CONTENTS 1.
OBJECTIVE
2.
TEST CODE
3.
TEST SCHEMATIC
4.
SELECTION OF INSTRUMENTS
5.
AGEING
6.
TOLERANCES
7.
FREQUENCY OF OBSERVATIONS
8.
DURATION OF TESTS
9.
ADVANCE PLANNING FOR THE TESTS
10.
PREPARING THE TG CYCLE FOR THE TESTS
11.
PRETEST SHUT DOWN ACTIVITIES
12.
INSTALLATION OF TEST INSTRUMENTS
13.
GENERAL GUIDE LINES
14.
INSTRUMENTS CALIBRATION AND CORRECTIONS
15.
ITEMS ESSENTIAL FOR AGREEMENT
16.
PROGRAMME OF TESTING
17.
PRESERVATION OF TEST FLOW ASSEMBLIES
18.
CONDITION AND CYCLE ISOLATION OF THE PLANT
19.
POST TEST ACTIVITIES
1.0
OBJECTIVE
The Performance Guarantee Tests on Khaperkheda Thermal Power Project, unit # 3 & 4 210 MW TG shall be carried out to prove the Guaranteed Heat Rate and Output of the TG Set. This Procedure has been prepared to carry out the tests at site as mentioned above for the following conditions. S.No. A 01.
Guarantee Conditions
Guarantee Values
TG PACKAGE Gen. Output at rated throttle pressure & temp with condenser backpressure of 67 mm of Hg (abs) at rated turbine parameters.
210 MW
02. 03.
Heat rate at 210 MW load. 30.5 deg C cooling water temp. with 67 mm of Hg (abs) condenser back pressure and 0% make up Auxiliary power consumption - Boiler feed pumps 2 x 50 %
B.
- Condensate pumps 1 x 100 % - excitation system – Vapour exhaust fan – Vacuum pumps – Lube oil system – Generator seal oil system OTHER BHEL
1939 .3 Kcal/Kwh
5320 Kw Total Aux. Power
440 Kw
5950 Kw. 190 Kw
1260.7 Kw. Per
MANUFACTURED PACKAGES
Pump.
CW pump power (2 pumps)
*
Aux. Power Consumption of all aux. Mentioned above (sr. no. 3) will be measured during PG
test with 67 mm of Hg (abs) condenser backpressure and 0% make up. Excitation Power shall be measured with plant instruments. HT Aux. Will be measured with DPM/Power Transducers and LT Aux. Will be measured with clamp on meter.
2.0
TEST CODE
The HEAT RATE Tests shall be carried out in line with the recommendations of ASME PTC-6, 1976 Test Code and in line with approved Document No. PE-4-183-100-211 Rev. 05 for method for computation of Heat Rate. 3.0
TEST SCHEMATIC
The approved test scheme titled PERFORMANCE GUARANTEE TEST INSTRUMENTATION SCHEME, NO. PE-3-183-100-210 REV. 02 shall be used. 4.0
SELECTION OF INSTRUMENTS
The instruments meeting accuracy requirements, as specified in ASME-PTC-6 1976 TEST CODE shall be used. Instruments selected and proposed to be used shall be as per the TG PG TEST INSTRUMENTATION SCHEME/LIST which specifies the type of instruments and their ranges etc. The brief details of the instruments to be used during the P.G. Test are
S.No.
PARAMETER TO BE
RANGE
MEASURED
MEASURING INSTRUMENT
01.
Differential pressure
0-2.5 Kg/Sq. Cm
Transmitters
02.
Pressure
0-250 Kg/Sq. Cm
Transmitters
03.
Cond. Back Pressure
0-780 mm Hg.
Transmitters
03.
Temperature
0-300 Deg. C
PRT - 100
04.
Temperature
300-600 Deg. C
K Type T.C.
05.
Generator Power
0-1000 Watts.
Digital Power mete
0-5 Amps. 0-65 Volts. 06.
Speed
0-1000 rpm
Non contact type Tachometer
5.0
AGEING
If the test is carried out after 4 months of the date of first commissioning, due to any reason what so ever, the specific heat consumption shall be increased by following amounts for each month or part of a month by which the period between the initial commissioning and the acceptance test exceeds 4 months. 0.01% for the following 8 months 0.06% for the period there after. 6.0
TOLERANCES
The tolerances on results shall be computed based on uncertainty/inaccuracy of the measuring instruments used during PG test. 7.0
FREQUENCY OF OBSERVATIONS
It will be carried out as per ASME-PTC-6 which is briefly given below. Heat rate and output test observations from indicating and differential measurement for primary flow shall be made at intervals not greater than 1 minute. Other important measurements shall also be made at not greater than 1-minute interval. Hot well and D/A levels shall be read at intervals not exceeding 5 minutes. 8.0
DURATION OF TESTS
As per ASME-PTC-6, tests shall be carried out at a steady state run of minimum 2 hours duration. However duration will be mutually decided, depending upon the conditions prevailing during conductance of P.G. Tests, Minimum two test for heat rate at 100% MCR and one for output test shall be conducted. 9.0
ADVANCE PLANNING FOR THE TEST
9.01 During the pretest unit commissioning/erection period, every effort shall be made by BHEL to ensure the provision of all test tapping points as per test scheme. BHEL shall inform to MSEB in advance for any missing point measurement which is not possible to be used due to unavoidable reasons and mutually agreed upon. Minimum two tests for heat rate at 100% MCR and one for output test shall be conducted. 9.02 Welded type thermowells shall be used by BHEL for temperature measurement on all critical high temperature lines. These thermowells shall remain permanently installed on the pipe lines. 9.03 Screwed type thermowells shall be used in low pressure lines (pressure less than 40 ata) for temperature measurement and shall be installed in the unit, just prior to the test. For these thermowells, matching stub with suitable plug will be provided in the engineering stage itself. In case these thermowells are found missing then these are to be obtained from the respective unit and supplied & installed during erection stage itself. 9.04 All the pressure test tappings as mentioned in PG Test Instrumentation Scheme No. PE-3-193100-210 Rev. 02 are supplied with single or double root valves depending upon the pressure rating of the pipe lines. They are supplied by BHEL piping centre in line with the erection drawings released for construction. In case some of the pressure tappings are not available, the same shall be provided or alternatively, either a T-off shall be taken from the operational tapping point or operational point
shall be used, as mutually agreed. Impulse pipe of suitable size shall be laid during pretest preparations. The pressure lines will be strong enough to withstand any type of vibrations and will have uniform gradient. 9.04a For Pressure and temperature tapping points in case not available/constraint in its use is observed before the commencement, alternate operational points will be used after mutual agreement. 9.05 Test CTs and PTs (MSEB scope) of 0.2 accuracy class are to be provided by BUS DUCT supplier. The installation and/or test data for ratio and phase angle errors at different VA burdens and power factors shall be provided by. MSEB for accurate power calculations. Additionally test certificates giving the above information, as submitted by the generator bus duct supplier shall also be arranged by MSEB. 9.06 CT terminals should be provided with termination arrangement for shorting or opening links. Effects of connecting leads shall be neutralized in power calculations by measuring voltage drop across PT terminals and measuring point. 9.07 It has to be checked during erection stage that no pipeline or installation etc. Fouls the test tapping. Test temperature element are 450 mm along. Enough space should be available for each tapping point so that the test temperature elements can be inserted without any difficulty. In case of any obstruction an alternate test stub is to be provided as per point No. 9.02 & 9.03 if possible. 9.08 link.
Test CTs & PTs terminals to be brought to UCB panel. CT terminals be provided with shorting
10.0
PREPARING THE TG CYCLE FOR THE TEST
Efforts are to be made to ensure that all the TG systems/equipment’s are brought into service within reasonable period of the first synchronisation and trial run should also be completed by this period. Normally with the increase in running hours, salt deposits take place and also turbine clearances change. This deteriorates the turbine performance and thus the test should be conducted preferably within four months after first synchronisation. The unit readiness for conducting the PG Tests is to be ensured as per the checklist. 10.01 To ensure that all LP & HP heaters are in normal operation and drips of these heaters are cascaded properly as per the cycle. It is to be checked that there is no by passing of the drips either to condenser or to deaerator and this is to be ensured for sufficient time before actual commencement of the test. 10.02 To check that there should not be any leakage in the tubes of HP & LP heaters tubes. 10.03 To ensure the cleanliness of condenser tubes and to get the same cleaned if required during the shut down prior to the tests. 10.04 To ensure that the machine is able to run on orie vacuum pump only. Further the vacuum obtained with this running pump should preferably be nearer to the design value. 10.05 To ensure that pressure of Main Steam First Stage, Cold Reheat. Hot Reheat Extractions to various heaters and condenser back pressure are near the design values at 210 MW load. 10.06 To ensure that the test flow assembly is available at site with all its matching flanges and fasteners. 10.07 To ensure that the CW pressure drop across the inlet and outlet of the condenser is within the design figure and there is no tube leakage in condenser. Conductivity and Oxygen content at condenser hot well should also be within the prescribed limits. 10.08 To ensure the cleanliness of the E.S.V. and I.V. strainers. In case of the excessive pressure drop, same should be cleaned. 10.09 To ensure that the unit is capable of attaining and maintaining the full load design parameters
i.e. Main Steam pressure and temperature, Hot Reheat temperature and Condenser Back Pressure. 10.10 To ensure that all the local gauge glasses of the condenser, hot well deaerator and HP & LP heaters are working and are clean and visible. There should not be any gauge glass leakage. 10.11 To ensure that there is adequate light to observe the levels at all places where the operators will log the test readings. 10.12 A system tightness check i.e. Deaerator Drop Test shall be done by keeping the interconnection on steam and load side isolated and also by closing the make-up inlet and by keeping the CBD, EBD, SOOT Blowing and steam supply to fuel oil heating, atomisation etc. shut off. The deaerator level is to be raised to the maximum permissible before this exercise. Fall in deaerator level i.e. system losses are then to be observed and calculated. It is to be ensured that the unit is able to run in the above condition for at least three hours. The problem if any, is to be rectified and the efforts shall be made to bring down the system unaccounted leakage. 10.13 To ensure the availability of coal in sufficient quantity so that the machine may be loaded to full load for any desired interval of time and the constancy of test conditions may be attained as per ASME-PTC-6 code. 10.14 To ensure the tightness of the system, steam/feed & condensate drain line valves connected to turbine flash tank for non passing as per the designed heat and mass balance diagram. 10.15 To ensure the availability of all tapping as per test scheme. This includes tapping points for individual equipment performance which may not be required for contractual tests. 10.16 To ensure that the HP & LP Bypass valves to the condenser are not passing. 10.17 To ensure the availability of all the BFPs, CEPs, CWPs coal mills, ID, FDA PA fans etc. so that there is no constraints in achieving and maintaining full load for at least 8 hrs. a day. 10.18 To ensure tightness of the vales as per the design heat & mass balance. For this purpose a specific list of isolation of valves & systems bearing valve numbers shall be prepared in advance of test. 11.0
PRETEST SHUT DOWN ACTIVITIES
After it is ensured that the unit is ready for the test, a suitable shut down shall have to be agreed between BHEL and MSEB. BHEL shall then supply the calibrated test instruments, prior to the start of the shut down. Major activities to be carried out during this shut down shall be as follows. 11.01 Mounting/installing missing screw type thermowells, test flow assembly, provision for T-off and laying of impulse pipe lines etc. 11.02 Providing any additional test tapping points if found necessary/applicable/missing. 11.03 Necessary arrangement/rectification for meeting the system requirements. 11.04 Necessary arrangement/rectification for meeting the requirement of system isolation i.e. attending the defective/passing valves identified during the joint inspection before shut down. To this effect, a list of valves to be kept closed during the test shall be jointly finalised with MSEB, prior to the test and the system shall be isolated as per this list. 11.05 In case of prolonged operation, if necessary the internals of the turbine shall be checked for its cleanliness. 11.06 The demagnetisation of test PTs and CTs will be carried out. 11.07 Mounting of temperature elements in identified hot areas and laying their cables. 11.08 Laying impulse pipe line (if not already laid) from the root valves in hot zones and terminating with isolating valves. Their root valves to be kept open.
11.09 Condenser tube cleaning and condenser air tightness checks to be done and leakages to be got attended. 12.0
INSTALLATION OF TEST INSTRUMENTS (ASME-PTC-6)
12.01 FLOW MEASURING DEVICES In most of the places spool pieces are not provided in the pipelines, location is only indicated on the isometric pipeline drawings. Spool pieces are to be made at site, in case the flow measuring assemblies along with the matching flanges are supplied during erection stage itself. Otherwise, the pipeline is to be cut as per the marked location and flanges along with flow assemblies are be mounted during the shutdown. Flow measuring assembly device in any case is to be mounted during the shutdown prior to the test so that these are not in use for longer duration prior to the test. Flow measuring devices are to be mounted during the shut down prior to the test so that the same is not in use for longer duration prior to the test. Correct installation of flow assembly as per requirement is to be ensured and installation arranged by BHEL in pretest shut down. It is preferable to check the impulse pipe line connections after installation for any leakage/choking etc. by pressurising the flow measuring device to the extent possible during the unit shut down itself. For flow orifice in the condensate line to deaerator, the system can be checked by running the condensate pump. Problem noticed if any has to be attended during the shut down itself. 12.02 TEMPERATURE MEASURING INSTRUMENTS Chromel Alumel thermocouples and Platinum Resistance Thermometers elements will be used for temperature measurements. After connecting extension leads (Compensating cable for TCs and lead wires for PRTs), these elements will be mounted into thermowells as per the instrument allocation list. Thermocouple wire is to be connected such that Chromel portion of the extension lead is connected to Chromel part of the sensor. To identify this a positive sign has been marked on each Chromel terminal. Thermocouples, PRT’s and transmitter out put shall be measured with precision Data Logger of accuracy 0.03%. 12.03 PRESSURE MEASURING INSTRUMENTS Impulse pipe lines are to be laid for the Pressure Transmitters. Impulse pipe lines for the vacuum (negative pressure) measurement points should be laid such that transmitter is mounted above the tapping point. Thus the line should be laid upwards. All the impulse lines should be rigid enough to avoid any vibration in the instrument. For height correction in pressure measuring points the vertical distance from the center of the transmitter to the tapping point is to be measured for each tag number and joint protocol to be signed. The distance above the tapping point is taken as positive whereas same below the tapping point is taken as negative for pressure correction. The impulse pipe lines are to be flushed/purged sufficiently and steam to be allowed to condense before mounting the transmitters. A transmitter/gauges will be charged only before use, otherwise it should be kept isolated to avoid its exposure to vacuum in case the unit trips. 12.04 POWER MEASURING INSTRUMENTS CTs and PTs for P.G. Test use should be identified well in advance and locations of their terminals in panels checked for connection of the power meters refer the generator schematic drawings. The CTs and the PTs should be damagnetised during the shut down and it should be ensured that no protection relay is connected in their circuit during the P.G. Test.
The lead resistance voltage drop in the circuit of PTs shall be measured along with MSEB representative and protocol for the same made before starting the P.G. Test. The digital power meter will be connected to the identified CTs’ and PTs’ terminals preferably in three phase four wire mode. 12.05 LEVEL MEASUREMENT Level measurements of all the storage tanks shall be noted by means of local gauge glass level indicators equipped with metric scales. It shall be ensured before carrying out the test, that the level indicators are in good working condition. Readings are to be recorded on the Data Sheet sample enclosed. Apart from it, the Control Room readings for levels of all storage tanks shall also be additionally recorded for reference. 13.0
GENERAL GUIDE LIENS
13.01 All electrical instruments should be placed away from any magnetic field. Their proper leveling should also be ensured. 13.02 If felt necessary, the mounting adjustable coupling can be removed and in that case T/Cs PRTs should be properly tied and pressed downward with a piece of wire. Stub projections and sensor stems, which are protruding out of thermowells should be covered with asbestos rope for providing thermal insulation. 13.03 Demagnetisation of CTs.
Any of the following two methods may be employed. 13.03a Short circuit the secondary through a 3C ohms resistor of sufficient current capacity and gradually increase the primary alternating current to full rated value. After this gradually reduce it to zero. 13.03b With the primary open circuit, gradually increase the alternating current through the secondary to 5/1Amp. After this gradually reduce it to zero. In case of voltage transformer case should be taken to avoid short circuit of secondary. 13.04 All the instruments should be stored in a clean dry place nearer to unit under test, preferably at Turbine Floor. 13.05 Tags giving Tag No., Serial No. and Service etc. should be provided at both tapping point end and the instrument end. 13.06 All the Pressure Transmitters gauges/differential manometer/kenometer/’U’ tube manometer should be mounted in vertical position. 13.07 Depending upon the likelihood of completion of the above activities a date is finalised for the conductance of P.G. Tests. BHEL representative shall then commission all the instruments and conduct the tests jointly with MSEB under mutually agreed conditions. 14.0
INSTRUMENTS CALIBRATION AND CORRECTION
14.01 All the test instruments except Pressure Transmitters shall be duly calibrated at recognised Test Houses. 14.02 The calibration certificates shall be furnished to MSEB before dispatching the instruments to site. 14.03 Pressure Transmitters reading shall be additionally corrected for height corrections by measuring the difference in levels between center of the transmitter & center of pipeline. 14.04 Pressure Transmitters shall be calibrated at site by BHEL Engineer before the conductance of the tests in the presence of MSEB representative and the calibration certificates shall be jointly
signed. 14.05 Correction due to actual mercury density and actual barometric pressure shall also be applied wherever applicable. 15.0
ITEMS ESSENTIAL FOR AGREEMENT
15.01 Nomination of coordinating Test Engineers from MSEB and BHEL. 15.02 The programme and the dates of the series of tests. In accordance with this programme, all the test instruments shall be transported to site. 15.03 Suitable shut down required prior to test to carry out the preparatory activities. 15.04 Means for obtaining steady operating parameters at their rated values. 15.05 Deputation of adequate qualified personnel by MSEB to note down the test readings for which exact number will be intimated to them well in advance. 15.06 Submission of drawings/information, as required and intimated by BHEL in advance for the non BHEL scope of equipment. 15.07 Provision of T & P by customer like compressed air, welding sets, power supply etc. 15.08 Provision of illumination at all measuring junctions and working places by MSEB. 16.0
PROGRAMME OF TESTING
16.01 The completion of test preparations, mounting of instruments and isolation of thermal cycle are to be checked before start of test. 16.02 The load is raised to rated capacity at rated parameters for taking a set of trial readings of all instruments and for aquatinting the observers with the operation of instrument. All observers shall be allotted with their respective junctions and shall note down the readings on the prescribed logsheets to be supplied by BHEL. 16.03 The readings of the trial test are analysed. If the results differ much from the design values, the case is to be investigated and rectification to be carried out wherever required. To this effect, it is essential that the load is maintained at rated values. The mock test can be repeated until the results are satisfactory. Then the time for test can be mutually decided. 16.04 During the trial test, it is checked that all the instruments are functioning/indicating properly and verified wherever necessary. The pressure transmitters are isolated after the trial test. 16.05 The load is raised to rated capacity at rated parameters at least one hour before the start of the test and the parameters shall be maintained constant throughout the test. 16.06 The system is isolated so that no unaccounted flow goes out of comes into cycle. The makeup quantity shall be measured by noting down the various storage tanks levels at regular intervals of the test. 16.07 Consistency of the load shall be accomplished by load limiter. Once the control valves have been set, they shall be left undisturbed throughout the test. 16.08 The operations which shall not be carried out during the test which are to be isolated are for the following which the isolations are to be carried out. • • • • • • •
Soot Blowing Continuous Blow Down. Dusting of the Associated Boiler Unit. Steam Supply to fuel Atomisation. Fuel Heating and SCAPH Chemical dozing. Water and Steam Sampling etc.
16.09 PRDS control valve spindle cooling water, atmospheric valve gland sealing water flow shall be adjusted for minimum flow. 16.10 Proper sealing water supply to vacuum system specially to atmospheric valve seals shall be ensured. 16.11 All efforts shall be made to maintain the parameters constant throughout the test. 16.12 After the preparations have been completed, the test shall be started by synchronising the watches of the observers with that of the control room. 16.13 The test readings shall be logged in the data logger and manual readings shall be noted down in the prescribed log sheets in triplicate, which shall be signed by the observers and countersigned by MSEB and BHEL at the end of the tests. 16.14 One set of the test readings shall be handed over to MSEB and two sets shall be retained by BHEL for their analysis at their works. 16.15 Sensitivity of the condenser hot well level control shall be reduced or preferably the level be controlled manually to avoid excessive fluctuation in the condensate flow to Dearator. 17.0
PRESERVATION OF TEST FLOW ASSEMBLIES
PG test “low measuring assemblies for measurement of test flow are normally supplied directly to site assembled condition in 2 halves. Flow measurement is an important measurement which effects the PG Test results appreciably. A minor dent on the sharp edge of the orifice or on its plain surface or on the inside surface of the flow nozzle causes a large inaccuracy in flow measurement. Thus orifice plates/nozzles should never be hung with a wire or a rope passing through their inner bore which may cause dent on them. Even the adjoining pipe pieces encompassing the orifices/nozzles, which are normally machined from inside, should be carefully handled during installation. In all cases these assemblies should be stored in covered shed and protected from corrosion as any roughness on them may add to inaccuracy. In view of above, it is needless to emphasize the importance of proper preservation of these assemblies. Also flow measuring assemblies received in assembled condition, should not be dismantled as it is calibrated before supply. Dismantling may affect its calibration. 18.0
CONDITION AND CYCLE ISOLATION OF THE PLANT
Before starting the performance test the plant has to be in a good state. To be familiar with the plant during operation and for finding out deficiencies, if any and for checking of all the measuring instruments, customer has to allow pretests with the plant. It is sufficient that the whole plant cycle is provided as presumed in the guarantee agreement. All cross connections to other units must be closed and all drainages must be ensured absolutely tight. Piping which are not utilized they have to be blanked off or it not possible they have to be checked for tightness. A special care will be used in isolating test cycle from any connection extraneous to the test, whether inside or outside the unit. These shall be attended in case founding passing. The following is the general list of the lines and the unit component that will be isolated or put out of service during test. A specific list of isolation of valves & systems bearing valve numbers for each valve shall be prepared in advance of the test which shall be used during performance testing. All the LP turbine by pass Make up line Auxiliary steam header Turbine sprays Drain lines on stop intercept and control valves
Common units header not fed Auxiliary boiler steam line Steam to air Preheaters Condensate chemical injection Feedwater chemical injection Steam generator vents Steam generator soot blowers Condensate and feed water flow by passing heaters Heater drain by pass Heater shell drains Heater water box vents Water lines for water washing the turbine Steam Generator blowdowns Emergency blow – down valve Main steam line to SSR Dearator overflow line The following lines will be throttled to a minimum Dearator vents The water sampling equipment flows will be measured by Weighing if any. The water level in the feed water tank and in the condenser have to be watched and all changes to be considered by making the quantity balance. Before starting the performance test all items which could influence the result of the test have to be brought into steady state. This has to be kept for the whole test. 19.0
POST TEST ACTIVITIES A shut down of the unit is to be arranged for removing flow measuring assembly.
TG-PG TEST INSTRUMENTATION LIST PRESSURE POINTS Sr. No.
Tag
Service
Instrument
Accuracy
Range
No. 1
P201
MS BEF. STRAINER (L)
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
2
P202
HRH AFT. STRAINER (L)
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
3
P203
MS BEF. STRAINER (R)
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
4
P204
HRH AFT. STRAINER (R)
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
5
P205
1st STAGE PR.
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
6
P206
FFW AT ECO. INLET
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
7
P207
HP EXHAUST (TE)
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
8
P208
HRH TO IPT BEF. STRAINER
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
(L). 9
P209
CRH AFT. RH SPRAY (R).
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
10
P210
HRH TO IPT BEF. STRAINER
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
(R). 11
P211
CRH AFT. RH SPRAY (L).
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
12
P212
MS TO APRDS
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
13
P213
APRDS SPRAY
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
14
P214
EXTN. TO HPH-6 (HE)
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
15
P215
FW HPH-6 INLET
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
16
P216
FW HPH-6 OUTLET
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
17
P218
HPH-6 DRIP TO HPH-5
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
18
P219
EXTN. TO HPH-5 (TE)
PR. TRANS.
0.1%
0-25Kg./Sq.Cm.
19
P220
EXTN. TO HPH-5 (HE)
PR. TRANS.
0.1%
0-25Kg./Sq.Cm.
20
P221
FW HPH-5 INLET
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
21
P222
FW HPH-5 OUTLET
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
22
P223
HPH-5 SHELL PR.
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
23
P225
BFP-A DISCHARGE
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
24
P226
BFP-B DISCHARGE
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
25
P227
BFP-C DISCHARGE
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
26
P229
SH SPRAY PR.
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
27
P230
RH SPRAY PR.
PR. TRANS.
0.1%
0-250Kg./Sq.Cm.
28
P231
CRH BEF. RH SPRAY (L)
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
29
P232
CRH BEF. RH SPRAY (R)
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
Instrument
Accuracy
PRESSURE POINTS Sr. No.
Tag No.
Service
Range
1
P102
IPT EXHAUST (L)
PR. TRANS.
0.1%
0-10Kg./Sq.Cm.
2
P104
IPT EXHAUST (R)
PR. TRANS.
0.1%
0-10Kg./Sq.Cm.
3
P105
LPT INLET (L)
PR. TRANS.
0.1%
0-10Kg./Sq.Cm.
4
P106
LPT INLET (R)
PR. TRANS.
0.1%
0-10Kg./Sq.Cm.
5
P107
EXTN. TO D/A (TE)
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
6
P108
EXTN. TO D/A (DE)
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
7
P109
D/A SHELL PR.
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
8
P110
BFP-A SUCTION
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
9
P111
HPH-5 DRIP TO D/A (HE)
PR. TRANS.
0.1%
0-60Kg./Sq.Cm.
10
P112
EXTN. TO LPH-3 (TE)
PR. TRANS.
0.1%
0-10Kg./Sq.Cm.
11
P113
EXTN. TO LPH-3 (HE)
PR. TRANS.
0.1%
0-10Kg./Sq.Cm.
12
P114
EXTN. TO LPH-2 (HE)
PR. TRANS.
0.1%
0-10Kg./Sq.Cm.
13
P115
EXTN. TO LPH-2 (HE)
PR. TRANS.
0.1%
0-10Kg./Sq.Cm.
14
P116
EXTN. TO LPH-1 (TE)
PR. TRANS.
0.1%
0-780mm. Hg.
15
P117
EXTN. TO LPH-1 (TE)
PR. TRANS.
0.1%
0-780mm. Hg.
16
P118
EXTN. TO LPH-1 (TE)
PR. TRANS.
0.1%
0-780mm. Hg.
17
P119
STEAM TO GSC
PR. TRANS.
0.1%
0-10Kg./Sq. Cm.
18
P120
LP BYPASS (R)
PR. TRANS.
0.1%
0-60Kg./Sq. Cm.
19
P121
LP BYPASS (L)
PR. TRANS.
0.1%
0-60Kg./Sq. Cm.
20
P122
CEP SUCTION
PR. TRANS.
0.1%
0-780mm. Hg.
21
P123
CEP DISCHARGE
PR. TRANS.
0.1%
0-25Kg./Sq. Cm.
22
P124
CONDENSATE NEAR FE.
PR. TRANS.
0.1%
0-10Kg./Sq. Cm.
23
P125
APRDS AFT.
PR. TRANS.
0.1%
0-25Kg./Sq. Cm.
DESUPERHEATER 24
P126
25
P127
26
P128
27
P129
28
CW DIFF. PR. AT COND-A
DP. TRANS.
0.1%
0-2.5Kg./Sq. Cm.
CW DIFF. PR. AT COND-B
DP. TRANS.
0.1%
0-2.5Kg./Sq. Cm.
P130
CONDENSER VACUUM
PR. TRANS.
0.1%
0-780mm. Hg.
29
P131
CONDENSER VACUUM
PR. TRANS.
0.1%
0-780mm. Hg.
30
P132
CONDENSER VACUUM
PR. TRANS.
0.1%
0-780mm. Hg.
31
P133
CONDENSER VACUUM
PR. TRANS.
0.1%
0-780mm. Hg.
32
P134
CONDENSER VACUUM
PR. TRANS.
0.1%
0-780mm. Hg.
33
P135
CONDENSER VACUUM
PR. TRANS.
0.1%
0-780mm. Hg.
34
P136
BFP-B SUCTION
PR. TRANS.
0.1%
0-10Kg./Sq. Cm.
35
P139
CEP SUCTION
PR. TRANS.
0.1%
0-780mm. Hg.
36
P140
BFP-C SUCTION
PR. TRANS.
0.1%
0-10Kg./Sq. Cm.
37
P141
DC INLET
PR. TRANS.
0.1%
0-25Kg./Sq. Cm.
Instrument
Accuracy
FLOW POINTS Sr. No.
Tag No.
Service
Range
1
F101A
MAIN CONDENSATE
DP. TRANS.
0.1%
0-2.5Kg./Sq.Cm.
2
F101B
MAIN CONDENSATE
DP. TRANS.
0.1%
0-2.5Kg./Sq.Cm.
3
F102A
RH SPRAY
DP. TRANS.
0.1%
0-2.5Kg./Sq.Cm.
4
F102B
RH SPRAY
DP. TRANS.
0.1%
0-2.5Kg./Sq.Cm.
5
F103A
SH SPRAY
DP. TRANS.
0.1%
0-2.5Kg./Sq.Cm.
6
F103B
RH SPRAY
DP. TRANS.
0.1%
0-2.5Kg./Sq.Cm.
Instrument
Accuracy
TEMPERATURE POINTS Sr. No.
Tag No.
Service
Range
1
T101
MS BEF. STRAINER (L)
T/C
1/2 DIN
250-550 Deg. C
2
T102
MS BEF. STRAINER (L)
T/C
1/2 DIN
250-550 Deg. C
3
T103
MS BEF. STRAINER (R)
T/C
1/2 DIN
250-550 Deg. C
4
T104
MS BEF. STRAINER (R)
T/C
1/2 DIN
250-550 Deg. C
5
T105
CRH AFTER SPRAY (L)
T/C
1/2 DIN
250-550 Deg. C
6
T106
CRH AFTER SPRAY (R)
T/C
1/2 DIN
250-550 Deg. C
7
T107
EXTN TO HPH-6 (TE)
T/C
1/2 DIN
250-550 Deg. C
8
T108
EXTN TO HPH-6 (TE)
T/C
1/2 DIN
250-550 Deg. C
9
T109
HRH BEF. STRAINER (L)
T/C
1/2 DIN
250-550 Deg. C
10
T110
HRH BEF. STRAINER (L)
T/C
1/2 DIN
250-550 Deg. C
11
T111
HRH BEF. STRAINER (R)
T/C
1/2 DIN
250-550 Deg. C
12
T112
HRH BEF. STRAINER (R)
T/C
1/2 DIN
250-550 Deg. C
13
T114
IPT EXHAUST (L)
T/C
1/2 DIN
250-550 Deg. C
14
T116
IPT EXHAUST (R)
T/C
1/2 DIN
250-550 Deg. C
15
T117
LPT INLET (L)
T/C
1/2 DIN
250-550 Deg. C
16
T118
LPT INLET (L)
T/C
1/2 DIN
250-550 Deg. C
17
T119
LPT INLET (R)
T/C
1/2 DIN
250-550 Deg. C
18
T120
LPT INLET (R)
T/C
1/2 DIN
250-550 Deg. C
19
T121
MS TO APRDS
T/C
1/2 DIN
250-550 Deg. C
20
T122
SPRAY TO APRDS
PRT Pt-100
1/2 DIN
250-550 Deg. C
21
T123
EXTN. TO HPH-6 (HE)
T/C
1/2 DIN
250-550 Deg. C
22
T124
EXTN. TO HPH-6 (HE)
T/C
1/2 DIN
250-550 Deg. C
23
T125
FW HPH-6 INLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
24
T126
FW HPH-6 INLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
25
T127
FW HPH-6 OUTLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
26
T128
FW HPH-6 OUTLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
27
T131
HPH-6 DRIP TO HPH-5
PRT Pt-100
1/2 DIN
0-300 Deg. C
28
T132
HPH-6 DRIP TO HPH-5
PRT Pt-100
1/2 DIN
0-300 Deg. C
29
T133
EXTN. TO HPH-5 (HE)
T/C
1/2 DIN
250-550 Deg. C
30
T134
EXTN. TO HPH-5 (HE)
T/C
1/2 DIN
250-550 Deg. C
31
T135
EXTN. TO HPH-5 (HE)
T/C
1/2 DIN
250-550 Deg. C
32
T136
EXTN. TO HPH-5 (HE)
T/C
1/2 DIN
250-550 Deg. C
33
T137
FW INLET TO HPH-5
PRT Pt-100
1/2 DIN
0-300 Deg. C
34
T138
FW INLET TO HPH-5
PRT Pt-100
1/2 DIN
0-300 Deg. C
35
T139
FW HPH-5 OUTLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
36
T140
FW HPH-5 OUTLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
37
T141
EXTN. TO D/A (TE)
T/C
1/2 DIN
250-550 Deg. C
38
T142
EXTN. TO D/A (TE)
T/C
1/2 DIN
250-550 Deg. C
39
T143
EXTN. TO D/A (DE)
T/C
1/2 DIN
250-550 Deg. C
40
T144
EXTN. TO D/A (DE)
T/C
1/2 DIN
250-550 Deg. C
41
T145
FFW AT ECO. INLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
Instrument
Accuracy
TEMPERATURE POINTS Sr. No.
Tag No.
Service
Range
46
T146
FFW AT ECO. INLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
47
T147
SH SPRAY
PRT Pt-100
1/2 DIN
0-300 Deg. C
48
T148
RH SPRAY
PRT Pt-100
1/2 DIN
0-300 Deg. C
49
T149
BFP-A DISCHARGE
PRT Pt-100
1/2 DIN
0-300 Deg. C
50
T150
BFP-B DISCHARGE
PRT Pt-100
1/2 DIN
0-300 Deg. C
51
T151
BFP-C DISCHARGE
PRT Pt-100
1/2 DIN
0-300 Deg. C
52
T152
HP BYPASS AFT.HPB VAL. (R)
T/C
1/2 DIN
250-550 Deg. C
53
T153
HP BYPASS AFT.HPB VAL. (L)
T/C
1/2 DIN
250-550 Deg. C
54
T154
CRH BEF. SPRAY (R)
T/C
1/2 DIN
250-550 Deg. C
55
T155
CRH BEF. SPRAY (R)
T/C
1/2 DIN
250-550 Deg. C
56
T156
CRH BEF. SPRAY (L)
T/C
1/2 DIN
250-550 Deg. C
57
T157
CRH BEF. SPRAY (L)
T/C
1/2 DIN
250-550 Deg. C
TEMPERATURE POINTS
Sr. No.
Tag No.
Service
Instrument
Accuracy
Range
1
T201
LPT EXHAUST (R) (TE)
PRT Pt-100
1/2 DIN
0-300 Deg. C
2
T202
LPT EXHAUST (L) (TE)
PRT Pt-100
1/2 DIN
0-300 Deg. C
3
T203
LPT EXHAUST (R) (COND.E)
PRT Pt-100
1/2 DIN
0-300 Deg. C
4
T204
LPT EXHAUST (L) (COND.E)
PRT Pt-100
1/2 DIN
0-300 Deg. C
5
T205
EXTN. TO LPH-3 (TE)
PRT Pt-100
1/2 DIN
0-300 Deg. C
6
T206
EXTN. TO LPH-3 (TE)
PRT Pt-100
1/2 DIN
0-300 Deg. C
7
T207
EXTN. TO LPH-3 (HE)
PRT Pt-100
1/2 DIN
0-300 Deg. C
8
T208
EXTN. TO LPH-3 (HE)
PRT Pt-100
1/2 DIN
0-300 Deg. C
9
T209
LPH-3 DRAIN TO LPH-2
PRT Pt-100
1/2 DIN
0-300 Deg. C
10
T210
LPH-3 DRAIN TO LPH-2
PRT Pt-100
1/2 DIN
0-300 Deg. C
11
T211
LPH-3 INLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
12
T212
LPH-3 OUTLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
13
T213
LPH-3 O/L D/S OF BP VALVE
PRT Pt-100
1/2 DIN
0-300 Deg. C
14
T214
EXTN. TO LPH-2 (TE)
PRT Pt-100
1/2 DIN
0-300 Deg. C
15
T216
EXTN. TO LPH-2 (HE)
PRT Pt-100
1/2 DIN
0-300 Deg. C
16
T217
EXTN. TO LPH-2 (HE)
PRT Pt-100
1/2 DIN
0-300 Deg. C
17
T218
LPH-2 DRAIN TO LPH-1
PRT Pt-100
1/2 DIN
0-300 Deg. C
18
T219
LPH-2 DRAIN TO LPH-1
PRT Pt-100
1/2 DIN
0-300 Deg. C
19
T220
LPH-2 OUTLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
20
T221
LPH-2 INLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
21
T222
EXTN. TO LPH-1
PRT Pt-100
1/2 DIN
0-300 Deg. C
22
T223
LPH-1 DRAIN TO DC
PRT Pt-100
1/2 DIN
0-300 Deg. C
23
T224
LPH-1 DRAIN TO DC
PRT Pt-100
1/2 DIN
0-300 Deg. C
24
T225
LPH-1 OUTLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
25
T226
DC OUTLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
26
T227
LPH-1 INLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
27
T228
DC DRAIN TO FLASH BOX-3
PRT Pt-100
1/2 DIN
0-300 Deg. C
28
T229
DC DRAIN TO FLASH BOX-3
PRT Pt-100
1/2 DIN
0-300 Deg. C
29
T230
DC INLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
30
T232
STEAM TO GSC
PRT Pt-100
1/2 DIN
0-300 Deg. C
31
T233
GSC DRAIN TO FLASH BOX-
PRT Pt-100
1/2 DIN
0-300 Deg. C
3 32
T234
GSC INLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
33
T235
GSC OUTLET
PRT Pt-100
1/2 DIN
0-300 Deg. C
34
T236
CW INLET-A
PRT Pt-100
1/2 DIN
0-300 Deg. C
35
T237
CW INLET-A
PRT Pt-100
1/2 DIN
0-300 Deg. C
36
T238
CW OUTLET-A
PRT Pt-100
1/2 DIN
0-300 Deg. C
37
T239
CW OUTLET-A
PRT Pt-100
1/2 DIN
0-300 Deg. C
38
T240
CW OUTLET-A
PRT Pt-100
1/2 DIN
0-300 Deg. C
39
T241
CW OUTLET-A
PRT Pt-100
1/2 DIN
0-300 Deg. C
40
T242
CW OUTLET-A
PRT Pt-100
1/2 DIN
0-300 Deg. C
41
T243
CW OUTLET-A
PRT Pt-100
1/2 DIN
0-300 Deg. C
42
T247
CW INLET-B
PRT Pt-100
1/2 DIN
0-300 Deg. C
43
T248
CW INLET-B
PRT Pt-100
1/2 DIN
0-300 Deg. C
44
T249
CW OUTLET-B
PRT Pt-100
1/2 DIN
0-300 Deg. C
45
T250
CW OUTLET-B
PRT Pt-100
1/2 DIN
0-300 Deg. C
46
T251
CW OUTLET-B
PRT Pt-100
1/2 DIN
0-300 Deg. C
47
T252
CW OUTLET-B
PRT Pt-100
1/2 DIN
0-300 Deg. C
48
T253
CW OUTLET-B
PRT Pt-100
1/2 DIN
0-300 Deg. C
49
T254
CW OUTLET-B
PRT Pt-100
1/2 DIN
0-300 Deg. C
50
T258
CEP SUCTION
PRT Pt-100
1/2 DIN
0-300 Deg. C
51
T259
CEP DISCHARGE
PRT Pt-100
1/2 DIN
0-300 Deg. C
52
T260
COND. TO D/A NEAR FE
PRT Pt-100
1/2 DIN
0-300 Deg. C
53
T261
COND. TO D/A NEAR FE
PRT Pt-100
1/2 DIN
0-300 Deg. C
54
T262
COND. TO D/A (DE)
PRT Pt-100
1/2 DIN
0-300 Deg. C
55
T263
COND. TO D/A (DE)
PRT Pt-100
1/2 DIN
0-300 Deg. C
56
T264
D/A SHELL TEMP.
PRT Pt-100
1/2 DIN
0-300 Deg. C
57
T265
BFP-A SUCTION
PRT Pt-100
1/2 DIN
0-300 Deg. C
58
T266
BFP-A SUCTION
PRT Pt-100
1/2 DIN
0-300 Deg. C
59
T267
BFP-B SUCTION
PRT Pt-100
1/2 DIN
0-300 Deg. C
60
T268
BFP-B SUCTION
PRT Pt-100
1/2 DIN
0-300 Deg. C
61
T269
BFP-C SUCTION
PRT Pt-100
1/2 DIN
0-300 Deg. C
62
T270
HPH-5 DRIP TO D/A
PRT Pt-100
1/2 DIN
0-300 Deg. C
63
T271
HPH-5 DRIP TO D/A
PRT Pt-100
1/2 DIN
0-300 Deg. C
64
T272
APRDS AFT.
PRT Pt-100
1/2 DIN
0-300 Deg. C
DESUPERHEATER 65
T273
LP BYPASS (R)
T/C
1/2 DIN
250-550 Deg. C
66
T274
LP BYPASS (L)
T/C
1/2 DIN
250-550 Deg. C
67
T275
BFP-C SUCTION
PRT Pt-100
1/2 DIN
0-300 Deg. C
68
T276
CEP SUCTION
PRT Pt-100
1/2 DIN
0-300 Deg. C
69
T277
CEP SUCTION
PRT Pt-100
1/2 DIN
0-300 Deg. C
AUXILIARY POWER MEASUREMENT Sr.
Tag No.
Service
Instrument
Accuracy
Range
No. 1
PAX-1
CWP-A discharge Pr.
PR. TRANS.
0.10%
0-10 Kg./Sq.Cm.
2
PAX-2
CWP-B discharge Pr.
PR. TRANS.
0.10%
0-10 Kg./Sq.Cm.
3
PAX-3
Booster pump suction Pr.
PR. TRANS.
0.10%
0-10 Kg./Sq.Cm.
4
PAX-4
BFP-A Suction Pr.
PR. TRANS.
0.10%
0-25 Kg./Sq.Cm.
5
PAX-5
BFP-A discharge Pr.
PR. TRANS.
0.10%
0-250 Kg./Sq.Cm.
6
PAX-6
BFP-A Suction flow
DP.TRANS.
0.10%
0-2.5 Kg./Sq.Cm.
7
PAX-7
Booster pump-B Suction Pr.
PR. TRANS.
0.10%
0-10 Kg./Sq.Cm.
8
PAX-8
BFP-B Suction Pr.
PR. TRANS.
0.10%
0-25 Kg./Sq.Cm.
9
PAX-9
BFP-B discharge Pr.
PR. TRANS.
0.10%
0-250 Kg./Sq.Cm.
10
PAX-10
BFP-B Suction flow
DP.TRANS.
0.10%
0-2.5 Kg./Sq.Cm.
11
PAX-11
CEP Suction Pressure
PR. TRANS.
0.10%
0-780 mm. Hg.
12
PAX-12
CEP discharge Pressure
PR. TRANS.
0.10%
0-60 Kg./Sq.Cm.
13
PAX-13
CEP discharge flow
DP.TRANS.
0.10%
0-2.5 Kg./Sq.Cm.
1
TAX-1
BFP-A Suction temp
RTD-100
1/2 DIN
0-300 Deg. C
2
TAX-2
BFP-B Suction temp
RTD-100
1/2 DIN
0-300 Deg. C
3
TAX-3
CEP discharge temp
RTD-100
1/2 DIN
0-300 Deg. C
1
P233
CW DISCH PR.
PR. TRANS.
0.10%
0-10 Kg./Sq.Cm.
2
P234
CW DISCH PR.
PR. TRANS.
0.10%
0-10 Kg./Sq.Cm.
1
F104
CONDENSATE FLOW (AUX.
DP. TRANS.
0.10%
0-2.5 Kg./Sq.Cm.
DP. TRANS.
0.10%
0-2.5 Kg./Sq.Cm.
POWER-PLANT ASSEMBLY) 2
F105
FEED FLOW (AUX. POWER BFP SUC-PLANT ASSEMBLY)
ANNEXURES 1.
CORRECTION CURVES
1.1
HEAT RATE CORRECTION CURVES MAIN STEAM PRESSURE MAIN STEAM TEMP REHEAT CIRCUIT PR. DROP REHEAT STEAM TEMP. CONDENSER PRESSURE
DRG No. PE-4-183-100-123 DRG No. PE-4-183-100-124 DRG No. PE-4-183-100-125 DRG No. PE-4-183-100-136
FINAL FEED WATER TEMP.
DRG No. PE-4-183-100-138
FREQUENCY
DRG No. PE-4-183-100-140
POWER FACTOR
DRG No. PE-4-183-100-142
SH SPRAY
DRG No. PE-4-183-100-144 DRG No. PE-4-183-100-137
OUTPUT CORRECTION CURVES MAIN STEAM PRESSURE MAIN STEAM TEMP. REHEAT CIRCUIT PR. DROP REHEAT STEAM TEMP
DRG No. PE-4-183-100-126 DRG No. PE-4-183-100-127 DRG No. PE-4-183-100-128 DRG No. PE-4-183-100-129
CONDENSER PRESSURE
DRG No. PE-4-183-100-130
RH SPRAY
DRG No. PE-4-183-100-135
FINAL FEED WATER TEMP.
DRG No. PE-4-183-100-139
FREQUENCY
DRG No. PE-4-183-100-141
POWER FACTOR
DRG No. PE-4-183-100-143
SH SPRAY D/A LEVEL DROP (Ref. HRCC above) 1.3
DRG No. PE-4-183-100-122
RH SPRAY
D/A LEVEL DROP 1.2
DRG No. PE-4-183-100-121
HOTWELL CURVE HXE/SK/1029
DRG No. PE-4-183-100-145 DRG No. PE-4-183-100-137
1.4
D/A CURVE DRG No. 4-16310-00347
1.5
METHOD FOR COMPUTATION OF HEAT RATE (DOCUMENT No. PE-4-183-100-211 REV 05)
2.0
CONNECTION BETWEEN PRESSURE SOURCE AND TRANSDUCER.
3.0
CONNECTION BETWEEN VACUUM SOURCE AND TRANSMITTER
4.0
TEMP. MEASUREMENT USING T/C’s AND PRT’s
5.0
CONNECTION DIAGRAM FOR DIGITAL POWER METER
6.0
DATA SHEET
7.0
HEAT BALANCE DRG No. PE-3-183-100-101
8.0
MS FLOW Vs FIRST STAGE PRESSURE DRG No. PE-4-183-100-131 (FOR INFORMATION CURVE)
DRG. NO. PE - 4 - 183 - 100 - 121
DRG. NO. PE - 4 - 183 - 100 - 122
DRG. NO. PE - 4 - 183 - 100 - 123
DRG. NO. PE - 4 - 183 - 100 - 124
DRG. NO. PE - 4 - 183 - 100 - 125
DRG. NO. PE - 4 - 183 - 100 -136
DRG. NO. PE - 4 - 183 - 100 - 138
DRG. NO. PE - 4 - 183 - 100 - 140
Drg. No. PE 4 - 183 - 100 - 142
DRG. NO. PE - 4 - 183 - 100 - 144
DRG. NO. PE - 4 - 183 - 100 - 137
DRG. NO. PE - 4 - 183 - 100 - 126
DRG. NO. PE - 4 - 183 - 100 - 127
DRG. NO. PE - 4 - 183 - 100 - 128
DRG. NO. PE - 4 - 183 - 100 - 129
DRG. NO. PE - 4 - 183 - 100 - 130
DRG. NO. PE - 4 - 183 - 100 - 135
DRG. NO. PE - 4 - 183 - 100 - 139
DRG. NO. PE - 4 - 183 - 100 - 141
DRG. NO. PE - 4 - 183 - 100 - 143
DRG. NO. PE - 4 - 183 - 100 - 145
Drg. No. 4 - 16310 - 00347
Doc. No. PE-4-183-100-211 REV 05
METHOD FOR THE COMPUTATION OF HEAT RATE The measurements which are directly connected with computation of Heat Rate are shown in sheet 1 of this document. The other measurements required for the PG test are shown in the PG Test Scheme (Drg. No. PE-3-183-100-210 REV. 02). The procedure for the computation of heat rate from the measurements envisaged is as given below. 1.0
EXTRACTION STEAM FLOWS TO HP-HEATERS AND DEAERATOR Steam extraction to HP-Heater and deaerator is evaluated from thermal balance.
HP-HEATER NO. 6 Z [H12 – H7] = [M1+X+Y+Z-Mshs-Mrhs±∆Mdea] (116-115) ……………............[A] HP-HEATER NO. 5 Y.[H11-H8] + Z [117-118] = [M1+X+Y+Z- Mshs-mrhs±Mdea].(114-113) ….. [B] DEAERATOR X.111+M1.H10+[Y+Z].119 = [M1+X+Y+Z].112 ………….................................[C] Three unknown X, Y and Z can be calculated from equation [A], [B] & [C] Feed water flow Mfw = M1 + X + Y + Z – Mshs-Mrhs ± ∆Mdea …………............[D] 1) When there is an increase in the level f deaerator, -ve sign shall be used for ∆Mdea 2) When there is a decrease in the level of deaerator, +ve sign shall be used for ∆Mdea Sum of storages [∆Msto] increases or decreased for the following tanks :a) Hotwell storage NOTE :
b) Drum storage c) Condensate make-up storage d) Dearator storage NOTE : For the above storages if there is a net increase in level, +ve sign is to be taken for ∆Msto and if there is a net decrease in level, -ve sign is to be taken for ∆Msto to arrive at the unaccounted
losses to be reflected in the main steam flow [Mms]. = Mfw + Mshs±∆Msto±∆Mdrum …………………………………….. [E]
Mms NOTE :1. 2.
When there is increase in level of boiler drum, -ve sign shall be used for ∆Mdrum When there is decrease in level of boiler drum, +ve sign shall be used for ∆Mdrum
Reheat steam flow Mrh = Mms + Mrhs – Z – Md ………………………….. (F) M1 = Condensate flow to deaerator measured from flow measuring device F101 …. Kg/hr Md = Gland leakages A, B and C from HP turbine to be computed (Mdi + Mdo) …….kg/hr Mdi = Gland leakages A, B and C from HPT inlet side ……………………….. kg/hr Mdo = Gland leakages A, B and C from HPT outlet side ……………………….kg/hr ∆Msto = Total increase/decrease of storage in system [from level gauges] during the test …kg/hr ∆Mdea = Change in deaerator storage during the test ……………….. kg/hr ∆Mdrum = Change in boiler drum level during the test ………………......kg/hr Mshs = Super heater spray measured from flow measuring device F103 ……...kg/hr Mrhs = Reheater spray quantity measured by flow measuring device F102 … kg/hr X = Extraction steam flow to deaerator [calculated from thermal balances] …....kg/hr Y = Extraction steam flow to HPH-5 [calculated from thermal balance] ………....kg/hr Z = Extraction steam flow to HPH-6 [calculated from thermal balance] ………....kg/hr H1 = Enthalpy of steam entering deaerator based on measurements P108 & T143, T144 …...kcal/kg H2
=
Enthalpy of feed water at deaerator outlet based on measurements P110, T265, T266 & P136, T267, T268 & P140, T269, T275 …………...........................kcal/kg H3 = kcal/kg
Enthalpy of feed water at HPH5 inlet based on measurements P221 & T137, T138 …….
H4 = kcal/kg
Enthalpy of feed water at HPH-5 outlet based on measurements P222 & T139, T140 …
H5 = Enthalpy of feed water at HPH-6 inlet based on measurements P215 & T125, T126 …….kcal/kg H6 = Enthalpy of feed water at HPH-6 outlet based on measurements P216 & T127, T128 ….kcal/kg H7 = Enthalpy of HPH-6 drain based on measurements P218 & T131, T132 ……....................kcal/kg H8 = Enthalpy of HPH-5 drain near heater based on measurements P111 & T270, T271 ……...kcal/kg H10
=
Enthalpy of condensate entering deaerator Based on measurements P124 & T262, T263 …………………...............kcal/kg
H11
=
Enthalpy of extraction steam entering HPH-5 Based on measurements P220 & T135, T136 …………………...............kcal/kg
H12
=
Enthalpy of extraction steam entering HPH-6 Based on measurements P214 & T123, T124 …………………...............kcal/kg
2.0
HEAT RATE :-
HR
=
Mms[Hms–Hffw]+Mrh[Hrho-Hrhi]+Mshs[Hffw-Hshs]+Mrhs[Hrhi-Hrhs]
--
--------------------------------------------------------------------------------------------------------------------..........…….. [G]
Pnet. HR = Heat Rate ………………………………………… kcal/kwh Mms = Main steam flow at HPT inlet [as calculated] …………….. kg/hr Mrh = Reheat steam flow [as calculated] …………………………......kg/hr Hms = Enthalpy of steam before ESV based on measurements P201, P203 & T101 to T104 ……………… kcal/kg Hffw = Enthalpy of final feed water after HP-heaters based on measurements P206 & T145, T146 ………………….. Kcal/kg Hrho = Enthalpy of hot reheat steam before IV based on measurements P208, P210 & T109 to T112 …………………… kcal/kg Hrhi = Enthalpy of cold reheat steam based on measurements P207 & T107 to T108 ……. Kcal/kg Hshs = Enthalpy of superheater spray based on any two of the measurements {P227, T151}, {P226, T150} and {P225, T149} depending upon working BFPs. Hrhsi = Enthalpy of CRH after mixing of RH spray based on measurements P209, T106 & P211, T105 ……………………………….. kcal/kg Pnet = Pgen – 63 (Towards integral auxiliaries) …………………..kw Pgen = Power measured at Generator terminals ………………….. kw
3.0
COMPUTATION OF TOTAL GLAND LEAKAGES :-
Steam leakage through the glands A, B and C is calculated using the formula given below
G = Steam leakage through the glands...............T/H. P1= Pressure before the glands.......................ata P2= Pressure after the glands......................ata V1= Specific volume at inlet conditions to the glands..........cum/kg.
Data for design case is given below [Refer HBD No. PE-3-183-100-101 REV 02] PARAMETER HPT INLET END G 3.051 P1 41.27 P2 6.835 V1 *0.0838 * Based on 41.27 ata & 816.0 kcal/kg. ** Based on 41.27 ata & 349.6 DEG C.
HPT OUTLET END 3.199 41.27 6.835 **0.0655
For design case P1, P2, V1 and G are known and hence K can be evaluated. K values calculated for the design case are as given below : a) For gland leakage from HPT inlet end K = 0.1394 b) For gland leakage from HPT outlet end K = 0.1292 For test case, by putting this value of K and the test values of P1, P2 and V1 and computation of G can be done. For the test case, the values of P1, P2 and V1 are determined as given below :
For HPT inlet end :
P1 is based on measurements P207 P2 is based on measurements P105 & P106 V1 is based on measurements P207 & TA
203 & T101 to T104.
TA is calculated on the basis of P207 and enthalpy corresponding to P201 and
For HPT outlet end : P1 is based on measurements P207 P2 is based on measurements P105 to P108 V1 is based on measurements P207 & T107 to T108 4.0
NOTE :
1. The heat rate is guaranteed with 0% make-up and hence no make-up will be supplied to the condenser during the performance guarantee test. Under these conditions the storage in the deaerator feed storage tank is utilised towards the leakage losses and the measured heat rate shall be corrected using the correction curve viz. Change in heat rate vs. change in storage of feed water storage tank. 2. In case the temperature measured at the HP turbine exhaust (measurements T107 to T108) is less than the temperature of extraction steam at HP Heater No. 6 inlet (measurements T123, T124) then leakage through the HP bypass valve is suspected. The leakage shall be estimated as given below : Mhpb
=
[Mms – Md] [H12 – Hrhi] _______________________ [Hms – Hrhi]
where Mhpb = Quantity of steam leakage through the HP bypass valve ………. T/HR The quantity of steam entering the HP turbine [Mms1] shall be corrected for the leakage through the HP bypass as given below and shall be used in the equation (G) instead of Mms. Mms1 = Mms – Mhpbp 5.0
GUARANTEE CONDITIONS.
1.
Guaranteed Heat Rate at 100% load = 1939.3 Kcal/Kwhr. (Ref HBD No. PE-3-183-100-101 REV 01 titled “210 MW 0% MU 0.0911 ata Back Pr).
2. Instrument uncertainly shall be computed with accuracy classes of various instruments to be used during the P.G. test in accordance with the document titled “Guidance for evaluation of measuring uncertainly in performance test of steam turbine – “A report by ASME Performance test code committee – G” 3. If the test is carried out after four months of the date of first commissioning, due to any reason whatsoever, the specific heat consumption shall be increased by following amounts for each month or part of a month by which the period between the initial commissioning and the acceptance test exceeds 4 months. 0.10% for the following 8 months 0.06% for the period thereafter 4.
The pressure drop between MS strainer and ESV & between ESV and HPT in the MS line and
between HRH strainer and IV & between IV & IPT in HRH line have not been considered in the heat balance calculations since same is to be accounted in the respective system piping pressure drops. The actual pressure drops shall be estimated during the PG test based on layout envisaged and the calculated steam flows and necessary corrections applied on the measured pressures. 6.0 A.
LIST OF CORRECTION CURVES HEAT RATE CORRECTION CURVES FOR :
i. Main steam pressure. ii. Main steam temperature. iii. Reheat steam temperature. iv. Reheat circuit pressure drop. v. Back pressure. vi. Reheat Spray/Superheater Spray. vii. Change in feed water storage in Deaerator FW storage tank. viii. Final feed water Temperature. ix. Power factor. x. Frequency. B.
OUTPUT CORRECTION CURVES FOR :
i. ii. iii. iv. v. vi. vii. viii. ix. x.
Main steam pressure. Main steam temperature. Reheat steam temperature. Reheat circuit pressure drop. Back pressure. Reheat Spray/Superheater Spray. Change in feed water storage in Deaerator FW storage tank. Final feed water temperature. Power factor. Frequency.
CONNECTION BETWEEN PRESSURE SOURCE AND TRANSDUCER.
CONNECTION BETWEEN VACUUM SOURCE AND TRANSMITTER.
TEMPERATURE MEASUREMENT USING T/Cs & PRTs.
CONNECTION DIAGRAM FOR DIGITAL POWER METER
HEAT BALANCE Drg. No. PE-3-183-100-101
Drg. No.: PE-4-183-100-131
P ROC EDU RE F OR SITE P ERF ORM ANC E G U ARANTEE TEST OF BF P PROJECT
:
2 x 210
CUSTOMER
:
MSEB
UNITS 3 & 4
1.0
KHAPERKHEDA TPS
INTENT : The intent of the site test is to prove the auxiliary power consumption of the Boiler Feed Pump set measured at the input terminals of the BFP drive motor at guaranteed parameters.
2.0
GUARANTEE PARAMETERS : The guaranteed parameters of the pump are given at cl.no. 9.0
3.0
TEST SET UP : The schematic arrangement for the test is illustrated in page no. 6.
4.0
MEASURING POINTS : a)
FLOW : The Feed water flow of the Boiler Feed Pump is measured using the plant flow nozzle and test differential pressure transmitter.
b)
HEAD : The head measurement is done by test pressure transmitters in Booster pump suctions, BFP suction and BFP discharge.
c)
TEMPERATURE : The temperature measurement is done by test RTD.
d)
SPEED : The speed measurement is carried out by non-contact type digital tachometer.
c)
POWER : The power input at the motor terminals shall be measured by test watt transducers which shall be connected to C.T's and P.T’s provided in the switchgear.
5.0
PERFORMANCE TOLERANCES : An overall tolerance of 3.5% will be used while comparing measured power with the guarantee power due to measurement uncertainties on flow, head and power. This is as per Table-7 of BS-5316, Class C.
6.0 6.1
TEST METHODOLOGY : The test instruments listed at cl.no. 10.0 will be connected as per the test scheme. All transducers will be connected to a data logger.
6.2
Preliminary test shall be conducted for checking up of instruments.
6.3
After stabilisation, the test will be conducted for about 1 hour and readings will be recorded at 5 minute intervals in the data logger. The data logger print out of the readings thus recorded shall be signed by Customer and BHEL Representatives. During the test, the customer shall try to maintain the flow through the BFP within
±3% of the flow at guarantee point, for recording
the various parameters. 6.4 7.0
Two tests will be conducted on each pump set. CALCULATION PROCEDURE : The auxiliary power consumption for BFP set is valid for a given set of guarantee parameters of BFP suction flow and the feed water temperature. In case the BFP is operated at a point different from the guaranteed parameters, the input power would be computed using the standard formulae relating Q, H and Efficiency, and the auxiliary power consumed at motor terminals is derived after considering the motor efficiency, pump efficiency and hydraulic
coupling losses corresponding to test flow, with reference to design curves of BFP and Booster pump. Evaluation is done by averaging the test results of the two test carried out on each pump. 8.0
AUXILIARY POWER GUARANTEE : BFP parameters corresponding to Auxiliary Power guarantee : (MRC Flow, 0% MU, 0.0911 ata back pr.) Suction Flow (m3/hr)
:
343.9 (per BFP)
Dynamic head (mlc)
:
1890 (BFP + BP)
Temperature (°C)
:
159.50
Specific Wt. (kg/m3)
:
907.77
Motor input power (kW)
:
2660 (per BFP)
Total Auxiliary Power (kW)
:
5320
NOTE : Auxiliary power is guaranteed with ‘ZERO’ interstage flow i.e. interstage valve in closed condition. 9.0
LIST OF INSTRUMENTS :
-----------------------------------------------------------------------------------PARAMETER TYPE AND RANGE OF
TAG NO. ACCURACY
Booster Pump Suction Pr.
Pressure Transmitter 010kg/sq.cm.
PT1
± 0.1%
BFP suction Pressure
Pressure Transmitter 030kg/sq.cm.
PT2
± 0.1%
BFP discharge Pressure
Pressure Transmitter 0300kg/sq.cm.
PT3
± 0.1%
BFP suction Flow
Diffl. Pr. Transmitter (Range will be selected based on flow nozzle data)
DPT
± 0.1%
TE
1/3 DIN
Optical non-contact Digital Tachometer.
N
± 1 RPM
Booster Optical non-contact Pump Speed Digital Tachometer.
N
± 1 RPM
Motor input Power.
W
0.25%
BFP Suction RTD 0 - 200°C Temperature BFP speed
Watt transducer
REMARKS
------------------------------------------------------------------------------------
10.0
SAMPLE CALCULATIONS : During the site test, pump parameters like flow, head and speed may be different from those guaranteed. The following illustrates sample calculation for new auxiliary power based on site test parameters.
A.
Site tested data : Feed water temp.
=
150 °C
Sp. wt. of feed water
=
916.9 kg/m3 from standards
Flow
=
345 t/hr
Booster pump suction pressure
=
p1 kg/cm2
BFP suction pressure
=
p2 kg/cm2
BFP discharge pressure
=
p3 kg/cm2
Booster pump speed
=
1510 rpm
BFP speed
=
4800 rpm
Power input to motor terminals
=
2770 kW
From the above data : Flow
B.
=
345/0.9169
376.27 m3/hr
=
Booster pump head
=
{(p2 - p1) x 10} / 0.9169
=
say 105 mlc
BFP head
=
{(p3 – p2) x 10} / 0.9169
=
say 1952 mlc
Estimated auxiliary power based on tested data : i.
Booster Pump : Tested flow corrected to design speed = (1485/1510)x376.27=370 m3/hr Efficiency at corrected flow from design curve = 77% 916.9 x 376.27 x 105 Power input to pump = ------------------------
=
128 kW
102 x 3600 x 0.77 ii.
Boiler Feed Pump: Tested flow corrected to design speed = (5075/4800)x376.27=398m3/hr Efficiency at corrected flow from design curve = 81% 916.9 x 376.27 x 1952 Power input to pump = -------------------------102 x 3600 x 0.81
iii.
Hydraulic Coupling :
= 2264 kW
Mechanical losses
=
100 kW (Approximate)
HC Prim. speed – BFP Test speed Slip losses
= ---------------------------------------- x Input power
(speed dependent)
BFP Test speed
5998 – 4800 =
------------------- x 2264
= 188 kW.
4800 Total losses in Hydraulic Coupling = 100 + 188 iv.
C.
= 288 kW
Total input power = (i) + (ii) + (iii) = 128+2264+288 = 2680 kW Motor efficiency from motor design curve
=
95 %
Power input at Motor terminals
=
2680/0.95
=
2821 kW
Auxiliary Power measured at site : Auxiliary power measured at test speed
D.
=
2770 kW
Auxiliary power at motor terminals measured at site (C) will be compared to the estimated auxiliary power (B-iv). In case the measured power is higher than the calculated power, the difference of the two will be treated as excess auxiliary power consumption.
RECORD OF REVISIONS Rev. No.
Date
Revision Details
Revised Approved By By
01
26.12.2000 Revised as per MSEB ltr. No. 3084 dt. 21.10.2000
02
12.01.2001
Parameters revised to 0% MU as per PEM ltr. dt. 11.01.2001
PROCEDURE FOR SITE PERFORMANCE GUARANTEE TEST OF CEP
Project Customer
1.0
:
KHAPERKHEDA TPS, UNIT – III & IV :
MSEB
INTENT : The intent of the site test is to prove the auxiliary power consumption of the Condensate Extraction Pump set measured at the input terminals of the CEP drive motor at guarantee parameters.
2.0
GUARANTEE PARAMETERS : The guarantee parameters of BFP set are given at cl. No. 8.0
3.0
TEST SET UP : The schematic arrangement for the test is illustrated at page no. 5
4.0
MEASURING POINTS : a.
FLOW : The condensate water flow of the Condensate Extraction Pump is measured using test Differential Pressure Transmitter across orifice in down stream of gland steam condenser. b. HEAD : The head measurement is done by test pressure transmitters in Pump suction and discharge branches. c. TEMPERATURE : The temperature measurement is done by test RTD. d. SPEED : The speed measurement is carried out by tachometer. e. POWER : The power input at the motor terminals shall be measured by test Wattmeter/ transducers by connecting these wattmeter/transducers to C.T’s and P.T’s provided in the switchgear. 5.0
PERFORMANCE TOLERANCES :
0.1 An overall tolerance of 3.5% will be used while comparing measured power with the guarantee power due to measurement uncertainties on flow, head and power. This is as per Table-7 of BS-5316, Class C. 6.0 6.1 will
TEST METHODOLOGY : The test instruments listed at cl.no. 9.0 will be connected as per the test scheme. Transducers
be connected to a data logger. 6.2
Preliminary test shall be conducted for checking the instruments.
6.3 After stabilisation, the test will be conducted for about 1 hour and readings will be recorded at (5) five minute intervals in the data logger. The data logger print out of the readings thus recorded shall be signed by Customer and BHEL Representatives. During the test, the customer shall try to maintain the flow through the BFP within ± 3% of the flow at guarantee point, for recording the various parameters. 6.4 7.0
Two tests will be conducted on each pump set. CALCULATION PROCEDURE : The auxiliary power consumption for CEP set is valid for a given set of guarantee parameters of CEP discharge flow and the temperature. In case the CEP is operated at a point different from the guaranteed parameters, the input power would be computed using the standard formulae relating Q, H and Efficiency, and the auxiliary power consumed at motor terminals is derived after considering the pump efficiency and motor efficiency corresponding to test flow from the design curves. Evaluation is done by averaging the test results of the two tests carried out on each pump. Sample calculations are given at cl.no. 10.0.
8.0
AUXILIARY POWER GUARANTEE : Condensate Extraction Pump parameters for Auxiliary Power Guarantee : (MRC Flow, 0% MU, 0.0911 ata back pr.)
9.0
Flow (m3/hr) Dynamic head (mlc) Temperature (°C)
: : :
498.5 219 (From Test Curve) 43.6
Specific Wt. (kg/m3) Motor input power (kW) Pump speed (rpm)
: : :
990 440 1485
LIST OF INSTRUMENTS :
-----------------------------------------------------------------------------------------------Parameter Accuracy
Type & range of
Tag No.
------------------------------------------------------------------------------------------------Suction Pressure
Pressure transducer -1 to +1 kg/sq.cm.
PT1
±0.1%
Discharge Pressure
Pressure transducer 0 - 40 kg/sq.cm.
PT2
±0.1%
Flow
Diffl. Pr. transmitter (Range will be selected before the test based on the flow orifice data sheet).
DPT
±0.1%
Temperature
RTD
TE
1/3 DIN
Speed
Optical non-contact digital tachometer.
N
±1 rpm
Power
Watt transducer
W
±0.25%
-----------------------------------------------------------------------------------------------10.0
SAMPLE CALCULATIONS : During the site test, pump parameters like flow, head and speed may be different from those guaranteed. The following illustrates sample calculation for correcting the site tested parameters to the design speed. A.
Site test data :
Speed
: 1513 rpm.
Discharge temp.
: 43°C (sp. wt. to be taken from standard)
Flow
: 540 m3/hr (TPH / sp. wt. at 43°C)
Pump dynamic head
:
Power input at motor terminals
: 456 kW.
B.
Estimated auxiliary power based on tested data : Flow corrected to design speed = 148/1513) X 540 = 530m3/hr.
1.
Dynamic head corrected to design speed = (1485/1513)2
2.
C.
3.
Pump efficiency at 530 m3/hr from design curve = 76%
4.
Power input to pump =
530 x 218.68 x 990 ------------------------ = 411.15 kW 3600 x 102 x 0.76
5.
Power input to motor =
Pump input power -----------------------Motor efficiency
411.15 = ---------- = 435 kW 0.945
Auxiliary power measured at site :
1. 2. D.
{(Disch. pr.- Suction pr.) x 10} / sp. wt. = say 227 mlc
Aux. power at tested speed of 1513 rpm = 456kW. Aux. power corrected to design speed = (1485/1513)3 x 456 = 431.149 kW.
Evaluation: Site measured auxiliary power at motor terminals, corrected to pump design speed (C2) will be compared to the estimated auxiliary power (B5). In case the measured power corrected to design speed is higher than the calculated power, the difference of the two will be treated as excess auxiliary
power consumption.
RECORD OF REVISIONS
Rev.
Date
No. 01
Revision Details
26.12.2000
Revised
Approved
By
By
Revised as per MSEB ltr. No. 3084 dt. 21.10.2000.
02
12.01.2001
Parameters revised to 0% MU as per PEM ltr. dt. 11.01.2001.
PROCEDURE FOR SITE PERFORMANCE GUARANTEE TEST OF CWP PROJECT
IV
CUSTOMER 1.0
: :
2 X 210 MW KHAPERKHEDA TPS UNIT – III & MSEB
INTENT : The intent of the site test is to prove the auxiliary power consumption of the Cooling water Pump set measured at the input terminals of the CWP drive motor at guarantee points.
2.0
GUARANTEE PARAMETERS : The guaranteed parameters shall be as per Annexure-I.
3.0
TEST SET UP : The schematic arrangement for the test shall be as per Annexure- III for CWP Set.
4.0
MEASURING POINTS : a)
DISCHARGE PRESSURE : Discharge Pressure measurement is done by a calibrated pressure gauge.
b)
STATIC HEIGHT : Static height of the pump discharge pressure gauge from the surface of the water line in the sump shall be measured as below. 1. Measure the height of pump discharge pressure gauge centre line from the operating floor level, Say "Z1". 2. Measure the depth of water surface from the operating floor level, say "Z2". Static Height = (Z1 + Z2).
c)
SPEED : The speed measurement is carried out by non-contact type digital tachometer.
c)
POWER : The power input at the motor terminals shall be measured by test Watt Meters.
5.0
PERFORMANCE TOLERANCES : An overall tolerance of 1.5% will be used while comparing measured power with the guaranteed power due to measurement uncertainties on head and power.
6.0
CALCULATION PROCEDURE : The auxiliary power consumption for CWP Set is valid for a given set of guaranteed parameters of CWP Discharge flow and bowl head. In case the CWP is operated at a point different from the guaranteed parameters, the input power would be computed using the standard formula relating Q,H and Efficiency. And the auxiliary power consumed at motor terminals is derived after considering pump efficiency and motor efficiency corresponding to designed flow, with reference to tested curves of CWP. Refer Annexure – IV for sample calculations. ANNEXURE –1 AUXILIARY POWER GUARANTEE
Project
:
Customer
2 x 210 MW Khaperkheda units 3 & 4 :
MSEB
CWP parameters corresponding to Auxiliary Power guarantee
Flow (cum/hr)
:
13600
Bowl head (m)
:
28.5
Motor input power (kw)
:
1260.7
ANNEXURE – II LIST OF INSTRUMENTS Parameter
Type and range
Tag Accuracy Remarks No.
Static height Measuring Tape
MT
--
-
Discharge pressure
Pressure gauge 07kg/sq.cm
PG
0.1%
-
Speed
Optical non-contact Digital tachometer
N
±1 RPM
-
Power
Watt Meter
W
0.25%
-
ANNEXURE – IV COMPUTATION OF POWER INPUT TO CWP MOTOR (SAMPLE CALCULATIONS)
1.
Pump discharge pressure (P1)
2.
Height of discharge pr. Gauge
=
center line from operating floor (Z1) 3.
2.2 Kg/sq.cm (g)
=
1.0 m
=
5.0 m
Depth of water surface in the sump from operating floor (Z2)
4.
Bowl Head (Hb) Where, V
=
(P1x10)+Z1+Z2+(V2/2g)+hr
= Velocity of water in discharge pipe. V2/2g
= 0.18 m (for a flow of 13600 m3 /hr)
hf
= Friction loss in pump column pipe
hf
= 0.5 m (committed value)
HL
= 22.0 + 1.0 + 5.0 + 0.18 + 0.5 = 28.68 m
5.
Flow corresponding to Hb (28.68 m) m3/hr
=
13600
6.
Bowl efficiency
=
89%
7.
Power input to pump bowl
=
(refer tested curve)
1000 x 13600 x 28.68 --------------------102 x 3600 x 0.89
= 8. a b
1193.5 kW
Thrust bearing loss
=
9 KW
Transmission loss
=
3
KW = 9.
Total loss (a + b) 12 kW
Pump shaft input power
=
1193.5 + 12
=
1205.5 kW
10.
Motor efficiency
=
96.0%
11.
Motor input power
=
1205.5/0.96
=
1255.73 kW
