8.2.2010
ABB
GENERAL TERMS AND CONDITIONS
Your Acceptance of our offer should be communicated through a written purchase order specifying the
following terms and conditions as an explicit acceptance of same.
BANGALORE.
Excise Duty The offered prices are exclusive of all taxes and excise duties, levies, cess & octroi,
Sales Tax Service Tax etc. which have to be borne by you at actual as per the prevailing rates
And Other at the time of delivery and service. Present prevailing rate, ED is 8.24%, Sales Tax is
Levies 2%. You shall furnish necessary declaration forms wherever applicable.
Terms of 100% payment against dispatch documents.

Payment
Delivery Delivery time for supply of the modules is about 16 weeks from the date of receipt of
the technically and commercially clear/firm order.
Packaging Included.
and Handling
Freight The prices quoted do not include cost towards freight and transit insurance. The
material will be dispatched on Freight at actual shall be applicable and insurance
will be in your scope.
Note We shall intimate you the dispatch details to enable you to arrange insurance.
If you do not arrange the insurance, goods will be dispatched to you at your risk.
Warranty 12 months from the date of dispatch.
The warranty period shall expire prematurely if the customer or a third party
undertakes inappropriate modifications or repairs to the Supply or if the customer, in
the event of a defect, does not immediately take all appropriate steps to mitigate the
damage and give ABB the opportunity to remedy such defect.
The above prices are valid for a period of 30 days from the date of offer.
Validity
LD Clause Not Applicable.
Consequenti Notwithstanding anything contained in the conditions to the contrary, the
al damages & Supplier shall not be liable for any special, indirect or consequential damages
liability production, loss of data, loss of contracts, costs of capital or costs connected
with interruption of operation.
Commercial Proposal
Page 3 of 4
Commercial Proposal
Project
Offer No
Enquiry ref
E.UAPS.RE.10.024.R0 Dated 8.2.2010
ABB
Force
Majeure Force Majeure is herein defines as any cause which is beyond the control of the
contractor or owner as the case may be, which they could not foresee, or with a
reasonable amount of diligence could not be foreseen, and which substantially
affects the performance of the contract such as:
a) Natural phenomena including but not limited to floods, droughts, earthquakes
and epidemics.
b) Act of Government, domestic or foreign including but not limited to war, declared
or undeclared priorities, quarantines, embargoes.
Transportation delay due to above force Majeure clause (a), (b) and (c) of above
Commercial Proposal
Page 4 of 4
Commercial Proposal
JOJOBERA, JHARKHAND
PROPOSAL FOR PROCONTROL P 13 SPARES

ABB OFFER NO: E.UAPS.RE.9.0257.R1 DATED 25.11.2009
Ref: Email Dated 23.11.2009
TECHNO-COMMERCIAL PROPOSAL
ABB LIMITED
PS POWER GENERATION
BANGALORE 560 058
ABB
Customer Tata Power , Jojobera
Project
Offer No
Enquiry ref
Quotation for Procontrol P 13 Spare
E.UAPS.RE.9.0257.R1 dated 25/11/2009
Email dated 23/11/2009
ABB
Commercial Offer
Price Offer:
Sl. Item Item Description Qty Unit Price Total Price

No. (INR)
1 70PR05b - Programmable Processor 3 580,500/- 1,741,500/-
HESG332204R0001
2 BK02C-E Bus Coupler 2 445,500/- 891,000/-

HESG332209R0001
3 BT01c- Bus Isolating Amplifier Module 2 180,000 /- 360,000/-

HESG447024R0001
4 70FA01B- Bus access coupler 1 180,000/- 180,000/-

HESG223140R0001
5 70FK01B- IPB Coupling module 10 90,500/- 905,000/-

HESG447016R0001
6 FV01B-E IPB Bus traffic Director 2 490,500 /- 981,000/-

HESG332164R0001
7 Firmware Upgradation of 35 32,000/- 1,120,000/-
70Pr05a to I/latest version *
Total in INR: Rupees Six Million One Hundred and Seventy Eight Thousand and 6,178,500 /-
Five hundred only
* We will require 2 days service for the same considering plant is under shutdown.
Page 2 of 4
Commercial Proposal
Project
Offer No
Enquiry ref
E.UAPS.RE.9.0257.R1 dated 25/11/2009
ABB
GENERAL TERMS AND CONDITIONS
Your Acceptance of our offer should be communicated through a written purchase order specifying the
following terms and conditions as an explicit acceptance of same.
BANGALORE.
Excise Duty The offered prices are exclusive of all taxes and excise duties, levies, cess & octroi,
Sales Tax Service Tax etc. which have to be borne by you at actual as per the prevailing rates
And Other at the time of delivery and service. Present prevailing rate, ED is 8.24%, Sales Tax is
Levies 2%. You shall furnish necessary declaration forms wherever applicable.
Terms of 100% payment through bank against dispatch documents.

Payment
Delivery Delivery time for supply of the modules is about 16 weeks from the date of receipt of
the technically and commercially clear/firm order.
Packaging Included.
and Handling
Freight The prices quoted do not include cost towards freight and transit insurance. The
material will be dispatched on Freight at actual shall be applicable and insurance
will be in your scope.
Note We shall intimate you the dispatch details to enable you to arrange insurance.
If you do not arrange the insurance, goods will be dispatched to you at your risk.
Warranty The warranty of the supplied system is limited against manufacturing defects for the
hardware items supplied as per the bill of material for a period of 12 months from
date of dispatch.
The warranty period shall expire prematurely if the customer or a third party
undertakes inappropriate modifications or repairs to the Supply or if the customer, in
the event of a defect, does not immediately take all appropriate steps to mitigate the
damage and give ABB the opportunity to remedy such defect.
Validity The above prices are valid till 11.12.2009. Prices will be having upward price
revision in the next financial year.
LD Clause Not Applicable as this is a spare offer.
Consequenti Notwithstanding anything contained in the conditions to the contrary, the
al damages & Supplier shall not be liable for any special, indirect or consequential damages
liability production, loss of data, loss of contracts, costs of capital or costs connected
with interruption of operation.
Page 3 of 4
Commercial Proposal
Project
Offer No
Enquiry ref
E.UAPS.RE.9.0257.R1 dated 25/11/2009
ABB
Force
Majeure Force Majeure is herein defines as any cause which is beyond the control of the
contractor or owner as the case may be, which they could not foresee, or with a
reasonable amount of diligence could not be foreseen, and which substantially
affects the performance of the contract such as:
a) Natural phenomena including but not limited to floods, droughts, earthquakes
and epidemics.
b) Act of Government, domestic or foreign including but not limited to war, declared
or undeclared priorities, quarantines, embargoes.
Transportation delay due to above force Majeure clause (a), (b) and (c) of above
Page 4 of 4
Commercial Proposal
$% % $% # !
>* !! D
!! D F #?
" 5 ! !
67

ABB wins Best Power Plant Upgrade award at Asian Power Awards 2010 Page 1 of 1
ABB wins Best Power Plant Upgrade Rating

Rate this page:
award at Asian Power Awards 2010 Average rating:
2010-11-16
Ratings:1
ABB' s project was recognized as the Best Power Plant Upgrade in Asia at
the Asian Power Awards 2010 held in Singapore. ABB received this award
for an upgrade project executed for Tata Power in Jojobera, Jharkhand - a
state in eastern India.
ABB upgraded the control system for a 2 X 120 MW coal based thermal
power plant of Tata Power. Tata Power, erstwhile known as Tata Electric,
pioneered the generation of electricity in India nine decades ago. Today, it is
the country'
s largest private power utility.
The power plant feeds the steel plant at Tisco Jamshedpur, Jharkhand and Rekha Subramaniam, the local
is very critical to the operations of the large steel plant. The plant was facing Business Unit manager for Power
a problem of availability of the control system affecting the availability of Generation in India receiving the
power supply to steel plant. ABB conducted a survey and analyzed that award on behalf of ABB.
upgrading the system would significantly improve the reliability and
availability of the control system. Thus the customer will be able to achieve Contact us
the objective at a fraction of the cost of a new system.
Page information:
ABBs scope included upgrade of Procontrol P13 control and existing HMI
(Human Machine Interface) system, supply of new engineering and Rajeev Kishore
diagnostic tool - Progress3 for the Procontrol P13 system and supply of Anshuman N
critical spare parts. The State of the Art HMI system improves the plant
operations and the Function Chart Builder facility of the Progress3 will Contact us
facilitate on-line functional logic monitoring and simulation features for the
Procontrol P13 System. The upgrade was completed within a short plant General information:
maintenance period. Contact ABB
ABBs solution benefitted the customer in:

- Eliminating unscheduled outages. Increased plant stability and
uninterrupted power generation.
- Increased reliability for turbine and boiler protection system
- Increased operational flexibility with a new state of the art operator interface
allowing efficient monitoring and Plant Operations
- Reduced maintenance costs
- Improved diagnostics and added Simulation facility for plant availability
- Extended life of the plant with latest technology at fraction of costs
This upgrade is in line with ABBs evolution without obsolescence policy

aimed at supporting customers in maximizing the return on asset
investments while keeping abreast of latest technology. The Procontrol P13
platform has large installed base of distributed control systems (DCS) in
power generation worldwide.
http://preview.inside.abb.com/cawp/seitp202/B24909EAC16B6A7F482577DC0029AA2... 12/13/2010

Energy Audit Report by CPRI

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No.

JOJOBERA TPS, TATA POWER

Volume 1 (Boiler, Turbine & Overall Unit)

01 Title: Energy Audit & Performance Test of 1 x 120 MW Unit at

08 Energy audit team : M. Siddhartha Bhatt, Additional Director

09 Objectives: Energy Audit and performance test for TPC-Gs thermal

in auxiliary consumption and specific oil consumption.

2: Suggest measures to improve performance parameters (SHR,

3: Preparation and submission of report.

11 Report No.: EC&DD/EA/76/2010

13 Date of issue of report: October 25th 2010/ December 21 2010

14 Signature of Energy Audit

Immediate measures include operational optimization of parameters such as

The savings are as follows:

Sl. Anticipated Anticipated Time Pay

with Inconel 750, plug by

16 Online performance analysis 10 30.0 36

solutions, Erosion and

Long term measures

Sl. Anticipated Anticipated Time Pay

9.4 Additional heat consumption due to year round variations

ABT Availability based tariff

UAT Unit auxiliary transformer

The energy audit study is carried out for the Unit 3.

1.1 Energy audit

1.2 Scope of the energy audit

The scope of the Energy Audit presented is as follows:

2: To quantify the performance of various sub-systems through an energy balance

3: Suggest measures to improve performance parameters (UHR, auxiliary

4: Preparation and submission of report

1.3 Period of the experimental work

1.4 Design rating of major equipment

1.5 Age and service period

1.6 Current level of performance measured by TPC-G

1.6.1 Routine measurements of critical parameters and its

Routine measurement of critical parameters is being done at present through the

Recommendation: Parameters which have a bearing on energy efficiency of the

Recommendation: A water monitoring software package is to be in place.

1.6.2 Trends and comparisons

1.6.3 Efficiency & performance test results

Recommendation: Monthly efficiency tests on boiler, turbine, feed water heater,

1.6.4 Detailed analysis

Detailed analysis is being done for the following:

Performance parameter variations

2. BOILERS AND ASSOCIATED EQUIPMENT

2.1 Coal analysis and boiler efficiency tests

Boiler efficiency test results

i. Boiler efficiency of the unit at a GCV of 4623 kcal/kg is 85.31 % .

The site observations along with recommendations are as follows:

Recommendation: Some measures for the boiler involving operational optimization

Sl. No. Parameter Optimal values

2.2 Boiler Temperature & pressure survey

2.3 Boiler and associated systems -component wise

The observations regarding the heating surfaces are as follows:

i. It is seen that the furnace gas tightness is OK.

Application of sacrificial weld overlays of hard materials like

Furnace combustion, thermal sealing and control: combustion equipment,

The observations regarding the furnace are as follows:

i. One of the objectives of achieving good combustion and efficiency is

ii. Particle size distribution and percentage of volatiles in coal affects

v. Erosion could be combated by measures such as:

Refractory/steel with hard facing liner shielding of faces

x. Oxygen measurement: The measurement process needs to be

xi. Recommendation: On-line CO measurement is presently not in